MH998281 Maintenance Manual 6D16 - Jan 2003 PDF
MH998281 Maintenance Manual 6D16 - Jan 2003 PDF
MH998281 Maintenance Manual 6D16 - Jan 2003 PDF
Fuse
Maintenance Manual
diesel engine (for industrial use)
601
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:
6D14 6D16-T
6D14-T 6D16-TE
6D15-T 6D16-TL
6D16 6D16-TLE
6D16-E
MITSUBISHI FUSO TRUCK & BUS CORPORATION
© 2003 Mitsubishi Fuso Truck & Bus Corporation Printed in Japan
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.
MITSUBfSHI MOTORS
GENUINE PARTS
00008
THINGS YOU SHOULD KNOW FOR SAFE OPERATION Page 1
* 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
-1-
Contents
Dust Indicator
ffiP.59
Replenishment and Replacement of ---.,.
Coolant, and Flushing of
Cooling System
ffiP.64
-11-
Contents
E0327 E0031
Inspection and Dealing with Engine Problems Operation in Cold Weather CD P.35
Replenishment CD P.25
of Engine Oil
mp.73 - - - - '
Inspection and
Replacement of Coolant and Adjustment of
Flushing of Cooling System V-belt Tension
mp64 mp63
E0117
E0032 E0033
Operation in Hot Weather CD P.39 Long-Term Storage OJ P.41 Inspection of Exhaust Color CD P.55 Battery Maintenance OJ P.55
-111-
Contents
A G
ABNORMAL OIL PRESSURE 32 GEAR OIL 76
AIR CLEANER 57
L
B LONG-TERM STORAGE .41
BATTERY 37, 40, 55 LUBRICATION 77
BATTERY SWITCH 18, 22
o
C OIL FILTER 60
COOLANT 64 OIL LEVEL GAUGE 73
OPERATION IN COLD WEATHER 35
D OPERATION IN HOT WEATHER 39
DAILY INSPECTIONS (PERFORMED BEFORE OPERATION) 14 OVERHEATING 31
DEFECTIVE CHARGING OF BATIERY 30
DUST INDICATOR 59 P
PERIODIC INSPECTION AND MAINTENANCE SCHEDULE .45
E
EMERGENCY SHUTDOWN 33 R
ENGINE NUMBER 11 REVERSE OPERATION OF ENGINE 30
ENGINE OIL 73 RUNNING OUT OF FUEL (AIR BLEEDING) 34
EXHAUST COLOR OF ENGINE 55
S
F STARTER SWITCH 19, 22
FUEL .4
FUEL FILTER 62 V
FUSE 56 V-BELT 63
I W
INTERCOOLER 69 WATER SEPARATOR 62
-IV -
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
Engine Number 11
00006
-1-
Things You Should Know for Safe Operation
-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 60hours of operation),
operations that may create sparks near the
rectify the abnormality before • Donot rev theengine;
• Allow theengine to warm upfully before operation; battery.
restarting the engine.
• Make every effort to avoid overloading theengine.
WARNING .&.
If battery fluid splashes in your eyes,
immediately wash it out with plenty of
water and seek medical attention.
o
CAUTION .&.
Battery fluid contains sulfuric acid, so it can
E0057
bum 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 bum yourself when after the following operation hours 9[IJ P.55
have reached:
performing inspections.
Engineoil: first 60 hours
Transmission oil: first 250 hours
EOOO3
-3-
Things You Should Know for Safe Operation
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 2-0 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 usa 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-
Things You Should Know for Safe Operation
-5-
Things You Should Know for Safe Operation
)}
EO008 EOO09
¢OJ P.30
-6-
~----------------~--~-~-
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.
¢m P.5?-P.62
E0010
¢m P.6?
-7-
Things You Should Know for Safe Operation
If the coolant temperature Never turn OFF the battery switch while the
exceeds 95°C {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 100°C {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.
E0017
Ammeter For instructions on dealing with an overheated Starter Switch
engine, see OJ 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/cm2}) 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 OJ P.30 For instructions on dealing with oil pressure
abnormalities, see OJ P.32 E0018
-8-
~------------------~-~--~----
• Long-Term Storage
-9-
Things You Should Know for Safe Operation
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.
E0020
E0327
~m P.13
-10-
Things You Should Know for Safe Operation
• Engine Number
B0205D
-11-
MEMO----------------------------------------------
-12-
V-belt Tension 14
Fuel Level 15
-13-
Daily Inspections (Performed Before Operation)
The user should inspect the engine before starting it each day.
E0327
-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.
• Previously Identified
Abnormalities
-15-
MEMO---------------------------------------------
-16-
Starting the Engine 18
-17-
Starting and Stopping the Engine
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 .
1. Perform your daily inspections (Crank the engine after it has been stored for a long period.)
before starting the engine.
E0023
1. Operate the shutdown
mechanism to terminate
fuel injection and thereby
stop the engine.
Turn ON the battery switch. 2. Turn the starter switch to the
"8" position, then crank the
engine for approximately
15 seconds.
CAUTION &.
Never tum OFF the battery switch
while the engine is running. All
¢ E0042
-18-
Starting and Stopping the Engine
( Starting the engine in cold weather) Move the control lever to the starting position.
NOTE
Do not preheat the engine continuously for longer than the periods
shown below since this can drain the battery. When the engine starts, immediately move the control lever to the
Standard air heater: 60 seconds idling position. Allow the engine to warm up until the needle in the
Optional air heater and glow plugs: 30 seconds coolant temperature gauge starts to move.
-19-
Starting and Stopping 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.
to move.
~m 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.
EOO46
Do not rev the engine since it can lead to poor
operation and/or faults.
EOO47
Check that the engine operates without
abnormal noise, vibration, and smells.
-20-
Starting and Stopping the Engine
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.
Z06947
Check that the needle indicates a pressure of at
least 0.1 MPa {14 psi; 1.0 kgf/cm 2 } or is in the
green zone.
-21-
Starting and 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 OFF
(j
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
ON
is not stopped, it may seize or suffer a
severe fault within a few minutes. Also, E0108
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.
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-
Starting and Stopping the Engine
If the engine does not stop After shutting down the engine, clean it and
<6D16-TLE (with electronically- perform the following inspections:
controlled fuel injection pump»
• 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
Z06949 the coolant is not drained, it may freeze and
cause cracks and other problems in the
If the engine does not stop when the starter crankcase and cooling system.
switch is turned to the OFF position, stop it by
pulling the engine stop button. Return the button For instructions on draining the coolant,
to its original position when the engine has see rnP.68
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.
-23-
MEMO----------------------------------------
-~-
Causes and Remedies of Faults 26
Overheating 31
Emergency Shutdown
<Engines with Emergency Shutdown Mechanism> 33
-25-
Dealing with Engine Problems
(~--~)
Symptom ( Possible cause) (~--~)
Remedy
E0068
/ 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
EOO69
abnormality.
-26-
Dealing with Engine Problems
(~---)
Symptom ( Possible cause)
(~---=---)
Remedy
<o
o The idling speed is too low
o The fuel filter element is clogged
o The air cleaner element is clogged
Have the idling speed adjusted by your dealer.
Replace the fuel filter element. ~m P.62
Clean or replace the air cleaner element.
~m P.57
E0070
Abnormally low power o The fuel filter element is clogged Replace the fuel filter element. ~m P.62
o The air cleaner element is clogged Clean or replace the air cleaner element.
~m P.57
o The clutch is slippir.g 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.
EOO71
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. ~m P.67
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. ~m P.63
o The coolant contains accumulated rust or scale ....... Flush out the radiator or replace the coolant.
EOO34 ~m P.68
-27-
Dealing with Engine Problems
-28-
Dealing with Engine Problems
(~-~)
Symptom ( Possible cause)
(~----')
Remedy
o The oil level is too low Make sure the engine contains the correct
amount of oil. ¢[O P.73
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.
¢[O P.73
o The oil filter(s) is clogged (indicated by Replace the engine oil filter elements.
illumination of the oil filter warning lamp). ¢[O P.60
EOO74
E0075
-29-
Dealing with Engine Problems
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.
06987
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-
Dealing with Engine Problems
• Overheating
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.
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.
-31-
Dealing with Engine Problems
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'}
to stop the engine.
During normal operation, the oil
pressure should not drop
below 0.2 MPa {28 psi; NOTE
2.0 kgf/em'}.
If the engine is not stopped, its bearings and
other components may seize.
{~
pressure after allowing the engine to warm
up.
/ I \ E0014
-32-
Dealing with Engine Problems
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. ~m P.64
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
Checkthat 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
~a:: P.63 the vehicle inspected by your dealer.
A6253
Check the
engine oil level
and add oil if
the level is too
NOTE low.
The emergency shutdown mechanism is designed ~m P.73
to minimize engine damage. In the event of an E0041
emergency engine shutdown, identify and rectify
the abnormality before restarting the engine.
-33-
Dealing with Engine Problems
CAUTION it.
Wipe up any spilled fuel after refueling and After confirming that air
air-bleeding the fuel system. Also, check Loosen the knob on bubbles stop emerging,
carefully for fuel leakage since leaking fuel the priming pump. tighten the air bleeding
could cause a fire. plug.
E0353
E0217
-34-
Fuel 36
Engine Oil 36
Coolant. 37
Battery 37
-35-
Operation in Cold Weather
Recommended prevent rain and snow from entering the tank. Engine starting temperature
Engine operating conditions 90] P.4
fuel
E0238
Normal operation at temperatures ASTM 0-975
of -12°C (10°F) or higher Grade 2-0 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[IJ P.73
-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
NOTE
If antifreeze is not used, open the crankcase and radiator drain
E0007
cocks every time the engine is shut down and allow all the
coolant to drain out. If the coolant is not drained, it may freeze
and cause cracks.
• Battery
NOTE
To prevent the battery fluid from freezing, always charge the
battery after topping up the fluid and when the fluid's specific
E0076 gravity is extremely low.
-37-
MEMO----------------------------------------------
-~-
Battery .40
Engine Oil 40
Cooling System 40
-39-
Operation in Hot Weather
1
'C ('f) 40c ~o • Check frequently that the V-belts are
40 (Io4'F) ~ tensioned correctly and free of damage.
30 /00 15c. ~ «r»
20 80 o'c m"F) :, 30'c.
~~
60
10
o 32 '32'FJ
\ c:: ~ = <of) (86'F)
-)0 20 = U')C§:'j ,.,
0""''' --:>C
-~~
-
-20 ~ e
;:u ~
-I~'c lZ3"F)
(S'F)
=cr
V) ....
-40-
If the engine might be required for immediate use ..42
-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...
o
o
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
One month or shorter One to three months Three to six months Six months to one year
• 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
E0023
-44-
Inspection and Maintenance Intervals .46
-45-
Periodic Inspection and Maintenance Schedule
-46-
Periodic Inspection and Maintenance Schedule
NOTE:
[0]: Inspection interval specified by Mitsubishi Motors
[i:r]: Replacement interval specified by Mitsubishi Motors
Interval
~
::J
...
til ...
til
...
til
...
til ...
til
Inspection/maintenance item 0
s: ::J ::J ::J ::J
::J
0 Key points
0,.... 0 0
.r:.
0
.r:.
0
s: s:
s: It)
0
0 0
~ 0
<0 N
,.... It)
N
0
0
o.
'iij It)
,....
C
Ql
Security of cylinder head, manifolds, • Call your dealer.
c: 0 • No inspection is required for parts with bolts
Ql
.g) and mounting brackets
tightened by the "plastic zone tightening" method.
Ql
c:
'c, Compression pressure 0 • Call your dealer.
c:
w
Valve clearances 0 • Call your dealer.
-47-
Periodic Inspection and Maintenance Schedule
NOTE:
[0]: Inspection interval specified by Mitsubishi Motors
[*]: Replacement interval specified by Mitsubishi Motors
Interval
...
1Il
Inspection/maintenance item
::J
0
.c ...
1Il ...
1Il
::J
...
1Il
::J
...
1Il
::J
l!?
::J
0 Key points
::J
...
0 0
s:
0
.c
0
.c
0
s: .c
0
:2-
'(lj
C
0
CD ...
LO
C\I
0
LO
C\I
0
0
LO
0
q,
...
Oil leakage
(including inspection for hose damage/deterioration)
0 • Replace hoses every 3,000 hours or 2 years.
-
E
Q)
1Il
>-
1Il
I::
• *: With new engine only
• Oil pan capacity
Approx. 9.5 drn" {10 US qts.; 9.5 L}
0 (engines for electric power generators)
+J
III Approx. 16 drn' {17 US qts.; 16 L}
o Engine oil
'1:: * (engines for construction machinery)
.c Replacement
::J
...J
* * • See page 73 for instructions.
• Required oil type
<Non-turbocharged engine models>
API classification CC (MIL-L-21 048) or better
<All engine models>
API classification CD (MIL-L-21 04C) or better
-48-
-----------------------------_._-
NOTE:
[0]: Inspection interval specified by Mitsubishi Motors
b~]: Replacement interval specified by Mitsubishi Motors
Interval
l!!
Inspection/maintenance item 0
::::l
e::::l ...
/I)
...::::l
/I)
...
/I) ...
/I)
Fuel leakage
(including inspection for hose damage/deterioration)
0 • Replace hoses every 3,000 hours or 2 years.
Fuel level 0
-
E
Q)
/ I)
~
Q)
Replacement of fuel filter element (filter-paper type) 1<
• See page 62 for instructions.
• Perform air-bleeding.
::::l
LL
(See page 34 for instructions.)
-49-
Periodic Inspection and Maintenance Schedule
NOTE:
[0]: Inspection interval specified by Mitsubishi Motors
[1:r]: Replacement interval specified by Mitsubishi Motors
Interval
...::J
l/)
Inspection/maintenance item 0
~
...
l/) ...
l/)
::J
~
::J
~
::J
~
::J
0 Key points
::J 0
0 0 0 s:
,..
0
~
~ s: s: 0
LO 0 0
2-
'(ij
0
<0 ,..
C\I LO
C\I
0
LO
0
~
,..
C
Q) Drain water and sediment from fuel tank 0 • Perform every 500 hours or 6 months.
::J
u,
Injection timing 0 • Call your dealer.
Water leakage
0
(including inspection for hose damage/deterioration)
If FUSO ANTIFREEZE or
1:r
RADIPET 9 is used • Coolant volume (engine-proper only)
-
E
Q)
l /)
>-
l/)
Cl
Flush out
cooling system
and replace coolant If FUSO DIESEL
LONGLIFE COOLANT 2 years
Approx. 13 drn" {13.5 US qts.; 13 L}
• Flush out cooling system when coolant is
replaced.
• See page 64 for instructions.
.5
'0 is used
0
0
• Check deflection when belts are pressed in center
V-belt looseness/damage 0 with force of approx. 98 N {22 Ibf; 10 kgf}.
• See page 63 for instructions.
-50-
Periodic Inspection and Maintenance Schedule
NOTE:
[0]: Inspection interval specified by Mitsubishi Motors
[1r]: Replacement interval specified by Mitsubishi Motors
Interval
l!!
Inspection/maintenance item
::::J
0
.I::.
...
III e::::J ...
III
::::J
...::::J
III l!!
::::J
0 Key points
::::J 0 0 0
0 .I::.
,..
0
.I::. .I::. .I::. .I::.
0
LO 0 0
~ 0
CD ,..
C\l LO 0
0
q,
'iii C\l LO ,..
0
Coolant level 0
-
E
Q)
III
>.
III
01
Radiator
Cap functionality
Core clogging/damage
0
0
• If core is severely clogged, wash it irrespective of
inspection interval.
,5
(5
0
o • See page 77 for instructions.
Lubrication of water pump 0 • Required grease type
Wheel bearing grease [NLGI No.2 (Li soap)]
-
0
'I:
0
Q)
m Loose wiring connections and
of tenninals
0
0
loose/damaged insulation
-51-
Periodic Inspection and Maintenance Schedule
NOTE:
[0]: Inspection interval specified by Mitsubishi Motors
b~]: Replacement interval specified by Mitsubishi Motors
Interval
...
Vl
e::l
Inspection/maintenance item
::l
0
J::
...
Vl ...
Vl
::l
...
Vl
::l
...
Vl
::l 0 Key points
::l 0 0 0
0 0 J::
,.... J:: J:: J:: J::
0
LO 0 0
~ 0
co C\l
,.... LO 0
0
q,
'(ij C\l LO ,....
0
Operation of emergency engine shutdown device 0 • Call your dealer for adjustments.
-52-
Safety Precautions 54
Battery Maintenance 55
Inspection of Intercooler 69
-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.
-54-
Simple Inspection and Maintenance
• Inspection of Exhaust Color • Battery Maintenance Inspect and top up the battery fluid
every 125 hours or two weeks
DANGER .& (once a week in summer).
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
gas color. ~_ _- _ -
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 (0.39 to
combustion) with soap and plenty of water. 0.59 in) above 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-
Simple Inspection and Maintenance
• Replacement of Preheating
Circuit Fuse
-56-
Simple Inspection and Maintenance
~p
Marks showing
Clamp ~ooaliqnrnent Clarrp
"Q~
Outer element
~~~D",
Element
D"'M~~
Dust indicator
Element
Wing nut
(with gasket)
Outer element
Inner element
-57-
Simple Inspection and Maintenance
Cartridge type Cleaning Procedure 2. Check the extent to which the element is
contaminated, then clean the element as
&.
©
U - A i r cleaner
CAUTION
NOTE
• Do not remove the inner element of a double-
Blow clean compressed air
along the pleats from the
inside of the element.
Replace the
element if the Mer
paper has small
holes. badly abraded
areas, or other damage
and/or the seal is
damaged.
E0219
-58- E0082
Simple Inspection and Maintenance
4. Clean the dust cup and baffle. Cartridge Type Dust Indicator
Loosen the wing nut to remove the baffle.
CAUTION .&. .....--::iClli;:::;~- Reset button
E0083
-59-
Simple Inspection and Maintenance
Be careful not to spill engine oil. If oil comes 3. Remove the element assembly by turning it in
into contact with the exhaust manifold or the direction of the arrow in the drawing. If it is
other hot components, it could catch fire.
Wipe up any oil that spills accidentally.
, •
v Mark
NOTE
To avoid damaging the element, be careful not
Mark
T;ghten~ 4. Prepare a genuine Mitsubishi replacement
element assembly.
DrainPIUg~
to overtighten the element assembly. '"Tighten Lightly smear the element assembly's gasket
iii>
1t
'''-,
Drain valve
Filter head
Air plug
E0355
Drain valve E0356 E0357
6. Start the engine and check for oil leakage.
-60-
Simple Inspection and Maintenance
Center bolt
(tightening torque:
<Replaceable Element type> 49to 59 Nrn 2. Remove the drain valve and then the air plug
{36 to 43 tt.lbs,
5 to 6 kgf'm}) ~ to allow the oil to drain out.
CAUTION .&. 1f £)-""" Air plug
other hot components, it could catch fire. 4. Wash all parts except the element in solvent.
O-ring
Wipe up any oil that spills accidentally.
• To avoid causing a fire, never smoke or use
Spring - blJ 5. Discard the old element, and prepare a
a lighter or other flame while washing genuine Mitsubishi replacement element. The
Element--U
components in solvent. O-ring must also be replaced with a new one.
Drainvalve E0131
-67 -
Simple Inspection and Maintenance
Mating marks
Drain plug
Gasket 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.
E0358
-62-
Simple Inspection and Maintenance
Mounting bolt
E0218 Z07248
1.Slightly loosen the alternator's upper and 1. Slightly loosen the alternator's upper and
lower mounting bolts. lower mounting bolts.
2. Using a wrench handle or similar implement 2. Screw in or out the adjusting bolt to adjust the
as a lever, change the alternator's mounting belt tension. Turning the bolt clockwise
position to adjust the belt tension. increases the tension.
B6522A
3. Securely tighten the alternator's mounting
NOTE bolts.
• Keep the V-belts free of oil and grease.
Contact with these substances can make the NOTE
belts slip and shorten their service life. • Be careful not to damage the stator coils and
• When replacement is necessary, replace both through bolts when moving the alternator.
V-belts at the same time.
-63-
Simple Inspection and Maintenance
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
RADIPET9 except 500 hours
(color: red) cold seasons inhibitor. In warm weather, the use of coolant
FUSO DIESEL containing antifreeze makes the engine prone
LONGLIFE COOLANT All seasons 2 years to overheating.
(color: yellow)
CAUTION .&
Remember that the coolant replacement
interval depends upon the additive used.
00634
-64-
Simple Inspection and Maintenance
Determine the correct concentration of FUSO RADIPET 9 should be added to the coolant at a
ANTIFREEZE in accordance with the lowest concentration of 5 %.
temperature at which the engine is to be used.
See the following table.
Lowest temperature
Concentration (%)
(OC ("F})
-10 {14} or hiqher 30
-15 {5} 35
-20 {-4} 40 00635
-25 {-13} 45
-30 {-22} 50
-35 {-31} 55
-40 {-40} 60
-65-
Simple Inspection and Maintenance
-66-
Simple Inspection and Maintenance
(~-----=------~)
Adding Coolant Radiatorcap
-67-
Simple Inspection and Maintenance
Flush out the cooling system and replace the Radiator 1. Remove the radiator cap, then loosen the
coolant at the following intervals: drain plug on the engine and radiator and
With FUSO ANTIFREEZE or RADIPET 9: allow the coolant to drain out.
500 hours
With FUSO DIESEL LONGLIFE COOLANT: 2. Pour soft water (preferably hot) into the
2 years radiator.
-68-
Simple Inspection and Maintenance
• Inspection of Intercooler
8. Securely fit the radiator cap. <6D16-TL,6D16-TLE>
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):
NOTE
To avoid damaging the intercooler core, clean it
with a soft brush. Do not use any sharp or hard
implement.
-69-
MEMO----------------------------------------------
-ro-
Engine Oil 73
Gear OiL 76
Lubrication 77
-71-
Lubricant Replacement and Maintenance
NOTE
To ensure optimal performance and a long
service life, always use lubricants of the
specified type.
-72-
Lubricant Replacement and Maintenance
• Engine Oil
-10
10~
o 60 '3'tF)
32
20
\
=
0'":'
a: ~
<.J')~
=
<J>
.. "
(go"F)
the level is checked immediately. clean.
2. Fully insert the oil level gauge, then carefully
o -.~ -";)C withdraw it again.
-~~ -20 ~8 -I':l°c (Z3°F)
- ;:u ~ (S"n 3. The engine oil adhering to the gauge should
=er
V'> .... be within the indicated range. If the level is
Enginestarting temperature too low, add oil of the specified type. If the oil
on the gauge is extremely dirty, the engine oil
E0238
must be replaced.
-73-
Lubricant Replacement and Maintenance
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. 9.5 drn" {10 US qts.; 9.5 L}
engine. (engines for electric power generators)
CAUTION & Approx. 16 drn" {17 US qts.; 16 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
For increased convenience, the engines for other hot components, it could catch fire. Approx. 2.1 drn" {2.2 US qts.; 2.1 L}
certain applications are provided with Wipe up any oil that spills accidentally. (Spin-on type A, B)
additional oil fillers on their right sides as Approx. 2.3 dm' {2.5 US qts.; 2.3 L}
shown in the figure. NOTE (Spin-on type C, Replaceable element type)
• Be careful not to pour too much oil into the
3. Refit the oil filler cap. engine. Spin-on Type
• The engine oil can be drained quickly while it
4. Wait 5 to 6 minutes, then check the oil level is still warm soon after the engine has been <Type A>
using the oil level gauge. If the level is too stopped.
high, allow some oil to escape via the oil pan
drain plug.
E0359
-74-
Lubricant Replacement and Maintenance
<Type B> Center Bolt Securing Type <Center bolt securing type>
• Gear Oil
Specified oil:
Gear Oil
[API classification GL-3 (MIL-L-21 05)]
('-------~)
Inspect the gear oil every 250 hours. Replace the gear oil after the first 250 hours
then every 500 hours.
-76-
Lubricant Replacement and Maintenance
• Lubrication
Water Pump Power Plant Clutch Bearing Case (Direct Clutch Fork Shaft
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]
(~----~)
Lubrication interval: 500 hours
(~----~)
Lubrication interval: 1,000 hours
(~-----)
Lubrication interval: 1,000 hours
c _
~
r
/~
I
,
I
E0221
E0137 NOTE
Excessive grease application can cause the
clutch to slip.
-77-
MEMO----------------------------------------------
-ro-
Main Specifications 80
-79-
Main Specifications
Item
~I 6D14
6D14-T
(Turbocharged)
6D15-T
(Turbocharged)
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} 110 x 115{4.33 x 4.53} 110 x 115 {4.33 x 4.53} 113 x 115 {4.45 x 4.53}
Total displacement dm' {eu-in ; L} 6.557 {400, 6.557} 6.557 {400, 6.557} 6.919 {422, 6.919}
Combustion chambers Direct injection type Direct injection type Direct injection type
Compression ratio 17.5 16 17.5
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 Honeywell T04B or
- Honeywell T04B type
Mitsubishi TF07 type
Engine dimensions
1145 x 731 x 825 1145 x 731 x 825 1245 x733 x 825
(with fan, without air cleaner) mm{in}
(45.1 x 28.8 x 32.5) {45.1 x 28.8 x 32.5} {49.0 x 28.9 x 32.5}
(total length x total width x total height)
Dry weight kg {Ibf} 500 {1103} 540 {1191} 540{1191}
Fuel Diesel fuel Diesel fuel Diesel fuel
Fuel injection pump Bosch type PES6A Bosch type PES6A Bosch type PES6A
Governor Centrifugal, mechanical Centrifugal, mechanical Centrifugal, mechanical
type allspeed control type allspeed control type ailspeed 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) CC 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 kW 24 V-5 kW 24 V-5 kW
Alternator 24 V-35A 24 V -35 A 24 V - 35 A
-80-
Main Specifications
el 6D16-T,6D16-TE 6D16-TL
6D16, 6D16-E
Item (Turbocharged) (Turbocharged with Intercooler)
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} 118 x 115 {4.65 x 4.53} 118 x 115 {4.65 x 4.53} 118 x 115 {4.65 x 4.53}
Total displacement dm' {cu-in ; L} 7.545 {460, 7.545} 7.545 {460, 7.545} 7.545 {460, 7.545}
Combustion chambers Direct injection type Direct injection type Direct injection type
Compression ratio 17.5 <6D16>, 19 <6D16-E> 16 16
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 Honeywell T04B or
- Honeywell T04E type
Mitsubishi TF07 type
Engine dimensions
1245 x 731 x 815 1308 x 731 x 830 1256 x 731 x 932
(with fan, without air cleaner) mm{in}
(49.0 x 28.8 x 32.1) {51.5 x 28.8 x 32.7} {49.4 x 28.8 x 36.7}
(total length x total width x total height)
Dry weight kg {Ibf} 500 {1103} 550 {1213} 560 {1235}
Fuel Diesel fuel Diesel fuel Diesel fuel
Fuel injection pump Bosch type PES6A Bosch type PES6AD Bosch type PES6AD
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) CC 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 kW 24 V-5 kW 24 V - 5 kW
Alternator 24 V -35 A 24 V - 35 A 24 V -35 A
-87 -
Main Specifications
el 6D16-TLE
Item (Turbocharged with Intercooler)
Type Diesel, 4-cycle, water-cooled
Number and configuration of cylinders. 6 in-line
Bore x stroke mm{in} 118 x 115 {4.65 x 4.53}
Total displacement dm3 {cu-in ; L} 7.545 {460, 7.545}
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
Honeywell TBP4
Engine dimensions
1321 x 799 x 991
(with fan, without air cleaner) mm{in}
{52.0 x 31.5 x 39.0}
(total length x total width x total height)
Dry weight kg {Ibf} 560 {1235}
Fuel Diesel fuel
Fuel injection pump Bosch type PES6MD
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 kW
Alternator 24 V -35 A
-82-
Maintenance Manual
diesel engine
(for industrial use)
SC1
JANUARY 2003