Mitsubishi S12U, S16U Maintance Manual

October 2003

OPERATION&MAINTENANCE MANUAL

OPERATION &
MAINTENANCE MANUAL

Printed in Japan

Pub.No.

NOTE

The operator and supervisor are requested to read this
Operation and Maintenance Manual carefully before
operating the engine or conducting inspection and
maintenance.
Never operate the engine or conduct maintenance work
without completely understanding this manual.

Pub.No.

October 2003

99080-20120

99080-20120

INTRODUCTION

This manual contains information for operation, inspection and maintenance of the Mitsubishi Engines.

Please read this manual carefully to understand the operation, inspection and maintenance procedures in

order to use the engine properly.

Failure to follow directions in this manual can lead to serious accidents.

Pub.No.

99080-20120

INTRODUCTION

Limited Warranty

The manufacturer, at its option, will repair or replace any parts returned intact to the manufacturer only when

the manufacturer, upon inspection, determines to be defective in material and/or workmanship.

The foregoing shall constitute the limited warranty provided by the manufacturer.

The manufacturer will provide the limited warranty only to the user with whom the manufacturer concludes the

original contract, and shall not provide the limited warranty to a user to whom the ownership of the product

may be transferred.

• The manufacturer makes no warranties, either express or implied, except as provided in this manual, includ-

ing without limitation thereof, warranties as to marketability, merchantability, fitness for a particular purpose

or use, or against infringement of any patent.

• The manufacturer will not be liable for any damages or consequential damages, including without limitation

thereof, damages or other costs resulting from any abuse, misuse, misapplication of the engine and devices

supplied by the manufacturer.

• The manufacturer will not be liable for any damages or personal injuries resulting from any modification,

without the manufacturer's written permission, of the engine and devices supplied by the manufacturer.

• The manufacturer will not be liable for any damages or production losses caused by the use of fuel, engine

oil and/or long life coolant that are not recommended by the manufacturer.

Important Information

• To avoid potential hazard, accident prevention

activities must be planned methodically and con-

ducted continually by considering all aspects of

engine operation, maintenance and inspection.

Everyone including managers and supervisors

should actively participate, recognize one's role

and organize oneself and one's work to ensure a

safe environment.

• The foremost safety objective is to prevent acci-

dents which could result in injury or death, or

damage equipment.

• Observe all related federal/national and local

codes and regulations to reduce the possibility of

personal injury.

• The manufacturer cannot foresee all potential

danger of the engine, potential danger resulting

from human error and others, or danger caused

by a specific environment in which the engine is

used.

Since there are many actions that cannot be per-

formed or must not be performed, it is not possi-

ble to indicate every caution in this manual or on

warning labels. As such, it is extremely important

to follow directions in this manual and also to take

general safety measures when operating, main-

taining and inspecting the engine.

• This manual has been prepared for people whose

native language is English. When the engine is

used by individuals whose native language is not

English, the customer is requested to provide

thorough safety guidance to the operators. Also

add safety, caution and operating signs that

describe the original warning label statements in

the native language of the operators.

• The engine must be operated, maintained and

inspected only by qualified persons who have

thorough knowledge of engines and their danger

and also received danger avoidance training.

• To prevent occurrence of an accident, do not

attempt to carry out any operation other than

those described in this manual, or to use the

engine for any unapproved purpose.

• When the ownership of the engine is transferred,

be sure to provide this manual with the engine to

the new owner. Also inform the manufacturer of

INTRODUCTION

the name and address of the new owner of the

engine.

• This manual is copyrighted and all rights are

reserved. The drawings and technical reference,

including this manual, may not, in whole or in

part, be duplicated, photocopied, translated, or

reproduced in any electronic medium or machine

readable form without prior written consent from

the manufacturer.

• The contents in this manual are subject to change

without notice for improvement of the engine.

• Your engine may differ from the photographs and

figures in this manual.

Please note that, depending on specifications,

items described in this manual may differ from

those on your engine in shape, or may not be

installed on your engine.

• If you need more detailed information or have

questions, contact a Mitsubishi dealer.

• If this manual is misplaced, obtain a new copy

from a Mitsubishi dealer as soon as possible.

INTRODUCTION

Warnings

The following two methods are used to call the attention of the operators and maintenance personnel to the

potential danger 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 by using the following five classifications to indicate the degree of potential hazard. Failure to follow

these directions can lead to serious accidents which can result in personal injury, or death in the worst case.

Indicates a highly hazardous situation which, if not avoided, can result in

death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, can result

in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, can result

in minor or moderate injury.

Indicates a potentially hazardous situation which, if not avoided, can result

in property damage.

Note Indicates important information or information which is useful for engine

operation.

INTRODUCTION

Explanation of Terms

Abbreviations, Standards and Others

• API = American Petroleum Institute

• ASTM = American Society for Testing and Materials

• JIS = Japanese Industrial Standards

• MIL = Military Specifications and Standards (U.S.)

• MSDS = Material Safety Data Sheet

• SAE = Society of Automotive Engineers (U.S.)

• LLC = Long Life Coolant

Units of Measurement

Measurements are based on the International System of Units (SI), and they are converted to the metric sys-

tem units in this manual based on 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 = 0.7 cmHg

• Meter of water: 1 kPa = 10.197 cmH

-1

• Engine speed: 1 min

= 1 rpm

2

2O (cmAq)

CONTENTS

Chapter 1 BASIC SAFETY PRECAUTIONS

Warning Fire and Explosion ...............1-1

Keep flames away............................................ 1-1

Keep engine and surrounding area clean ........ 1-1

Never open crankcase until engine cools ........ 1-1

Check for fuel, oil and exhaust gas leaks......... 1-1

Use flameproof light ......................................... 1-1

Do not short electrical wires ............................. 1-1

Keep fire extinguishers and first-aid kit

nearby .............................................................. 1-1

Warning Stay Clear of All Rotating and

Moving Parts........................................1-2

Install protective covers on rotating parts......... 1-2

Check surrounding area for safety ................... 1-2

Stay clear of all rotating and moving parts while

engine is operating........................................... 1-2

Lock out and Tag out ....................................... 1-2

Always stop engine before inspection and

maintenance..................................................... 1-2

Always return turning tools to original

position............................................................. 1-2

Warning Be Careful of Burns..............1-3

Do not touch engine during operation or

Engine Oil and LLC............................. 1-4

Use only specified fuel, engine oil and coolant

(LLC).............................................................. 1-4

Handle LLC carefully........................................ 1-4

Properly dispose of drained oil and LLC .......... 1-4

Caution Service Battery ..................... 1-5

Handle battery carefully ................................... 1-5

Caution When Abnormality Occurs.... 1-5

If engine overheats, conduct cooling operation

before stopping engine..................................... 1-5

If engine stops due to abnormality, exercise caution

when restarting................................................. 1-5

If engine oil pressure drops, stop engine

immediately ...................................................... 1-5

Caution Other Cautions ..................... 1-6

Never modify engine ........................................ 1-6

Never break seals ............................................ 1-6

Perform all specified pre-operation inspections and

periodic inspections.......................................... 1-6

Perform engine break-in................................... 1-6

Warm up engine before use............................. 1-6

Never operate engine under overload

condition ........................................................... 1-6

Conduct cooling operation before stopping

immediately after operation.............................. 1-3

Open radiator filler cap carefully ...................... 1-3

Add coolant only after coolant temperature

drops ................................................................ 1-3

Do not dismount heat protection covers........... 1-3

Warning Be Careful of Exhaust Fume

Poisoning.............................................1-3

Perform engine operation in a well-ventilated

site ................................................................... 1-3

Warning Protect Ears from Noises .....1-3

Wear earplugs.................................................. 1-3

Warning Be Careful When Lifting

Engine .................................................1-4

Lifting engine carefully ..................................... 1-4

Do not climb onto engine ................................. 1-4

Always watch your footing................................ 1-4

Caution Be Careful of Handling Fuel,

engine .............................................................. 1-6

Do not splash water on engine......................... 1-6

Conduct proper maintenance of air cleaner/pre-

cleaner ............................................................. 1-7

Observe safety rules at workplace ................... 1-7

Wear proper work clothes and protective gear. 1-7

Use appropriate tools for maintenance work.... 1-7

Cautions concerning transportation ................. 1-7

Do not operate engine continuously under low

load .................................................................. 1-7

Ventilate the engine room sufficiently .............. 1-7

Do not touch high-pressure injection fuel ......... 1-7

Caution About Warning Labels .......... 1-8

Maintain and inspect warning labels ................ 1-8

Warning labels ................................................. 1-9

CONTENTS-1

CONTENTS

Chapter 2

NAME OF PARTS

Engine External Diagrams...................2-1

S12U Left View ................................................ 2-1

S12U Right View .............................................. 2-1

S16U Left View ................................................ 2-2

S16U Right View ............................................. 2-2

Equipment and Instrument ..................2-3

Starting and Shutdown Devices ....................... 2-3

Start Switch ............................................................. 2-3

Stop Switch ............................................................. 2-3

Start Lever ................................................................ 2-3

M

anual Stop Lever.................................................... 2-3

Instruments..........................................2-4

Tachometer............................................................... 2-4

Hour Meter................................................................ 2-4

Oil Pressure Gage .................................................... 2-4

Oil Temperature Gage.............................................. 2-4

Jacket Coolant Temperature Gage........................... 2-4

Oil Cooler Coolant Temperature Gage..................... 2-4

Air Cooler Coolant Temperature Gage ..................... 2-4

Jacket Coolant Pressure Gage................................. 2-4

Oil Cooler Coolant Pressure Gage ........................... 2-4

Air Cooler Coolant Pressure Gage ........................... 2-4

Exhaust Temperature Gage ..................................... 2-4

Fuel Pressure Gage.................................................. 2-4

Inlet Pressure Gage.................................................. 2-4

Engine Protection Devices ..................2-5

Low Oil Pressure Alarm............................................ 2-5

High Coolant Temperature Alarm ............................. 2-5

Oil Filter Clog Alarm.................................................. 2-5

Overspeed Alarm...................................................... 2-5

Using Turning Gear .............................2-6

Chapter 3 OPERATION

Preparation for Operation of New or

Overhauled Engine..............................3-1

Fuel System ..................................................... 3-1

Pouring fuel............................................................... 3-1

Bleeding Fuel System............................................... 3-2

Bleeding Air from Fuel Filters

(Wire-Element Type)................................................. 3-2

Bleeding Air from Fuel Feed Pipe............................. 3-3

Lubricating System........................................... 3-4

Pouring engine oil..................................................... 3-4

Cooling System ................................................ 3-5

Pouring coolant......................................................... 3-5

Electrical Systems............................................ 3-6

Checking Battery.............................................. 3-6

Electrolyte level..........................................................3-6

Checking specific gravity of electrolyte......................3-6

Checking loosened wire ................................... 3-6

Checking Valves for Open/Closed Position...... 3-7

Test Operation ................................................. 3-7

Normal Engine Operation ................... 3-8

Preparations for Operation

(Pre-Start Inspection) ....................................... 3-8

External Inspection....................................................3-8

Cleaning Fuel Filters (Wire-Element Type)................3-8

Checking Fuel Level in Tank .....................................3-9

Draining Water from Fuel Tank..................................3-9

Checking Engine Oil Level.........................................3-9

Checking Coolant Level...........................................3-10

Inspection of Air Cleaner Indicator...........................3-10

Draining Water from Air Starter Tank ......................3-11

Inspection of Air Tank Air Pressure .........................3-11

Starting.............................................. 3-12

Warming-up Operation ................................... 3-12

Inspection of Oil Pressure........................................3-12

External Inspection during Warming-up...................3-12

Operation ....................................................... 3-13

Inspection During Operation....................................3-13

Stopping ......................................................... 3-14

Emergency Stop............................................. 3-14

Inspection After Stopping ............................... 3-14

Chapter 4 MAINTENANCE

Cautions Concerning Maintenance..... 4-1

Stop the engine before checking or adding fuel, oil or

coolant. ......................................................................4-1

Handle electrolyte carefully........................................4-1

Handle LLC carefully. ................................................4-1

Always wear protective gear......................................4-1

Use recommended fuel, engine oil and coolant.........4-1

Perform all specified pre-start inspections and periodic

inspections.................................................................4-1

Use only genuine Mitsubishi parts.............................4-1

Fuel ..................................................... 4-2

Recommended Fuel ......................................... 4-2

Handling Fuel ................................................... 4-2

Engine Oil ........................................... 4-4

Recommended Engine Oil ............................... 4-4

CONTENTS-2

CONTENTS

Selection of Oil Viscosity .......................................... 4-4

Handling Engine Oil ......................................... 4-5

Coolant ................................................4-6

Recommended Coolant ................................... 4-6

Long Life Coolant (LLC)................................... 4-6

Recommended LLC ......................................... 4-7

Features and Performance of Recommended

LLC .................................................................. 4-7

Maintenance of LLC ......................................... 4-7

Replacement timing of LLC ...................................... 4-7

LLC concentration..................................................... 4-7

Importance of LLC............................................ 4-8

Characteristics of LLC Additive and Important

Notes................................................................ 4-8

Examples of Abnormalities Caused by LLC..... 4-8

Pitting on iron parts................................................... 4-8

Corrosion of aluminum parts..................................... 4-8

Pitting and clogging of radiator ................................. 4-8

Filters...................................................4-9

Electrical Parts.....................................4-9

Cautions in Operating Engine in Cold

Weather Season................................4-10

Fuel ................................................................ 4-10

Engine Oil....................................................... 4-10

Coolant........................................................... 4-10

Battery............................................................ 4-10

Maintenance After Cold Season .................... 4-10

General definition of emergency engine....................5-2

General definition of general-purpose engine............5-2

Periodic Maintenance Chart for Engine in

Regular Use ........................................ 5-3

Periodic Maintenance Chart for

Emergency Engine.............................. 5-8

Periodic Maintenance Chart for General-

Purpose Power Supply Engine ......... 5-13

Chapter 6 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Fuel System ........................................ 6-1

Draining Water from Fuel Filters

(Wire-Element Type)..................................................6-1

Draining Water from Fuel Filters

(Center-Bolt Type) .....................................................6-1

Draining Water from Fuel Tank..................................6-2

Cleaning inside of Fuel Filters

(Wire-Element Type)..................................................6-2

Changing Fuel Filters (Center-Bolt Type)......... 6-3

Changing Fuel Filters (Cartridge Type) ............ 6-4

Changing Fuel Filters with Engine Stop.....................6-4

Changing Fuel Filters while Engine in

Operation...................................................................6-5

Inspection of Fuel Control Linkage Ball

Joints................................................................ 6-6

Lubricating System ............................. 6-7

Changing Engine Oil, Oil Filters and Bypass Oil

Chapter 5 PERIODIC MAINTENANCE CHART

How to Use Periodic Maintenance

Chart....................................................5-1

Periodic Maintenance Chart............................. 5-1

Periodic maintenance chart for regular-use

engine ....................................................................... 5-1

Periodic maintenance chart for emergency

engine ....................................................................... 5-1

Periodic maintenance chart for general-purpose

engine ....................................................................... 5-1

General Definition of Regular-Use Engine,

Emergency Engine and General-Purpose

Engine .............................................................. 5-2

General definition of regular-use engine................... 5-2

Filter ................................................................. 6-7

Draining Engine Oil....................................................6-7

Changing Oil Filters (S12U).......................................6-7

Changing Oil Filters (Swithover Type)

(S12U) .............................................................. 6-8

Changing Oil Filters with Engine Stop .......................6-8

Changing Oil Filters While Engine in Operation ........6-8

Changing Oil Filters (Swithover Type)

(S16U) .............................................................. 6-9

Changing Oil Filters with Engine Stop .......................6-9

Changing Oil Filters While Engine in Operation ........6-9

Changing Bypass Oil Filter ......................................6-10

Pouring Engine Oil...................................................6-11

Inspection of Engine Oil Leakage After Replacing

Oil Filter .......................................................... 6-11

CONTENTS-3

CONTENTS

Inspection of Engine Oil for Mixing of Fuel and

Water.............................................................. 6-11

Analysis of Engine Oil Properties................... 6-12

Engine Oil Sampling Tool Sets and Ordering

Procedure ............................................................... 6-12

Cooling System .................................6-13

Checking LLC Concentration ......................... 6-13

Inspection and Replacement of Zinc Rods .... 6-13

Changing Coolant .......................................... 6-14

Draining Coolant..................................................... 6-14

Cleaning the Cooling System ................................. 6-14

Pouring coolant....................................................... 6-15

Inlet and Exhaust Systems................6-16

Inspection and Draining Water of Exhaust Pipes

and Exhaust Muffler ....................................... 6-16

Draining Water From Air Cooler Chamber and

Inspection for Water Leakage ........................ 6-16

Cleaning, Inspection and Changing

Pre-Cleaner.................................................... 6-16

Cleaning, Inspecting and Changing Air Cleaner

Element .......................................................... 6-17

Chapter 9

TROUBLESHOOTING

General Precautions ........................... 9-1

Contact a Mitsubishi Dealer for Repair

Service ............................................................. 9-1

Examination before Work ................................. 9-1

Notes Regarding Contamination ...................... 9-1

Notes Regarding Parts Handling ...................... 9-1

Work Safety...................................................... 9-1

Conditions Required for Proper Engine

Operation ......................................................... 9-2

Troubleshooting .................................. 9-3

Engine Turns, But It Does Not Start ................. 9-3

Engine Does Not Turn...................................... 9-5

Engine Output is Low.................................................9-6

Engine Knocks ................................................. 9-7

Engine Produces Large Amount of Smoke While in

Operation ......................................................... 9-8

Engine Operates at High Speed and Does Not

Stop.................................................................. 9-8

Malfunction of Lubricating System ................... 9-9

Air Starter System .............................6-18

Draining Water and Cleaning Air Starter

Strainer........................................................... 6-18

Draining Water from Air Starter Compressor . 6-18

Chapter 7 LONG-TERM STORAGE

Storing Engine in Non-Operable Condition for More

Than 3 Months ................................................. 7-1

Preparation for Storage ............................................ 7-1

Maintenance during Storage..................................... 7-1

Using Engine after Storage....................................... 7-1

Storing Engine in Operable Condition for More Than

3 Months .......................................................... 7-2

Operating Engine for Maintenance Purposes........... 7-2

Chapter 8 TRANSPORTATION

Lifting Engine Carefully .................................... 8-1

Chapter 10 MAIN SPECIFICATIONS

Main Specifications........................... 10-1

List of Illustrations

fig.1-1 Warning for flywheel entanglement..............1-9

fig.1-2 Warning for moving parts.............................1-9

fig.1-3 Warning for oil mist ......................................1-9

fig.1-4 Caution for footing........................................1-9

fig.1-5 Caution for electric shock.............................1-9

fig.1-6 Warning for rotating parts.............................1-9

fig.1-7 Caution for burns .........................................1-9

fig.1-8 Warning for rotating parts.............................1-9

fig.1-9 Caution for referring to manual ....................1-9

fig.1-10 Caution for burns .........................................1-9

fig.2-1 S12U engine left view ..................................2-1

fig.2-2 S12U engine right view................................2-1

CONTENTS-4

fig.2-3 S16U engine left view ..................................2-2

fig.2-4 S16U engine right view................................2-2

fig.2-5 Start switch and stop switch.........................2-3

CONTENTS

fig.2-6 Start lever.................................................... 2-3

fig.2-7 Manual stop lever........................................ 2-3

fig.2-8 Air cleaner indicator .................................... 2-5

fig.2-9 Preparation for turning ................................ 2-6

fig.2-10 Turning........................................................ 2-6

fig.2-11 Locking turning gear.................................... 2-6

fig.3-1 Priming pump operating method................. 3-2

fig.3-2 Bleeing air from fuel filters

(wire-element type) ..................................... 3-2

fig.3-3 Bleeding air from fuel filters

(center-bolt type)......................................... 3-2

fig.3-4 Bleeding air from fuel filters

(cartridge-type)............................................ 3-3

fig.3-5 Fuel filter switchover cock........................... 3-3

fig.3-6 Bleeding air from fuel feed pipe (1)............. 3-3

fig.3-7 Bleeding air from fuel feed pipe (2)............. 3-3

fig.3-8 Oil filler and oil level gage ........................... 3-4

fig.3-9 Engine oil priming pump.............................. 3-4

fig.3-10 Coolant drain cock on the engine................ 3-5

fig.6-2 Draining water from fuel filter

(center-bolt type)..........................................6-1

fig.6-3 Draining water from fuel tank .......................6-2

fig.6-4 Cleaning inside of fuel filter

(wire-element) type).....................................6-2

fig.6-5 Changing fuel filters (center-bolt type).........6-3

fig.6-6 Fuel filter switchover handle.........................6-4

fig.6-7 Changing fuel filters (cartridge type) ............6-4

fig.6-8 Fuel filter switchover handle.........................6-5

fig.6-9 Changing fuel filters (cartridge type) ............6-5

fig.6-10 Inspection of the ball joints for

looseness.....................................................6-6

fig.6-11 Changing oil filter element (S12U) ...............6-7

fig.6-12 Inspection of oil filter ....................................6-7

fig.6-13 Changing oil filters (switchover type)........ 6-8

fig.6-14 Changing oil filter elements..........................6-9

fig.6-15 Oil filter switchover handle ...........................6-9

fig.6-16 Changing bypass oil filters .........................6-10

fig.6-17 Inspection of bypass oil filter......................6-10

fig.3-11 Coolant drain cock on the water pump........ 3-5

fig.3-12 Water tank coolant level.............................. 3-5

fig.3-13 Inspecting electrolyte level.......................... 3-6

fig.3-14 Inspecting specific gravity of electrolyte...... 3-6

fig.3-15 Checking valves for open/closed

position........................................................ 3-7

fig.3-16 Checking valves for open/closed position... 3-8

fig.3-17 Cleaning fuel filter (wire-element type)........ 3-8

fig.3-18 Draining water from fuel tank ...................... 3-9

fig.3-19 Oil filler and oil level gage ........................... 3-9

fig.3-20 Checking coolant level .............................. 3-10

fig.3-21 Air cleaner indicator .................................. 3-10

fig.3-22 Draining water from air starter tank........... 3-11

fig.3-23 Inspection of air tank air pressure............. 3-11

fig.3-24 Stop button................................................ 3-14

fig.3-25 Manual stop lever...................................... 3-14

fig.4-1 Recommended fuel..................................... 4-2

fig.4-2 Recommended fuel according to air

fig.6-18 Bypass oil filter...........................................6-10

fig.6-19 Oil filler and level gage...............................6-11

fig.6-20 Engine oil priming pump.............................6-11

fig.6-21 Engine oil sampling tool sets......................6-12

fig.6-22 Zinc rod good/bad......................................6-13

fig.6-23 Coolant drain cock (on engine) ..................6-14

fig.6-24 Coolant drain cock (on water pump) ..........6-14

fig.6-25 Coolant drain cock on the engine...............6-15

fig.6-26 Coolant drain cock on the water pump.......6-15

fig.6-27 Water tank coolant level.............................6-15

fig.6-28 Inspection and raining water of exhaust pipes

and exhaust muffler ...................................6-16

fig.6-29 Coolant drain cock on air cooler

chamber .....................................................6-16

fig.6-30 Cleaning pre-cleaner..................................6-16

fig.6-31 Removal of air cleaner element .................6-17

fig.6-32 Cleaning air cleaner element .....................6-17

fig.6-33 Inspecting air cleaner element ...................6-17

temperature................................................. 4-2

fig.4-3 Recommended oil viscosity according to air

temperature................................................. 4-4

fig.6-1 Draining water from fuel filter

(wire-element type) ..................................... 6-1

fig.6-34 Air cleaner indicator ...................................6-17

fig.6-35 Air starter strainer.......................................6-18

fig.6-36 Air starter compressor................................6-18

fig.8-1 Hangers for lifting.........................................8-1

fig.8-2 Lifting the engine..........................................8-1

CONTENTS-5

CONTENTS

List of Tables

Table 3-1 Specific gravity of electrolyte.................. 3-6

Table 3-2 Data for rated speed............................. 3-13

Table 4-1 Recomended Fuel .................................. 4-2

Table 4-2 Fuel Use Limit Property Guideline.......... 4-3

Table 4-3 Water quality standards.......................... 4-6

Table 4-4 Recommended brands of LLC................ 4-7

Table 4-5 Recommended LLC concentration (for

reference only)........................................ 4-7

Table 5-1 Periodic maintenance chart for engine in

regular use.............................................. 5-3

Table 5-2 Periodic maintenance chart for emergency

engine..................................................... 5-8

Table 5-3 Periodic maintenance chart for general-

purpose power supply engine............... 5-13

Table 6-1 Engine oil sampling tool sets ................ 6-12

Table 7-1 Recommended rust-preventive

oil and corrosion inhibitor........................ 7-1

Table 9-1 Conditions required for proper engine

operation................................................. 9-2

Table 9-2 Engine turns, but it does not start........... 9-3

Table 9-3 Engine does not turn .............................. 9-5

Table 9-4 Engine output is low ............................... 9-6

Table 9-5 Engine knocks ........................................ 9-7

Table 9-6 Engine produces large amount of smoke while

in operation............................................. 9-8

Table 9-7 Engine operates at high speed and does not

stop......................................................... 9-8

Table 9-8 Malfunction of lubrication system ........... 9-9

Table 10-1 Main specifications table ...................... 10-1

CONTENTS-6

Chapter 1 BASIC SAFETY PRECAUTIONS

Warning Fire and Explosion

Keep flames away

Store fuel and engine oil in a

well-ventilated area.

Make sure that the caps of fuel

and engine oil containers are

tightly closed, and store them in

the designated site.

Do not use flames or smoke where fuel or oil is

handled or cleaning solvent is used for washing

parts.

Spilled fuel, oil and LLC should be wiped immedi-

ately and thoroughly. Spilled fuel, oil and LLC can

ignite and cause fire.

Keep engine and surrounding area clean

Do not store combustible (such as fuel, engine oil

and LLC), explosive or dangerous materials near

the engine. Those substances can cause a fire or

explosion.

Keep the engine and the surrounding area free of

dust, dirt and foreign materials, since they can

cause fire or the engine to overheat.

Clean the top surface of the battery after perform-

ing maintenance work. Dust on the battery may

cause a short-circuit.

The engine must be used at least 1 m [3.3 ft.] away

from buildings and other equipment to prevent pos

sible fire caused by engine heat.

Never open crankcase until engine cools

If the cover is opened while the engine is still hot,

fresh air comes into crankcase and oil mist can be

ignited by engine heat, then it may lead to the

explosion of the engine.

Never open the engine crankcase cover before the

engine becomes cool, wait at least 10 minutes after

the engine stops.

Check for fuel, oil and exhaust gas leaks

Inspect fuel, oil and exhaust pipes regularly for

damage and looseness. If a fuel, oil and exhaust

gas leak is found, repair the leakage immediately.

Fuel or oil spilled on a hot surface of the engine,

and exhaust gas blown onto a combustible material

may cause fire and result in personal injury and/or

damage to equipment.

Use flameproof light

When inspecting fuel, engine oil, coolant, battery

electrolyte, etc., use a flameproof light. An ordinary

light may ignite and cause an explosion.

Do not short electrical wires

Before inspecting or servicing any electrical compo-

nent, disconnect the ground cable from the nega-

tive (-) battery terminal to prevent short-circuit and

fire.

Loose terminals or damaged cables/wires can

cause a short-circuit that may result in fire. Before

operating the engine, inspect the cables and wires,

and repair or replace if necessary.

Keep fire extinguishers and first­aid kit nearby

­Keep fire extinguishers nearby,

and be familiarized with their

usage.

Keep a first-aid kit at the desig-

nated place, and make sure it is

easily accessible at anytime.

Establish response procedures to follow in the

event of fire or accident, and post information con

cerning emergency contact locations and their con-

tact methods.

-

1-1

Chapter 1 BASIC SAFETY PRECAUTIONS

Warning Stay Clear of All Rotating and Moving Parts

Install protective covers on rotat­ing parts

Make sure the protective covers of

the engine are correctly installed.

Repair any damaged or loose covers.

When the engine is coupled to other

equipment or the radiator, install pro

tective covers on the exposed connecting belt and

coupling.

Never remove protective covers for rotating parts

such as the damper cover, camshaft cover or

rocker cover while the engine is operating.

-

Check surrounding area for safety

Before starting the engine, check to make sure no

one is near the engine and tools are not left on or

near the engine. Verbally notify persons within the

immediate area when starting the engine.

When the starter device is posted with a sign that

prohibits startup operation, do not operate the

engine.

Stay clear of all rotating and mov­ing parts while engine is operat­ing

Do not approach rotating and moving

parts of the engine while the engine is

in operation.

Rotating parts can entangle your

body or tools and result in serious

injury.

Keep items that can be easily entangled by rotating

parts away from the engine.

If your body or tool contacts rotating and moving

parts, serious injury may occur as a result.

Lock out and Tag out

Be sure to lock out and tag out before starting

inspection and maintenance.

Lockout and tagout are effective methods of cutting

off machines and equipment from energy sources.

To lock out and tag out, pull out the key from the

starter switch, turn off the battery switch, and post a

tag on the starter switch indicating “Do Not Oper

ate.” The starter key switch should be kept by the

person performing the inspection and maintenance.

For the air starter system, close the main valve of

the air tank, and post a tag indicating “Do Not Open

the Valve.”

-

Always stop engine before inspection and maintenance

Be sure to stop the engine before conducting

inspection and maintenance. Never attempt to

adjust the engine parts while the engine is running.

Conducting inspection and maintenance on an

operating engine can result in a serious accident of

entanglement by rotating parts.

Always return turning tools to original position

Be sure to remove all turning tools used during

maintenance and inspection.

Starting the engine with the turning tools inserted or

turning gears engaged may not only cause engine

damage but personal injury as well.

1-2

Chapter 1 BASIC SAFETY PRECAUTIONS

Warning Be Careful of

Burns

Do not touch engine during oper­ation or immediately after opera­tion

Do not touch the main and exhaust

parts of the engine during operation

or immediately after operation to

prevent burns.

To conduct maintenance and

inspection, wait until the engine cools sufficiently as

indicated with the temperature gage.

Open radiator filler cap carefully

Never open the radiator filler cap while the engine

is operating or immediately after it is stopped.

The engine coolant is hot during engine operation

and immediately after operation. If the radiator filler

cap is opened when the coolant is at operating tem

perature, steam and hot coolant may blow out,

causing skin burns as a result.

When opening the cap, stop the engine and allow

the coolant temperature to drop sufficiently. Cover

the cap with a cloth or use thick rubber glove, and

then slowly open the cap.

When closing the cap, be sure to tighten securely.

Add coolant only after coolant temperature drops

Do not add coolant immediately after the engine

stops. Wait until the coolant temperature lowers

sufficiently to prevent burns.

Warning Be Careful of

Exhaust Fume Poisoning

Perform engine operation in a well-ventilated site

Exhaust gas from the engine

contains carbon monoxide and

other harmful substances.

Do not operate the engine in an

enclosed area (inside a ware

house, tunnel, etc.) or in a site where all sides are

blocked, since exhaust fumes can cause gas poi

soning.

If the engine must be operated in an enclosed area,

discharge the exhaust gas to the outside and pro

vide adequate ventilation.

Connect an exhaust duct to the exhaust pipe to

lead exhaust gas to the outside, and make sure

exhaust gas does not leak from the duct joints.

-

Make sure the exhaust gas does not blow in the

direction of plants or animals.

-

-

-

Warning Protect Ears

from Noises

Wear earplugs

Be sure to wear earplugs when

entering into the engine room.

The earplugs can be quite use

ful to protect ears from various

engine noises.

-

Do not dismount heat protection covers

The high-temperature exhaust components are

installed with heat protection covers. Do not dis

mount these heat protection covers. If they must be

removed during inspection and maintenance, be

sure to reinstall them after completing the inspec

tion and maintenance.

-

-

1-3

Chapter 1 BASIC SAFETY PRECAUTIONS

Warning Be Careful

When Lifting Engine

Lifting engine carefully

To lift the engine, use slings capa-

ble of supporting the weight of the

engine.

Attach appropriate slings to the

hangers on the engine.

Keep the engine balanced during lifting by consid-

ering the center of gravity of the engine.

Keep the angle formed by slings attached to hang-

ers within 60°. If the angle exceeds this limit, exces-

sive load is applied on the hangers and may

damage the hangers.

If wire ropes contact the engine, place a cloth or

other soft padding to prevent damage to the engine

and wire ropes.

Do not climb onto engine

Never climb onto the engine.

To work on parts located on the upper section, use

a ladder, stand, etc.

Climbing on the engine can not only damage entire

parts, but also cause parts to fall off and result in

injury.

Always watch your footing

Use a stable work platform to

stand on when working on the

upper part of the engine and

other hard-to-reach places.

Standing on a decrepit stand or

parts box may result in personal injury.

Do not put obstacles on the stand.

Caution Be Careful of Handling Fuel, Engine Oil and LLC

Use only specified fuel, engine oil and coolant (LLC)

Use fuel, oil and LLC specified in this manual, and

handle them carefully.

Use of any other fuel, oil or LLC, and improper han-

dling may cause various engine problems and mal-

functions.

Obtain the MSDSs issued by the fuel, oil and LLC

suppliers, and follow the directions on the MSDSs

for proper handling.

Handle LLC carefully

Wear safety mask and rubber gloves when han-

dling LLC. Avoid contact with skin and eyes to pre-

vent personal injury.

Should LLC be accidentally swallowed, induce

vomiting immediately and seek medical attention.

Should LLC enter eyes, flush immediately with

plenty of water and seek medical attention. If LLC is

spilled on skin or clothes, wash immediately with lot

of water.

Keep flammable materials away from LLC to pre-

vent fire. Never use flames or generate sparks near

LLC since flames or sparks can cause fire.

Drained LLC is harmful. Do not dispose of into con-

ventional sewage. Contact a Mitsubishi dealer for

the disposal of drained LLC.

Properly dispose of drained oil and LLC

Do not dispose of engine oil, used cleaning oil or

LLC into conventional sewage.

Prepare drip pan or other containers to receive oil

and LLC drained from the engine. Do not drain

them directly onto the ground.

For disposal of drained oil and LLC, consult a Mit-

subishi dealer.

1-4

Chapter 1 BASIC SAFETY PRECAUTIONS

Caution Service Bat-

tery

Handle battery carefully

• Batteries release flammable

hydrogen gas and oxygen.

Never use flames or generate

sparks near the battery since

flames or sparks can cause

an explosion.

• Do not use the battery when the fluid surface is

lower than the minimum required level. Using a

battery with a low electrolyte level can result in an

explosion.

• Do not short the battery terminals with a tool or

other metal object.

• When disconnecting battery cables, remove the

cable from the negative (-) terminal first. When

reconnecting cables, attach the cable to the posi-

tive (+) terminal first.

• Charge the battery in a well-ventilated area, with

all filling hole plugs removed.

• Make sure the cable clamps are securely

installed on the battery terminals. A loose cable

clamp can cause sparks that may result in an

explosion.

• Before servicing electrical components or con-

ducting electric welding, set the battery switch to

the [OFF] position or disconnect the cable from

the negative (-) battery terminal to cut off the

electrical current.

• Electrolyte contains dilute sulfuric acid. Careless

handling of the battery can cause loss of sight

and burns.

• Wear safety goggles and rubber gloves when

working with the battery (replenishment of fluid,

charging, etc.)

• If electrolyte is spilled on skin or clothes, wash

immediately with lots of water. Then, use soap to

clean thoroughly.

• If electrolyte enters eyes, flush immediately with

lots of fresh water and see a physician as soon as

possible.

• Should you accidentally swallow electrolyte, gar-

gle with plenty of water, then drink lots of water.

Consult a physician immediately.

Caution When Abnor­mality Occurs

If engine overheats, conduct cool­ing operation before stopping
engine

If the engine overheats, do not stop the engine

immediately. Abrupt stopping of an overheated

engine may cause the coolant temperature to rise,

resulting in seizing of the engine. If the engine over

heats, operate the engine at low idling speed (cool-

ing operation), and stop the engine after the coolant

temperature lowers sufficiently.

Do not add coolant immediately after stopping the

engine. Adding coolant to a hot engine may cause

damage to the cylinder head from sudden change

in temperature. Add coolant gradually after the

engine cools to room temperature.

If engine stops due to abnormal­ity, exercise caution when restart­ing

If the engine stops due to an abnormality, do not

restart the engine immediately. If the engine stops

with an alarm, check and correct the cause of the

problem before restarting. Operating the engine

without correcting the problem may result in serious

engine problems.

If engine oil pressure drops, stop engine immediately

If the engine oil pressure decreases, stop the

engine immediately, and inspect the lubricating sys

tem including the oil level and pump. Operating the

engine with low oil pressure may cause seizing of

bearings and other parts.

-

-

1-5

Chapter 1 BASIC SAFETY PRECAUTIONS

Caution Other Cautions

Never modify engine

Unauthorized modification of the engine will void

the maker's warranty.

Modification of the engine may not only cause

engine damage but may result in personal injury as

well.

If there is a need to modify the engine, please con-

tact a Mitsubishi dealer.

Never break seals

To ensure proper engine operation, the fuel control

links are attached with seals that prevent accidental

change of the injection volume and rotation speed

settings. Operating the engine without these seals

in place can result in the following problems, and

also invalidates the warranty.

• Rapid wear of moving and rotating parts

• Engine damage such as seizing of engine parts

• Increased consumption of fuel and lubricating oil

• Degradation of engine performance due to

improper balance between fuel injection volume

and governor operation.

Perform all specified pre-opera­tion inspections and periodic
inspections

Conduct the pre-operation inspections and periodic

inspections as described in this manual.

Failure to conduct the specified inspections may

cause various engine problems and damage to

parts, as well as serious accidents.

Perform engine break-in

Break in a new engine by operating it with a light

load and at a speed lower than normal during the

first 50 hours of operation.

Operating a new engine under high load or severe

conditions during the break-in period can shorten

the service life of the engine.

Warm up engine before use

If the auxiliary devices for the starter (water heater,

engine oil priming pump etc.) are not installed, let

the engine idle for 5 to 10 minutes before using the

engine for work.

Warm-up operation circulates lubricants in the

engine and contributes to a longer service life and

economical operation.

Do not conduct warm-up operation for an extended

period of time. Prolonged warm-up operation

causes carbon build-up in the cylinders that leads

to incomplete combustion.

Never operate engine under over­load condition

If the engine shows an overload condition such as

the emmision of exhaust smoke, decrease the load

immediately so that the engine operates at appro

priate output and load.

Overloading the engine causes not only high fuel

consumption but also excessive carbon deposits

inside the engine. Carbon deposits cause various

problems and can shorten the service life of the

engine.

-

Conduct cooling operation before stopping engine

Before stopping the engine, let it idle at low speed

for 5 to 6 minutes to cool.

Stopping the engine immediately after high-speed

operation can cause engine parts to heat up and

shorten the service life of the engine.

During cooling operation, check the engine for

abnormalities.

Do not splash water on engine

Do not allow rainwater, etc., to enter the engine

through the air inlet or exhaust openings.

Do not wash the engine while it is in operation,

since the engine may suck in the cleaning fluid

(water). If the engine is started with water inside the

combustion chambers, water hammer action can

damage the engine and result in serious accidents.

1-6

Chapter 1 BASIC SAFETY PRECAUTIONS

Conduct proper maintenance of air cleaner/pre-cleaner

The major cause of abnormal wear on engine parts

is dust entering with intake air. Worn parts result in

an increase of oil consumption, decrease of output,

and starting difficulties. Conduct maintenance of

the air cleaner/pre-cleaner according to the follow

ing directions to ensure optimum air filtering perfor-

mance.

• Do not conduct maintenance of the air cleaner/

pre-cleaner while the engine is operating.

Without the air cleaner/pre-cleaner in place, the

turbocharger can suck foreign particles into the

engine, decrease the load immediately so that

the engine operates at appropriate output and

load.

• When removing the air cleaner, do not allow dust

attached on the air cleaner/pre-cleaner to enter

into the engine.

• If equipped with a dust indicator, conduct mainte-

nance only when the clog warning sign appears.

While servicing the air cleaer/pre-cleaner, do not

let dust enter into the air cleaner/pre-cleaner,

damage or deform the element.

Observe safety rules at workplace

Observe the safety rules established at your work-

place when operating and maintaining the engine.

Do not operate the engine if you are feeling ill.

Operation of the engine with reduced awareness

may cause accidental operations that may result in

accidents. In such case, you should inform your

supervisor of your condition.

When working in a team of two or more persons,

use specified hand signals to communicate among

the workers.

Wear proper work clothes and protective gear

Wear the work clothes specified by your workplace.

Wear a hardhat, face shield, safety shoes, dust pro-

tective mask, gloves and other protective gear as

needed.

When handling compressed air, wear safety gog-

gles, hardhat, gloves and other necessary protec-

tive gear. Compressed air may cause personal

injury when not wearing the proper protective gear.

Use appropriate tools for mainte­nance work

Use appropriate tools according to the type of

maintenance work, and use them correctly.

If tools are damaged, replace with new tools.

-

Cautions concerning transporta­tion

When transporting the engine using a truck, con-

sider the engine weight, width and height to ensure

safety. Abide by the pertinent laws and regulations.

Do not operate engine continu­ously under low load

When operating the engine with a 30 % load or

lower, limit each operation to 10 minutes. Operating

the engine under low load tends to result in

unburned fuel, which can adhere on internal engine

parts to cause malfunctions and shorten the engine

service life.

Ventilate the engine room suffi­ciently

Be sure to provide sufficient ventilation in the

engine room. Insufficient air in the room can cause

the engine temperature to rise and the output

power and performance to lower.

It is highly recommended to calculate the required

amount of air supply to the engine and install an

appropriate ventilation system before installing an

engine.

Do not touch high-pressure injec­tion fuel

Should injected fuel leak from a fuel injection pipe,

do not touch the spurting fuel.

Fuel in the fuel injection pipes is under high pres-

sure. Touching high-pressure fuel can cause the

fuel to penetrate the skin and result in gangrene.

1-7

Chapter 1 BASIC SAFETY PRECAUTIONS

Caution About Warning Labels

Maintain and inspect warning labels

Make sure all warning labels are legible.

If the description and/or illustration on a warning

label cannot be seen clearly, clean or replace the

label.

To clean warning labels, use a cloth, water and

soap. Do not use solvents, gasoline or other chemi

cals to clean warning labels. Cleaning with chemi-

cals may cause the labels to peel off.

If warning labels are damaged or missing, replace

with new labels.

If a part of the engine with warning label is replaced

with new part, also attach new warning label to the

new part.

To obtain replacement warning labels, contact a

Mitsubishi dealer.

-

1-8

Warning labels

Chapter 1 BASIC SAFETY PRECAUTIONS

fig.1-1 Warning for flywheel

entanglement

fig.1-4 Caution for footing fig.1-5 Caution for electric shock

fig.1-2 Warning for moving parts fig.1-3 Warning for oil mist

fig.1-6 Warning for rotating parts

fig.1-7 Caution for burns

fig.1-9 Caution for referring to manual

fig.1-10 Caution for burns

fig.1-8 Warning for rotating parts

1-9

Chapter 2 NAME OF PARTS

Engine External Diagrams

The external diagram is for standard type of S12U/S16U engine.
The installed equipment and shapes differ on the engine type.

S12U Left View

Cylinder head

Fuel injection pipe

Fuel injection pump

Air starter main pipe

Distributor

Front

Breather

Oil level gage

Low temoerature
water pump

Oil pump

Front gear case

Oil filler

Nameplate

Bypass oil filter

Turbocharger

Silencer, pre-cleaner

Pipe cover

Air cooler

Fuel filter
(center-bolt type)

Air cooler chamber
water drain cock

Governor

Governor oil filter

Rear

Fuel feed pump

Fuel priming pump

Fuel filter
(wire-element type)

Timing gear case

Crankcase side cover

S12U Right View

% 

 

 

 







 

!"

&'$





 #

fig.2-1 S12U engine left view








 

 
$ "


  

 

!

 # 

 



 

 

 

 

fig.2-2 S12U engine right view

2-1

Chapter 2 NAME OF PARTS

r



S16U Left View

Fuel injection pipe

Turbocharger

Silencer

Pre-cleaner

Air starter
main pipe

Damper cover

Front

Damper

Breather

Oil filler

Low temperature
water pump

Front gear case

S16U Right View

Nameplate

Oil level gage

Bypass oil filter

fig.2-3 S16U engine left view

Fuel injection pump

Pipe cover

Cylinder head

Fuel filter
(center-bolt type)

Coolant drain cock

Governor

Rear

Governor oil filte

Fuel feed pump

Fuel priming pump

Fuel filter
(wire-element type)

Crankcase side cover



! 



" 

 



!



 

#$%

  

 



fig.2-4 S16U engine right view

 

 







#


 

& 

% 

 

2-2

Chapter 2 NAME OF PARTS

Equipment and Instrument

Starting and Shutdown Devices

The shape and type of the starting and shutdown devices may vary from those described below depending on

the engine specifications.

Start Switch

When the start switch on the operation panel is

pressed, starting air is supplied to the air starter

system and cranks the engine.

Stop Switch

When the stop switch on the operation panel is

pressed, the shutdown cylinder operates and

moves the control shaft of the fuel injection pump to

the no-injection position to shut down the engine

operation.

fig.2-5 Start switch and stop switch

STOPSTART

Start Lever

The start lever is provided on the air starter pipe.

When the lever is moved toward the OPEN posi

tion, air flows and cranks the engine. Once the

engine starts, return the lever to the CLOSE posi

tion immediately.

Manual Stop Lever

Use the manual stop lever to shut down the engine

in the event of an emergency.

If the stop button is not working, use the manual

stop lever. The lever is installed to the fuel control

link and when the lever is moved in the STOP

direction, the engine stops operation.

Should the engine continue operating even after

the manual stop lever is operated, cut off the fuel

supply to stop the engine.

-

-

Start lever

OPEN

CLOSE

From air starter tank

fig.2-6 Start lever

  



fig.2-7 Manual stop lever

2-3

Chapter 2 NAME OF PARTS

Instruments

The instruments indicate the internal conditions of

the engine in operation. In normal operation, record

the numerical values indicated on the instruments

at regular intervals. If the numerical value is far dif

ferent from that in normal operation, the indications

of the instruments allow prompt judgment of engine

problems.

The instrument shape (round, square) and indica-

tion type (analog, digital) can vary depending on

the engine specifications.

Tachometer

This indicates the engine revolutions per minute
(rpm).
Note: The tachometer may have a built-in hour

meter.

Hour Meter

This indicator shows cumulative engine operating

hours.

Use the meter indication as a guigeline for deter-

mining the need for regular inspection and servic-

ing.

Oil Cooler Coolant Pressure Gage

This indicates the coolant pressure in the oil cooler.

-

Air Cooler Coolant Pressure Gage

This indicates the coolant pressure in the air cooler.

Exhaust Temperature Gage

This indicates the temperature of exhaust gas at

the cylinder outlets or turbocharger inlet or outlet.

Fuel Pressure Gage

This indicates the pressure of fuel supplied to the

fuel injection pump by the fuel feed pump.

Inlet Pressure Gage

This indicates the pressure of inlet supplied to the

air cooler.

Oil Pressure Gage

This indicates the engine oil pressure.

Oil Temperature Gage

This indicates the engine oil temperature.

Jacket Coolant Temperature Gage

This indicates coolant temperature inside of the

crankcase.

Oil Cooler Coolant Temperature Gage

This indicates coolant temperature in the oil cooler.

Air Cooler Coolant Temperature Gage

This indicates coolant temperature in the air cooler.

Jacket Coolant Pressure Gage

This indicates the pressure of coolant in the crank-

case, cylinder heads and other parts.

2-4

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, examine the cause of the abnormality, and take corrective measures.

If the cause of the problem is unknown, contact a Mitsubishi dealer.

Protection devices installed on the engine and their types (setting values) and shapes vary depending on the

engine specifications. The following describes the typical protection devices installed in a Mitsubishi engine.

Low Oil Pressure Alarm

The oil pressure switch activates an alarm when the engine oil pressure drops to an abnormally low level.

High Coolant Temperature Alarm

The high coolant temperature alarm device generates a warning or stops the engine when the coolant tem-

perature rises to an abnormally high level due to an engine malfunction or other reason.

Oil Filter Clog Alarm

The oil filter clog detector generates a warning when the oil filter becomes clogged and causes an abnormally

large pressure difference between before and after the oil filter. When it generates an alarm, replace it with a

new filter immediately and change engine oil, as well.

Overspeed Alarm

The overspeed alarm device generates a warning and stops the engine operation when the engine speed

starts operating at abnormally high speed due to an engine malfunction or other reason.

Air Cleaner Clog Alarm (Air Cleaner Indicator)

A red signal appears as a warning when the air cleaner

element becomes clogged and causes an abnormally

large pressure difference between before and after the

air cleaner. When a red signal appears, clean the air

cleaner element immediately or replace it with a new

element.

After the element is cleaned or replaced, press the

reset button located at the upper part of the indicator to

cancel the red signal.

While serving the air cleaner, do not enter dust into the

air cleaner or damage the element.

Signal

Reset button

fig.2-8 Air cleaner indicator

2-5

Chapter 2 NAME OF PARTS

Using Turning Gear

Before starting the engine, return (pull out) the turning gear to 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 Untighten the retaining bolt.

2 Move the turning gear fully to engage the ring gear

and tighten the bolt.

Turning gear
shaft

Retaining bolt

fig.2-9 Preparation for turning

3 Turn the shaft using the socket wrench and the

rachet handle.

4 After turning, move the turning gear, disengage the

turning gear with the ring gear and tighten the retain-

ing bolt.

Make sure the lock pin is securely inserted.

Rachet handle

Socket

Shaft

fig.2-10 Turning

Shaft

Retaining bolt

fig.2-11 Locking turning gear

2-6

Chapter 3 OPERATION

Preparation for Operation of New or Overhauled Engine

Before operating a new or overhauled engine, do the following inspection. For second operation onward, do

the following normal operation outlined on page

Fuel System

When handling fuel, make sure there are no flames near the engine.

Wipe any spilled fuel completely. Spilled fuel can ignite and cause fire.

Do not remove the strainer when filling the fuel tank.

Use fuel specified in "Fuel" (4-2).

Pouring fuel

3-8 "Normal Engine Operation".

1 Make sure the insides of the fuel tank and fuel pipes are clean.

2 Pour fuel into the fuel tank.

3 Remove the fuel feed pipe and drain plug from the fuel inlet of the engine, and check the discharged fuel

for dust particles.

4 Reinstall the drain plug and fuel feed pipe.

5 Add fuel until the fuel level gage indicates "FULL."

3-1

Chapter 3 OPERATION

Bleeding Fuel System

When fuel overflows from the air vent plug, wipe

thoroughly with a cloth. Spilled fuel is a fire haz-

ard.

After bleeding, lock the priming pump cap

securely. If the cap is not locked tightly, the

priming pump can be damaged, causing fuel

leakage that may lead to a fire.

Closing all air vent plugs before locking the priming

pump cap disallows the priming pump cap from

returning to the original position due to internal pres-

sure.

Bleed air from the location closest to the fuel tank

that are the fuel filter (wire-element type), fuel filter

(center-bolt type), then the fuel feed pipe.

Bleeding Air from Fuel Filters (Wire-Element Type)

[Unlock]

Turn counterclockwise

[Priming]
Move back and force

Priming pump cap

[Lock]
Press the cap
and turn clockwise

fig.3-1 Priming pump operating method

Replace to a new part if there is a damage on the air

vent plug, thread area of bracket or sealing washer.

1 Loosen the air vent plug on the fuel filter (wire-

element type) by rotating about 1.5 turns.

2 Loosen the priming pump cap by turning counter-

clockwise and move it back and forth.

3 When there are no air bubbles in the fuel flowing

from the air vent plug, tighten the air vent plug to
the specified torque.

Bleeding Air from Fuel Filters

(Center-Bolt Type)

Replace to a new part if there is a damage on the air

vent plug, thread area of bracket or sealing washer.

1 Loosen the air vent plug on the fuel filter (center-

bolt type) by rotating about 1.5 turns.

2 Move its priming pump cap back and forth.

3 When there are no air bubbles in the fuel flowing

from the air vent plug, tighten the air vent plug to

the specified torque.

Bracket

fig.3-2 Bleeing air from fuel filters

Air vent plug and
sealing washer

Air vent plug and
sealing washer

(wire-element type)

Air vent plug and
sealing washer

3-2

fig.3-3 Bleeding air from fuel filters

(center-bolt type)

Chapter 3 OPERATION

Bleeding Air from Fuel Filters
(Cartridge-Type)

1 Set the handle of the fuel filters (cartridge-type)

to the "Left - Open, Right - Bleed position, and

loosen the right-side air vent plug by rotating it

about 1.5 turns.

2 Move the priming pump cap back and forth.

When the fuel flowing from the right-side air vent

plug no longer contains air bubbles, tighten the

air vent plug.

3 Set the handle to the "Right - Open, Left - Bleed

position, and open the left-side air vent plug.

4 Move the priming pump cap back and forth.

When the fuel flowing from the left side air vent

plug no longer contains air bubbles, tighten the

air vent plug.

5 Return the handle to the normal position.

Replace to a new part if there is a damage on the

air vent plug, thread area of bracket or sealing

washer.

Right side air vent plug
and sealing washer

Bracket

Handle

Left side
air vent plug and
sealing washer

Left side fuel filters

Right side fuel filters

fig.3-4 Bleeding air from fuel filters (cartridge-type)

Right side

bleeding position

Normal position
(Fuel flows through
left side fuel filters only.)

Left side
bleeding position

Left side filter
replacement position
(Fuel flows through
right-side fuel filter only)

fig.3-5 Fuel filter switchover cock

Bleeding Air from Fuel Feed Pipe

1 Loosen the air vent cock on the fuel feed pipe by

rotating about 1.5 turns.

2 Move the priming pump cap back and forth

repeatedly. When there are no air bubbles in the

fuel flowing from the air vent cock, press the

priming pump cap and turn the cap clockwise to

lock.

3 Tighten the air vent cock on the fuel feed pipe.

Tighten the priming cap before closing the air vent

plug.

Closing all air vent plugs before the priming pump

cap disalllows the priming pump cap from returning

to the original position due to internal pressure.

When fuel overflows from the air vent plug, wipe

throughly with a cloth. Spilled fuel causes fire haz-

ard.

Air vent cock

Fuel feed pipe

fig.3-6 Bleeding air from fuel feed pipe (1)

Air vent cock

Fuel feed pipe

fig.3-7 Bleeding air from fuel feed pipe (2)

3-3

Chapter 3 OPERATION

Lubricating System

Pouring engine oil

1 Remove the cap from the oil filler.

2 Pour engine oil of the specified type.

Specified engine oil:Class CD or CF
(API Service Classification)

Engine oil capacity (oil pan)

S12U: approx. 450 L [118.88 U. S. gal.]
S16U: approx. 600 L [158.50 U. S. gal.]

Note: Regarding engine oil, refer to "Engine Oil" (4-

4).

3 Check the oil level with the oil level gage.

If the automatic oil feeder is installed, check if it

works normally.

The oil level should be between the MAXIMUM

and MINIMUM marks on the oil level gage.

If the oil level is low, add specified type of engine

oil.

4 Check the oil pan and other parts for oil leaks.

Repair any oil leakage found.

5 Operate the engine oil priming pump to circulate

oil in the engine.

6 Remove the rocker cover, and make sure that oil

is supplied to the valve mechanisms.

7 Stop the priming pump. After about 30 minutes,

add engine oil until the oil level reaches the Maximum line on the oil level gage.

8 Reinstall the cap on the oil filler.

Oil filler

fig.3-8 Oil filler and oil level gage

Engine oil
priming pump

fig.3-9 Engine oil priming pump

Oil level gage

3-4

Cooling System

Pouring coolant

1 Make sure the drain cocks on the engine and

water pump are closed firmly.

2 Remove the cap from the water supply inlet of

the coolant tank, and pour undiluted LLC.

Note:(a) Determine the amounts of LLC and water

to be poured by using the LLC concentra-

tion chart.

(b) Regarding coolant, refer to "Coolant" (4-6).

Coolant capacity (engine only)

S12U: approx. 520 L [137.37 U. S. gal]
S16U: approx. 700 L [184.92 U. S. gal]

3 Pour soft water with minimal impurities slowly to

the full level.

4 When coolant reaches the full level securely,

close the water supply inlet cap of the coolant

tank.

5 To release air from the water pump and coolant

pipes, pull the manual stop lever fully to the

STOP position and hold it in that position to keep

the fuel injection pump in no-injection condition,

then supply starting air and crank the engine for

about 10 seconds.

6 Wait for about 1 minute, then repeat the above

cranking operation twice to remove air from the

water pump.

7 Check the level gage on the coolant tank to make

sure there is sufficient coolant (surface level at

about the center of the level gage). If the coolant

level is low, add coolant.

8 Start the engine, and operate it under light load

until the thermostat opens the valve to allow soft

water and LLC to mix thoroughly.

9 Stop the engine, check the level gage on the

coolant tank again. If the coolant level is low, add

coolant (so that the surface level rises to about

the center of the level gage).

Note: Always add coolant having the same LLC con-

centration.

10 Check the pipe joint and other parts for coolant

leaks.

Chapter 3 OPERATION

fig.3-10 Coolant drain cock on the engine

Coolant drain cocks

fig.3-11 Coolant drain cock on the water pump

Water supply inlet

Fluid level gage

fig.3-12 Water tank coolant level

3-5

Chapter 3 OPERATION

Electrical Systems
Checking Battery

If electrolyte is spilled on the eyes, skin or clothes, wash immediately with plenty of water. If electrolyte enters

the eyes, flush immediately with lots of fresh water and see a physician.

Do not use flames near the battery. When handling the battery, be careful of sparks generated by accidental

shorting.

Regarding other cautions in handling the battery, refer to "Caution Service Battery" (1-5).

Electrolyte level

Electrolyte evaporates during use and the fluid level

gradually decreases. The fluid surface should be

between the LOWER LEVEL and UPPER LEVEL lines.

If there are no level lines on the battery, make sure that

the fluid surface is about 10 to 15 mm [0.394 to 0.591

in.] above the top edges of the plate. If the fluid level is

lower, remove the caps and add distilled water to the

proper level.

Note: When pouring fresh electrolyte, pour the fluid

carefully.

10 to15 mm
(0.394 to 0.591 in.)

L

E

V

E

L

R

E

P

P

U

O

L

L

E

V

E

L

R

E

W

fig.3-13 Inspecting electrolyte level

Proper
level

Checking specific gravity of electrolyte

Check the specific gravity of the electrolyte. If the spe-

cific gravity measured at 20 °C [68 °F] is lower than

1.22, then charge the battery.

Table 3-1 Specific gravity of electrolyte

Specific gravity

at 20°C [68°F]

From 1.26 to

1.28

From 1.22 to

1.26

Less than 1.22 Discharged Charge

Condition Remedy

Fully
charged

-

Charged Charge

Checking loosened wire

Check the faulty wire connection for other parts of the

electrical system and the battery terminal.

Float

Electrolyte
level

Electrolyte

Glass pipe

fig.3-14 Inspecting specific gravity of electrolyte

3-6

Chapter 3 OPERATION

Checking Valves for Open/Closed Position

Make sure the following valves, plugs and cocks

are open or closed properly.

• Fuel feed valve: Open

• Coolant drain cock (coolant tank): Closed

• Coolant drain cock (engine): Closed

• Coolant drain cock (water pump): Closed

• Oil drain valve: Closed

• Air supply valve (air tank): Open
fig.3-15 Checking valves for open/closed position

Test Operation

To conduct a test operation, follow the procedures below.

Note: Refer to "Normal Engine Operation" (3-8) to operate the engine.

1 To circulate engine oil throughout the engine, pull the manual stop lever fully to the STOP position and hold

it in that position to keep the fuel injection pump in no-injection condition, then supply starting air and crank

the engine for about 10 seconds.

Then, wait for about one minute, and repeat the above process twice to fully circulate engine oil.

2 Start the engine.

3 Operate the engine under no load and at low idling speed for 10 minutes.

4 Stop the engine.

Leave the engine for about 30 minutes. While waiting, check the engine exterior for leakage of fuel, engine

oil, coolant and exhaust gas.

After 30 minutes, check the engine oil level and coolant level. If they are low, add engine oil or coolant to

the specified level.

5 Operate the engine under no load and at low idling speed for 5 minutes.

6 Operate the engine under no load and at rated speed for 5 minutes.

7 Operate the engine under 25% rated load and at rated speed for 30 minutes. (In the case of a main marine

engine, apply load according to a cube curve.)

8 Operate the engine under 50% rated load and at rated speed for 30 minutes. (In the case of a main marine

engine, apply load according to a cube curve.)

9 Operate the engine under 70% rated load and at rated speed for 30 minutes. (In the case of a main marine

engine, apply load according to a cube curve.)

10 Operate the engine under 100% rated load and at rated speed for 60 minutes. (In the case of a main

marine engine, apply load according to a cube curve.)

11 Stop the engine.

3-7

Chapter 3 OPERATION

Normal Engine Operation

The following describes the procedures for operating the engine in normal operating condition.

Should an engine abnormality be observed during operation, stop the engine and correct the problem, or con-

tact a Mitsubishi dealer.

Preparations for Operation (Pre-Start Inspection)

Always conduct the following inspection before starting the engine.

External Inspection

A fire can be caused by combustible materials placed near hot engine parts (exhaust manifolds and other

exhaust gas passages) or battery, fuel leaks, and oil leaks. Check the engine exterior carefully. If an abnor

mality is found, be sure to repair or contact a Mitsubishi dealer.

Before starting the engine, clean the top surface of the battery with wet cloth.

-

Inspect the engine exterior as described below.

1 Make sure there is no combustible material near the engine or battery. Also, check to make sure the

engine and battery are clean.

If combustible materials or waste are found near the engine or battery, remove them.

2 Check the entire engine for leakage of fuel, engine oil coolant. If leaks are found, repair leakage or contact

a Mitsubishi dealer.

3 Visually check for loose bolts and nuts.

4 Check the electrical wiring including the starters and

alternator.

5 Make sure the following valves, plugs and cocks are

open or closed properly:

Fuel feed valve...................... Open

Coolant drain cock (plug) ......Closed

Oil drain valve .......................Closed

Air supply valve (air tank)......Open

fig.3-16 Checking valves for open/closed position

Cleaning Fuel Filters (Wire-Element Type)

Rotate the handle of the fuel filter (wire-element) 1 or 2

turns in the direcion of the arrow (clockwise) to clean

the element inside the filter.

3-8

fig.3-17 Cleaning fuel filter (wire-element type)

Checking Fuel Level in Tank

When handling fuel, make sure there are no flames near the engine.

Wipe any spilled fuel completely. Spilled fuel can ignite and cause fire.

Do not remove the strainer when filling the fuel tank.

Use fuel specified in "Fuel" (4-2).

Check the fuel level if it is full.

If the fuel level is low, add fuel to FULL level in the level gage.

Draining Water from Fuel Tank

When handling fuel, make sure there are no flames or heat source in the area.

Wipe any spilled fuel completely. Spilled fuel can ignite and cause fire.

Chapter 3 OPERATION

Do not remove the strainer when filling the fuel tank.

Use fuel specified in "Fuel" (4-2).

Fuel mixed with water and/or dust not only reduces the

output but can also cause malfunctions of the fuel sys

tem. Drain water from the fuel tank by following proce-

dures below.

1 Place a fuel receiving tray (capacity: 2 L [0.53 U. S.

gal] or more) under the drain cock on the fuel tank.

2 Open the drain cock on the fuel tank, and drain at

least 1 to 2 L [0.26 to 0.53 U. S. gal] of fuel.

3 Make sure water and dust particles were drained

together with fuel, then close the drain cock.

-

Checking Engine Oil Level

1 Pull out the oil level gage and wipe it with a cloth.

2 Insert the oil level gage fully into the oil level gage

guide, then pull out the gage again.

3 The oil level should be between the MAXIMUM and

MINIMUM marks on the oil level gage.

4 If the oil level is low, remove the oil filter cap and add

engine oil of the specified type to the MAXIMUM

level.

5 Securely tighten the oil filler cap after adding the

engine oil.

6 Check the oil pan and other parts for oil leakage.

Drain cock

fig.3-18 Draining water from fuel tank

Oil filler

Oil level gage

fig.3-19 Oil filler and oil level gage

3-9

Chapter 3 OPERATION

Checking Coolant Level

Water supply inlet

Never check the coolant level while the engine

is in operation or immediately after it is stopped

but wait until the coolant temperature drops

sufficiently. If not, hot water blow out, causing

skin burns as a result.

Check if the coolant level is appropriate in the cool-

ant tank (at around center of the level gage). If the

coolant level is low, add coolant to the specified

level.

Always add coolant having the same LLC concen-

tration. Never add plain water.

Note:(a) Determine the amounts of LLC and water

to be poured by using the LLC concentra-

tion chart.

(b) Regarding coolant, refer to "Coolant" (4-6).

Inspection of Air Cleaner Indicator

Fluid level gage

fig.3-20 Checking coolant level

1 Check the air cleaner indicator for the element

clog.

2 If the element clogs, the red signal mark is visi-

ble.

3 Immediately clean or replace the air cleaner ele-

ment when the signal turns red.

Note: Regarding cleaning of the air cleaner ele-

ment, refer to "Cleaning, Inspecting and

Changing Air Cleaner Element" (6-18).

Signal

Reset button

fig.3-21 Air cleaner indicator

3-10

Chapter 3 OPERATION

Draining Water from Air Starter Tank

Slowly open the starting air handle of the air tank. If

the handle is opened quickly, the engine can start

abruptly and cause an unexpected accident.

1 Close the starting air handle of the air tank.

2 Open the drain valve handle located under the

drain valve on the front side of the tank to drain

accumulated water from the tank.

Note: The amount of drained water can vary

depending on the relative humidity and air

consumption.

3 Close the drain valve handle after draining water.

4 Open the starting air handles slowly.

Inspection of Air Tank Air Pressure

Check the air pressure gage to see if the air pres-

sure in the air tank conforms to the standard.

Air tank internal pressure standard:

2.94 MPa (30 kgf/cm2) [426 psi]

Starting 
air handles

Drain valve
handle

fig.3-22 Draining water from air starter tank

Air pressure
gages

fig.3-23 Inspection of air tank air pressure

3-11

Chapter 3 OPERATION

Starting

The starting method varies depending on the appli-

cation and specifications. Start the engine accord-

ing to the specified procedure.

Before starting the engine, check to make sure

no one is near the engine and tools are not left

on or near the engine. In loud voice, notify peo-

ple in the area when starting the engine.

Never load the engine at starting time. (Disengage

the clutch if it is installed.)

1 Check to make sure the air tank internal pres-

2

sure is 2.94 MPa (30 kgf/cm

2 Open the air tank main valve.

3 Set the start lever to OPEN or press the Start

button to start the engine.

After confirming the engine startup, set the start

lever to CLOSE and close the air tank main

valve.

In the case of automatic startup, keep the air

tank main valve open.

If the engine does not start, wait for 2 minutes,

then set the air tank pressure to the specified

level and start the engine again.

Note: If the engine fails to start after three attempts,

contact a Mitsubishi dealer.

Warming-up Operation

Do not approach rotating parts while in opera-

tion.

Entanglement by rotating parts can cause seri-

ous injury.

) [426 psi].

Do not operate the engine under excessive load

(indicated by discharge of black smoke) during a

warm-up operation. Operating the engine under

excessive load not only consumes fuel unnecessar-

ily, but also causes incomplete combustion, which

can result in carbon deposits and shorten the

engine service life.

Conduct a warm-up operation according to the

ambient temperature.

When the air temperature is lower than 5 oC [41 oF],

operate the engine under no load and at low idling

speed for 5 to 10 minutes.

When the air temperature is higher than 5 oC [41

o

F], operate the engine under no load and at low

idling speed for at least 20 seconds.

The above guidelines for warm-up operation do not

apply when the engine is equipped with an auxiliary

starting device (water heater, engine oil priming

pump, etc.).

Inspection of Oil Pressure

During warming-up operation, check if the oil pres-

sure is in the range of standard value.

Also, make sure the oil pressure gage is operating

properly.

Oil pressure standard value during warming-up:

2

0.20 to 0.39 MPa (2.0 to 4.0 kgf/cm

psi] (at low idling)

Note: The oil pressure gage indicates higher pres-

sure than normal immediately after the

engine starts since the oil temperature is low.

This does not denote an abnormality. The

pressure gradually lowers to the normal level

as the oil temperature rises.

) [29 to 56.56

Do not conduct warm-up operation for an extended

period of time.

Prolonged warm-up operation causes carbon

buildup in the cylinders that leads to incomplete

combustion.

Emergency engines do not require a warm-up

operation since they start up for immediate opera-

tion. However, be sure to check all items on the

inspection and maintenance chart.

3-12

External Inspection during Warming-up

Check the external view of the engine to make sure

there is no fuel, oil, cooling water or exhaust gas

leakage from joints.

Operation

Do not approach rotating parts while in opera-

tion. Entanglement by rotating parts can cause

serious injury.

Do not touch any part of the engine while it is oper-

ating or immediately after it is shut down. A hot

engine can cause burns.

Provide adequate ventilation in the engine room. If
air supplied to the engine room is restricted, the

room temperature increases and can affect engine

output and performance.

During the first 50 hours of operation, break-in the

engine by operating it with light load and at lower

speed than normal.
Operating the engine under high load or severe

conditions during the break-in period can shorten

the service life of the engine.

After the warm-up operation, start operating the

engine with load.

Inspection During Operation

Check for leakages.

Inspect the exterior of the engine to make sure

there is no leakage from joints.

Check to make sure the engine does not produce
abnormal noise or vibrations.

Inspect the engine for abnormal operating sound

and vibrations such as knocking.

Check to make sure the exhaust gas is normal

color.

Check the color of the exhaust gas discharged from
the exhaust pipe.

Note: Regarding abnormal exhaust gas conditions,

refer to "Engine Produces Large Amount of

Smoke While in Operation" (9-8).

Check to make sure that the mist discharged from

the breather is not abnormal in the amount or color.

Chapter 3 OPERATION

Check to make sure the instruments and gages

indicate normal values.

Table 3-2 Data for rated speed

Item Standard value

No load,
low idling

Engine oil
pressure

Engine oil
temperature

Jacket coolant
pressure

Jacket coolant
temperature

Oil cooler/air cooler
coolant pressure

Oil cooler/air cooler
coolant temperature

Exhaust
tempera­ture

speed

Rated
speed

Cylinder
outlets

Turbo­charger
outlet

0.20 to 0.39 MPa
(2.0 to 4.0 kgf/cm

[29 to 56.56 psi]

0.39 to0.69 MPa
(4.0 to 7.0 kgf/cm2)

[56.56 to 100.08 psi]

70 to 100 °C
[158 to 212 °F]

0.05 to 0.34 MPa
(0.5 to 3.5 kgf/cm

[7.25 to 49.31 psi]

65 to 85 °C
[149 to 185 °F]

0.05 to 0.34 MPa
(0.5 to 3.5 kgf/cm

[7.25 to 49.31 psi]

30 to 85 °C
[86 to 185 °F]

250 to 650 °C
[482 to 1202 °F]

250 to 600 °C
[482 to 1112 °F]

2

)

2

)

2

)

Note:(a) When the oil pressure drops below 0.29

2

MPa (3 kgf/cm

ation, or below 0.10 MPa (1 kgf/cm

) [42.7 psi] in normal oper-

2

) [14.2

psi] at minimum speed with no load, stop

the engine immediately. Before restarting

the engine, check and correct the cause of
the problem.

(b) When the high temperature alarm switch

is activated in normal operation, change

the engine operation immediately to no-

load idling condition until the engine tem-

perature decreases to normal operating
level. Then, operate the engine for

another 5 or 6 minutes for cooling before

stopping the engine.

Before restarting the engine, check and

correct the cause of the problem.

If the above inspection finds an abnormality, stop
the engine immediately, correct all problems, and

restart the engine. If the engine cannot be repaired,

contact a Mitsubishi dealer.

3-13

Chapter 3 OPERATION

Stopping

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 service life of the engine. Before stopping the engine, let it operate at

low idle speed for 5 to 6 minutes to cool down operation. Stopping the engine immediately after high-speed

operation can cause engine parts to be heated up and result in bad effects.

During cooling operation, check the engine for abnormalities.

Do not accelerate the engine prior to shutting it down.

Do not restart the engine immediately after it shuts down due to an abnormality. If an alarm is generated when

the engine stops, locate the cause of the problem and correct the problem before restarting the engine.

Continuing engine operation without correcting the problem can result in a serious accident.

For stopping the engine, follow the instructions

since stopping procedure varies depending upon

the models and its installed equipment.

STOPSTART

fig.3-24 Stop button

Emergency Stop

  

When stopping the engine by pulling the speed con-

trol lever, continue pulling the lever until the engine

stops completely. If not, the engine may start again

To stop the engine with emergency lever, pull the

manual lever to the arrow direction and continue

pulling the lever until the engine stops completely.

Note: If the operation of the manual stop lever fails

to shut down the engine, cut off the fuel sup-

ply.

fig.3-25 Manual stop lever



Inspection After Stopping

Inspect the engine parts to make sure there is no fuel, oil or coolant leakage. If a fuel or oil leak is found, repair

the leakage or contact a Mitsubishi dealer.

3-14

Chapter 4 MAINTENANCE

Cautions Concerning Maintenance

Stop the engine before checking or

adding fuel, oil or coolant.

Be sure to stop the engine before checking and

adding fuel, engine oil or coolant.

Make sure the coolant temperature is suffi-

ciently low before checking coolant. Do not

check coolant immediately after the engine

stops.

Do not attempt to adjust the parts while the

engine is operating.

Failure to follow the above directions may

cause fire, skins burns or entanglement by

rotating parts.

Handle electrolyte carefully.

Should electrolyte enter eyes or contact the skin or

clothes, flush immediately with plenty of water.

Should electrolyte enter eyes, wash immediately

with water and seek medical attention.

Always wear protective gear.

Wear protective gear such as a hardhat, face

shield, work clothes, safety shoes, dust protective

mask, etc.

Be sure to wear protective goggles and other pro-

tective devices when handling compressed air.

Compressed air can cause personal injury if han-

dled carelessly.

Use recommended fuel, engine oil and

coolant.

Use fuel, engine oil and coolant specified in this

manual, and handle them with utmost caution.

When adding engine oil, use oil of the same brand.

Do not mix oils of different brands.

Perform all specified pre-start inspec-

tions and periodic inspections.

Handle LLC carefully.

Should LLC be accidentally swallowed, induce

vomiting immediately and seek medical attention.

Should LLC enter eyes, flush immediately with

plenty of water and seek medical attention.

LLC is a potent alkaline solution. Do not drink or

allow it to enter your eyes.

Conduct the pre-start inspection and periodic

inspection as specified in this manual.

Failure to conduct pre-start inspections and peri-

odic inspections may cause various engine prob-

lems and damage to parts as well as serious

accidents.

Use only genuine Mitsubishi parts.

When replacing new parts, use only genuine Mit-

subishi parts.

To obtain new parts, contact a Mitsubishi dealer.

4-1

Chapter 4 MAINTENANCE

Fuel

Recommended Fuel

Use commercially available diesel fuel (JIS K2204).

Note: Some Class-A heavy oils are unsuitable for

use in the Mitsubishi diesel engine. Use fuel

that meets the Use Limit Property Guideline

for Diesel Fuel. If the engine is continuously

used for many hours, refer to the recom-

mended use limit.

It is necessary to use fuel that has a pour point suit-

able for the ambient temperature. Choose the fuel

type from the chart on the right.

Table 4-1 Recommended Fuel

Standard Classification

JIS K2204 TYPE 1, TYPE 2, TYPE 3

ASTM D975 No. 1-D, No. 2-D

BS 2869 CLASS-A1, CLASS A-2

DIN 51601 DIESEL-FUEL

ISO 8217 DMX-CLASS

Diesel fuel

In 

Compliance

with

JIS K2204

fig.4-1 Recommended fuel

Tempe-

rature

[-21] [-4] [14] [32] [50] [68] [86] [104]

C [F]

Special No. 3

No. 3

No. 2

Diesel oil

fig.4-2 Recommended fuel according to air

temperature

No. 1

Special No. 1

Handling Fuel

When using fuel kept in a storage tank, allow it to sit

for more than 24 hours so dust and water can settle at the bottom. Then, use clean fuel from the upper layer.

Fill the fuel tank or service tank after each work day. This prevents water from mixing with fuel in the tank and

gives time for dust and water to separate and settle at the bottom of the tank.

Before removing the caps from the drum and tank, clean the areas around the caps thoroughly. Also clean

your hands and the hose used for refueling. When a hand-operated pump is used, be careful not to pump

water or sediment accumulated at the bottom of the storage tank.

Be sure to pour fuel through a strainer. Use of a clean, lint-free cheesecloth is recommended.

4-2

Chapter 4 MAINTENANCE

Table 4-2 Fuel Use Limit Property Guideline

Property Recommend use limit Current use limit Remarks

JIS K2204, 2205

Flash point As stipulated by regulation

Diesel fuel: 50
Class-A heavy oil: 60 °C [140
°F] or higher

Distillation

Pour point

First distillation
point

90% distillation
point

170 °C [338 °F] or higher

330 to 380 °C
[626 to 716 °F]

More than 6°C [10.8 °F] below ambient tempera­ture

170 °C [338 °F] or
higher

330 to 380 °C
[626 to 716 °F]

JIS K2254

JIS K2269

Cloud point Below ambient temperature

Carbon residue (10% residual
oil)

0.4 weight % or lower 1.0 weight % or lower JIS K2270

Cetane number 45 or higher

Cetane index (new) 45 or higher JIS K2280-1996

2

/s [0.0031 in2] or higher (30 °C [86 °F])

2

/s [0.0124 in2] or lower (50 °C [122 °F])

2

/s [0.0163 in2] or lower (40 °C [104 °F])

Kinetic viscosity

2.0 mm

8.0 mm

10.5 mm

16.0 mm2/s [0.0248 in2] or lower (30 °C [86 °F])

JISK25410.05 weight %

Sulfur content 0.2 weight % or lower 1.0 weight % or lower

(same as diesel fuel) is rec­ommended.

Water and sediment 0.1 volume % or lower JIS K2275

Ash 0.03 weight % or lower JIS K2272

Copper plate corrosion

°C [212°F], 3 hrs.)

(100

No.3 or lower No.3 or lower

ASTM - No.3
JIS K2513 - Discoloration
No.3

Specific gravity (15°C [59°F]) 0.83 to 0.87 0.80 to 0.87

Should not be carbonized
more than 75% at 250 °C

Coking test

[482 °F]

Should not be evapo­rated more than 55% at
230 °C [446 °F]

Should not be carbon­ized 100% at 250 °C
[482 °F]

Fed791B (U.S.)
250 °C [482 °F] X 24Hr
230 °C [446 °F] X 24Hr
180 °C [356 °F] X 48Hr

Should not be turn to tar
at 180 °C [356 °F]

Aromatics content
(HPLC method)

38 weight % or lower 38 weight % or lower

JIS K 2536
Total of aromatic content

Asphaltene 0.1 weight % or lower 0.1 weight % or lower ICP analysis (U.K.)

JIS B9931

Particulate contaminant 5.0 mg/l or lower 5.0 mg/l or lower

Including foreign substance in
the fuel pipe lines

°C or higher

4-3

Chapter 4 MAINTENANCE

Engine Oil

Recommended Engine Oil

Use class CD (recommended) and CF engine oils. Class CE and CF-4 engine oils are designed for diesel fuel

with a sulfur content of less than 0.5% and less than 0.2%, respectively. Since the sulfur content of most

Class-A heavy oil exceeds 0.5%, do not use Class CE or CF-4 engine oil when using Class-A heavy oil as

fuel.

Use of improper or inferior oil can cause excessive wear of bearings and moving parts, thus shortening the

engine life. It can also result in the sticking of piston rings and seizing of pistons in the cylinders, thus causing

major damage.

Selection of Oil Viscosity

Use the following chart to select the appropriate oil

viscosity according to the ambient temperature.

Excessively high oil viscosity causes power loss

and an abnormal rise of oil temperature, while

excessively low oil viscosity results in inadequate

lubrication and leakage of combustion gas that

cause increased wear and reduced output.

Recommended oil viscosity is SAE 15W-40 for all

seasons.



 

  

 ! "

       

# # # # # $%# %$##











fig.4-3 Recommended oil viscosity according to air

temperature

4-4

Chapter 4 MAINTENANCE

Handling Engine Oil

Before pouring engine oil into the engine, stop the engine and make sure there are no flames near the engine.

Oil leaked or spilled onto hot surfaces or electrical components can cause a fire. Wipe any spilled oil immedi-

ately and thoroughly.

After pouring engine oil, close filler cap surely.

Never mix different brands of engine oil. Mixing different brands of engine oil may cause a chemical reaction

by the additives in the engine oil that could degrade the engine oil quality.

If oil of more than the legally specified amount must be handled, be sure to have the work performed by a ser-

vice station in compliance with the legal regulations.

Use an oil pump to remove oil from the engine or oil can. Do not use a hose to siphon with the mouth.

Be sure to close the cap on the oil can after use.

Keep oil in a well-ventilated place and out of direct sunlight.

Be sure to obtain the MSDS (material safety data sheet) of the engine oil used and follow the instructions.

4-5

Chapter 4 MAINTENANCE

Coolant

Recommended Coolant

Water used in the engine cooling system must be soft water. The water quality must meet the following

requirements.

Water quality should meet with recommended limit, however, within limit is acceptable.

Table 4-3 Water quality standards

Item

pH (25°C [77°F]) - - 6.5 to 8.5 6.5 to 8.5 O O

Electrical conductiv­ity (25°C [77

To t a l h a r d n e s s

M alkalinity

Chlorine ion

Sulfuric acid ion

To t a l i r o n

Silica

Residue from evap­oration

Note: Figures in parentheses are the standard value. In addition to the items specified above, turbidity is spec-

ified to be below 15 mg/liter.

°F])

Chemical

symbol

-

CaCO3 ppm < 95 < 100 - O

CaCO3 ppm < 70 < 150 - O

-

Cl ppm < 100 < 100 O -

4-

SO2 ppm < 50 < 100 O -

Fe ppm < 1.0 < 1.0 - O

SiO2 ppm - < 50 - O

- ppm < 250 < 400 - O

Unit Recommended Limit

µ

/cm

<250 <400 O O

Main adverse effect

Corrosion

and rust

Scale

formation

Long Life Coolant (LLC)

Should LLC be accidentally swallowed, induce vomiting immediately and seek medical attention.

If LLC should enter eyes, flush immediately with plenty of water and seek medical attention.

Be sure to use long life coolant (LLC) as coolant, because it prevents not only freezing of coolant but also

rusting of the cooling system.

Use an all-season, non-amine type LLC.

4-6

Chapter 4 MAINTENANCE

Recommended LLC

Recommended brands of LLC are shown in the

chart below.

Table 4-4 Recommended brands of LLC

Manufacturer Brand

Nippon Oil Corporation Super Coolant X

Mitsubishi Fuso Truck &
Bus Corporation

TEXACO Code 7998

Note: When using an LLC other than the above, fre-

quent inspections are required since the ser-

vice life may be shorter.

Fuso Diesel Long Life
Coolant

Features and Performance of Rec­ommended LLC

• Use LLC with no amine content.

• Use LLC with no silicate or borate.

• Use LLC that is close to neutral on the pH scale

and slightly alkaline.

• Use LLC that contains balanced chemical addi-

tives as substitutes for amines.

• Use LLC that offers long life (with 30% LLC con-

centration and service life of more than 1 year).

Maintenance of LLC

Coolant (containing LLC) drained from an engine is

toxic, and must not be disposed of into regular sew-

age.

For disposal of used coolant, consult a Mitsubishi

dealer.

Replacement timing of LLC

When a coolant mixed with the LLC recommended

by our company is used, replace coolamt every

12000 hours or 2 years, whichever comes first, in a

regular-use or general-purpose engine. In an emer

gency engine, replace coolant every 2 years.

LLC concentration

When determining the LLC concentration, provide a

margin of 5°C [41°F] below the expected lowest

temperature in your region. Maintain the LLC con

centration between 30 and 60% throughout the

year.

LLC of less than 30% concentration does not pro-

vide sufficient corrosion protection. If the LLC con-

centration is as low as several percent, it may

promote corrosion.

LLC of more than 60% concentration can adversely

affect its freeze protection characteristic and cause

the engine to overheat easily.

When adding coolant without changing all coolant,

do not add plain water. Always use coolant having

the same LLC concentration.

-

-

Table 4-5 Recommended LLC concentration (for

reference only)

Lowest

ambient

temperature

(°C [°F])

LLC concentra­tion (%)

up to

-15

up to

-24

[5]

[-11]

30 40 50 55

up to

-36

[-32]

up to

-43

[-45]

Note: For determining the accurate LLC concentra-

tion, refer to the instructions for the LLC used.

4-7

Chapter 4 MAINTENANCE

Importance of LLC

Today's trend is toward smaller and more light-

weight engines offering greater output, lower fuel

consumption and lower exhaust emission level.

Conditions to which engine coolant is subjected are

becoming severer due to longer operating hours,

higher coolant temperature and higher coolant cir

culating speed.

Many different materials (such as steel, aluminum,

copper, solder and rubber) are used in the cooling

system, and they are also subjected to the severe

conditions described above.

These materials differ in ionizing tendency, and this

difference promotes corrosion through the medium

of engine coolant.

To prevent the above problem, it is necessary to

use LLC (long life coolant).

-

Characteristics of LLC Additive and Important Notes

LLC contains several chemicals in such proportions

as to produce chemical reactions that suppress

corrosion (ionization) of engine parts in contact with

the coolant.

LLC loses its effectiveness after many months of

use.

Moreover, if the chemicals are not well propor-

tioned to match the metals used in the cooling sys-

tem, certain chemicals in the LLC become rapidly

used up and result in dissolving of metals.

Moreover, other corrosion preventing chemicals

react with dissolving metals and further accelerate

corrosion. This condition can result in more corro

sion than when plain soft water is used. This prob-

lem is often caused by the use of inappropriate

LLC.

-

Examples of Abnormalities Caused by LLC

Pitting on iron parts

Amines are generally effective in suppressing the

rusting of ferrous metals, but they are said to cause

problems for copper parts.

Dissolved copper (copper corrosion) in the cooling

system deposits on iron parts, and copper deposits

produce galvanic or local-cell action, thus corroding

and pitting iron that has a higher ionizing tendency.

Corrosion of aluminum parts

Silicate is highly effective in protecting aluminum

against rusting. However, it is unstable in a solution

in which pH is 9 or lower, and can turn to gel and

precipitate in the solution. For this reason, the pH is

usually specified to be about 10 to ensure a high

alkaline level.

This means, after silicate is used up, the high alka-

linity causes chemical attacks on aluminum. To pre-

vent this problem, proper maintenance of the

coolant is required.

(Example)

Rapid wear of mechanical seals in the water pump

due to secondary effects of silicate gel formed.

Corrosion of aluminum parts after silicate is con-

sumed.

Pitting and clogging of radiator

As LLC's general performance deteriorates or

when its concentration in the coolant is too low, its

anti-corrosion performance lowers and results in

the corrosion of metals.

Brass and solder tend to corrode faster than other

metals, and corrosion of these metals is said to

cause water leakage and clogs.

(Example)

Holes and clogs in radiator

4-8

Filters

Filters remove impurities such as dust particles

from fuel, engine oil and air starter system. While it

is important to use clean fuel, engine oil and air

supply, filters must be changed regularly to ensure

maximum engine performance and extend the ser

vice life of the engine.

Refer to "PERIODIC MAINTENANCE CHART" (5-

1) for the procedure for changing filters. The inter-

val of changing filters can be shortened depending

on the usage and operating conditions as well as

quality of fuel and oil in use.

When replacing filters, use genuine Mitsubishi

parts.

Do not wash and reuse cartridge-type filters.

Always use new filters.

When filters are changed, inspect the removed fil-

ters for metal particles. If metal particles are found,

consult a Mitsubishi dealer.

Chapter 4 MAINTENANCE

-

Electrical Parts

Do not splash water on electrical parts. Water can

cause electrical leakage and short-circuiting, result

ing in equipment damage. Wet electrical parts can

also cause electric shock.

When cleaning the engine, keep water away from

electrical parts.

If malfunctioning of electrical parts is suspected,

consult a Mitsubishi dealer.

Also, do not use disassembled or reassembled

electrical parts.

-

4-9

Chapter 4 MAINTENANCE

Cautions in Operating Engine in Cold Weather Season

When the ambient temperature is low, fuel and

engine oil become thick and coolant can freeze,

thus making it difficult to start the engine or causing

damage to the cylinder heads. To prevent these

problems, observe the following directions.

Fuel

Battery

Never use flames near the battery, and be care-

ful to handle battery since flames can cause an

explosion.

When handling fuel, make sure there are no

flames near engine.

Wipe any spilled fuel completely. Spilled fuel

can ignite and cause fire.

Use appropriate fuel according to the ambient tem-

perature.

Note: Regarding fuel, refer to "Fuel" (4-2).

Engine Oil

Replace engine oil suitable to the ambient tempera-

ture.

Note: Regarding engine oil, refer to "Engine Oil" (4-

4).

Coolant

Remove the radiator cap only after the engine cools

to room temperature. Place a cloth over the cap,

and turn the cap about a half turn to release pres-

sure. Opening the radiator cap while the engine is

hot causes steam and hot coolant to blow out,

resulting in skin burns.

Freezing of coolant due to cold temperatures can

damage the crankcase. Be sure to use all-season

long life coolant that prevent freezing of cooling

water and rusting of the engine cooling system.

Note: Regarding coolant, refer to "Coolant" (4-6).

If electrolyte is spilled on skin or clothes, wash

immediately with lots of water. If electrolyte gets

into your eyes, flush immediately with lots of fresh

water and consult a physician as soon as possible.

For other cautions to handle battery, refer to "Cau-

tion Service Battery" (1-5)

When the ambient temperature drops to a very low

level, the charging rate becomes low even if the

specific gravity of electrolyte remains the same.

Therefore, in a cold area the battery may not pro

vide sufficient power to start the engine immedi-

ately. Furthermore, electrolyte becomes easier to

freeze when its specific gravity is low. Therefore, it

is recommended to additionally charge the battery

to increase the specific gravity of electrolyte and

the charging rate.

Note: For the inspection of specific gravity of elec-

trolyte, refer to "Checking specific gravity of

electrolyte" (3-6).

-

Maintenance After Cold Season

After a cold season ends, change fuel, engine oil

and coolant to those suitable for the outside tem

perature in accordance with the specifications

described in this manual.

-

4-10

Chapter 5 PERIODIC MAINTENANCE CHART

How to Use Periodic Maintenance Chart

Periodic inspection not only extends the service life

of the engine but also serves to ensure safe opera

tion. Be sure to conduct inspections and mainte-

nance according to the periodic maintenance chart.

The maintenance chart shows the standard service

intervals. Whenever you notice the abnormalities

mentioned below, make sure the service must be

performed to the defective part of the engine,

regardless recommended service intervals in the

“Periodic Maintenence Chart”; abnormal noise,

black exhaust smoke, white exhaust smoke, abnor

mally high temperature of exhaust gas, abnormal

vibration in engine, fuel, oil or exhaust gas leakage.

Note: Appropriate service intervals vary depending

on the usage and operating conditions as well

as consumption of fuel, oil and coolant.

Check the operating record of the engine to

determine the most appropriate service inter-

vals. (Feel free to consult a Mitsubishi dealer

regarding service intervals.)

Perform service items listed under the service inter-

val. Service items with shorter intervals should also

be included in the longer interval service.

Items marked with ½ in the maintenance chart

require special tools or large equipment. For the

servicing of these items, consult a Mitsubishi

dealer.

-

-

Periodic maintenance chart for emer-

gency engine

When the engine is used as an emergency engine,

perform the periodic inspection and maintenance in

accordance with the "

for Emergency Engine".

Due to the nature of application, an emergency

engine is subject to demanding operating condi

tions such as a quick startup and immediate supply

of power. In addition, it must operate reliably in the

event of an emergency. Therefore, be sure to per

form the daily inspection and also conduct the fol-

lowing operation for maintenance purposes.

Once every week: Operate the engine under no

load (for 3 to 5 minutes).

(When operating the engine for the adjustment of

peripheral devices, limit the operating time to 10

minutes.)

Once every month: Operate the engine under load

(for 15 to 30 minutes with more than 1/2 load).

If the engine cannot be operated under load every

month, operate the engine under load (more than 1/

2 load) for more than 2 hours.

During the engine maintenance operation, check

the ease of startup, oil pressure, and exhaust color

and vibration.

Periodic Maintenance Chart

-

-

Periodic Maintenance Chart

Appropriate service intervals vary depending on the

engine specifications. Perform all daily inspection

and maintenance items in an accordance with the

following 3 categories.

Periodic maintenance chart for regular-

use engine

When the engine is used as a regular use engine,

perform the periodic inspection and maintenance in

accordance with the "

for Engine in Regular Use".

Periodic Maintenance Chart

Periodic maintenance chart for general-

purpose engine

If the engine is used for different purposes other

than the above usage, do maintenance according

to the “

Purpose Power Supply Engine”.

Periodic Maintenance Chart for General-

5-1

Chapter 5 PERIODIC MAINTENANCE CHART

General Definition of Regular-Use Engine, Emergency Engine and General-Purpose 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 independently or in combination with commer

cial power supply.

An engine operated under a fluctuating load

throughout a day for supplying rated electric power

in lieu of commercial power.

General definition of emergency engine

An engine used for emergency power generation

such as main power supply and commercial power

supply.

-

General definition of general-purpose

engine

An engine used for a purpose other than power

generation - for example, to drive a pump, as the

main engine for a ship, and for an industrial vehicle

- and operated under constant or cylically varying

load and speed.

5-2

Chapter 5 PERIODIC MAINTENANCE CHART

Periodic Maintenance Chart for Engine in Regular Use

Table 5-1 Periodic maintenance chart for engine in regular use (1 / 5)

Service
interval

Every day

Every 500
service
hours

First 1500
service
hours

Every 1500
service
hours

External

Fuel tank Inspect fuel level and drain water. 3-9

Fuel filters (wire-element) Clean inside of the filter by using handle. 3-8

Engine oil

Coolant

Air cleaner Inspect air cleaner indicator for element clog. 3-10

Air starter tank Inspect air pressure and drain water. 3-11

Operating condition

Air cooler

Fuel filters Drain water. 6-1

Fuel control linkage

Engine oil

Oil filter and bypass oil filter Change. 6-7

Exhaust pipes and exhaust
muffler

Air starter compressor Drain water. 6-18

Zinc rod Inspect and change. 6-13

Valve clearance

Camshafts and tappets Inspect. ½

Air cooler cover

Fuel filters Change. 6-3

Coolant Inspect LLC concentration. 6-14

Pre-cleaner Clean. 6-16

Air cleaner element Clean and inspect. 6-17

Air starter strainer Drain water and clean. 6-18

Service item Service contents Page

Inspect leakage and looseness of bolts and nuts.
Retighten bolts and nuts.

Inspect oil level and add oil by using oil level
gage. Inspect level regulator operation.

Inspect coolant level and add coolant by using
fluid level gage.

Check operating period, performance record,
sound, vibration and gage function.

Inspect water leakage from air cooler chamber
and drain water.

Inspect ball joints, bolts and nuts for looseness
and smooth movement.

Inspect engine oil for mixing of fuel and water.

Analyze engine oil properties
(according to engine oil analysis service)

Change. 6-7

Inspect and drain water. 6-16

Inspect and adjust (also inspect inside of rocker
chamber).

Retighten air cooler cover mounting bolt (Also
after first 1500 service hours from gasket
replacement).

3-10

3-13

6-16

6-11

6-12

3-8

3-9

6-6

½

½

5-3

Chapter 5 PERIODIC MAINTENANCE CHART

Table 5-1 Periodic maintenance chart for engine in regular use (2 / 5)

Service
interval

Every 3000
service
hours

After 3000
services
hours or 2
years,
whichever
comes first

Every 6000
service
hours

After 12000
service
hours or 2
years,
whichever
comes first

Valve clearance

Fuel injection nozzles Change nozzle tipes and adjust pressure. ½

Fuel filters (wire-element) Disassemble and clean inside. 6-1

Breather

Governor oil filter Change. ½

Pre-cleaner Change. 6-17

Air cleaner element Change. 6-18

Magnetic pickup

Fuel system accumulator Refill with nitrogen gas. ½

Camshafts and tappets Inspect. ½

Crankcase

Water pump

Damper

Turbocharger

Inspection of pipe clamps of
fuel lines, oil lines, instrument
pipes and starting air pipes

Coolant Change.

Service item Service contents Page

Inspect and adjust (also inspect inside of rocker
chamber).

Inspect and clean mist separator, and change
expendable parts.

Inspect clearance with the flywheel, attachment
of foreign items on the tip, mounting nut tight­ness, an open-circuit and connector disconnec­tion.

Inspect inside (remove the side cover for inspec­tion).

Change oil seals, unit seals and other expend­able parts.

Check temperature with thermo label and check
for silicon oil leakage.

Inspection of shaft and wheel smooth rotation
and thrust for looseness.

Inspection of interference and wear, and repair
rubber tape.

½

½

½

6-13

5-4

Service
interval

Every 12000
service
hours

Chapter 5 PERIODIC MAINTENANCE CHART

Table 5-1 Periodic maintenance chart for engine in regular use (3 / 5)

Service item Service contents Page

Overhaul of top end of engine (remove the cylinder heads for inspection and main­tenance.)

Disassemble and maintain, clean and change expendable parts.

Valve seat Inspect, regrind and lap.

Cylinder head
gasket

Copper tubes Change copper tubes and O-rings.

Inlet and
exhaust valves

Valve guides,
Cylinder
heads and
valve mech­anisms

Safety valve Inspect and change expendable parts.

Cylinder liners Inspect and clean.

Pistons Inspect including overhaul and clean.

Piston rings Change.

Connecting rods

Crankshaft Inspect and adjust deflection.

Damper

Front gear and timing gear Inspect gear teeth.

valve rotator,

valve cotter,

pushrods,

rocker arm

bushings, valve

springs, tappet

rollers, tappet

roller bushing,

tappet shafts,

tappet guides,

tappet guide

set screws.

Stem seal Change.

Change.

Inspect, regrind and lap.

Inspect.

Inspect bolts, inspect Magnaflux serrations,
change big-end bearing shells and inspect small­end bushings.

Analyze silicon oil properties and change thermo
label.

½

5-5

Chapter 5 PERIODIC MAINTENANCE CHART

Table 5-1 Periodic maintenance chart for engine in regular use (4 / 5)

Service
interval

Every 12000
service
hours

Fuel system

Lubricating
system

Cooling
system

Inlet and
exhaust
systems

Air starter
system

Protection
device

Flexible hoses Change.

Service item Service contents Page

Fuel control

linkage

Fuel injection

pump

Fuel feed pump Change oil seals and O-rings.

Fuel injection

pipes

Fuel injection

timing

Fuel pressure

regulator valve

Fuel system

accumulator

Fuel pipes Change O-rings and sealing washers.

Oil pump Change bushings.

Oil cooler Inspect and clean element.

Regulator valve Disassemble and maintain.

Oil pipes Change O-rings and gaskets.

Water pump Change bearings.

Coolant pipes Change O-rings.

Turbocharger

Air cooler Clean element.

Air cooler cover Change gaskets.

Air inlet pipes Change O-rings.

Exhaust pipes Change gaskets, bolts and nuts.

Exhaust duct Change V-clamps.

Starting valve Inspect, lap and change O-rings and gaskets.

Air pipes Change gaskets.

Air tank Inspect safety valve operation.

Distributor Change valve, shaft, bushings, pins and gaskets.

Increasing cool-

ant tempera-

ture,

decreasing oil

pressure, over-

speed and

emergency

stop device

Change ball joints and ball bearings.

Disassembe and maintain, and change deflec­tors and O-rings.

Change.

Inspect and adjust.

Inspect.

Change.

Remove carbon deposits and change seal rings,
bearings and expendable parts.

Inspect operation.

½

5-6

Service
interval

Every 24000
service
hours

Chapter 5 PERIODIC MAINTENANCE CHART

Table 5-1 Periodic maintenance chart for engine in regular use (5 / 5)

Service item Service contents Page

Major overhaul (complete disassembly and inspection)
Change all O-rings, gaskets and seals.

Cylinder
heads and
valve mech­anisms

Cylinder liners Change.

Main bearings

Cam bushings

Pistons

Connecting rods Change bolts and small-end bushings.

Crankshaft Inspect journals and pins, and change slingers.

Damper

Spring coupling

Timing gear
and front
gear

Fuel system

Lubricating
system

Cooling
system

Inlet and
exhaust
systems

Governor

Change inlet and exhaust valves, valve seats, valve guides, valve

rotators and valve cotters.

Inspect and change pushrods, rocker arm bushings, valve springs,

tappet rollers, tappet roller bushings, tappet shafts, tappet guides

and tappet guide set screws.

Inspect caps and bolts, and change main bear­ings.

Inspect and change (in 2nd 24000-service-hour­interval inspection and maintenance).

Disassemble and inspect piston crown, and
change O-rings.

Change (in 2nd 24000-service-hour-interval
inspection and maintenance).

Disassemble and maintain (by spring coupling
manufacturer).

All shafts Inspect.

Rear idler gear

Change front idler bearing, camshaft roller bearing, front seal, rear

seal, front gear case gasket and rear gear case gasket.

Fuel injection

nozzles

Fuel injection

pump

Fuel feed pump

(trochoid type)

Regulator valve Change.

Oil pump Change safety valve and spring.

Oil thermostat Change.

Oil pan Clean and change gasket.

Engine oil regu-

lator valve

Water pump Change shaft and impeller.

Coolant ther-

mostat

Air cooler

Exhaust pipes Inspect and change bellows.

Exhaust duct Change seal rings.

Actuator

Governor case Change bearings, O-rings and gaskets.

Control shaft Change oil seals.

Inspect and change assemblies (including bush­ings).

Change nozzle holder assemblies.

Change plunger assembly and delivery valve.

Change pump assembly.

Inspect and change.

Change.

Change element (in 2nd 24000-hour-interval
inspection and maintenance).

Disassemble and maintain (by governor manu­facturer).

½

5-7

Chapter 5 PERIODIC MAINTENANCE CHART

Periodic Maintenance Chart for Emergency Engine

Table 5-2 Periodic maintenance chart for emergency engine (1 / 5)

Service
interval

Every week

Every month

Every 6
months

After 6
months or
500 service
hours,
whichever
comes first

Conducting maintenance operation

External

Fuel tank Inspect fuel level. 3-9

Engine oil

Coolant

Air cooler

Air starter tank Inspect air pressure. 3-11

Conducting maintenance operation

Fuel filter (wire-element) Clean inside of the filter by using handle. 6-2

Fuel control linkage

Engine oil

Air cleaner

Pre-cleaner Inspect for clog. -

Air starter compressor Drain water. 6-18

Air starter tank Drain water. 3-11

Fuel filter
(wire-element and center-bolt)

Zinc rod Inspect and change.

Service item Service contents Page

Operate the engine under no load for 3 to 5
minutes.
Inspect starting property, exhaust color,
abnormal vibrations, abnormal sounds and
abnormal odors.
Inspect displayed value of each gage (such
as oil pressure gage, water temperature
gage, oil temperature gage, exhaust tem­perature and rotating speed gage).

Inspect leakage and looseness of bolts and
nuts. Retighten bolts and nuts.

Inspect oil level and add oil by using oil level
gage. Inspect level regulator operation.

Inspect coolant level and coolant oil by
using fluid level gage.

Inspect water leakage from air cooler cham­ber and drain water.

Operate the engine under load (at 50 % or
more) for 15 to 30 minutes.
Inspect starting property, exhaust color,
abnormal vibrations, abnormal sounds,
abnormal odors.
Inspect displayed value of each gage (such
as oil pressure gage, water temperature
gage, oil temperature gage, exhaust tem­perature, rotating speed gage).

Inspect ball joints, bolts and nuts for loose­ness and smooth movement.

Inspect engine oil for mixing of fuel and
water.

Inspect air cleaner indicator for element
clog.

Drain water.

3-13

3-8

3-9

3-10

6-16

3-13

6-6

6-11

3-10

6-1

6-13

5-8

Service
interval

After 1 year
or 500 ser­vice hours,
whichever
comes first

Every year

After 2 years
or 500 ser­vice hours,
whichever
comes first

After 2 years
or 1500 ser
vice hours,
whichever
comes first

Chapter 5 PERIODIC MAINTENANCE CHART

Table 5-2 Periodic maintenance chart for emergency engine (2 / 5)

Service item Service contents Page

Engine oil

Conducting maintenance operation

Valve clearance

Camshaft and tappets Inspect. ½

Damper

Magnetic pickup

Fuel tank Drain water. 6-2

Fuel injection nozzles Change nozzle tips and adjust pressure. ½

Fuel injection timing Inspect and adjust. ½

Coolant Inspect LLC concentration. 6-13

Exhaust pipes and exhaust muffler Inspect and drain water. 6-16

Pre-cleaner Clean. 6-16

Air cleaner element Clean and inspect. 6-17

Increasing coolant

temperature,
Protection
device

Engine oil Change.

Oil filter and bypass oil filter Change. 6-7

Fuel filters
(center-bolt and cartridge)

-

Fuel filter (wire-element) Clean inside. 6-2

decreasing oil pres-

sure, overspeed

and emergency

stop device

Analyze engine oil properties.
(according to engine oil analysis service)

Operate the engine under no load for 2
hours (more than 1/2 load).
Inspect starting property, exhaust color,
abnormal vibrations, abnormal sounds and
abnormal odors.
Inspect displayed value of each gage (such
as oil pressure gage, water temperature
gage, oil temperature gage, exhaust tem­perature and rotating speed gage).

Inspect and adjust (also inspect inside of
rocker chamber).

Check temperature with thermo label and
check for silicon oil leakage.

Inspect clearance with the flywheel, attach­ment of foreign items on the tip, mounting
nut tightness, an open-circuit and connector
disconnection.

Inspect operation.

Change.

6-12

3-13

½

½

½

½

6-7

6-3

5-9

Chapter 5 PERIODIC MAINTENANCE CHART

Table 5-2 Periodic maintenance chart for emergency engine (3 / 5)

Service
interval

Every 2
years

Every 4
years

Turbocharger

Fuel system accumulator Refill with nitrogen gas. ½

Coolant Change. 6-14

Coolant thermostat Inspect. ½

Starting valve

Distributor

Air starter strainer Drain water and clean. 6-18

Overhaul of top end of engine
Disassemble one cylinder, and inspect cylinder head, piston and connecting rod. If
abnormalities are found, disassemble all cylinders for inspection.

Cylinder
heads and
valve mech­anisms

Safety valve Inspect and change expendable parts.

Cylinder liners Inspect and clean.

Crankcase

Pistons Inspect including overhaul and clean.

Piston rings Inspect.

Connecting rods

Crankshaft

Damper

Inspection of pipe clamps of fuel
lines, oil lines, instrument pipes
and starting air pipes

Flexible hoses Change.

Service item Service contents Page

Disassemble and maintain, clean and change expendable parts.

Valve seat Inspect, regrind and lap.

Inlet and exhaust

valves

Cylinder head gas-

ket

Valve guides,

valve rotator,

valve cotter,

pushrods,

rocker arm bush-

ings,

valve springs,

tappet rollers,

tappet brush,

tappet shafts,

tappet guides,

tappet guide set

screws

Stem seal Change.

Inspection of shaft for smooth rotation and
and wheel thrust for looseness.

Inspect, lap and change O-rings and gas­kets.

Inspect valve, shafts, bushings and pins,
and change gaskets.

Inspect, regrind and lap.

Change cylinder head gaskets.

Inspect.

Inspect inside(remove the side cover for
inspection).

Inspect bolts, inspect Magnaflux serrations,
change big-end bearing shells and inspect
small-end bushings.

Inspect and adjust deflection, and inspect
journals and pins.

Analyze silicon oil properties and change
thermo label.

Inspection of interference and wear, and
repair rubber tape.

½

½

½

½

5-10

Service
interval

Every 4
years

Every 8
years

Chapter 5 PERIODIC MAINTENANCE CHART

Table 5-2 Periodic maintenance chart for emergency engine (4 / 5)

Service item Service contents Page

Fuel injection

nozzles

Fuel system

Lubricating
system

Cooling
system

Inlet and
exhaust
systems

Major overhaul (complete disassembly and inspection)
Change all O-rings, gaskets and seals.

Cylinder
heads and
valve mech­anisms

Safety valves Inspect and change expendable parts.

Cylinder liners Inspect, clean and change O-rings.

Main bearings

Cam bushings Inspect.

Pistons Inspect including overhaul and clean.

Piston rings Change.

Connecting rods

Front gear and timing gear

Fuel injection pump

Fuel tank Clean inside.

Oil pump Inspect discoloration and external.

Oil cooler Inspect and clean element.

Breather

Governor oil filter Change.

Coolant thermostat Change.

Turbocharger

Air cooler Disassemble and clean element.

Pre-cleaner Change.

Air cleaner element Change. 6-17

Disassemble and maintain, clean and change expendable parts.

Inlet and exhaust

valves and valve

seats

Valve guides, valve

rotators, valve cot-

ters, pushrods,

rocker arm bush-

ings, valve springs,

tappet rollers, tap-

pet roller bushings,

tappet shafts, tap-

pet guides and tap-

pet guide set

screws

Stem seal Change.

Copper tubes and

copper tube O-rings

Change nozzle tips and adjust pressure.

Disassemble, maintain, adjust and change
O-rings.

Clean mist separator and change expend­able parts.

Remove carbons, change seal rings and
change expendable parts.

Inspect, regrind and lap.

Inspect.

Change.

Inspect main bearing caps, bolts and main
bearings, and inspect thrust plate.

Inspect bolts, inspect Magnaflux serrations,
change big-end bearing shells and inspect
small-end bushings.

Inspect gear teeth, bearings and shafts.
Change front seal, rear seal, front gear
case gasket and rear gear case gasket.

½

6-16

½

5-11

Chapter 5 PERIODIC MAINTENANCE CHART

Table 5-2 Periodic maintenance chart for emergency engine (5 / 5)

Service
interval

Every 8
years

Fuel system

Lubricating
system

Cooling
System

Inlet and
exhaust
systems

Air starter
system

Governor

Service item Service contents Page

Fuel regulator valve Inspect.

Fuel pipes Change O-rings and sealing washers.

Fuel control linkage Change ball joints and ball bearings.

Fuel system accu-

mulator

Fuel feed pump Change oil seals and O-rings.

Fuel injection pipes Inspect.

Oil pump Disassemble and maintain.

Oil thermostat Inspect.

Engine oil regulator

valve

Oil pipes Change O-rings and gaskets.

Water pump

Coolant pipes Change O-rings.

Air cooler cover Change gaskets.

Air inlet pipes Change O-rings.

Exhaust pipes Change gaskets, bolts and nuts.

Exhaust duct Change seal rings, gaskets and V-clamps.

Air pipes Change gaskets.

Air tank Inspect safety valve operation.

Actuator

Governor case Change bearings, O-rings and gaskets.

Control shaft Change oil seals.

½

Change.

Disassemble and maintain.

Change oil seals, unit seals, expendable
parts and bearings.

Disassemble and maintain (by governor
manufacturer).

5-12

Chapter 5 PERIODIC MAINTENANCE CHART

Periodic Maintenance Chart for General-Purpose Power Supply Engine

Table 5-3 Periodic maintenance chart for general-purpose power supply engine (1 / 5)

Service
interval

Every day

After 500
services
hours or 1
month,
whichever
comes first

After 500
services
hours or 6
months,
whichever
comes first

After 500
services
hours or 1
year, which
ever comes
first

After first
1500 ser
vices hours
or 1 year,
whichever
comes first

After 1500
services
hours or 1
year, which­ever comes
first

-

External

Fuel tank Inspect fuel level and drain water. 3-9

Fuel filters (wire-element) Clean inside of the filter by using handle. 3-8

Engine oil

Coolant

Air cleaner Inspect air cleaner indicator for element clog. 3-10

Air starter tank Inspect air pressure and drain water. 3-11

Operating condition

Air cooler

Fuel filters Drain water. 6-1

Fuel control linkage

Engine oil Inspect engine oil for mixing of fuel and water. 6-11

Exhaust pipes and exhaust
muffler

Air starter compressor Drain water. 6-19

Zinc rod Inspect and change.

Engine oil

-

Oil filter and bypass oil filter Change. 6-7

Valve clearance

Camshaft and tappets Inspect. ½

Air cooler cover

Fuel filters Change.

Coolant Inspect LLC concentration. 6-13

Pre-cleaner Clean. 6-17

Air cleaner element Clean and inspect. 6-18

Air starter strainer Drain water and clean. 6-19

Service item Service contents Page

Inspect leakage and looseness of bolts and nuts.
Retighten bolts and nuts.

Inspect oil level and add oil by using oil level
gage. Inspect level regulator operation.

Inspect coolant level and add coolant by using
fluid level gage.

Check operating period, performance record,
sound, vibration and gage function.

Inspect water leakage from air cooler chamber
and drain water.

Inspect ball joints, bolts and nuts for looseness
and smooth movement.

Inspect and drain water.

Change.

Analyze engine oil properties
(according to engine oil analysis service).

Inspect and adjust (also inspect inside of rocker
chamber).

Retighten air cooler cover mounting bolt (Also
after first 1500 service hours or first 1 year,
whichever comes first from gasket replacement).

3-8

3-9

3-10

3-13

6-18

6-6

6-16

6-13

6-7

6-12

½

½

6-4

5-13

Chapter 5 PERIODIC MAINTENANCE CHART

Table 5-3 Periodic maintenance chart for general-purpose power supply engine (2 / 5)

Service
interval

Every 3000
service
hours

After 3000
services
hours or 2
years,
whichever
comes first

After 6000
services
hours or 4
years,
whichever
comes first

After 12000
service
hours or 4
years,
whichever
comes first

After 12000
service
hours or 2
years,
whichever
comes first

Valve clearance

Fuel injection nozzles

Fuel filter (wire-element) Clean inside. 6-3

Breather

Governor oil filter Change. ½

Air cleaner element Change. 6-17

Pre-cleaner Change. 6-18

Magnetic pickup

Fuel system accumulator Refill with nitrogen gas. ½

Camshafts and tappets Inspect. ½

Crankcase

Water pump

Damper

Turbocharger

Inspection of pipe clamps of
fuel lines, oil lines, instrument
pipes and starting air pipes

Flexible hoses Change.

Protection
device

Flexible hoses Change.

Fuel system accumlator Change.

Coolant Change. 6-13

Service item Service contents Page

Increasing cool­ant tempera­ture,
decreasing oil
pressure, over­speed and
emergency
stop device

Inspect and adjust (also inspect inside of rocker
chamber).

Inspect and change nozzle tipes and adjust pres­sure.

Inspect and clean mist separator, and change
expendable parts.

Inspect clearance with the flywheel, attachment
of foreign items on the tip, mounting nut tight­ness, an open-circuit and connector disconnec­tion.

Inspect inside (remove the side cover for inspec­tion).

Change oil seals, unit seals and other expend­able parts.

Check temperature with thermo label and check
for silicon oil leakage.

Inspection of shaft and wheel for smooth rotation
and thrust for looseness.

Inspection of interference and wear, and repair
rubber tape.

Inspect operation.

½

½

½

½

½

5-14

Table 5-3 Periodic maintenance chart for general-purpose power supply engine (3 / 5)

Service
interval

After 12000
service
hours or 8
years,
whichever
comes first

Chapter 5 PERIODIC MAINTENANCE CHART

Service item Service contents Page

Overhaul of top end of engine (remove the cylinder heads for inspection and main­tenance.)

Disassemble and maintain, clean and change expendable parts.

Valve seat Inspect, regrind and lap.

Inlet and
exhaust valves

Cylinder head
gasket

Copper tubes Change copper tubes and O-rings.

Valve guides,
Cylinder
heads and
valve mech­anisms

Safety valve Inspect and change expendable parts.

Cylinder liners Inspect and clean.

Pistons Inspect including overhaul and clean.

Piston rings Change.

Connecting rods

Crankshaft Inspect and adjust deflection.

Damper

Front gear and timing gear Inspect gear teeth.

valve rotator,

valve cotter,

pushrods,

rocker arm

bushings, valve

springs, tappet

rollers, tappet

roller bushings,

tappet shafts,

tappet guides,

tappet guide

set screws.

Stem seal Change.

Inspect, regrind and lap.

Change.

Inspect.

Inspect bolts, inspect Magnaflux serrations,
change big-end bearing shells and inspect small­end bushings.

Analyze silicon oil properties and change thermo
label.

½

5-15

Chapter 5 PERIODIC MAINTENANCE CHART

Table 5-3 Periodic maintenance chart for general-purpose power supply engine (4 / 5)

Service
interval

After 12000
service
hours or 8
years,
whichever
comes first

Fuel system

Lubricating
system

Cooling
system

Inlet and
exhaust
systems

Air starter
system

Service item Service contents Page

Fuel control

linkage

Fuel injection

pump

Fuel feed pump Change oil seals and O-rings.

Fuel injection

pipes

Fuel injection

timing

Fuel pressure

regulator valve

Fuel system

accumulator

Fuel pipes Change O-rings and sealing washers.

Oil pump Change bushings.

Oil cooler Inspect and clean element.

Regulator valve Disassemble and maintain.

Oil pipes Change O-rings and gaskets.

Oil pipes Change bearings.

Coolant pipes Change O-rings.

Turbocharger

Air cooler Clean element.

Air cooler cover Change gasket.

Air inlet pipes Change O-rings.

Exhaust pipes Change gaskets, bolts and nuts.

Exhaust duct Change V-clamps.

Starting valve Inspect, lap and change O-rings and gaskets.

Air pipes Change gaskets.

Air tank Inspect safety valve operation.

Distributor Change valve, shaft, bushings, pins and gaskets.

Change ball joints and ball bearings.

Disassemble and maintain, and change deflec­tors and O-rings.

Change.

Inspect and adjust.

Inspect.

Change.

Remove carbon deposits and change seal rings,
expendable parts and bearings.

½

5-16

Service
interval

Every 24000
service
hours

Chapter 5 PERIODIC MAINTENANCE CHART

Table 5-3 Periodic maintenance chart for general-purpose power supply engine (5 / 5)

Service item Service contents Page

Major overhaul (complete disassembly and inspection)
Change all O-rings, gaskets and seals.

Cylinder
Heads and
Valve
Mecha­nisms

Cylinder liners Change.

Main bearing

Cam bushings

Pistons

Connecting rods

Crankshaft Inspect journals and pins, and change slingers.

Damper

Spring coupling

Timing gear
and front
gear

Fuel system

Lubricating
system

Cooling
system

Inlet and
exhaust
systems

Governor

Change inlet and exhaust valves, valve seats, valve guides, valve

rotators and valve cotters.

Inspect and change pushrods, rocker arm bushings, valve springs,

tappet rollers, tappet roller bushings, tappet shafts, tappet guides

and tappet guide set screws.

Inspect main bearing caps and bolts, and change
main bearings.

Inspect and change (in 2nd 24000-service-hour­interval inspection and maintenance).

Disassemble and inspect piston crown, and
change O-rings.

Change connecting rod bolts and small-end
bushings.

Change (in 2nd 24000-service-hour-interval
inspection and maintenance).

Disassemble and maintain (by spring coupling
manufacturer).

All shafts Inspect.

Rear idler gear

Change front idler bearing, camshaft roller bearing, front seal, rear

seal, front gear case gasket and rear gear case gasket.

Fuel injection

nozzles

Fuel injection

pump

Fuel feed pump Change pump assembly.

Regulator valve Change.

Oil pump Change safety valve and spring.

Oil thermostat Change.

Oil pan Clean and change gasket.

Engine oil regu-

lator valve

Water pump Change shaft and impeller.

Coolant ther-

mostat

Air cooler

Exhaust pipes Inspect and change bellows.

Exhaust duct Change seal rings.

Actuator

Governor case Change bearings, O-rings and gaskets.

Control shaft Change oil seals.

Inspect and change rear idler gear assemblies
(including bushings).

Change nozzle holder assemblies.

Change plunger assembly and delivery valve.

Inspect and change.

Change.

Change element (in 2nd 24000-service--hour­interval inspection and maintenance).

Disassemble and maintain (by governor manu­facturer).

½

5-17

Chapter 6
PERIODIC INSPECTION AND MAINTE­NANCE PROCEDURES

Fuel System

Draining Water from Fuel Filters (Wire-Element Type)

Before handling fuel, make sure there is no flame or heat source in the area.

Wipe spilled fuel thoroughly. Spilled fuel can cause a fire.

Check for damage of threaded section of the filter case, the drain plug and the sealing washer, if any damage

are found, replace with the new one.

1 Close the fuel feed valve to cut off the fuel supply to

the engine.

2 Place a container under the fuel filter to receive

drained fuel.

3 Turn the handle at the top of the fuel filter to remove

dust and other particles from the element.

4 Remove the drain plug and the sealing washer to dis-

charge sediment from the filter.

5 Reinstall the drain plug and the sealing washer.

6 Bleed air from the fuel system.

Note: Refer to "Bleeding Fuel System" (3-2) for the pro-

cedure for releasing air from the fuel system.

fig.6-1

Draining Water from Fuel Filters (Center-Bolt Type)

Handle

Filter case

Sealing washer

Drain plug

Draining water from fuel filter (wire-element type)

Before handling fuel, make sure there is no flame or heat source in the area.

Wipe spilled fuel thoroughly. Spilled fuel can cause a fire.

Check for damage of the center bolt, drain plug threaded section and the sealing washer. If any damage are

found, replace with the new one.

1 Close the fuel feed valve to cut off the fuel supply to

the engine.

2 Place a container under the fuel filter to receive

drained fuel.

3 Remove the drain plug and the sealing washer to dis-

charge sediment from the filter.

4 Reinstall the drain plug and the sealing washer.

5 Bleed air from the fuel system.

Note: Refer to "Bleeding Fuel System" (3-2) for the pro-

cedure for releasing air from the fuel system.

fig.6-2

Draining water from fuel filter (center-bolt type)

Center bolt,
Sealing washer,
Drain plug

6-1

Chapter 6 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Draining Water from Fuel Tank

When handling fuel, make sure there are no flames or heat source in the area.

Wipe any spilled fuel completely. Spilled fuel can ignite and cause fire.

Do not remove the strainer when filling the fuel tank.

Use fuel specified in "Fuel" (4-2).

Fuel mixed with water and/or dust not only reduces

the output but can also cause malfunctions of the

fuel system. Drain water from the fuel tank by fol

lowing procedures below.

1 Place a fuel receiving tray (capacity: 2 L [0.53 U.

S. gal] or more) under the drain cock on the fuel

tank.

2 Open the drain cock on the fuel tank, and drain

at least 1 to 2 L [0.26 to 0.53 U. S. gal] of fuel.

3 Make sure water and dust particles were

drained together with fuel, then close the drain

cock.

-

fig.6-3 Draining water from fuel tank

Drain cock

Cleaning inside of Fuel Filters (Wire-Element Type)

Before handling fuel, make sure there is no flame or heat source in the area.

Wipe spilled fuel thoroughly. Spilled fuel can cause a fire.

Check for damage of the filter case, the drain plug threaded section and the sealing washer, if any damage

are found, replace with the new one.

1 Close the fuel feed valve to cut off the fuel supply to

the engine.

2 Place a container under the fuel filter to receive

drained fuel.

3 Drain fuel by removing the drain plug and the sealing

washer.

4 Remove the filter case by loosening the mounting

bolt at the top of the filter.

5 Remove dust and other particles from the element

using the soft brush with diesel fuel.

6 Also clean inside of the case.

7 Reinstall the drain plug, the sealing washer and the

filter case to the original position.

8 Bleed air from the fuel system.

Note: Refer to "Bleeding Fuel System" (3-2) for the procedure for releasing air from the fuel system.

Mounting bolt

Wire element

Filter case

Drain plug

fig.6-4 Cleaning inside of fuel filter (wire-element)

Sealing washer

6-2

Chapter 6 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Changing Fuel Filters (Center-Bolt Type)

When handling fuel, make sure there are no flames or heat source in the area.

Wipe any spilled fuel completely. Spilled fuel can ignite and cause fire.

The fuel filter (center-bolt type) uses a paper element. It cannot be cleaned for reuse.

When installing a new element, be careful not to damage the element.

Check the threaded sections of the air vent plugs, the bracket, the drain plugs, the center bolts and the seal-

ing washers. If the threads are damaged, replace the damaged part.

1 Close the fuel supply valve to the engine.

2 Clean the area around the fuel filters.

3 Place a fuel receiving tray under the fuel filters.

4 Remove the drain plug and the sealing washers

Case

to discharge fuel from the filter.

5 After fuel is drained, reinstall the drain plug and

the sealing washers.

6 Remove the center bolt, and disassemble the

fuel filter unit.

Sealing washer

O-ring

Washer

Center-bolt

Drain plug

7 Clean the inside surface of the case and O-ring

groove.

fig.6-5 Changing fuel filters (center-bolt type)

8 Wipe off fuel from element mounting surface of

the bracket and external O-ring seal surface with

a cloth.

9 Use the O-rings provided in a new filter element kit to replace old parts.

10 Reassemble the fuel filter unit.

11 Tighten the center bolt to 63.7±4.9 N·m (6.5±0.5 kgf·m) [46.98±3.61 lbf·ft].

12 After replacing the fuel filter, open the fuel supply valve to the engine, then bleed air from the fuel system.

Note: Regarding bleeding of the fuel system, refer to "Bleeding Fuel System" (3-2).

13 Start the engine and let it idle for several minutes.

14 Check the fuel filter mounting sections for fuel leakage. If fuel leakage is found, disassemble the fuel filter

and check the O-rings for damage. If there is no gasket damage, reassemble the fuel filter.

Air vent plugs
Sealing washers
Bracket
O-ring

Element

Retainer

Element kit

6-3

Chapter 6 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Changing Fuel Filters (Cartridge Type)

When handling fuel, make sure there are no flames or heat source in the area.

Wipe any spilled fuel completely. Spilled fuel can ignite and cause fire.

This fuel filter (cartridge type) uses a paper element. It cannot be cleaned for reuse.

The fuel filter cartridges must be installed by hand, and caution should be exercised to prevent denting or

scratching the cartridge surfaces. Do not use a filter wrench for installation.

Check the threaded sections of the air vent plugs, bracket and sealing washers. If the threads are damaged,

replace the damaged part.

Changing Fuel Filters with Engine Stop

1 Close the fuel supply valve to the engine.

2 Clean the area around the fuel filters.

3 Place a fuel receiving tray under the fuel filters.

4 Set the filter handle to the “Left-Close, Right-

Open”.

5 Using the filter wrench, remove 2 fuel filters from

left side.

6 Apply clean fuel to the gasket on the new fuel fil-

ters.

7 Install the fuel filters. When the gasket contacts

the mounting surface on filter bracket, further

rotate 3/4 to a full turn.

8 Set the fuel filter handle to the “Left-Close,

Right-Open”, then take same measures stated in

5 to 7 and replace 2 fuel filters from right side.

9 After replacing the filters, open the fuel feed

valve to the engine, then bleed air from the fuel

system.

Note: Regarding bleeding of the fuel system, refer

to "Bleeding Fuel System" (3-2).

10 Start the engine and let it idle for several min-

utes.

11 Check each fuel filter for fuel leaks. If fuel leaks

from a filter, remove the filter and check the gas-

ket for scratches or other abnormalities, then

reinstall the filter.

 
 


  

    

 
 

fig.6-6 Fuel filter switchover handle

 
  



 
 

fig.6-7 Changing fuel filters (cartridge type)

 

 
 


  

    

 
 

 
  




 
 

 
 

6-4

Chapter 6 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Changing Fuel Filters while Engine in Operation

To replace the fuel filters while the engine is in operation, be sure to run the engine under no load low idling

and at rated speed.

If the fuel filter is replaced during the engine is in high-speed operation, fuel can leak from the switchover

lever.

1 Clean the area around the fuel filters.

2 Place a fuel receiving tray under the fuel filters.

3 Set the fuel filter handle to the "“Left-CLOSE,

Right-OPEN”.

 
 


  

    

 

 
 


  

    

4 Using a filter wrench, remove 2 fuel filters either

from left side or right side.

5 Coat the gaskets of new fuel filters with clean

fuel.

6 Mount the new fuel filters to the bracket.

Tighten each filter until it contacts the bracket,

the further tighten 3/4 to 1 turn by hand.

7 Set the handle to the “Left-AIR PURGE, Right-

OPEN”.

8 Loosen the air vent plug of the left side fuel filter.

 
 

fig.6-8 Fuel filter switchover handle

 
  

 
 

 
  



9 When the fuel flows from the air vent plug no

longer contains air bubbles, tighten the air vent

plug.




 
 

10 Return the handle to the "Left-OPEN, Right-

CLOSE”.

11 Using the filter wrench, remove 2 right fuel filters.

 
 

 
 

12 Apply clean fuel to the gasket on the new fuel fil-

ters.

fig.6-9 Changing fuel filters (cartridge type)

13 Install the fuel filters. When the gasket contacts

the mounting surface on filter bracket, further rotate 3/4 to full turn.

14 Set the fuel filter handle to the “Right-AIR PURGE, Left-OPEN” position.

15 Loosen the air vent plug of the right side fuel filter.

16 When the fuel flows from the air vent plug no longer contains air bubbles, tighten the air vwnt plug.

17 Return the handle to the NORMAL position.

18 Start the engine, and let it under no load low idling for several minutes.

19 Check each fuel filter for fuel leaks. If fuel leaks from a filter, loosen the filter and check the gasket for

scratches or other abnormalities.

6-5

Chapter 6 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Inspection of Fuel Control Link­age Ball Joints

Check the ball joints in the fuel control linkage for

looseness.

If the amount of looseness is more than 0.1 mm

[0.004 in.], consult a Mitsubishi dealer to replace

the ball joints.

Never break a seal of fuel control link to replace the

ball joints.

If the seal on the ball joint is broken, the warranty

may be invalidated.

0.1 mm
[0.004 in.]

fig.6-10 Inspection of the ball joints for looseness

0.1 mm [0.004 in.]

Lever

Ball joint

Rod

6-6

Chapter 6 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Lubricating System

Changing Engine Oil, Oil Filters and Bypass Oil Filter

To drain oil or change oil filters, wear gloves. Hot engine oil and parts may cause burns.

When changing engine oil, change the oil filters and bypass oil filter at the same time.

It is recommended to analyze engine oil properties at the same time.

Also change the oil filters whenever the filter alarm turns on.

The oil filters use paper elements. Never clean and reuse them. When replacing the filters, be sure to install

new packings.

Draining Engine Oil

To ensure thorough drainage, drain engine oil from the oil pan while it is still warm at 30 to 40 °C [86 to 104 °F]

after engine operation.

Be sure to suck out the engine oil when draining.

Engine oil capacity (oil pan)

S12U: approx. 450 L [118.88 U. S. gal.]
S16U: approx. 600 L [158.50 U. S. gal.]

Changing Oil Filters (S12U)

Inspect the damage of the drain plug and filter bracket threaded sections, the center bolt and the gasket, if

any damage are found, replace it with the new one.

1 Clean the area around the oil filters.

2 Remove the center bolts and the gaskets, and

remove the cases and elements.

3 Remove the packing from the bracket.

Note: Disassemble the removed elemenets to see if

they have collected metal particles. If there

are metal particles on the elements, consult

your Mitsubishi dealer.

4 By using a clean cloth, wipe off oil from the filter

bracket surface and inside the groove of packing

that contacts the oil filter mounting sections.

5 Mount a packing provided in a new element kit

into each grovve on the bracket.

6 Install the element, and set the spring retainer

and set spring on top of each element.

7 Install each case and the gaskets of the center

bolts, then tighten the center bolt to 83.4

N

··m (8.5±0.5 kgf·m) [61.51±3.61 lbf·ft].

±4.9

Drain plug

fig.6-11 Changing oil filter element (S12U)

Bracket

Center bolt

Gasket

Case

Element

Packing

Set spring

Spring 
retainer

fig.6-12 Inspection of oil filter

6-7

Chapter 6 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Changing Oil Filters (Swithover Type) (S12U)

Inspect the damage of the drain plug and filter bracket threaded sections, the center bolt and the gasket, if

any damage are found, replace it with the new one.

Changing Oil Filters with Engine Stop

Refer to "Changing Fuel Filters (Center-Bolt Type)" (6-3) for the procedure for changing oil filter element.

Changing Oil Filters While Engine in Operation

To replace the oil filters while the engine is in operation, be sure to run the engine under no load low idling and

rated speed. If the oil filter is replaced during the engine is in high-speed operation, oil can leak from switcho-

vwe lever.

1 Clean the surrounding area of the oil filters.

2 Place a container under the oil filters to receive

drained oil.

3 Remove the cover from the oil filter switchover

cock.

4 Turn the switchover cock to have pin position

“Left-Close, Right-Open”.

5 Refer to "Changing Oil Filters (S12U)" (6-7) for

the procedure for changing 3 new sets of left oil

filter elements.

6 Turn the switchover cock to have pin position

“Right-Close, Left-Open”.

7 Refer to "Changing Oil Filters (S12U)" (6-7) for

the procedure for changing 3 new sets of right

oil filter elements.

8 Return the switchover cock pin to the NORMAL

position and reinstall the cover to the switchover

cock.

Left side oil filters

Right side oil filters

Left-CLOSE,
Right-OPEN

"NORMAL

position"

Open both sides

of oil filter

Right-CLOSE,

Left-OPEN

fig.6-13 Changing oil filters (switchover type)

6-8

Chapter 6 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Changing Oil Filters (Swithover Type) (S16U)

Changing Oil Filters with Engine Stop

1 Clean the surrounding area of the oil filters.

2 Open the air vent valves on the filter covers to

Nut

release the internal pressure of the oil filters.

3 Open the drain valve located located below the

Spindle

filter body to discharge engine oil from the oil fil-

ters.

4 Remove the bolts and nuts, and dismount the fil-

ter covers.

5 Remove the filter bodies, wing nuts and wash-

Drain valve

ers, and dismount the oil filter elements.

Note: Open the removed elements to see if they

fig.6-14 Changing oil filter elements

have collected metal particles. If metal parti-

cles are found on the elements, consult your

Mitsubishi dealer.

6 By using a clean cloth, wipe off oil from the oil filter mounting surfaces and O-ring mounting surfaces of the

filter bodies.

7 Install the packings provided in a new element kit securely into the grooves on the filter bodies.

8 Install the elements, packings and washers, and secure them in place by tightening the wing nuts.

9 Install the filter covers to the filter bodies with the bolts and nuts.

10 Close the air vent valves and drain plug.

Bolt

Cover

O-ring

Wing nut

Washer

Element

Body

Packing

Changing Oil Filters While Engine in Operation

To replace the oil filters while the engine is in operation, be sure to run the engine under no load low idling and

rated speed. If the oil filter is replaced during the engine is in high-speed operation, oil can leak from switcho-

vwe lever.

1 Clean the surrounding area of the oil filters.

2 Turn the oil filter tightening handle for an angle of

90 to 180 degrees in the counterclockwise direc-

tion.Remove the cover from the oil filter switcho-

ver cock.

3 Move the switchover handle to the "Left-STOP"

or "Right-STOP" position.

Note: When the switchover handle is operated, the

stopper located on the back side of the handle

enters the stopper hole on the flange to secure

the handle in place.

4 Change the element and packing in the oil filter

on the side selected by the switchover handle.

5 Change the element and packing in the other oil

filter by following the same procedure.

6 Return the switchover handle to the "Both Right and Left Filters in Use" position (center position), and turn

the oil filter tightening handle to the right to tighten.

Switchover handle

"Both Right and Left Filters in Use"

Left side oil filter

"Left side
CLOSE"
position

Stopper hole

Drain valve

fig.6-15 Oil filter switchover handle

Tightening handle

Right side oil filter

"Right side
CLOSE"
position

Drain valve

6-9

Chapter 6 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Changing Bypass Oil Filter

1 Clean the area around the oil filters.

2 Place an oil-receiving tray under the bypass oil

filter.

3 Using the provided filter wrench, remove each

bypass oil filter.

fig.6-16 Changing bypass oil filters

Note: Check the filter elements in the removed oil

filter for metal particles. If metal particles are

found, consult a Mitsubishi dealer.

4 Wipe oil from the oil filter mounting surface on

the filter bracket with a cloth.

5 Check the new bypass oil filter for proper seat-

ing of the packing.

6 Apply clean engine oil to the packing.

7 Install the bypass oil filter to the filter bracket.

When the packing contacts the mounting sur-

face on the filter bracket, further rotate 3/4 to a

full turn.

fig.6-17 Inspection of bypass oil filter

Apply engine oil

Bypass oil filters

Apply clean engine oil
to packing

Do not use the filter wrench for the installation of fil-

ters to prevent filters from deformation.

fig.6-18 Bypass oil filter

6-10

Chapter 6 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Pouring Engine Oil

1 Remove the cap from the oil filler.

2 Pour designated engine oil to the specified level.

Specified engine oil Class CD or CF

(API Service Classification)

Specified engine oil capacity (oil pan)

S12U: approx. 450 L [118.88 U. S. gal]
S16U: approx. 600 L [158.50 U. S. gal]

Note: Regarding engine oil, refer to "Engine Oil" (4-4).

3 Check the oil level with the oil level gage.

If the automatic oil feeder is installed, check if it

works normally.

The oil level should be between the MAXIMUM and

MINIMUM marks on the oil level gage.

If the oil level is low, add specified type of engine oil.

4 Check the oil pan and other parts for engine oil

leaks. Repair any oil leakage found.

5 Operate the engine oil priming pump to circulate oil

in the engine.

6 Remove the rocker cover, and make sure that oil is

supplied to the valve mechanisms, and install the

rocker cover.

7 Stop the priming pump. After about 30 minutes, add engine oil until the oil level reaches the MAXIMUM

line on the oil level gage.

8 Reinstall the cap on the oil filler.

Oil filler

Oil level gage

fig.6-19 Oil filler and level gage

 
 

fig.6-20 Engine oil priming pump

Inspection of Engine Oil Leakage After Replacing Oil Filter

1 Start the engine, and let it idle for several minutes.

2 Check the oil filter for engine oil leakage. If any leakage are found, remove and reassemble, making sure

that there are no scratches on the packing, then reinstall or reassemble the filter.

Inspection of Engine Oil for Mixing of Fuel and Water

If the engine continues to operate with engine oil mixed with fuel or water, the engine oil viscosity decreases

and this can cause serious accidents such as seizing of bearings.

Sample 1 to 2 L [0.26 to 0.53 U. S. gal] of engine oil, and check for abnormal odor and discoloration to deter-

mine the mixing of fuel and water.

If fuel is mixed with the engine oil, the oil will smell like fuel.

If water is mixed with the engine oil, the oil will be milky white.

If fuel or water is detected in the engine oil, find the cause of the problem, and repair. If the problem cannot be

corrected easily, contact a Mitsubishi dealer.

6-11

Chapter 6 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Analysis of Engine Oil Properties

For many years of trouble-free engine operation, Mitsubishi offers engine oil analysis service. This service
provides detailed information of your engine condition by analyzing a sample of engine oil collected from
your engine with special oil sampling tools.
The engine oil analysis service can provide the following information:

• It can detect the amount of extremely fine metal powder in engine oil which could result from friction. This

information helps you to locate abnormally worn internal engine parts.

• It can detect water, LLC or salt in the engine oil, which should not be contained in the engine oil.

• It can provide the information of engine oil degradation. This information helps you to arrange proper oper-

ating conditions and maintenance and to plan the most appropriate oil change intervals.

The engine oil analysis service is designed to diagnose the internal condition of an engine, which previously
required engine disassembly. It is highly recommended to take advantage of our engine oil analysis service
so you can understand your engine condition before the engine manifests abnormalities or malfunctions.

Engine Oil Sampling Tool Sets and Ordering Procedure

Table 6-1 Engine oil sampling tool sets

Product

name

Engine oil
sampling
set

Oil sample
bottle set

Part no. Remarks

Contains oil sam-

36291-19100

36291-00098

pling pump, pipes
and bottles

1 carton: 6 bottles
Includes suction
pipes and oil sam­ple data labels.

Oil sampling pump

Oil sampling bottle

The oil sampling pump is reusable, but a new oil

sample bottle and new suction pipe must be used

fig.6-21 Engine oil sampling tool sets

each time.

Order an engine oil sampling tool set through the regular parts ordering channel. The analysis fee is included

in the price of the sample oil bottle. Note that an oil sample will not be analyzed unless it is contained in the

specified oil sample bottle.

There will be an additional charge for the analysis of optional items.

6-12

Chapter 6 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Cooling System

Checking LLC Concentration

Check the LLC concentration in the coolant by using an optical hydrometer for battery fluid and antifreeze.

Regarding LLC concentration, refer to "Coolant" (4-6).

Inspection and Replacement of Zinc Rods

Zinc rods (zinc electrodes) are installed at various sec-

tions of the sea water passage to prevent corrosion

caused by sea water.

1 Remove each zinc rod and remove deposits (scale)

from the surface.

2 If the zinc rod has worn to half the original size,

replace it with a new zinc rod. If the zinc rod is larger

than half the original size, reinstall it.

Good

fig.6-22 Zinc rod good/bad

Bad

6-13

Chapter 6 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Changing Coolant

Coolant (containing LLC) drained from an engine is toxic, and must not be disposed of into regular sewage.
For disposal of used coolant, consult a Mitsubishi dealer.

When a coolant mixed with the LLC recommended by our company is used, replace coolamt every 12000

hours or 2 years, whichever comes first, in a regular-use or general-purpose engine. In an emergency engine,

replace coolant every 2 years.

Draining Coolant

1 Allow the coolant temperature to lower to 30 to

40

°C [86 to 104 °F].

2 Prepare a container to receive drained coolant.

3 Open the drain cocks on the engine, low-temper-

ature water pump, high-temperature water
pump, coolant pipe and expansion tank to drain
coolant.

Cleaning the Cooling System

fig.6-23 Coolant drain cock (on engine)

Coolant drain cocks

fig.6-24 Coolant drain cock (on water pump)

1 Close the drain cocks or plug.
2 Pour a cleaning solution (non-corrosive solution to rubber and metals) in the cooling system, and operate

the engine with low idling for about 10 minutes, stop the engine, then drain the cleaning solution.
3 Close the drain cocks or plugs.
4 Pour fresh water, and operate the engine with low idling for about 10 minutes.

Continue flushing the cooling system in the above manner until the draining water is clear.

6-14

Chapter 6 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Pouring coolant

1 Make sure the drain cocks on the engine and

water pump are closed firmly.

2 Remove the cap from the water supply inlet of the

coolant tank, and pour undiluted LLC.

Note:(a) Determine the amounts of LLC and water to

be poured by using the LLC concentration

chart.

(b) Regarding coolant, refer to "Coolant" (4-6).

Coolant capacity (engine only)

S12U: approx. 520 L [137.37 U. S. gal]
S16U: approx. 700 L [184.92 U. S. gal]

3 Pour soft water with minimal impurities slowly to

the full level.

4 When coolant reaches the full level securely, close

the water supply inlet cap of the coolant tank.

5 To release air from the water pump and coolant

pipes, pull the manual stop lever fully to the STOP

position and hold it in that position to keep the fuel

injection pump in no-injection condition, then sup-

ply starting air and crank the engine for about 10

seconds.

6 Wait for about 1 minute, then repeat the above

cranking operation twice to remove air from the

water pump.

7 Check the level gage on the coolant tank to make

sure there is sufficient coolant (surface level at

about the center of the level gage). If the coolant

level is low, add coolant.

8 Start the engine, and operate it under light load

until the thermostat opens the valve to allow soft

water and LLC to mix thoroughly.

9 Stop the engine, check the level gage on the cool-

ant tank. If the coolant level is low, add coolant to

the center of the fluid level gage.

Note: Always add coolant having the same LLC con-

centration.

10 Check the pipe joint and other parts for coolant

leaks.

fig.6-25 Coolant drain cock on the engine

Coolant drain cocks

fig.6-26 Coolant drain cock on the water pump

Water supply inlet

Fluid level gage

fig.6-27 Water tank coolant level

6-15

Chapter 6 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Inlet and Exhaust Systems

Inspection and Draining Water of
Exhaust Pipes and Exhaust Muf­fler

Check the exhaust pipes and muffler for damage

and cracks. If they are damaged or cracked, con

tact a Mitsubishi dealer.

Remove the drain plug and allow water to drain

from the exhaust muffler. Be sure to reinstall the

drain plug after draining water.

-

Draining Water From Air Cooler Chamber and Inspection for Water Leakage

Loosen the water drain cock on the air cooler

chamber to drain condensed water from the air

cooler chamber, and also check the air cooler for air

leaks.

Be sure to close the drain cock after draining con-

densed water or checking water leakage.

If a large amount of water is discharged from the

water drain cock, there may be water leaks in the

air cooler or water pipes. If this happens, contact a

Mitsubishi dealer.

 

 

fig.6-28 Inspection and raining water of exhaust

pipes and exhaust muffler

Water drain cock
on air cooler
chamber

fig.6-29 Water drain cock on air cooler chamber

(S12U)

Cleaning, Inspection and Changing Pre-Cleaner

Do not service the air cleaner while the engine is

running. Maintenance of the air cleaner while the

engine is in operation can cause dust to enter the

engine and result in rapid wear of parts, leading to a

shorter service life.

Remove dust from the inlet side of the pre-cleaner

installed to the silencer of the turbocharger. Be sure

to keep the pre-cleaner clean to ensure optimum

engine performance.

1 Remove the pre-cleaner from the silencer, and

hand-wash the pre-cleaner with a mild detergent.

2 Rinse the pre-cleaner with clean water.

3 After drying thoroughly, inspect the pre-cleaner for cracks and damage.

If the pre-cleaner is cracked or damaged, replace it with a new part.

4 After cleaning, inspecting or changing the pre-cleaner, reinstall it to the silencer.







fig.6-30 Cleaning pre-cleaner

6-16








Chapter 6 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Cleaning, Inspecting and Chang­ing Air Cleaner Element





When handling compressed air, wear safety gog-

gles, hardhat, gloves and other necessary protec-

tive gear. Compressed air may cause personal

injury when not wearing the proper protective gear.

Do not service the air cleaner while the engine is

running. Maintenance of the air cleaner while the

engine is in operation can cause dust to enter the

engine and result in rapid wear of parts, leading to a

shorter service life.

Never knock or hit the element.

1 Remove the air cleaner cap or the wing nut.

2 Pull out the air cleaner element from the body.

3 Blow compressed air (0.69 MPa (7 kgf/cm2) [100

psi] or lower) onto the inside surface of the ele-

ment to remove dust and other contaminants.

4 To remove dust stuck on the element, blow dry

compressed air onto the outside surface from a

distance.

Blow compressed air on the inside surface

toward outside along the net pattern.

Then, blow compressed air on the outside and

inside surface again.

5 After cleaning, place a light bulb in the element

to check for damage, pinholes and worn sec-

tions.

6 If any breakage are found, replace the air

cleaner element with the new one.

7 Reinstall the air cleaner element after cleaning,

inspecting or replacing the air cleaner element.

 

fig.6-31 Removal of air cleaner element

fig.6-32 Cleaning air cleaner element

fig.6-33 Inspecting air cleaner element

If abnormalities such as damage, pinholes and thin

sections are found in the element or if the air

cleaner indicator shows red sign soon after the

cleaned element is installed, install a new filter ele-

ment in the air cleaner.

If the indicator shows a red sign, after the clean ele-

ment is installed, reset the indicator by pressing the

reset button.

Signal

Reset button

fig.6-34 Air cleaner indicator

6-17

Chapter 6 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Air Starter System

Draining Water and Cleaning Air Starter Strainer

1 Close the starter valve handle of the air starter

tank.

2 Remove the drain plug of air starter strainer and

drain water from the air strainer.

3 Remove the cap and remove the filter from the

cap.

4 Clean the filter with diesel fuel, then blow com-

pressed air to dry.

5 Reinatall the air strainer as it is.

6 Open the air starter handle slowly.

Draining Water from Air Starter

Compressor

1 Check the starter valve handle of the air strainer

tank.

2 Remove the drain plug and drain water from the

air strainer compressor.

3 Install the drain plug after draining water.

4 Open the starter valve handle of the air starter

tank slowly.

Note: The air compressor model and shape differ on

the type of the engine.

Air starter

inlet

Filter

Spring

Packing

fig.6-35 Air starter strainer

fig.6-36 Air starter compressor

Cap

Plug

Drain plug

Air starter

outlet

6-17

Chapter 7 LONG-TERM STORAGE

The following describes the method to store the

engine in a non-operable condition for more than

three months and the method for storing the engine

in an operable condition for more than three

months.

If the engine is not properly prepared for a long-

term storage of more than three months, internal

engine parts can rust and become damaged. Be

sure to follow the directions below when storing the

engine for an extended period of time.

Storing Engine in Non-Operable Condition for More Than 3 Months

Preparation for Storage

1 Drain engine oil, and pour rust-preventive oil

(NP-10-2) into the engine.

2 Prepare a fuel mixture containing 50% rust-pre-

ventive oil (NP-9), and pour it into the fuel tank.

3 Operate the engine at a speed of 500 to 600

-1

min

(idling) for 5 to 10 minutes under no load.

4 Immediately before stopping the engine, spray

volatile corrosion inhibitor (V.C.I.) through the

inlet side to prevent rust on the air intake sys-

tem.

5 With the engine not in operation, drain the fuel

mixture from the fuel tank.

6 Apply rust-preventive oil (NP-3) liberally on the

exposed sections of the machine.

7 Seal air inlet, exhaust outlet, breather and other

openings with adhesive cloth tape.

8 Cover the entire engine.

Note:(a) Store the engine in a well-ventilated indoor

location.

(b) Coolant does not need to be drained since

it contains long life coolant. (Add long life

coolant to increase the concentration

between 30 and 60%.)

(c) Post a sign at an easily noticeable location

to warn that the rust-preventive oil in the

engine must be replaced with engine oil

and the fuel tank must be filled with fuel

before operating the engine.

(d) New engine oil may be used in place of

rust-preventive oil (NP-10-2).

Table 7-1 Recommended rust-preventive

oil and corrosion inhibitor

K2246

Z1519

JIS No.

NP-3

NP-9

NP-10-2

-

Recommended

product

Nippon Oil Corpo­ration
Anti Rust P-1400

Nippon Oil Corpo­ration
Anti Rust P-2100

Nippon Oil Corpo­ration
Anti Rust P-230

Ryoukou Kagaku
V.C.I.Diana
volatile corrosion
inhibitor

Application

Prevention of
rust on
exposed
machine sur
faces

Prevention of
rust on fuel
system

Prevention of
rust on lubri
cating sys­tem

Prevention of
rust on air
intake sys
tem

-

-

-

Maintenance during Storage

Charge the battery once a month.

After checking proper electrolyte level in the bat-

tery, charge the battery.

Using Engine after Storage

1 Remove the cover from the engine.

2 Remove sealing tapes from the openings of the

engine.

3 Drain rust-preventive oil, and pour appropriate

engine oil.

Note: Regarding engine oil, refer to "Engine Oil" (4-

4).

4 Prepare the engine for operation by following

the directions in "Preparation for Operation of

New or Overhauled Engine" (3-1).

5 Start the engine.

Note: With regaes to starting the engine, refer to

"Normal Engine Operation" (3-8).

6 Conduct a warm-up operation to circulate oil

throughout the engine.

7 Apply load and increase the engine speed to the

rated speed.

7-1

Chapter 7 LONG-TERM STORAGE

Storing Engine in Operable Con­dition for More Than 3 Months

When the engine is not operated during storage of

more than three months, internal engine parts can

rust and lose oil film. As a result, the engine can

seize when it is started after storage. To prevent

this, the engine must be operated periodically for

maintenance purposes during storage.

Operating Engine for Maintenance Pur-

poses

Operate the engine for maintenance purposes at

least once a month by following the directions

below.

1 With no fuel supplied to the engine (press the

engine stop button to shut off fuel injection),

operate the air starters three times for 10 sec-

onds at intervals of about 1 minute and check

the engine oil pressure gage to make sure the

oil pressure increases.

2 After the engine starts, operate under no load

for 5 to 10 minutes.

Note: Regarding operation of the engine, refer to

"Preparations for Operation (Pre-Start Inspec-

tion)" (3-8).

7-2

Chapter 8 TRANSPORTATION

Lifting Engine Carefully

To lift the engine, use wire ropes, shackles

and slings capable of supporting the weight

of the engine.

Attach slings to the hangers provided on the

engine to lift the engine.

Keep the engine balanced during lifting by

considering the engine's center of gravity.

Keep the angle formed by slings attached to

hangers within 60°. If the angle exceeds this

limit, excessive load is applied on the hang-

ers and may damage the hangers.

Attach wire ropes to the hanger after remov-

ing the pipe cover and the insulator near the

hanger for lifting.

To prevent wire ropes from contacting the

engine, place a cloth or other soft padding to

prevent damage to the engine and wire

ropes.

fig.8-1 Hangers for lifting

fig.8-2 Lifting the engine

8-1

Chapter 9 TROUBLESHOOTING

General Precautions

Contact a Mitsubishi Dealer for Repair Service

Repairing a malfunctioning engine may require

special equipment or potentially dangerous work,

except for relatively simple procedures such as the

change and addition of fuel, engine oil and coolant.

In the event of the engine generates a malfunction,

contact a Mitsubishi dealer.

Examination before Work

Before troubleshooting, examine possible causes

of the problem and try to see if the same problem

has occurred in the past.

Check the parts that may be causing the problem in

the most efficient order.

When disassembling a component, pay close

attention to the disassembly sequence so that you

can reassemble the component efficiently.

Notes Regarding Parts Handling

Handle parts carefully.

When replacing parts, use only genuine parts by

referring to the parts catalog.

Work Safety

Be sure to use wrenches of correct size. Using a

wrench of a wrong size not only damages nuts but

can also cause personal injury.

Use correct tools and perform work with utmost

caution.

Be sure to estimate the weight of the part being dis-

mounted. If the removed part is too heavy, it may

fall during lifting, causing damage to the part as well

as personal injury.

Notes Regarding Contamination

Dust and foreign particles are the most common

cause of rapid wear of parts.

When disassembling a component, take measures

to prevent dust and foreign particles from entering

the component being disassembled.

9-1

Chapter 9 TROUBLESHOOTING

Conditions Required for Proper Engine Operation

The following table shows the conditions required for proper engine operation, and the locations that affect

those conditions.

Table 9-1 Conditions required for proper engine operation

Required condition Affecting locations

Complete compression of air

Appropriate quantity of fuel injected in proper spray
pattern and at correct timing

Appropriate air volume

All bearings in good condition

Proper circulation of engine oil and coolant and
proper temperature control

If any of the above conditions is not met, the engine can manifest problems such as output decrease, lack of
smoothness in operation, inability to run at low speed, excessive vibrations, and other general engine
problems.

Affected by cylinder liners, pistons, piston rings,
exhaust valves, inlet valves, and their related parts

Affected by fuel injection pump, fuel injection noz­zles, governor, and their related parts

Affected by air cleaner, turbocharger, air cooler, and
their related parts

Affected by bearing adjustment and engine lubricat­ing system

Affected by engine oil circulated inside and outside
engine, coolant circulating parts, oil pump, water
pump, etc

9-2

Chapter 9 TROUBLESHOOTING

Troubleshooting

Engine Turns, But It Does Not Start

Table 9-2 Engine turns, but it does not start (1 / 2)

Problem Cause Remedy

(1) No fuel supplied to fuel injection pump

Bleed air from fuel filter and fuel feed
pipes, and inspect each part for damage
and air leaks. Disassemble and repair, if
necessary.

Disassemble and clean, or replace ele­ment.

Disassemble and inspect, or replace fuel
feed pump or drive unit.

Inspect control link. If there is a fuel lever
linkage problem, disassemble and repair.
Remove cam chamber cover, and operate
by hand. If parts are defective, disassem­ble and repair, or replace.

Inspect two-way delivery valve, and disas­semble and clean.

Disassemble and repair, or replace if
defective.

Check relation of movement with fuel
lever, and disassemble and repair if defec­tive.

Check for uneven movement, and disas­semble and repair, or replace.

Replace, if worn.

Check for uneven movement, and disas­semble and repair, or replace.

Tighten screw.

Disassemble and repair, or replace.

Use fuel with viscousity suitable for ambi­ent temperature. If fuel quality is improper,
change fuel.

Check leak-off pipe for amount of fuel
leaks, check with nozzle tester, and
replace defective parts if necessary.

A
Engine emits
hardly any
exhaust smoke.

B
Engine emits
small amount of
exhaust smoke.
(Check the
cause of insuffi­cient injected
fuel.
Check all items
in A-(1) and (2)-

b, and also

check items at
right.)

a Air trapped in fuel supply system

b Empty daily fuel tank Add fuel.

c Clogged fuel filter

d Clogged fuel feed pipe Clean inside of pipe.

e Fuel not supplied due to malfunction of

fuel feed pump or drive unit

(2) Fuel supplied to fuel injection pumps

a Loose fuel injection pipe If loosened, tighten.

b Seized or damaged parts in fuel injection

pump
Malfunction of fuel lever
Control rack does not move

c Seized plunger Replace, if defective.

d Clogged two-way delivery valve

e Broken plunger spring

a Fuel lever does not open fully

b Seized tappet in fuel injection pump

c Worn tappet roller or camshaft in fuel

injection pump (reduced amount of
injected fuel)

d Seized or worn plunger in fuel injection

pump, worn broken plunger spring
(reduced amount of injected fuel)

e Loose tightening screw of control rack of

fuel injection pump

f Defective oil sealing performance of

two-way delivery valve, or broken two­way delivery valve spring

g Fuel viscosity too high to allow smooth

flow

h Large amount of fuel leaks from fuel

injection nozzles, and insufficient
injected fuel

9-3

Chapter 9 TROUBLESHOOTING

Table 9-2 Engine turns, but it does not start (2 / 2)

Problem Cause Remedy

(1) Improper fuel injection timing

Inspect camshaft drive section, and adjust
fuel injection timing correctly.

Replace if worn.

Check with nozzle tester, and disassemble
and repair, or replace.

Using nozzle tester, adjust adjustment
screw so that fuel is injected at specified
valve opening pressure.

Clean mounting surfaces of nozzle and
holder. Replace if necessary.

If starting air pressure is low, increase
pressure.
If engine oil viscosity is high, heat oil or
change oil to one with appropriate viscos­ity.
Repair if there are other abnormalities.

Disassemble and repair by lapping valve
in valve seat, or replace if necessary.

Check for sticking of valve and valve
guide, incorrect tappet assembly, and
valve clearance, and correct abnormalities
if necessary.

Disassemble and repair, or replace if nec­essary.

Check for gas leaks, and tighten cylinder
cover properly. Repair gas seal surface or
replace gas seal ring, if necessary.

Drain fuel and check. Change to higher­quality fuel, if necessary.

C
Engine emits
large amount of
exhaust smoke.
(Check the
cause of igni­tion failure
despite suffi­cient amount of
injected fuel.)

a Malfunction of camshaft drive

b Deviation of fuel ignition timing due to

worn fuel injection pump tappet roller or
camshaft cam

(2) Poor spray condition of fuel injection nozzles

a Sticking of needle valve in fuel injection

nozzle, or improper valve seat sealing

b Fuel injection nozzle valve opening

pressure is low

c Damaged or broken nozzle spring Replace if damaged.

d Large amount of fuel leaks from nozzle

(3) Insufficient compression pressure (cylinder internal temperature does not reach igni-

tion temperature)

a Inadequate rotation speed

b Inlet/exhaust valve not contacting valve

seat properly

c Valve remaining open

d Leaking of compression pressure due to

worn cylinder liners or sticking of piston
rings

e Leaking of compression pressure from

cylinder cover

(4) Inappropriate fuel

a Inappropriate fuel or water in fuel

9-4

Chapter 9 TROUBLESHOOTING

Engine Does Not Turn

Table 9-3 Engine does not turn

Problem Cause Remedy

A
Malfunction of
starting air sys­tem.

B
Malfunction of
mechanical
engine parts

a Malfunction of starting valve

b Starting air pressure lower than specified

a Seizing of moving parts in engine

b Deviation of timing due to incorrect

engine assembly
Pistons are hitting valves

c Viscosity of engine oil too high, or clotted

oil

Inspect starting valve, and repair or
replace.

Check air tank pressure, and increase
pressure if low.

Disassemble and inspect pistons, con­necting rods, crankshaft, camshaft, bush­ings of timing gear and others, inlet and
exhaust valves, etc., and repair.

Disassemble and repair.

Change oil to one with lower viscosity.

9-5

Chapter 9 TROUBLESHOOTING

Engine Output is Low

Table 9-4 Engine output is low

Problem Cause Remedy

(1) Tendency of engine moving parts toward seizing

Check abnormal heating of parts listed in

B-a in Table 9-3, and repair defective

parts.

Check oil level, oil pressure and oil viscos­ity, and add, adjust or replace oil, and also
clean lubricating system if there is oil clog­ging.

Clean or replace. (Refer to B in Table 9-2.)

Check for valve, valve guide sticking and
valve clearances, and repair.

Disassemble and correct by lapping valve
in valve seat, or replace if necessary.

Disassemble and repair, or replace if nec­essary.

Disassemble and repair, or replace if nec­essary.

Open drain cock and check fuel. Drain
water or change fuel.

Replace if worn.

Disassemble, repair or replace.

Refer to C-(2) in Table 9-2.

Disassemble and repair, or replace if nec­essary.

Disassemble and clean, or replace if nec­essary.

A
Engine emits
small amount of
exhaust.
(Engine output
and speed are
inadequate due
to insufficient
injected fuel.)

B
Engine emits
excessive white
exhaust smoke.

C
Engine emits
excessive black
exhaust smoke.

a Tendency toward seizing due to insuffi-

cient clearances of engine parts

b Inadequate lubrication

(2) Insufficient amount of fuel supply

a Clogged fuel system or loose pipe Clean or replace. (Refer to A in Table 9-2.)

b Malfunction of fuel supply or injection

system

(1) Engine knocking and excessive white smoke when engine is cold

Injection timing too advanced Correct. (Refer to C-(1) in Table 9-2.)

(2) Poor combustion due to low compression pressure

a Valve remaining open.

b Inlet/exhaust valve not contacting valve

seat properly

c Broken inlet/exhaust valve spring

d Leaking of compression pressure due to

worn cylinders or sticking of piston rings.

(3) Poor fuel condition (water in fuel)

(1) Fuel injection timing too retarded Correct. (Refer to C-(1) in Table 9-2.)

(2) Uneven fuel injection among cylinders

(Poor combustion condition, unstable rotation with knocking)

a One or more worn tappet rollers or cams

on camshaft in fuel injection pumps
causing deviation of fuel injection timing

b One or more plunger springs seized,

worn or broken

(3) Poor spray condition of some fuel

injection nozzles
(Exhaust temperature of cylinders with
poor fuel spray condition may become
high.)

(4) Poor combustion due to insufficient inlet

a Malfunction of turbocharger (damage of

vanes, seizing of bearing, etc.)

b Malfunction of inlet/exhaust valve Refer to B-(2) in Table 9-4.

c Air cleaner clogged with dust

9-6