MH998283 Maintenance Manual 6D24 - Jan 2003

~~----
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 * Particularly important points for the prevention of faults and
procedures to help ensure safe, efficient operation of your engine. accidents are given in the "Things You Should Know for Safe
Improper use of the engine may lead to a fault or accident, so read this Operation" section of this manual and in "DANGER," "WARNING,"
manual carefully before using the engine. "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 ~
• Use this manual in conjunction with the instruction manual for the Particularly important information which, if not heeded, could
machine in which the engine is fitted. lead to serious personal injury or death.
• The information in this manual applies to the standard engine model.
• Due to ongoing improvements, the specifications and appearance of WARNING ~
your engine may differ slightly from those shown in this manual. 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.
Applicable engine models:

6024 6D24-TC
MITSUBISHI FUSO TRUCK & BUS CORPORATION
6D24-T 6D24-TL
© 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
CONTENTSI I
THINGS YOU SHOULD KNOW FOR SAFE OPERATION ......................... Page 1
DAILY INSPECTIONS (PERFORMED BEFORE OPERATION) ................ Page 13
* To help you find the information you need, STARTING AND STOPPING THE ENGINE ............................................. Page 17
the contents of this manual are organized
as follows:
DEALING WITH ENGINE PROBLEMS ....................................................Page 25
Contents Organized Visually According to
Engine Parts ............................................. 11 OPERATION IN COLD WEATHER ........................................................... Page 35
Contents Organized According to
Component Names ................................. IV OPERATION IN HOT WEATHER .............................................................Page 39
LONG-TERM STORAGE .........................................................................Page 41
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

. , - - - Cleaning and Replacement of
Replacement of Fuel Filter Element-------... Air Cleaner Element
CDP60 CD P57
Inspection and Adjustment of
V-belt Tension - - - -...... Dust Indicator
CD P61 CD P.58
Replenishment and Replacement of
Coolant, and Flushing of
Cooling System
CDP62
" ' - - - - - Air-Bleeding of Fuel System

CD P34
" ' - - - - Replacement of Oil Filter

Elements
CD P.59
Replacement of Engine Oil

Lubrication of Fan Drive and - - - - - - - - - - "
Tension pulley CD P.71
CDP.74
E0364
-11-
Contents
Contents Organized Visually According to

Daily Inspections ~i P.13 Starting and Stopping the Engine
Engine Parts
P.17
Replacement of coolant and E0031

Flushing of Cooling System Dealing with Engine Problems P.35
mp62 P.25
Inspection and Replenishment

m
of Engine Oil P.71 E0251 E0032
Operation in Hot Weather P .39 Long-Term Storage:::: P.41 P.55
E0034 E0019 E0035

Replacement of Preheating Circuit Draining Water Separator Inspection of Intercooler Lubricant Replacement and
Fuse P.56 P.60 '~ P.67 P.69
E0036 E0349 07404 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
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. ....................................................................... 10
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.
00006
~1-
Precautions for
. . ' .. ..
• Inspection and Maintenance
CAUTION it. WARNING it.

Always operate the engine in a well ventilated place. Operation of
• Inspections should normally be performed when the engine is not the engine in a poorly ventilated place can result in a poisonous
running. If you must perform an inspection while the engine is buildup of exhaust gases.
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.
Before inspecting E0326

electrical components,
turn OFF the battery
Always wear appropriate
switch or disconnect
clothing and use tools
the H terminal of
correctly.
the battery.
E0250
-2-
------------- ------------------- - - - - - - - - - - - - - - - -
• Operation of New Engine • Battery
DANGER .&.
The battery emits explosive hydrogen gas.
In the event of an emergency During your engine's running-in period Never use naked flames or perform
engine shutdown, identity and (the first 60 hours of operation),
operations that may create sparks near the
rectify the abnormality before • Do not rev the engine;
• Allow the engine to warm up fully before operation; battery.
restarting the engine.
• Make every effort to avoid overloading the engine.
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
E0057
burn the skin and make holes in clothing if
spilled. Always handle battery fluid carefully
CAUTION .&. The engine and transmission oils will and wash away any spilled fluid with soap and
deteriorate rapidly during the running-in plenty of water.
The engine is hot immediately after being period. Thus, the oils must be replaced
stopped. Be careful not to burn yourself when after the following operation hours 9I P.55
have reached:
performing inspections.
Engine oil: first 60 hours
Transmission oil: first 250 hours
E0003
-3-
• Fuel Diesel Fuel Properties Fuel-Related Precautions
Use only diesel fuel, without any compound, • After filling a fuel storage tank, allow 24 hours
Engine operating Recommended
for the diesel engine. for dirt and water to sink to the bottom.
conditions fuel
• Always refill the engine's fuel tank completely
WARNING .& Normal operation at *ASTM 0-975 after engine operation. By minimizing the
Never use gasoline or alcohol. If gasoline or temperatures of -12°C Grade 2-D amount of air in the fuel tank, this reduces the
alcohol is put into the ·fuel tank {10°F} or higher likelihood of moisture (the air's water content)
accidentally, it must be completely drained Operation at temperatures ASTM 0-975 freezing and causing corrosion and starting
from the fuel system. Operation of the below -12 °C {10 OF} or Grade 1-0 difficulties.
engine with gasoline or alcohol in the fuel prolonged idling • When refueling the engine from a storage
system could cause a fire or explosion. tank, be careful not to draw up sediment from
the bottom of the tank.
* ASTM: American Society for Testing Materials. • To prevent dirt and water from entering the
CAUTION .& The ASTM recommends the use of fuel with a fuel storage tank and the engine's fuel tank, fit
sulfur content of 0.5% or less. The use of fuel the caps securely when refueling is complete.
Always stop the engine before refueling it. with a sulfur content exceeding 0.5% shortens Periodically allow dirt and water to escape via
Never smoke or use a lighter or other naked the engine oil replacement interval by 50%. the drain plug at the bottom of each tank.
flame while filling the fuel tank.
CAUTION .&
The lower the fuel's cetane number, the
greater is the likelihood of internal engine
damage.
-4-
r--------------------~-~---- -- - - - --~--------- ------ ---
• Engine Oil • Coolant
When tap water is used, it should have the

following properties:
Use oil with a viscosity
appropriate for the ambient
temperature. 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
'e (r) 40c ~o pH 6 to 8

(lo4"F) ~
40
30 [00 I Soc ~ <.f')
2.0 -go • (Sq"F) ~ '30·c.

10
o
60 0 C
32 l
3tF) ex: ~ a::Or."
c.r>
UJ
(86 F)
°
-10 20 0 lfJ~ "'.

0 ...... " -:>C
-20 -20 ~ 8 _,~oc (Z3°F)
-30 Q ...... (S·F)
U,J 0-
a:: «X
V ) ......
Engine starting temperature Use anti-rust additive in

hot weather.
<}C:Q P.71 E023?
Use anti-freeze additive in
Lubrication cold weather.
Classification Remarks
point
All models API CD MIL-L-2104C EOOO?
<}CJ] P.62
-5-
• Reverse Operation of Engine • Fuel Leakage

CAUTION & CAUTION &
If the engine operates in reverse, immediately operate the shutdown Fuel leakage can cause a fire. If you discover a leak, rectify it
mechanism to stop the engine. If the engine is not stopped, it may immediately.
seize or suffer a severe fault within a few minutes. Also, exhaust gases
may emerge from the air cleaner, leading to a fire.
)j
if you hear a knocking sound

Wipe up any spilled fuel.
or see black smoke emerging
from the air cleaner.
E0008 E0009
<>[0 P.30
-6-
.--------------~----------------- --- - - - - - - - - - - - - - - - - - - - - -
• Radiator Cap • Filter Elements
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.
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
E0010
~o P.65
-7-
• Normal Engine Operation
Coolant Temperature Gauge Battery Switch
If the coolant temperature Never turn OFF the battery switch while the
exceeds 95°e {203°F} engine is running. All gauges and switches
(when the engine is would stop functioning, and the electrical
cooled with water from a system could suffer a fault.
tank) or 1000 e {212°F} FF
(when the engine is cooled
using a radiator) and/or the
AJ
g 1>1 i
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.
11 E0142
Ammeter For instructions on dealing with an overheated Starter Switch
engine, see CO P.31.
If the needle points to the Always keep the starter switch in the "ON" ("0")
"-" side of the scale or Oil Pressure Gauge position while the engine is running.
the charge lamp
illuminates, the battery is If the needle enters the
not charging properly. red zone (below 0.2 MPa
The engine must be {28 psi; 2 kgf/cm'}) or the
stopped. oil pressure warning lamp
Z06944 illuminates, the oil
pressure is abnormal. The
engine must be stopped.
For instructions on dealing with battery charging Z06945
problems, see:: P.30 For instructions on dealing with oil pressure
abnormalities, see P.32 E0018
-8-
• Long-Term Storage
(Planned strage) ( Preparations for Storage)

If you do not plan to use the engine
for a while, take the steps described • Clean the air cleaner, then spray antirust oil
on this page. (MIL-L-644B) and seal off all openings with
Qj waterproof tape.
t:: • Clean the starter, alternator, and relays with
o
o r.
en dry compressed air, and cover them with
o (;
r.
polyethylene sheets or polyethylene-coated
C paper.
o
E • Loosen the V-belts.
Q)
c • Make sure the battery fluid is full and the
o battery is fully charged and store the battery
in a cool and dry place. Recharge the battery
en
r. once a month.
C
o
E
.9 Q) • Touch up painted surfaces and apply a thin
Q) Q)
C L- coat of antirust oil (MIL-L-21260) to other
o~ metal surfaces.
If you want to keep the engine ready for
immediate use, just turn it over and let it en • Spray antirust oil (MIL-L-644B) into the intake
r.
warm up once a week. It is not necessary .9 C system.
Q) 0
to take any other steps.
~ E • Sprinkle vaporizing-type antirust powder
r. x
I- ·00 (MIL-P-3420) into the cooling system.
E0019
en ~ • Fill the lubrication system with antirust oil
¢c P.41 r. Q)
C >-
0 Q)
(MIL-L-21260), run the engine at idle, then
E c drain out the antirust oil.
x 0
If the storage period exceeds a year, repeat the • Replace the fuel with an antirust fuel, run the
U5 .9
same steps. engine at idle, then drain out the antirust fuel.
-9-
• Inspection and Adjustment • Daily Inspections
To be sure of optimum engine operation, it is • Your engine was adjusted for optimal
essential to perform inspections and operation before leaving the factory. Under no
maintenance on a regular basis. circumstances should you make adjustments
yourself.
• Unnecessary adjustment or removal of
engine components can detract from
performance and lead to excessive exhaust To help prevent faults, the user
emissions and noise. should inspect the engine before
• Faults resulting from improper adjustment are starting it each day.
not covered by your warranty.
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
E0327
<>[CP.14
-10-
-----~---- -- -- - - - - - - - - - - - - - - - - - - - - - - - -
I· §ngl,.Nurnber I
• 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.
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.
Check that the V-belts are free

of damage and that they are
correctly tensioned.
For instructions on adjustment deflect by the following amount

when pressed with a force of
of V-belt tension, see P.61 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
E0327
• 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
E0146
-14 -
.~~~~--------~-. -- -----------~~~--~~~~~~-
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
• Fuel Level
checked accurately with the engine
tilted, when the engine is running, or
Check that the fuel tank contains sufficient fuel.
immediately after engine operation
Check also that the engine is free of fuel
leakage.
Oil level gauge

E0328
• Previously Identified
Abnormalities
If any abnormality was identified

when the engine was last
operated, determine whether it will
interfere with continued operation.
To check the engine oil level, withdraw the oil level
If you cannot rectify the problem
gauge, wipe it clean, then insert and remove it
yourself, have the engine
again. Check also the viscosity of the oil and the
inspected by your dealer.
extent to which the oil is soiled.
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
1. Perform your daily inspections (Crank the engine after it has been stored for a long period.)
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.
E0023
1. Operate the shutdown
mechanism to terminate
fuel injection and thereby
stop the engine.
c)
Turn ON the battery switch.
"8" poSition, then crank the
engine for approximately
15 seconds.
CAUTION &
Never turn OFF the battery switch Q~ E0042
while the engine is running. All
gauges and switches would stop NOTE
functioning. and the electrical To ensure that oil is distributed to all parts of the engine, be sure to crank
system could suffer a fault. the engine before starting it. This is particularly important with a
turbocharged engine since the turbocharger's rotating parts will seize if the
E0148 engine is started before they are lubricated.
- 18-
- - - - _ _--- .. -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Starting and Stopping the Engine
~\ ---I
( Starting the engine in cold weather)
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 J
POSiti_o_n_._ _ _ _ _
~~~
1. Turn the starter switch to 2. Check that the indicator ~~========================~--------~
ON
Turn the starter switch to the "S" position to
the "H" position. glows red. (It should glow
start the engine. When the engine starts,
within 40 to 60 seconds.)
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
E0043 E0044 • Never operate the starter for more than 15 seconds since the starter
• If the indicator does not glow red, the fuse that serves the air may malfunction and the battery may be drained.
heater relay may have blown. ~I P.56 • Never turn the starter switch to the "S" position while the engine is
• In extremely cold conditions, the engine oil's fluidity decreases running since the starter may suffer damage .
significantly. To facilitate starting of the engine, warm the oil pan
with an electric heater.
NOTE When the engine starts, immediately move the control lever to the
Do not preheat the engine continuously for longer than 60 seconds idling position. Allow the engine to warm up until the needle in the
since this can drain the battery. coolant temperature gauge starts to move.
- 19-
• Warming Up the Engine
WARNING .&.
Always operate the engine in a well
Let the engine warm up until
ventilated place. Operation of the engine in
the needle in the coolant
a poorly ventilated place can result in a
temperature gauge starts
poisonous buildup of exhaust gases.
~. '! P.55
CAUTION .&. E0035

Check that the exhaust color is normal.
The exhaust pipe and related components
become extremely hot during engine
operation. To prevent a fire, check that the CLUNK SQUEAK
area is free of grass, waste paper, and other
flammable materials.
E0046
Do not rev the engine since it can lead to poor
operation and/or faults.
E0047
Check that the engine operates without
abnormal noise, vibration, and smells.
Check that no oil, water, or fuel is leaking from

the engine.
-20-
Ammeter or Charge Lamp Warning Lamp
E0106
Check that no warning lamps are illuminated.
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.
-21-
• Stopping the Engine
CAUTION &.
• The engine and exhaust pipe become Operate the shutdown mechanism to stop the
extremely hot during engine operation. To engine. (For details, refer to the instruction
prevent a fire, check that the area is free of manual supplied with the machine.)
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, E0149
exhaust gases may emerge from the air Turn the starter switch to
cleaner, leading to a fire. the "OFF" position, then Turn OFF the battery switch.
remove the key.
NOTE
If the battery switch is left in the "ON" position
for a long period, the battery may be drained.
Let the engine warm

up for at least three
minutes.
E0042
NOTE
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-
- - - - - - - ------ ----- - - - - - - - - - - - - -
• Inspections after Engine Operation
If the engine does not stop After shutting down the engine, clean it and
<6D24-TL> 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
Z06949 the coolant if antifreeze has not been used. If
the coolant is not drained, it may freeze and
If the engine does not stop when the starter cause cracks and other problems in the
switch is turned to the OFF position, stop it by crankcase and cooling system.
pulling the engine stop button. Return the button
to its original position when the engine has For instructions on draining the coolant,
stopped. see P.66
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.
-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
_ _) ( Possible cause) (~_ _R_em_e_d--,--y_~)
The starter does not turn, or the starter turns
slowly and the engine does not start.
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
E0068
The starter turns but the engine does not

start. 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
I 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
E0069
abnormality.
-26-
~-----.~----------------- - - ------------- ------- -----~------
(_ _S_ym_pt_om
_ _) ( Possible cause) ( Remedy ~
The engine tends to stall at low speeds.
qJJ
o
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
E0070
Abnormally low power o The fuel filter element is clogged .............................. Replace the fuel filter element. ~~~: P.60
~.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.
E0071
The engine overheats. 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
_ _) ( Possible cause) ( _ _~Re~m~e~d~y_~)
Black exhaust emissions

<>(: P.57
Excessive fuel consumption

o Fuel is leaking ........................................................... Have any leaks repaired by your dealer.
<>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.
Excessive engine oil consumption

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
_ _) ( Possible cause) (~_ _R_e_m_ed_y_ _)
The oil pressure does not increase.
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
E0074
The battery goes flat repeatedly.

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.
E0075
~29~
• Reverse Operation of Engine • Defective Charging of Battery
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.
06987
Check that the V-belts are free

of damage and that they are
correctly tensioned. ~Il P.61
deflect by the following amount
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
After stopping the engine, inspect the air cleaner and the rubber hoses of
the intake system. Replace any item that appears abnormal. Check for looseness in the alternator, If all connections and
relays and wiring. If the engine has a terminals are normal, the
charge lamp, check that it illuminates charging circuit is probably
when the starter switch is turned to the faulty. Have the electrical
"ON" position and goes out when the system inspected by your
engine is stopped. dealer.
-30-
• Overheating
If the coolant temperature ---- . \

WARNING 6 exceeds 100 °C {212 OF} Stop the engine when the needle in the coolant I
Do not open the radiator cap until the (when the engine is cooled temperature gauge reaches the middle of the I
coolant temperature has dropped. When using a radiator) or 95°C scale. Then, wait a while for the engine to cool, I
removing the radiator cap, cover the cap {203 OF} (when the engine remove the radiator cap, and pour coolant into!
is cooled with water from
with a cloth and turn it slowly. Unless the the radiator until it reaches the bottom of the
a tank) and/or the coolant
cap is opened carefully, boiling coolant and temperature warning lamp opening. If a reservoir tank is fitted, pour coolant
steam could spray out and scald you. illuminates, the engine is into the reservoir tank until it reaches the "FULL"
close to overheating. 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.
E0052
If the radiator cap has a pressure relief lever,
If the engine overheats, stop the machine raise the lever and allow the pressure to
E0010 immediately and let the engine idle until the escape before slowly removing the cap.
coolant temperature has decreased.
Pressure relief lever
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. E0053
-31 -
• Abnormal Oil Pressure
During Idling, the oil pressure If the oil pressure drops abnormally, Check for oil leakage and rectify any leaks.
should not drop below 0.1 MPa immediately operate the shutdown mechanism
{14 psi; 1.0 kgf/em'l
to stop the engine.
During normal operation, the oil
pressure should not drop
below 0.2 MPa {28 psi; NOTE
2.0 kgffem 2 }
If the engine is not stopped, its bearings and
other components may seize.
Check the engine

oil level and add Z06948 E0106
oil if the level is If the oil pressure is normal and there is no oil
too low. leakage, check whether the oil pressure gauge
If the oil pressure drops abnormally,
¢LJ P.71 and warning lamps are faulty. Measure the oil
the oil pressure warning lamp and/or
oil filter warning lamp illuminates.
pressure using a gauge that you know to be
working normally.
E0054 • Check whether the oil filter elements are

Immediately after the engine is started, the oil clogged.
pressure gauge may show a high reading • Replace the oil filter elements if the oil filter If these steps fail to rectify the abnormality, have
since the engine is still cold. Check the oil warning lamp illuminates. ¢tll P.59 the engine inspected by your dealer.
pressure after allowing the engine to warm
up.
~~ / I \
E0151 E0014
-32-
• Emergency Shutdown <Engines with Emergency Shutdown Mechanism>
CAUTION & After rectifying the abnormality, wait for the Check the coolant level and add coolant if the
coolant temperature to drop before attempting level is too low. <}il: P.62
The engine is hot immedeately after being to restart the engine, The engine will not start
stopped. Be careful not to burn yourself when while it is extremely hot.
performing inspections.
Check for oil leakage, for water leakage, and for
Check that the clogging of the radiator.
V-velts are free of
damage and that
they are correctly
tensioned. If these steps fail to rectify the abnormality, have
<}CJ P.61 the vehicle inspected by your dealer.
deflect by the follOWing amount
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
Check the
engine oil level
and add oil if
the level is too
NOTE low.
The emergency shutdown mechanism is designed <}r~i P.71
to minimize engine damage. In the event of an E0041
emergency engine shutdown, identify and rectify
the abnormality before restarting the engine.
-33-
• Running Out of Fuel (Air Bleeding)
CAUTION ~
Wipe up any spilled fuel after refueling and
air-bleeding the fuel system. Also, check After comfirming that air
carefully for fuel leakage since leaking fuel Loosen the knob on bubbles stop emerging,
could cause a fire. the priming pump. tighten the air bleeding
plug.
If air enters the fuel system, it must be expelled
in accordance with the following procedure
E0216 E0156
before the engine can be started. It is not
sufficient only to fill the fuel tank.
<6024, 6024-T, 6024-TC>
• Loosen the air Move the knob up and

bleeding plug on the down a few times
fuel filter. more, then press it
• Cover the air bleeding down and screw it into
plug with a cloth. position.
E0217
E0152
<6024-Tl>
Completely wipe up any spilled fuel, then start

Air bleeding plug
Moving the knob up the engine and check for fuel leakage.
and down, pump fuel
out of the air bleeding
plug until air bubbles The fuel injection pump will be air-bled
stop emerging. automatically when the engine is started.
E0215
07182
-34-
Fuel ...........................................................................................................36
Engine Oil .. ...............................................................................................36
Coolant. .....................................................................................................37
Battery .......................................................................................................37
-35-
Operation in Cold Weather
In extremely cold weather, special measures • Engine Oil

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 'c c'F) 40c ~O
40 (lo4"FJ l:!E
winter operation in general. 30 /00 15'c ~ c.r>
o.c
1°1
m'F) :. 30'Co
0'" =
20 80
60
o 32 '3'tFJ
\ a:::;.: <..r> (8&'F)
-10 20 0 t.n~ ~'
O....,~ -:>C
-~~ -20 ~8 -I!:l'c (Zj'F)
• Fuel - ;:U~ (S'F)
Cl:([
Keep the fuel tank cap securely tightened to v)'-'
Recommended prevent rain and snow from entering the tank.

Engine operating conditions Engine starting temperature
fuel 9:=:: P.4
E0238
Normal operation at temperatures ASTM 0-975
of -12°C (10°F) or higher Grade 2-D NOTE Use oil whose viscosity is appropriate for the
Operation at temperatures below ASTM 0-975 • Always refill the fuel tank completely after ambient temperature. 9[J P.71
-12°C (10°F) at prolonged no-load Grade 1-0 engine operation. By minimizing the amount of
operation air in the fuel tank, this reduces the likelihood
of moisture (the air's water content) freezing
Use diesel fuel appropriate to the ambient and causing corrosion and starting difficulties.
temperature. • Periodically allow dirt and water to escape via
the drain plug at the bottom of the tank.
-36-
.---------~----------~---------
Operation in Cold Weather
• Coolant
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
EOOO?
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 .
• Battery
• 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.
-37-
MEMO---------------------------------------------
-~-
Battery .......................................................................................................40
Engine Oil .................................................................................................40
Cooling System ........................... ....................... ... ... ........... ................ ..... .40
-39-
Operation in Hot Weather
To prevent the engine from overheating in • Battery • Cooling System

extremely hot weather, special care must be
taken to ensure efficient operation of the The battery fluid may be consumed quickly, so Water scale and rust will tend to occur in the
cooling system. inspect it more frequently than in cold weather cooling system. To prevent them from causing
and make sure it never drops below the UPPER the engine to overheat, flush out the cooling
level. ~c: P.55 system and replace the coolant from time to
time.
~~J P.66
-----
• Engine Oil NOTE
• Keep the coolant topped up completely at all
times, and check frequently for coolant
leakage.
4o'c ~o • Check frequently that the V-belts are
40
30
20
'c c'F)
100
80
o'c
15'c [;J
(104'1')
"F......
(Sq ) LU
~
<fl
30c.
tensioned correctly and free of damage.
10~
o 60
32 t3tF) ~c-;<
a: ~ =..n (go"F)
-10 20 0 (j');§:l ~"
O ...... ~ -:>C
-~~ -20 ~ 8 -I~'c (1,3"F)
- ~~ (S"n
cI:<t
V)"'"
Engine starting temperature

E0238 ~CJ P.61
deflect by the follOWing amount
approximately 98 N (22 Ibl; to kgl):
Use oil whose viscosity is appropriate for the <Models with fan drive>
10 to 15 mm (0.39 to 0 59 In)
ambient temperature. ~~ P.71 <Models without fan dnve>
17 to 22 mm (0.67 to 0.87 In)
A6253
• If the engine overheats, allow it to idle for a

E0034 while before stopping it. ~(rl P.31
-40-
- - - - - - - - - - - - ---- ----- ---------------
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 • If the engine will definitely not be required ...
use ...
Make the appropriate preparations for

Once a week, start the engine and
the expected storage period, and cover
allow it to warm up to ensure that all
the engine completely prior to storage.
components are supplied with oil.
o
o
E0042
E0019
NOTE NOTE
• Before starting the engine, be sure to crank it with the starter and check • If the engine is stored for longer than initially expected, make additional
that the oil pressure gauge indicates an increase in oil pressure. preparations in accordance with the longer storage period.
• Warm up the engine at the lowest speed possible. Do not increase the • If the storage period exceeds one year, repeat the preparatory steps.
engine speed until the coolant has reached an appropriate temperature. • Do not cover any engine components with vinyl sheets.
-42-
Long-Term Storage
( Planned storage period)
One month or shorter One to three months Three to six months Six months to one year
( Preparations for storage)
• Clean the air cleaner, then spray • Touch up painted surfaces and • Remove the air cleaner, move • Drain the lubricating oil from the
antirust oil (MIL-L-644B) into it apply a thin coat of antirust oil the control lever to the stop oil pan, oil filter, injection pump,
and seal the opening with (MIL-L-21260) to machined position, then crank the engine cam chamber, and governor
waterproof tape. surfaces and to aluminum and with the starter three times at chamber. Then, replace the
• Clean the starter, alternator, and plated parts. intervals of 15 seconds. While drained lubricating oil with the
relays with dry compressed air, cranking the engine, spray same amount of antirust oil (MIL-
and cover them with polyethylene antirust oil (MIL-L-644B) into the L-21260).
sheets or polyethylene-coated intake manifold with an oil spray • Replace the fuel with a mixture of
paper. gun. 50% diesel fuel and 50% antirust
Do not use vinyl sheets. • Drain the coolant and remove the oil (MIL-L-644B). Then, let the
• Loosen the V-belts. thermostat. Then, blow engine idle at 800 to 1,000 rpm
• Top up the battery fluid with compressed air through the for 10 minutes so that the mixture
distilled water such that the fluid coolant inlet and outlet to expel reaches all parts of the fuel
level is slightly higher than usual, all remaining moisture. system.
charge the battery fully, clean the Sprinkle vaporizing-type antirust • After stopping on engine, drain
battery terminals, and store the (MIL-P-3420) into the coolant out both the antirust oil and gas
battery in a cool, dry place. inlet and outlet. Then, fit the oil/antirust oil mixture.
Recharge the battery once a thermostat and close the drain
month during storage. cock.
-43-
Long-Term Storage
• Steps to Take before Reusing Take the following steps:

the Engine • 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
When the engine has stored for three
leakage caused by gasket deterioration.
months or longer, it is important to perform
certain inspections and adjustments before
NOTE
using it. (These inspections and adjustments
Before starting the engine to test its operation,
are not necessary if the engine has been
remove the rocker cover and lubricate the
started and warmed up once a week
rocker arm bearings and push rods sufficiently.
throughout the storage period.)
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.
E0023
-44-
~------------~---------- - --------------
....
--------......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 The timing of inspections and maintenance
operations should be based on the engine's
ensure that your engine operates safely and
aggregate operating time, which is
.efficiently, be sure to perform the indicated indicated by the hour meter.
inspections and maintenance operations at The inspection and maintenance inteNals
the specified intervals. 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
-46-
NOTE:
[0]: Inspection interval specified by Mitsubishi Motors
[~'r]: Replacement interval specified by Mitsubishi Motors
Interval
....
II)
::J
....
II)
....
II)
....
II) ....
II)
Inspection/maintenance item ~
0 ....::J
II)
::J ::J ::J
::J
0 Key points
0 0 0 0 0 ~
,.... ~
~ ~ ~
0
....... 0
I[) 0 0 0
2- <0 C\I
,.... I[) 0 o.
·iii C\I I[)
,....
C
Startability and noise 0 • Call your dealer if adjustments are required.
Low-speed operation and acceleration • Check for hunting.

0
(under normal conditions) • Call your dealer if adjustments are required.
• Let engine warm up completely before inspecting

exhaust gases.
Exhaust gases 0
• See page 55 for instructions.
• Call your dealer.
~
~
Q)
c Security of cylinder head, manifolds,
Q) 0 • Cail your dealer.
and mounting brackets
.9
Q)
c
·OJ Compression pressure 0 • Call your dealer.
c
w
Valve clearances 0 • Call your dealer.
• When red signal appears in dust indicator, clean or

Condition 0 replace element irrespective of inspection interval.
Air cleaner element • See page 57 for instructions.
(cyclone type air cleaner)
Replacement P: • See page 57 for instructions.
Rotation of turbocharger bearings 0 • Call your dealer.
-47-
NOTE:
['tr]: Replacement interval specified by Mitsubishi Motors
Interval
....
VI
::J VI
.... ~ ~
....
VI
Inspection/maintenance item 0
..c: ....
VI
::J ::J ::J
::J
0 Key points
::J
0 0 0
..c:
0
..c:
0
..c: ..c:
.- ..c:
2- °CD
LO
C\I
0
LO
0
0 °o.
0
'iii .- C\I LO
.-
C
Oil leakage
(including inspection for hose damage/deterioration)
0 • Replace hoses every 3,000 hours or 2 years.
E Contamination and level 0 • See page 71 for instructions.
-
Q)
VI
>- • *: With new engine only
.
VI
c: • Oil pan capacity
0
Approx. 27 dm 3 {28.5 US qts.; 27 L}
co
u
.;: Engine oil (engines for electric power generators)
*
..0
::J
Replacement {'.{
'tr Approx. 25 dm3 {26.5 US qts.; 25 L}
...J (engines for construction machinery)
• Required oil type
API classification CD (MIL-L-21 04C) or better
-48-
--------------
NOTE:
[u]: Replacement interval specified by Mitsubishi Motors
Interval
rJ)
"- rJ)
::l rJ) rJ) rJ) "-
Inspection/maintenance item 0 ~ "- "- "- ::l Key points
.s::. ::l ::l ::l ::l 0
0 0 0 0 .s::.
,..
0
.s::. .s::. .s::. .s::. 0
LO 0 0
~ 0
CD ,..
C\I LO 0
0
~
'iii C\I LO ,..
0
E Chogging (center bolt type filter) 0

....
Q)
!/)
>.
!/) • If oil filter warning lamp illuminates, replace oil
c: Oil filter
0 filter elements irrespective of inspection interval.
~ elements
u Replacement u • See page 59 for instructions.
'C
.0 • Oil filter capacity
::J
..J 4.0 to 4.5dm 3 {4.2 to 4,7 US qts.; 4.0 to 4.5 L}
Fuel leakage
0 • Replace hoses every 3,000 hours or 2 years,
Fuel level 0
E
Q)
+'
rJ)
>- • See page 60 for instructions.
rJ)
Qj
Replacement of fuel filter element (filter-paper type) u • Perform air-bleeding.
::l (See page 34 for instructions.)
LI..
• If water reaches level line, drain it irrespective of

Drain water and sediment
0 inspection interval.
from water separator
• See page 60 for instructions,
-49-
NOTE:
[u]: Replacement interval specified by Mitsubishi Motors
Interval
...:::J
II)
...
II)
..r::: ...:::J
II) ~
:::J
...:::J
II)
~
:::J
:::J
0 Key points
0 0 0 0 ..r:::
0,.... ..r::: ..r::: ..r:::
..r::: 0
LO 0 0
~ 0
<0 C\I
,.... LO 0
0
0
'co C\I LO ,....
C
Injection nozzle spray pressure/spray condition 0 • Call your dealer.

E
Q)
+"
II)
Inspect and clean gauze filter of injection pump 0 • Call your dealer.
>0-
Il)
Qj Drain water and sediment from fuel tank 0 • Perform every 500 hours or 6 months.
:::J
IJ..
Injection timing 0 • Call your dealer.
Water leakage
0
• Coolant volume (engine-proper only)

If FUSO ANTIFREEZE or {::[ <6D24, 6D24-T, 6D24-TL>
RADIPET 9 is used
Approx. 22dm 3 {23.5 US qts.; 22L}
E Flush out
Q) <6D24-TC>
+"
II) cooling system
>0- Approx. 24dm 3 {25.5 US qts.; 24L}
II) and replace coolant If FUSO DIESEL
Cl • Flush out cooling system when coolant is
c: LONGLIFE COOLANT 2 years
replaced.
'0 is used
0 • See page 62 for instructions.
U
• Check deflection when belts are pressed in center

V-belt looseness/damage 0 with force of approx. 98 N {22 Ibf; 10 kgf}.
Fan damage/mounting security 0 • Call your dealer.
-50-
-------------------~~--~---- ---- - --- - - - - - - - - - - -----------------~
NOTE:
['tr]: Replacement interval specified by Mitsubishi Motors
Interval
...
!Il
Inspection/maintenance item
::J
0
.s= ~
!Il
....
::J
...
!Il
::J
!Il
....
::J
!Il
....
::J
0 Key points
::J
0 0 0 .s=
....a
......
0
.s= .s=
In
.s=
a
.s=
a a
a
~ a a
'ffi
CD ....
C\I In
C\I In ~
....
C
Coolant level 0
E Cap functionality 0
Q)
+"
Radiator
!Il
>-
!Il • If core is severely clogged, wash it irrespective of
Cl Core clogging/damage 0
.S: inspection interval.
'0
0
() • See page 74 for instructions.
Lubrication of fan drive and tension pulley 0 • Required grease type
Wheel bearing grease [NLGI No.2 (Li soap)]
• Inspect every 125 hours or 2 weeks (every 1 week

Fluid level 0 in summer). if sooner than specified interval.
E
Q) Battery
+"
!Il
Specific gravity of fluid 0
>-
!Il
(ij Security/contamination
()
.;:
0
+"
of terminals
()
Q)
iIi Loose wiring connections and
0
loose/damaged insulation
Functionality of meters, gauges, and warning lamps 0
-51 -
NOTE:
[i'f]: Replacement interval specified by Mitsubishi Motors
Interval
~
:I
....
1/1
....
1/1
....
1/1 ....
1/1
.J:.
....
1/1
:I :I :I :I
:I
0 Key points
0 0 0 0 .J:.
,..
0
.J:. .J:. .J:. .J:.
0
L() 0 0
~ 0
co ,..
C'II L() 0
0
o.
·iii C'II L()
,..
0
Operation of emergency engine shutdown device 0 • Call your dealer for adjustments.
Inspect couplings (rubber bushings) 0 • Check exposed rubber.
• See page 74 for instruction.

• Required grease type
Lubricate clutch fork shaft and shifter 0
1/1
Heat-resisting grease
Q)
.;: [NLGI No.3 (Li soap); MIL-G-3545C]
0
1/1
1/1
Q) • See page 74 for instruction.
0 Lubricate power plant clutch bearing case
0
<{ (direct drive)
0 • Required grease type
Wheel bearing grease [NLGI No.2 (Li soap)]
0 • *: With new engine only

Inspect and replace transmission and gear box oils * 'v7 • Required oil type
i'f Gear oil [API classification GL-3]
Operation of clutch and transmission 0 • Call your dealer for adjustments.
-52-
· .
-------------~ 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 Improper adjustments can detract from the WARNING &
for inspections and maintenance operations you engine's performance and can cause the Always operate the engine in a well
can do yourself. engine to pollute the environment by emitting ventilated place. Operation of the engine in
black smoke and excessive exhaust gases. a poorly ventilated place can result in a
CAUTION & poisonous buildup of exhaust gases.
• Inspections should normally be performed Always wear appropriate

when the engine is not running. If you must clothing and use tools
perform an inspection while the engine is correctly.
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.
E0326
NOTE
Before inspecting electrical components,
• Maintenance and inspection intervals should
stop the engine, then turn OFF the battery
be shortened if the engine operates under
switch or disconnect the (-) terminal of
particularly severe conditions.
the battery.
• 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. E0327
-54 -
• Inspection of Exhaust Color • Battery Maintenance

DANGER .&
Inspect and top up the battery fluid
every 125 hours or two weeks
(once a week in summer).
J
The battery emits explosive hydrogen gas.
Let the engine warm up fully
Never use naked flames or perform
before inspecting the exhaust
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 .&
Acceptable range
• Battery fluid contains sulfuric acid, so it can A5574
E0035 burn the skin and make holes in clothing if
Colorless/pale blue:Normal spilled. Always handle battery fluid The fluid level should be between the UPPER
Black ......... Bad (indicates incomplete carefully and wash away any spilled fluid and LOWER level lines or 10 to 15 mm above
combustion) with soap and plenty of water. the plates.
White ........ Bad (indicates that oil is leaking • Do not use the battery with the fluid level Some types of battery have only one level line.
past piston rings and burning in below the LOWER level line. Doing so In this case, the line indicates the LOWER level.
combustion chambers) would shorten the battery's service life and
could cause the battery to overheat and
In the winter months, low temperatures may explode.
make the exhaust gases appear white even • Store any used battery with its terminals at
when the engine is operating normally. the top. Storing the battery on its side
could result in fluid leakage and in a fire.
-55-
• Replacement of Preheating
Circuit Fuse
Clean the battery terminals every 250 hours. CAUTION .&.

Use a Mitsubishi genuine replacement fuse of
10to 15mm
(0.39 to 0.59 in) the specified amperage. A fuse with a
------------- different amperage could cause a fire.
---'=-f~- -----
_-=~Plate
----.------~~
~------
---- -
--
----
--
-------
-
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
----- --
-------
--- - A5577 whether the fuse has blown.
-- -
---
--
----
- - • Make sure the caps are tightened securely on In the event that the fuse blows, rectify the fault
A5575 the ports to prevent foreign matter from and replace the fuse with a new one.
entering the battery case.
If the fluid level is too low, remove the caps and • Remove any dirt from the terminals.
top up the fluid with electrolyte or distilled water. • If the terminals are contaminated by white
powder (this indicates corrosion), clean them
NOTE with warm water. If the corrosion is severe,
• Do not allow the fluid level to rise above the disconnect the battery cables and rub the
UPPER level line or rise more than 15 mm terminals with sandpaper or a wire brush.
(0.59 in) above the plates. • Lightly smear the terminals with grease after
• Top up the fluid before charging the battery or cleaning them.
running the engine. Note that in winter the
fluid can freeze and damage the battery when NOTE
its specific gravity is low. When disconnecting the battery cables, Amperage rating E0351
• Before inspecting/maintaining the battery or disconnect the (-) cable first. When reconnecting
inspecting electrical components, stop the the cables, connect the (+) cable first. NOTE
engine, then turn OFF the battery switch or It is dangerous to have only the (-) battery cable Before replacing the fuse, stop the engine, then
disconnect the (-) terminal of the battery. connected since sparks could be produced if a turn OFF the battery switch or disconnect the (-)
• Remove the battery from the machine before tool or other metal object short-circuited the (+) terminal of the battery.
charging it. terminal to the frame.
-56-
• Cleaning and Replacement of Air Cleaner Element
Inspect and clean the element Cyclone (Single-Element) Type Cleaning Procedure
Every 250 hours and whenever the red signal
appears in the dust indicator. (With a double- CAUTION .&
element air filter, only the outer element can
be inspected and cleaned.) When cleaning the element(s) with
compressed air, wear safety spectacles to
Replace the element protect your eyes from dust.
Every 1,000 hours. (With a double-element air
filter, replace the outer and inner elements at
the same time.)
Air cleaner body
Dust indicator
Element
tN)
Gasket
~ ,
NOTE
• Do not remove the inner element of a dauble-
~
Wing nut
element air filter except for replacement.
~ Wi~9 nut cove;With gasket) • When cleaning the element with compressed
NOTE air, make sure the air pressure does not
• Shorten the inspection/cleaning and ~ Vacuator valve exceed 685 kPa {tOO psi; 7 kgf/Crn"}.
Air cleaner body
replacement intervals if the engine is used in • Never attempt to clean the element by
a particularly dusty environment. Cyclone (Double-Element) Type · knocking it against another object or by
• It is not possible to clean and reuse the inner striking it.
element of a double-element air filter. • If the element is blackened by oily soot,
• Make sure the element(s) and clamp are fitted replace it with a new one irrespective of the
Air cleaner
securely in position. If they are not fitted Dust body specified replacement interval.
securely, dust or other foreign matter may be Indicator showing
drawn into the engine and prevent normal Installed alignment 1. Remove the element.
operation.
Dust
indicator Air cleaner body
E0158
~ E0159
2. Check the extent to which the element is 4. Clean the dust cup and baffle. Dust Indicator
contaminated, then clean the element as Loosen the wing nut to remove the baffle.
follows: Reset button
Blow clean compressed air

along the pleats from the
Window (red signal)
C7210B
A1304 The dust indicator shows when the air cleaner
5. When all parts are clean, assemble them by needs to be cleaned. Whenever the red signal
reversing the disassembly sequence. appears in the window, clean the element
irrespective of the specified inspection interval.
After cleaning or replacing the element, press
E0079 the reset button to cancel the red signal.
3. Shine a lamp through the element from the

inside and inspect the filter paper.
Replace the
element if the filter
E0083
areas, or other damage

If the air cleaner is mounted horizontally on the
and/or the seal is engine, the dust cup should be fitted such that its
damaged. alignment marks point upward. (Note that some air
cleaners do not have alignment marks.)
-58- E0082
-------~~~~----- - - -------------------------------------
• Replacement of Oil Filter Element
CAUTION & Perform the following steps for each filter:

Filter head
• Be careful not to spill engine oil. If oil comes Gasket 2. Remove the drain plug and allow the oil to
into contact with the exhaust manifold or Gasket Element drain out.
other hot components, it could catch fire. Element (may be fitted
(may be fitted either way up)
Wipe up any oil that spills accidentally. 3. Remove the center bolt, then remove the filter
either way up) Spring
• To avoid causing a fire, never smoke or use Spring
case, element, spring, and other parts.
a lighter or other flame while washing Filter case
components in solvent.. Filter case 4. Wash all parts except the element in solvent.
Drain plug
Drain plug
NOTE _ _ _---- O-ring
5. Discard the old element, and prepare a
• The elements cannot be washed and reused. O-ring genuine Mitsubishi replacement element. The
• Make sure the O-rings are not twisted. They Washer O-ring must also be replaced with a new one.
may be cut or otherwise damaged if they are Washer
twisted when fitted. Bypass Full-flow Center bolt 6. Fit the new element and other parts by
Center bolt filter filter (tightening torque:
(tightening torque: 59 to 69 N·m
following the disassembly procedure in
59 to 69 N·m {43 to 58 fUbs. reverse. Tighten the center bolt to the torque
(43 to 58 tUbs. 6 to 7 kgt·mj) 6 to 7 kgf·mj)
Replace the elements every 500 hours or shown in the drawing.
when the oil filter warning lamp illuminates. E0253
1. Place a container under the oil filters to hold 7.lf the engine oil has not been replaced, add
the oil when it is drained out. 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.
Drain plug E0161

-59~
• Replacement of Fuel Filter Element • Draining Water Separator

<6024-Tl>
CAUTION & Air bleeding cock"
Filter head CAUTION &
After replacing the filter element, wipe up any The water separator contains fuel in addition
spilled fuel. Also, check that no fuel is leaking to water. When draining the contents of the
from the filter since leaking fuel could cause a Alignment mark /"Gasket water separator, wipe up any fuel that
fire. splashes on the surrounding area. Unless
Alignment mark wiped up, it could cause a fire.
NOTE
To avoid damaging the element, be careful not Element Orain the contents of the water separator
to overtighten the element assembly. ~ assembly every 60 hours and whenever the float
I Tighten
05365
reaches the level line.
( Replace the element every 500 hours. )
1. Remove the element assembly by turning it
<6024, 6024-T, 6024-TC> counterclockwise. Use a filter wrench if the
element assembly is difficult to turn.
Filter wrench part number:
Filter head
MH061572 <6024, 6024-T, 6024-TC>
MH063200 <6024-TL>
2. Fit a Mitsubishi genuine replacement element
Air bleeding plug
assembly as follows: Lightly smear engine oil
onto the gasket of the new element assembly,
Drain plug
Gasket then tighten the element assembly by hand
until the gasket touches the filter head. Next, E0350
tighten the element assembly by the
1. Loosen the drain plug and allow the contents
additional number of turns shown below.
of the water separator to drain out.
Element assembly 6024, 6024-T, and 6024TC: 3/4 to 1 turn
2. Tighten the drain plug when the float reaches
6024-TL: 1 to 1 1/8 turn
the bottom.
3. Air-bleed the fuel system. c}JJ P.34 3. Check the water separator for fuel leakage.
E0162 4. Start the engine and check for fuel leaks.
-60-
-------~--------~~--------------
• Inspection and Adjustment of V-Belt Tension
Excessively slack or tight V-belts can cause Alternator Tension pulley

defective charging of the battery and
malfunctions of the alternator and water pump. Adjusting bolt
Keep the belts adjusted to the correct tension at
all times.
Tension pulley
The center of each belt should deflect

by the amount shown when pressed
Mounting nut
with a force of approximately 98 N
{22 Ibf; 10 kgf}. ~ .
Mounting bolt
E0165 E0166
1. Slightly loosen the alternator's upper and 1. Slightly loosen the tension pulley's mounting
lower mounting bolts. nut.
2. Using a wrench handle or similar implement 2. Adjust the V-belt tension by moving the pulley
as a lever, change the alternator's mounting using the adjusting bolt.
position to adjust the belt tension.
3. Securely tighten the tension pulley's mounting
3. Securely tighten the alternator's mounting nut.
bolts.
E0164 NOTE
NOTE Be careful not to damage the stator coils and
• Keep the V-belts free of oil and grease. through bolts when moving the alternator.
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.
- 61-
• Inspection and Replacement of Coolant
Additives for Coolant Water for Coolant Using FUSO ANTIFREEZE
When the coolant requires replacement, flush Use soft water with the properties shown below. • Since FUSO ANTIFREEZE has anticorrosion
out the cooling system and fill it with coolant that Do not use hard water from a well or river since properties, no additional corrosion inhibitor is
contains the appropriate one of the additives it is liable to form water scale and cause required.
shown below. Additives are necessary to keep corrosion. • Use FUSO ANTIFREEZE at a concentration
the coolant free of water scale and rust and to of 30% to 60%. At a concentration below
prevent the coolant from freezing. Total hardness 300 ppm or less 30%, Fuso Antifreeze does not prevent
Sulfate SO; 100 ppm or less corrosion effectively, and at a concentration
Additive Season Replacement Chloride CI- 100 ppm or less exceeding 60% it does not effectively prevent
interval Total dissolved solids 500 ppm or less the coolant from freezing.
Antifreeze: pH 6 to 8 • When the ambient temperature is high
FUSO ANTIFREEZE Cold seasons 500 hours enough that there is no risk of the coolant
(color: blue)
freezing, replace coolant containing
Corrosion inhibitor: All seasons
antifreeze with coolant containing a corrosion
RADIPET 9 except 500 hours
(color: red) cold seasons inhibitor. In warm weather, the use of coolant
FUSO DIESEL containing antifreeze makes the engine prone
LONGLIFE COOLAN All seasons 2 years to overheating.
(color: yellow)
CAUTION .L:t.
Remember that the coolant replacement
interval depends upon the additive used.
00634
-62-
---------------~------------- -----
Required Concentration Using RADIPET 9 (Corrosion

Inhibitor)
Determine the correct concentration of FUSO
ANTIFREEZE in accordance with the lowest RADIPET 9 should be added to the coolant at a
temperature at which the engine is to be used. concentration of 5 %.
See the following table.
FUSO ANTIFREEZE concentration

(% of coolant volume)
Lowest temperature
Concentration (%)
(OC eF})
-10 {14} or higher 30
-15 {5} 35
00635
-20 {-4} 40
-25 {-13} 45
-30 {-22} 50
-35 {-31} 55
-40 {-40} 60
For instructions on coolant replenishment,

see" P.65
-63-
Using FUSO DIESEL LONG LIFE COOLANT
FUSO DIESEL LONGLIFE COOLANT is an Required Concentration

ethylene-glycol-based antifreeze (SAE J-814-C)
with both antifreeze and anticorrosion Determine the correct concentration of FUSO
properties. Mix it with soft water in the specified DIESEL LONGLIFE COOLANT in accordance
ratio. with the lowest temperature at which the engine
WARNING it. is to be used. See the following table .
• FUSO DIESEL LONGLIFE COOLANT is
toxic. If it is accidentally swallowed, FUSO DIESEL LONGLIFE COOLANT
immediately induce vomiting and seek concentration (% of coolant volume)
medical attention. If it splashes in the 00264
Lowest temperature
eyes, immediately flush it out with plenty • Use only FUSO DIESEL LONGLIFE Concentration (%)
(OC eF})
of water and seek medical attention. COOLANT. Do not use other brands of coolant. -10 {14} or higher 30
• Store FUSO DIESEL LONGLIFE • Since FUSO DIESEL LONGLIFE COOLANT -15 {5} 35
COOLANT out of children's reach. has anticorrosion properties, it can be used in -20 {-4} 40
the summer months. (Maintain a -25 {-13} 45
concentration of 30% or higher.) -30 {-22} 50
• Use FUSO DIESEL LONGLIFE COOLANT at -35 {-31} 55
CAUTION it. a concentration of 30% to 60%. The exact -40 {-40} 60
concentration required depends upon the
FUSO DIESEL LONGLIFE COOLANT is ambient temperature. At a concentration below For instructions on coolant replenishment,
flammable. Keep it away from naked flames. 30%, FUSO DIESEL LONGLIFE COOLANT see P.65
does not prevent corrosion effectively. At a
NOTE concentration exceeding 60% it does not
Never mix FUSO DIESEL LONGLIFE effectively prevent the coolant from freezing
COOLANT with antifreeze, corrosion inhibitor, and makes the engine prone to overheating.
or other brands of longlite coolant. • 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.
-64 -
--------------------------
( _______A_d_d_in_g_c_O_OI_a_n_t_ _ _ _ _~) Radiator cap
WARNING .&. Cap

Do not open the radiator cap until the
coolant temperature has dropped. When
removing the radiator cap, cover the cap ,=,~~l'<-;:"x Reservoir tank
with a cloth and turn it slowly. Unless the
cap is opened carefully, boiling coolant and
steam could spray out and scald you. 83514 FULL line
E0204
Remove the radiator cap and top up the coolant
NOTE until it reaches the bottom of the opening.
• If the coolant in the system contains antifreeze, If the radiator has a reservoir tank, coolant
a corrosion inhibitor, or longlife coolant, make Pressure relief lever should be poured into the reservoir tank, not
sure the additional coolant contains the same directly into the radiator. Add coolant until it
additive in the same concentration. The reaches the "FULL" line.
Radiator cap
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.
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.
-65-
Radiator 1. Remove the radiator cap, then loosen the

Flush out the cooling system and replace the drain plug on the engine and radiator and
coolant at the following intervals: allow the coolant to drain out. If the
With FUSO ANTIFREEZE or RADIPET 9: aftercooler has an air bleeding plug, remove
500 hours it. Tighten the drain plugs when the coolant
With FUSO DIESEL LONGLIFE COOLANT: has drained out completely.
2 years
2. Pour soft water (preferably hot) into the
E0168 radiator until it emerges from the aftercooler's
CAUTION .&. air bleeding hole. Then, refit the air bleeding
Engine crankcase plug.
The coolant may be extremely hot when
drained. Take care to avoid being scalded. 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
E0169 until clean water emerges.
Aftercooler (with air bleed opening) 4. If the front of the radiator core is clogged with
mud or dirt, wash it clean to ensure that air
y Air bleeding plug 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
Aftercooler E0329 with the air bleeding plug removed. Refit the
air bleeding plug when coolant mixture
-66-
,----------------------------- ---
• Inspection of Intercooler
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.

Clogging of the intercooler core can detract from
9. If a reserve tank is fitted, drain the coolant engine performance. Remove all mud, dust, and
from the tank, then fill the tank with the type of other contamination from the front of the core.
mixture that the radiator contains.
NOTE
NOTE To avoid damaging the intercooler core, clean it
If the radiator is severely clogged or the coolant with a soft brush. Do not use any sharp or hard
is exceptionally dirty, have the engine inspected implement.
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}
-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 Remarks

Oil pan Approx. 27 dm 3 {28.5 US qts.; 27 L} (engines for electric power generators) Engine oil
Approx. 25 dm 3 {26.5 US qts.; 25 L} (engines for construction machinery) [API classification CD (MIL-L-2104C) or better]
Oil filter 4 to 4.5 dm 3 {4.2 to 4.7 US qts.; 4 to 4.5 L}
Fan drive As required Wheel bearing grease
Tension pulley As required [NLGI No.2 (Li soap)]
Power plant As required

clutch bearing case
(direct drive)
Clutch fork shaft As required Heat-resisting grease
Clutch shifter As required [NLGI No.3 (Li soap); MIL-G-3545C]
-70-
• Engine Oil
The performance, service life, and startability of ( Inspection and Replenishment )

---------------~
the engine depend to a large degree upon the
engine oil. Always use engine oil of the
specified classification and viscosity. CAUTION ,&
API service Be careful not to spill engine oil. If oil comes

Application Remarks into contact with the exhaust manifold or
Classification
other hot components, it could catch fire.
All engine
CD MIL-L-2104C Wipe up any oil that spills accidentally.
models
NOTE
Oil level gauge E0328
Use a type of engine oil that is appropriate for • Check the engine oil level on a level surface
the ambient temperature 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
1
'c c'F) 40(, ~o
40 (io4'F) ~ before checking the oil level. The oil will take E0041
30 /00 I !'i'e ~ <f' time to reach the oil pan, so the oil level
10 80 o'c (59"F) :: 30·c.
10
60 gauge may give an incorrectly low reading if Inspection
o 32 t3tF)@",=(Sbl)
a:::30..n
-10 20 0
o ,..., ~
lfJ""
~.
-:oC
the level is checked immediately.
1. Withdraw the oil level gauge and wipe it
-~~ -20 ~ 8 -'~·c (Z3·F)
- ;:;:; ~ (son clean.
c:cr
v)'-' 2. Fully insert the oil level gauge, then carefully
Engine starting temperature withdraw it again.
3. The engine oil adhering to the gauge should
E0238
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 Replace the engine oil after the first 60 hours Oil capacity
of operation. Thereafter, replace it every 250
1. Wipe the area around the oil filler cap to hours. Oil pan
prevent dust and dirt from entering the Approx. 27 dm 3{28.5 US qts.; 27 L}
engine. (engines for electric power generators)
CAUTION .it. Approx. 25 dm3{26.5 US qts.; 25 L}
2. Remove the oil filler cap and add oil as (engines for construction machinery)
required. Be careful not to spill engine oil. If oil comes
into contact with the exhaust manifold or Oil filter
3. Refit the oil filler cap. other hot components, it could catch fire. 4 to 4.5 dm3 {4.2 to 4.7 US qts.; 4 to 4.5 L}
Wipe up any oil that spills accidentally.
4. Wait 5 to 6 minutes, then check the oil level
using the oil level gauge. If the level is too NOTE
high, allow some oil to escape via the oil pan • Be careful not to pour too much oil into the
drain plug. engine.
• The engine oil can be drained quickly while it
is still warm soon after the engine has been
stopped.
-72-
1. Wipe the area around the oil filler cap to 5. Refit the drain plug securely, then supply the
prevent dust and dirt from entering the engine with oil via the oil filler.
engine. Then, remove the cap.
6. Crank the engine in accordance with the
2. Remove the oil pan drain plug and allow the procedure on ~: P.1B. Then, start the engine
oil to drain out. 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
Drain plug
checked immediately.
Drain plug
Drain plug
Oil filler cap Drain plug E0161
E0170
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
-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 Power Plant Clutch Bearing Case (Direct Clutch Fork Shaft and Clutch Shifter
Required grease type: Drive) Required grease type:
Wheel bearing grease [NLGI No.2 (Li soap)] Required grease type: Heat-resisting grease
Wheel bearing grease [NLGI No.2 (Li soap)] [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
E0173 E0172
Water pump Water pump NOTE
E0171 E0180 Excessive grease application can cause the
clutch to slip.
-74 -
..------~-~---~------------
---- -------------~
Main Specifications ...................................................................................76
-75-
Main Specifications
el 6D24-T 6D24-TC
6024
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
1473 x 866 x 1058 1473 x 881 x 1169 1473 x 881 x 1209
(with fan, without air cleaner) mm{in}
{58.0 x 34.1 x 41.7} {58.0 x 34.7 x 46.0} {58.0 x 34.7 x 47.6}
(total length x total width x total height)
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
1473 x 869 x 1246
(with fan, without air cleaner) mm {in}
{58.0 x 34.2 x 49.1}
(total length x total width x total height)
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.
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MEMO----------------------------------------------
-ffl-
~~~~--~---------------------- --- -----
Maintenance Manual
diesel engine
(for industrial use)
SC2
JANUARY 2003
MITSUBISHI FUSO TRUCK & BUS CORPORATION

MH998283 Maintenance Manual 6D24 - Jan 2003

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MH998283 Maintenance Manual 6D24 - Jan 2003

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J.. Maintenance Manual

Pub. No. MH998283

Applicable engine models:

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

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

LONG-TERM STORAGE .........................................................................Page 41

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

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

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

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

Contents Organized Visually According to Engine Parts

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

" ' - - - - Replacement of Oil Filter

Replacement of Engine Oil

Contents Organized Visually According to

Replacement of coolant and E0031

Inspection and Replenishment

E0034 E0019 E0035

E0036 E0349 07404 E0038

Contents Organized According to Component Names

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

Precautions for Operation

Inspection and Maintenance

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

) This section contains information, recommendations, and (

• Inspection and Maintenance

CAUTION it. WARNING it.

Before inspecting E0326

• Operation of New Engine • Battery

• Fuel Diesel Fuel Properties Fuel-Related Precautions

Things You Should Know for Safe Operation

• Engine Oil • Coolant

When tap water is used, it should have the

'e (r) 40c ~o pH 6 to 8

2.0 -go • (Sq"F) ~ '30·c.

-10 20 0 lfJ~ "'.

Engine starting temperature Use anti-rust additive in

• Reverse Operation of Engine • Fuel Leakage

if you hear a knocking sound

Things You Should Know for Safe Operation

• Radiator Cap • Filter Elements

• Normal Engine Operation

Coolant Temperature Gauge Battery Switch

lamp illuminates, the engine is close to

(Planned strage) ( Preparations for Storage)

This manual contains simple

Things You Should Know for Safe Operation

Make a note of the engine number.

It is stamped on the crankcase in the position

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

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

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

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

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

Check that the V-belts are free

For instructions on adjustment deflect by the following amount

• Coolant Level and Coolant Leakage

• Check the coolant level in the radiator or coolant tank.

Daily Inspections (Performed Before Operation)

Oil level gauge

If any abnormality was identified

For instructions on oil replenishment, see