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FOREWORD

&$/,)251,$(0,66,21&21752/:$55$17<67$7(
0(17<28:$55$17<5,*+76$1'2%/,*$7,216

The following warranty applies to the engines that are approved of the emission regulation of the California Air
Resources Board (CARB).

The &DOLIRUQLD$LU5HVRXUFHV%RDUG&$5%DQG0LWVXELVKL+HDY\,QGXVWULHV/WG DUH pleased to explain the

HPLVVLRQFRQWUROV\VWHPZDUUDQW\RQ\ou 20 or later engine. In California, new heavy-duty off-road engines
PXVWEHGHVLJQHGEXLOWDQGHTXLSSHGWRmeet the State's stringent anti-smog standards. Mitsubishi Heavy
,QGXVWULHV/WGPXVWZDUUDQWWKHHPLVVLRQFRQWUROVystem on your engine for the periods of time listed below
SURYLGHGWKHUHKDVEHHQQRDEXVHQHJOHFWRULPSURSHUmaintenance 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.

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The  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.

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ŒAs the heavy-duty off-road engine owner, you are responsible for the performance of the UHTXLUHGPDLQWHQDQFH
OLVWHGLQ\RXURZQHU
VPDQXDO. Mitsubishi Heavy Industries, Ltd. recommends that you retain all receipts covering
maintenance on your heavy-duty off-road engine, but Mitsubishi Heavy Industries, Ltd. FDQQRW deny warranty sole
lyfor the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.
ŒAs 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.
ŒYour 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.
ŒYou 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 will 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 .

iv
 FOREWORD

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(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 19 kW, 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 coverage, 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 replace 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. according to Subsection (4) below. Any such 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) $Q\UHSODFHPHQWSDUWDVGHILQHGLQ6HFWLRQE7LWOHPD\EHXVHGLQWKHSHUIRUPDQFHRIDQ\
PDLQWHQDQFHRUUHSDLUVDQGPXVWEHSURYLGHGZLWKRXWFKDUJHWRWKHRZQHU,WLVQRWQHFHVVDU\IRUUHSODFH
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6XFKXVHVKDOOQRWUHGXFHWKHZDUUDQW\REOLJDWLRQVRIWKHHQJLQHPDQXIDFWXUHU

v
FOREWORD

(10) $GGRQRUPRGLILHGSDUWVDVGHILQHGLQ6HFWLRQEDQGE7LWOHWKDWDUHQRWH[HPSWHGE\

WKH$LU5HVRXUFHV%RDUGPD\QRWEHXVHG7KHXVHRIDQ\QRQH[HPSWHGDGGRQRUPRGLILHGSDUWVVKDOOEH
JURXQGVIRUGLVDOORZLQJDZDUUDQW\FODLPPDGHLQDFFRUGDQFHZLWKWKLVDUWLFOH7KHHQJLQHPDQXIDFWXUHU
VKDOOQRWEHOLDEOHXQGHUWKLVDUWLFOHWRZDUUDQWIDLOXUHVRIZDUUDQWHGSDUWVFDXVHGE\WKHXVHRIDQRQ
H[HPSWHGDGGRQRUPRGLILHGSDUW
(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 device used to regenerate 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

vi
 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.

/LPLWHGZDUUDQW\
Refer to "LIMITED WARRANTY" (Page ii).

vii
FOREWORD

,03257$17,1)250$7,21

ŒTo avoid the potential hazard, accident prevention ŒThe engine must be operated, maintained and
activities must be planned methodically and con- inspected only by qualified persons who have thor-
ducted continually by considering all aspect of ough knowledge of engines and their dangers and
engine operation, maintenance and inspection. All who also have received risk avoidance training.
related personnel, including managers and supervi- ŒTo prevent an accident, do not attempt to carry out
sors, should actively participate, recognize their roles any operation other than those described in this man-
and organize themselves and their work to ensure a ual, and do not use the engine for any unapproved
safe environment. purpose.
ŒThe foremost safety objective is to prevent accidents ŒWhen the ownership of the engine is transferred, be
which may result in injury or death, or equipment sure to provide this manual with the engine to the
damage. new owner. Also inform Mitsubishi Heavy Industries,
ŒAlways observe laws or regulations of the local or Ltd. of the name and address of the new owner of the
federal/national government. engine.
ŒMitsubishi Heavy Industries, Ltd. cannot foresee all ŒThis manual is copyrighted and all rights are
potential dangers of the engine, potential danger reserved. No part of this manual, including illustra-
resulting from human error and other causes, or dan- tions and technical references, may be photocopied,
ger caused by a specific environment in which the translated, or reproduced in any electronic medium
engine is used. Since there are many actions that or machine readable form without prior written con-
cannot be performed or must not be performed, it is sent from Mitsubishi Heavy Industries, Ltd.
impossible to indicate every caution in this manual or ŒThe contents in this manual are subject to change at
on warning labels. As such, it is extremely important any time without notice for improvement of the
to follow directions in this manual and also to take engine.
general safety measures when operating, maintain- ŒPictures or illustrations of the product in this manual
ing and inspecting the engine. may differ from those of product you have. Please
ŒWhen the engine is used by individuals whose native note that, depending on specifications, items
language is not English, the customer is requested to described in this manual may differ from those on
provide thorough safety guidance to the operators. your engine in shape, or may not be installed on your
Also add safety, caution and operating signs that engine.
describe the original warning label statements in the ŒPlease contact a dealer of Mitsubishi Heavy Indus-
native language of the operators. tries, Ltd. if you need more information or if you have
any questions.
ŒIf you lost or damaged this manual, obtain a new
copy at a dealer of Mitsubishi Heavy Industries, Ltd.
as soon as possible.
ŒMitsubishi 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.

viii
 FOREWORD

:$51,1*,1',&$7,21

The following means are used to call the attention of the operators and maintenance personnel to potential dangers
of the engine.
ŒWarning statements in the manual
ŒWarning labels affixed on the engine

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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.
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.

ix
FOREWORD

8NITSOF 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.
ŒPressure :1 MPa = 10.197 kgf/cm2
ŒTorque:1 N•m = 0.10197 kgf•m
ŒForce:1 N = 0.10197 kgf
ŒHorsepower:1 kW = 1.341 HP = 1.3596 PS
ŒMeter of mercury:1 kPa = 0.75 cmHg
ŒMeter of water:1 kPa = 10.197 cmH2O (cmAq)
ŒRotation speed:1 min-1 = 1 rpm
ŒKinetic viscosity:1 mm2/s = 1 cSt

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ΠAPI = American Petroleum Institute

ΠASTM = American Society for Testing and Materials
ΠISO = International Organization for Standardization
ΠJIS = Japanese Industrial Standards
ΠLLC = Long Life Coolant
ΠMIL = Military Specifications and Standards
ΠMSDS = Material Safety Data Sheet
ΠSAE = Society of Automotive Engineers

x
 CONTENTS
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 Chapter 1 BASIC SAFETY PRECAUTIONS

Warning Labels

Maintenance of Warning Labels

Make sure all warning/caution labels are legible.
Clean or replace the warning/caution labels when the description and/or illustration are not clear to read.
For cleaning the warning/caution labels, use a cloth, water and soap. Do not use cleaning solvents, gasoline or
other chemicals to prevent the letters from getting blurred or the adhesion from being weakened.
Replace damaged or fractured labels with new ones.
If any engine part on which a warning label is attached is replaced with a new one, attach a new identical warning
label to the new part.
To obtain new warning labels, contact a dealer of Mitsubishi Heavy Industries, Ltd.

Fig. 1-1 Warning labels

1-9
 Chapter 2 NAME OF PARTS
Engine External Diagrams
Left Side
Fuel filter
Front hanger Rear hanger
Turbocharger

Breather
Fuel injection pump

Governor actuator
Oil cooler

Front Rear

Fan Coolant drain cock

Fuel feed pump

Damper
Starter
Bypass oil filter Oil filler
Oil filter Fuel return port
Oil level gauge
Fuel inlet
)LJ(QJLQH/HIW6LGH9LHZ

Right Side

Rear hanger Fuel filter

Exhaust outlet Front hanger
Turbocharger
Alternator

Stop solenoid
Water pump

Fuel injection pump

Rear Front

Coolant inlet

Coolant drain cock

Oil pump

Oil pan
Fuel feed pump Oil cooler

)LJ(QJLQH5LJKW6LGH9LHZ


Chapter 2 NAME OF PARTS

Equipment and Instrument

The installed equipment and shapes differ on the engine type.

Start and Stop Instrument

Start Switch
When the start switch on the operation panel is
pressed, starting system operates to crank the engine. START STOP
Stop Switch
When the stop switch on the operation panel is
pressed, the shutdown cylinder operates and moves
the control shaft of the fuel injection pump to the no-
injection position to shut down the engine operation.

(Example)
Fig. 2-3 Start Switch and Stop Switch
Manual Stop Lever

When stopping the engine with manual stop lever,

keep the manual stop lever at the stop position until ST
OP
the engine completely stops. If release the lever, the
engine may restart.
Use the manual stop lever to shut down the engine in
the event of an emergency. If the starter switch fails to
stop engine operation, use the manual stop lever.
When the manual stop lever, which is located in the
fuel control link, is moved in the "STOP" direction, the Fig. 2-4 Manual Stop Lever
engine stops.
If the engine continues to operate even after the man-
ual stop lever is moved in the "STOP" direction, cut off
the fuel supply to stop the engine.

Stop Solenoid
The stop solenoid operates for normal shutdown of
engine operation. The stop solenoid moves the rack of
fuel injection pump to cut the fuel, and consequently
stops the engine. Two types of stop solenoids are
available.
ŒRUN OFF type
Not energized while the engine is running. Energized
by a stop signal to stop the engine.
ŒRUN ON type
Energized while the engine is running, and de-ener-
gized by stop signal to stop the engine. Fig. 2-5 Stop Solenoid

2-2
 &KDSWHU1$0(2)3$576

Instruments
7KLVVHFWLRQGHVFULEHVDERXWGHYLFHVZKLFKWUDQVPLWVLJQDOVWRQHFHVVDU\LQVWUXPHQWVRIWKHHQJLQHRSHUDWLRQ
5HDGFDUHIXOO\DQGXQGHUVWDQGIXQFWLRQVRIHDFKGHYLFH

Oil Pressure Unit

,QGLFDWHWKHRLOSUHVVXUH
Oil pressure unit

)LJ2LO3UHVVXUH8QLW
Thermo Unit
$OZD\VGHWHFWWKHFRRODQWWHPSHUDWXUHRIHQJLQH

Thermo unit
)LJ7KHUPR8QLW
Revolution Detection Pickup
,WLVLQVWDOOHGLQWKHWLPLQJJHDUFDVHDQGDOZD\V
GHWHFWHQJLQHVSHHG

)LJ5HYROXWLRQ'HWHFWLRQ3LFNXS


&KDSWHU1$0(2)3$576

Engine Protection Devices

7KHHQJLQHSURWHFWLRQGHYLFHVDFWLYDWHDQDODUPZKHQDQDEQRUPDOLW\RFFXUVLQWKHHQJLQHLQRUGHUWRSURWHFWWKH
HQJLQHDQGSUHYHQWVHULRXVSUREOHPVDQGDFFLGHQWV:KHQDSURWHFWLRQGHYLFHLVDFWLYDWHGVWRSWKHHQJLQHH[DP
LQHWKHFDXVHRIWKHDEQRUPDOLW\DQGWDNHFRUUHFWLYHPHDVXUHV,IWKHFDXVHRIWKHSUREOHPLVXQNQRZQFRQWDFWD
GHDOHURI0LWVXELVKL+HDY\,QGXVWULHV/WG3URWHFWLRQGHYLFHVLQVWDOOHGRQWKHHQJLQHDQGWKHLUW\SHVVHWWLQJYDOXHV
DQGVKDSHVYDU\GHSHQGLQJRQWKHHQJLQHVSHFLILFDWLRQV

Oil Pressure Switch

7KHRLOSUHVVXUHVZLWFKJHQHUDWHVDQDODUPZKHQWKH
HQJLQHRLOSUHVVXUHEHFRPHVORZDQGUHDFKHVWKH
Oil pressure
VSHFLILHGSUHVVXUH switch

)LJ2LO3UHVVXUH6ZLWFK

Thermo Switch
7KHRLOSUHVVXUHVZLWFKJHQHUDWHVDQDODUPZKHQWKH
HQJLQHFRRODQWWHPSHUDWXUHEHFRPHVKLJKDQG
UHDFKHVWKHVSHFLILHGWHPSHUDWXUH

Thermo switch

)LJ7KHUPR6ZLWFK

Oil Filter Alarm Switch

7KHRLOILOWHUDODUPVZLWFKJHQHUDWHVDQDODUPWRVWRS
WKHHQJLQHZKHQRLOILOWHUVEHFRPHFORJJHGWKHGLIIHU Oil filter alarm switch
HQFHLQSUHVVXUHEHWZHHQLQOHWDQGRXWOHWRIRLODQG
UHDFKHVWKHVSHFLILHGYDOXH

)LJ2LO)LOWHU$ODUP6ZLWFK


 &KDSWHU1$0(2)3$576

Revolution Detection Pickup

7KHRYHUUXQGHWHFWLRQSLFNXSJHQHUDWHVDQDODUP
ZKHQWKHHQJLQHVSHHGEHFRPHVKLJKDQGUHDFKHV
WKHVSHFLILHGHQJLQHVSHHG

)LJ5HYROXWLRQ'HWHFWLRQ3LFNXS

Air Cleaner Indicator

,IWKHHOHPHQWLVFORJJHGWKHLQWDNHDLULVGHFUHDVHG
DQGWKHUHGVLJQDOPDUNZLOOEHGLVSOD\HG7KHVLJQDO Reset button
LQGLFDWHVRQO\DQGGRHVQRWJHQHUDWHDQDODUP Signal
7KHUHIRUHWKHSHULRGLFYLVXDOO\LQVSHFWLRQLVQHHGHG (red)

3UHVVWKHUHVHWEXWWRQRQWKHWRSRIDLUFOHDQHULQGLFD
WRUDQGUHVWRUHWKHVLJQDODIWHUFOHDQHGWKHDLUFOHDQHU
LQGLFDWRURUUHSODFHGZLWKDQHZRQH

)LJ$LU&OHDQHU,QGLFDWRU


&KDSWHU1$0(2)3$576

Using Turning Gear

%HIRUHVWDUWLQJWKHHQJLQHPDNHVXUHWKDWWKHPDQXDOWXUQLQJJHDULVSXOOHGRXWLQWKHRULJLQDOSRVLWLRQ6WDUWLQJWKH
HQJLQHZLWKWKHWXUQLQJJHDUSXVKHGLQQRWRQO\GDPDJHVWKHULQJJHDUEXWDOVRPD\UHVXOWLQSHUVRQDOLQMXU\
1. /RRVHQWKHWZREROWVDQGUHPRYHWKHSODWHIURP
WKHVKDIWJURRYH
6KDIW
%ROW

%ROW 3ODWH

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:KLOH(QJLQHLV5XQQLQJ
2. 3XVKLQWKHVKDIWIXOO\WRHQJDJHLWZLWKWKHULQJ
JHDU

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:KHQ3XVKLQJ6KDIWLQ
3. 8VLQJDVRFNHWZUHQFKDQGDUDWFKHWKDQGOHWXUQ
WKHVKDIW
6RFNHW
4. $IWHUWXUQLQJSXOORXWWKHVKDIWLQVHUWWKHSODWHLQ
WKHVKDIWJURRYHDQGWLJKWHQWKHEROWV

0DNHVXUHWKHSODWHLVVHFXUHO\LQVWDOOHGLQWKHVKDIW
JURRYH

5DWFKHWKDQGOH

)LJ7XUQLQJ*HDU3RVLWLRQ:KHQ7XUQLQJ6KDIW


 Chapter 3 OPERATION
Operational Environment
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SUREOHPVDQGZLOOVKRUWHQWKHVHUYLFHOLIHRIWKHHQJLQH
Œ3UHYHQWIURPVSUHDGLQJZDWHUHVSHFLDOO\VHDZDWHURUUDLQZDWHUDQGHQWHULQJIRUHLJQPDWHULDOVWRWKHDLULQOHW
RSHQLQJ
Œ3UHYHQWIURPHQWHULQJIRUHLJQPDWHULDOVWRWKHURWDWLQJSDUWV
Œ3UHYHQWIURPDWWDFKLQJZDWHUDQGGXVWWRWKHHOHFWULFDOV\VWHP
Œ8VHWKHHQJLQHDWWRƒ&>WRƒ)@
Œ.HHSWKHFRRODQWWHPSHUDWXUHSURSHUO\E\VZLWFKLQJ21WKHZDWHUKHDWHUDXWRPDWLFPRGH(PHUJHQF\JHQHUDWRU
ZLWKZDWHUKHDWHU

Preparation for Operating New or Overhauled Engine

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)RUVHFRQGRSHUDWLRQRQZDUGIROORZWKHLQVWUXFWLRQVGHVFULEHGLQWKH1RUPDO(QJLQH2SHUDWLRQ

Preparation of Fuel System

:KHQKDQGOLQJIXHOPDNHVXUHWKHUHDUHQRRSHQIODPHVRURWKHUILUHKD]DUGVQHDUWKHHQJLQH
:LSHRIIDQ\VSLOOHGIXHOFRPSOHWHO\6SLOOHGIXHOFDQLJQLWHDQGFDXVHDILUH

'RQRWUHPRYHWKHVWUDLQHUGXULQJIXHOWDQNILOOLQJ
)RUIXHOWREHXVHGUHIHUWR)8(/
1. 0DNHVXUHWKHLQVLGHVRIWKHIXHOWDQNDQGIXHOVXSSO\SLSHVWRWKHHQJLQHDUHWKRURXJKO\FOHDQ
2. &KHFNWKHGUDLQYDOYHDQGDLULQOHWYDOYHLVFORVHGDWWKHWLPH
3. )LOOIXHOWDQNZLWKIXHO
4. 5HPRYHWKHIXHOIHHGSLSHDQGGUDLQSOXJIURPWKHIXHOLQOHWRIHQJLQHDQGFKHFNWKHGLVFKDUJHGIXHOIRUIRUHLJQ
PDWHULDOVVXFKDVGXVW
5. 5HLQVWDOOWKHGUDLQSOXJDQGWKHIXHOIHHGSLSH
6. &ORVHWKHGUDLQYDOYHWRILOOWKHIXHO
7. 5HILOOIXHOWDQNXQWLOIXHOOHYHOJDXJHLQGLFDWHV)8//OHYHOOLQHDIWHUFKHFNLQJWKHFRQWDFWRIIORDWVZLWFK


&KDSWHU23(5$7,21

Fuel System - Bleed Air

:KHQIXHORYHUIORZIURPWKHDLUYHQWSOXJZLSHWKRU >8QORFN@ >3ULPLQJ@ >/RFN@

RXJKO\6SLOOHGIXHOFDXVHVILUHKD]DUG
7XUQOHIW 0RYHXS
$IWHUEOHHGLQJORFNWKHSULPLQJSXPSVHFXUHO\,IWKH DQGGRZQ +ROGDQG
FDSLVQRWORFNHGWLJKWO\WKHSULPLQJSXPSFDQEH WXUQULJKW

GDPDJHGFDXVLQJDIXHOOHDNWKDWFRXOGOHDGWRD
ILUH
:KLOHIHHGLQJIXHOZLWKSULPLQJSXPSEOHHGDLUIURP
WKHORFDWLRQFORVHVWWRWKHIXHOWDQNWKDWDUHWKHZDWHU
VHSDUDWRUIXHOILOWHUWKHQWKHIXHOLQMHFWLRQSXPS )LJ3ULPLQJ3XPS+DQGOH
/RFNWKHSULPLQJSXPSDFFRUGLQJWR3ULPLQJ3XPS
7LJKWHQLQJ0HWKRG

Fuel Filter - Bleed Air

Tightening torque Air vent plug

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VHDOLQJZDVKHUVDUHGDPDJHGUHSODFHWKHPZLWK {0.9 ± 0.1 kgf·m}
[6.4 ± 0.7 lbf·ft]
QHZRQHV
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WXUQV
2. 0RYHWKHSULPLQJSXPSXSDQGGRZQWKHQIHHGIX
HO
3. :KHQWKHIXHOIURPWKHDLUYHQWSOXJEHFRPHVIUHH
IURPDLUEXEEOHVVWRSSULPLQJDQGWLJKWHQWKHDLU )LJ)XHO)LOWHU%OHHG$LU
YHQWSOXJWRWKHVSHFLILHGWRUTXH
Fuel Injection Pump - Bleed Air
1. /RRVHQWKHDLUYHQWSOXJRQWKHIXHOLQMHFWLRQSXPS
E\URWDWLQJDERXWWXUQV Air vent plug
2. 0RYHWKHSULPLQJSXPSXSDQGGRZQXQWLOWKHIXHO
IORZIURPWKHDLUYHQWSOXJLVIUHHIURPDLUEXEEOHV
3XVKDQGWXUQWKHSULPLQJSXPSFORFNZLVHWRORFN
LQWKHRULJLQDOSRVLWLRQZKHQWKHIXHOIORZVLVIUHH
IURPEXEEOHV
3. 7LJKWHQWKHDLUYHQWSOXJRQWKHIXHOLQMHFWLRQSXPS
Priming pump

)LJ)XHO,QMHFWLRQ3XPS%OHHG$LU


 &KDSWHU23(5$7,21

Priming Pump Tightening Method

Position where 90° ± 10°

1HYHUIDLOWRWLJKWHQWKHSULPLQJSXPSWRWKHVSHFL hand-tightening
ILHGDQJOH,IWKHSULPLQJSXPSLVQRWILUPO\WLJKWHQHG becomes suddenly Priming pump
heavy
LQWHUQDOWKUHDGZLOOEHZRUQGXHWRHQJLQHYLEUDWLRQ
UHVXOWLQJLQVXGGHQHMHFWLRQRIWKHFDSWRFDXVHIXHO
Head can be damaged
IORZRXW2ULIWKHSULPLQJSXPSLVH[FHVVLYHO\WLJKW if the cap is excessively
tightened.
HQHGWKHKHDGRIWKHSULPLQJSXPSFDQEHGDP
(120° or more)
DJHG
1. *HQWO\WLJKWHQWKHSULPLQJSXPSFDSE\KDQGXQWLO
WKHWLJKWHQLQJIRUFHVXGGHQO\LQFUHDVHV )LJ3ULPLQJ3XPS7LJKWHQLQJ0HWKRG
2. 8VHDZUHQFKRUDQRWKHUDSSURSULDWHWRROWRWLJKWHQ
WKHSULPLQJSXPS“ƒ
3. &KHFNWKHPRXQWLQJSRVLWLRQRIKHDGSDFNLQJ +HDGSDFNLQJ
1RWH ,IWKHKHDGSDFNLQJKDVDEQRUPDOLW\VXFKDVGH
IRUPDWLRQRUVFUDWFKHV FRQVXOWD GHDOHURI0LW
VXELVKL+HDY\ ,QGXVWULHV/WG DV WKHSULPLQJ
SXPSQHHGVWREHFKDQJHG

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&KDSWHU23(5$7,21

Preparation of Lubrication System

Engine Oil - Refill
Oil filler
Oil level gauge
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UHILOOLQJRLOJRHVRYHUWKHKLJKPDUNVRQWKHRLOOHYHO
JDXJHHQJLQHRLOPD\EORZRXW$QGDOVRWKHHQJLQH
FRPSRQHQWSDUWVDUHDGYHUVHO\DIIHFWHGE\LQFUHDV H
Improper
High
LQJLQRLOWHPSHUDWXUH Proper
L
Low Improper
1. 5HPRYHWKHFDSIURPWKHRLOILOOHU Oil level gauge
2. )LOOWKHHQJLQHRLOSDQZLWKVSHFLILHGHQJLQHRLOWR
WKHVSHFLILHGOHYHO
1RWH )RUHQJLQHRLOUHIHUWR (1*,1(2,/)RU )LJ2LO)LOOHUDQG2LO/HYHO*DXJH
HQJLQHRLOFDSDFLW\ UHIHUWR0$,163(&,),&$
7,216
3. 5HPRYHWKHURFNHUFRYHUDQGSRXUHQJLQHRLOWR
WKHYDOYHPHFKDQLVPDQGFDPVKDIWRLOEDWK3RXU
HQJLQHRLOWRFDPVKDIWRLOEDWKIURPF\OLQGHUKHDG
VLGH
2LOFDSDFLW\SHUF\OLQGHU/>86JDO@
4. 5HLQVWDOOWKHURFNHUFRYHUV
Camshaft
5. &KHFNWKHRLOOHYHOLQWKHRLOSDQ
oil bath
6. 3XOORXWWKHRLOOHYHOJDXJHDQGZLSHLWFOHDQZLWKD
)LJ3RXULQJ(QJLQH2LORQ9DOYH0HFKDQLVPVDQG
ZDVWHFORWK &KDPEHU
7. ,QVHUWWKHRLOOHYHOJDXJHIXOO\LQWRWKHRLOOHYHO
JDXJHJXLGHDQGWKHQSXOOLWRXWDJDLQ
8. 7KHSURSHURLOOHYHOLVEHWZHHQWKHKLJKDQGORZ
PDUNVRQWKHRLOOHYHOJDXJH
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OHYHOJDXJHRSHQWKHHQJLQHRLOGUDLQYDOYHWR
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9. &KHFNWKHRLOSDQDQGRWKHUDUHDIRURLOOHDNV5H
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10. :KLOHSXOOLQJWKHVWRSOHYHUURWDWHWKHFUDQNVKDIW
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WKHRSHUDWLRQIRUPLQXWHWKHQUHSHDWWKHRSHUD
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11. 6WDUWWKHHQJLQHDQGUXQWKHHQJLQHLQDQRORDG
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12. &KHFNWKHRLOOHYHOZLWKWKHRLOOHYHOJDXJHDJDLQ
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 &KDSWHU23(5$7,21

Preparation of Cooling System

Radiator Cap - Open/Close

Turn the cap about Stand the lever to

:KHQXVLQJWKHHQJLQHZLWKUDGLDWRUFRROLQJV\VWHP half a turn the upright position
UHPRYHWKHUDGLDWRUFDSRQO\DIWHUWKHHQJLQHKDV
FRROHGWRWKHURRPWHPSHUDWXUH3ODFHDZDVWHFORWK
RYHUWKHFDSDQGORRVHQWKHFDSDERXWDKDOIWXUQRU
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QDOSUHVVXUH2SHQLQJWKHUDGLDWRUFDSRIFRRODQW
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DQGKRWFRRODQWWREORZRXWDQGFDQUHVXOWLQVNLQ
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1RWH ,IWKHVSHFLILFDWLRQRIUDGLDWRU GLIIHUVIURPWKH
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PDQXIDFWXUHU
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Coolant - Refill

Left side Right side

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WLRQ

1. &ORVHWKHFRRODQWGUDLQFRFNRIHQJLQHDQGZDWHU
SXPSVHFXUHO\
Coolant
2. 2SHQWKHFRRODQWILOOHUDQGDGGDPL[WXUHRIZDWHU
drain cocks
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The coolant drain cocks located in the crankcase
1RWH D 'HWHUPLQHWKHTXDQWLWLHVRI//&EDVHGRQWKH respectively (behind the each fuel injection pump
FRRODQWFDSDFLW\DQGWKH//&FRQFHQWUDWLRQ accessory drive unit).

FKDUW )LJ&RRODQW'UDLQ&RFN(QJLQH

)RUWKHFRRODQWUHIHUWR &22/$17 
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3. &KHFNWKHKHDWH[FKDQJHHTXLSPHQWDQGRWKHU
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Coolant
4. :KHQFRRODQWUHDFKHVWKHIXOOOHYHOFORVHWKHFRRO
drain cock
DQWILOOHUVHFXUHO\
5. :KLOHSXOOLQJWKHPDQXDOVWRSOHYHUURWDWHWKH
)LJ&RRODQW'UDLQ&RFN:DWHU3XPS
FUDQNVKDIWIRUDSSUR[VHFRQGVXVLQJWKHVWDUW
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6. &KHFNWKHOHYHORIFRRODQW


&KDSWHU23(5$7,21

Preparation of Electrical System

Battery - Check

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JHWLQWR\RXUH\HVIOXVKWKHPLPPHGLDWHO\ZLWKSOHQW\RIZDWHUDQGWKHQJHWPHGLFDODWWHQWLRQ
'RQRWXVHRSHQIODPHVRURWKHUILUHKD]DUGVQHDUWKHEDWWHU\:KHQKDQGOLQJWKHEDWWHU\EHFDUHIXORIVSDUNVJHQ
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VRS
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Battery Electrolyte Level - Inspect
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HOHFWURO\WHOHYHOJUDGXDOO\GHFUHDVHV7KHSURSHUHOHF
10 to 15 mm
WURO\WHVXUIDFHOHYHOLVEHWZHHQWKH/2:(5/(9(/ [0.39 to 0.59 in.]
DQG833(5/(9(/OLQHV
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ER L
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 &KDSWHU23(5$7,21

Test Operation
7RFRQGXFWDWHVWRSHUDWLRQIROORZWKHSURFHGXUHVEHORZ

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HQJLQH8QEXUQHGIXHOPD\H[SORGHLQWKHH[KDXVWSLSH(PHUJHQF\JHQHUDWRUZLWKZDWHUKHDWHU
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Starting and Stopping
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3. 6WRSWKHHQJLQH
Inspection
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2. 'XULQJWKLVSHULRGFKHFNWKHHQJLQHDQGVXUURXQGLQJDUHDIRUOHDNVRIIXHOHQJLQHRLORUFRRODQW
3. $WPLQXWHVDIWHUWKHHQJLQHVWRSFKHFNWKHRLOOHYHOZLWKWKHRLOOHYHOJDXJH7KHSURSHURLOOHYHOLVEHWZHHQ
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4. ,IWKHHQJLQHRLOJRHVRYHUWKHKLJKPDUNVRQWKHRLOOHYHOJDXJHRSHQWK
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5. 2SHQWKHFRRODQWILOOHUFDSDQGFKHFNWKHFRRODQWOHYHO
6. ,IWKHFRRODQWOHYHOLVORZDGGFRRODQWWRWKHVSHFLILHGOHYHO

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&KDSWHU23(5$7,21

Normal Engine Operation

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6KRXOGDQHQJLQHDEQRUPDOLW\EHREVHUYHGGXULQJRSHUDWLRQVWRSWKHHQJLQHDQGFRUUHFWWKHSUREOHPRUFRQWDFWD
GHDOHURI0LWVXELVKL+HDY\,QGXVWULHV/WG

Preparations for Operation

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Engine External - Inspect

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Fuel Tank Oil Level - Check

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Fuel Control Link - Check

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Warming-up Operation

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Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES
Basic Engine
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Fuel System
Fuel System - Inspect

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:LSHRIIDQ\VSLOOHGIXHOFRPSOHWHO\6SLOOHGIXHOFDQLJQLWHDQGFDXVHDILUH

Fuel Tank - Clean

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1. &ORVHWKHIXHOIHHGYDOYHWRFXWRIIWKHIXHOVXSSO\WRWKHHQJLQH
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Fuel Tank - Drain Water

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3. 0DNHVXUHWKDWZDWHUDQGSDUWLFOHVRIIRUHLJQPDWH
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Water Separator - Drain Water

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PDQXIDFWXUHU
VRSHUDWLRQPDQXDO Outlet cock
Inlet cock
Drain cock

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Water Separator Element - Replace

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2. 7XUQWKH7KDQGOHDQGUHPRYHWKHZDWHUVHSDUDWRU Outlet cock

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3. 2SHQWKHGUDLQFRFNDQGGUDLQIXHOLQWKHZDWHU
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4. &ORVHWKHDOOGUDLQFRFNVDIWHUGUDLQLQJ
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6. )LOOWKHZDWHUVHSDUDWRUZLWKIXHO
Element
7. $WWDFKWKHZDWHUVHSDUDWRUFRYHUDQGWLJKWHQWKH7 Inlet cock
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9. $IWHUUHSODFLQJWKHHOHPHQWRSHQWKHIXHOIHHG
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Gauze Filter - Clean

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LQVXIILFLHQWUHVXOWLQJLQGHFUHDVHLQSRZHURXWSXWRU
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Gauze filter
1. 5HPRYHWKHH\HEROWDWWKHLQOHWSRUWRIIXHOIHHG
SXPS Eyebolt
2. 8VLQJDVFUHZGULYHUUHPRYHWKHJDX]HILOWHUWKDWLV
ILWWHGLQVLGHWKHH\HEROW
3. 6RDNWKHJDX]HILOWHULQWKHIXHODQGFOHDQLWZLWKD
Fuel feed pump
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4. $IWHUFOHDQLQJLQVWDOOWKHJDX]HILOWHULQWRWKHH\H
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Fuel Filter - Replace

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2. 3UHSDUHDGULSSDQDQGSODFHLWXQGHUWKHIXHOILO
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3. 8VLQJDILOWHUZUHQFKUHPRYHWKHIXHOILOWHUV
4. :LSHRIIIXHORQWKHIXHOILOWHUFDUWULGJHPRXQWLQJ
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5. &KHFNQHZIXHOILOWHUVIRUSURSHUVHDWLQJRIWKHJDV
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6. $SSO\FOHDQIXHOWRWKHJDVNHWRIWKHQHZIXHOILOWHU
7. ,QVWDOOWKHIXHOILOWHUWRWKHILOWHUEUDFNHW:KHQWKH Apply fuel to
JDVNHWFRQWDFWVWKHPRXQWLQJVXUIDFHRIWKHILOWHU the gasket.

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Fuel Control Link Ball Joint - Inspect

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0.1 mm
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Lever
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Fuel Pipe - Inspect

High Pressure Fuel Injection Pipe and Clamp Seat - Inspect and Replace
Visual Inspection in Every 2000 Service Hours
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Low Pressure Fuel Pipe and Clip - Inspect

Visual Inspection in Every 2000 Service Hours
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Lubricating System
Engine Oil, Oil Filter and Bypass Oil Filter - Replace

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:KHQGUDLQLQJRLORUFKDQJLQJWKHRLOILOWHUZHDUJORYHV+RWHQJLQHRLODQGSDUWVPD\FDXVHEXUQV

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WULHV/WG
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'RQRWUHXVHWKHRLOILOWHUHOHPHQWDVLWLVDSDSHUW\SH:KHQUHSODFLQJILOWHUVDOZD\VUHSODFHJDVNHWZLWKQHZ
RQHV

Engine Oil - Drain

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Engine Oil - Refill

Oil filler
Oil level gauge
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Oil Filter and Bypass Oil Filter - Replace

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Bypass oil filter
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Oil filter

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E\SDVVRLOILOWHU
Oil tray
'RQRWGHQWRUVFUDWFKWKHRLOILOWHUVXUIDFHV Filter wrench

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5HSODFH
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3. 8VLQJDILOWHUZUHQFKUHPRYHRLOILOWHUVDQGDE\ to gasket.
SDVVRLOILOWHU
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Engine Oil for Mixing of Fuel and Water - Inspect

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Governor Oil Filter - Change

Air vent plug

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JORYHV+RWHQJLQHRLODQGSDUWVPD\FDXVHEXUQV
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2. /RRVHQWKHDLUYHQWSOXJDQGUHPRYHWKHGUDLQSOXJ Drain plug

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3. 5HPRYHWKHRLOSLSHIURPWKHFHQWHUEROW
4. 5HPRYHWKHFHQWHUEROWDQGUHPRYHWKHFDVHIURP Oil pipe
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EROW Element
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7. ,QVWDOOWKHRLOSLSHWRWKHFHQWHUEROW Case
8. ,QVWDOOWKHGUDLQSOXJ
9. 5HPRYHWKHDLUYHQWSOXJ)LOOXSWKHILOWHUZLWKHQ
JLQHRLO Center bolt
10. $IWHUILOOLQJXSUHLQVWDOOWKHDLUYHQWSOXJ
)LJ*RYHUQRURLOILOWHU&KDQJH

Oil Pipe - Inspect

Oil Pipe and Clip - Inspect and Replace
Visual Inspection at Overhaul
/RRVHQFODPSIL[LQJEROWDQGFKHFNFOLSZHDUDQGSLSH
ZHDU,IGHIHFWLYHUHSODFHWKHSLSHDVVHPEO\ZLWKD
QHZRQH
In Every Other Major Overhaul
5HSODFHWKHSLSHDVVHPEO\ZLWKDQHZRQH

Clip

Clamp

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Cooling System
Coolant - Change

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Radiator Cap - Open/Close

Turn the cap about Stand the lever to

:KHQXVLQJWKHHQJLQHZLWKUDGLDWRUFRROLQJV\VWHP half a turn the upright position
UHPRYHWKHUDGLDWRUFDSRQO\DIWHUWKHHQJLQHKDV
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Coolant - Drain
1. :KHQGUDLQLQJFRRODQWLPPHGLDWHO\DIWHUHQJLQH Left side Right side
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Coolant
3. 3ODFHFRRODQWUHFHLYLQJFDQVXQGHUWKHGUDLQFRFNV
drain cocks
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The coolant drain cocks located in the crankcase
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accessory drive unit).
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Cooling System - Clean

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RUKHDWH[FKDQJHHTXLSPHQWILUVWWLPHRUUHVWDUWLQJ
WKHHQJLQHDIWHUVWRUDJHZLWKFRRODQWGUDLQHG

1. &ORVHFRRODQWGUDLQFRFNVDQGSOXJV
2. 3RXULQDFOHDQLQJVROXWLRQDVROXWLRQWKDWLVQRQ
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Coolant - Refill

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Radiator Fins - Check and Clean

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Inlet and Exhaust Systems

Turbocharger - Inspect

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$OVRPDNHVXUHWKDWWKHFRPSUHVVRUZKHHOLVQRW
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Exhaust Muffler - Drain Water

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WKHH[KDXVWPXIIOHU Drain plug
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Air Cleaner - Check for Clogging

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Reset button
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2. ,IWKHHOHPHQWLVFORJJHGWKHUHGVLJQDOPDUNZLOO Signal
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Air Cleaner Element - Clean, Check and Replace

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3. %ORZFRPSUHVVHGDLU03D^NJIFP`>
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7. 5HDVVHPEOHWKHDLUFOHDQHUHOHPHQWDVLWZDV

Clean Check

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Electrical System
Battery - Check

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Battery Electrolyte Level - Inspect
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10 to 15 mm
WURO\WHVXUIDFHOHYHOLVEHWZHHQWKH/2:(5/(9(/ [0.39 to 0.59 in.]
DQG833(5/(9(/OLQHV
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Specific Gravity of Battery Electrolyte - Check
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Float
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Starter - Inspect
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1RWH ,IWKHVWDUWHULVGHIHFWLYHFRQVXOWDGHDOHURI0LW
VXELVKL+HDY\,QGXVWULHV/WG

Starter
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Alternator - Inspect
9LVXDOO\FKHFNWKHDOWHUQDWRUIRUGDPDJH
Alternator
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0LWVXELVKL+HDY\,QGXVWULHV/WG

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Air Starter System

Air Strainer - Drain Water and Clean

:KHQRSHQLQJWKHGUDLQYDOYHRIDLUVWUDLQHURSHQLW
Starting air Starting air
VORZO\+LJKSUHVVXUHGDLULVLQWKHSLSHRQO\HYHQLI inlet outlet
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1. &ORVHWKHKDQGOHIRUVWDUWLQJRIWKHDLUWDQN
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Cap
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Packing Plug
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Air Tank - Drain Water

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2. $IWHUZDWHULVGUDLQHGDQGWKHDLULVGLVFKDUJHGLQ pipe
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handle
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Air Tank - Inspect Safety Valve Operation

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2. )LOODLUZLWKWKHDLUFRPSUHVVRU
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 Chapter 9 LONG-TERM STORAGE

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GDPDJHWRWKHHQJLQH
:KHQVWRULQJWKHHQJLQHIRUDQH[WHQGHGSHULRGRIWLPHEHVXUHWRIROORZWKHVWHSVEHORZ

Storing the Engine in an Inoperable Condition

for 3 Months or More
Preparation for Storage
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2. 3UHSDUHDIXHOPL[WXUHFRQWDLQLQJUXVWSUHYHQWLYHIXHO13DQGILOOWKHIXHOWDQNZLWKLW
3. 5XQWKHHQJLQHDWORZLGOLQJVSHHGVIRUWRPLQXWHV
4. ,PPHGLDWHO\EHIRUHVWRSSLQJWKHHQJLQHVSUD\YRODWLOHFRUURVLRQLQKLELWRU9&,WKURXJKWKHLQOHWSRUWWRSUHYHQW
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Using the Engine After Storage

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Storing the Engine in an Operable Condition

for 3 Months or More
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Operating the Engine for Maintenance

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 Chapter 10 TRANSPORTATION
Lifting the Engine
Rear hanger
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$WWDFKWKHZLUHURSHWRWKHKDQJHUVSURYLGHGRQWKH
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7KHKDQJHUVHTXLSSHGZLWKWKHHQJLQHLVGHVLJQHG
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RQWKHHQJLQHXVHWKHVSHFLDOKDQJHURIFRPPRQ )LJ+DQJHU
EHG
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60 mm
:KHQPRXQWLQJPDULQHJHDURQWKHHQJLQHEHVXUH
[2.36 in.]
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ORDGFRXOGEHLPSRVHGRQWKHKDQJHUVDQGWKLVFRXOG [8.27 in.]

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$WWDFKZLUHURSHVWRWKHKDQJHUVDIWHUUHPRYLQJWKH
The center of gravity
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 Chapter 11 TROUBLESHOOTING
General Precautions
Contact a Dealer of Mitsubishi Cautions Against Contamina-
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