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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.
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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.
FOREWORD LIMITED WARRANTY If Mitsubishi Heavy Industries, Ltd. examines the returned parts for the warranty period and any failure at manufac- turing is found, Mitsubishi Heavy Industries, Ltd. shall repair or exchange the parts. For warranty period, contact a dealer of Mitsubishi Heavy Industries, Ltd.
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Protection Agency. Warranty overage 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.
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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...
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Subsection (e) shall be warranted for the warranty period defined in Subsection (b) (2). If any such part fails during the period of warranty coverage, it shall be repaired or replaced by Mitsubishi Heavy Industries, Ltd. according to Subsection (4) below. Any such part repaired or replaced under the war- ranty shall be warranted for the remaining warranty period.
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(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.
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(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.
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.
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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.
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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...
CONTENTS Do Not Add Coolant Immediately After a Sudden Chapter 1 Stop Due to Overheating........1-5 BASIC SAFETY PRECAUTIONS Stop Operation Immediately If You Notice Any Fire and Explosions ......1-1 Unusual Symptoms .......... 1-5 Keep Flames Away .......... 1-1 Avoid Immediate Restart After Abnormal Stop. 1-5 Always Swich the Water Heater ON Avoid Continuous Engine Operation at Low Oil (Emergency generator with water heater)..
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CONTENTS Handling Engine Oil ......5-3 Oil Pressure Switch.......... 2-5 Oil Filter Alarm Switch........2-5 Service Limits of Engine Oil ....5-4 Definition of Properties of Engine Oil .. 5-5 Kinetic Viscosity ..........5-5 Chapter 3 Base Number ........... 5-5 OPERATION Acid Number ............
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TROUBLESHOOTING Damper - Inspect..........8-3 General Precautions ......11-1 Fuel System.........8-5 Contact a Dealer of Mitsubishi Heavy Industries, Fuel System - Inspect ........8-5 Ltd. for Repair Service ........11-1 Fuel Tank - Clean..........8-5 Considerations Before Work ......11-1 Fuel Tank - Drain Water........
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CONTENTS Fig. 8-7 Inside of Fuel Filters (Wire-element Type) List of Illustrations Fig. 2-1 Engine Front View ....... 2-1 - Clean...........8-7 Fig. 2-2 Engine Rear View......... 2-1 Fig. 8-8 Fuel Filter - Replace ......8-8 Fig. 2-3 Engine Left Side View ......2-2 Fig.
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CONTENTS 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 .......... 4-2 Table 5-1 Table of Recommended Limit of Engine Oil Properties......5-2 Table 5-2 Table of engine oil properties ....
Chapter 1 BASIC SAFETY PRECAUTIONS Fire and Explosions Keep Flames Away Do Not Open Side Cover Until Do not use flames near the engine (in Engine Cools 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.
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.
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 To lift the engine, use slings capable lated Area of supporting the weight of the Check the exhaust pipes and where engine.
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.
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.
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.
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.
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.
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.
Chapter 2 NAME OF PARTS Engine External Diagrams Front Face Coolant outlet Air inlet Oil pump Fuel inlet port Fuel return port Fig. 2-1 Engine Front View Rear Face Air inlet Rotational direction Flywheel Fig. 2-2 Engine Rear View...
Chapter 2 NAME OF PARTS Equipment and Instrument The installed equipment and shapes differ on the engine type. 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.
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. 2-7 Oil Pressure Unit Revolution Detection Pickup It is installed in the timing gear case, and always detect engine speed.
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. Oil Pressure Switch When the engine oil pressure decreases and reaches to 0.3 MPa {3.1 kgf/cm...
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.
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...
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...
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...
Chapter 3 OPERATION Preparation of Cooling System Radiator Cap - Open/Close Turn the cap Remove the radiator cap only after the engine has about half a turn. cooled to room temperature. Place a waste cloth over the cap, and loosen the cap about a half-turn to release internal pressure.
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.
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.
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.
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"...
Chapter 3 OPERATION Engine Oil Level - Check 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 Always use the same engine oil as the first.
5E-50 mality of temperature alteration. If the abnormality of temperature alteration is found, Fig. 3-16 Thermo label of damper consult a dealer of Mitsubishi Heavy Industries, Ltd. Note: For damper temperature limit and inspection, re- fer to "Damper - Inspect"...
Chapter 3 OPERATION Start 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.
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.
Fig. 3-17 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 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"...
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)
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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-...
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.
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...
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.
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.
Chapter 5 ENGINE OIL Definition of Properties of Engine Oil Water Content Kinetic Viscosity Water in oil promotes corrosion/wear, and decreases Kinetic viscosity is a basic physical property of engine lubricity in sliding parts. oil and is considered as the most important aspect when evaluating oil.
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.
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.
Heavy Industries, Ltd. genuine LLC. use of LLC that does not meet the following specifica- When using LLC other than Mitsubishi Heavy Indus- tion. tries, Ltd. genuine long life coolant (LLC) "GLASSY General Demands of LLC long life coolant (Ethylene glycol type)"...
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/...
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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.
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)."...
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-...
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.
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 Every 50 service hours or Water Separator - Drain Water *1 every month Fuel Filters (Wire-element Type) - Drain Water Bolts and Nuts on the Engine - Retighten...
Couplings - Inspect or Replace *1 Vibration-isolating Rubber - Inspect *1 *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...
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 Valve Clearance - Inspect and Adjust (Check valve mechanism at the same time.)) Basic engine Inspecting the Vibration-isolating Rubber *1...
Chapter 7 MAINTENANCE SCHEDULE Table 7-2 Periodic Maintenance Chart for Emergency Engine Refer- Interval and service item ence page Engine Oil, Oil Filter and Bypass Oil Filter - Replace It is recommended to check the engine oil characteristics at the same time. 8-11 The oil filters must be replaced when the filter alarm lights.
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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...
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...
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.
Chapter 10 TRANSPORTATION Lifting the Engine 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.
When repairing malfunctioning engine, contact a Cautions Regarding Parts Han- dealer of Mitsubishi Heavy Industries, Ltd. dling Handle parts carefully. Considerations Before Work When replacing parts, use only genuine parts by refer- Before troubleshooting, consider possible causes of ring to the parts catalogue.
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.
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.
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.
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.
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.
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.
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.
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.
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"...
Approx. 100 L [26.42 U.S. gal.] (in engine only) Starting system Electric motor starting Starter 24V DC - 6.0 kW × 2 Alternator DC 24 V - 25 A Turbocharger Mitsubishi TD13 x 2 Note: The specification above are subject to change without prior notice. 12-1...