Mitsubishi Heavy Industries L Maintance Manual
July 2009
Pub. No. 99610-15140
The operator and supervisor are requested to read this Oper-
ation and Maintenance Manual carefully before operating the
engine or conducting inspection and maintenance.
Never operate the engine or conduct maintenance work with-
out completely understanding this manual.
OPERATION &
MAINTENANCE MANUAL
199610-15140
i
INTRODUCTION
This operation and maintenance manual contains detailed operation, inspection
and maintenance information for engines from Mitsubishi Heavy Industries, Ltd.
Please read this manual thoroughly before proceeding with operation, inspection,
and maintenance work for correct use and servicing.
Failure to follow directions in this manual may result in serious accidents.
ii
FOREWORD
Limited warranty
Mitsubishi Heavy Industries, Ltd. will repair or replace parts returned to us when we judges that the parts are defec-
tive in material and/or workmanship after conducting inspection.
Mitsubishi Heavy Industries, Ltd.'s warranty is limited to the compensation work of repair or replacement of parts.
The warranty coverage is effective for the original purchaser only. Those to whom ownership is later transferred are
not provided with the warranty.
Mitsubishi Heavy Industries, Ltd.'s makes no warranties, either expressed or implied,
except as provided in this manual, including, but not limited to, warranties as to marketability , merchantability, fitness for a p articular purpose or use, or against infringement of
any patent.
Mitsubishi Heavy Industries, Ltd. will not be liable for any damages or consequential
damages, including, but not limited to, damages or other cost s resulting from any abuse,
misuse, misapplication of the engine and devices supplied from us.
Mitsubishi Heavy Industries, Ltd. will not be liable for any damages or personal injuries
resulting from any modification, without our written permission, of the engine and
devices supplied from us.
Mitsubishi Heavy Industries, Ltd. will not be li able for any damages or production losses
caused by the use of fuel, engine oil and/or long life coolant (LLC) that we are not recommended.
The owner of the engine is responsible for the p erf orm ance of th e r equir ed maint enan ce
listed in this operation manual.
Mitsubishi Heavy Industries, Ltd. may deny the warranty coverage if the engine or part
has failed due to inadequate or improper maintenance.
iii
FOREWORD
Emission warranty
Warranty coverage
Mitsubishi Heavy Industries, Ltd. warrants to the first owner and each subsequent purchaser of a new non-road die-
sel engine that the emission control system of your engine:
is designed, built and equipped so as to conform at the time of sales with all applicable regulation of the U.S. Envi-
ronmental Protection Agency.If the vehicle in which the engine is installed is registered in the state of California, a
separate California emission regulation also applies.
is free from the defects in material and workmanship which will cause the engine to fail to meet these regulations
within the warranty period.
Then its warranty period is
The emission warranty period is shown below.
However, if your engine warranty period is longer than the emission warranty period, the emission warranty period
extends to same as the engine warranty period.
Below warranty period shall begin on the date the engine is delivered to the first owner.
Warranted parts
Mitsubishi Heavy Industries, Ltd. warrants the parts which will increase the emission of pollutants when they
become defective.
The followings are examples.
Inlet/Exhaust manifold
Crankcase ventilation system
Fuel system
Fuel injection nozzle
LIMITED WARRANTY
Refer to "LIMITED WARRANYT".
The following warranty applies to the engines that are approved of the emission regulation of the U.S. Environ-
mental Protection Agency.
If your engine is certified as
And its maxi-
mum power is
And its rated speed is Then its warranty period is
Variable speed or constant
speed
kW < 19 Any speed
1,500 hours or 2 years, whichever
comes first.
Constant speed 19 ≤ kW < 37
3800 min
-1
or more
1,500 hours or 2 years, whichever
comes first.
Constant speed 19 ≤ kW < 37
Less than 3000 min
-1
3000 hours or 5 years, whichever
comes first.
Variable speed 19 ≤ kW < 37 Any speed
3000 hours or 5 years, whichever
comes first.
Variable speed or constant
speed
kW ≥ 37 Any speed
3000 hours or 5 years, whichever
comes first.
iv
FOREWORD
California emission control warranty statement
your warranty rights and obligations
The California Air Resources Board (CARB) is pleased to explain the emission control system warranty on
you 2008 or later engine.In California, new heavy-duty off-road engines must be designed, built, and equipped to
meet the State's stringent anti-smog standards.Mitsubishi Heavy Industries, Ltd. must warrant the emission control
system on your engine for the periods of time listed below provided there has been no abuse, neglect or improper
maintenance of your engine.
Your emission control system may include parts such as the fuel-injection system and the air induction system. Also
included may be hoses, belts, connectors and other emission-related assemblies.
Where a warrantable condition exists, Mitsubishi Heavy Industries, Ltd. will repair your heavy-duty off-road engine
at no cost to you including diagnosis, parts, and labor.
MANUFACTURER'S WARRANTY COVERAGE:
The 2008 and later heavy-duty off-road engines are warranted for the Warranty Period. If any emission-related part
on your engine is defective, the part will be repaired or replaced by Mitsubishi Heavy Industries, Ltd.
OWNER'S WARRANTY RESPONSIBILITIES:
As the heavy-duty off-road engine owner, you are responsible for the performance of the required maintenance
listed in your owner's manual.Mitsubishi Heavy Industries, Ltd. recommends that you retain all receipts covering
maintenance on your heavy-duty off-road engine, but Mitsubishi Heavy Industries, Ltd. cannot deny warranty
solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.
As the heavy-duty off-road engine owner, you should however be aware that Mitsubishi Heavy Industries, Ltd. may
deny you warranty coverage if your heavy-duty off-road engine or a part has failed due to abuse, neglect, improper
maintenance or unapproved modifications.
Your engine is designed to operate on diesel fuel only. Use of any other fuel may result in your engine no longer
operating in compliance with California's emissions requirements.
You are responsible for initiating the warranty process. The Air Rexources Board suggests that you present your
heavy-duty off-road engine to a Mitsubishi Heavy Industries, Ltd. dealer or distributor dealer as soon as problem
exists. The warranty repairs should be completed by the dealer or distributor as expeditiously as possible.
If you have any questions regarding your warranty rights and responsibilities, you should contact Mitsubishi
Engine North America at 1-630-268-0750.
The following warranty applies to the engines that are approved of the emission regulation of the California Air
Resources Board (CARB).
v
FOREWORD
Warranty coverage
(a) The warranty period shall begin on the date the engine or equipment is delivered to an ultimate purchaser.
(b) Mitsubishi Heavy Industries, Ltd. warrants to the ultimate purchaser and each subsequent purchaser of the en-
gine registered in the state of California that the engine is:
(1) Designed, built and equipped so as to conform with all applicable regulations adopted by the Air Resources
Board.
(2) Free from defects in materials and workmanship which cause the failure of a warranted part to be identical
in all material respects to the parts as described in Mitsubishi Heavy Industries, Ltd.'s application for certifi-
cation for a period of 5 years or 3,000 hours of operation, whichever occurs first. In the absence of a device
to measure hours of use, the engine shall be warranted for a period of 5 years. For all engines rated less
than 19kW, and for constant-speed engines rated under 37 kW with rated speeds higher than or equal to
3,000 min
-1
, the period of 2 years or 1,500 hours of operation, whichever occurs first, shall apply. In the ab-
sence of a device to measure hours of use, the engine shall be warranted for a period of 2 years.
(c) The warranty on emission-related parts shall be interpreted as follows:
(1) Any warranted part which is not scheduled for replacement as required maintenance in the written instruc-
tions required by Subsection (e) shall be warranted for the warranty period defined in Subsection (b) (2). If
any such part fails during the period of warranty cove rage, it shall be repaired or replaced by Mitsubishi
Heavy Industries, Ltd. according to Subsection (4) below. Any such part repaired or replaced under the war-
ranty shall be warranted for the remaining warranty period.
(2) Any warranted part which is scheduled only for regular inspection in the written instructions required by Sub-
section (e) shall be warranted for the warranty period defined in Subsection (b) (2). A statement in such writ-
ten instructions to the effect of "repair or repla ce as necessary" shall not reduce the period of warranty
coverage. Any such part repaired or replaced under the warranty shall be warranted for the remaining war-
ranty period.
(3) Any warranted part which is scheduled for replacement as required maintenance in the written instructions
required in Subsection (e) shall be warranted for the period of time prior to the first scheduled replacement
point for that part.If the part fails prior to the first scheduled replacement, the part shall be repaired or re-
placed by Mitsubishi Heavy Industries, Ltd. accordi ng to Subsection (4) below. Any s uch part repaired or
replaced under warranty shall be warranted for the remainder of the period prior to the first scheduled re-
placement point for the part.
(4) Repair or replacement of any warranted part under the warranty provisions shall be performed at no charge
to the owner at a warranty station.
(5) Notwithstanding the provisions of Subsection (4) above, warranty services or repairs shall be provided at all
Mitsubishi Heavy Industries, Ltd. distribution centers that are franchised to service the subject engines.
(6) The owner shall not be charged for diagnostic labor that leads to the determination that a warranted part is
in fact defective, provided that such diagnostic work is performed at a warranty station.
(7) Mitsubishi Heavy Industries, Ltd. shall be liable for damages to other engine components proximately caused
by failure under warranty of any warranted part.
(8) Throughout the engine's warranty period defined in Subsection (b) (2), Mitsubishi Heavy Industries, Ltd. shall
maintain a supply of warranted parts sufficient to meet the expected demand for such parts.
(9) Any replacement part may be used in the performance of any maintenance or repairs and must be provided
without charge to the owner. Such use shall not reduce the warranty obligations of Mitsubishi Heavy Indus-
tries, Ltd..
vi
FOREWORD
(10) Add-on or modified parts that are not exempted by the Air Resources Board may not be used. The use o f
any non-exempted add-on or modified p arts shall be grounds for disallowing a warranty claim. Mitsubishi
Heavy Industries, Ltd. shall not be liable to warrant failures of warranted parts caused by the use of a non-
exempted add-on or modified part.
(11) The Air Resources Board may request and, in such case, Mitsubishi Heavy Industries, Ltd. shall provide,
any documents which describe that Mitsubishi Heavy Industries, Ltd.'s warranty procedures or policies.
(d) Warranted parts list.
(1) Fuel metering system
(A) Fuel injection system.
(B) Air/fuel ratio feedback and control system.
(C) Cold start enrichment system.
(2) Air induction system
(A) Controlled hot air intake system.
(B) Intake manifold.
(C) Heat riser valve and assembly.
(D) Turbocharger/supercharger systems.
(E) Charged air cooling systems.
(3) Exhaust gas recirculation (EGR) system
(A) EGR valve body, and carburetor spacer if applicable.
(B) EGR rate feedback and control system.
(4) Air injection system
(A) Air pump or pulse valve.
(B) Valves affecting distribution of flow.
(C) Distribution manifold.
(5) Catalyst or thermal reactor system
(A) Catalytic converter.
(B) Thermal reactor.
(C) Exhaust manifold.
(6) Particulate controls
(A) Traps, filters, precipitators, and any other devices used to capture particulate emissions.
(B) Regenerators, oxidizers, fuel additive devices, and any other devic e used to regenerat e or aid in the
regeneration of the particulate control device.
(C) Control device enclosures and manifolding.
(D) Smoke puff limiters.
(7) Advances oxides of nitrogen (NOx) controls
(A) NOx absorbers.
(B) Lean NOx catalysts.
(C) Selective catalyst reduction.
(D) Reductant (urea/fuel) containers/dispensing systems.
(8) Positive crankcase ventilation (PCV) system
(A) PCV valve.
(B) Oil filler cap.
vii
FOREWORD
(9) Miscellaneous items used in above systems
(A) Vacuum, temperature, and time sensitive valves and switches.
(B) Electronic control units, sensors, solenoids, and wiring harnesses.
(C) Hoses, belts, connectors, assemblies, clamps, fittings, tubing, sealing gaskets or devices, and mount-
ing hardware.
(D) Pulleys, belts and idlers.
(E) Emission control information labels.
(F) Any other part with the primary purpose of reducing emissions or that can increase emission during fail-
ure without significantly degrading engine performance.
(e) Mitsubishi Heavy Industries, Ltd. shall furnish with each new engine written instructions for the maintenance and
use of the engine by the owner.
LIMITED WARRANTY:
Refer to "LIMITED WARRANTY".
viii
FOREWORD
Important information
To avoid the potential hazard, accident prevention
activities must be planned methodically and con-
ducted continually by considering all aspect of
engine operation, maintenance and inspection.All
related personnel, including managers and supervi-
sors, should actively participate, recognize their roles
and organize themselves and their work to ensure a
safe environment.
The foremost safety objective is to prevent accidents
which may result in injury or death, or equipment
damage.
Always observe laws or regulations of the local or
federal/national government.
Mitsubishi Heavy Industries, Ltd. cannot foresee all
potential dangers of the engine, potential danger
resulting from human error and other causes, or dan-
ger caused by a specific environment in which the
engine is used. Since there are many actions that
cannot be performed or must not be performed, it is
impossible to indicate every caution in this manual or
on warning labels. As such, it is extremely important
to follow directions in this manual and also to take
general safety measures when operating, maintain-
ing and inspecting the engine.
When the engine is used by individuals whose native
language is not English, the customer is requested to
provide thorough safety guidance to the opera-
tors.Also add safety, caution and operating signs that
describe the original warning label statements in the
native language of the operators.
The engine must be operated, maintained and
inspected only by qualified persons who have thor-
ough knowledge of engines and their dangers and
who also have received risk avoidance training.
To prevent an accident, do not attempt to carry out
any operation other than those described in this man-
ual, and do not use the engine for any unapproved
purpose.
When the ownership of the engine is transferred, be
sure to provide this manual with the engine to the
new owner. Also inform Mitsubishi Heavy Industries,
Ltd. of the name and address of the new owner of the
engine.
This manual is copyrighted and all rights are
reserved.No part of this manual, including illustra-
tions and technical references, may be photocopied,
translated, or reproduced in any electronic medium
or machine readable form without prior written con-
sent from Mitsubishi Heavy Industries, Ltd.
The contents in this manual are subject to change at
any time without notice for improvement of the
engine.
Pictures or illustrations of the product in this manual
may differ from those of product you have. Please
note that, depending on specifications, items
described in this manual may differ from those on
your engine in shape, or may not be installed on your
engine.
Please contact a dealer of Mitsubishi Heavy Indus-
tries, Ltd. if you need more information or if you have
any questions.
If you lost or damaged this manual, obtain a new
copy at a dealer of Mitsubishi Heavy Industries, Ltd.
as soon as possible.
Mitsubishi Heavy Industries, Ltd. recommends the
engine owner to install an hour meter on the engine
due to monitor correct running intervals and to per-
form the maintenance at the appropriate timing.
ix
FOREWORD
Wa rning indication
The following means are used to call the attention of the operators and maintenance personnel to potential dangers
of the engine.
Warning statements in the manual
Warning labels affixed on the engine
Warning statements
The warning statements in this manual describe potential danger in operating, inspecting or maintaining the engine,
using the following 5 classifications to indicate the degree of potential hazard.
Failure to follow these directions could lead to serious accidents which could result in personal injury, or death in
the worst case.
Understand the directions well, and handle engines with following directions.
Indicates an immediately hazardous situation which, if not avoided, will result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury.
Indicates a potentially hazardous situation which, if not avoided, may result in property
damage.
Note : Indicates important information or information which is useful for engine operation.
x
FOREWORD
Units of measurement
Measurements are based on the International System of Units (SI), and they are converted to the metric system
units in this manual using the following conversion rates.
Pressure :1 MPa = 10.197 kgf/cm
2
Torque :1 N·m = 0.10197 kgf·m
Force :1 N = 0.10197 kgf
Horsepower :1 kW = 1.341 HP = 1.3596 PS
Meter of mercury :1 kPa = 0.75 cmHg
Meter of water :1 kPa = 10.197 cmH
2O(cmAq)
Engine speed :1 min
-1
= 1 rpm
Kinetic viscosity:1 mm
2
/s = 1 cSt
Abbreviations, standards and others
API = American Petroleum Institute
ASTM = American Society for Testing and Materials
ISO = International Organization for Standardization
JIS = Japanese Industrial Standards
LLC = Long Life Coolant
MIL = Military Specifications and Standards
MSDS = Material Safety Data Sheet
SAE = Society of Automotive Engineers
CONTENTS-1
CONTENTS
Chapter 1
BASIC SAFETY PRECAUTIONS
Fire and explosions .............................1-1
Keep flames away............................................ 1-1
Keep engine surrounding area tidy and clean.. 1-1
Care for fuel, oil and exhaust gas leakage....... 1-1
Use explosion-proof lighting apparatus............ 1-1
Prevent electrical wires from short-circuiting.... 1-1
Keep fire extinguishers and a first-aid kit
handy ............................................................... 1-1
Stay clear of all rotating and moving
parts ....................................................1-2
Install protective covers around rotating parts . 1-2
Check work area for safety .............................. 1-2
Stay clear of moving parts while engine is
running ............................................................. 1-2
Lockout and tagout .......................................... 1-2
Keep engine stopped during servicing............. 1-2
Always restore engine turning tools after use .. 1-2
Changing the engine speed setting is
prohibited ......................................................... 1-2
Be careful of exhaust fume
poisoning .............................................1-3
Operate engine in a well-ventilated area.......... 1-3
Be careful of falling down ....................1-3
Lift engine carefully .......................................... 1-3
Do not climb onto the engine ........................... 1-3
Always prepare stable scaffold ........................ 1-3
Protect ears from noise .......................1-4
Wear ear plugs................................................. 1-4
Be careful of burns ..............................1-4
Do not touch the engine during or
immediately after operation.............................. 1-4
Do not open the radiator filler cap when the
engine is hot..................................................... 1-4
Do not touch high pressure injection fuel ......... 1-4
Refill coolant only after the coolant temperature
dropped ............................................................ 1-4
Be careful when handling fuel, engine
oil or LLC .............................................1-5
Use only specified fuel, engine oil and LLC ..... 1-5
Handle LLC carefully........................................ 1-5
Proper disposal of waste oil, LLC and
coolant ............................................................. 1-5
When abnormality occurs....................1-5
Do not add coolant immediately after a
sudden stop due to overheating....................... 1-5
Avoid immediate restart after abnormal stop.... 1-5
Avoid continuous engine operation at low oil
pressure ........................................................... 1-5
If belt breaks, stop engine immediately ............ 1-5
Service battery .................................... 1-6
Handle the battery correctly ............................. 1-6
Other cautions..................................... 1-7
Never modify engine ........................................ 1-7
Observe safety rules at work site ..................... 1-7
Work clothing and protective gear.................... 1-7
Never break seals ............................................ 1-7
Perform all specified pre-operation inspections
and periodic inspections................................... 1-7
Break-in the engine .......................................... 1-7
Warm up the engine before use....................... 1-7
Never operate the engine in an overloaded
condition........................................................... 1-7
Conduct cooling operation before stopping
the engine ........................................................ 1-8
Protection of the engine against water entry.... 1-8
Conduct proper maintenance of air cleaner ..... 1-8
Use of tools optimum for each work................. 1-8
Avoidance of prolonged time of starter
operation .......................................................... 1-8
Do not turn off the battery switch during
operation .......................................................... 1-8
Cautionary instructions for transporting the
engine .............................................................. 1-8
Chapter 2
NAME OF PARTS
Engine external diagrams ................... 2-1
Equipment and instrument .................. 2-3
Starter switch ................................................... 2-3
Preheat indicator .............................................. 2-3
Water temperature meter and thermo unit ....... 2-4
Ammeter........................................................... 2-4
Hour meter ....................................................... 2-4
Stop solenoid ................................................... 2-5
Engine protection devices................... 2-6
Oil pressure switch ........................................... 2-6
Thermo switch .................................................. 2-6
Air cleaner indicator ......................................... 2-6
CONTENTS-2
CONTENTS
Chapter 3
OPERATION
Preparations for operation...................3-1
Engine external - Inspect ................................. 3-1
Battery electrolyte level - Inspect ..................... 3-1
Fuel tank oil level - Check ................................ 3-2
Engine oil level - Check.................................... 3-2
Coolant level - Check ....................................... 3-3
Starting ................................................3-4
Automatic glow plug......................................... 3-4
Manual glow plug ............................................. 3-4
Warm up operation..............................3-5
Checking engine oil pressure........................... 3-5
External inspection during warm up ................. 3-5
Operation.............................................3-6
Cautions when operating ................................. 3-6
Inspection during operation.............................. 3-6
Stopping ..............................................3-7
Inspection after stopping .................................. 3-7
Chapter 4
FUEL
Recommended fuel .............................4-1
Handling fuel........................................4-1
Chapter 5
ENGINE OIL
Recommended engine oil....................5-1
Selection of oil viscosity.......................5-1
Handling engine oil ..............................5-1
Engine oil performance requirements..5-2
Engine oil deterioration mechanisms...5-2
Definition of properties of engine oil ....5-3
Viscosity ........................................................... 5-3
Total base number ........................................... 5-3
Total acid number ............................................ 5-3
Water content................................................... 5-3
Flash point........................................................ 5-3
Insoluble........................................................... 5-3
Service Limits of engine oil..................5-4
Chapter 6
COOLANT
Recommended water for coolant ........ 6-1
Long life coolant (LLC)........................ 6-1
Genuine LLC....................................... 6-1
Other brand LLCs ............................... 6-2
Standard for other brand LLC ............. 6-2
General demands of LLC ................................. 6-2
LLC specification .............................................. 6-3
Maintenance of LLC............................ 6-5
Replacement intervals of LLC .......................... 6-5
LLC concentration ............................................ 6-5
Importance of LLC .............................. 6-6
Characteristics of LLC additive and
important notes ................................... 6-6
Examples of abnormalities caused by
LLC (amine type) ................................ 6-6
Pitting of iron parts ........................................... 6-6
Corrosion of aluminum parts ............................ 6-6
Pitting and clogging of the radiator................... 6-6
Chapter 7
MAINTENANCE SCHEDULE
How to use the maintenance
schedule.............................................. 7-1
Maintenace schedule .......................... 7-2
CONTENTS-3
CONTENTS
Chapter 8
PERIODIC INSPECTION AND
MAINTENANCE PROCEDURES
Basic engine........................................8-1
Belt and belt tension - Inspect and Adjust........ 8-1
Fuel system .........................................8-2
Fuel tank - Drain water..................................... 8-2
Solenoid fuel pump filter - Inspect and clean ... 8-2
Fuel system - Bleed air .................................... 8-3
Water sedimenter - Drain water ....................... 8-5
Fuel filter (cartridge type) - Replace................. 8-5
Fuel filter element (switching cock type)
- Replace.......................................................... 8-6
Solenoid fuel pump filter - Replace .................. 8-6
Lubricating system...............................8-7
Engine oil and Oil filter - Replace..................... 8-7
Cooling system..................................8-10
Coolant - Change........................................... 8-10
Radiator fins - Check and Clean .................... 8-13
Inlet and exhaust systems.................8-14
Air cleaner - Check......................................... 8-14
Air cleaner element - Clean, Check and
Replace .......................................................... 8-15
Electrical system................................8-16
Starter - Inspect.............................................. 8-17
Alternator - Inspect......................................... 8-17
Chapter 9
LONG-TERM STORAGE
Long-term storage ...............................9-1
Storing the engine in a non-operable
condition for 3 months or more............9-1
Preparation for storage .................................... 9-1
Maintenance during storage............................. 9-1
Using the engine after storage ......................... 9-2
Storing the engine in an operable
condition for 3 months or more............9-2
Operating the engine for maintenance............. 9-2
Chapter 10
TRANSPORTATION
Lifting the engine............................... 10-1
Chapter 11
TROUBLESHOOTING
General precautions.......................... 11-1
Contact a dealer of Mitsubishi Heavy
Industries, Ltd. for repair service .................... 11-1
Considerations before work ........................... 11-1
Cautions against contamination ..................... 11-1
Cautions regarding parts handling ................. 11-1
Work safety .................................................... 11-1
Troubleshooting ................................ 11-2
The starter does not crank or cranks slowly,
resulting in start failure ................................... 11-2
The starter cranks, but the engine does not
start ................................................................ 11-2
Output decrease............................................. 11-3
Exhaust smoke is white or blue...................... 11-4
Exhaust smoke is black or charcoal ............... 11-5
Fuel consumption is high ............................... 11-6
Engine oil consumption is high....................... 11-7
Overheating.................................................... 11-8
Low engine oil pressure ................................. 11-8
When fuel has run out....................... 11-9
Chapter 12
MAIN SPECIFICATIONS
Main specifications............................ 12-1
CONTENTS-4
CONTENTS
List of illustrations
Fig. 2-1 Engine left view .................................... 2-1
Fig. 2-2 Engine right view .................................. 2-1
Fig. 2-3 Engine left view .................................... 2-2
Fig. 2-4 Engine right view .................................. 2-2
Fig. 2-5 Starter switch........................................ 2-3
Fig. 2-6 Preheat indicator .................................. 2-3
Fig. 2-7 Water temperature meter and thermo
unit........................................................ 2-4
Fig. 2-8 Ammeter............................................... 2-4
Fig. 2-9 Hour meter ........................................... 2-4
Fig. 2-10 Stop solenoid........................................ 2-5
Fig. 2-11 Oil pressure switch ............................... 2-6
Fig. 2-12 Thermo switch ...................................... 2-6
Fig. 2-13 Air cleaner indicator.............................. 2-6
Fig. 3-1 Battery electrolyte level - Inspect ......... 3-1
Fig. 3-2 Fuel tank oil level - Check .................... 3-2
Fig. 3-3 Oil filler and Oil level gauge.................. 3-2
Fig. 3-4 Radiator filler cap ................................. 3-3
Fig. 3-5 Radiator coolant level........................... 3-3
Fig. 3-6 Reserve tank coolant level ................... 3-3
Fig. 4-1 Recommended fuel .............................. 4-1
Fig. 5-1 Recommended engine oil..................... 5-1
Fig. 5-2 Selection of oil viscosity ....................... 5-1
Fig. 6-1 GLASSY - LLC ..................................... 6-1
Fig. 8-1 Belt and belt tension - Inspect and
Adjust ................................................... 8-1
Fig. 8-2 Fuel tank - Drain water ......................... 8-2
Fig. 8-3 Solenoid fuel pump filter - Inspect and
clean..................................................... 8-2
Fig. 8-4 Fuel filter element
(switching cock type) - Bleed air........... 8-3
Fig. 8-5 Fuel filters (cartridge type) - Bleed air .. 8-3
Fig. 8-6 Water sedimenter - Bleed air................ 8-4
Fig. 8-7 Water sedimenter - Drain water ........... 8-5
Fig. 8-8 Fuel filter (cartridge type) - Replace ..... 8-5
Fig. 8-9 Fuel filter element
(switching cock type) - Replace............ 8-6
Fig. 8-10 Solenoid fuel pump filter - Replace ...... 8-6
Fig. 8-11 Engine oil drain plug............................. 8-7
Fig. 8-12 Engine oil - Refill .................................. 8-8
Fig. 8-13 Oil filter - Change ..................................8-9
Fig. 8-14 Oil filter ..................................................8-9
Fig. 8-15 Radiator filler cap ................................8-10
Fig. 8-16 Coolant drain cock (radiator) ...............8-10
Fig. 8-17 Coolant drain plug (engine) .................8-11
Fig. 8-18 Radiator coolant level..........................8-12
Fig. 8-19 Reserve tank .......................................8-12
Fig. 8-20 Radiator fins - Clean ...........................8-13
Fig. 8-21 Air cleaner - Check..............................8-14
Fig. 8-22 Air cleaner element - Remove.............8-15
Fig. 8-23 Air cleaner element - Clean and
Check ..................................................8-15
Fig. 8-24 Air cleaner - Check..............................8-15
Fig. 8-25 Battery electrolyte level - Inspect ........8-16
Fig. 8-26 Specific gravity of battery electrolyte
- Check................................................8-16
Fig. 8-27 Starter - Inspect...................................8-17
Fig. 8-28 Alternator - Inspect..............................8-17
Fig. 10-1 Hangers...............................................10-1
Fig. 10-2 Engine's center of gravity
(standard specification) .......................10-1
CONTENTS-5
CONTENTS
List of tables
Table 3-1 Preheat duration
(automatic grow plug)........................... 3-4
Table 3-2 Preheat duration (manual grow plug) ... 3-4
Table 3-3 Standard values at rated speed ........... 3-6
Table 4-1 Recommended limit and use limit of
fuel property ......................................... 4-2
Table 5-1 Engine oil properties............................. 5-4
Table 6-1 Water quality standards........................ 6-1
Table 6-2 LLC specification.................................. 6-3
Table 6-3 Recommended LLC concentration....... 6-5
Table 7-1 Maintenace schedule ........................... 7-2
Table 8-1 Specific gravity of electrolyte.............. 8-16
Table 9-1 Recommended rust-preventive oil
and corrosion inhibitor .......................... 9-1
Table 11-1 The starter does not crank or cranks
slowly, resulting in start failure ........... 11-2
Table 11-2 The starter cranks, but the engine
does not start...................................... 11-2
Table 11-3 Output decrease................................. 11-3
Table 11-4 Exhaust smoke is white or blue.......... 11-4
Table 11-5 Exhaust smoke is black or charcoal ... 11-5
Table 11-6 Fuel consumption is high.................... 11-6
Table 11-7 Engine oil consumption is high........... 11-7
Table 11-8 Overheating........................................ 11-8
Table 11-9 Low engine oil pressure ..................... 11-8
Table 12-1 Main specifications............................. 12-1
1-1
Chapter 1 BASIC SAFETY PRECAUTIONS
Fire and explosions
Keep flames away
Do not use flames near the engine (in
the engine room). Fuel vapor or other
gas can catch fire and produce dan-
gerous situations.
Wipe off spilled fuel, oil and LLC
immediately and thoroughly. Spilled fuel, oil and LLC
may ignite and cause a fire.
Store fuel and engine oil in a well-ventilated area.
Make sure that the caps of fuel and engine oil contain-
ers are tightly closed.
Keep engine surrounding area
tidy and clean
Do not leave combustible or explosive materials, such
as fuel, engine oil and LLC, near the engine. Such
substances can cause fire or explosion.
Remove dust, dirt and other foreign materials accu-
mulated on the engine and surrounding parts thor-
oughly. Such materials can cause fire or the engine to
overheat. In particular, clean the top surface of the
battery thoroughly. Dust can cause a short-circuit.
Care for fuel, oil and exhaust
gas leakage
If any fuel, oil or exhaust gas leakage is found, imme-
diately take corrective measures to stop it.
Such leakages, if left uncorrected, can cause fuel or
engine oil to reach hot engine surfaces or hot exhaust
gas to contact flammable materials, possibly leading
to personal injury and/or damage to equipment.
Use explosion-proof lighting
apparatus
When inspecting fuel, engine oil, coolant, battery elec-
trolyte, etc., use a flameproof light. An ordinary light-
ing apparatus may ignite gas and cause it to explode.
Prevent electrical wires from
short-circuiting
Avoid inspecting or servicing the electrical system with
the ground cable connected to the battery. Otherwise,
a fire could result from short-circuiting. Be sure to dis-
connect the battery cable from the negative (-) termi-
nal before beginning with the work procedure.
Short-circuits, possibly resulting in fire, may be
caused by a loose terminal or damaged cable/wire.
Inspect the terminals, cables and wires, and repair or
replace the faulty parts before beginning with the ser-
vice procedure.
Keep fire extinguishers and a
first-aid kit handy
Keep fire extinguishers handy, and
become familiar with their usage.
Keep a first-aid kit at the designated
place where it is easily accessible by
anyone at any time.
Establish response procedures to follow in the event
of fire or accident. Provide an emergency evacuation
route and contact points and means of communication
in case of emergency.
1-2
Chapter 1 BASIC SAFETY PRECAUTIONS
Stay clear of all rotating and moving parts
Install protective covers around
rotating parts
Make sure the protective covers of
the engine are correctly installed.
Repair any damaged or loose covers.
Never remove the covers such as
damper cover, camshaft cover, or
rocker cover that enclose the revolving parts during
operation.
When the engine is coupled to driven equipment, be
sure to provide protective covers over the parts such
as the connecting belts and couplings that are
exposed.
Never remove protective covers.
Check work area for safety
Before starting the engine, make sure no one is near
the engine and tools are not left on or near the engine.
Verbally notify persons within the immediate area
when starting the engine.
When the starter device is posted with a sign that pro-
hibits startup operation, do not operate the engine.
St ay clear of moving parts while
engine is running
Do not approach rotating or sliding
parts of the engine while the engine is
running. Keep objects likely to be
caught by rotating parts away from
such parts.
If any part of the clothing or outfitting is caught by a
rotating part, serious bodily injuries could result.
Lockout and tagout
Be sure to lockout and tagout before starting inspec-
tion and maintenance.
Lockout and tagout are effective methods of cutting off
machines and equipment from energy sources.
To accomplish the lockout/tagout, remove the starter
switch key, set the battery switch to "OFF" position
and attach a "Do Not Run" or similar caution tag to the
starter switch.
The starter switch key must be kept by the person
who performs inspection and maintenance during the
work.
Keep engine stopped during
servicing
Be sure to stop the engine before proceeding to
inspection and service procedure. Never attempt to
make adjustments on the engine parts while the
engine is running.
Rotating parts such as belt can entangle your body
and cause serious injuries.
Always restore engine turning
tools after use
Be sure to remove all turning tools used during main-
tenance and inspection work. Remember also that the
turning gear must be returned to the operating condi-
tion before starting the engine.
Starting the engine with the turning tools inserted or
with the turning gear in engagement can lead to not
only engine damage but also personal injuries.
Changing the engine speed setting is prohibited
Never change engine speed setting. Tampering with
the setting can cause the engine and its coupled
machine to operate at excessive speeds and result in
accidents.
1-3
Chapter 1 BASIC SAFETY PRECAUTIONS
Be careful of exhaust
fume poisoning
Operate engine in a well-ventilated area
If the engine is installed in an
enclosed area, and the exhaust gas
is ducted outside, ensure that there is
no exhaust gas leakage from duct
joints.
When using the engine as portable generator set, do
not run it in doors such as a warehouse or tunnel, or in
an poorly-ventilated area near the shielding. When
running it indoors by necessity, discharge the exhaust
gas to outside and thoroughly ventilate the room.
Make sure the exhaust gas is not discharged directly
to surrounding buildings, plants or living passersby.
Exhaust gas from the engine contains carbon monox-
ide and other harmful substances. Operating the
engine in an poorly-ventilated area can produce gas
poisoning.
Be careful of falling down
Lift engine carefully
To lift the engine, use slings capable
of supporting the weight of the
engine.
Attach the wire rope to the hangers
provided on the engine using a cor-
rect sling.
During lifting process, keep the engine in a well-bal-
anced position by taking the center of gravity of the
engine into consideration.
Keep the angle formed by slings attached to hangers
within 60°. If the angle exceeds this limit, excessive
load could be imposed on the hangers and this could
damage the hangers and result in a serious accident.
If the wire rope contacts the engine directly, place a
cloth or other soft padding to avoid damage to the
engine and wire rope.
Do not climb onto the engine
Do not climb onto the engine, nor step on any engine
parts located on the lateral sides.
To work on parts located on the upper section of
engine, use a ladder, stool, etc., that was firmly
secured.
Climbing on the engine may not only damage engine
parts but also cause falling down from the engine and
result in personal injuries.
Always prepare stable scaffold
When working on the upper part of
the engine and other hard-to-reach
places, use a stable work platform.
Standing on a decrepit stool or parts
box may result in personal injury.
Do not place any unnecessary objects on a work plat-
form.
1-4
Chapter 1 BASIC SAFETY PRECAUTIONS
Protect ears from noise
Wear ear plugs
Always wear ear plugs when entering
the machine room (engine room).
Combustion sound and mechanical
noise generated by the engine can
cause hearing problems.
Be careful of burns
Do not touch the engine during
or immediately after operation
To avoid burns, do not touch the
engine during or immediately after
operation.
A hot engine can cause burns.
To conduct maintenance and inspec-
tion work, wait until the engine has cooled sufficiently
by checking the temperature gauge.
Do not open the radiator filler
cap when the engine is hot
Never open the radiator filler cap while the engine is
running or immediately after the engine is stopped.
When opening the cap, stop the engine and allow the
coolant temperature to lower sufficiently.
When opening the radiator filler cap, open slowly to
discharge the pressure inside the tank. Also to avoid a
risk of getting scalded by steam, wear thick rubber
gloves or wrap a cloth around the cap.
When closing the cap, be sure to tighten securely.
The coolant is hot while engine is running and immedi-
ately after the engine stops. If the cap is opened when
the coolant is at operating temperature, steam and hot
coolant may blow out and result in burns.
Do not touch high pressure
injection fuel
If fuel leaks or sprays out from the high pressure injec-
tion pipe, do not touch the fuel.
Fuel in the fuel injection pipes is under high pressure
and if the fuel contact your skin, it goes into deep tis-
sues and may result gangrene.
Refill coolant only after the
coolant temperature dropped
When refilling of coolant, perform it after coolant tem-
perature drops, not immediately after the engine is
stopped. Otherwise you are scalded with hot coolant.
1-5
Chapter 1 BASIC SAFETY PRECAUTIONS
Be careful when handling
fuel, engine oil or LLC
Use only specified fuel, engine
oil and LLC
Use fuel, oil and LLC specified in this manual, and
handle them carefully.
Use of any other fuel, oil or LLC, or improper handling
may cause various engine problems and malfunc-
tions.
Obtain the MSDS issued by the fuel, oil and LLC sup-
pliers, and follow the directions in the MSDSs for
proper handling.
Handle LLC carefully
When handling LLC, always wear rubber gloves and a
protective face mask. If LLC or cooling water contain-
ing LLC comes into contact with your skin or eyes, or if
it is swallowed, you would suffer from inflammation,
irritation or poisoning.
Should LLC be accidentally swallowed, induce vomit-
ing immediately and seek medical attention. Should
LLC enter your eyes, flush them immediately with
plenty of water and seek medical attention. If LLC
splashes onto your skin or clothing, wash it away
immediately with plenty of water.
Keep flames away from LLC. The LLC can catch
flames, causing a fire. Coolant (containing LLC)
drained from the engine is toxic. Never dispose of
coolant into regular sewage. Abide by the applicable
law and regulations when discarding drained coolant.
Proper disposal of waste oil,
LLC and coolant
Do not discharge waste engine oil, LLC and coolant
into sewerage, river, lake or other similar places. Such
a way of disposal is strictly prohibited by laws and reg-
ulations.
Dispose of waste oil, LLC and coolant and other envi-
ronmentally hazardous waste in accordance with the
applicable law and regulations.
When abnormality occurs
Do not add coolant immediately
after a sudden stop due to overheating
If the engine stops suddenly or if you have no choice
but stop the engine suddenly due to overheating, do
not add coolant immediately.
Adding water while the engine is hot can damage
parts such as cylinder heads due to a sudden drop of
temperature. Add coolant gradually after the engine
has completely cooled.
Avoid immediate restart after
abnormal stop
If the engine stops abnormally, do not restart the
engine immediately. If the engine stops with an alarm,
check and remedy the cause of the problem before
restarting. Sustained use of the engine without any
remedy could result in serious engine problems.
Avoid continuous engine operation at low oil pressure
If an abnormal engine oil pressure drop is indicated,
stop the engine immediately, and inspect the lubrica-
tion system to locate the cause. Continuous engine
operation with low oil pressure could cause bearings
and other parts to seize.
If belt breaks, stop engine
immediately
If the belt breaks, stop the engine immediately. Con-
tinuous engine operation with the broken belt could
cause the engine to overheat and thereby the coolant
to boil into steam, which may gush out from the
reserve tank or radiator, and you may be scalded with
it.
1-6
Chapter 1 BASIC SAFETY PRECAUTIONS
Service battery
Handle the battery correctly
Never use flames or allow sparks to
generate near the battery. The bat-
tery releases flammable hydrogen
gas and oxygen gas. Any flames or
sparks in the vicinity could cause an
explosion.
Do not use the battery when the battery electrolyte
level of which is below "LOWER LEVEL" line. Sus-
tained use of the battery could result in an explosion.
Do not short the battery terminals with a tool or other
metal object.
When removing battery, always remove the plug from
the negative (-) terminal first. When connecting bat-
tery, always connect the plug to the positive (+) termi-
nal first.
Remove all plugs, then charge the battery in a well-
ventilated area.
Make sure the cable clamps are securely installed on
the battery terminals. A loose cable clamp can cause
sparks that may result in an explosion.
Before servicing electrical components or conducting
electric welding, set the battery switch to the "Open/
OFF" position or remove the plug from the negative (-
) terminal to cut off the electrical current.
Battery electrolyte contains dilute sulfuric acid. Care-
less handling of the battery can cause the loss of sight
and/or skin burns. Also, do not consume the battery
electrolyte.
Wear protective goggles and rubber gloves when
working with the battery (when adding water, charg-
ing, etc.)
If battery electrolyte is spilled onto the skin or clothing,
immediately wash it away with lots of water. Use soap
to thoroughly clean.
The battery electrolyte can cause the loss of sight if
splashing into the eyes. If it gets into the eyes, imme-
diately flush it away with plenty of clean water, and
seek immediate medical attention.
If the battery electrolyte is accidentally consumed,
gargle with plenty of water, then drink lots of water,
and seek immediate medical attention.
1-7
Chapter 1 BASIC SAFETY PRECAUTIONS
Other cautions
Never modify engine
Unauthorized modification of the engine will void our
warranty.
Modification of the engine may not only cause engine
damage but also produce personal injuries.
If there is a need to modify the engine, contact a
dealer of Mitsubishi Heavy Industries, Ltd.
Observe safety rules at work
site
Observe the safety rules established at your work-
place when operating and maintaining the engine.
Do not operate the engine if you are feeling ill, inform
your supervisor of your condition. Operation of the
engine with reduced awareness may cause improper
operation that could result in accidents.
When working in a team for two or more people, use
specified hand signals to communicate among work-
ers.
Work clothing and protective
gear
Wear a hardhat, face shield, safety shoes, dust mask,
gloves and other protective gear as needed. When
handling compressed air, wear safety goggles, a hard-
hat, gloves and other necessary protective gear.
Works without wearing proper protective gear could
result in serious injuries.
Never break seals
To ensure proper engine operation, the fuel control
linkage is sealed to prevent accidental change of the
injection volume and rotation speed settings. Operat-
ing the engine without these seals in place can cause
problems described below, and also invalidates the
warranty.
Rapid wear of sliding and rotating parts
Engine damage such as seizing of engine parts
Considerably increased consumption of fuel and lu-
bricating oil
Degradation of engine performance due to improper
balance between fuel injection volume and governor
operation or overrunning of the engine which could
result in a serious accident
Perform all specified pre-operation inspections and periodic
inspections
Conduct the pre-operation inspections and periodic
inspections as described in this manual.
Failure to conduct the specified inspections may
cause various engine problems, damage to parts, and
serious accidents.
Break-in the engine
To break-in new engines or overhauled engines, oper-
ate the engine at a speed lower than the rated speed
in a light load condition during the first 50 hours of
operation.
Operating new engines or overhauled engines in a
severe condition during the break-in period shortens
the service life of the engine.
Warm up the engine before use
After starting the engine, run the engine at low idling
speeds for 5 to 10 minutes for warm up. Start the work
after this operation is completed. Warm up operation
circulates the lubricant through the engine. Therefore,
individual engine parts are well lubricated before they
are subjected to heavy loads.
Warm up operation circulates lubricants in the engine
and contributes to a longer service life and economi-
cal operation.
Do not conduct warm up operation for prolonged
period of time. Prolonged warm up operation causes
carbon build-up in the cylinders that leads to incom-
plete combustion.
Never operate the engine in an
overloaded condition
If the engine shows an overloaded condition such as
black exhaust smoke, reduce the load immediately to
operate the engine at an appropriate output and load.
Overloading causes not only high fuel consumption
but also excessive carbon deposits inside the engine.
Carbon deposits cause various problems and will
shorten the service life of the engine.
1-8
Chapter 1 BASIC SAFETY PRECAUTIONS
Conduct cooling operation
before stopping the engine
Before stopping the engine, let it idle in low gear for 5
to 6 minutes to cool down.
Stopping the engine immediately after high-load oper-
ation will cause engine parts to heat up and shorten
the service life of the engine.
During cooling operation, check the engine for abnor-
malities.
Protection of the engine against
water entry
Do not allow rainwater, etc. to enter the engine
through the air inlet or exhaust openings.
Do not wash the engine while it is operating. Cleaning
fluid (water) can be sucked into the engine.
Starting the engine with water inside the combustion
chambers can cause the water hammer action which
may result in internal engine damage and serious
accidents.
Conduct proper maintenance of
air cleaner
The major cause of abnormal wear on engine parts is
dust from intake air. Worn parts produce many prob-
lems such as an increase of oil consumption,
decrease of output, and starting difficulties. For effec-
tive removal of dust from intake air, maintain the
engine with air cleaner according to the following
instructions.
Never service the air cleaner while the engine is run-
ning. Operating the engine without the air cleaner can
suck particles of foreign matter into the engine and
could result in serious accidents.
Remove theair cleaner slowly to prevent dust accu-
mulated on the element from falling off. After remov-
ing the air cleaner, immediately cover the air inlet with
plastic sheet or similar means to prevent dust from en-
tering the engine.
Use of tools optimum for each
work
Always keep in mind to select most appropriate tools
for the work to be performed and use them correctly. If
tools are damaged, replace them with new tools.
Avoidance of prolonged time of
starter operation
Do not use the starter for more than 10 seconds at a
time. If the engine does not start, wait for at least 1
minute before cranking again.
Continuous operation of the starter will drain the bat-
tery power and cause the starter to seize.
Do not turn off the battery
switch during operation
Do not turn off the battery switch during operation.
If the battery switch is turned OFF when the engine is
running, not only various meters will stop working but
also the alternator may have its diode and transistor
deteriorated.
Cautionary instructions for
transporting the engine
When transporting the engine on a truck, consider the
engine weight, width and height to ensure safety.
Abide by road traffic law, road vehicles act, vehicle
restriction ordinance and other pertinent laws.
2-1
Chapter 2 NAME OF PARTS
Engine external diagrams
The external diagram is for the standard type of the engine. The installed equipment and shapes differ according to
the engine type.
L2E left view
Fig. 2-1 Engine left view
L2E right view
Fig. 2-2 Engine right view
Rear
Rear hanger
Exhaust manifold
Starter
Flywheel
Oil pan
Belt
Thermostat
Oil filler
Alternator
Fan
Front
Rear
Front
Oil drain plug
Oil level gauge
PTO
Oil filler
Water pump
Fuel injection pump
Front hanger
Oil filter
Coolant drain plug
Fuel filter
Stop solenoid
Inlet cover
Fuel injection nozzle
Flywheel housing
2-2
Chapter 2 NAME OF PARTS
L3E left view
Fig. 2-3 Engine left view
L3E right view
Fig. 2-4 Engine right view
Oil filler
Thermostat
Fan
Alternator
Front
Belt
Oil pan
Flywheel
Starter
Rear
Exhaust manifold
Rear hanger
Stop solenoid
Fuel filter
Coolant drain plug
Rear
Flywheel housing
Oil filter
Oil drain plug
Oil level gauge
PTO
Oil filler
Front
Water pump
Fuel injection pump
Front hanger
Fuel injection nozzle
Inlet cover
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