Home

99410-12140_Operation & Maintenance Manual S6R

1. peas o Condition Remedy From 1 26 to 1 28 Fully charged Electrolyte From 1 22 to 1 26 Charged Charge Glass tube Less than 1 22 Discharged Charge Fig 8 31 Specific Gravity of Battery Electrolyte Check 8 23 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Starter Inspect Visually check the starter for damage Note If the starter is defective consult a dealer of Mit subishi Heavy Industries Ltd Starter Fig 8 32 Starter Inspect Alternator Inspect Visually check the alternator for damage Remove the belt and turn the pulley by hand to make sure that it rotates smoothly Note If the alternator is defective consult a dealer of Mitsubishi Heavy Industries Ltd Fig 8 33 Alternator Inspect 8 24 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Air Starter System Air Strainer Drain Water and Clean When opening the drain valve of air strainer open it slowly High pressured air is in the pipe only even if the air tank valve is closed Do not open it suddenly 1 Close the handle for starting of the air tank 2 Remove the drain plug of air starter strainer and drain water from the air strainer 9 Remove the cap and remove the filter from the cap Clean the filter with diesel fuel then blow com pressed air to dry 5 Reassemble the air strainer as it is 6 Open the starting air handles slowly Note If the specif
2. Fuel system Faulty fuel injection timing o Consult a dealer of Mitsubishi Heavy Industries Ltd __ Check oil leakage Oil leakage to the outside of engine oe Consult a dealer of Mitsubishi Heavy Industries Ltd Faulty engine oil property Analyze oil property Use appropriate engine oil Refer to P5 Lubricating viscosity 3 system vai Check amount of engine oil and lubrication system Refer to P3 9 Engine oil temperature is high Check oil cooler and oil thermostat Consult a dealer of Mitsubishi Heavy Industries Ltd Check heat exchanger Cooling Check control system Overheatin system g Thermostat Inspect Consult a dealer of Mitsubishi Heavy Industries Ltd Check oil leakage to the turbocharger Inlet and Spread oil to intake part 3 Pe exhaust Consult a dealer of Mitsubishi Heavy Industries Ltd wens Wear of valve operating system Consult a dealer of Mitsubishi Heavy Industries Ltd Control ee ee Check control system and governor controller system Consult a dealer of Mitsubishi Heavy Industries Ltd Basic engine Wear of sliding parts Consult a dealer of Mitsubishi Heavy Industries Ltd Note The table above also include the parts Mitsubishi Heavy Industries Ltd does not supply For the parts Mitsub ishi Heavy Industries Ltd does not supply inspect and maintain them following the manufacturer s operation manual 11 8 Chapter 11 TROUBLESHOOTING Ove
3. acceptable Table 6 1 Water Quality Standards Item pias Unit oa Limit Main adverse effect 5 Corrosion and rust scale pH 25 C 77 F 6 5 to 8 0 6 5 to 8 5 formation Electrical conductivity Corrosion and rust scale 25 C 77 F mS m lt 25 lt 40 formation Total hardness CaCO3 ppm lt 95 lt 100 Scale formation M alkalinity CaCO3 ppm lt 70 lt 150 Scale formation Chlorine ion Ck ppm lt 100 lt 100 Corrosion and rust Sulfuric acid ion S042 ppm lt 50 lt 100 Corrosion and rust Total iron Fe ppm lt 1 0 lt 1 0 Scale formation Silica SiO2 ppm lt 30 lt 50 Scale formation Residue from evaporation ppm lt 250 lt 400 Scale formation Note Other than those above turbidity must be below 15 mg liter Long Life Coolant LLC CAUTION Should coolant or LLC be accidentally swallowed induce vomiting immediately and seek medical attention If LLC should enter eyes flush immediately with plenty of water and seek medical attention Be sure to use Mitsubishi Heavy Industries Ltd genuine long life coolant LLC GLASSY long life coolant Ethyl ene glycol type or PG GLASSY long life coolant Non amine type as coolant When using other brand LLCs by necessity be sure to use the non amine type LLC that meets the specification in Mitsubishi Heavy Industries Ltd Mitsubishi heavy industries disclaims the warranty claims about malfunctions due to the use of LLC that does not meet the follo
4. RN Install the belt cover Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Table 8 1 Ribbed Belt Tension Force Num Belt direct distance mm Item ber of 2 300 or more 400 or more 500 or more ribs Up to 300 Up to 400 Up to 500 Up to 600 eee 3 74N 7 55 kgf 49 N 5 00 kgf 37 N 3 77 kgf 29 N 2 96 kgf 25 N 2 55 kgf 16 64 Ibf 11 02 Ibf 8 31 Ibf 6 53 Ibf 5 62 Ibf 4 88 N 8 97 kgf 59 N 6 02 kgf 44 N 4 49 kgf 35 N 3 57 kgf 29 N 2 96 kgf 19 78 Ibf 13 27 Ibf 9 90 Ibf 7 87 Ibf 6 53 Ibf 5 103 N 10 50 kgf 69 N 7 04 kgf 51 N 5 20 kgf 41 N 4 18 kgf 34 N 3 47 kgf 23 15 Ibf 15 52 Ibf 11 46 Ibf 9 22 Ibf 7 65 Ibf 6 118 N 12 03 kgf 79 N 8 06 kgf 59 N 6 02 kgf 47 N 4 79 kgf 39 N 3 98 kgf 26 52 Ibf 17 77 Ibf 13 27 Ibf 10 56 Ibf 8 77 Ibf 7 132 N 13 46 kgf 88 N 8 97 kgf 66 N 6 73 kgf 53 N 5 40 kgf 44 N 4 49 kgf sii 29 67 Ibf 19 78 Ibf 14 84 Ibf 11 90 Ibf 9 90 Ibf attaching a new belt 8 147 N 14 99 kgf 98 N 9 99 kgf 74N 7 55 kgf 59 N 6 02 kgf 49 N 5 00 kgf 33 05 Ibf 22 02 Ibf 16 64 Ibf 13 27 Ibf 11 02 Ibf 9 162 N 16 52 kgf 108 N 11 01 kgf 81 N 8 26 kgf 65 N 6 63 kgf 54 N 5 51 kgf 36 42 Ibf 24 27 Ibf 18 21 Ibf 14 62 Ibf 12 15 Ibf 10 176 N 17 95 kgf 118 N 12 03 kgf 88 N 8 97 kgf 71
5. ceeeeee 5 3 Service Limits of Engine Oil 5 4 Definition of Properties of Engine Oil 5 5 Kinetic Viscosity ceeeeeeeeeeeenteeeeeeenteeeeeeeee 5 5 Base Number cccceeeeeeeeeeeeeeeseeeeceeeeeeeeeees 5 5 Acid Number seet eneeier coteenesdceetteles 5 5 Water Content ccceceeceeeseeeeesessseeeesessenaees 5 5 Flash Point ccscet eric acto ink deeded 5 5 INSOlUDIG Ss22cccdeexc E A E eens E E 5 5 Engine Oil Analysis Service 5 6 Chapter 6 COOLANT Recommended Water for Coolant 6 1 Long Life Coolant LLC 0 06 6 1 Genuine LING extant a ssoee tees eerste 6 1 Other Brand LLCsS cccccceeeeeees 6 2 Standard for Other Brand LLC 6 2 General Demands of LLC cee cceeeteeeeeeees 6 2 LLC Specification ccccceceeseeceeeeeeeeseeeeseees 6 3 Maintenance of LLC 000cceeee 6 6 Replacement Intervals of LLC ee 6 6 LLC Concentration ccccccccsseeeeeesesteeeeeeeees 6 6 Importance of LLC ceeeeeeeeeees 6 7 Characteristics of LLC Additive and Important Notes vc ie ascend icdentesedebabences 6 7 Examples of Abnormalities Caused by LLC Amine Typa nrar aiid ace aaa 6 7 Pitting of Iron Parts 6 7 Corrosion of Aluminum Parts c cccccecee 6 7 Pitting and Clogging of the Heat Exchange EQUIPIMGMN ee aa NA 6 7 Chapter 7 MAINTENANCE SCHEDULE How to Use the Maintenance Schedule7 1 Gener
6. EMISSION WARRANTY IMPORTANT The following warranty applies to the engines that are approved of the emission regulation of the U S Environ mental Protection Agency 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 Warranty Period Then its warranty period is 5 years or 3000 hours whichever comes first 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 pParts 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 Limited Warranty It conforms to LIMITED WARRANTY page ii F
7. Fig 8 29 Air Cleaner Check for Clogging 8 22 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Electrical System Battery Check If battery electrolyte is spilled on your skin or clothes flush immediately with plenty of water If battery electrolyte get into your eyes flush them immediately with plenty of water and then get medical attention Do not use open flames or other fire hazards near the battery When handling the battery be careful of sparks gen erated by accidental shorting Note If the specification of battery differs from the contents of this operation manual follow the manufacturer s op eration manual Battery Electrolyte Level Inspect Battery electrolyte evaporates during use and the electrolyte level gradually decreases The proper elec 10 to 15 trolyte surface level is between the LOWER LEVEL 0 39 io a in and UPPER LEVEL lines ey i Proper For the battery without level lines the proper electro lyte surface level is about 10 to 15 mm 0 39 to 0 59 in above the top of the plates If the electrolyte level is low remove the caps and add distilled water to the proper level Note When adding distilled water add little by little Fig 8 30 Battery Electrolyte Level Inspect Specific Gravity of Battery Electrolyte Check If the specific gravity measured at 20 C 68 F is lower than 1 22 then charge the electrolyte Table 8 4 Specific gravity of electrolyte
8. contents of this operation manual follow the Fig 8 23 Radiator fins Clean manufacturer s operation manual 8 18 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Inlet and Exhaust Systems Turbocharger Inspect Check the turbocharger when the engine is cold Also make sure that the compressor wheel is not rotating before inspecting the turbocharger If the color of the exhaust gas is abnormal also inspect the turbocharger Disconnect the pipe from the air inlet side Hold the compressor wheel nut by hand and turn the wheel to check for looseness or rotation smoothness Replace the turbocharger if any abnormal movement is found Note When removing and inspecting turbocharger contact a dealer of Mitsubishi Heavy Industries Ltd Also inspect that there is any discoloration or damage on the compressor wheel fins Exhaust Muffler Drain Water The exhaust muffler is very hot immediately after operation Never touch the exhaust muffler by hand Work must be conducted after the exhaust muffler cools at the room temperature Remove the drain plug and allow water to drain from the exhaust muffler Note If the specification of exhaust muffler differs from the contents of this operation manual follow the manufacturer s operation manual Fig 8 24 Turbocharger Inspect 0 Drain plug Fig 8 25 Draining Water From the Exhaust Muffler 8 19 Chapter 8 PERIODIC INSPECTION AND MAI
9. 8 3 Table 8 2 Damper Temperature Managemenrt 8 4 Table 8 3 Thermo Label for Temperature Management cessceesseeeesneeeeesneeeeeneees 8 5 Table 8 4 Specific gravity of electrolyte 8 23 Table 9 1 Recommended Rust preventive Oil and Corrosion Inhibitor c eee 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 ceceeecseeeeseeeeeeeseeeees 11 3 Table 11 3 Output Decrease cccceeeesteeeeees 11 4 Table 11 4 Exhaust Smoke is White or Blue 11 5 Table 11 5 Exhaust smoke is black or charcoal 11 6 Table 11 6 Fuel Consumption is High 0 11 7 Table 11 7 Engine oil Consumption is High 11 8 Table 11 8 Overheating eeeeeeeeeeeeteeeeeeeneetaes 11 9 Table 11 9 Low Engine Oil Pressure 0060 11 9 Table 12 1 Main Specifications cceeeeeeee 12 1 CONTENTS 5 Chapter 1 BASIC SAFETY PRECAUTIONS Fire and Explosions Keep Flames Away Do not use flames near the engine in the engine room Fuel gas vapor or other gas can catch fire and produce dangerous 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 ar
10. 8 19 Exhaust Muffler Drain Water 8 19 Air Cleaner Check for Clogging 0 8 20 Air Cleaner Element Clean Check and Replace A E E T OE eens 8 21 Electrical System ccceeeeeeeeees 8 23 Starter INSP Ct ccecececeeeeeeeeeeeeteeeeeneeeeees 8 24 Alternator Inspect 8 24 Air Starter System eee 8 25 Air Strainer Drain Water and Clean 8 25 Air Tank Drain Water aee 8 25 CONTENTS Air Tank Inspect Safety Valve Operation 8 26 Chapter 9 LONG TERM STORAGE Storing the Engine in an Inoperable Condition for 3 Months or More 9 1 Preparation for Storage seeen 9 1 Maintenance During Storage cseeeee 9 1 Using the Engine After Storag cccee 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 ceeeeeeeeeeees 10 1 Chapter 11 TROUBLESHOOTING General Precautions 00eee 11 1 Contact a Dealer of Mitsubishi Heavy Industries Ltd for Repair Service cccceeeeeceeeeeeees 11 1 Considerations Before Work aseeseen 11 1 Cautions Against Contamination 0 11 1 Cautions Regarding Parts Handling 11 1 Safety Work c cceeceeeeeeeeeeeteeeeeeeeeeeaeeeeeeeees 11 1 Case of Problems and Conceivable Causes and Remedies 00008 11 2
11. Air Cleaner Indicator If the element is clogged the intake air is decreased and the red signal mark will be displayed The signal indicates only and does not generate an alarm Therefore the periodic visually inspection is needed Press the reset button on the top of air cleaner indica tor and restore the signal after cleaned the air cleaner indicator or replaced with a new one Fig 2 12 Revolution Detection Pickup Reset button Signal red Fig 2 13 Air Cleaner Indicator Chapter 2 NAME OF PARTS Using Turning Gear Before starting the engine make sure that the manual turning gear is pulled out in the original position Starting the engine with the turning gear pushed in not only damages the ring gear but also may result in personal injury 1 Loosen the two bolts and remove the plate from the shaft groove Fig 2 14 Manual Turning Gear Position While Engine is Running 2 Push in the shaft fully to engage it with the ring gear A Fig 2 15 Manual Turning Gear Position When Pushing Shaft in 3 Using a socket wrench and a ratchet handle turn the shaft 4 After turning pull out the shaft insert the plate in the shaft groove and tighten the bolts Make sure the plate is securely installed in the shaft groove Ratchet handle Fig 2 16 Turning Gear Position When Turning Shaft Chapter 3 OPERATION Operational Environment a rae aE Check that the following contents
12. engine stall 1 Remove the eye bolt at the inlet port of fuel feed pump 2 Using a screw driver remove the gauze filter that is fitted inside the eye bolt 3 Soak the gauze filter in the fuel and clean it with a brush 4 After cleaning install the gauze filter into the eye bolt using a screw driver Fig 8 7 Gauze Filter Clean 5 Install the eye bolt to the fuel feed pump 6 Bleed the air from the fuel filter Note For bleeding the fuel filter refer to Fuel Filter Bleed Air 3 2 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Fuel Filter Replace 1 Clean the area around the fuel filters 2 Prepare a drip pan and place it under the fuel fil ters 9 Using a filter wrench remove the fuel filters gt Wipe off fuel on the fuel filter cartridge mounting surface of the filter bracket with a waste cloth o Check new fuel filters for proper seating of the gas ket Do not use a filter with the dented case Filter dam age or fuel leakage may occur and it can cause fire hazard 9 Apply clean fuel to the gasket of the new fuel filter Install the fuel filter to the filter bracket When the gasket contacts the mounting surface of the filter N bracket further rotate 3 4 to a full turn Do not use a filter wrench to install the fuel filter Do not dent or scratch the fuel filter surfaces 8 After installing the new fuel filter bleed the fuel fil ter Note For ble
13. 14 5 C 6 F Frozen temperature 50 vol Maximum 34 0 C 29 F Boiling temperature 155 C 311 F or higher Stock solution pH 7 0 to 11 0 30 vol 30 vol 4 0 ml or less Bubbling character 150 mi 0 032 gal or m ASTM D3306 01 ml 0 gal or less Disappearance o 331 3 vol bubble within 5 seconds Hard water adaptability 1 0 or less 50 vol Aluminum 0 30 mg cm Cast iron 0 15 mg cm Mass Steel 0 15 mg cm change Brass 0 15 mg cm2 Metal specimen p Solder 0 30 mg cm Metallic causticity Copper 0 15 mg cm a No visible si f i th f 190 4 35 6 F o visible signs of corrosion on the surface 3362 Hr Re EA of the specimen excluding the area contacting to spacer 30 vol E G 9 However discoloration is acceptable Po vale RIA Bubbling during the test Not bubbling overflow pH 6 5 to 11 0 Properties of pH change 1 0 ae after the Precipitation 0 5 vol or less ce No remarkable discoloration separation Appearance of liquid and gel generation Chapter 6 COOLANT Table 6 2 LLC Specification Property Standard Aluminum Cast iron Steel Brass 0 30 mg cm Solder Copper Mass change Metal specimen No visible signs of corrosion on the surface Appearance of the specimen excluding the area contacting to spacer a A aner testing However discoloration is acceptable 1208 4235 6 F pr PATOSA 1000 Hr pH change 1 0 EG Pradaniesict Pre al
14. 5 1 5 2 6 1 8 1 8 2 8 3 8 4 8 5 8 6 8 7 8 8 8 9 8 10 8 11 8 12 8 13 8 14 8 15 8 16 8 17 8 18 8 19 8 20 8 21 8 22 8 23 8 24 8 25 8 26 8 27 8 28 8 29 Thermo label of damper n se 3 11 Manual Stop Lever cccsseeeees 3 14 Engine Oil Grade 0 eee 5 1 Selection of Oil Viscosity 5 3 GLASSY LLC e 6 1 Belt and Belt Tension Inspect and HAUST a eae ee 8 2 Damper Check Visually 8 4 Damper Temperature Managemert 8 5 Fuel Tank Drain Water eee 8 6 Water Separator Drain Water 8 7 Water Separator Element Replace 8 7 Gauze Filter Clean cccccccceeeeeees 8 8 Fuel Filter Replace eeeeeseeeeee 8 9 FUGIIFINGE E E toi ee Soe 2 8 9 Ball Joints For Looseness Inspect 8 10 Fuel Control Link Remove 4 8 10 High Pressure Fuel Injection Pipe and Clamp Seat Inspect and Replace 8 11 Low Pressure Fuel Pipe and Clip sinspeel enaa Gab ale 8 11 Oil Filler and Oil Level Gauge 8 13 Oil Filter and Bypass Oil Filter Replace sche haan elas 8 14 Oil Fillehirecha eka aiden 8 14 Governor oil filter Drain 8 15 Governor oil filter Change 4 8 15 Oil Pipe and Clip Inspect and Replace ei icihintiet lie tenidine 8 15 Radiator Cap cecceeceeesereseeseteeeseeesees 8 16 Coolant Drain Cock Engine 8 16 Coolant Drain Cock Water Pump 8 1
15. The Starter Does Not Crank or Cranks Slowly Resulting in Start Failure c cesses 11 2 The Starter Cranks but the Engine Does Not SIAM ea S avs eda eet agen es 11 3 Output Decrease ccccceessceceseeeteeeesseeaees 11 4 Exhaust Smoke is White or Blue 11 5 Exhaust Smoke is Black or Charcoal 11 6 Fuel Consumption is High 11 7 Engine Oil Consumption is High 0 11 8 Overheating cccceeeeeeeeeeeeeeeeeeeesetaeeeteeeees 11 9 Low Engine Oil Pressure 11 9 When Fuel has Run Out 11 10 Chapter 12 MAIN SPECIFICATIONS Main Specifications cccee 12 1 CONTENTS 3 CONTENTS List of illustrations Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig 1 1 2 1 2 2 2 3 2 4 2 5 2 6 2 7 2 8 2 9 2 10 2 11 2 12 2 13 2 14 2 15 2 16 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8 3 9 3 10 3 11 3 12 3 13 3 14 3 15 3 16 3 17 Warning labels 1 9 Engine Left Side View eceeeeeeeeee 2 1 Engine Right Side View assecca 2 1 Start Switch and Stop Switch 2 2 Manual Stop Lever nsss 2 2 Stop Solenoid oe eee eeeeeeeeeeeeeeeeeeees 2 2 Oil Pressure Unit aseeseen 2 3 Thermo Unit syties Aa lees 2 3 Revolution Detection Pickup 2 3 Oil Pre
16. and Table 4 2 of Rec ommended Limit and Use Limit of Fuel Property It is necessary to use fuel that has a pour point suitable for the ambient temperature Note Please use the fuel that meet the control of the countries or areas where the engine is used if the control is applied Table 4 1 Recommended Fuel Specification Classification ISO 8217 DMX CLASS ASTM D975 No 1 D No 2 D BS 2869 CLASS A1 CLASS A2 DIN 51601 DIESEL FUEL JIS K2204 TYPE1 TYPE2 TYPE3 EN 590 DIESEL FUEL Handling Fuel When using fuel from a storage tank leave it to sit for more than 24 hours so that dust and water can settle at the bottom Then use the upper clean fuel Fill up the fuel tank or service tank after each operation This prevents water from mixing with fuel in the tank and also gives time for dust and water to separate and settle at the bottom of the tank Before refilling clean the areas around the caps thoroughly and remove the caps from the drum and tank Also clean your hands and the hose before refueling When using a hand operated pump be careful not to pump water or sediment accumulated at the bottom of the storage tank Be sure to use a strainer when filling fuel tank For a complete filtration it is recommended to use a clean lint free cloth together with the strainer 4 1 Chapter 4 FUEL Fuel Specification Use fuel which meets the requirements specified in the table below Table 4 2 Recommen
17. and check the engine for abnormalities Never accelerate the engine immediately before shutting it down Do not restart the engine immediately after abnormal shut down When the engine stops with alarms be sure to locate the cause of the problem and correct the problem before restarting the engine After restarting the opera tion check the engine for abnormalities again If the engine has an abnormality repair it immediately Engine stopping method varies depending on the specifications To stop the engine follow the instructions of the equipment Emergency Stop A CAUTION When stopping the engine by pulling the manual stop lever continue pulling the lever until the engine stops completely If not the engine may start again To perform the emergency stop pull the manual stop lever to the arrow direction Continue pulling the lever until the engine stops completely Note When the engine does not stop even if the man ual stop lever is pulled stop fuel supply Fig 3 19 Manual Stop Lever Inspection After Stopping Inspect the engine for fuel oil or coolant leaks If any leak is found repair the leak or contact a dealer of Mitsubishi Heavy Industries Ltd 3 14 Chapter 4 FUEL Recommended Fuel WARNING Use a fuel specified in this manual only Do not refill the fuel tank more than the specified level Otherwise fire may result Use fuel that meets the values specified in the following Table 4 1 of Recommended Fuel
18. and result in serious engine problems 1 5 Chapter 1 BASIC SAFETY PRECAUTIONS 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 is below the LOWER LEVEL mark Sustained 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 dug 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 ae securely installed on the battery terminals A loose cable clamp cancause sparks that may result in an explosion Before servicing electrical components or conducting electric welding set the batteryswitch to Open OFF position or remove the plug from the negative ter minal to cut off the electrical current Battery electrolyte contains dilute sulfuric acid Care less handling of the battery can cause the loss ofight and or skin burns Also do not swallow the battery electrolyte Wear protective goggles and rubber gloves when working with the battery e g adding water charging battery If battery eledrolyte is spil
19. close 2 84 MPa 29 kgf cm 412 psi 4 lf defective in safety valve operation contact a dealer of Mitsubishi Heavy Industries Ltd Note If the specification of air tank differs from the contents of this operation manual follow the manufacturer s operation manual 8 26 Chapter 9 LONG TERM STORAGE a If the engine has been left unattended for 3 months or more the internal engine parts can rust and that may cause damage to the engine When storing the engine for an extended period of time be sure to follow the steps below Storing the Engine in an Inoperable Condition for 3 Months or More Preparation for Storage Drain the engine oil in use and pour rust preventive oil NP 10 2 Prepare a fuel mixture containing 50 rust preventive fuel NP 9 and fill the fuel tank with it Run the engine at low idling speeds for 5 to 10 minutes Peps Immediately before stopping the engine spray volatile corrosion inhibitor VCI through the inlet port to prevent rust on the air intake system Stop the engine and drain the fuel mixture from the fuel tank Apply rust preventive oil NP 3 liberally on the exposed sections of mechanical surfaces Seal the air inlet exhaust outlet breather and other openings with an adhesive cloth tape Loosen the belt OO Peg Wrap adhesive cloth tape on the terminals of the starters and alternator and seal the openings Cover these sec tions with polyethylene sheet or processed polyeth
20. repeat the opera tion two or three times Circulate engine oil to each engine parts Note Prepare for the cooling system 10 Check the oil level with the oil level gauge again and add oil to the specified level Oil level gauge 5 i 0 oQ i Improper Oil filler High Proper Low J Improper Oil level gauge Fig 8 14 Oil Filler and Oil Level Gauge 8 13 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Oil Filter and Bypass Oil Filter Replace Do not use a filter with the dented case Filter dam ie s 4 s oll Titer age or oil leakage may occur and it can cause fire hazard Do not use a filter wrench to install the oil filter and Filter wrench bypass oil filter Do not dent or scratch the oil filter surfaces 1 Clean around the oil filters Fig 8 15 Oil Filter and Bypass Oil Filter 2 Prepare drip pans and place them under oil filters Replace and a bypass oil filter Apply engine oil 3 Using a filter wrench remove oil filters and a by to gasket pass oil filter Note Disconnect the removed oil filters and a bypass oil filter and check elements for metal particles If metal particles are found contact a dealer of Mitsubishi Heavy Industries Ltd gt Thoroughly wipe off oil on the oil filter mounting surface of the filter bracket
21. 3 OPERATION Preparation of Lubrication System Engine Oil Refill Refilling engine oil must be specified level If the i gt oq llsvel gatas refilling oil goes over the high marks on the oil level gauge engine oil may blow out And also the engine l i component parts are adversely affected by increas Sa High Improper ing in oil temperature puns E Proper 1 Remove the cap from the oil filler Low J Improper 2 Fill the engine oil pan with specified engine oil to the specified level Note For engine oil refer to ENGINE OIL 5 1 For Fig 3 6 Oil Filler and Oil Level Gauge engine oil capacity refer to MAIN SPECIFICA TIONS 12 1 3 Remove the rocker cover and pour engine oil to the valve mechanism and camshaft oil bath Pour engine oil to camshaft oil bath from cylinder head side Oil capacity per cylinder 0 8 L 0 21 U S gal 4 Reinstall the rocker covers 5 Check the oil level in the oil pan Camshaft oil bath 6 Pull out the oil level gauge and wipe it clean with a Fig 3 7 Pouring Engine Oil on Valve Mechanisms and waste cloth Chamber 7 Insert the oil level gauge fully into the oil level gauge guide and then pull it out again 8 The proper oil level is between the high and low marks on the oil level gauge If
22. 7 MAINTENANCE SCHEDULE Periodic Maintenance Chart for Regular Use Engine Table 7 1 Periodic Maintenance Chart for Regular Use Engine Refer Interval and Service item ence page Every 50 service hours or Fuel Tank Drain Water 1 8 6 every month Water Separator Drain Water 1 8 7 Bolts and Nuts on the Engine Retighten 2 First 50 service hours for a new or overhauled Engine Oil Oil Filter and Bypass Oil Filter Replace engine It is recommended to check the engine oil characteristics at the same time 8 12 The oil filters must be replaced when the filter alarm lights Engine Oil Oil Filter and Bypass Oil Filter Replace Every 250 service hours It is recommended to check the engine oil characteristics at the same time 8 12 The oil filters must be replaced when the filter alarm lights First 250 service hours fora new or overhauled Valve Clearance Inspect and Adjust 9 Check valve mechanism at the same time engine Fuel Filter Replace 8 9 Water Separator Element Replace 1 8 7 Every 1000 service hours Gauze Filter Clean 8 8 Belt and Belt Tension Inspect and Adjust 8 2 Fuel Tank Drain Water Replace Parts as Necessary 1 8 6 Valve Clearance Inspect and Adjust D Check valve mechanism at the same time Fuel Injection Timing Inspect and Adjust 2 Fuel Injection Nozzle Nozzle Tip Replacement Every 2000 hours Check the spray condition a
23. Engine Protection Devices 2 4 Oil Pressure Switch ccceeceeeeeeeeeteeeeeneeeeees 2 4 Thermo Switch 0 ccceceeeeeeeeceeeeeeeeeeeeaeeeeeeeeees 2 4 CONTENTS 1 CONTENTS Oil Filter Alarm SWitch c ccccecseseeseees Revolution Detection Pickup 0 08 Air Cleaner Indicator ccccccsssseeeeees Using Turning Gear eeeee Chapter 3 OPERATION Operational Environment Preparation for Operating New or Overhauled Engine 000 Preparation of Fuel System c Preparation of Lubrication System Preparation of Cooling System 200 Preparation of Electrical System Test Operation cccccceessseeeeesessteeeeesenaees Normal Engine Operation Preparations for Operation Engine External Inspect Fuel Tank Oil Level Check Fuel Control Link Check Engine Oil Level Check Coolant Level Check Air Cleaner Check for Clogging Air Tank Drain Water 0 0 Chapter 4 FUEL Recommended Fuel sccccee Handling Fuel catcs eevee dee Fuel Specification ccsssscees CONTENTS 2 Chapter 5 ENGINE OIL Recommended Engine Oil 5 1 Engine Oil Gla vais rock ties tt adebacets 5 1 Engine Oil Specification 5 2 Selection of Oil Viscosity 00 5 3 Handling Engine Oil
24. FED791 3462 617 F 300 or lower 1 It must have been certified API service classification CF by 2009 2 Temperature of test 24 C 75 2 F Temperature of test II 93 5 C 200 3 F Temperature of test III 24 C 75 2 F after 93 5 C 200 3 F 3 Temperature of aluminum panel 300 C 572 F and 325 C 617 F Temperature of engine oil 100 C 212 F Splatter time 15 seconds Downtime 45 seconds Test time 8 hours the properties are the weight of solid product Selection of Oil Viscosity Use the following chart to select the appropriate oil viscosity according to the ambient temperature Excessively high oil viscosity causes power loss and 30 20 ra 7 P Temperature 3h 4 HA 32 50 68 86 104 n22 l an abnormal rise of oil temperature while excessively C PF Patri riral low oil viscosity accelerates wear due to inadequate aS lubrication and also causes a decrease in engine out Engine ol ore j g viscosity put due to leakage of combustion gas lt q SAEISW 40 gt Fig 5 2 Selection of Oil Viscosity Handling Engine Oil WARNING Before filling the engine with engine oil stop the engine and make sure there are no open flames and other fire hazards near the engine Leaked or spilled oil on hot surfaces or electrical components can cause a fire Wipe off any spilled oil immediately and thoroughly After filling oil securely close the filler cap When handling a l
25. above also include the parts Mitsubishi Heavy Industries Ltd does not supply For the parts Mitsub ishi Heavy Industries Ltd does not supply inspect and maintain them following the manufacturer s operation manual 11 3 Chapter 11 TROUBLESHOOTING Output Decrease Table 11 3 Output Decrease Cause Remedies Improper fuel property Use appropriate fuel Refer to P4 1 Clogged fuel filter Inspect and replace fuel filter Refer to P8 9 Clean gauze filter Refer to P8 8 Check fuel injection pump couplings E a a cv ecuen uN Consult a dealer of Mitsubishi Heavy Industries Ltd Check fuel injection pump rack stroke Improper amount of injected fuel aaa Consult a dealer of Mitsubishi Heavy Industries Ltd Faulty fuel feed pump Consult a dealer of Mitsubishi Heavy Industries Ltd Check fan and heat exchange equipment Overheat overcooled Check control system Consult a dealer of Mitsubishi Heavy Industries Ltd Check turbocharger Refer to P8 19 Clean inspect and replace air cleaner element Refer to P8 Insufficient amount of air Inlet and Check intake air pressure and leakage of intake air exhaust Check intake air temperature and ventilation device systems Consult a dealer of Mitsubishi Heavy Industries Ltd Check turbocharger Refer to P8 19 Increase resistance of exhaust air Check exhaust pipes and silencer Consult a dealer of M
26. are performed before the engine is operated Failure to do so may cause various problems and will shorten the service life of the engine Prevent from spreading water especially seawater or rainwater and entering foreign materials to the air inlet opening Prevent from entering foreign materials to the rotating parts Prevent from attaching water and dust to the electrical system Use the engine at 5 to 40 C 41 to 104 F Keep the coolant temperature properly by switching ON the water heater automatic mode Emergency generator with water heater Preparation for Operating New or Overhauled Engine Before proceeding with operation of a new overhauled engine conduct the inspections described in this section For second operation onward follow the instructions described in the Normal Engine Operation 3 8 Preparation of Fuel System a CAUTION When handling fuel make sure there are no open flames or other fire hazards near the engine Wipe off any spilled fuel completely Spilled fuel can ignite and cause a fire Do not remove the strainer during fuel tank filling For fuel to be used refer to FUEL 4 1 1 Make sure the insides of the fuel tank and fuel supply pipes to the engine are thoroughly clean 2 Check the drain valve and air inlet valve is closed at the time 3 Fill fuel tank with fuel 4 Remove the fuel feed pipe and drain plug from the fuel inlet of engine and check the discharged fuel for foreign ma
27. gear case and always detect engine speed Fig 2 8 Revolution Detection Pickup Chapter 2 NAME OF PARTS Engine Protection Devices The engine protection devices activate an alarm when an abnormality occurs in the engine in order to protect the engine and prevent serious problems and accidents When a protection device is activated stop the engine exam ine the cause of the abnormality and take corrective measures If the cause of the problem is unknown contact a dealer of Mitsubishi Heavy Industries Ltd Protection devices installed on the engine and their types setting values and shapes vary depending on the engine specifications Oil Pressure Switch The oil pressure switch generates an alarm when the engine oil pressure becomes low and reaches the specified pressure Thermo Switch The oil pressure switch generates an alarm when the engine coolant temperature becomes high and reaches the specified temperature Oil Filter Alarm Switch The oil filter alarm switch generates an alarm to stop Oil filter the engine when oil filters become clogged the differ alarm switch ence in pressure between inlet and outlet of oil and reaches the specified value Oil pressure switch Fig 2 11 Oil Filter Alarm Switch Chapter 2 NAME OF PARTS Revolution Detection Pickup The overrun detection pickup generates an alarm when the engine speed becomes high and reaches the specified engine speed
28. in 170 x 220 mm 6 69 x 8 66 in Displacement 24 5 L 1495 31 cu in 30 0 L 1830 99 cu in Combustion type Direct injection system Compression ratio 14 0 1 Firing order 1 5 3 6 2 4 Direction of rotation Counterclockwise as viewed from flywheel side Dimensions L x W x H Approx 1946 x 1082 x 1498 mm Approx 1946 x 1051 x 1578 mm 76 61 x 42 60 x 58 98 in 76 61 x 41 38 x 62 13 in Dry weight Approx 2800 kg 6173 Ib Approx 2900 kg 6393 Ib Fuel Diesel fuel Fuel injection pump Mitsubishi PS6 Governor Mechanical oil pressure or electrical type Fuel filter Paper element type Fuel injection nozzle Hole type Fuel injection starting pressure 34 3 MPa 350 kgf cm 4978 psi Lubrication method Forced circulation pressure feed by oil pump Lubrication oil Class CF or CH 4 oil API service classification Engine oil capacity Oil pan Approx 84 L 22 19 U S gal Whole engine Approx 94 L 24 83 U S gal Oil filter Paper element type Oil cooler Water cooled multi plate Cooling method Forced water cooling Coolant capacity Approx 50 L 13 21 U S gal Approx 55 L 14 53 U S gal in engine only in engine only Starting system Electrical or pneumatic type Starter DC 24 V 7 5 kW Alternator DC 24 V 30 A Turbocharger Mitsubishi TD13 or TD15 Fl
29. inappropriate or inferior oils will result in sticking of piston rings seizure between piston and cylinder or premature wear of bearings and moving parts and significantly shortens the service life of the engine Engine Oil Grade Many oil standards which are established through special engine tests are available to determine the quality of oil depending on the engines to which they will be applied and on operating conditions Among those standards API American Petroleum Institute service classifications are mostly used to classify engine oils SAE specifies the viscosity only while the API service classification indicates the quality level of engine oil For engine lubrication oil please use API service clas sification CF or CH 4 When using the CF class engine oil it must be certi fied according to API service classification CF by 2009 and satisfied the following Table 5 1 Recommended Limit of Engine Oil Properties When using the CH 4 class engine oil the sulfur con tent of fuel must be 0 2 weight or lower OIL OIL Class CF Class CH 4 API Service API Service Classification Classification Fig 5 1 Engine Oil Grade 5 1 Chapter 5 ENGINE OIL Engine Oil Specification Use engine oil which meets the requirements specified in the table below Table 5 1 Recommended Limit of Engine Oil Properties Item Unit Recom
30. maintain them following the manufacturer s operation manual Chapter 11 TROUBLESHOOTING The Starter Cranks but the Engine Does Not Start Table 11 2 The Starter Cranks but the Engine Does Not Start Cause Remedies Inspect fuel tank supply fuel bleed air Refer to P8 6 Run out of fuel blocked pipe Check fuel pipes valves al i Use appropriate fuel Refer to P4 1 mproper fuel proper PRG er Remove dust water impurities Refer to P8 6 Fuel leakage in fuel pipes and Check faults and retighten fuel pipes and injection pipes injection pipes Consult a dealer of Mitsubishi Heavy Industries Ltd Fuel system Inspect and replace fuel filter Refer to P8 9 Clogged fuel filter i Clean gauze filter Refer to P8 8 Faulty fuel feed pump Consult a dealer of Mitsubishi Heavy Industries Ltd SN Check fuel injection pump rack stroke Faulty fuel injection pump f oe i Consult a dealer of Mitsubishi Heavy Industries Ltd Faulty fuel injection nozzle Consult a dealer of Mitsubishi Heavy Industries Ltd E Check turbocharger Refer to P8 19 a Ei Insufficient amount of air Clean inspect and replace air cleaner element Refer to P8 21 Fuel control link Check Refer to P3 9 Control Faulty governor ao system Consult a dealer of Mitsubishi Heavy Industries Ltd Basic engine Low compression pressure Consult a dealer of Mitsubishi Heavy Industries Ltd Note The table
31. 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 ona 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 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 identi
32. of rated load limit each operation to an hour Prolonged warm up operation causes carbon build up in the cyl inders that leads to incomplete combustion Operate the engine with a30 of rated load or more for over 5 minutes to prevent carbon build up after one hour continuous operation is conducted 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 Maintain the engine with air cleaner according to the following instructions Never service the air cleaner while the engine is run ning The turbocharger may suck particles of foreign materials into the engine and could result in serious accidents Remove the air cleaner slowly to prevent foreign ma terials accumulated on the element from falling off Af ter removing the air cleaner immediatelycover the air inlet with plastic sheet or similar means to prevent for eign materials from entering the engine 1 8 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
33. operating record of the engine to determine the most appropriate service intervals Feel free to consult a dealer of Mitsubishi Heavy Industries Ltd regarding service intervals Service the items at multiples of the original requirement For example at 1000 service hours also service those items listed under every 250 service hours and every 50 service hours Periodic Maintenance Chart Appropriate service intervals vary depending on the engine specifications Perform all daily inspection and mainte nance items in an accordance with the following 3 categories Periodic Maintenance Chart for Regular Use Engine When the engine is used as a regular use engine perform the periodic inspection and maintenance in accordance with the Periodic Maintenance Chart for Engine in Regular Use Periodic Maintenance Chart for Emergency Engine When the engine is used as an emergency engine perform the periodic inspection and maintenance in accordance with the Periodic Maintenance Chart for Emergency Engine Due to the nature of application an engine for emer gency use is subject to demanding operating conditions such as a quick startup and immediate supply of power In addition it must operate reliably in the event of an emergency Therefore be sure to perform the daily inspection and also conduct the following operation for maintenance purposes Once every week Operate the engine under no load for 3 to 5 minutes When operating the engine for th
34. the drain cock and drain water in the water separator Close the all drain cocks after draining Note If the specification of water separator differs from Water Separator Element Replace the contents of this operation manual follow the manufacturer s operation manual Fig 8 5 Water Separator Drain Water Open the inlet valve slowly to prevent overflowing fuel Wrap a cloth around the water separator before the fuel may spill 1 2 NO Oo PF Close the inlet cock and outlet cock Turn the T handle and remove the water separator cover Open the drain cock and drain fuel in the water separator Close the all drain cocks after draining Replace the element with a new one Fill the water separator with fuel Attach the water separator cover and tighten the T handle Open the inlet cock and outlet cock After replacing the element open the fuel feed valve to the engine then bleed air from the fuel system Note a For bleeding fuel system refer to Fuel Sys tem Bleed Air 3 2 b If the specification of water separator differs from the contents of this operation manual follow the manufacturer s operation manual Element Fig 8 6 Water Separator Element Replace 8 7 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Gauze Filter Clean If the gauze filter is clogged the fuel supply becomes insufficient resulting in decrease in power output or
35. visually Checking LLC Concentration Level in the Coolant 2 Every 6 months Cleaning the Inside of the Coolant Tank 1 Chapter 7 MAINTENANCE SCHEDULE Table 7 2 Periodic Maintenance Chart for Emergency Engine Refer Interval and service item ence page Belt and Belt Tension Inspect and Adjust 8 2 Bolts and Nuts on the Engine Check and Retighten 2 Damper Inspect 8 4 Valve Clearance Inspect and Adjust Basic engine Check valve mechanism at the same time 2 Inspecting the Vibration isolating Rubber 1 2 Foundation Bolts Inspect 1 2 Couplings Inspect or Replace 1 2 Every one year Fuel Tank Drain Water 1 8 6 Water Separator Drain Water 1 8 7 Fuel Injection Nozzle Spray Condition and Spray Pres Fuel system sure Inspect and Adjust 2 Fuel Injection Timing Inspect and Adjust 2 Fuel Pipe Inspect 8 11 Oil Pipe Inspect 8 15 Lubricating Engine Oil Properties Analyze 2 system Engine Oil Pressure Maintenance Operation Inspect 9 and Adjust Chapter 7 MAINTENANCE SCHEDULE Table 7 2 Periodic Maintenance Chart for Emergency Engine Refer Interval and service item ence page Water Pump Inspect 2 Solenoid Valve and Pressure Reducing Valve of the Cool 9 ing System Inspect Disassemble and Clean 1 Cooling system Strainer Including With Ball Tap of Cooling Water 9 Inspect Disassemble a
36. your eyes flush them immediately with plenty of water and then get medical attention Do not use open flames or other fire hazards near the battery When handling the battery be careful of sparks gen erated by accidental shorting Note If the specification of battery differs from the contents of this operation manual follow the manufacturer s op eration manual Battery Electrolyte Level Inspect Battery electrolyte evaporates during use and the electrolyte level gradually decreases The proper elec 10 to 15 trolyte surface level is between the LOWER LEVEL 0 39 A I in Za and UPPER LEVEL lines For the battery without level lines the proper electro lyte surface level is about 10 to 15 mm 0 39 to 0 59 in above the top of the plates If the electrolyte level is low remove the caps and add distilled water to the proper level Note When adding distilled water add little by little Proper Fig 3 11 Battery Electrolyte Level Inspect Chapter 3 OPERATION Test Operation To conduct a test operation follow the procedures below Always switch the water heater ON automatic mode through a whole year If the switch is not ON automatic mode each cylinder varies considerably in combustion at the starting up the engine Unburned fuel may explode in the exhaust pipe Emergency generator with water heater Before starting the engine switch the water heater ON automatic mode and keep the coolant tem
37. 142 psi 4 Close the air pressure gauge valve Note If the specification of air tank differs from the contents of this operation manual follow the manufacturer s operation manual Temperature of Damper Check Air pressure gauge Fig 3 17 Starting Air Tank Air Pressure Check Damper temperature management by thermo label It is recommended to use the thermo label for temper ature management of the damper Check the thermo label before starting engine 1 Check the thermal part of thermo label is black 2 Note the highest temperature of thermal part Note the temperature periodically and check the abnor mality of temperature alteration If the abnormality of temperature alteration is found consult a dealer of Mitsubishi Heavy Industries Ltd Note For damper temperature limit and inspection re fer to Damper Inspect 8 4 Display example When thermal part of the thermo label is black until 80 it indicates that the maximum Thermo label temperature of damper during operating is 5 p lt 5E 100 gt from 80 C 176 F to 85 C 185 F Oty OD 100 105 110 115 120 DAIL lt 5E 75 gt e0OO00 75 80 85 90 95 H EDAIL lt 5E 50 gt e0e080 50 55 60 65 70 Fig 3 18 Thermo l
38. 4 to 54 3123 Ib ft 49 9424 to 54 3123 Ib ft3 ISO 3675 24 hrs at 250 C 482 F 75 carbonization or less 80 carbonization or less Caulking a hrs at 230 C 55 carbonization or less Fed 791B 446 F 48 hrs at 180 C 356 F Tar free Aromatics substances by HPLC 38 by volume or less JIS K 2536 2003 Polycyclic aromatic content 8 volume or lower ISO 3837 Asphaltene 0 1 weight or lower 4 2 Chapter 4 FUEL Table 4 2 Recommended Limit and Use Limit of Fuel Property Item Recommended limit Use limit Test method Foreign substances foreign materials at engine fuel 5 0 mg liter or less JIS B 9931 2000 ISO 4405 inlet Lubricity MWSD Measured mean 460 um 0 02 in or less Wear Scar Diameter by HFRR calculated wear scar diame i ISO 12156 1 wear test at 60 C 140 F fuel tem perature ter at WS 1 4 kPa 0 0143 kgf cm 0 2031 psi JIS K 2390 2008 BDF Biodiesel fuel FAME Fatty BDF quality shall ee a or ASTM D 6751 or ang for Acid Methyl Ester BDF blending of 5 by volume or less is approved ASTM D 6751 EN 14214 Selection PE for regular prime use for emergency use E according to AGING appicangns Regular Emergency sppllcalion Chapter 5 ENGINE OIL Recommended Engine Oil Use the engine oils recommended in this manual only Never use oil other than that specified in this manual The use of
39. 7 Radiator fins Clean s s s 8 18 Turbocharger Inspect eee 8 19 Draining Water From the Exhaust MUTI Cf ievccn eth ove atiets tet etan 8 19 Air Cleaner Check for Clogging 8 20 Air Cleaner Element Remove 8 21 Air Cleaner Element Clean and CONTENTS Fig Fig Fig Fig Fig Fig Fig Fig 8 30 8 31 8 32 8 33 8 34 8 35 10 1 10 2 Battery Electrolyte Level Inspect 8 23 Specific Gravity of Battery Electrolyte GNOCK EAEAP EE 8 23 Starter INSPOCt eee eeeeeeeeeteees 8 24 Alternator Inspect 8 24 Air Strainer Drain Water and Clean 8 25 Engine s center of gravity standard specification 0 10 1 List of tables Table 3 1 Inspection During Operation 3 13 Table 4 1 Recommended Fuel 4 1 Table 4 2 Recommended Limit and Use Limit of Fuel Property scat ni wennein aii 4 2 Table 5 1 Recommended Limit of Engine Oil Properties n ieee ak 5 2 Table 5 2 Engine Oil Properties c eee 5 4 Table 6 1 Water Quality Standards eee 6 1 Table 6 2 LLC Specification eeeeeeeeeeees 6 3 Table 6 3 Recommended LLC Concentration 6 6 Table 7 1 Periodic Maintenance Chart for Regular Use Engine ceecee 7 3 Table 7 2 Periodic Maintenance Chart for Emergency Engine sesser 7 5 Table 7 3 Periodic Maintenance Chart for General Purpose Engine ceeee 7 9 Table 8 1 Ribbed Belt Tension Force
40. C 4 9F 30 C 22 F 45 C 49 F or above or above or above or above LLC concentration GLASSY Green 30 40 50 60 PG GLASSY Red 40 55 70 2 Note a If the outside air temperature is 30 C 22 F or lower use GLASSY b The concentration above is based on Mitsubishi Heavy Industries Ltd genuine LLC GLASSY long life coolant Ethylene glycol type or PG GLASSY long life coolant Non amine type For determining the accurate LLC concentration refer to the instructions for the LLC used 6 6 Chapter 6 COOLANT Importance of LLC Today s trend is toward smaller and lighter engines offering greater output lower fuel consumption and lower exhaust emission levels Conditions to which engine coolant is subjected therefore are becoming severer due to longer operat ing hours higher coolant temperature and higher cool ant circulating speed Many different materials such as steel aluminum copper solder and rubber are used in the cooling sys tem and they are also subjected to the severe condi tions described above Those materials have different ionization characteristics and this difference acceler ates corrosion through the medium of engine coolant To prevent such a problem it is necessary to use the LLC having the additive that prevents rust Characteristics of LLC Additive and Important Notes LLC contains several chemicals in such proportions as to produce chemical react
41. Ltd disclaims the war ranty claim concerning malfunctions caused by the use of LLC that does not meet the following specifica tion General Demands of LLC LLC must be a homogeneous liquid without sedi ment When the LLC is diluted to 30 to 60 density the LLC shall not cause troubles such as corrosion and precip itation deposits in the engine cooling system LLC shall be mixed with other LLC that satisfies this specification and shall not separate elements each other and shall not decrease the performance each other LLC shall not allow the container to be corroded and shall not has precipitation products etc even if LLC is left in the container for 6 months LLC shall not has extraction products etc even if LLC is kept in 20 to 25 C 4 to 13 F The validity term of the quality that provides with this specification is 2 years after it delivers with the indoor normal temperature keeping Chapter 6 COOLANT LLC Specification LLC shall be examined according to JIS K2234 Section 7 Test method and satisfy this requirements General matters and the specimen sampling shall comply with JIS K2234 Table 6 2 LLC Specification Property Standard Appearance No precipitation Minimum 1 112 g cm 69 4199 Ib ft 20 Density 20 C 68 68 F Stock solution Water content Maximum 5 0 weight Stock solution 30 vol Maximum
42. N 7 24 kgf 59 N 6 02 kgf 39 57 Ibf 26 52 Ibf 19 78 Ibf 15 96 Ibf 13 27 Ibf 11 191 N 19 48 kgf 127 N 12 95 kgf 96 N 9 79 kgf 76 N 7 75 kgf 64 N 6 53 kgf 42 95 Ibf 28 55 Ibf 21 58 Ibf 17 09 Ibf 14 40 Ibf 42 206 N 21 01 kgf 137 N 13 97 kgf 103 N 10 50 kgf 82 N 8 36 kgf 69 N 7 04 kgf 46 32 Ibf 30 80 Ibf 23 15 Ibf 18 43 Ibf 15 52 Ibf 3 51 N 5 20 kgf 34 N 3 47 kgf 26 N 2 65 kgf 21 N 2 14 kgf 17 N 1 73 kgf 11 46 Ibf 7 65 Ibf 5 84 Ibf 4 72 Ibf 3 81 Ibf 4 62 N 6 32 kgf 41 N 4 18 kgf 31 N 3 16 kgf 25 N 2 55 kgf 21 N 2 14 kgf 13 93 Ibf 9 22 Ibf 6 97 Ibf 5 62 Ibf 4 72 Ibf 5 72 N 7 34 kgf 48 N 4 89 kgf 36 N 3 67 kgf 29 N 2 96 kgf 24 N 2 45 kgf 16 18 Ibf 10 78 Ibf 8 09 Ibf 6 53 Ibf 5 40 Ibf 6 82 N 8 36 kgf 55 N 5 61 kgf 41 N 4 18 kgf 33 N 3 37 kgf 27 N 2 75 kgf 18 43 Ibf 12 37 Ibf 9 22 Ibf 7 43 Ibf 6 06 Ibf 7 93 N 9 48 kgf 62 N 6 32 kgf 46 N 4 69 kgf 37 N 3 77 kgf 31 N 3 16 kgf 5 F 20 90 Ibf 13 93 Ibf 10 34 Ibf 8 31 Ibf 6 97 Ibf euse 8 103 N 10 50 kgf 69 N 7 04 kgf 51 N 5 20 kgf 41 N 4 18 kgf 34 N 3 47 kgf 23 15 Ibf 15 52 Ibf 11 46 Ibf 9 22 Ibf 7 65 Ibf 9 113 N 11 52 kgf 75 N 7 65 kgf 57 N 5 81 kgf 45 N 4 59 kgf 38 N 3 87 kgf 25 40 Ibf 16 87 Ibf 12 81 Ibf 10 12 Ibf 8 53 Ibf 10 123 N 12 54 kgf 82 N 8 36 k
43. NTENANCE PROCEDURES Air Cleaner Check for Clogging 1 Check the air cleaner indicator for the element Reset button clogging 2 Ifthe element is clogged the red signal mark will ae be displayed me wed 3 Immediately clean or replace the air cleaner ele ment when the signal turns red Note a For cleaning of the air cleaner element refer to Air Cleaner Element Clean Check and Replace 8 21 b If the specification of air cleaner differs from Fig 8 26 Air Cleaner Check for Clogging the contents of this operation manual follow the manufacturer s operation manual 8 20 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Air Cleaner Element Clean Check and Replace When handling compressed air wear safety goggles a dust mask a hardhat gloves and other necessary protec tive gear Working without wearing proper protective gear could result in serious injuries Never perform maintenance on the air cleaner while the engine is running Servicing the pre cleaner while the engine is running can cause particles of foreign material to enter the engine and result in rapid wear of parts lead ing to a shorter service life of the engine Never tap hit or wash the air cleaner element If defects such as cuts pinholes or local wear are found in the element or if the air cleaner indicator shows a red sign soon after the cleaned element is installed change it for new one Remove the air cleaner
44. OCPERATION amp MAINTENANCE MANUAL MITSUBISHI DIESEL ENGINES 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 MITSUBISHI 2 HEAVY INDUSTRIES LTD Pub No 99410 12140 FOREWORD This operation and maintenance manual contains detailed operation inspection and maintenance information for engines from Mitsubishi Heavy Industries Ltd Please be forewarned that there are contents which are overlapping between the chapters 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 Please observe the contents of the controls which are applied in the countries or areas when using the engines from Mitsubishi Heavy Industries Ltd FOREWORD LIMITED WARRANTY If Mitsubishi Heavy Industries Ltd examines the returned parts and any failure at manufacturing is found Mitsubi shi Heavy Industries Ltd shall repair or exchange the parts 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 tr
45. OREWORD CALIFORNIA EMISSION CONTROL WARRANTY STATE MENT YOU WARRANTY RIGHTS AND OBLIGATIONS IMPORTANT The following warranty applies to the engines that are approved of the emission regulation of the California Air Resources Board CARB The California Air Resources Board CARB and Mitsubishi Heavy Industries Ltd are pleased to explain the emission control system warranty on you 2011 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 Manufacurer s warranty coverage The 2011 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 responsiblities As the heavy duty off road engine owner you are respo
46. OTATING BELT DO NOT PUT FINGERS NEAR ROTATING BELT 45493 50800 1 9 Chapter 2 NAME OF PARTS Engine External Diagrams Left Side Governor oil filter Fuel filter Breather Fuel injection pump Hanger Hanger i Governor Oil cooler Fuel feed pump Water pump Froni D ee Coolant inlet Coolant drain cock Coolant drain cock Stop solenoid Oil filter Bypass oil filter Oil level gauge Fuel inlet Fuel return port Oil filler Fig 2 1 Engine Left Side View Right Side Turbocharger Exhaust outlet Coolant outlet Air intake inlet Thermostat Hanger Fan Air cooler io MUTSUBISH Starter Alternator Damper Name plate Fig 2 2 Engine Right Side View 2 1 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 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 the engine complete
47. a low idling speed for 5 to 10 minutes for warming up Start the work after this operation is completed Warm up oper ation circulates the lubricant around the engine and thereby individual engine parts are well lubricated before they are subjected to heavy loads Warm up operation circulates lubricant oil around the engine and contributes to a longer service life and economical 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 Chapter 1 BASIC SAFETY PRECAUTIONS Conduct Cooling Operation Before Stopping the Engine Before stopping the engine idle the engine 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 Do Not Operate Engine Contin uously Under Low Load When operating the engine with less than 30
48. abel of damper 3 11 Chapter 3 OPERATION Start The starting method varies depending on the application and specifications Start the engine according to the spec ified procedure Before starting the engine check to make sure no one is near the engine and that tools are not left on or near the engine In a loud voice notify people in the area when starting the engine Do not apply a load to the engine at starting Disengage the clutch if equipped Continuous operation of the starter will drain the battery power and cause the starter to seize Do not use the starter for more than 10 seconds at a time When the engine does not start wait for more than 1 minute before cranking again Warming up Operation Do not approach rotating parts during operation Entanglement by rotating parts can result in serious injury After the engine starts operate the engine in a no load condition at low idling speed for 5 to 10 minutes to warm up the engine Checking Engine Oil Pressure During warm up operation check if the oil pressure is in the range of standard value 0 3 MPa 3 1 kgf cm 21 psi or more Also make sure the oil pressure gauge is actuated properly External Inspection During Warm up During warm up operation walk around the engine and check for fuel oil coolant or exhaust gas leaks oO 12 Chapter 3 OPERATION Run Cautions During Operation Do not approach rotating parts during
49. ace 1 8 7 Gauze Filter Clean 8 8 meyara aa an a rons ao Coolant Change 8 16 Thermostat Inspect 2 Turbocharger Inspect 8 19 Exhaust Muffler Drain Water 1 8 19 Air Compressor Overhaul Air motor type or direct inlet type 2 7 17 Chapter 7 MAINTENANCE SCHEDULE Table 7 2 Periodic Maintenance Chart for Emergency Engine Refer Interval and service item ence page Top End of the Engine Overhaul Remove the cylinder head and inspect and service the combustion cham o bers If the abnormalities of first and second cylinders are found inspect all cylinders Checking Oil Cooler for Contamination Clogging and Leakage 2 Checking Oil Pump for Discoloration and Other External Defects 2 Governor Oil Filter Change 8 15 Fuel Tank Clean 1 8 6 Every 4 years Fuel Injection Pump Inspect and Test Replace parts as necessary 2 Governor Inspect and Test Replace parts as necessary 2 Radiator Fins Check and Clean 1 8 18 Rubber Hose Replace 2 Air Cleaner Element Clean Check and Replace 1 8 21 Protective Devices Repair or Replace 1 Oil pressure gauge coolant temperature gauge oil temperature gauge 32 exhaust temperature gauge tachometer Engine Major Overhaul Disassemble engine clean check and change major parts 2 Damper Replace 2 Oil Pump Repair or Replace 2 Fuel Injection Nozzle Nozzle Tip Replacement Check the spray condition and adj
50. al Definition of Engine 7 2 Periodic Maintenance Chart for Regular Use Engine eeeeeee 7 3 Periodic Maintenance Chart for Emergency Engine eeeeeeeees 7 5 Periodic Maintenance Chart for General Purpose Engine 000 7 9 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Basic ENnQin apccccsiceureioeeaeitec 8 1 Engine External INSpe Ct seese 8 1 Belt and Belt Tension Inspect and Adjust 8 2 Damper INS poii conesa aa 8 4 Fel Systemie eaaa ias 8 6 Fuel System Inspect s s s 8 6 Fuel Tank Cl6an e ccceeceeeeeeseeeeeeeeeeeneeeeeees 8 6 Fuel Tank Drain Water 8 6 Water Separator Drain Water 0008 8 7 Water Separator Element Replace 8 7 Gauze Filter Clean s 8 8 Fuel Filter Replace sssensnserreesrrrrrssens 8 9 Fuel Control Link Ball Joint Inspect 8 10 Fuel Pipe INSPe Ct srren 8 11 Lubricating SySteM 0 ceeeee 8 12 Engine Oil Oil Filter and Bypass Oil Filter Replace oenar iarain a iie 8 12 Engine Oil for Mixing of Fuel and Water E E EE E E ETE S 8 14 Governor Oil Filter Chang 0cee 8 15 Oil Pipe Inspect nerne 8 15 Cooling System sxictsicces teeta teetastrce 8 16 Coolant Change cccceceeeseeeeseeeeeeeseeeeeees 8 16 Radiator Fins Check and Clean 05 8 18 Inlet and Exhaust Systems 8 19 Turbocharger Inspect
51. als 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 Chapter 1 BASIC SAFETY PRECAUTIONS Fire and Explosions ececeee 1 1 Keep Flames AWay eeeeseeeeeeeeeeeeeeeeeeeeeees 1 1 Always Swich the Water Heater ON Emergency generator with water heater 1 1 Keep Engine Surrounding Area Tidy and Clean1 1 Ventilation of Engine ROOM 1 1 Do Not Open Side Cover Until Engine Cools 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 TIANY oreo tec sbcee event bhestasnccdhege tact T 1 1 Stay Clear of All Rotating and Moving PONG srt ate in ae et 1 2 Install Protective Covers Around Rotating Parts1 2 Check Work Area for Safety 1 2 Stay Clear of Moving Parts While Engine is RUNNING Svc eee es 1 2 Lockout and Tagout iseenesesse 1 2 Keep Engine Stopped During Servicing 1 2 Always Restore Engine Turning Tools After Use1 2 Be Careful of Exhaust Fume Poisoning1 3 Operate Engine in a Well ventilated Area 1 3 Protect Ears From Noise 000 1 3 Wear Ear PIUS sia 1 3 Be Careful of Falling Down 1 3 Lift Engine Car
52. alve bridges valve springs tappets camshaft thrust plates pistons piston pins connecting rod Every 8000 hours bolts connecting rod bushings rocker bushings fuel pipe assembly oil pipe assembly Fuel Injection Pump Inspect and Test Replace Parts as Necessary 2 Governor Inspect and Test Replace Parts as Necessary 2 Protective Devices Repair or Replace High coolant temperature low oil pressure overspeeding starting failure 9 water supply failure undervoltage overvoltage overcurrent low coolant level in tank low fuel level in tank low air pressure in tank etc Auxiliary Devices Operation Check Water heater oil heater oil priming pump fuel transfer pump governor 2 motor etc Every 8000 service hours or every 2 years Coolant Change 8 16 Fuel System Bleed Air 1 3 2 Radiator Fins Check and Clean 1 8 18 Air Cleaner Element Clean Check and Replace 1 8 21 As required Cleaning the Inside of the Engine Breathers 2 Stop Solenoid Inspect or Replace 2 Couplings Inspect or Replace 1 2 Inspecting the Vibration isolating Rubber 1 2 1 If itis not a item supplied from Mitsubishi Heavy Industries maintain the part following the manufacture s opera tion manual as required 2 Items require special tools or large equipment For the servicing of those items contact a dealer of Mitsubishi Heavy Industries Ltd Chapter 7 MAINTENANCE SCHEDULE Periodic Maintenance Chart for Emergency Eng
53. ansferred are not provided with the warranty However the warranty coverage is effective for the ultimate purchaser and each sub sequent purchaser for emission related parts Mitsubishi Heavy Industries Ltd makes no warranties either expressed or implied except as provided in this manual including but not limited to warranties as to market ability merchantability fitness for a particular 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 costs 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 liable for any damages or production losses caused by the use of fuel engine oil and or long life coolant LLC that we are not recom mended The owner of the engine is responsible for the performance of the required maintenance listed in this operation manual When performing the maintenance follow the service manual published by Mitsubishi Heavy Industries Ltd Mitsubishi Heavy Industries Ltd may deny the warranty coverage if the engine or part has failed due to inadequate or improper maintenance FOREWORD
54. arge amount of engine oil more than the legally specified quantities be sure to have the work per formed by a service station operated under the provision of the law When removing oil from the engine or oil can use an oil pump Do not suck oil using you mouth and a pipe Be sure to close the cap on the oil can after use Keep oil in a well ventilated place and out of direct sunlight Be sure to obtain the MSDS of the engine oil and follow the instructions of the MSDS Chapter 5 ENGINE OIL Service Limits of Engine Oil Engine oil degrades through the use and by lapse of time The quality of engine oil and fuel and the operating condition of the engine affect the deterioration of the engine oil Replace the engine oil in accordance with Chapter 7 MAINTENACE SCHEDULE However only if the operating load is stable and engine oil analyze result allows oil replacement interval may be changed Refer to the following table for the determination of engine oil performance If any of the following properties exceeds the limit replace the engine oil with new oil Table 5 2 Engine Oil Properties Properties Standard Test method 30 or less rate of change from new oil 10 mm2 s 0 155 in s or more croicvizosy gist sos NEUC VISCOSIY 100 C 2129F 30 or less rate of change from new oil SO 2909 20 or less rate of change from new oil 2 0 or more with hydrochloric acid HCL method JIS K 2501 2003 Bas
55. at 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 as defined in Section 1900 b 13 Title 13 may be used in the performance of any maintenance or repairs and must be provided without charge to the owner It is not necessary for replace ment parts to be the same brand or by the same manufacturer as the original part sold with the engine Such use shall not reduce the warranty obligations of the engine manufacturer FOREWORD 10 Add on or modified parts as defined in Section 1900 b 1 and b 10 Title 13 that are not exempted by the Air Resources Board may not be used The use of any non exempted add on or modified parts shall be grounds for disallowing a warranty claim made in accordance with this article The engine manufacturer shall not be liable under this article to warrant failures of warranted parts caused by the use of a non exempted add on or mod
56. cal warning label to the new part To obtain new warning labels contact a dealer of Mitsubishi Heavy Industries Ltd ROTATING PARTS X CAN CAUSE SEVERE CF PERSONAL INJURY e KEEP AWAY FROM ROTATING FLYWHEEL e DO NOT OPERATE WITHOUT FLYWHEEL COVER 45A93 51 100 Ss TURNING CAN Ds CAUSE SEVERE PERSONAL INJURY e BE SURE NO DANGER AROUND MOVING PARTS BEFORE TURNING e KEEP TURNING DEVICE OR BAR IN OFF POSI TION WHEN NOT IN USE 45A93 51200 OIL MIST IS W FLAMMABLE AND lt EXPLOSIVE DO NOT OPEN INSPECTION COVER WITHIN 10 MINUTES AFTER ENGINE STOP 45493 51300 HIGH PLACE MAY CAUSE FALLING e BE CAREFUL WHERE YOU STEP ON SCAFFOLD DO NOT PUT ANY IMPROPER MATERIALS ON ENGINE AND SCAFFOLD 45493 51400 VOLTAGE MAY CAUSE ELECTRIC SHOCK TURN OFF POWER BEFORE CHECKING OR MAINTENANCE DO NOT TOUCH ANY ELECTRIC EQUIPMENT WHEN POWER IS ON DO NOT OPERATE WITH DOOR AND PROTECTIVE COVER OPEN 45493 51500 TENAN PER ANCE ATION AND e HOT WATER MAY CAUSE BURNS DO NOT REMOVE RADIATOR CAP UNDER HOT CONDITIONS 4593 50600 HOT SURFACES za MAY CAUSE BURN diilit HOT SURFACE MAY CAUSE BURNS DO NOT TOUCH HOT SURFACE 45493 50900 Fig 1 1 Warning labels BE CAREFUL OF ROTATING FAN DO NOT PUT FINGERS NEAR ROTATING FAN 45A93 50700 AZN BE CAREFUL OF R
57. d refer to FUEL 4 1 Close the fuel feed valve to cut off the fuel supply to the engine Place a drip tray under the drain cock Drain all fuel in the tank from drain cock on the bottom of fuel tank Clean the inside of fuel tank Add fuel to the fuel tank Open the fuel feed valve and bleed air for the fuel system Note a For bleeding fuel system refer to Fuel System Bleed Air 3 2 b If the specification of fuel tank differs from the contents of this operation manual follow the manufacturer s operation manual PAR wn o Fuel Tank Drain Water If fuel gets mixed with particles of foreign material such as dust dirt or water it can cause not only decrease of output but also malfunctions of the fuel system To avoid such a problem drain fuel tank as described below 1 Prepare the oil pan capacity of 2 L 0 5 U S gal Drain cock or more under the drain cock of fuel tank 2 Open the drain cock of fuel tank and drain fuel at NU least 1 to 2 liters 3 Make sure that water and particles of foreign mate rial discharged with fuel Close the drain cock Fig 8 4 Fuel Tank Drain Water Note If the specification of fuel tank differs from the contents of this operation manual follow the manufacturer s operation manual Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Water Separator Drain Water 1 3 Prepare a plate and place it under the drain cock of water separator Open
58. ded Limit and Use Limit of Fuel Property Item Recommended limit Use limit Test method JIS K 2265 2007 f 50 C 122 F or higher ae In accordance with the regulation fae aes Initial boiling point 170 C 338 F or higher Distillation oh i JIS K2254 1998 alae cs 330 to 380 C 626 to 716 F RO Aa Pour point PP 6 C 42 8 F or lower than ambient temperature rae aa anal Cloud point CP Below ambient temperature eee Cold filter plugging point CFPP 3 C 37 4 F or lower than ambient temperature asa JIS K 2270 2000 Carbon residue 10 residual oil 0 4 weight or lower 1 0 weight or lower ISO 6615 ISO 10370 Cetane number 45 or higher rrr alae Cetane index new type 45 or higher mane ey 2 0 mm s 0 0031 in s or more at 30 C 86 F JIS K 2283 2000 Pere eee 8 0 mm s 0 0124 in2 s or more at 30 C 86 F ISO 3104 JIS K 2541 2000 The content 1 0 weight or lower should be as Sulfur content 0 2 weight or lower Shorten lub oil change low as the die intervals sel fuel ISO 4260 ISO 8754 o JIS K 2275 1996 Water content and sediment 0 1 volume or lower ISO 3733 ae Ahio JIS K 2272 1998 Ash content 0 01weight or lower 0 03 weight or lower ISO 6245 Copper corrosion _ JIS K2513 2000 3 hrs at 50 C 122 F Color change Copper plate No 3 or less ISO 2160 0 83 to 0 87 g cm 0 80 to 0 87 g cm JIS K 2249 1995 Density at 15 C 59 F 49 942
59. e adjustment of peripheral devices limit the operating time to 10 minutes Once every month Operate the engine under load for 15 to 30 minutes with more than 1 2 load If the engine cannot be operated under load every month operate the engine under load more than 1 2 load for more than 2 hours During the engine maintenance operation check the ease of startup oil pressure and exhaust color and vibration Periodic maintenance chart for general purpose engine If the engine is used for different purposes other than the above usage do maintenance according to the Periodic Maintenance Chart for General Purpose Power Supply Engine 7 1 Chapter 7 MAINTENANCE SCHEDULE General Definition of Engine General Definition of Regular Use Engine An engine operated with a constant base load for the purpose of generating electric power which is used indepen dently or in combination with commercial power supply An engine operated under a fluctuating load throughout a day for supplying rated electric power in lieu of commercial power General definition of emergency engine An engine used for emergency power generation such as main power supply and commercial power supply General Definition of General purpose Engine An engine used for a purpose other than power generation for example to drive a pump as the main engine for a ship and for an industrial vehicle and operated under constant or cyclically varying load and speed Chapter
60. e number mgKOH g 1 2 of new oil or more with perchlo ISO 3771 ric acid PCA method Acid number mgKOH g Up to 3 0 of new oil e Water Content Vol 0 2 or less EE Sie JIS K 2265 2007 Flash point open cup C F 180 356 or higher ISO 3769 ISO 2719 Pentane insoluble Wt 0 5 or less oe en AS TRUD Pentane insoluble coag 5 Compliance with ASTM D ulated Wt 3 0 or less 893 Chapter 5 ENGINE OIL Definition of Properties of Engine Oil Kinetic Viscosity Kinetic viscosity is a basic physical property of engine oil and is considered as the most important aspect when evaluating oil Contamination of oil by blow by gas and deterioration of oil by its natural aging increase the kinetic viscosity and degrade the performance of viscosity which will cause the deposition of sludge inside the engine and oil filter clogging Contamination of oil by fuel and sheared molecules of viscosity index improver in oil decrease the viscosity and degrade the performance of viscosity which will cause insufficient lubrication and friction wear of engine parts Base Number Base number shows the ability to neutralize acids such as organic acid due to engine oil oxidation or sulfurous or sulfuric acid due to the sulfur content of fuel Because base number indicates the amount of disper sant detergent in oil it can be used to estimate con sumption of basic dispersant detergent The ability to disperse sludge declines as dispersant det
61. e tightly closed Always Swich the Water Heater ON Emergency generator with water heater Always swich the water heater ON automatic mode through a whole year If the switch is not ON automatic mode each cylin der varies considerably in combustion at the starting up the engine Unburned fuel may explode in the exhaust pipe 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 Ventilation of Engine Room Always provide adequate ventilation in the engine room Insufficient air in the room can cause an increase in the engine temperature and a decrease in the output power and performance It is highly recom mended to calculate the required amount of air supply to the engine and install an adequate ventilation sys tem before installing the engine Do Not Open Side Cover Until Engine Cools Do not attempt to open the side cover of the crank case before the engine cools down Wait at least 10 minutes after stopping the engine Opening the cover when the engine is hot allows fresh air to flowinto the crankcase which can causeoil
62. eding the fuel filter refer to Fuel Filter Bleed Air 3 2 9 Start the engine and run it at idle speed for several minutes 10 Make sure that there is no fuel leak during the en gine operation If fuel leakage is found loosen the fuel filter and check the gaskets for damage If there is no damage retighten the fuel filter the gasket Fig 8 9 Fuel Filter Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Fuel Control Link Ball Joint Inspect Check ball joint in the fuel control link for play If the 0 1mm 0 004 in Ball joint amount of play is 0 1 mm 0 004 in or more replace the ball joint with the new one i OON 0 004 in TIH If the sealed ball joints are found loosened contact a dealer of Mitsubishi Heavy Industries Ltd If the seal on the ball joint is broken the warranty is invalidated If the ball joints are integrated in the control link replace the control link when the ball joints have loos ened When installing ball joints be sure to tighten the nuts firmly Control link Fig 8 11 Fuel Control Link Remove 8 10 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Fuel Pipe Inspect High Pressure Fuel Injection Pipe and Clamp Seat Inspect and Replace Visual Inspection in Every 2000 Service Hours Check clamp seat cracks and wear or high pressure fuel injection pipe wear If defective replace the clamp seat
63. eeeeeeenees 1 7 Observe Safety Rules at Work Site 1 7 Work Clothing and Protective Gear 1 7 Never Break Seals ccccccssteeeeesesteeeeeeeeees 1 7 Perform All Specified Pre operation Inspections and Periodic Inspections eeeeeeeeeeeteeeeeees 1 7 Break in the Engine 1 7 Warm up the Engine Before Use a e 1 7 Never Operate the Engine in an Overloaded CONGILION eean dededdy ed nabieeas ce ANS 1 7 Conduct Cooling Operation Before Stopping the ENGINE ae AAEE AATA ARE IREO IRATE 1 8 Do Not Operate Engine Continuously Under Low oreta DE PAEA E AE A TT 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 Operations is iiaeetes este ileesct iareaeaet teat anii 1 8 Do Not Turn Off the Battery Switch During Operation sissies ie ae aaar iia eee 1 8 Cautionary Instructions for Transporting the ENGNG een a ce TevebeteMaieect Marees 1 8 Warning Labels ceeceeeeeeeeeees 1 9 Maintenance of Warning Labels 1 9 Chapter 2 NAME OF PARTS Engine External Diagrams 2 1 Let SidGs iit tiie hoi i ee at 2 1 Right Side aene Magu lett aust seein ts 2 1 Equipment and Instrument 2 2 Start and Stop Instrument ceeeeeesseeeees 2 2 INSTPUIMONS 2 ee e eee eee eeee eee eeeeeeeeeeeeenseeeeeeeeetanes 2 3
64. efully sasssa 1 3 Do Not Climb Onto the Engine 1 3 Always Prepare Stable Scaffold 008 1 3 Be Careful of Burns c eeeeeeeees 1 4 Do Not Touch the Engine During or Immediately After Operation cccccceceeceseceeeeeereeeeseeeeenees 1 4 Refill Coolant Only After the Coolant Temperature DIO PDOs unseen nian a a 1 4 Be careful of burns when changing oil 1 4 Never Remove Heat Shields 0 ceee 1 4 Be Careful of Opening and Closing Radiator Cape ven EA ee 1 4 Do Not Touch High Pressure Injection Fuel 1 4 Be Careful When Handling Fuel Engine Oil or LEG vacetecsteicarosecainiecsasecs 1 5 Use Only Specified Fuel Engine Oil and LLC 1 5 Handle LLC Carefully cccececeeeeeeeeeeereees 1 5 Proper Disposal of Waste Oil LLC and Coolant1 5 When Abnormality OccurS 0 1 5 Do Not Add Coolant Immediately After a Sudden Stop Due to Overheating cceceeseeeee 1 5 Stop Operation Immediately If You Notice Any Unusual Symptoms cccccceeeceereeesteeeeeeees 1 5 Avoid Immediate Restart After Abnormal Stop 1 5 Avoid Continuous Engine Operation at Low Oil PFESSUPG riin uaii eee yee el ie 1 5 If Belt Breaks Stop Engine Immediately 1 5 BAU ONY ade tit nainhiectecurenicet hahaa haents 1 6 Handle the Battery Correctly ceeeeeee 1 6 Other Cautions ccccccceeeeeeeeeeeeeeees 1 7 Never Modify Engine eeccseeeeeest
65. el and oil leaks Remove dust from the top surface of the battery A fire can be caused by combustible materials placed near hot engine parts If any abnormality is found be sure to repair it or contact your local dealer Inspect the engine exterior as described below 1 Make sure there is no combustible material near the engine or battery Also check to make sure that the engine and battery are clean If combustible materials or dust are found near the engine or battery remove them 2 Check the electrical wiring for such components as the starter and alternator for looseness 3 Check the whole engine for leaks of fuel engine oil or coolant If leaks are found repair or contact your local dealer 4 Check that valves plugs or cocks are properly positioned Fuel feed valve Open Coolant drain cock plug Closed Engine oil drain plug Closed 8 1 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Belt and Belt Tension Inspect and Adjust If defects such as cuts or surface separations are found during inspection replace the belt Keep oil and grease away from the belt They may cause the belt to slip and shorten the service life Excessive belt tension can cause rapid wear of the alternator bearing and shorten the service life of the belt Adjust the belt tension accurately by following the procedures below Belt Inspect 1 Inspect the belt visually for separation or damage If any abnormality is found replace the belt
66. er and Bypass Oil Filter Replace a new or overhauled It is Recommended to Check the Engine Oil Characteristics at the Same engine time 8 12 The Oil Filters Must be Replaced When the Filter Alarm Lights Engine Oil Oil Filter and Bypass Oil Filter Replace 8 12 The Oil Filters Must be Replaced When the Filter Alarm Lights Governor Oil Filter Change 8 15 Every 250 service hours Belt and Belt Tension Inspect and Adjust 8 2 or every 1 year Radiator Fins Check and Clean 1 8 18 Exhaust Muffler Drain Water 1 8 19 Air Tank Inspect Safety Valve Operation 8 26 First 250 service hours Valve Clearance Inspect and Adjust for a new or overhauled Check valve mechanism at the same time 2 engine Fuel Filter Replace 8 9 Water Separator Element Replace 1 8 7 Every 1000 service hours lear or every 2 years Gauze Filter Clean 8 8 Air Strainer Drain Water and Clean Air motor type or direct inlet type 8 25 Zinc Rod Replace 2 Bolts and Nuts on the Engine Retighten 2 Valve Clearance Inspect and Adjust 9 Check valve mechanism at the same time Fuel Injection Timing Inspect and Adjust 2 Every 2000 service hours Fuel Pipe Inspect om or every 3 years Oil Pipe Inspect 8 15 Fuel Injection Nozzle Nozzle Tip Replacement Check the spray condition and adjust the fuel injection pressure after 2 replacement Protection Devices Operation Inspect High water temperature low oil pressure overspeed Chap
67. er from the starter and alternator 4 Adjust the belt tension Note Refer to Belt and Belt Tension Inspect and Adjust 8 2 for belt tension adjustment 5 Remove sealing tapes from the openings of the engine 6 Connect pipes 7 Fill the fuel tank with fuel and bleed air from the fuel system Note For bleeding fuel system refer to Fuel System Bleed Air 3 2 8 Check the engine oil and coolant level 9 Inspect the whole engine 10 Remove the rocker covers and lubricate the valve mechanisms 11 While pulling the manual stop lever crank the engine for approx 10 seconds using the starter Stop the operation for approx 1 minute then repeat the operation two or three times 12 After starting up the engine make sure the engine oil pressure rises 13 Conduct a warm up operation for a sufficient duration to fit each part Note For starting the engine refer to Start 3 12 14 Apply load and increase the engine speed to the rated speed Storing the Engine in an Operable Condition for 3 Months or More When the engine is not operated during storage of 3 months or more internal engine parts can rust and lose oil film As a result the engine can seize when it is started after storage To prevent such a risk the engine must be oper ated periodically during storage Operating the Engine for Maintenance Operate the engine for maintenance at least once a month as described below 1 While pulling the manual stop
68. ergent is used up Acid Number The acid number in oil increases as the organic acid is being derived by the engine oil oxidation or sulfurous acid or sulfuric acid derived by the combustion of sul fur content of fuel or the oil becomes contaminated with imperfect combustion products An increase in the acid number will result in corrosion or wear of the inner parts of the engine such as cylin der liners or metal due to sulfur content and piston ring seizure due to sludge Water Content Water in oil promotes corrosion wear and decreases lubricity in sliding parts Flash Point The flash point is lowered by contamination with fuels Flash point is measured to check the dilution of fuel The dilution of fuel reduces oil film and causes insuffi cient lubrication that will cause friction or wear of engine parts Insoluble Insoluble includes acid products of engine oil imper fect combustion products sludge or soot metal abra sive particles and dust Insoluble is an indication of degradation contamination of oil Dispersant detergent which is an additive in engine oil absorbs sludge particles and disperses them as fine particles in oil Total insoluble density and remaining dispersibility can be obtained by measuring insoluble and coagulated insoluble chemical speciali ties which stop action of disperse detergent and col lect the sludge dispersed in oil to understand engine oil contamination level and thereby
69. erheating 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 Stop Operation Immediately If You Notice Any Unusual Symp toms Stop the operation immediately if you notice any unusual noise odor or vibration during operation In case of emergency press the emergency stop button to stop the engine Contact your local dealer if the cause of problem cannot be located after stopping the generator Continuous operation neglecting an unusual symptom could cause serious or fatal acci dent 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 Oper ation 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 and replace the belt Sustained use of the engine without any remedy could cause defective charge and cooling failure
70. ersonal injury Use correct tools and perform apposite work with the most careful attention Be sure to accurately estimate the weight of the part being dismounted If the removed part is much heavier than you have estimated it may fall down during lifting and can result in the damage to the parts or personal injury Chapter 11 TROUBLESHOOTING Case of Problems and Conceivable Causes and Remedies The Starter Does Not Crank or Cranks Slowly Resulting in Start Failure Table 11 1 The Starter Does Not Crank or Cranks Slowly Resulting in Start Failure Cause Remedies Check the DC fuse Faulty wire connection Check wiring connection between battery starter and starter switch inenten charged Dalian Check alternator Refer to P8 24 eee Check and adjust belt Refer to P8 2 Check specific gravity of battery electrolyte Refer to P8 23 Faulty battery Charge battery Change battery Faulty starter or starter relay Consult a dealer of Mitsubishi Heavy Industries Ltd Oil viscosity too high Use appropriate engine oil Refer to P5 1 SA Check amount of engine oil and lubrication system Refer to P3 y Excessive oil 9 Basic engine ee of sliding parts or Consult a dealer of Mitsubishi Heavy Industries Ltd Note The table above also include the parts Mitsubishi Heavy Industries Ltd does not supply For the parts Mitsub ishi Heavy Industries Ltd does not supply inspect and
71. for gas leaks a Exhaust gas from the engine contains carbon monoxide and other harmful A substances Operating the engine in an poorly ventilated area can produce gas poisoning Protect Ears From Noise WARNINGS 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 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 The hangers equipped with the engine are designed for lifting the engine only When mounting generator on the engine use the special hangerof common bed Hangers of engine cannot be used When mounting marine gear on the engine be sure not to apply the load on the hangers of engine only 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 engi
72. gf 62 N 6 32 kgf 49 N 5 00 kgf 41 N 4 18 kgf 27 65 Ibf 18 43 Ibf 13 93 Ibf 11 02 Ibf 9 22 Ibf 11 134 N 13 66 kgf 89 N 9 08 kof 67 N 6 83 kgf 54 N 5 51 kgf 45 N 4 59 kgf 30 12 Ibf 20 02 Ibf 15 06 Ibf 12 15 Ibf 10 12 Ibf 12 144 N 14 68 kgf 96 N 9 79 kgf 72 N 7 34 kgf 58 N 5 91 kgf 48 N 4 89 kgf 32 36 Ibf 21 58 Ibf 16 18 Ibf 13 03 Ibf 10 78 Ibf The pressing force when pressing the belt downward till 15 mm 0 59 in at the midway of the belt direct distance Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Damper Inspect Damper Check Visually When installing a damper protective cover to the engine do not use a cover that encloses the damper It may cause serious engine problems because the damper deteriorates by heat or not deliver enough its performance Silicon Check the vibration damper for oil leakage scratches oil deformation discoloration and peeling of paint Check carefully for swelling on the cover use a scale oil leaks from the shim discoloration and peeling of paint Fig 8 2 Damper Check Visually due to heat Note If defects are found in the damper contact a dealer of Mitsubishi Heavy Industries Ltd Damper Temperature Management For making damper function well heat of damper must be dissipated from its surface to prevent excessive damper heating Mitsubishi inspects each engine before shipment to ensure prope
73. gine is operating is pro vided with various heat shields Do not remove these heat shields If any of these heat shields have been removed owing to unavoidable circumstances during the work be sure to restore them after the work is completed _ P Be Careful of Opening and Closing Radiator Cap Never open the radiator cap while the engine is run ning or immediately after the engine is stopped To open the cap stop the engine and allow the coolant temperature to lower sufficiently To open the radiator 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 radiator cap be sure to tighten securely The coolant is hot while engine is running and immedi ately after the engine stops If the cap isopened 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 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 an
74. gt Remove the center bolt and remove the case from the bracket Remove the used element from the case 5 Put anew element in the case using the center bolt 6 Install the case to the filter bracket Tighten the center bolt 7 Install the oil pipe to the center bolt 8 Install the drain plug 9 Remove the air vent plug Fill up the filter with en gine oil 10 After filling up reinstall the air vent plug Oil Pipe Inspect Oil Pipe and Clip Inspect and Replace Visual Inspection at Overhaul Loosen clamp fixing bolt and check clip wear and pipe wear If defective replace the pipe assembly with a new one In Every Other Major Overhaul Replace the pipe assembly with a new one Drain plug Element Fig 8 18 Governor oil filter Change Fig 8 19 Oil Pipe and Clip Inspect and Replace 8 15 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Cooling System Coolant Change The service life of LLC is 2 years Be sure to change coolant at least once every 2 years Radiator Cap Open Close When using the engine with radiator cooling system remove the radiator cap only after the engine has Turn the cap about Stand the lever to half a turn the upright position cooled to the room temperature Place a waste cloth over the cap and loosen the cap about a half turn or stand the lever to the upright position to release inter nal pressure Opening the radiator cap of coolant expa
75. hen engine stops Note the temper ature periodically and check the abnormality of temperature alteration Note a When the temperature of thermo label increased identify the abnormality of engine or other cause Then reattach new thermo label and check the change of temperature b If the temperature indication of thermo label comes close to the limit temperature of damper or the abnor mality is found in change of temperature contact a dealer of Mitsubishi Heavy Industries Ltd c For damper temperature limit and inspection refer to Damper Inspect 8 4 Table 8 3 Thermo Label for Temperature Management Thermo label Part Temperature Y E5AJL__ lt 5E 100 gt Name Part No measuring TOO DO range 100 105 110 115 120 oe 32522 04211 100 to 120 C 100 120 20 labels set 32522 04200 212 to 248 F LIN O00000 VAr 75 80 85 90 95 ko 32522 04111 75 to 95 C YOESAIL lt 5E 50 gt 75 95 20 labels set 32522 04100 167 to 203 F OOOO 0 50 55 60 65 70 eee 32522 04311 50 to 70 C 50 70 20 labels set 32522 04300 122 to 158 F Fig 8 3 Damper Temperature Management Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Fuel System Fuel System Inspect WARNING When handling fuel make sure there are no open flames or other fire hazards near the engine Wipe off any spilled fuel completely Spilled fuel can ignite and cause a fire Fuel Tank Clean CAUTION For fuel to be use
76. hi 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 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 S
77. ication of air tank strainer differs from the contents of this operation manual follow the A manufacturer s operation manual Air Tank Drain Water CAUTION There are 2 places for draining water in the air tank drain valve on the top of air tank and drain handle on the bottom of drain separator 1 Open the drain valve slowly and check that water in the tank is drained from drain pipe 2 After water is drained and the air is discharged in the tank tighten the drain valve firmly 3 Loosen the drain handle on the bottom of drain separator Check that water in the drain separator is discharged from the drain pipe 4 Close the drain handle after draining water firmly Note If the specification of air tank differs from the contents of this operation manual follow the manufacturer s operation manual Starting air Fig 8 34 Air Strainer Drain Water and Clean Drain valve Fig 8 35 Air tank Drain water 8 25 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Air Tank Inspect Safety Valve Operation 1 Open the inlet valve of air tank and air pressure gauge valve 2 Fill air with the air compressor 3 Check to make sure the safety valve opens to re lieve pressure when the air pressure value in the tank is over the standard Pressure in the air tank 2 94 MPa 30 kgf cm 427 psi Safety valve operating pressure open 3 14 MPa 32 kgf cm 455 psi Safety valve operating pressure
78. ified 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 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 dispens
79. ine Table 7 2 Periodic Maintenance Chart for Emergency Engine Refer Interval and service item ence page Engine External Inspect 3 8 Check for leakage of fuel oil and coolant Fuel Tank Oil Level Check 1 3 9 Engine Oil Level Check 1 3 9 Coolant Level Check 3 10 Air Tank Air Pressure Check 3 11 Every week Air motor type or direct inlet type Water Leakage of Aircooler Inspect Operating the Engine for Maintenance Operate the engine under no load for 5 to 10 minutes Check for ease of starting color of exhaust smoke abnormal vibration abnormal noise abnormal smell and gauge indication oil pressure gauge coolant temperature gauge oil temperature gauge exhaust temperature gauge tachometer etc Engine Oil for Mixing of Fuel and Water Inspect 8 14 Fuel Control Link Check 3 9 Battery Electrolyte Level Inspect 1 8 23 Air Tank Drain Water 8 25 Air compressor Oil Level Inspect and Refill Every month Conducting Engine Maintenance Operation Operate the engine with more than 1 2 load for 15 to 30 minutes Check for ease of starting color of exhaust smoke abnormal vibration abnormal noise abnormal smell and gauge indication oil pressure gauge coolant temperature gauge oil temperature gauge exhaust temperature gauge tachometer etc Check fuel injection pump and the movement and rack of governor check temperature of damper check damper
80. ing 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 Limited warranty Refer to LIMITED WARRANTY Page ii vii 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 fede
81. injection pipes Consult a dealer of Mitsubishi Heavy Industries Ltd Cooling system Overcooled Check fan and heat exchanger Check control system Thermostat Inspect Consult a dealer of Mitsubishi Heavy Industries Ltd Inlet and exhaust systems Insufficient amount of air Check turbocharger Refer to P8 19 Clean inspect and replace air cleaner element Refer to P8 21 Check intake air pressure and leakage of intake air Check intake air temperature and ventilation device Consult a dealer of Mitsubishi Heavy Industries Ltd Increase resistance of exhaust air Check turbocharger Refer to P8 19 Check exhaust pipes and silencer Consult a dealer of Mitsubishi Heavy Industries Ltd Basic engine Low compression pressure Consult a dealer of Mitsubishi Heavy Industries Ltd Faulty valve timing Consult a dealer of Mitsubishi Heavy Industries Ltd Rapid wear of sliding parts Consult a dealer of Mitsubishi Heavy Industries Ltd Note The table above also include the parts Mitsubishi Heavy Industries Ltd does not supply For the parts Mitsub ishi Heavy Industries Ltd does not supply inspect and maintain them following the manufacturer s operation manual 1127 Chapter 11 TROUBLESHOOTING Engine Oil Consumption is High Table 11 7 Engine oil Consumption is High Cause Remedies Check fuel injection pump couplings
82. ions that suppress corro sion ionization of engine parts in contact with the coolant LLC loses its effectiveness by hours of use as well as lapse of time Moreover if the chemicals in LLC are not maintained certain chemicals in the LLC become rapidly used up and result in dissolution of metals instead of protecting metals from corrosion Consequently other corrosion preventing chemicals react with dissolving metals and accelerate corrosion This condition generates more severe corrosion than when plain soft water is used This is a typical problem caused by the use of inap propriate LLC Examples of Abnormali ties Caused by LLC Amine Type Pitting of Iron Parts Amines are generally effective in suppressing the rust ing of ferrous metals but they are said to cause prob lems for copper parts Dissolved copper copper corrosion in the cooling system deposits on iron parts and the copper deposits cause corrosion and then pitting on iron parts that have a high ionization characteristics due to galvanic or local cell action Corrosion of Aluminum Parts Silicate is highly effective in protecting aluminum against rusting However it is unstable in a solution in which the pH is 9 or lower and can turn to gel and pre cipitate in the solution For this reason the pH is usu ally specified to be about 10 to ensure a high alkaline level This means after silicate is used up the high alkalinity causes chemical attacks on alu
83. itsubishi Heavy Industries Ltd Low compression pressure Consult a dealer of Mitsubishi Heavy Industries Ltd Basic engine Faulty valve timing Consult a dealer of Mitsubishi Heavy Industries Ltd Wear of sliding parts Consult a dealer of Mitsubishi Heavy Industries Ltd Mas Faulty governor control Consult a dealer of Mitsubishi Heavy Industries Ltd Note The table above also include the parts Mitsubishi Heavy Industries Ltd does not supply For the parts Mitsub ishi Heavy Industries Ltd does not supply inspect and maintain them following the manufacturer s operation manual 11 4 Chapter 11 TROUBLESHOOTING Exhaust Smoke is White or Blue Table 11 4 Exhaust Smoke is White or Blue Cause Remedies Improper fuel property Check cetane index and use appropriate fuel Refer to P4 1 E ee at Check fuel injection pump couplings Faulty fuel injection timing te Consult a dealer of Mitsubishi Heavy Industries Ltd Fuel system ee Check ignition noise exhaust smoke temperature Uneven fuel injection f a f Consult a dealer of Mitsubishi Heavy Industries Ltd Faulty fuel injection nozzle Consult a dealer of Mitsubishi Heavy Industries Ltd Check amount of engine oil and lubrication system Refer to Lubricating l system Combustion of engine oil P3 9 Consult a dealer of Mitsubishi Heavy Industries Ltd Check heat exchanger Cooling Check control system Overcooled system Thermo
84. kalinity change 15 P G oe after the Precipitation 1 0 vol or less No remarkable discoloration separation Appearance of liquid and gel generation Density Fe Cu Al Zn Pb of i n NH4 10 ppm or less Aluminum 0 60 mg cm Cast iron 0 30 mg cm Mass Steel 0 30 mg cm change Brass 0 30 mg cm2 Metal specimen p Solder 0 60 mg cm Circulation metal Copper 0 30 mg cm lic causticity hoviea r m P 88 3 C o visible signs of corrosion on the surface 190 4 37 4 F Beats ene specimen excluding the area contacting to spacer 10002 Hr g However discoloration is acceptable 30 vol roperties o liquid after the pH change Maximum 1 0 test a No remarkable discoloration separation Appearance of liquid and gel generation Free from any malfunction liquid leak and Condition of Pump seal abnormal noise during operation arts p Inside of pump case and blade Free from remarkable corrosion Tensile strength change 60 to 0 Elongation change 40 to 20 Silicon Volume change 0 to 40 Hardness change 20 to 10 i h ch 109 Rubber adapt Tensile strength change O to 10 ability Acrylonitrile Elongation change 15 to 15 30 vol butadiene rub 115 C 239 F ber Volume change 0 to 40 360 Hr Hardness change 10t00 Tensile strength change 0to 10 Ethylene pro Elongation change 30 to 0 pylene diene monomer Vo
85. ks Carefully check the following items whether there is any abnormality Table 3 1 Inspection During Operation Item to be inspected Criterion Reference value Warning indicator lamps Instruments Lighting Numerical anomaly Engine speed Fre No large fluctuation quency Breather mist volume As usual Exhaust color As usual Damper temperature 90 C 194 F or lower 0 39 MPa 4 kgf cm Engine oil pressure 57 psi or more Oil Temperature oil pan 110 C 230 F or lower Coolant temperature 70 to 90 C 158 to 194 F Exhaust temperature 550 C 1022 F or lower 0 15 to 0 25 MPa 1 5 to 2 5 kgf cm 10 85 to 18 08 psi Intake air pressure Note a If the engine stops because of decreasing engine oil pressure be sure to locate the cause of problem and correct it before re starting the engine b When the thermo switch is activated during normal operation run the engine with the idle speed at low Roms for 5 or 6 minutes to cool the engine before stopping the engine Be sure to locate the cause of problem and cor rect it before restarting the engine 3 13 Chapter 3 OPERATION Stop Stopping the engine abruptly while engine parts are hot due to high speed operation can be a cause for heat up of the engine parts and shorten the engine life Before stopping the engine run the engine with the idle speed at low Rpms for 5 or 6 minutes to cool the engine
86. led onto the skin or clothing immediately wash itaway withlots 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 lf you accidentally swallow battery electrolyte gargle with plenty of water and then drink lots of water and seek immediate medical attention 1 6 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 not feeling well and inform your supervisor of your condition Opera tion 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 ear plugs and other protective gear as needed When handling compressed air wear safety goggles a hardhat glove
87. lever crank the engine for approx 10 seconds using the starter Stop the operation for approx 1 minute then repeat the operation two or three times 2 After starting up the engine make sure the engine oil pressure rises 3 Operate the engine about 5 to 10 minutes under no load as the maintenance operation Note For starting the engine refer to Start 3 12 Chapter 10 TRANSPORTATION Lifting the Engine 4 WARNING Front hanger Rear hanger To lift the engine use wire ropes shackles and slings capable of supporting the weight of the engine Attach the wire rope to the hangers provided on the engine using a correct sling Keep the engine balanced during lifting by consider ing the engine s center of gravity The hangers equipped with the engine is designed for lifting the engine only When mounting generator WAN WY ANY ANY AN YP AR Y A on the engine use the special hanger of common bed Hangers of engine cannot be used When mounting marine gear on the engine be sure Fig 10 1 Hanger not to apply the load on the hangers of engine only 60mm Keep the angle formed by slings attached to hangers _ 2 35 irk within 60 If the angle exceeds this limit excessive eee 0 e i load could be imposed on the hangers and this could i damage the hangers and result in a serious accident Attach wire ropes to the hangers after removing the pipe cover and the insulator near the hangers To The center of gravity preven
88. lume change 0 to 10 Hardness change 10 to 0 Chapter 6 COOLANT Table 6 2 LLC Specification Property Standard Storage stability vol 30 vol room temperature 6 Hr 0 3 or less 6 5 Chapter 6 COOLANT Maintenance of LLC Should coolant or LLC be accidentally swallowed induce vomiting immediately and seek medical attention If LLC should enter eyes flush immediately with plenty of water and seek medical attention LLC is toxic Never dispose of coolant containing LLC drained from engine into regular sewage For disposal of used coolant consult LLC distributor Replacement Intervals of LLC Be sure to renew LLC coolant at the intervals specified in this manual Failure to renew LLC may cause malfunctions due to performance degradation of preventing rust and cavitation When a coolant mixed with the LLC recommended by our company is used replace coolant every 8000 hours or 2 years whichever comes first LLC Concentration Keep the LLC concentration of 30 GLASSY and 40 PG GLASSY on any temperature conditions LLC of less than 30 concentration does not provide sufficient corrosion protection If the LLC concentration is lower than 10 it may accelerate corrosion When adding coolant do not add plain water Always use coolant with the same LLC concentration Table 6 3 Recommended LLC Concentration Lowest ambient temperature Item Type Appear yp ance 10 C 14 F 20
89. ly 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 RUN OFF type Not energized while the engine is running Energized by astop signal to stop the engine RUN ON type Energized while the engine is running and de ener gized by stop signal to stop the engine Fig 2 5 Stop Solenoid Chapter 2 NAME OF PARTS Instruments This section describes about devices which transmit signals to necessary instruments of the engine operation Read carefully and understand functions of each device Oil Pressure Unit Indicate the oil pressure Oil pressure unit Thermo Unit Always detect the coolant temperature of engine Fig 2 7 Thermo Unit Revolution Detection Pickup It is installed in the timing
90. mended limit Test method API JASO CF class 1 SAE viscosity 15W 40 JIS K 2580 Color ASTM L4 0 ISO 2049 JIS K 2249 ISO 3675 Density 15 C 59 F g cm 0 87 to 0 90 1SO3838 ISO 649 4 ISO 91 1 40 C 104 F 100 to 110 JIS K 2283 Kinetic Viscosity mm s ISO 3107 150 C 302 F 13 5 to 15 5 ISO 2904 JIS K 2283 Viscosity ISO 3107 ISO 2904 JIS K 2265 4 225 to 250 ISO 3679 Flash point C F 437 to 482 ISO 2719 ISO 2592 1 0 weight 10 or higher Hydrochloric Sulfur contents 9 lower mgKOH g up to 13 acid method of fuel 0 2 weight 8 or higher JIS K 2501 Base or lower up to 13 Be eal number 1 0 weight 13 or higher ISO 6619 Perchloric Sulfur contents lower mgKOH g up to 16 ISO 7537 acid method of fuel 0 2 weight 11 or higher or lower up to 16 JIS K 2501 ISO 3771 Acid number mgKOH g 1 5 to 2 0 ISO 6618 ISO 6619 ISO 7537 JIS K 2541 Sulfur content 0 5 or less ISO 4260 ISO 8754 JIS K 2272 Sulfuric acid ash 2 0 or lower ISO 3987 ISO 6245 JIS K 2270 Carbon residue content 2 0 or lower ISO 10370 ISO 6615 High temperature shear viscosity Ree mP aS 3 7 or higher JPI 5S 36 91 JIS K 2269 Pour point C F 25 13 or lower ISO 3015 ISO 3016 Chapter 5 ENGINE OIL Table 5 1 Recommended Limit of Engine Oil Properties Item Unit Recommended limit Test method 10 0 Bubbling test JIS K 2518 9 II mL 30 0 ISO 6247 Ill 10 0 apts 140 or lower al caulking test ae mg
91. minum To prevent this problem proper maintenance of the coolant is required For case example rapid wear of mechanical seals in the water pump due to secondary effects of silicate gel formed Corrosion of aluminum parts after silicate is consumed Pitting and Clogging of the Heat Exchange Equipment When LLC deteriorates or when its concentration in the coolant is too low the anti corrosion performance of LLC lowers and results in the corrosion of metals Brass and solder tend to corrode faster than other metals and corrosion of these metals is said to cause water leakage and clogs Example Holes and clogs in heat exchange equipment 6 7 Chapter 7 MAINTENANCE SCHEDULE How to Use the Maintenance Schedule Periodic inspection not only extends the service life of the engine but also serves to ensure safe operation Be sure to conduct inspections and maintenance according to the maintenance schedule The maintenance schedule shows the standard service intervals If you notice any abnormalities such as abnormal noise black exhaust smoke white exhaust smoke extremely high temperature of exhaust gas abnormal vibration and fuel oil or exhaust gas leakage make sure to conduct the inspection and maintenance work regardless of rec ommended service intervals in the Maintenance schedule Note Appropriate service intervals vary depending on the usage and operating conditions as well as consumption of fuel oil and coolant Check the
92. mist to ignite and explode Care for Fuel Oil and Exhaust Gas Leakage If any fuel oil or exhaust gas leaks are found immedi ately stop the engine and take corrective measures to stop leakage 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 Pr
93. nd Clean 1 Coolant Properties When Only Soft Water is Used Inspect 2 Change coolant according to the analysis results Air intake system Air Cleaner Element Clean Check and Replace 1 8 21 Starter Inspect 8 24 Alternator Inspect 8 24 Electrical system Specific Gravity of Battery Electrolyte Check 1 8 23 Air Heater Inspect a Every one year Air Strainer Drain Water and Clean 8 25 Air Tank Inspect Safety Valve Operation 8 26 Air Starter Valve Inspect 2 Air starter l system Solenoid Valve and Pressure Reducing Valve Inspect 9 and Clean Air Distribution Valve Inspect 2 Air Compressor Belt Tension Inspect 2 Auxiliary Devices Operation Check 1 High coolant temperature low oil pressure overspeeding starting failure 9 water supply failure undervoltage overvoltage overcurrent low coolant level in tank low fuel level in tank low air pressure in tank etc Auxiliary Devices Operation Check Engine control fuel transfer pump governor motor room ventilating fan 9 solenoid storage pump water tank ball tap water heater oil heater oil prim ing pump etc Engine Oil Oil Filter and Bypass Oil Filter Replace It is recommended to check the engine oil characteristics at the same time 8 12 The oil filters must be replaced when the filter alarm lights Fuel Filter Replace 8 9 Water Separator Element Repl
94. nd adjust the fuel injection pressure after 2 replacement Checking Movement of the Rack During Operation of the Fuel Injection 9 Pump Including the Governor Fuel Pipe Inspect 8 11 Oil Pipe Inspect 8 15 Top End of the Engine Overhaul Remove the cylinder head and inspect and service the combustion cham 2 bers Turbocharger Inspect 8 19 Damper Inspect 8 4 Every 4000 service hours Starter Inspect 8 24 Protection Devices Operation Inspect 2 Unit Seal and Oil Seal of Water Pump Replace 2 Checking LLC Concentration Level in the Coolant 2 Chapter 7 MAINTENANCE SCHEDULE Table 7 1 Periodic Maintenance Chart for Regular Use Engine Refer Interval and Service item ence page Engine Major Overhaul Disassemble engine clean check and change major parts Parts to be changed at major overhaul Inlet and exhaust valves inlet and exhaust valve seats valve rotators valve cotters rocker arm adjusting screws valve push rods bridge caps camshaft bushings camshaft expansion plugs main bearings cylinder liners main bearing cap bolts and washers piston rings connecting rod bearings damper crankcase thrust plate and consumable items gaskets oil seals O 2 rings etc At second overhaul replace the following parts in addition to the parts listed above gt Cylinder head bolts valve guides valve bridge guides v
95. ne 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 Chapter 1 BASIC SAFETY PRECAUTIONS Be Careful of Burns Do Not Touch the Engine Dur ing or Immediately After Opera tion To avoid burns do not touch the gt tion work wait until the engine has cooled sufficiently engine during or immediately after operation A hot engine can cause burns To conduct maintenance and inspec by checking the temperature gauge Refill Coolant Only After the Coolant Temperature Dropped When adding coolant check that the coolant tempera ture lowers sufficiently with temperature gauge Add ing coolant immediately after the engine stops may result in burns Be careful of burns when changing oil Wear gloves when draining oil or changing oil filters If hot oil or parts touch your skin it may cause burns Never Remove Heat Shields The inlet and exhaust system which becomes extremely hot while the en
96. ner element refer to Air Cleaner Element Clean Check and Replace 8 21 b If the specification of air cleaner differs from the contents of this operation manual follow the manufacturer s operation manual Air Tank Drain Water CAUTION There are 2 places for draining water in the air tank drain valve on the top of air tank and drain handle on the bottom of drain separator 1 Open the drain valve slowly and check that water in the tank is drained from drain pipe 2 After water is drained and the air is discharged in the tank tighten the drain valve firmly 3 Loosen the drain handle on the bottom of drain separator Check that water in the drain separator is discharged from the drain pipe 4 Close the drain handle after draining water firmly Note If the specification of air tank differs from the contents of this operation manual follow the manufacturer s operation manual 3 10 Reset button Fig 3 15 Air Cleaner Check for Clogging Drain valve Drain separator Drain handle Fig 3 16 Air Tank Drain Water Chapter 3 OPERATION Air Tank Air Pressure Check 1 Check the air pressure gauge to see if the air pres sure in the air tank conforms to the standard 2 Open the air pressure gauge valve 3 Check air pressure in the air tank with air pressure gauge Specified value For air direct starting 2 94 MPa 30 kgf cm 427 psi For air motor 0 98 MPa 10 kgf cm
97. not reuse the oil filter element as it is a paper type When replacing filters always replace gasket with new ones Engine Oil Drain After stopping the engine drain the engine oil form the engine oil drain port of oil pan 8 12 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Engine Oil Refill Refilling engine oil must be specified level If the refilling oil goes over the high marks on the oil level gauge engine oil may blow out 1 Remove the cap from the oil filler 2 Fill the engine oil pan with specified engine oil to the specified level Note For engine oil refer to ENGINE OIL 5 1 For engine oil capacity refer to MAIN SPECIFICA TIONS 12 1 Check the oil level in the oil pan as follows PY Pull out the oil level gauge and wipe it clean with a waste cloth 5 Insert the oil level gauge fully into the oil level gauge guide and then pull it out again 6 The proper oil level is between the high and low marks on the oil level gauge If the engine oil goes over the high marks on the oil level gauge open the engine oil drain valve to drain oil If the engine oil is low refill the specified engine oil 7 Install the oil filler cap after adding engine oil 8 Check the oil pan and other area for oil leaks Re pair the oil leakage if any 9 While pulling the stop lever rotate the crankshaft for approx 10 seconds to turn on the starter Stop the operation for 1 minute then
98. nsible 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 can not deny warranty sole ly 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 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 1 630 268 0750 FOREWORD Warranty coverage a The warranty period shall begin on the date the engine or equipment is delivered to an ultimate purchaser b Mitsubis
99. nsion tank while the engine is hot causes steam and hot coolant to blow out and can result in skin burns Fig 8 20 Radiator Cap Note If the specification of radiator differs from the contents of this operation manual follow the manufacturer s operation manual Coolant Drain 1 When draining coolant immediately after engine operation idle the engine in low gear for 5 to 6 min utes to lower the coolant temperature to 70 to 80 C 158 to 176 F Open the coolant inlet 9 N Place coolant receiving cans under the drain cocks and plugs and open the coolant drain cocks and plugs to drain the coolant Coolant drain cock Fig 8 21 Coolant Drain Cock Engine 8 16 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Cooling System Clean Clean the cooling system when operating the engine or heat exchange equipment first time or restarting the engine after storage with coolant drained 1 Close coolant drain cocks and plugs 2 Pour in a cleaning solution a solution that is non corrosive to rubber and metals in the cooling sys tem and operate the engine at 800 to 900 min for about 15 minutes then drain the cleaning solution o3 Close coolant drain cocks and plugs gt Pour in fresh water and operate the engine at 800 to 900 min for about 10 minutes Repeat the above rinsing steps until the draining water becomes clear and clean Coolant Refill Always use the coolant ha
100. ntake air exhaust Check intake air temperature and ventilation device systems Consult a dealer of Mitsubishi Heavy Industries Ltd Check turbocharger Refer to P8 19 Increase resistance of exhaust air Check exhaust pipes and silencer Consult a dealer of Mitsubishi Heavy Industries Ltd Low compression pressure Consult a dealer of Mitsubishi Heavy Industries Ltd Basic engine Faulty valve timing Consult a dealer of Mitsubishi Heavy Industries Ltd Wear of sliding parts Consult a dealer of Mitsubishi Heavy Industries Ltd Check control system and governor controller Control Increase in load y 9 f system Consult a dealer of Mitsubishi Heavy Industries Ltd Note The table above also include the parts Mitsubishi Heavy Industries Ltd does not supply For the parts Mitsub ishi Heavy Industries Ltd does not supply inspect and maintain them following the manufacturer s operation manual 11 6 Chapter 11 TROUBLESHOOTING Fuel Consumption is High Table 11 6 Fuel Consumption is High Cause Remedies Fuel system Faulty fuel injection nozzle Consult a dealer of Mitsubishi Heavy Industries Ltd Faulty fuel injection timing Check fuel injection pump couplings Consult a dealer of Mitsubishi Heavy Industries Ltd Improper fuel property Use appropriate fuel Refer to P4 1 Fuel leakage in fuel pipes and injection pipes Check faults and retighten fuel pipes and
101. nual 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 FOREWORD WARNING 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 ins
102. oil as the first 3 e High lah Improper 1 Pull out the oil level gauge and wipe oil off the oil Proper level gauge using a clean waste cloth ial O Low Improper 2 Insert the oil level gauge fully into the oil level Oil level gauge gauge guide and then pull it out again 3 The proper oil level is between the high and low Fig 3 14 Oil Filler and Oil Level Gauge marks on the oil level gauge If the engine oil goes over the high marks on the oil level gauge open the engine oil drain valve to drain oil If the engine oil is low refill the specified engine oil 4 Install the oil filler cap after adding engine oil 5 Check the oil pan and other area for oil leaks Chapter 3 OPERATION Coolant Level Check Always use the coolant having the same concentration If the coolant level is low add coolant to the specified level Note Determine the quantities of LLC based on the coolant capacity and the LLC concentration chart For the coolant refer to COOLANT 6 1 For the coolant capacity refer to MAIN SPECIFICATIONS 12 1 Air Cleaner Check for Clogging 1 Check the air cleaner indicator for the element clogging 2 Ifthe element is clogged the red signal mark will be displayed 3 Immediately clean or replace the air cleaner ele ment when the signal turns red 4 After checking press the bottom on top of the indi cator to re set the alarm signal Note a For cleaning of the air clea
103. operation Entanglement by rotating parts can result in serious injury Do not touch any hot part of the engine such as exhaust pipes during operation or immediately after shut down A hot engine can cause burns Always provide adequate ventilation in the engine room If air supply to the engine room is not sufficient the room temperature rises and can affect engine output and performance For the first 50 hours of the new engine or after the overhaul operate the engine under a light load for break in operation Operating the new engine under heavy load or severe conditions during the break in period can shorten the service life of the engine Do not turn the battery switch OFF when the engine is running Turning off the battery switch during oper ation not only stops the instrument operations but also may deteriorate the alternator diode and regula tor Never turn the key to the START position during operation The starter may be damaged When operating the engine with a 30 of rated load or lower limit each operation to an hour Prolonged warm up operation causes carbon build up in the cyl inders that leads to incomplete combustion Operate the engine with a 30 of rated load or more for over 5 minutes after continuous operation for an hour to prevent causing carbon build up Inspection During Operation Check for abnormal engine noises or vibrations such as knocking or the exterior of engine such as piping joints for lea
104. ovide an emergency evacuation route and contact points and means of communication in case of emergency 1 1 Chapter 1 BASIC SAFETY PRECAUTIONS Stay Clear of All Rotating and Moving Parts WARNING Install Protective Covers Around Rotating Parts Make sure the protective covers of INI the engine are correctly installed Repair any damaged or loosecovers eet LU USE LS LULL 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 gine 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 Stay Clear of Moving Parts While Engine is Running Stay away from rotating or sliding parts of the engine while the engine is running Put objects which might be ay easily caught by rotating parts away from rotating parts If any part of the clothing or outfitting is caught by a rotating part serious bodily injuries could result Locko
105. pecting 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 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 Torque 1 Nem 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 cmH20 cmAq Rotation speed 1 min 1 rpm Kinetic viscosity 1 mm s 1 cSt ABBREVIATIONS STANDARD AND OTHERS API American Petroleum Institute ASTM American Society for Testing and Materi
106. perature prop erly Emergency generator with water heater Note For engine operation refer to Normal Engine Operation 3 8 Starting and Stopping 1 Start the engine 2 Operate the engine at low idling speed under no load for 5 to 10 minutes for a warm up operation 3 Stop the engine Inspection 1 Leave the engine be stopped for about 30 minutes 2 During this period check the engine and surrounding area for leaks of fuel engine oil or coolant 3 At30 minutes after the engine stop check the oil level with the oil level gauge The proper oil level is between the high and low marks on the oil level gauge 4 lf the engine oil goes over the high marks on the oil level gauge open the engine oil drain valve to drain oil If the engine oil is low refill the specified engine oil 5 Open the coolant filler cap and check the coolant level 6 Ifthe coolant level is low add coolant to the specified level Always use the coolant having the same concentration Chapter 3 OPERATION Normal Engine Operation This section of the manual covers the procedures for the engine operation in normal condition Should an engine abnormality be observed during operation stop the engine and correct the problem or contact a dealer of Mitsubishi Heavy Industries Ltd Preparations for Operation Always conduct the following inspection before starting the engine Engine External Inspect Be sure to keep combustible material
107. piston ring sei zure or premature wear can be prevented before it occurs 5 5 Chapter 5 ENGINE OIL Engine Oil Analysis Service For a long term service life of engine it is recommended to get an engine oil analysis service It is a system to understand the availability of the engine oil using in your engine by sampling it with the special sam pling tools The engine oil analysis service provides the followings The quantity of fine metal powder in engine oil due to abrasion by which worn parts can be located Water LLC or salt that should not be in engine oil can be detected Engine oil deteriorating conditions by which appropriate engine oil renewal intervals operating conditions proper inspection and maintenance schedule can be planned The engine oil analysis service can diagnose the internal condition of the engine which is necessary when disas sembling the engine It is highly recommended to take advantage of our engine oil analysis service so that you can learn the engine condition before any malfunction occurs to the engine 5 6 Chapter 6 COOLANT Note In this operation manual the word coolant represents a mixture of water and LLC Recommended Water for Coolant Use soft water such as tap water for the engine cooling system The water quality must meet the requirements in the Table below Basically the water quality should be within the recommended value however up to the limit is
108. r operating temperature of the vibration damper However the vibration damper temperature varies depending on ambient conditions Therefore observe the following suggestions and provide sufficient ventilation for the vibration damper and equipment 1 Make sure the temperature of the outside damper surface does not exceed the temperature that described in the following table when operating the engine with rated power for an hour able 8 2 Damper Temperature Management Type of damper Continuous Standby Viscous damper 90 C 194 F 100 212 F Viscous rubber damper 80 C 176 F 90 C 194 F 2 When installing a safety cover to damper check ventilation carefully and make sure the damper temperature re mains below the temperature specified above with the cover in place 3 It is recommended to use the thermo label for the temperature management of damper in regular use engine Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Thermo Label Handle The white thermal part of thermo label becomes black when reaching the specified value Note The thermal part that becomes black once does not return to white Therefore if the engine stops and then the temperature of damper drops the thermo label continues indicating the maximum temperature while engine is running 1 Attach a thermo label to the periphery or front end of damper 2 Note the maximum temperature to check the thermal part of thermo label w
109. ral 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 operators Also add safety caution and operating signs that describe the original warning label statements in the native language of the operators viii 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 ma
110. rheating Table 11 8 Overheating Cause Remedies Low coolant level Check coolant leakage Check coolant level Refer to P3 10 oars Faulty water pump operation Consult a dealer of Mitsubishi Heavy Industries Ltd Faulty thermostat operation Consult a dealer of Mitsubishi Heavy Industries Ltd Faulty heat exchanger operation Check and clean heat exchanger Check fuel injection pump rack stroke Se Increase in load Check control system and governor controller Consult a dealer of Mitsubishi Heavy Industries Ltd Basic engine Wear of sliding parts Consult a dealer of Mitsubishi Heavy Industries Ltd Note The table above also include the parts Mitsubishi Heavy Industries Ltd does not supply For the parts Mitsub ishi Heavy Industries Ltd does not supply inspect and maintain them following the manufacturer s operation manual Low Engine Oil Pressure Table 11 9 Low Engine Oil Pressure Cause Remedies Insufficient amount of engine oil Check amount of engine oil and lubrication system Refer to P3 9 Faulty engine oil property viscosity Analyze oil property Use appropriate engine oil Refer to P5 1 Check coolant system Lubricating Engine oil temperature is high system g j i Consult a dealer of Mitsubishi Heavy Industries Ltd a Inspect and replace oil filter and bypass oil filter Refer to P8 Oil filter clogged 14 Fault
111. riming pump clockwise to lock in the original position when the fuel flows is free from bubbles P 3 Tighten the air vent plug on the fuel injection pump Unlock Priming Lock Fig 3 1 Priming Pump Handle Tightening torque 8 8 1N m 0 9 0 1 kgf m 6 4 0 7 Ibf ft Fig 3 2 Fuel Filter Bleed Air Air vent plug 15 2 Nm 1 53 0 20 kgf m 11 06 1 48 Ibf ft Fig 3 3 Fuel Injection Pump Bleed Air Chapter 3 OPERATION Priming Pump Tightening Method CAUTION sic were 90 10 Never fail to tighten the priming pump to the speci hand tightening fied angle If the priming pump is not firmly tightened becomes suddenly Priming pump internal thread will be worn due to engine vibration resulting in sudden ejection of the cap to cause fuel Head can be damaged flow out Or if the priming pump is excessively tight if the cap is excessively mi Pa tightened ened the head of the priming pump can be dam w 120 or more aged 1 Gently tighten the priming pump cap by hand until the tightening force suddenly increases 2 Use a wrench or another appropriate tool to tighten the priming pump 90 10 3 Check the mounting position of head packing Note If the head packing has abnormality such as de formation or scratches consult a dealer of Mit subishi Heavy Industries Ltd as the priming pump needs to be changed Head packing Fig 3 5 Priming Pump Head Packing Chapter
112. s and other necessary pro tective gear Working without wearing proper protec tive gear could result in serious injuries Never Break Seals To ensure proper engine operation the fuel control links are sealed to prevent accidental change of the injection volume and rotation speed settings If the seal is tampered no guarantee will be provided If the seal is tampered the defects shown below can occur 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 re sult in a serious accident Perform All Specified Pre oper ation 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
113. s away from the engine especially from the hot engine parts such as exhaust manifolds or the battery Check for fuel and oil leaks Remove dust from the top surface of the battery A fire can be caused by combustible materials placed near hot engine parts If any abnormality is found be sure to repair it or contact your local dealer Inspect the engine exterior as described below 1 Make sure there is no combustible material near the engine or battery Also check to make sure that the engine and battery are clean If combustible materials or dust are found near the engine or bat tery remove them 2 Check the whole engine for leaks of fuel engine oil or coolant If leaks are found repair the leak or contact a dealer of Mitsubishi Heavy Industries Ltd 3 Visually check bolts and nuts for looseness 4 Check the electrical wiring including the starters Fig 3 12 Valves for open closed position Check and alternator 5 Check that valves plugs or cocks are properly po sitioned Fuel feed valve Open Coolant drain cock plug Closed Engine oil drain plug Closed Air supply valve air tank Open Chapter 3 OPERATION Fuel Tank Oil Level Check WARNING When working around fuel make sure there are no open flames heaters or other fire hazards Wipe off any spilled fuel completely Spilled fuel can ignite and cause a fire Do not remove the strainer when filling the fuel tank If the engine has a float swi
114. slowly to prevent foreign materials accumulated on the element from falling off After removing the air cleaner immediately cover the air inlet with plastic sheet or similar means to prevent foreign materials from entering the engine 1 Remove the air cleaner cap and wing bolt Remove the air cleaner element from the body 3 Blow compressed air 0 69 MPa 7 kgf cm 100 psi or lower onto the inside surface of the element EN fp Wing to remove foreign materials RNN vA bolt 4 To remove dust stuck on the air cleaner element blow dry compressed air onto the outside surface N Air cleaner from a distance S element Blow compressed air on the inside surface toward the outside along the pleats Then blow com pressed air on the outside and inside surface again 5 After cleaning hold the air cleaner element near a light bulb to illuminate the inside to check for de fects such as cuts pinholes or local wear 6 If any defect is found replace the air cleaner ele ment with a new one 7 Reassemble the air cleaner element as it was Fig 8 28 Air Cleaner Element Clean and Check 8 21 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES 8 After cleaning or replacing the air cleaner element press the reset button to reset the indicator Reset button Note If the specification of air cleaner differs from the Signal contents of this operation manual follow the red manufacturer s operation manual
115. ssure Switch eee eeeeeeeeeee 2 4 Thermo Switch oe eeeeeeeeeeeeeeeeeeeeneees 2 4 Oil Filter Alarm Switch cee 2 4 Revolution Detection Pickup 2 5 Air Cleaner Indicator cceeeeee 2 5 Manual Turning Gear Position While Engine is Running seese 2 6 Manual Turning Gear Position When Pushing Shaft in e ee 2 6 Turning Gear Position When Turning Shaft eee 2 6 Priming Pump Handle eee 3 2 Fuel Filter Bleed Air 3 2 Fuel Injection Pump Bleed Air 3 2 Priming Pump Tightening Method 3 3 Priming Pump Head Packing 3 3 Oil Filler and Oil Level Gauge 3 4 Pouring Engine Oil on Valve Mechanisms and Chamber 3 4 Radiator Cap ceceeceeeeeesreeeteeeeeeesees 3 5 Coolant Drain Cock Engine 3 5 Coolant Drain Cock Water Pump 3 5 Battery Electrolyte Level Inspect 3 6 Valves for open closed position GHOCK onra no 3 8 Fuel Control Link Check n se 3 9 Oil Filler and Oil Level Gauge 3 9 Air Cleaner Check for Clogging 3 10 Air Tank Drain Water 0000 3 10 Starting Air Tank Air Pressure CONTENTS 4 Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig 3 18 3 19
116. stat Inspect Consult a dealer of Mitsubishi Heavy Industries Ltd Faulty valve timing Consult a dealer of Mitsubishi Heavy Industries Ltd Basic engine ae Low compression pressure Consult a dealer of Mitsubishi Heavy Industries Ltd Note The table above also include the parts Mitsubishi Heavy Industries Ltd does not supply For the parts Mitsub ishi Heavy Industries Ltd does not supply inspect and maintain them following the manufacturer s operation manual 11 5 Chapter 11 TROUBLESHOOTING Exhaust Smoke is Black or Charcoal Table 11 5 Exhaust smoke is black or charcoal Cause Remedies Improper fuel property Use appropriate fuel Refer to P4 1 Faulty fuel feed pump Consult a dealer of Mitsubishi Heavy Industries Ltd Faulty fuel injection pump Consult a dealer of Mitsubishi Heavy Industries Ltd Faulty fuel injection nozzle Consult a dealer of Mitsubishi Heavy Industries Ltd Fuel system Fanie tel iieotion timi Check fuel injection pump couplings aulty fuel injection timin Consult a dealer of Mitsubishi Heavy Industries Ltd ae Check ignition noise exhaust smoke temperature Uneven fuel injection Bo l Consult a dealer of Mitsubishi Heavy Industries Ltd Check turbocharger Refer to P8 19 Clean inspect and replace air cleaner element Refer to P8 a 21 Insufficient amount of air l inlet and Check intake air pressure and leakage of i
117. t wire ropes from contacting the engine use a Fig e cloth or other soft padding 10 1 Chapter 11 TROUBLESHOOTING General Precautions Contact a Dealer of Mitsubishi Heavy Industries Ltd for Repair Service Repairing a malfunctioning engine may require special equipments or involve potentially dangerous work except for relatively simple procedures such as the change and addition of fuel engine oil and coolant When repairing malfunctioning engine contact a dealer of Mitsubishi Heavy Industries Ltd Considerations Before Work Before troubleshooting consider possible causes of the problem and try to find out if the same problem have occurred in the past Check the parts that may be causing the problem in the most efficient order When disassembling a component pay close atten tion to the disassembly sequence so that you can reassemble the component in reverse order of disas sembly Cautions Against Contamina tion Dust and foreign materials are the most common cause of rapid wear of parts When disassembling a component take measures to prevent dust and foreign materials from entering the component being disassembled Cautions Regarding Parts Han dling Handle parts carefully When replacing parts use only genuine parts by refer ring to the parts catalogue Safety Work Be sure to use wrenches of the correct size Using a wrench of the wrong size can cause not only nut dam age but also the p
118. tch and the fuel level is higher the LOW level line the float switch failure may occur Inspect and repair the float switch For fuel to be used refer to FUEL 4 1 Check that fuel is contained to the specified level in the fuel tank If the fuel level is low refill the tank to the FULL level line Note If the specification of fuel tank differs from the contents of this operation manual follow the manufacturer s op eration manual Fuel Control Link Check Check fuel control link for smooth movement Rack cance Push the manual stop lever to the fuel increase direc Spring tion check the movement of the rack cancel spring Then relax your grip on the lever little by little check that the manual stop lever returns to the no fuel injec Lek tion position smoothly Manual sto Also check ball joint for looseness and play Engine Oil Level Check CAUTION Oil level gauge Refilling engine oil must be specified level If the refilling oil goes over the high marks on the oil level gauge engine oil may blow out Always use the same engine
119. ter 7 MAINTENANCE SCHEDULE Table 7 3 Periodic Maintenance Chart for General Purpose Engine Refer Interval and service item ence page Top End of the Engine Overhaul Remove the Cylinder Head and Inspect and Service the Combustion Cham 2 bers Every 4000 service hours Fuel Control Link Ball Joint Inspect 8 10 oreve a years Damper Inspect 8 4 Air Cleaner Clean 2 Heat Exchanger Wash 2 Engine Major Overhaul 9 Disassemble Engine Clean Check and Change Major Parts Fuel Injection Pump Inspect and Test Replace parts as necessary 2 8000 hours Governor Inspect and Test Replace parts as necessary 2 Protective Devices Repair or Replace 2 Auxiliary Devices Operation Check 2 Every 8000 service hours or every 2 years Coolant Change 8 16 Fuel System Bleed Air 3 2 As required Air Cleaner Element Clean Check and Replace 1 8 21 1 If itis not a item supplied from Mitsubishi Heavy Industries maintain the part following the manufacture s opera tion manual as required 2 Items require special tools or large equipment For the servicing of those items contact a dealer of Mitsubishi Heavy Industries Ltd Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Basic Engine Engine External Inspect Be sure to keep combustible materials away from the engine especially from the hot engine parts such as exhaust manifolds or the battery Check for fu
120. terials such as dust 5 Reinstall the drain plug and the fuel feed pipe 6 Close the drain valve to fill the fuel 7 Refill fuel tank until fuel level gauge indicates FULL level line after checking the contact of float switch 3 1 Chapter 3 OPERATION Fuel System Bleed Air WARNINGS When fuel overflow from the air vent plug wipe thor oughly Spilled fuel causes fire hazard After bleeding lock the priming pump securely If the cap is not locked tightly the priming pump can be damaged causing a fuel leak that could lead to a fire While feeding fuel with priming pump bleed air from the location closest to the fuel tank that are the water separator fuel filter then the fuel injection pump Lock the priming pump according to Priming Pump Tightening Method Fuel Filter Bleed Air CAUTION If air vent plugs the thread portion of the bracket or sealing washers are damaged replace them with new ones 1 Loosen the air vent plug of the fuel filter about 1 5 turns N Move the priming pump up and down then feed fu el 9 When the fuel from the air vent plug becomes free from air bubbles stop priming and tighten the air vent plug to the specified torque Fuel Injection Pump Bleed Air 1 Loosen the air vent plug on the fuel injection pump by rotating about 1 5 turns Move the priming pump up and down until the fuel flow from the air vent plug is free from air bubbles Push and turn the p
121. the engine oil goes over the high marks on the oil level gauge open the engine oil drain valve to drain oil If the engine oil is low refill the specified engine oil 9 Check the oil pan and other area for oil leaks Re pair the oil leakage if any 10 While pulling the stop lever rotate the crankshaft for approx 10 seconds to turn on the starter Stop the operation for 1 minute then repeat the opera tion two or three times Circulate engine oil to each engine parts Note Prepare for the cooling system 11 Start the engine and run the engine in a no load condition at low idling speed for 5 to 10 minutes 12 Check the oil level with the oil level gauge again and add oil to the specified level after leaving the engine stopped for 30 minutes or more For details refer to Test Operation 3 7 3 4 Chapter 3 OPERATION Preparation of Cooling System Radiator Cap Open Close When using the engine with radiator cooling system remove the radiator cap only after the engine has cooled to the room temperature Place a waste cloth over the cap and loosen the cap about a half turn or stand the lever to the upright position to release inter nal pressure Opening the radiator cap of coolant expansion tank while the engine is hot causes steam and hot coolant to blow out and can result in skin burns Note If the specification of radiator differs from the contents of this operation manual follow the manufacturer s opera
122. tion manual Coolant Refill Always use the coolant having the same concentra tion 1 Close the coolant drain cock of engine and water pump securely 2 Open the coolant filler and add a mixture of water and coolant having the specified concentration Note a Determine the quantities of LLC based on the coolant capacity and the LLC concentration chart For the coolant refer to COOLANT 6 1 For the coolant capacity refer to MAIN SPECIFICATIONS 12 1 b For absolute air bleeding loosen the air vent plug on the upper section of thermostat 3 Check the heat exchange equipment and other parts for coolant leaks Repair leakage if found 4 When coolant reaches the full level close the cool ant filler securely 5 While pulling the manual stop lever rotate the crankshaft for approx 10 seconds using the start er Stop the operation for approx 1 minute then re peat the operation two or three times to bleed the cooling system Note Prepare for the engine oil system 6 Check the level of coolant Turn the cap about Stand the lever to half a turn the upright position Fig 3 8 Radiator Cap Coolant drain cock Coolant drain cock Water pump Fig 3 10 Coolant Drain Cock Water Pump Chapter 3 OPERATION Preparation of Electrical System Battery Check If battery electrolyte is spilled on your skin or clothes flush immediately with plenty of water If battery electrolyte get into
123. ubsection 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 th
124. ust the fuel injection pressure after 2 replacement Rubber Parts and O rings Replace 2 Unit Seal and Oil Seal of Water Pump Replace 2 Every 8 years Turbocharger Disassemble and Inspect 2 Aircooler Disassemble and Clean 2 Vibration isolating Rubber Repair or Replace 1 2 Couplings Repair or Replace 1 2 Protective Devices Repair or Replace 1 2 Protective Devices Repair or Replace 1 2 Stop Solenoid Inspect or Replace 2 Ball Tap of Water Tank Repair or Replace 1 2 Other Consumables Replace 2 1 If it is not a item supplied from Mitsubishi Heavy Industries maintain the part following the manufacture s opera tion manual as required 2 Items require special tools or large equipment For the servicing of those items contact a dealer of Mitsubishi Heavy Industries Ltd Chapter 7 MAINTENANCE SCHEDULE Periodic Maintenance Chart for General Purpose Engine Table 7 3 Periodic Maintenance Chart for General Purpose Engine Refer Interval and service item ence page Fuel Control Link Ball Joint Inspect 8 10 Every 50 service hours or i every month Air Strainer Drain Water and Clean Air motor type or direct inlet type 8 25 Air Tank Drain Water Air motor type or direct inlet type 3 10 Bolts and Nuts on the Engine Retighten 2 First 50 spay nou for Engine Oil Oil Filt
125. ut 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 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 In the case of pneumatic starting type close the main valve of the air tank and post a tag saying Do Not Open the Valve or the like 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 Turn ing Tools After Use Be sure to remove all turning tools used during main tenance and inspection work Remember also that the manual turning gear shaft must be pulled out 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 Chapter 1 BASIC SAFETY PRECAUTIONS Be Careful of Exhaust Fume Poisoning Operate Engine in a Well venti lated Area Check the exhaust pipes and where the pipes joint together
126. ving the same concentra tion 1 Close coolant drain cocks and plugs firmly 2 Open the coolant filler and add a mixture of water and coolant having the specified concentration Note Determine the amounts of LLC and water to be added by using the LLC concentration chart For the coolant refer to COOLANT 6 1 For the coolant capacity refer to MAIN SPECIFICA TIONS 12 1 3 Check the heat exchange equipment and other parts for coolant leaks If a coolant leak is found re pair it 4 When coolant reaches the full level close the cool ant filler securely 5 While pulling the manual stop lever rotate the crankshaft for approx 10 seconds using the starter Stop the operation for 1 minute then repeat the operation two or three times to bleed the cooling system Note Prepare for the engine oil system 6 Check the level of coolant Coolant drain cock Water pump Fig 8 22 Coolant Drain Cock Water Pump 8 17 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Radiator Fins Check and Clean A CAUTION When handling compressed air wear safety goggles a hardhat gloves and other necessary protective gear Working without wearing proper protective gear could result in serious injuries Check the radiator fins for holes and cracks To clean the radiator fins blow compressed air from the opposite direction of the normal air flow Note If the specification of radiator differs from the
127. wing specification Genuine LLC Mitsubishi Heavy Industries Ltd recommends the use of our genuine long life coolant GLASSY long life coolant Ethylene glycol type and Eco friendly prod uct PG GLASSY long life coolant propylene glycol type which are most appropriate coolant for Mitsubi shi diesel engines Be sure to use our Genuine LLC CUSST on Fig 6 1 GLASSY LLC 6 1 Chapter 6 COOLANT Other Brand LLCs CAUTION Never mix Mitsubishi Heavy Industries Ltd genuine LLC with other brand LLCs Mixing with other brand LLCs degrades the performance of the Mitsubishi Heavy Industries Ltd genuine LLC When using LLC other than Mitsubishi Heavy Indus tries Ltd genuine long life coolant LLC GLASSY long life coolant Ethylene glycol type or PG GLASSY long life coolant propylene glycol type be sure to use the LLC which meets specification in Mit subishi Heavy Industries Ltd The quality and performance of commercially avail able LLCs as well as their component variations are the responsibility of LLC suppliers Before purchasing commercial LLC be sure to dis cuss the suitability of LLC with the LLC supplier Use all season LLC non amine type only Do not use antifreeze alone instead of LLC Standard for Other Brand LLC When using other brand LLCs by necessity be sure to use the LLC that meets the following specification Mitsubishi heavy industries
128. with a cloth g Check the new oil filters and a bypass filter for Fig 8 16 Oil Filter proper seating of gasket Apply clean engine oil to gasket Install oil filters and a bypass oil filter to the filter P bracket When the gasket contacts the mounting surface of the filter bracket further rotate 3 4 to a full turn Engine Oil for Mixing of Fuel and Water Inspect If the engine continues to operate with engine oil mixed with fuel or water the engine oil viscosity decreases and this can cause serious accidents such as seizing of bearings Sample 1 to 2 L 0 26 to 0 53 U S gal of engine oil and check for abnormal odor and discoloration to determine the mixing of fuel and water If fuel is mixed with the engine oil the oil will smell like fuel If water is mixed with the engine oil the oil will be milky white If fuel or water is detected in the engine oil find the cause of the problem and repair If the problem cannot be cor rected easily contact a dealer of Mitsubishi Heavy Industries Ltd 8 14 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Governor Oil Filter Change When draining oil or changing the oil filter wear gloves Hot engine oil and parts may cause burns 1 Prepare a drip pan and place it under the governor oil filter 2 Loosen the air vent plug and remove the drain plug Drain oil from the filter into the drip pan 9 Remove the oil pipe from the center bolt
129. with a new one 2 Inspect belt tension deflection and pressing force V belt Push the belt downward at the midway between pulleys with approximately 98 to 147 N 10 to 15 kgf 22 05 to 33 05 Ibf If the deflection is 10 to 15 mm 0 39 to 0 59 in the tension is correct If the deflection of belt is not within the standard adjust the belt tension Ribbed belt Refer to Table 8 1 Ribbed Belt Tension Force adjust the pressing force if it is not average level when pushing the belt downward till 15 mm 0 59 in at the midway between pulleys with gauge Belt Tension Alternator Side Adjust 1 Remove the belt cover Tension pulley 2 Loosen all retaining bolts of the alternator and ad a Slide plate Water pump Adjusting rod justing rod 3 Loosen the upper and lower lock nuts on the ad justing rod Note That the lower nut on the adjusting rod has left hand threads 4 Turn the adjusting rod to adjust the belt tension 5 After adjusting deflection fix the upper and lower pulley lock nuts 6 Tighten all retaining bolts of the alternator and ad Fig 8 1 Belt and Belt Tension Inspect and Adjust justing plate 7 Reinstall the belt cover and front cover Belt Tension Water Pump Side Adjust 1 Remove the belt cover Loosen all slide plate retaining bolts Loosen the lock nut of adjusting bolt and turn the adjusting bolt Then adjust the belt tension After adjusting fix the slide plate and adjusting bolt
130. with a new one Replace the high pressure fuel injection pipe with a new one as needed In Every Major Overhaul Replace clamp seat with a new one Also check high pressure fuel injection pipe wear If defective replace the high pressure fuel injection pipe with a new one In Every Other Major Overhaul Clamp seat Replace all clamp seats and high pressure fuel injec tion pipes with new ones Fig 8 12 High Pressure Fuel Injection Pipe and Clamp Seat Inspect and Replace Low Pressure Fuel Pipe and Clip Inspect Visual Inspection in Every 2000 Service Hours Loosen clamp fixing bolt and check clip wear and pipe metal contact with clamp If defective replace the pipe assembly with a new one In Every Other Major Overhaul Replace the pipe assembly with a new one Fig 8 13 Low Pressure Fuel Pipe and Clip Inspect 8 11 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Lubricating System Engine Oil Oil Filter and Bypass Oil Filter Replace a CAUTION When draining engine oil check that the oil temperature is low When draining oil or changing the oil filter wear gloves Hot engine oil and parts may cause burns Do not dump waste oil It is forbidden by law For disposal of waste oil consult a dealer of Mitsubishi Heavy Indus tries Ltd Change the engine oil oil filter and bypass oil filter at the same time Also checking and analyzing the oil properties is recommended when changing the engine oil Do
131. y oil pump operation Consult a dealer of Mitsubishi Heavy Industries Ltd Faulty relief valve operation Consult a dealer of Mitsubishi Heavy Industries Ltd Check control system and wire Control Oil pressure gauge failure 4 a l system Consult a dealer of Mitsubishi Heavy Industries Ltd Check fuel injection pump rack stroke Increase in load a s Consult a dealer of Mitsubishi Heavy Industries Ltd Basic engine Rapid wear of sliding parts Consult a dealer of Mitsubishi Heavy Industries Ltd Increase clearance of sliding part Consult a dealer of Mitsubishi Heavy Industries Ltd 11 9 Chapter 11 TROUBLESHOOTING When Fuel has Run Out When fuel runs out while engine is running and the engine has stopped restart the engine as described below 1 Return the starter switch to the OFF position 2 Add fuel to the fuel tank For filling fuel tank refer to Fuel Tank Oil Level Check 3 9 3 Bleed air from the fuel system For bleeding fuel system refer to Fuel System Bleed Air 3 2 4 Restart the engine For starting the engine refer to Start 3 12 11 10 Chapter 12 MAIN SPECIFICATIONS Main Specifications Table 12 1 Main Specifications Item Specifications Engine model S6R S6R2 Type Water cooled 4 stroke cycle turbocharged with aircooler No of cylinders arrangement 6 cylinder in line Cylinder bore x stroke 170 x 180 mm 6 69 x 7 09
132. y other fuel gas oil or LLC than the specified ones or improper handling may cause various engine problems and malfunctions Obtain the MSDS issued by the oil and LLC suppliers and follow the directions in the MSDSs for proper han dling Handle LLC Carefully When handling LLC always wear rubber glovesand 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 LLC is highly flammable and can easily catch a fire if exposed to a flame Proper Disposal of Waste Oil LLC and Coolant Do not discharge waste engine oil LLC and coolant into sewerage river lake or other similarplaces 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 CAUTION Do Not Add Coolant Immedi ately 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 ov
133. ylene paper and place desiccants in the polyethylene covers 10 Disconnect the cables from the battery terminals and charge the battery Clean the terminals apply a thin coat of grease to the terminals and store the battery in a cool and dry room 11 Cover the whole engine Note a Store the engine in a well ventilated and dried indoor area b It is not necessary to drain coolant since it contains LLC LLC must be specified concentration For LLC concentration refer to LLC Concentration 6 6 c Post a sign at an easily noticeable place to warn that the fuel tank must be filled with fuel before operating the engine for the first time after storage Recommended Rust preventive Oil and Corrosion Inhibitor Table 9 1 Recommended Rust preventive Oil and Corrosion Inhibitor JIS No Recommended product Usage NP 3 Nippon Oil Corporation Prevention of rust on exposed Anti Rust P 1600 machined surfaces K2246 NP 9 Nippon Oil Corporation Prevention of Rust in Fuel Sys Anti Rust P 2400 tem Ryoukou Chemi 21519 cal Co Ltd Prevention of rust in air intake VCI Diana ND volatile system corrosion inhibitor Maintenance During Storage Charge the battery once a month Check the battery electrolyte for proper level and then charge the battery 9 1 Chapter 9 LONG TERM STORAGE Using the Engine After Storage 1 Remove the cover from the engine 2 Connect a fully charged battery 3 Remove the cov
134. ywheel Equivalent of SAE 18 in Flywheel housing Equivalent of SAE No 0 Note a The specification above are subject to change without prior notice b The specification above are described for the standard model The special model specifications may differ from those 12 1

99410-12140_Operation & Maintenance Manual S6R

Contents

Download Pdf Manuals

Related Search

Related Contents

99410-12140_Operation &amp; Maintenance Manual S6R

Contents

Download Pdf Manuals

Related Search

Related Contents

99410-12140_Operation & Maintenance Manual S6R