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OPERATION &
MAINTENANCE MANUAL
1
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.
September 2012
Pub. No. 99400-71100
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Table of Contents
Related Manuals for Mitsubishi S16R2-PTAW
Summary of Contents for Mitsubishi S16R2-PTAW
- Page 1 OPERATION & MAINTENANCE MANUAL The operator and supervisor are requested to read this Oper- ation and Maintenance Manual carefully before operating the engine or conducting inspection and maintenance. Never operate the engine or conduct maintenance work with- out completely understanding this manual. September 2012 Pub.
- Page 3 INTRODUCTION This operation and maintenance manual contains detailed operation, inspection and maintenance information for engines from Mitsubishi Heavy Industries, Ltd. Please be noticed that some contents are repeated among chapters for better understanding. Please read and understand this manual before proceeding with operation, inspection, and maintenance work.
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Page 4: Limited Warranty
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. -
Page 5: Important Information
If the manual is lost or damaged, please obtain a new provide thorough safety guidance to the operators. copy at a dealer of Mitsubishi Heavy Industries, Ltd. Also attach safety, caution and operating decals that as soon as possible. - Page 6 FOREWORD Warning Indication The following signs and symbols are used to call attention of the operators and maintenance personnel to potential dangers of the engine. Warning statements in the manual Warning labels affixed on the engine Warning Statements The warning statements in this manual describe potential danger in operating, inspecting or maintaining the engine, using the following five classifications to indicate the degree of potential hazard.
- Page 7 FOREWORD Units of Measurment Measurements are based on the International System of Units (SI), and they are converted to the metric system units in this manual. Conversion rates are as follows: Pressure: 1 MPa = 10.197 kgf/cm Torque: 1 N•m = 0.10197 kgf•m Force: 1 N = 0.10197 kgf Horsepower: 1 kW = 1.341 HP = 1.3596 PS Rotation speed: 1 min...
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Page 9: Table Of Contents
CONTENTS Use Only Specified Fuel, Engine Oil and LLC.. 1-6 Chapter 1 Handle LLC Carefully ........1-6 BASIC SAFETY PRECAUTIONS Proper Disposal of Waste Oil, LLC and Fire and Explosions ......1-1 Coolant ............1-6 Keep Flames Away .......... 1-1 If Problem Occurs ....... 1-6 Always Place the Water Heater Switch in Stop Operation Immediately If You Notice the ON Position (Emergency Generator With... - Page 10 CONTENTS Equipment and Instrument ....2-3 Chapter 5 Start and Stop Instrument ........ 2-3 ENGINE OIL Transmitters to Instruments ......2-4 Recommended Engine Oil ....5-1 Engine Protection Devices ....2-5 Engine Oil Grade ........ 5-1 Thermo Switch ..........2-5 Engine Oil Specifications ....5-2 Oil Filter Differential Pressure Alarm Switch ..
- Page 11 TROUBLESHOOTING Belt and Belt Tension - Inspect and Adjust ..8-2 General Precautions ......11-1 Damper - Inspect..........8-5 Contact a Dealer of Mitsubishi Heavy Industries, Fuel System.........8-7 Ltd. for Repair Service ........11-1 Fuel System - Inspect ........8-7 Considerations Before Proceeding with Fuel Tank - Clean..........
- Page 12 CONTENTS Fig. 3-19 Thermo Label of Damper ....3-13 List of Illustration Fig. 1-1 Warning Labels ........1-11 Fig. 3-20 Manual Stop Lever ......3-16 Fig. 2-1 Engine Front View ........ 2-1 Fig. 5-1 Engine Oil Grade........5-1 Fig. 2-2 Engine Rear View......... 2-1 Fig.
- Page 13 CONTENTS Fig. 8-27 Turbocharger - Inspect ....... 8-21 List of Table Fig. 8-28 Pre-cleaner - Clean ......8-21 Table 3-1 Specific Gravity of Electrolyte....3-8 Fig. 8-29 Air Cleaner Element - Remove... 8-23 Table 3-2 Standard values at rated speed ..3-15 Fig.
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Page 15: Basic Safety Precautions Fire And Explosions
Chapter 1 BASIC SAFETY PRECAUTIONS Fire and Explosions Keep Flames Away Ventilation of Engine Room Do not use flames near the engine (in Always provide adequate ventilation in the engine the engine room). Fuel gas vapor or room. Insufficient air in the room can cause an other gas can catch fire and produces increase in the engine temperature and a decrease in hazardous situations. -
Page 16: Do Not Open Side Cover Until Engine Cools
Chapter 1 BASIC SAFETY PRECAUTIONS Do Not Open Side Cover Until Keep Fire Extinguishers and a Engine Cools First-Aid Kit Handy Do not attempt to open the side cover of the Crank- Keep fire extinguishers handy, and case before the engine cools down. Wait at least 10 become familiar with their usage. -
Page 17: Stay Clear Of All Rotating And Moving Parts
Chapter 1 BASIC SAFETY PRECAUTIONS Stay Clear of All Rotating and Moving Parts Install Protective Covers Lockout and Tagout Around Rotating Parts Be sure to lockout/tagout before starting inspection Make sure the protective covers of and maintenance work. the engine are correctly installed. Lockout and tagout are effective methods of cutting off Repair any damaged or loose covers. -
Page 18: Watch Out For Exhaust Fume Poisoning
Chapter 1 BASIC SAFETY PRECAUTIONS Watch Out for Exhaust Watch Out for Falling Fume Poisoning Down Operate Engine in a Well-venti- Lift Engine Carefully To lift the engine, use slings capable lated Area of supporting the weight of the Check exhaust pipes and pipe joints engine. -
Page 19: Be Careful Not Burn Yourself
Chapter 1 BASIC SAFETY PRECAUTIONS Be Careful Not Burn Your- self Do Not Touch the Engine Dur- Be Careful When Opening and ing or Immediately After Opera- Closing of Radiator Cap tion Never open the radiator cap while the engine is run- Do not touch any part of the engine ning or immediately after stopping. -
Page 20: Be Careful When Handling Fuel, Engine Oil And Coolant (Llc)
Chapter 1 BASIC SAFETY PRECAUTIONS Be Careful When Handling If Problem Occurs Fuel, Engine Oil and Cool- ant (LLC) Stop Operation Immediately If You Notice Any Unusual Symp- toms Use Only Specified Fuel, Stop the operation immediately if you notice any Engine Oil and LLC unusual noise, odor or vibration. -
Page 21: Battery
Chapter 1 BASIC SAFETY PRECAUTIONS Battery Handle Battery Correctly Never use flames or allow sparks near the battery. The battery 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"... -
Page 22: Other Cautions
Chapter 1 BASIC SAFETY PRECAUTIONS Other Cautions Never Modify Engine Perform All Specified Pre-oper- Unauthorized modification of the engine will void your ation Inspections and Periodic warranty. Inspections Modification of the engine may not only cause dam- Conduct pre-operation inspections and periodic age to the engine but also may result in personal inspections as described in this manual. -
Page 23: Never Operate The Engine Under Over Load
Chapter 1 BASIC SAFETY PRECAUTIONS Never Operate the Engine Conduct Proper Maintenance of Under Over Load Air Cleaner or Pre-cleaner If overload symptoms such as black exhaust smoke is Pay attention to the Air Cleaner or Pre-cleaner main- observed, reduce the load immediately and assure the tenance. -
Page 24: Do Not Turn Off The Battery Switch During Operation
Chapter 1 BASIC SAFETY PRECAUTIONS 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, it stops the operation of meters and also may deteriorate alternator diode and transistor. -
Page 25: Warning Labels
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. -
Page 27: Name Of Parts
Chapter 2 NAME OF PARTS Engine External Views Front View Aircooler coolant outlet Thermostat Engine coolant outlet Aircooler water pump Engine water pump Aircooler water pump coolant drain cock Oil pump Damper Fig. 2-1 Engine Front View Rear View Exhaust gas outlet Turbocharger Turbocharger Governor actuator... -
Page 28: Left View
Chapter 2 NAME OF PARTS Left View Fuel filter Oil filter alarm switch Rear hanger Front hanger Intake air inlet Bypass oil filter Aircooler Manual stop lever coolant inlet Front Rear Engine coolant drain cock (Behind of coupling cover) Front accessory drive Fuel injection pump Starter... -
Page 29: Equipment And Instrument
Chapter 2 NAME OF PARTS Equipment and Instrument The installed equipment and shapes vary with specifications. Start and Stop Instrument Manual Stop Lever When stopping the engine with manual stop lever, keep the manual stop lever at the stop position until the engine completely stops. -
Page 30: Transmitters To Instruments
Chapter 2 NAME OF PARTS Transmitters to Instruments This section describes about devices which transmit signals to instruments for operation. Read carefully and under- stand functions of each device. Revolution Detection Pickup Located on the timing gear case, and detects engine speed at all times. -
Page 31: Engine Protection Devices
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. -
Page 32: Using Manual Turning Gear
Chapter 2 NAME OF PARTS Using Manual Turning Gear Before starting the engine, make sure that the 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. -
Page 33: Operational Environment
Chapter 3 OPERATION Operational Environment Check that the following contents 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. -
Page 34: Fig. 3-1 Priming Pump - Operate
Chapter 3 OPERATION Fuel System - Bleed Air [Unlock] [Prime] [Lock] When fuel overflows from the air vent plug, wipe Move cap up Turn clockwise Turn counterclockwise and down while pressing thoroughly with a cloth. Spilled fuel can cause a fire. After air bleeding, lock the priming pump securely. -
Page 35: Fig. 3-4 Priming Pump Tightening Method
3. Check the mounting position of head packing. Note: If the head packing has abnormality such as de- formation or scratches, the priming pump should be replaced. Consult a dealer of Mitsubishi Heavy Industries, Ltd. for replacement of the priming pump. -
Page 36: Preparation Of Lubrication System
Chapter 3 OPERATION Preparation of Lubrication System Engine Oil - Filling Oil level gauge Refill the engine with the specified engine oil to the specified level.If the oil level is higher than the maxi- mum mark on the level gauge, engine oil may blow Improper out during operation.Also, the increase of oil temper- High... -
Page 37: Preparation For Cooling System
Chapter 3 OPERATION Preparation for Cooling System Coolant - Refill (Engine) Left side Right side When adding coolant, use the same LLC concentra- tion coolant that is currently in the cooling system. Note: If the specification of radiator differs from the contents of this operation manual, follow the manufacturer's operation manual. - Page 38 Chapter 3 OPERATION Coolant - Refill (Air Cooler) Always use the coolant having the same concentra- tion. Note: If the specification of radiator differs from the contents of this operation manual, follow the manufacturer's operation manual. 1. Make sure coolant drain cocks are closed securely. 2.
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Page 39: Preparation Of Electrical System
Chapter 3 OPERATION Preparation of Electrical System Battery - Check Never use flames or allow sparks near the battery. The battery 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. Continual use may result in an explosion. -
Page 40: Fig. 3-14 Specific Gravity Of Battery Electrolyte
Chapter 3 OPERATION Specific Gravity of Battery Electrolyte - Check If the specific gravity measured at 20°C [68°F] is lower Float than 1.22, charge the battery. Electrolyte Table 3-1 Specific Gravity of Electrolyte surface Specific gravity Conditions Remedy at 20°C [68°F] From 1.26 to 1.28 Fully charged Electrolyte... -
Page 41: Test Operation
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 and abundant white exhaust gas generates at the starting up the engine. -
Page 42: Normal Engine Operation
Chapter 3 OPERATION Normal Engine Operation This section of the manual covers the procedures for the engine operation in normal condition. If the engine abnormality is observed during operation, stop the engine and correct the problem, or contact your local dealer. Preparations for Operation Always conduct daily pre-start inspection before starting the engine for the day. -
Page 43: Fuel Tank - Drain Water
Chapter 3 OPERATION Fuel Tank - Drain Water When handling 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. For fuel to be used, refer to "FUEL"... -
Page 44: Engine Oil Level - Check
Chapter 3 OPERATION Engine Oil Level - Check Oil level gauge Always add engine oil to the specified level. If the oil level is higher than the maximum mark on the level gauge, engine oil may blow out during operation. Improper Also, the increase of oil temperature may adversely High... -
Page 45: Air Cleaner - Check For Clogging
5E-50 5E-50 teration. If the abnormality of temperature alteration is found, Fig. 3-19 Thermo Label of Damper consult a dealer of Mitsubishi Heavy Industries, Ltd. Note: For damper temperature limit and damper in- spection, refer to "Damper - Inspect" (8-5). -
Page 46: Starting-Up
Chapter 3 OPERATION Starting-up Before starting the engine, 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 load to the engine when starting. -
Page 47: Operation
Chapter 3 OPERATION Operation Cautions During Operation Inspection During Operation Carefully check the exterior of engine such as piping joints for leaks during operation. Stay away from rotating parts during operation. Check engine for abnormal noise, odor or vibration Entanglement in rotating parts can cause serious during warmimg-up operation. -
Page 48: Stopping
Chapter 3 OPERATION Stopping Stopping the engine abruptly during high-speed operation or while engine is hot will shorten the engine life. Before stopping the engine, run the engine with the idle speed at low Rpm for 5 or 6 minutes to cool the engine, and check the engine for abnormalities. -
Page 49: Recommended Fuel
Chapter 4 FUEL Recommended Fuel Use the fuel specified in this manual only. And, do not refill the fuel tank more than the specified level. It could lead a fire. Use fuel that meets the values specified in the following "Recommended Fuel"... -
Page 50: Fuel Specification
Chapter 4 FUEL Fuel Specification Use fuel which meets the requirements specified in the table below. Table 4-2 Recommended Limit and Use Limit of Fuel Property Item Recommended limit Use limit Test method JIS K 2265 :2007 50°C [122°F] or higher Flash point ISO 3769 (In accordance with the regulation) - Page 51 Chapter 4 FUEL Table 4-2 Recommended Limit and Use Limit of Fuel Property Item Recommended limit Use limit Test method Foreign substances JIS B 9931 :2000 (foreign materials at engine fuel 5.0 mg/liter or less ISO 4405 inlet) 460 μm [0.02 in.] or less Lubricity: MWSD (Measured mean (calculated wear scar Wear Scar Diameter) by HFRR...
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Page 53: Engine Oil
Chapter 5 ENGINE OIL Recommended Engine Oil Use the engine oil recommended in this manual only. Never use oil other than that specified in this manual. The use of 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. -
Page 54: Engine Oil Specifications
Chapter 5 ENGINE OIL Engine Oil Specifications Use engine oil that meets the requirements specified in the table below. Table 5-1 Table of Recommended Limit of Engine Oil Properties Item Unit Recommended limit Test method API/JASO CF class *1 SAE viscosity 15W-40 JIS K 2580 Color ASTM... -
Page 55: Selection Of Oil Viscosity
Chapter 5 ENGINE OIL Table 5-1 Table of Recommended Limit of Engine Oil Properties Item Unit Recommended limit Test method 10/0 JIS K 2518 Bubbling test *2 30/0 ISO 6247 10/0 300°C 140 or lower [572°F] Panel caulking test *3 FED791-3462 325°C 300 or lower... -
Page 56: Handling Engine Oil
Chapter 5 ENGINE OIL Handling Engine Oil 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. -
Page 57: Definition Of Properties Of Engine Oil
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 due to blow-by gas and deterioration of oil or its natural aging increases the kinetic viscosity and degrades the performance of viscosity, which will cause the deposition of sludge inside the engine and oil filter clogging. -
Page 58: Water Content
Chapter 5 ENGINE OIL 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 used to check the dilution of fuel. The dilution of fuel reduces oil film, and causes insufficient lubrication that will cause friction or wear of engine parts. -
Page 59: Engine Oil Analysis Service
Chapter 5 ENGINE OIL Engine Oil Analysis Service For a long productive service life of engine, it is recommended to have an engine oil analysis service. The sample oil is taken from the engine using dedicated sampling tool and the oil is analyzed whether it is appropri- ate for the use. -
Page 61: Recommended Water For Coolant
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 (propylene glycol type)." If you have to use other brand LLCs, be sure to use the non-amine type LLC that meets the requirements by Mitsubishi Heavy Industries, Ltd. -
Page 62: Other Brand Llcs
LLC Heavy Industries, Ltd. genuine LLC. that does not meet our requirements. When using LLC other than Mitsubishi Heavy Indus- General Quality Requirements tries, Ltd. genuine long life coolant (LLC) "GLASSY long life coolant (Ethylene glycol type)" or "PG... -
Page 63: Llc Quality Requirements
Chapter 6 COOLANT LLC Quality Requirements LLC shall be tested according to JIS K2234, Section 7 "Test method", and satisfy the requirements. General mat- ters and specimen sampling method shall comply with JIS K2234. Table 6-2 LLC Quality Requirements Property Standard Appearance No precipitation... -
Page 64: Table
Chapter 6 COOLANT Table 6-2 LLC Quality Requirements Property Standard Aluminum, Cast Mass iron, Steel, Brass, ±0.30 mg/cm change Solder, Copper Metal speci- No visible signs of corrosion on the surface Appearance of the specimen excluding the area contacted to the spacer. Circulation metal- after testing However, discoloration is acceptable. - Page 65 Chapter 6 COOLANT Table 6-2 LLC Quality Requirements Property Standard Tensile strength change -60 to 0 % Elongation change -40 to +20 % Silicon Volume change 0 to +40 % Hardness change -20 to +10 % Tensile strength change 0 to +10 % Rubber adapt- ability Acrylonitrile...
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Page 66: Maintenance Of Llc
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. -
Page 67: Llc Concentration (Glassy
Chapter 6 COOLANT LLC Concentration (GLASSY, PG GLASSY) 1. To prevent cavitations of water pump and cylinder liners, LLC concentration must be at least 30% for GLASSY (ethylene glycol) and 40% for PG GLASSY (propylene glycol) by volume under any temperature conditions throughout the year. -
Page 68: Importance Of Llc
Chapter 6 COOLANT Importance of LLC Examples of Abnormali- Today's trend is smaller and lighter engines that can ties Caused by LLC offer greater output, lower fuel consumption and lower (Amine Type) exhaust emission levels. Conditions to which engine coolant is subjected, Pitting of Iron Parts therefore, are becoming severer due to longer operat- Amines are generally effective in suppressing the rust-... -
Page 69: Maintenance Schedule
Check the 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 500 service hours. -
Page 70: General Definition Of Engine
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. -
Page 71: Periodic Maintenance Chart For Regular (Prime) Use Engine
Chapter 7 MAINTENANCE SCHEDULE Periodic Maintenance Chart for Regular (Prime) Use Engine Table 7-1 Periodic Maintenance Chart for Continuous Use Engine Refer- Inspection and maintenance intervals and items inspected/maintained ence page Fuel Tank - Drain Water Every 50 service hours or every month Water Separator - Drain Water *1 Bolts and Nuts on the Engine Exterior - Retighten... -
Page 72: Fig. 3-2 Fuel Filter - Bleed Air
Couplings - Inspect or Replace *1 Vibration-isolating Rubber - Inspect *1 *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 scale maintenance. For maintenance of those items, contact your local... -
Page 73: Table
Chapter 7 MAINTENANCE SCHEDULE Periodic Maintenance Chart for Emergency Engine Table 7-2 Periodic Maintenance Chart for Emergency Engine Refer- Inspection and maintenance intervals and items inspected/maintained ence page Engine External - Inspect (Check for leakage of fuel, oil and coolant) 3-10 Fuel Tank Oil Level - Check 3-10... -
Page 74: Table
Chapter 7 MAINTENANCE SCHEDULE Table 7-2 Periodic Maintenance Chart for Emergency Engine Refer- Inspection and maintenance intervals and items inspected/maintained ence page Belt and Belt Tension - Inspect and Adjust Bolts and Nuts on the Engine Exterior - Check and Retighten Valve Clearance - Inspect and Adjust Engine Proper... -
Page 75: Table
Chapter 7 MAINTENANCE SCHEDULE Table 7-2 Periodic Maintenance Chart for Emergency Engine Refer- Inspection and maintenance intervals and items inspected/maintained ence page Engine Oil, Oil Filter and Bypass Oil Filter - Replace Engine oil analysis is also recommended at the same time. 8-13 The oil filters must be also replaced when the filter alarm lamp is turned on. -
Page 76: Table
Chapter 7 MAINTENANCE SCHEDULE Table 7-2 Periodic Maintenance Chart for Emergency Engine Refer- Inspection and maintenance intervals and items inspected/maintained ence page Vibration-isolating Rubber - Repair or Replace *1 Couplings - Repair or Replace *1 Protective Devices - Repair or Replace *1 Every 8 years Protective Devices - Repair or Replace *1 Stop Solenoid - Inspect or Replace... -
Page 77: Periodic Inspection And Maintenance Procedures
Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Basic Engine Engine External - Inspect Check external parts of the engine, particularly hot part (exhaust manifold, etc.) and battery unit for any accumula- tion of flammables, fuel leaks, and engine oil leaks, etc. Remove dust from the top surface of the battery. If some- thing goes wrong with the hot parts, it may cause a fire. -
Page 78: Belt And Belt Tension - Inspect And Adjust
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. Belts must be free from grease and oils. Grease and oils cause belts to slip and shorten their service life. Excessive belt tension can cause rapid wear of the alternator bearing and shorten the service life of the belt. -
Page 79: Table 8-1 Ribbed Belt Tension Force
Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Table 8-1 Ribbed Belt Tension Force Belt direct distance (mm) Num- Item ber of 300 or more 400 or more 500 or more Up to 300 600 or more ribs Up to 400 Up to 500 Up to 600 74 N {7.55 kgf }... - Page 80 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Table 8-1 Ribbed Belt Tension Force Belt direct distance (mm) Num- Item ber of 300 or more 400 or more 500 or more Up to 300 600 or more ribs Up to 400 Up to 500 Up to 600 51 N {5.20 kgf }...
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Page 81: Damper - Inspect
Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Damper - Inspect Damper - Check Visually Cover The protective cover for the damper should not be air-tight. The damper deteriorates or slows down the perfor- mance by heat, which may cause serious engine problems. -
Page 82: Table 8-2 Types Of Thermo Labels
Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Thermo Label - Use When the thermo label reaches a specified temperature, the white heat-sensitive area turns into black. Note: Once the heat-sensitive area turns its color, it will never return to the original color again.Therefore, if the en- gine is stopped, thereby dropping the temperature of damper, the thermo label still indicates the highest tem- perature when engine was running. -
Page 83: Fuel System
Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Fuel System Fuel System - Inspect 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 For fuel to be used, refer to"FUEL"... -
Page 84: Oil-Water Separator - Drain Water
Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Oil-water Separator - Drain Water 1. Prepare a plate, and place it under the drain cock of water separator. 2. Open the drain cock, and drain water in the water separator. 3. Close the all drain cocks after draining. Note: If the specification of water separator differs from the contents of this operation manual, follow the manufacturer's operation manual. -
Page 85: Gauze Filter - Clean
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 engine stall. 1. Remove the union bolt at the inlet port of fuel feed Gauze filter pump. -
Page 86: Fuel Filter - Replace
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. 3. Using a filter wrench, remove the fuel filters. 4. -
Page 87: Fuel Control Link Ball Joint - Inspect
Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Fuel Control Link Ball Joint - Inspect Check ball joint in the fuel control link for looseness or 0.1 mm sluggish movement. If the amount of looseness is 0.1 [0.004 in.] Ball joint mm [0.004 in.] or more, replace the ball joint with the new one. -
Page 88: Fuel Pipe - Inspect
Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Fuel Pipe - Inspect High Pressure Fuel Injection Pipe and Clamp Seat - Inspect and Replace Visual Inspection Check clamp seat for cracks and wear. Check high pressure fuel injection pipe for wear. If defective, replace the clamp seat with a new one. -
Page 89: Lubrication System
When draining oil or replacing oil filters, be sure to wear gloves. You can get burned if you touch the hot engine oil or parts. Do not dump waste oil. It is forbidden by law. For disposal of waste oil, consult a dealer of Mitsubishi Heavy Indus- tries, Ltd. - Page 90 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Oil Filter and Bypass Oil Filter - Replace Container Filter bracket If filter case is dented, do not use the filter. It can damage the filter during operation, and may result in a fire due to oil leaks. Filter Do not use a filter wrench to install the oil filter and bypass oil filter.
- Page 91 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Engine Oil - Refill Oil level gauge Always refill with specified quantity of engine oil. If the oil level is higher than the maximum mark on the level gauge, engine oil may blow out during opera- Improper tion.
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Page 92: Fuel And Water Ingress In Engine Oil - Inspect
Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Fuel and Water Ingress In Engine Oil - Inspect If the engine operation is continued with fuel or water mixed in the engine oil, the engine oil viscosity will decrease and this can cause serious accidents such as bearing seizure. Sample 1 to 2 Liters [0.26 to 0.53 U.S. -
Page 93: Cooling System
Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Cooling System Coolant - Change Do not dump the coolant (containing LLC) drained from the engine. Such a way of disposal is strictly prohibited by laws and regulations. Abide by the applicable law and regulations when discarding drained coolant. When a coolant mixed with the LLC recommended by our company is used, replace coolant every 8000 hours or 2 years, whichever comes first for continuous use engine and general purpose engine. - Page 94 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Coolant - Drain 1. To drain coolant immediately after engine opera- tion, run the engine at low idle for 5 to 6 minutes to Left side Right side lower the coolant temperature to 70 to 80 °C [158 to 176 °F].
- Page 95 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Coolant - Refill (Engine) Left side Right side When adding coolant, use the same LLC concentra- tion coolant that is currently in the cooling system. Note: If the specification of radiator differs from the contents of this operation manual, follow the manufacturer's operation manual.
- Page 96 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Coolant - Refill (Air Cooler) Always use the coolant having the same concentra- tion. Note: If the specification of radiator differs from the contents of this operation manual, follow the manufacturer's operation manual. 1.
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Page 97: Inlet And Exhaust Systems
Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Inlet and Exhaust Systems Turbocharger - Inspect Inspect the turbocharger when the engine is cold. Also, make sure that the compressor wheel is not rotating. The turbocharger inspection should be also con- ducted if the color of the exhaust gas is abnormal. Disconnect the pipe on the inlet side. -
Page 98: Air Cleaner Element - Clean, Check And Replace
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 gears. Working without wearing proper protective gear could result in serious injuries. Never service the air cleaner while the engine is running. -
Page 99: Fig. 8-29 Air Cleaner Element - Remove
Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES 1. Remove the air cleaner cap or wing bolt. 2. 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 Wing to remove foreign materials. -
Page 100: Electrical System
Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Electrical System Battery - Check Never use flames or allow sparks near the battery. The battery 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"... -
Page 101: Specific Gravity Of Electrolyte
Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Specific Gravity of Battery Electrolyte - Check If the specific gravity measured at 20°C [68°F] is lower than 1.22, charge the battery. Float Electrolyte Table 8-3 Specific Gravity of Electrolyte surface Specific gravity Conditions Remedy at 20°C [68°F]... -
Page 102: Starter - Inspect
Also, visually inspect the inside of alternator for dust and salt accumulation since the alternator is an air cooling type. Note: If the alternator is defective, consult a dealer of Mitsubishi Heavy Industries, Ltd. Fig. 8-35 Alternator - Inspect 8-26... -
Page 103: Long-Term Storage
Chapter 9 LONG-TERM STORAGE If the engine is not in use for more than 3 months, the internal engine parts can rust, and it may cause damage to the engine. If the engine is being stored for an extended period of time, be sure to follow the instructions below. Storing Engine in an Inoperable Condition for 3 Months up to 1 Year Preparation for Storage... -
Page 104: Maintenance During Storage
Chapter 9 LONG-TERM STORAGE Maintenance During Storage Charge the battery once a month. Check battery electrolyte level and then charge the battery. When Using Engine After Storage 1. Remove the cover placed over the entire engine. 2. Connect a fully charged battery. 3. -
Page 105: Lifting Engine
Chapter 10 TRANSPORTATION Lifting Engine Front hanger Rear hanger To lift the engine, use wire ropes, shackles and slings capable of supporting the weight of the engine. Hitch slings to the hangers provided on the engine to lift the engine. Consider the engine's center of gravity and maintain the balance during lifting. -
Page 107: Troubleshooting
Chapter 11 TROUBLESHOOTING General Precautions Cautions Against Contamina- Contact a Dealer of Mitsubishi tion Heavy Industries, Ltd. for Dust and foreign materials are the most common Repair Service cause of rapid wear of parts. Except for relatively simple maintenance work such as... -
Page 108: Cases Of Problems, And Probable Causes And Solutions
Consult a dealer of Mitsubishi Heavy Industries, Ltd. Note: The table above also includes the parts not supplied by Mitsubishi Heavy Industries, Ltd. For the parts not sup- plied by Mitsubishi Heavy Industries, Ltd., inspect and maintain them by following the manufacturer's operation manual. -
Page 109: Starter Cranks, But Engine Does Not Start
Consult a dealer of Mitsubishi Heavy Industries, Ltd. Note: The table above also includes the parts not supplied by Mitsubishi Heavy Industries, Ltd. For the parts not sup- plied by Mitsubishi Heavy Industries, Ltd., inspect and maintain them by following the manufacturer's operation manual. -
Page 110: Output Decrease
Consult a dealer of Mitsubishi Heavy Industries, Ltd. Note: The table above also includes the parts not supplied by Mitsubishi Heavy Industries, Ltd. For the parts not sup- plied by Mitsubishi Heavy Industries, Ltd., inspect and maintain them by following the manufacturer's operation manual. -
Page 111: Exhaust Smoke Is White Or Blue
Consult a dealer of Mitsubishi Heavy Industries, Ltd. Note: The table above also includes the parts not supplied by Mitsubishi Heavy Industries, Ltd. For the parts not sup- plied by Mitsubishi Heavy Industries, Ltd., inspect and maintain them by following the manufacturer's operation manual. -
Page 112: Exhaust Smoke Is Black Or Charcoal
Consult a dealer of Mitsubishi Heavy Industries, Ltd. Note: The table above also includes the parts not supplied by Mitsubishi Heavy Industries, Ltd. For the parts not sup- plied by Mitsubishi Heavy Industries, Ltd., inspect and maintain them by following the manufacturer's operation manual. -
Page 113: Fuel Consumption Is High
Consult a dealer of Mitsubishi Heavy Industries, Ltd. Note: The table above also includes the parts not supplied by Mitsubishi Heavy Industries, Ltd. For the parts not sup- plied by Mitsubishi Heavy Industries, Ltd., inspect and maintain them by following the manufacturer's operation manual. -
Page 114: Engine Oil Consumption Is High
Consult a dealer of Mitsubishi Heavy Industries, Ltd. Note: The table above also includes the parts not supplied by Mitsubishi Heavy Industries, Ltd. For the parts not sup- plied by Mitsubishi Heavy Industries, Ltd., inspect and maintain them by following the manufacturer's operation manual. -
Page 115: Overheating
Consult a dealer of Mitsubishi Heavy Industries, Ltd. Note: The table above also includes the parts not supplied by Mitsubishi Heavy Industries, Ltd. For the parts not sup- plied by Mitsubishi Heavy Industries, Ltd., inspect and maintain them by following the manufacturer's operation manual. -
Page 116: Low Engine Oil Pressure
(Refer to P5-7). Cooling System - Check Lubricating Engine oil temperature is high. system Consult a dealer of Mitsubishi Heavy Industries, Ltd. Inspect and replace oil filter and bypass oil filter. Clogged oil filter (Refer to P8-13). Faulty oil pump operation Consult a dealer of Mitsubishi Heavy Industries, Ltd. -
Page 117: Main Specifications
Approx 3117.5 x 1478.3 x 2029.5 mm [122.74 x 58.20 x 79.90 in.] Dry weight Approx 7750 kg [17086 lb] Fuel Diesel fuel Fuel injection pump Mitsubishi PS8A × 2 Fuel filter Paper-element type (Spin-on type) Fuel injection nozzle Hole type Fuel injection starting pressure 34.32 MPa {350 kgf/cm... - Page 120 99400-71100 Printed in Japan Pub. No.