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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.
January 2011
Pub. No. 99260-201B0
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Table of Contents
Related Manuals for Mitsubishi Heavy Industries SA
Summary of Contents for Mitsubishi Heavy Industries SA
- 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. January 2011 Pub.
- Page 2 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.
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Page 3: 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 4: Warranty Coverage
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. - Page 5 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 responsible for the performance of the required maintenance...
- Page 6 (a) The warranty period shall begin on the date the engine or equipment is delivered to an ultimate purchaser. (b) Mitsubishi Heavy Industries, Ltd. warrants to the ultimate purchaser and each subsequent purchaser of the en- gine registered in the state of California that the engine is: (1) Designed, built and equipped so as to conform with all applicable regulations adopted by the Air Resources Board.
- Page 7 (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.
- Page 8 (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.
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Page 9: Important Information
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. - Page 10 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 tatements 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 11 FOREWORD 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 N•m = 0.10197 kgf•m Force:1 N = 0.10197 kgf Horsepower:1 kW = 1.341 HP = 1.3596 PS Meter of mercury:1 kPa = 0.75 cmHg Meter of water:1 kPa = 10.197 cmH...
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Page 12: Table Of Contents
CONTENTS Use Only Specified Fuel, Engine Oil and LLC.. 1-5 Chapter 1 Handle LLC Carefully ........1-5 BASIC SAFETY PRECAUTIONS Proper Disposal of Waste Oil, LLC and Fire and Explosions ......1-1 Coolant ............. 1-5 Keep Flames Away .......... 1-1 When Abnormality Occurs ....1-5 Always Swich the Water Heater ON Do Not Add Coolant Immediately After a (Emergency generator with water heater).. - Page 13 CONTENTS Equipment and Instrument ....2-2 Fuel Specification........ 4-2 Start and Stop Instrument ........ 2-2 Instruments ............2-3 Chapter 5 Engine Protection Devices ....2-4 ENGINE OIL Oil Pressure Switch.......... 2-4 Recommended Engine Oil ....5-1 Thermo Switch ..........2-4 Engine Oil Grade ........ 5-1 Oil Filter Alarm Switch........
- Page 14 CONTENTS General Definition of Engine....7-2 Starter - Inspect..........8-25 Alternator - Inspect ......... 8-25 Periodic Maintenance Chart for Air Starter System......8-26 Regular Use Engine ......7-3 Air Strainer - Drain Water and Clean....8-26 Periodic Maintenance Chart for Air Tank - Drain Water ........8-26 Emergency Engine ......7-5 Air Tank - Inspect Safety Valve Operation ..
- Page 15 CONTENTS Fig. 3-18 Starting Air Tank Air Pressure Chapter 12 - Check ..........3-11 MAIN SPECIFICATIONS Main Specifications......12-1 Fig. 3-19 Thermo label of damper ......3-11 Fig. 3-20 Manual Stop Lever ......3-14 Fig. 5-1 Engine Oil Grade........5-1 Fig. 5-2 Selection of Oil Viscosity .......5-3 List of illustrations Fig.
- Page 16 CONTENTS Fig. 8-28 Air Cleaner Element - Remove... 8-22 List of tables Fig. 8-29 Air Cleaner Element - Clean and Table 3-1 Inspection During Operation....3-13 Check ..........8-22 Table 4-1 Recommended Fuel ........4-1 Fig. 8-30 Air Cleaner - Check for Clogging ..8-23 Table 4-2 Recommended Limit and Use Limit of Fig.
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Page 17: Basic Safety Precautions Fire And Explosions
Chapter 1 BASIC SAFETY PRECAUTIONS Fire and Explosions Keep Flames Away Do Not Open Side Cover Until Engine Cools Do not use flames near the engine (in the engine room). Fuel gas vapor or Do not attempt to open the side cover of the crank- other gas can catch fire and produce case before the engine cools down. -
Page 18: 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 and tagout before starting inspec- Make sure the protective covers of tion and maintenance. the engine are correctly installed. -
Page 19: Be Careful Of Exhaust Fume Poisoning
Chapter 1 BASIC SAFETY PRECAUTIONS Be Careful of Exhaust Be Careful of Falling Fume Poisoning Down Operate Engine in a Well-venti- Lift Engine Carefully lated Area To lift the engine, use slings capable of supporting the weight of the Check the exhaust pipes and where engine. -
Page 20: Be Careful Of Burns
Chapter 1 BASIC SAFETY PRECAUTIONS Be Careful of Burns Do Not Touch the Engine Dur- Be Careful of Opening and ing or Immediately After Opera- Closing Radiator Cap tion Never open the radiator cap while the engine is run- To avoid burns, do not touch the ning or immediately after the engine is stopped. -
Page 21: Be Careful When Handling Fuel, Engine Oil Or Llc
Chapter 1 BASIC SAFETY PRECAUTIONS Be Careful When Handling When Abnormality Occurs Fuel, Engine Oil or LLC Do Not Add Coolant Immedi- ately After a Sudden Stop Due Use Only Specified Fuel, to Overheating Engine Oil and LLC If the engine stops suddenly or if you have no choice Use fuel, oil and LLC specified in this manual, and but stop the engine suddenly due to overheating, do handle them carefully. -
Page 22: Battery
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. -
Page 23: Other Cautions
If there is a need to modify the engine, contact a Failure to conduct the specified inspections may dealer of Mitsubishi Heavy Industries, Ltd. cause various engine problems, damage to parts, and serious accidents. -
Page 24: Conduct Cooling Operation Before Stopping The Engine
Chapter 1 BASIC SAFETY PRECAUTIONS Conduct Cooling Operation Use of Tools Optimum for Each Before Stopping the Engine Work Before stopping the engine, idle the engine in low gear Always keep in mind to select most appropriate tools for 5 to 6 minutes to cool down. for the work to be performed and use them correctly. -
Page 25: Warning Labels
If any engine part on which a warning label is attached is replaced with a new one, attach a new identical warning label to the new part. To obtain new warning labels, contact a dealer of Mitsubishi Heavy Industries, Ltd. Fig. 1-1 Warning labels... -
Page 26: Name Of Parts
Chapter 2 NAME OF PARTS Engine External Diagrams Left Side Turbocharger Coolant outlet Air cooler Thermostat Fuel injection pump Fuel feed pump Alternator Front Rear Governor Damper Governor oil filter Coolant drain cock Starter Water pump Oil pan Oil filler Fuel filter (Wire element type Breather... -
Page 27: Equipment And Instrument
Chapter 2 NAME OF PARTS Equipment and Instrument The installed equipment and shapes differ on the engine type. Start and Stop Instrument Start Switch When the start switch on the operation panel is pressed, starting system operates to crank the engine. START STOP Stop Switch... -
Page 28: Instruments
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 Fig. 2-6 Oil Pressure Unit Thermo Unit Always detect the coolant temperature of engine. -
Page 29: Engine Protection Devices
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. -
Page 30: Revolution Detection Pickup
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. Fig. 2-12 Revolution Detection Pickup Air Cleaner Indicator If the element is clogged, the intake air is decreased and the red signal mark will be displayed. -
Page 31: 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 32 Chapter 3 OPERATION Fuel System - Bleed Air [Unlock] [Prime] [Lock] When fuel overflow from the air vent plug, wipe thor- Turn counterclockwise Move cap up and down oughly. Spilled fuel causes fire hazard. After bleeding, lock the priming pump securely. If the Turn clockwise cap is not locked tightly, the priming pump can be while pressing...
- Page 33 Chapter 3 OPERATION Fuel Injection Pump - Bleed Air 1. Loosen the air vent plug on the fuel injection pump Air vent plug by rotating about 1.5 turns. 2. 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 priming pump clockwise to lock Fuel injection pumps in the original position when the fuel flows is free...
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Page 34: Preparation Of Lubrication System
Chapter 3 OPERATION Preparation of Lubrication System Engine Oil - Refill Oil filler 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. And also, the engine Improper component parts are adversely affected by increas- High... -
Page 35: Preparation Of Cooling System
Chapter 3 OPERATION Preparation of Cooling System Radiator Cap - Open/Close Stand the lever to Turn the cap about When using the engine with radiator cooling system, the upright position half a turn remove the radiator cap only after the engine has cooled to the room temperature. -
Page 36: Preparation Of Electrical System
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 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. -
Page 37: 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 at the starting up the engine. -
Page 38: Normal Engine Operation
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. -
Page 39: Fuel Tank Oil Level - Check
Chapter 3 OPERATION Fuel Tank Oil Level - Check 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 switch and the fuel level is higher the "LOW"... -
Page 40: Coolant Level - Check
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"... -
Page 41: Air Tank Air Pressure - Check
5E-50 If the abnormality of temperature alteration is found, consult a dealer of Mitsubishi Heavy Industries, Ltd. Fig. 3-19 Thermo label of damper Note: For damper temperature limit and inspection, re- fer to "Damper - Inspect"... -
Page 42: Start
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. -
Page 43: Run
Chapter 3 OPERATION Cautions During Operation Inspection During Operation Check for abnormal engine noises or vibrations such as knocking or the exterior of engine such as piping Do not approach rotating parts during operation. joints for leaks. Entanglement by rotating parts can result in serious Carefully check the following items whether there is injury. -
Page 44: Stop
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, and check the engine for abnormalities. -
Page 45: Recommended Fuel
Chapter 4 FUEL Recommended Fuel 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"... -
Page 46: 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 47 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) Lubricity: MWSD (Measured mean 460 μm [0.02 in.] or less Wear Scar Diameter) by HFRR (calculated wear scar diame-...
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Page 48: Engine Oil
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 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 49: Engine Oil Specification
Chapter 5 ENGINE OIL Engine Oil Specification Use engine oil which 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 50: 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 Bubbling test JIS K 2518 30/0 ISO 6247 10/0 300°C 140 or lower [572°F] Panel caulking test FED791-3462 325°C 300 or lower [617°F] *1 It must have been certified API service classification CF by 2009. -
Page 51: Service Limits Of Engine Oil
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. -
Page 52: Definition Of Properties Of Engine Oil
Chapter 5 ENGINE OIL Definition of Properties of Engine Oil Kinetic Viscosity Water Content Kinetic viscosity is a basic physical property of engine Water in oil promotes corrosion/wear, and decreases oil and is considered as the most important aspect lubricity in sliding parts. when evaluating oil. -
Page 53: Engine Oil Analysis Service
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. -
Page 54: 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 (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. -
Page 55: Other Brand Llcs
Other Brand LLCs Standard for Other Brand When using other brand LLCs by necessity, be sure to Never mix Mitsubishi Heavy Industries, Ltd. genuine use the LLC that meets the following specification. LLC with other brand LLCs. Mixing with other brand Mitsubishi heavy industries, Ltd. -
Page 56: Llc Specification
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 lb/ft ] (20/... - Page 57 Chapter 6 COOLANT Table 6-2 LLC Specification Property Standard Aluminum, Cast Mass iron, Steel, Brass, ±0.30 mg/cm change Solder, Copper Metal specimen No visible signs of corrosion on the surface Appearance of the specimen excluding the area contacting to spacer. Circulation metal- after testing However, discoloration is acceptable.
- Page 58 Chapter 6 COOLANT Table 6-2 LLC Specification Property Standard Storage stability vol % (30 vol %, room temperature, 6 Hr) 0.3 or less...
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Page 59: Maintenance Of Llc
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)."... -
Page 60: Importance Of Llc
Chapter 6 COOLANT Importance of LLC Examples of Abnormali- Today's trend is toward smaller and lighter engines ties Caused by LLC offering greater output, lower fuel consumption and (Amine Type) lower 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 61: 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 50 service hours. -
Page 62: 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 63: Periodic Maintenance Chart For Regular Use Engine
Chapter 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 Fuel Tank - Drain Water*1 Every 50 service hours or Water Separator - Drain Water*1 every month Fuel Filters (Wire-element Type) - Drain Water... -
Page 64: Clean
Couplings - Inspect or Replace *1 Inspecting the Vibration-isolating Rubber *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 equipment. For the servicing of those items, contact a dealer of Mitsubishi... -
Page 65: Periodic Maintenance Chart For Emergency Engine
Chapter 7 MAINTENANCE SCHEDULE Periodic Maintenance Chart for Emergency Engine Table 7-2 Periodic Maintenance Chart for Emergency Engine Refer- Interval and service item ence page Engine External - Inspect (Check for leakage of fuel, oil and coolant) Fuel Tank Oil Level - Check Engine Oil Level - Check Coolant Level - Check 3-10... - Page 66 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 Bolts and Nuts on the Engine - Check and Retighten Damper - Inspect Valve Clearance - Inspect and Adjust Basic engine (Check valve mechanism at the same time.)
- Page 67 Chapter 7 MAINTENANCE SCHEDULE Table 7-2 Periodic Maintenance Chart for Emergency Engine Refer- Interval and service item ence page Water Pump - Inspect Solenoid Valve and Pressure Reducing Valve of the Cool- ing System - Inspect, Disassemble and Clean Strainer (Including With Ball Tap) of Cooling Water - Cooling system Inspect, Disassemble and Clean Coolant Properties (when Only Soft Water is Used) -...
- Page 68 Ball Tap of Water Tank - Repair or Replace *1 Other Consumables - Replace *1 It is not a item supplied from Mitsubishi Heavy Industries, Ltd., however, please maintain the part regularly to use the engine securely and effectively. *2 Items require special tools or large equipment. For the servicing of those items, contact a dealer of Mitsubishi...
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Page 69: Periodic Maintenance Chart For General Purpose Engine
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 8-11 Every 50 service hours or Air Strainer - Drain Water and Clean (Air motor type or direct inlet type) 8-26... - Page 70 Air Cleaner Element - Clean, Check and Replace 8-22 *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.
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Page 71: Periodic Inspection And Maintenance Procedures
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 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. -
Page 72: 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. 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. -
Page 73: 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 74: Damper - Inspect
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. -
Page 75: Table 8-3 Thermo Label For 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"... -
Page 76: 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 77: Water Separator - Drain Water
Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES 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 78: 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 Gauze filter engine stall. 1. Remove the eye bolt at the inlet port of fuel feed pump. -
Page 79: Fuel Filters (Wire-Element Type) - Drain Water
Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Fuel Filters (Wire-element Type) - Drain Water 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. Check that the thread of the filter case and drain plug, or sealing washers. -
Page 80: Fuel Filter - Replace
Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Fuel Filter - Replace 1. Clean the area around the fuel filters. Air vent plug 2. Prepare a drip pan, and place it under the fuel fil- ters. Gasket 3. Using a filter wrench, remove the fuel filters. 4. -
Page 81: Fuel Control Link Ball Joint - Inspect
0.1 mm [0.004 in.] 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. Lever If the ball joints are integrated in the control link, replace the control link when the ball joints have loos- ened. -
Page 82: 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 in Every 2000 Service Hours Check clamp seat cracks and wear, or high pressure fuel injection pipe wear. If defective, replace the clamp seat with a new one. -
Page 83: Lubricating System
Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Lubricating System Engine Oil, Oil Filter and Bypass Oil Filter - Replace 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. - Page 84 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Engine Oil - Refill Oil filler 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. Improper High 1.
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Page 85: Engine Oil For Mixing Of Fuel And Water - Inspect
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. 8-15... -
Page 86: Governor Oil Filter - Change
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. -
Page 87: Cooling System
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 Stand the lever to Turn the cap about When using the engine with radiator cooling system, the upright position half a turn... - Page 88 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.
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Page 89: Radiator Fins - Check And Clean
Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Radiator Fins - Check and Clean 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. -
Page 90: Inlet And Exhaust Systems
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. -
Page 91: Air Cleaner - Check For Clogging
Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Air Cleaner - Check for Clogging 1. Check the air cleaner indicator for the element Reset button clogging. Signal 2. If the element is clogged, the red signal mark will (red) be displayed. 3. -
Page 92: 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 gear. Working without wearing proper protective gear could result in serious injuries. Never perform maintenance on the air cleaner while the engine is running. -
Page 93: Fig. 8-30 Air Cleaner - Check For Clogging
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 (red) contents of this operation manual, follow the manufacturer's operation manual. -
Page 94: Electrical System
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. -
Page 95: Starter - 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. Alternator Fig. 8-34 Alternator - Inspect 8-25... -
Page 96: Air Starter System
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 Starting air Starting air slowly. High pressured air is in the pipe only even if outlet inlet the air tank valve is closed. -
Page 97: Air Tank - Inspect Safety Valve Operation
{29 kgf/cm } [412 psi] 4. If 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. -
Page 98: Long-Term Storage
Chapter 9 LONG-TERM STORAGE 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... -
Page 99: Using The Engine After Storage
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 cover 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. -
Page 100: Lifting The Engine
Chapter 10 TRANSPORTATION Lifting the Engine 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. -
Page 101: Troubleshooting
When repairing malfunctioning engine, contact a Cautions Regarding Parts Han- dealer of Mitsubishi Heavy Industries, Ltd. dling Considerations Before Work Handle parts carefully. Before troubleshooting, consider possible causes of... -
Page 102: Case Of Problems, And Conceivable Causes And Remedies
Consult a dealer of Mitsubishi Heavy Industries, Ltd. Basic engine locked 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. -
Page 103: The Starter Cranks, But The Engine Does Not Start
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. -
Page 104: Output Decrease
Consult a dealer of Mitsubishi Heavy Industries, Ltd. Faulty governor control system 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. -
Page 105: Exhaust Smoke Is White Or Blue
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. -
Page 106: Exhaust Smoke Is Black Or Charcoal
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. -
Page 107: Fuel Consumption Is High
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. -
Page 108: Engine Oil Consumption Is High
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. -
Page 109: Overheating
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. -
Page 110: When Fuel Has Run Out
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"... -
Page 111: Table 12-1 Main Specifications
Chapter 12 MAIN SPECIFICATIONS Main Specifications Table 12-1 Main Specifications Item Specifications Engine model S12A2 Type Water-cooled 4-stroke cycle, turbocharged with aircooler No. of cylinders - arrangement 12-V Cylinder bore x stroke ø150 x 160 mm [5.91 x 6.30 in.] Displacement 33.93 L [8.96 U.S.