Operation & Maintenance Manual: November 2007
Operation & Maintenance Manual: November 2007
Operation & Maintenance Manual: November 2007
OPERATION &
MAINTENANCE MANUAL
OPERATION&MAINTENANCE MANUAL
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.
November 2007
Pub. No.
99610-15130
This operation and maintenance manual contains detailed operation, inspection and maintenance
information for Mitsubishi engines.
Please read this manual thoroughly before proceeding with operation, inspection, and maintenance
work for correct use and servicing.
Limited warranty
The manufacturer will repair or replace parts returned to the manufacturer when the manufacturer judges after
inspection that the parts are defective in material and/or workmanship.
The manufacturer's warranty is limited to the repair work or replacement of parts for the defective parts only.
The warranty coverage is effective for the original purchaser only. Those to whom ownership is later transferred are
not provided with the warranty.
• The manufacturer 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
particular purpose or use, or against infringement of any patent.
• The manufacturer will not be liable for any damages or consequential damages, including, but
not limited to, damages or other costs resulting from any abuse, misuse, misapplication of the
engine and devices supplied by the manufacturer.
• The manufacturer will not be liable for any damages or personal injuries resulting from any
modification, without the manufacturer's written permission, of the engine and devices supplied
by the manufacturer.
• The manufacturer will not be liable for any damages or production losses caused by the use of
fuel, engine oil and/or long life coolant (LLC) that are not recommended by the manufacturer.
• The owner of the engine is responsible for the performance of the required maintenance listed
in this operation manual. The manufacturer may deny the warranty coverage if the engine or
part has failed due to inadequate or improper maintenance.
ii
FOREWORD
Emission warranty
The following warranty applies to the engines that are approved of the emission regulation of the U.S Environmental
Protection Agency.
Warranty coverage
Mitsubishi Heavy Industries warrants to the first owner and each subsequent purchaser of a new L series diesel
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 sate 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.
Warranty period
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.
And its maximum
If your engine is certified as And its rated speed is Then its warranty period is
power is
1,500 hours or two years, whichever
Variable speed or constant speed kW < 19 Any speed
comes first.
1,500 hours or two years, whichever
Constant speed 19 ≤ kW < 37 3,000 min-1 or higher
comes first.
3,000 hours or five years, whichever
Constant speed 19 ≤ kW < 37 Less than 3,000 min-1
comes first.
3,000 hours or five years, whichever
Variable speed 19 ≤ kW < 37 Any speed
comes first.
3,000 hours or five years, whichever
Variable speed or constant speed kW ≥ 37 Any speed
comes first.
Warranted parts
Mitsubishi Heavy Industries 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 warranty"
iii
FOREWORD
Important information
• To avoid potential hazard, accident prevention activ- • This manual is copyrighted and all rights are
ities must be planned methodically and conducted reserved. No part of this manual, including illustra-
continually by considering all aspects of engine tions and technical references, may be reproduced,
operation, maintenance and inspection. photocopied, translated, or reproduced in any elec-
All related personnel, including managers and tronic medium or machine readable form without
supervisors, should actively participate, recognize prior written consent from the manufacturer.
their roles and organize themselves and their work • The contents in this manual are subject to change at
to ensure a safe environment. any time without notice, for improvement of the
• The foremost safety objective is to prevent acci- engine.
dents that may result in injury or death, or equip- • Pictures or illustrations of the product in this manual
ment damage. may differ from those of product you have.
• Always observe laws or regulations of the local or • Please note that, depending on specifications, items
federal/national government. described in this manual may differ in shape, or may
• The manufacturer cannot foresee all potential dan- not be installed on the product you have.
gers of the engine, potential danger resulting from • Please contact your Mitsubishi dealer if you need
human error and other causes, or danger caused by more information or if you have any questions.
a specific environment in which the engine is used. • If you lose or damage this manual, obtain a new
Since there are many actions that cannot be per- copy at your Mitsubishi dealer as soon as possible.
formed or must not be performed, it is impossible to • Mitsubishi Heavy Industries recommends the
indicate every caution in this manual or on warning engine owner to install an hourmeter on the engine
labels. As such, it is extremely important to follow due to monitor correct service intervals and to per-
directions in this manual and also to take general form the maintenance at the proper timing.
safety measures when operating, maintaining and
inspecting the engine.
• This manual has been prepared for people whose
native language is English. When the engine is used
by individuals whose native language is not English,
the customer is requested to provide thorough
safety guidance to the operators. Also add safety,
caution and operating signs that describe the origi-
nal 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
manual, and do not use the engine for any unap-
proved purpose.
• When the ownership of the engine is transferred, be
sure to provide this manual with the engine to the
new owner. Also inform the manufacturer of the
name and address of the new owner of the engine.
iv
FOREWORD
Warning Indication
The following two means are used to call the attention of the operators and maintenance personnel to potential dan-
gers 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 five 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.
Indicates an imminently hazardous situation which, if not avoided, will result in death or
'$1*(5
serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in death or
:$51,1*
serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or
&$87,21
moderate injury.
Indicates a potentially hazardous situation which, if not avoided, can result in property
&$87,21
damage.
Note: Indicates important information or information which is useful for engine operation.
v
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/cm2
• 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 cmH2O (cmAq)
• Engine speed: 1 min-1 = 1 rpm
vi
CONTENTS
CONTENTS-1
CONTENTS
Chapter 5
ENGINE OIL Chapter 7
Properties of engine oil and MAINTENANCE SCHEDULE
its influence on engine performance....5-1 How to use the maintenance schedule7-1
CONTENTS-2
CONTENTS
Chapter 8 Chapter 9
PERIODIC INSPECTION AND LONG-TERM STORAGE
MAINTENANCE PROCEDURES Long-term storage............................... 9-1
Every 50 service hours ........................8-1 Storing the engine in a non-operable
Draining water from the fuel tank ..................... 8-1 condition for 3 months or more ........... 9-1
Checking the air cleaner .................................. 8-1 Preparation for storage .................................... 9-1
Checking and cleaning solenoid fuel pump filter8-2 and corrosion inhibitor ...............................................9-1
Maintenance during storage............................. 9-1
Every 250 service hours ......................8-3
Changing the engine oil and oil filter ................ 8-3 Using the engine after storage ......................... 9-2
CONTENTS-3
CONTENTS
CONTENTS-4
CONTENTS
Fig. 8-12 Changing solenoid fuel pump filter............ 8-8 List of Tables
Fig. 8-13 Checking starter........................................ 8-9 Table 3-1 Pre-heating duration
Fig. 8-14 Inspecting alternator ................................. 8-9 (automatic grow plug).............................3-4
Fig. 8-15 Radiator cap............................................ 8-10 Table 3-2 Pre-heating duration
Fig. 8-16 Draining coolant (radiator) ...................... 8-10 (manual grow plug).................................3-4
Fig. 8-17 Draining coolant (engine main parts) ...... 8-10 Table 3-3 Standard values at rated speed .............3-6
Fig. 8-18 Radiator .................................................. 8-11 Table 5-1 Service limit for engine oil properties .....5-4
Fig. 8-19 Reserve tank........................................... 8-11 Table 6-1 Water quality standards..........................6-1
Fig. 8-20 Removing air cleaner element ................ 8-12 Table 6-2 LLC specification ....................................6-3
Fig. 8-21 Cleaning air cleaner element .................. 8-12 Table 6-3 Recommended LLC concentration.........6-6
Fig. 8-22 Checking air cleaner element ................. 8-12 Table 7-1 Maintenance schedule ...........................7-1
Fig. 8-23 Air cleaner indicator ................................ 8-12 Table 8-1 Specific gravity of electrolyte................8-14
Fig. 8-24 Bleeding fuel filter (change cock type) .... 8-13 Table 9-1 Recommended rust-preventive oil
Fig. 8-25 Bleeding fuel filter (cartridge type) .......... 8-13 and corrosion inhibitor ............................9-1
Fig. 8-26 Bleeding water sedimenter ..................... 8-13 Table 11-1 The starter does not crank or
Fig. 8-27 Draining water from sedimenter.............. 8-14 cranks slowly, resulting in start failure..11-2
Fig. 8-28 Checking specific gravity Table 11-2 The starter cranks,
of battery electrolyte................................ 8-14 but the engine does not start................11-2
Fig. 10-1 Hangers for lifting.................................... 10-1 Table 11-3 Engine output is low .............................11-3
Table 11-4 Exhaust smoke is white or blue............11-3
Table 11-5 Exhaust smoke is black or dark gray....11-4
Table 11-6 Fuel consumption is high......................11-4
Table 11-7 Engine oil consumption is high.............11-4
Table 11-8 Engine overheats .................................11-5
Table 11-9 Engine oil pressure is faulty .................11-5
Table 12-1 Main specifications ...............................12-1
CONTENTS-5
Chapter 1 BASIC SAFETY PRECAUTIONS
:$51,1*
1-1
Chapter 1 BASIC SAFETY PRECAUTIONS
:$51,1*
1-2
Chapter 1 BASIC SAFETY PRECAUTIONS
:$51,1* :$51,1*
:$51,1*
1-3
Chapter 1 BASIC SAFETY PRECAUTIONS
:$51,1* &$87,21
cap when the engine is hot Handle LLC (long life coolant)
Never open the radiator filler cap while the engine is
carefully
running or immediately after the engine is stopped.
When handling LLC, always wear rubber gloves and a
The engine coolant is hot during engine operation and
protective face mask. If LLC or cooling water contain-
immediately after operation.
ing LLC comes into contact with your skin or eyes, or if
If the radiator filler cap is opened when the coolant is
it is swallowed, you would suffer from inflammation,
at operating temperature, steam and hot coolant may
irritation or poisoning.
blow out and result in burns.
Should LLC be accidentally swallowed, induce vomit-
When opening the cap, stop the engine and allow the
ing immediately and seek medical attention. Should
coolant temperature to lower sufficiently. Cover the
LLC enter your eyes, flush them immediately with
cap with a cloth or use thick rubber glove, and then
plenty of water and seek medical attention. If LLC
slowly open the cap. When closing the cap, be sure to
splashes onto your skin or clothing, wash it away
tighten securely.
immediately with plenty of water.
Add coolant only after the cool- Keep flames away from LLC. The LLC can catch
flames, causing a fire.
ant temperature dropped
Do not add coolant immediately after the engine Proper disposal of waste oil
stops. Wait until the coolant temperature lowers suffi-
and coolant (LLC)
ciently to avoid a risk of burns.
Do not discharge waste engine oil or coolant into sew-
erage, river, lake or other similar places. Such a way
of disposal is strictly prohibited by laws and regula-
tions.
Dispose of waste oil, coolant and other environmen-
tally hazardous waste in accordance with the applica-
ble law and regulations, or consult a Mitsubishi dealer.
1-4
Chapter 1 BASIC SAFETY PRECAUTIONS
&$87,21 &$87,21
1-5
Chapter 1 BASIC SAFETY PRECAUTIONS
&$87,21
Other cautions
Never modify engine Warm up the engine before use
Unauthorized modification of the engine will void the
When starting auxiliary devices, such as a water
manufacturer's warranty.
heater and an engine oil priming pump, are not
Modification of the engine may not only cause engine
installed, let the engine idle for 5 to 10 minutes before
damage but also produce personal injuries.
operating the engine for work. Warm-up operation cir-
If there is a need to modify the engine, contact your
culates lubricants in the engine and contributes to a
Mitsubishi dealer.
longer service life and economical operation. Do not
Never break the seals conduct warm-up operation for prolonged period of
To ensure proper engine operation, the fuel control time.
links are sealed to prevent accidental change of the Prolonged warm-up operation causes carbon build-up
injection volume and rotation speed settings. Operat- in the cylinders that leads to incomplete combustion.
ing the engine without these seals in place can cause Never operate the engine in an
the problems described below, and also invalidates
the warranty.
overloaded condition
If the engine shows an overloaded condition such as
• Rapid wear of sliding and rotating parts
black exhaust smoke, reduce the load immediately to
• Engine damage such as seizing of engine parts
operate the engine at an appropriate output and load.
• Considerably increased consumption of fuel and
Overloading causes not only high fuel consumption
lubricating oil
but also excessive carbon deposits inside the engine.
• Degradation of engine performance due to improper
Carbon deposits cause various problems and will
balance between fuel injection volume and governor
shorten the service life of the engine.
operation or overrunning of the engine which could
result in a serious accident. Conduct cooling operation
Perform all specified pre-opera- before stopping the engine
tion inspections and periodic Before stopping the engine, let it idle at low speed for
5 to 6 minutes to cool down.
inspections Stopping the engine immediately after high-load oper-
Conduct the pre-operation inspections and periodic
ation will cause engine parts to heat up and shorten
inspections as described in this manual.
the service life of the engine.
Failure to conduct the specified inspections may
During cooling operation, check the engine for abnor-
cause various engine problems, damage to parts, and
malities.
serious accidents.
Protection of the engine against
Break-in the engine
To break in new engines or overhauled engines, oper-
water entry
Do not allow rainwater, etc. to enter the engine
ate the engine at a speed lower than the rated speed
through the air inlet or exhaust openings.
in a light load condition during the first 50 hours of
Do not wash the engine while it is operating. Cleaning
operation.
fluid (water) can be sucked into the engine.
Operating new engines or overhauled engines in a
Starting the engine with water inside the combustion
severe condition during the break-in period shortens
chambers can cause the water hammer action which
the service life of the engine.
may result in internal engine damage and serious
accidents.
1-6
Chapter 1 BASIC SAFETY PRECAUTIONS
1-7
Chapter 2 NAMES 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.
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