Mitsubishi S16R2-PTAW Maintance Manual

September 2012

Pub. No. 99400-71100

The operator and supervisor are requested to read this Oper-

ation and Maintenance Manual carefully before operating the

engine or conducting inspection and maintenance.

Never operate the engine or conduct maintenance work with-

out completely understanding this manual.

OPERATION &
MAINTENANCE MANUAL

1

i

INTRODUCTION

This operation and maintenance manual contains detailed operation, inspection

and maintenance information for engines from Mitsubishi Heavy Industries, Ltd.

Please be noticed that some contents are repeated among chapters for better

understanding.

Please read and understand this manual before proceeding with operation,

inspection, and maintenance work.

Failure to follow instructions in this manual may result in serious accidents.

Please observe the contents of the controls which are applied in the countries or

areas when using the engines from Mitsubishi Heavy Industries, Ltd.

ii

FOREWORD

Limited Warranty

If Mitsubishi Heavy Industries, Ltd. examines the returned parts and any failure at manufacturing is found, Mitsubi-

shi Heavy Industries, Ltd. shall repair or exchange the parts.

Mitsubishi Heavy Industries, Ltd.'s warranty is limited to the compensation work of repair or replacement of parts.

The warranty coverage is effective for the original purchaser only. Those to whom ownership is later transferred are

not provided with the warranty. However the warranty coverage is effective for the ultimate purchaser and each sub-

sequent purchaser for emission-related parts.

Mitsubishi Heavy Industries, Ltd. makes no warranties, either expressed or implied,

except as provided in this manual, including, but not limited to, warranties as to market­ability , merchant ability, fitness for a p articular purpose or use, or against infringement of
any patent.

Mitsubishi Heavy Industries, Ltd. will not be liable for any damages or consequential

damages, including, but not limited to, damages or other cost s resulting from any abuse,
misuse, misapplication of the engine and devices supplied from us.

Mitsubishi Heavy Industries, Ltd. will not be liable for any damages or personal injuries

resulting from any modification, without our written permission, of the engine and
devices supplied from us.

Mitsubishi Heavy Industries, Ltd. will not be liable for any damages or production losses

caused by the use of fuel, engine oil and/or coolant (LLC) that we are not recommended.

The owner of the engine is responsible for the perf orm ance of th e r equir ed maintenance

listed in this operation manual.
When performing the maintenance, follow the service manual published by Mitsubishi
Heavy Industries, Ltd.
Mitsubishi Heavy Industries, Ltd. may deny the warranty coverage if the engine or part
has failed due to inadequate or improper maintenance.

iii

FOREWORD

Important Information

To avoid the potential hazard, accident prevention

activities must be planned methodically and con-

ducted continually by considering all aspect of

engine operation, maintenance and inspection. All

related personnel, including managers and supervi-

sors, should actively participate, recognize their roles

and organize themselves and their work to ensure a

safe environment.

The foremost safety objective is to prevent accidents

which may result in injury or death, or equipment

damage.

Always observe laws or regulations of the local or

federal/national government.

Mitsubishi Heavy Industries, Ltd. cannot foresee all

potential dangers of the engine, potential dangers

resulting from human error and other causes, or a

danger caused by a specific environment in which

the engine is used. Since there are many actions that

cannot be performed or must not be performed, it is

impossible to indicate every caution in this manual or

on warning labels. As such, it is extremely important

to follow instructions in this manual and also to take

general safety measures when operating, maintain-

ing and inspecting the engine.

When the engine is used by individuals whose native

language is not English, the customer is requested to

provide thorough safety guidance to the operators.

Also attach safety, caution and operating decals 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 thor-

ough knowledge of engines and their dangers and

who also have received risk avoidance training.

To prevent an accident, do not attempt to carry out

any operation other than those described in this man-

ual, and do not use the engine for any unapproved

purpose.

When the ownership of the engine is transferred, be

sure to give this manual to the new owner though we

do not warrant the engine. Also inform Mitsubishi

Heavy Industries, Ltd. of the name and address of

the new owner of the engine.

This manual is copyrighted and all rights are

reserved. No part of this manual, including illustra-

tions and technical references, may be photocopied,

translated, or reproduced in any electronic medium

or machine readable form without prior written con-

sent from Mitsubishi Heavy Industries, Ltd.

For improvement of the engine, the contents in this

manual are subject to change at any time without

notice.

Pictures or illustrations of the product in this manual

may differ from those of the product you have.

Please note that, depending on specifications, items

described in this manual may differ from those on

your engine in shape, or may not be installed on your

engine.

Please contact your local dealer if you need more

information, or if you have any questions.

If the manual is lost or damaged, please obtain a new

copy at a dealer of Mitsubishi Heavy Industries, Ltd.

as soon as possible.

Mitsubishi Heavy Industries, Ltd. recommends the

engine owner to install an hour meter on the engine

so that you can learn the exact engine operating

time, thereby performing the specified maintenance

at the appropriate time as described herein.

iv

FOREWORD

Warning Indication

The following signs and symbols are used to call attention of the operators and maintenance personnel to potential

dangers of the engine.

Warning statements in the manual

Warning labels affixed on the engine

Warning Statements

The warning statements in this manual describe potential danger in operating, inspecting or maintaining the engine,

using the following five classifications to indicate the degree of potential hazard.

Failure to follow these directions could lead to serious accidents which could result in personal injury, or death in the

worst case.

Understand the directions well, and handle engines by following directions.

Indicates an immediately hazardous situation which, if not avoided, will result in death or
serious injury.

Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.

Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury.

Indicates a potentially hazardous situation which, if not avoided, may result in property
damage.

Note: Indicates important information or information which is useful for engine operation.

v

FOREWORD

Units of Measurment

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

units in this manual. Conversion rates are as follows:

Pressure: 1 MPa = 10.197 kgf/cm

2

Torque: 1 N•m = 0.10197 kgf•m

Force: 1 N = 0.10197 kgf

Horsepower: 1 kW = 1.341 HP = 1.3596 PS

Rotation speed: 1 min

-1

= 1 rpm

Kinetic viscosity: 1 mm

2

/s = 1 cSt

Abbreviations, Standards and Others

 API = American Petroleum Institute

 ASTM = American Society for Testing and Materials

 ISO = International Organization for Standardization

 JIS = Japanese Industrial Standards

 LLC = Long Life Coolant

 MIL = Military Specifications and Standards

 MSDS = Material Safety Data Sheet

 SAE = Society of Automotive Engineers

CONTENTS-1

CONTENTS

Chapter 1
BASIC SAFETY PRECAUTIONS

Fire and Explosions.............................1-1

Keep Flames Away .......................................... 1-1

Always Place the Water Heater Switch in
the ON Position (Emergency Generator With

Water Heater).................................................. 1-1

Keep Engine Surrounding Area Tidy and

Clean................................................................ 1-1

Ventilation of Engine Room.............................. 1-1

Do Not Open Side Cover Until Engine Cools... 1-2
Watch Out for Leaks of Fuel, Oil and

Exhaust Gas..................................................... 1-2

Use Explosion-Proof Lighting Apparatus ......... 1-2

Prevent Electrical Wires From Short-Circuiting 1-2
Keep Fire Extinguishers and a First-Aid Kit

Handy............................................................... 1-2

Stay Clear of All Rotating and

Moving Parts........................................1-3

Install Protective Covers Around Rotating

Parts................................................................. 1-3

Check Work Area for Safety............................. 1-3

Stay Clear of Moving Parts During Operation.. 1-3

Lockout and Tagout ......................................... 1-3

Stop the Engine Before Servicing .................... 1-3

Always Restore Engine Turning Tools

After Use ......................................................... 1-3

Watch Out for Exhaust Fume

Poisoning.............................................1-4

Operate Engine in a Well-ventilated Area........ 1-4

Protect Ears From Noise .....................1-4

Wear Ear Plugs ................................................ 1-4

Watch Out for Falling Down.................1-4

Lift Engine Carefully......................................... 1-4

Do Not Climb Onto Engine............................... 1-4

Always Prepare Stable Scaffold....................... 1-4

Be Careful Not Burn Yourself ..............1-5

Do Not Touch the Engine During or Immediately

After Operation................................................. 1-5

Refill Coolant Only After the Coolant

Temperature Lowered...................................... 1-5

Be Careful of Burns When Changing Oil.......... 1-5

Never Remove Heat Shields............................ 1-5

Be Careful When Opening and Closing of

Radiator Cap .................................................... 1-5

Do Not Touch a High Pressure Fuel Jet .......... 1-5

Be Careful When Handling Fuel,

Engine Oil and Coolant (LLC)..............1-6

Use Only Specified Fuel, Engine Oil and LLC.. 1-6

Handle LLC Carefully ....................................... 1-6

Proper Disposal of Waste Oil, LLC and

Coolant............................................................ 1-6

If Problem Occurs ............................... 1-6

Stop Operation Immediately If You Notice

Any Unusual Symptoms ................................... 1-6

Do Not Add Coolant Immediately After a Sudden

Stop Due To Overheating ................................ 1-6

Avoid Restart Immediately After Abnormal

Stop................................................................. 1-6

Avoid Continuous Engine Operation at

Low Oil Pressure.............................................. 1-6

If Belt Breaks, Stop Engine Immediately .......... 1-6

Battery................................................. 1-7

Handle Battery Correctly .................................. 1-7

Other Cautions.................................... 1-8

Never Modify Engine ........................................ 1-8

Observe Safety Rules at Work Site.................. 1-8

Wear Clothing and Protective Gear ................. 1-8

Never Break Seals ........................................... 1-8

Perform All Specified Pre-operation Inspections

and Periodic Inspections .................................. 1-8

Break-in Engine................................................ 1-8

Warm-up Engine Before Use ........................... 1-8

Conduct Cooling Operation Before Stopping

the Engine ........................................................ 1-8

Never Operate the Engine Under Over Load... 1-9
Do Not Operate Engine Continuously Under Low

Load ................................................................. 1-9

Protection of Engine Against Water Entry ........ 1-9

Conduct Proper Maintenance of Air Cleaner or

Pre-cleaner....................................................... 1-9

Use of Tools Optimum for Each Work.............. 1-9

Avoidance of Prolonged Starting Operation..... 1-9

Do Not Turn Off the Battery Switch During

Operation ....................................................... 1-10

Precautions for Transporting Engines............ 1-10

Warning Labels ................................. 1-11

Maintenance of Warning Labels..................... 1-11

Chapter 2
NAME OF PARTS

Engine External Views ........................ 2-1

Front View ........................................................ 2-1

Rear View......................................................... 2-1

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

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

CONTENTS

CONTENTS-2

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

Start and Stop Instrument ................................ 2-3

Transmitters to Instruments ............................. 2-4

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

Thermo Switch ................................................. 2-5

Oil Filter Differential Pressure Alarm Switch .... 2-5

Air Cleaner Indicator ........................................ 2-5

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

Chapter 3
OPERATION

Operational Environment.....................3-1

Preparation for Operating New or

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

Preparation of Fuel System.............................. 3-1

Preparation of Lubrication System ................... 3-4

Preparation for Cooling System ....................... 3-5

Preparation of Electrical System ...................... 3-7

Test Operation ................................................. 3-9

Normal Engine Operation ..................3-10

Preparations for Operation ................3-10

Engine External - Inspect............................... 3-10

Fuel Tank Oil Level - Check........................... 3-10

Fuel Tank - Drain Water................................. 3-11

Fuel Control Link - Check............................... 3-11

Engine Oil Level - Check................................ 3-12

Coolant Level - Check.................................... 3-12

Air Cleaner - Check for Clogging ................... 3-13

Temperature of Damper - Check ................... 3-13

Starting-up.........................................3-14

Warm-up Operation...........................3-14

Engine Oil Pressure - Check.......................... 3-14

External Inspection During Warm-up ............. 3-14

Operation...........................................3-15

Cautions During Operation............................. 3-15

Inspection During Operation .......................... 3-15

Stopping ............................................3-16

Emergency Stop............................................. 3-16

Inspection After Stopping ............................... 3-16

Chapter 4
FUEL

Recommended Fuel ............................4-1

Handling Fuel ......................................4-1

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

Chapter 5
ENGINE OIL

Recommended Engine Oil .................. 5-1

Engine Oil Grade ................................ 5-1

Engine Oil Specifications .................... 5-2

Selection of Oil Viscosity..................... 5-3

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

Service Limits of Engine Oil ................ 5-4

Definition of Properties of Engine Oil .. 5-5

Kinetic Viscosity ............................................... 5-5

Base Number ................................................... 5-5

Acid Number .................................................... 5-5

Water Content .................................................. 5-6

Flash Point ....................................................... 5-6

Insolubles ......................................................... 5-6

Engine Oil Analysis Service ................ 5-7

Chapter 6
COOLANT

Recommended Water for Coolant ...... 6-1

Long Life Coolant (LLC)...................... 6-1

Genuine LLC....................................... 6-1

Other Brand LLCs ............................... 6-2

Requirements for Other Brand LLC .... 6-2

General Quality Requirements for LLC ............ 6-2

LLC Quality Requirements ............................... 6-3

Maintenance of LLC............................ 6-6

Replacement Intervals of LLC .......................... 6-6

LLC Concentration (GLASSY, PG GLASSY)... 6-7

Importance of LLC .............................. 6-8

Characteristics of LLC Additive and

Points to Remember ........................... 6-8

Examples of Abnormalities Caused by

LLC (Amine Type).............................. 6-8

Pitting of Iron Parts........................................... 6-8

Corrosion of Aluminum Parts ........................... 6-8

Pitting and Clogging of Radiator ...................... 6-8

Chapter 7
MAINTENANCE SCHEDULE

How to Use Maintenance Schedule.... 7-1

General Definition of Engine ............... 7-2

Periodic Maintenance Chart for

Regular (Prime) Use Engine ............... 7-3

CONTENTS-3

CONTENTS

Periodic Maintenance Chart for

Emergency Engine .............................7-5

Chapter 8
PERIODIC INSPECTION AND
MAINTENANCE PROCEDURES

Basic Engine........................................8-1

Engine External - Inspect................................. 8-1

Belt and Belt Tension - Inspect and Adjust ...... 8-2

Damper - Inspect.............................................. 8-5

Fuel System.........................................8-7

Fuel System - Inspect ...................................... 8-7

Fuel Tank - Clean............................................. 8-7

Fuel Tank - Drain Water................................... 8-7

Oil-water Separator - Drain Water.................... 8-8

Oil-water Separator Element - Replace ........... 8-8

Gauze Filter - Clean ......................................... 8-9

Fuel Filter - Replace....................................... 8-10

Fuel Control Link Ball Joint - Inspect.............. 8-11

Fuel Pipe - Inspect ......................................... 8-12

Lubrication System............................8-13

Engine Oil, Oil Filter and Bypass Oil Filter -

Replace.......................................................... 8-13

Fuel and Water Ingress In Engine Oil -

Inspect .......................................................... 8-16

Oil Pipe - Inspect............................................ 8-16

Cooling System .................................8-17

Coolant - Change ........................................... 8-17

Inlet and Exhaust Systems................8-21

Turbocharger - Inspect................................... 8-21

Pre-cleaner - Clean, Inspect and Replace ..... 8-21

Air Cleaner Element - Clean, Check and

Replace ......................................................... 8-22

Electrical System...............................8-24

Starter - Inspect.............................................. 8-26

Alternator - Inspect......................................... 8-26

Chapter 9
LONG-TERM STORAGE

Storing Engine in an Inoperable

Condition for 3 Months up to 1 Year....9-1

Preparation for Storage.................................... 9-1

Maintenance During Storage ........................... 9-2

When Using Engine After Storage ................... 9-2

Storing Engine in an Operable

Condition ............................................9-2

Operating Engine for Maintenance .................. 9-2

Chapter 10
TRANSPORTATION

Lifting Engine .................................... 10-1

Chapter 11
TROUBLESHOOTING

General Precautions ......................... 11-1

Contact a Dealer of Mitsubishi Heavy Industries,

Ltd. for Repair Service ................................... 11-1

Considerations Before Proceeding with

Corrective Action ............................................ 11-1

Cautions Against Contamination .................... 11-1

Cautions Regarding Parts Handling ............... 11-1

Safety Work.................................................... 11-1

Cases of Problems, and Probable

Causes and Solutions ....................... 11-2

The Starter Does not Crank or Cranks Slowly,

Resulting in Start Failure................................ 11-2

Starter Cranks, but Engine Does Not Start .... 11-3

Output Decrease ............................................ 11-4

Exhaust Smoke is White or Blue .................... 11-5

Exhaust Smoke is Black or Charcoal ............. 11-6

Fuel Consumption is High .............................. 11-7

Engine Oil Consumption is High .................... 11-8

Overheating.................................................... 11-9

Low Engine Oil Pressure.............................. 11-10

When Fuel has Run Out ................. 11-10

Chapter 12
MAIN SPECIFICATIONS

Main Specifications ........................... 12-1

CONTENTS

CONTENTS-4

List of Illustration

Fig. 1-1 Warning Labels .................................. 1-11

Fig. 2-1 Engine Front View ................................ 2-1

Fig. 2-2 Engine Rear View................................. 2-1

Fig. 2-3 Engine Left View .................................. 2-2

Fig. 2-4 Engine Right View ................................ 2-2

Fig. 2-5 Manual Stop Lever ............................... 2-3

Fig. 2-6 Stop Solenoid ....................................... 2-3

Fig. 2-7 Revolution Detection Pickup ................ 2-4

Fig. 2-8 Thermo Switch ..................................... 2-5

Fig. 2-9 Oil Filter Differential Pressure Alarm

Switch .................................................. 2-5

Fig. 2-10 Air Cleaner Indicator ............................ 2-5

Fig. 2-11 Manual Turning Gear Position

(While Engine is Running).................... 2-6

Fig. 2-12 Manual Turning Gear Position

(When Pushing Shaft in) ...................... 2-6

Fig. 2-13 Manual Turning Gear Position

(When Turning Shaft) ........................... 2-6

Fig. 3-1 Priming Pump - Operate ...................... 3-2

Fig. 3-2 Fuel Filter - Bleed Air............................ 3-2

Fig. 3-3 Fuel Injection Pump - Bleed Air............ 3-2

Fig. 3-4 Priming Pump Tightening Method ........ 3-3

Fig. 3-5 Priming Pump Head Packing ............... 3-3

Fig. 3-6 Oil Filler and Oil Level Gauge .............. 3-4

Fig. 3-7 Pouring Engine Oil on Valve Mechanisms

and Chamber........................................ 3-4

Fig. 3-8 Coolant Drain Cock (Engine)................ 3-5

Fig. 3-9 Coolant Drain Cock

(Engine water pump) ............................ 3-5

Fig. 3-10 Air Vent Plug (Engine Cooling System) 3-5

Fig. 3-11 Coolant Drain Cock (Air Cooler)........... 3-6

Fig. 3-12 Coolant Drain Cock

(Air Cooler water pump) ....................... 3-6

Fig. 3-13 Battery Electrolyte Level - Inspect........ 3-7

Fig. 3-14 Specific Gravity of Battery Electrolyte -

Check ................................................... 3-8

Fig. 3-15 Fuel Tank - Drain Water ..................... 3-11

Fig. 3-16 Check Fuel Control Link ..................... 3-11

Fig. 3-17 Oil Filler and Oil Level Gauge ............ 3-12

Fig. 3-18 Air Cleaner - Check for Clogging ....... 3-13

Fig. 3-19 Thermo Label of Damper ....................3-13

Fig. 3-20 Manual Stop Lever ..............................3-16

Fig. 5-1 Engine Oil Grade...................................5-1

Fig. 5-2 Selection of Oil Viscosity.......................5-3

Fig. 6-1 GLASSY - LLC ......................................6-1

Fig. 6-2 Coolant Freezing Temperature

(GLASSY, PG GLASSY).......................6-7

Fig. 8-1 Belt Tension (Alternator Side) - Adjust..8-2

Fig. 8-2 Belt Tension (Air Cooler water pump Side) -

Adjust ....................................................8-2

Fig. 8-3 Damper - Check Visually.......................8-5

Fig. 8-4 Damper Temperature Control ...............8-6

Fig. 8-5 Fuel Tank - Drain Water ........................8-7

Fig. 8-6 Water Separator - Drain Water..............8-8

Fig. 8-7 Water Separator Element - Replace .....8-8

Fig. 8-8 Gauze Filter - Clean ..............................8-9

Fig. 8-9 Fuel Filter - Replace ............................8-10

Fig. 8-10 Fuel Filter ............................................8-10

Fig. 8-11 Ball Joints Looseness - Inspect...........8-11

Fig. 8-12 Fuel Control Link - Remove.................8-11

Fig. 8-13 High Pressure Fuel Injection Pipe and

Clamp Seat - Inspect and Replace ....8-12

Fig. 8-14 Low Pressure Fuel Pipe and Clip -

Inspect.................................................8-12

Fig. 8-15 Oil Filter and Bypass Oil Filter -

Replace ...............................................8-14

Fig. 8-16 Oil Filter...............................................8-14

Fig. 8-17 Oil Filler and Oil Level Gauge .............8-15

Fig. 8-18 Oil Pipe and Clip - Inspect and

Replace ...............................................8-16

Fig. 8-19 radiator Cap .......................................8-17

Fig. 8-20 Coolant Drain Cock (Engine)...............8-18

Fig. 8-21 Coolant Drain Cock (water pump) .......8-18

Fig. 8-22 Coolant Drain Cock (Engine)...............8-19

Fig. 8-23 Coolant Drain Cock

(Engine water pump)...........................8-19

Fig. 8-24 Air Vent Plug (Engine Cooling

System) ...............................................8-19

Fig. 8-25 Coolant Drain Cock (Air Cooler)..........8-20

Fig. 8-26 Coolant Drain Cock

(Air Cooler water pump) ......................8-20

CONTENTS-5

CONTENTS

Fig. 8-27 Turbocharger - Inspect ....................... 8-21

Fig. 8-28 Pre-cleaner - Clean ............................ 8-21

Fig. 8-29 Air Cleaner Element - Remove........... 8-23

Fig. 8-30 Air Cleaner Element - Clean and

Check ................................................. 8-23

Fig. 8-31 Air Cleaner - Check for Clogging........ 8-23

Fig. 8-32 Battery Electrolyte Level - Inspect...... 8-24

Fig. 8-33 Specific Gravity of Battery Electrolyte -

Check ................................................. 8-25

Fig. 8-34 Starter - Inspect.................................. 8-26

Fig. 8-35 Alternator - Inspect............................. 8-26

Fig. 10-1 Lifting hangers.................................... 10-1

Fig. 10-2 Engine's Center of Gravity.................. 10-1

List of Table

Table 3-1 Specific Gravity of Electrolyte................3-8

Table 3-2 Standard values at rated speed ..........3-15

Table 4-1 Recommended Fuel..............................4-1

Table 4-2 Recommended Limit and Use Limit of

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

Table 5-1 Table of Recommended Limit of

Engine Oil Properties ...........................5-2

Table 5-2 Table of Engine Oil Properties ..............5-4

Table 6-1 Water quality standards ........................6-1

Table 6-2 LLC Quality Requirements ....................6-3

Table 6-3 Recommended LLC Concentration .......6-7

Table 7-1 Periodic Maintenance Chart for

Continuous Use Engine ........................7-3

Table 7-2 Periodic Maintenance Chart for

Emergency Engine................................7-5

Table 8-1 Ribbed Belt Tension Force....................8-3

Table 8-2 Types of Thermo Labels .......................8-6

Table 8-3 Specific Gravity of Electrolyte..............8-25

Table 9-1 Table of Recommended Rust-Preventive

Oil and Corrosion Inhibitor ....................9-1

Table 11-1 The Starter Does not Crank or Cranks

Slowly, Resulting in Start Failure.........11-2

Table 11-2 The Starter Cranks, but the Engine

Does Not Start.....................................11-3

Table 11-3 Output decrease..................................11-4

Table 11-4 Exhaust Smoke is White or Blue.........11-5

Table 11-5 Exhaust Smoke is Black or Charcoal ..11-6

Table 11-6 Fuel Consumption is High ...................11-7

Table 11-7 Engine Oil Consumption is High..........11-8

Table 11-8 Overheating.........................................11-9

Table 11-9 Low Engine Oil Pressure...................11-10

Table 12-1 Main Specifications .............................12-1

1-1

Chapter 1 BASIC SAFETY PRECAUTIONS

Fire and Explosions

Keep Flames Away

Do not use flames near the engine (in

the engine room). Fuel gas vapor or

other gas can catch fire and produces

hazardous situations.

Wipe off spilled fuel, oil and LLC

immediately and thoroughly. Spilled fuel, oil and LLC

may ignite and cause a fire.

Store fuel and engine oil in a well-ventilated area.

Make sure that the caps of fuel and engine oil contain-

ers are tightly closed.

Always Place the Water Heater
Switch in the ON Position
(Emergency Generator With
Water Heater)

Always place the water heater switch in the ON (auto-

matic mode) position throughout the year.

If the switch is not placed in the ON position (auto-

matic mode), each cylinder varies considerably in

combustion and abundant white exhaust gas gener-

ates at the starting up the engine. Unburned fuel may

explode in the exhaust pipe.

Keep Engine Surrounding Area
Tidy and Clean

Do not leave combustible or explosive materials, such

as fuel, engine oil and LLC, near the engine. Such

substances can cause fire or explosion.

Remove dust, dirt and other foreign materials accu-

mulated on the engine and surrounding parts. Such

materials can cause a fire or the engine to overheat.

In particular, clean the top surface of the battery. Dust

can cause a short-circuit.

Always operate the engine at a position at least 1 m

[3.28 ft.] away from buildings and other equipment to

prevent possible fire caused by engine heat.

Ventilation of Engine Room

Always provide adequate ventilation in the engine

room. Insufficient air in the room can cause an

increase in the engine temperature and a decrease in

the output power and performance. It is highly recom-

mended to calculate the required amount of air supply

to the engine and install an adequate ventilation sys-

tem before installing the engine.

1-2

Chapter 1 BASIC SAFETY PRECAUTIONS

Do Not Open Side Cover Until
Engine Cools

Do not attempt to open the side cover of the Crank-

case before the engine cools down. Wait at least 10

minutes after stopping the engine.

Opening the cover when the engine is hot causes

fresh air to flow into the Crankcase, which can cause

oil mist to ignite and explode.

Watch Out for Leaks of Fuel, Oil
and Exhaust Gas

If any fuel, oil or exhaust gas leak is found, immedi-

ately stop the engine. After the engine has completely

cooled, repair the leak.

If oil/fuel is sprayed or leaking onto hot surfaces of the

engine, or if exhaust gas comes in contact with flam-

mable materials, it may ignite and you could burn

yourself or it may cause damage to the engine.

Use Explosion-Proof Lighting
Apparatus

When inspecting fuel, engine oil, cooling water, bat-

tery electrolyte, etc., use a flameproof light. An ordi-

nary lighting apparatus may ignite gas and cause it to

explode.

Prevent Electrical Wires From
Short-Circuiting

Avoid inspecting or servicing the electrical system with

the ground cable connected to the battery. Otherwise,

a fire could result from short-circuiting. Be sure to dis-

connect the battery cable from the negative (-) termi-

nal before proceeding with work.

Short-circuits, which possibly resulting in fire, can be

caused by a loose terminal or damaged cable/wire.

Inspect terminals, cables and wires, and repair or

replace faulty parts before proceeding with work.

Keep Fire Extinguishers and a
First-Aid Kit Handy

Keep fire extinguishers handy, and

become familiar with their usage.

Keep a first-aid kit at the designated

place where it is easily accessible by

anyone at any time.

Establish response procedures to follow in the event

of fire or accident. Provide an emergency evacuation

route and contact points and means of communication

in case of emergency.

1-3

Chapter 1 BASIC SAFETY PRECAUTIONS

Stay Clear of All Rotating and Moving Parts

Install Protective Covers
Around Rotating Parts

Make sure the protective covers of

the engine are correctly installed.

Repair any damaged or loose covers.

Do not remove the protective covers

of the rotating parts during operation.

When the engine is coupled to the radiator or other

equipment, install protective covers around the

exposed connecting belt and coupling.

Never remove protective covers.

Check Work Area for Safety

Before starting the engine, make sure no one is near

the engine and tools are not left on or near the engine.

Alert people in the area when starting the engine.

When the starter device is posted with a sign that pro-

hibits startup operation, do not operate the engine.

Stay Clear of Moving Parts Dur­ing Operation

Stay away from rotating parts of the

engine while the engine is running.

Do not place any objects, which might

be easily caught in rotating parts,

near the rotating parts.

If any part of the clothing or tool is caught in rotating

parts, it could result in serious injury or death.

Lockout and Tagout

Be sure to lockout/tagout before starting inspection

and maintenance work.

Lockout and tagout are effective methods of cutting off

machines and equipment from energy sources.

To accomplish the lockout/tagout, remove the starter

switch key, place the battery switch to the OFF posi-

tion and attach a "DO NOT OPERATE" or similar cau-

tion tag to the starter switch.

The starter switch key must be kept by the person

who performs inspection and maintenance during the

work.

Stop the Engine Before Servic­ing

Be sure to stop the engine before proceeding with

inspection and maintenance work. Never attempt to

make adjustments on the engine parts while the

engine is running.

Entanglement in rotating parts can result in serious

injury or death.

Always Restore Engine T urning
Tools After Use

Be sure to remove all turning tools after maintenance

and inspection work. Remember also that the manual

turning gear shaft must be pulled out before starting

the engine.

Starting the engine with the turning tools inserted or

with the turning gear in engagement can lead to not

only engine damage but also personal injuries.

1-4

Chapter 1 BASIC SAFETY PRECAUTIONS

Watch Out for Exhaust
Fume Poisoning

Operate Engine in a Well-venti­lated Area

Check exhaust pipes and pipe joints

for gas leaks.

Exhaust gas from the engine may

contain harmful substances. Operat-

ing the engine in a poorly-ventilated

area can cause gas poisoning.

Protect Ears From Noise

Wear Ear Plugs

Always wear ear plugs when entering

the machine room (engine room).

Combustion sound and mechanical

noise generated by the engine can

cause hearing problems.

Watch Out for Falling
Down

Lift Engine Carefully

To lift the engine, use slings capable

of supporting the weight of the

engine.

Hitch proper slings to the hangers

provided on the engine to lift the

engine.

During the lifting process, keep the engine in a well-

balanced position by paying attention to the center of

gravity of the engine.

The hangers equipped on the engine are designed for

lifting the engine only. When coupling the generator to

the engine, use the special hangers provided on the

common bed. Hangers of engine cannot be used.

Keep the angle formed by slings that is attached to

hangers within 60 degrees. If the angle exceeds this

limit, excessive load could be imposed on the hangers

and this could damage the hangers and result in a

serious accident.

Attach wire ropes to the hangers after removing pipe

covers and insulators near the hangers.

If the sling contacts the engine parts directly, place a

cloth or other soft padding to avoid damage to the

engine parts and sling. Depending on circumstances,

remove the engine parts.

Do Not Climb Onto Engine

Do not climb onto the engine, nor step on any engine

parts, which located on the lateral sides.

When working in a high place such as the upper part

of engine use a step, or other work platform, and be

careful not to fall off.

Climbing on the engine may not only damage engine

parts but also cause a falling-down accident which

can result in a personal injury.

Always Prepare Stable Scaffold

When working on the upper part of
the engine and other hard-to-reach
places, use a stable work platform.
Standing on a decrepit stool or parts
box may result in personal injury.
Do not put any unnecessary objects
on a work platform.

1-5

Chapter 1 BASIC SAFETY PRECAUTIONS

Be Careful Not Burn Your­self

Do Not Touch the Engine Dur­ing or Immediately After Opera­tion

Do not touch any part of the engine

during or immediately after opera-

tion. You could burn yourself.

To conduct maintenance and inspec-

tion work, wait until the engine has

cooled sufficiently by checking the temperature with

the temperature gauge.

Refill Coolant Only After the
Coolant Temperature Lowered

When adding coolant, make sure that coolant temper-

ature is sufficiently lowered using temperature gauge.

Adding coolant immediately after engine shutdown

may result in burns.

Be Careful of Burns When
Changing Oil

Before draining oil or changing oil filters, wear leather

gloves or be sure to check the engine temperature. If

hot oil or parts touch your skin, it can cause burns.

Never Remove Heat Shields

The exhaust system, which becomes extremely hot

while the engine is operating, is provided with various

heat shields. Do not remove these heat shields. If any

of these heat shields have been removed owing to

unavoidable circumstances during the work, be sure

to restore them after the work is completed.

Be Careful When Opening and
Closing of Radiator Cap

Never open the radiator cap while the engine is run-

ning or immediately after stopping. Stop the engine

and open the cap after the coolant temperature lowers

sufficiently.

To open the radiator cap, open slowly to discharge the

pressure inside the tank.

The coolant is hot while the engine is running and

immediately after stopping. If the cap is opened when

the coolant is at an operating temperature, steam and

hot coolant may blow out and result in burns. To avoid

a risk of getting scalded by steam, wear thick rubber

gloves or wrap a cloth around the cap.

When fastening the radiator cap, be sure to tighten

securely.

Do Not Touch a High Pressure
Fuel Jet

If fuel leaks or sprays out from the high pressure injec-

tion pipe, do not touch the fuel jet.

Fuel in the fuel injection pipes is under a high pres-

sure and if the fuel contact your skin, it goes into deep

skin tissues and may result gangrene.

1-6

Chapter 1 BASIC SAFETY PRECAUTIONS

Be Careful When Handling
Fuel, Engine Oil and Cool­ant (LLC)

Use Only Specified Fuel,
Engine Oil and LLC

Use fuel, oil and Coolant (LLC) specified in this man-

ual, and handle them carefully.

Use of any other fuel, gas, oil or LLC than the speci-

fied ones, or improper handling may cause various

engine problems and malfunctions.

Obtain the MSDS issued by the oil and LLC suppliers,

and follow the directions in the MSDS for proper han-

dling.

Handle LLC Carefully

When handling LLC, always wear rubber gloves, a

protective face mask and protective eyeglasses. If

LLC or cooling water containing LLC comes into con-

tact with your skin or eyes, or if it is swallowed, you

would suffer from inflammation, irritation or poisoning.

Should coolant (LLC) be accidentally swallowed,

induce vomiting immediately and seek medical atten-

tion. Should coolant (LLC) enter your eyes, flush them

immediately with plenty of water and seek medical

attention. If coolant (LLC) splashes onto your skin or

clothing, wash it away immediately with plenty of

water.

Keep flames away from LLC. LLC is highly flammable

and can easily catch a fire if exposed to a flame.

Proper Disposal of Waste Oil,
LLC and Coolant

Do not discharge waste engine oil, LLC and coolant

into sewerage, river, lake or other similar places. Such

a way of disposal is strictly prohibited by laws and reg-

ulations.

Dispose of waste oil, LLC and coolant and other envi-

ronmentally hazardous waste in accordance with the

applicable laws and regulations.

If Problem Occurs

Stop Operation Immediately If
You Notice Any Unusual Symp­toms

Stop the operation immediately if you notice any

unusual noise, odor or vibration. In case of emer-

gency, press the emergency stop button to stop the

generator set. Contact your local dealer if the cause of

problem cannot be located after stopping the genera-

tor. Continuous operation neglecting an unusual

symptom could cause serious or fatal accident.

Do Not Add Coolant Immedi­ately After a Sudden Stop Due
To Overheating

If the engine stops suddenly or if you have no choice

but stop the engine suddenly due to overheating, do

not add coolant immediately.

Adding water while the engine is hot may cause dam-

age to cylinder heads, etc. due to a sudden drop of

temperature. Add coolant gradually after the engine

has completely cooled.

Avoid Rest art Immediately After
Abnormal Stop

After abnormal stop, do not restart immediately. If the

engine stops because of abnormality, check and rem-

edy the cause of the problem before starting again.

Continued operation of the engine without proper

repairs and maintenance could result in serious

engine problems.

Avoid Continuous Engine Oper­ation at Low Oil Pressure

When abnormal engine oil pressure drop is observed,

stop the engine immediately, and inspect the lubrica-

tion system to locate the cause. Continued engine

operation could cause bearings and other parts to

seize.

If Belt Breaks, Stop Engine
Immediately

If the belt breaks, stop the engine immediately and

replace the belt. Continued use of the engine without

any remedy could cause charging failure or cooling

failure, and result in serious engine problems.

1-7

Chapter 1 BASIC SAFETY PRECAUTIONS

Battery

Handle Battery Correctly

Never use flames or allow sparks

near the battery. The battery

releases flammable hydrogen gas

and oxygen gas. Any flames or

sparks in the vicinity could cause an explosion.

Do not use the battery when the battery electrolyte

level is below the "LOWER LEVEL" mark. Continual

use may result in an explosion.

Do not short the battery terminals with a tool or other

metal object.

When removing battery, always remove the plug from

the negative (-) terminal first. When connecting bat-

tery, always connect the plug to the positive (+) termi-

nal first.

Remove all battery cables, then charge the battery in

a well ventilated area.

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 conducting

electric welding, set the battery switch to [Open/OFF]

position or remove the plug from the negative (-) ter-

minal to cut off the electrical current.

Battery electrolyte contains dilute sulfuric acid. Care-

less handling of the battery can lead to loss of sight

and/or skin burns. Also, do not swallow the battery

electrolyte.

Wear protective goggles and rubber gloves when

working with the battery (e.g. when adding water or

charging battery).

If battery electrolyte is spilled onto the skin or clothing,

immediately wash it away with lots of water. Use soap

to thoroughly clean.

The battery electrolyte can cause sight loss if splash-

ing into your eyes. If it gets into your eyes, immediate-

ly flush it away with plenty of clean water, and seek

immediate medical attention.

If you accidentally swallow battery electrolyte, gargle

with plenty of water and then drink lots of water, and

seek immediate medical attention.

If the battery does not fully recover after 24 hours

charging or more, do not use the battery.

1-8

Chapter 1 BASIC SAFETY PRECAUTIONS

Other Cautions

Never Modify Engine

Unauthorized modification of the engine will void your

warranty.

Modification of the engine may not only cause dam-

age to the engine but also may result in personal

injury.

If you have to modify the engine, please contact your

local dealer.

Observe Safety Rules at Work
Site

Observe the safety rules established at your work-

place.

Do not operate the engine if you are not feeling well,

and inform your supervisor of your condition. Opera-

tion of the engine with reduced awareness may cause

improper operation that could result in accidents.

When working in a team for two or more people, use

specified hand signals to communicate among work-

ers.

Wear Clothing and Protective
Gear

Wear a hardhat, face shield, safety shoes, dust mask,

gloves, ear plugs and other protective gear as

needed. When handling compressed air, wear safety

goggles, a hardhat, gloves and other necessary pro-

tective gear. Working without wearing proper protec-

tive gear could result in serious injuries.

Never Break Seals

To ensure proper engine operation, the fuel control

links are sealed to prevent accidental change of the

injection volume and rotation speed settings. Remov-

ing these seals of the engine set will void the war-

ranty. The following problems may occur if these seals

are removed.

 Rapid wear of sliding and rotating parts.

 Failure due to seizure or damage of parts.

 Considerably increased consumption of fuel and lu-

bricating oil.

 Degradation of performance due to improper balance

between fuel injection volume and governor operation

or overrunning, which could result in a serious acci-

dent.

Perform All Specified Pre-oper­ation Inspections and Periodic
Inspections

Conduct pre-operation inspections and periodic

inspections as described in this manual.

Failure to conduct specified inspections may cause

various engine problems and damage to parts, which

may result in serious accidents.

Break-in Engine

For the first 50 hours of a new or overhauled engine,

operate the engine under a light load for break-in

operation.

Operating new engines or overhauled engines in a

severe condition during the break-in period shortens

the service life of the engine.

Warm-up Engine Before Use

After starting the engine, run the engine at a low idling

speed until the coolant temperature become approx

50°C [122°F]. Start the actual work after this operation

is completed. Warm-up operation circulates the lubri-

cant through the engine, and thereby, individual

engine parts are well lubricated before they are sub-

jected to heavy loads.

Warm-up operation circulates lubricant oil through the

engine and contributes to a longer service life and

economical operation.

However, do not perform the warm-up operation for

longer than necessary. Prolonged warm-up operation

causes carbon build-up in the cylinders that leads to

incomplete combustion.

Conduct Cooling Operation
Before Stopping the Engine

Before stopping the engine, operate the engine at low

idling speed for 5 to 6 minutes to cool down.

Stopping the engine immediately after high-load oper-

ation will cause engine parts to heat up and shorten

the service life of the engine.

During cooling operation, check the engine for abnor-

malities.

1-9

Chapter 1 BASIC SAFETY PRECAUTIONS

Never Operate the Engine
Under Over Load

If overload symptoms such as black exhaust smoke is

observed, reduce the load immediately and assure the

proper output and load.

Overloading causes not only high fuel consumption

but also excessive carbon deposits. Carbon deposits

cause various problems and will shorten the service

life of the engine.

Do Not Operate Engine Contin­uously Under Low Load

When operating the engine with less than 30 % of

rated load, limit each operation to an hour. Prolonged

warm-up operation causes carbon build-up in the cyl-

inders that leads to incomplete combustion. Operate

the engine with a 30 % of rated load or more for over 5

minutes to prevent carbon build-up after one hour

continuous operation is conducted.

Protection of Engine Against
Water Entry

Do not allow rainwater, etc. to enter the engine

through the air inlet or exhaust ports.

Do not wash the engine while it is running. Cleaning

fluid (water) can be sucked into the engine.

Starting the engine with water inside the combustion

chambers can cause the water hammer action which

may result in internal engine damage and serious

accidents.

Conduct Proper Maintenance of
Air Cleaner or Pre-cleaner

Pay attention to the Air Cleaner or Pre-cleaner main-

tenance.

Never service the air cleaner while the engine is run-

ning.The turbocharger may suck particles of foreign

materials into the engine and could result in serious

accidents.

Remove the air cleaner slowly to prevent foreign ma-

terials accumulated on the element from falling off. Af-

ter removing the air cleaner or pre-cleaner,

immediately cover the opening (inlet port of air clean-

er; port in body for pre-cleaner) with plastic sheet or

similar means to prevent foreign materials from enter-

ing the engine.

Wash pre-cleaner periodically. The pre-cleaner clog-

ging can cause insufficient intake air or increase of the

exhaust temperature.

If the engine is equipped with a dust indicator, con-

duct maintenance when a warning sign of a clogging

appears.

Use of Tools Optimum for Each
Work

Always keep in mind to select most appropriate tools

for the work to be performed and use them correctly. If

tool is damaged, replace it with new one.

Avoidance of Prolonged Start­ing Operation

Do not use the starter for more than 10 seconds at a

time. If the engine does not start, wait for at least 1

minute before cranking again.

Continuous operation of the starter will drain the bat-

tery power or cause the starter to seize.

1-10

Chapter 1 BASIC SAFETY PRECAUTIONS

Do Not Turn Off the Battery
Switch During Operation

Do not turn off the battery switch during operation.

If the battery switch is turned OFF when the engine is

running, it stops the operation of meters and also may

deteriorate alternator diode and transistor.

Precautions for Transporting
Engines

When transporting the engine on a truck, consider the

engine weight, width and height to ensure safety.

Abide by road traffic law, road vehicles act, vehicle

restriction ordinance and other pertinent laws.

1-11

Chapter 1 BASIC SAFETY PRECAUTIONS

Warning Labels

Maintenance of Warning Labels

Make sure all warning/caution labels are legible.

Clean or replace the warning/caution labels when the description and/or illustration are not clear to read.

For cleaning the warning/caution labels, use a cloth, water and soap. Do not use cleaning solvents, gasoline or

other chemicals to prevent the letters from getting blurred or the adhesion from being weakened.

Replace damaged or fractured labels with new ones.

If any engine part on which a warning label is attached is replaced with a new one, attach a new identical warning

label to the new part.

To obtain new warning labels, contact your local dealer.

Fig. 1-1 Warning Labels

6*'4'+5('#41(#(+4'

6 * ' 4 '  + 5  ( ' # 4  1 (  #  ( + 4 ' 

#

#   

241*+$+6+10

241*+$+6+10

2.'#5'&1016$4+0)

2 . ' # 5 '  & 1  0 1 6  $ 4 + 0 )

(+4'%.15'

( + 4 '  % . 1 5 ' 

2-1

Chapter 2 NAME OF PARTS

Engine External Views

Front View

Fig. 2-1 Engine Front View

Rear View

Fig. 2-2 Engine Rear View

Aircooler coolant outlet

Thermostat

Aircooler water pump

Aircooler water pump
coolant drain cock

Oil pump

Engine water pump

Engine coolant outlet

Damper

Governor actuator

Turbocharger

Turbocharger

Exhaust gas outlet

Flywheel

O

I

T

A

O

R

N

T

2-2

Chapter 2 NAME OF PARTS

Left View

Fig. 2-3 Engine Left View

Right View

Fig. 2-4 Engine Right View

Rear

Starter

Front hanger

Oil filter alarm switch

Fuel filter

Aircooler
coolant inlet

Front accessory
drive

Bypass oil filter

Oil filter

Rear hanger

Intake air inlet

Manual stop lever

Fuel feed pump

Engine coolant
drain cock
(Behind of coupling cover)

Fuel injection pump

Front

Rear hanger

Fuel filter

Front hanger

Alternator

Engine coolantinlet

Breather

Fuel injection pump

Fuel feed pump

Engine coolant
drain cock
(Behind of coupling cover)

Stop solenoid

Intake air inlet

Rear

Front

Oil filler

Oil level gauge

2-3

Chapter 2 NAME OF PARTS

Equipment and Instrument

The installed equipment and shapes vary with specifications.

Start and Stop Instrument

Manual Stop Lever

A manual stop lever is equipped so that you can stop

the engine in the event of an emergency and also for

the use when the engine will not stop by the stop but-

ton.

You can stop the engine by moving the manual stop

lever, which is located in the fuel control link, in the

"STOP" direction.

If the engine continues to run even after the manual

stop lever is moved to the "STOP" position, cut off the

fuel supply to the engine.

Fig. 2-5 Manual Stop Lever

Stop Solenoid

The stop solenoid is used for normal shutdown of

engine operation.

The stop solenoid moves the rack of fuel injection

pump to cut the fuel so that the engine stops.

The RUN ON type stop solenoid is equipped in this

engine. The stop solenoid is energized while the

engine is running. To stop the engine, it is de-ener-

gized by breaking contact between governor power

and electrical circuit.

Fig. 2-6 Stop Solenoid

When stopping the engine with manual stop lever,

keep the manual stop lever at the stop position until

the engine completely stops. If you release the lever

before the engine completely stops, the engine may

restart.

STOP

2-4

Chapter 2 NAME OF PARTS

Transmitters to Instruments

This section describes about devices which transmit signals to instruments for operation. Read carefully and under-

stand functions of each device.

Revolution Detection Pickup

Located on the timing gear case, and detects engine

speed at all times.

Fig. 2-7 Revolution Detection Pickup

2-5

Chapter 2 NAME OF PARTS

Engine Protection Devices

The engine protection devices activate an alarm when an abnormality occurs in the engine in order to protect the

engine and prevent serious problems and accidents. When a protection device is activated, stop the engine, exam-

ine the cause of the abnormality, and take corrective measures. If you cannot find the cause of the problem, contact

your local dealer. Protection devices installed on the engine and their types (setting values) and shapes vary

depending on the engine specifications.

Thermo Switch

The oil pressure switch generates an alarm when the

engine coolant temperature becomes high and

reaches the specified temperature.

Fig. 2-8 Thermo Switch

Oil Filter Differential Pressure Alarm Switch

The oil filter alarm switch generates an alarm to stop

the engine when the difference in pressure across the

filter reaches the specified lever due to filter clogging.

Fig. 2-9 Oil Filter Differential Pressure Alarm Switch

Air Cleaner Indicator

If the element is clogged, the intake air is decreased

and the red signal mark will be displayed. The signal

indicates only, and does not generate an alarm,

Therefore, the periodic visually inspection is needed.

Press the reset button on the top of air cleaner indica-

tor and restore the signal after cleaned the air cleaner

indicator or replaced with a new one.

Fig. 2-10 Air Cleaner Indicator

Thermo switch

Oil filter alarm switch

Reset button

Signal
(red)

2-6

Chapter 2 NAME OF PARTS

Using Manual Turning Gear

1. Loosen two bolts, and remove the plate from the

shaft groove.

Fig. 2-11 Manual Turning Gear Position

(While Engine is Running)

2. Push the shaft fully to engage it with the ring gear.

Fig. 2-12 Manual Turning Gear Position

(When Pushing Shaft in)

3. Using a socket wrench and a ratchet handle, turn

the shaft.

4. After turning, pull out the shaft, insert the plate in

the shaft groove, and tighten the bolts.

Fig. 2-13 Manual Turning Gear Position

(When Turning Shaft)

Before starting the engine, make sure that the turning gear is pulled out in the original position. Starting the engine

with the turning gear pushed in not only damages the ring gear but also may result in personal injury.

Bolt

Bolt

Plate

Shaft

Make sure the plate is securely installed in the shaft

groove.

Socket

Ratchet handle

3-1

Chapter 3 OPERATION

Operational Environment

Preparation for Operating New or Overhauled Engine

Before proceeding with operation of a new or overhauled engine, conduct the inspections described in this section.

For second operation onward, follow the instructions described in the "Normal Engine Operation" (3-10)

Preparation of Fuel System

1. Make sure the inside of the fuel tank and the fuel supply pipes to the engine are thoroughly clean.

2. Close the fuel tank drain valve.

3. Fill fuel tank with fuel.

4. Remove the fuel feed pipe, and check the discharged fuel for foreign materials such as dust.

5. Install the fuel supply pipe to the engine fuel inlet port.

6. After the contact of the float switch is checked, add fuel to "FULL" level.

Check that the following contents are performed before the engine is operated. Failure to do so may cause various

problems and will shorten the service life of the engine.

Prevent from spreading water (especially, seawater or rainwater) and entering foreign materials to the air inlet

opening.

Prevent from entering foreign materials to the rotating parts.

Prevent from attaching water and dust to the electrical system.

Use the engine at 5 to 40 °C [41 to 104 °F].

Keep the coolant temperature properly by switching ON the water heater (automatic mode). (Emergency generator

with water heater)

When handling fuel, make sure there are no open flames or other fire hazards near the engine.

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

Do not remove the strainer during fuel tank filling.

For fuel to be used, refer to "FUEL" (4-1)

3-2

Chapter 3 OPERATION

Fuel System - Bleed Air

When bleeding the fuel system, start with the compo-

nent closest to the fuel tank, that is, from the oil-water

separator to fuel filter to fuel injection pump.

Bleeding air from the oil-water separator differs

depending on fuel piping. Bleed air in an appropriate

way.

Bleed air from fuel filter or fuel injection pump using

priming pump.

Fig. 3-1 Priming Pump - Operate

Fuel Filter - Bleed Air

1. Loosen the air vent plug of the fuel filter about 1.5

turns.

2. Move the priming pump up and down to feed fuel.

3. When the fuel from the air vent plug becomes free

from air bubbles, stop priming and tighten the air

vent plug to the specified torque.

Fig. 3-2 Fuel Filter - Bleed Air

Fuel Injection Pump - Bleed Air

1. Loosen the air vent plug on the fuel injection pump

by rotating about 1.5 turns.

2. Move the priming pump up and down. When the

fuel flow from the air vent plug becomes free of

bubbles, turn the priming pump clockwise while

pushing it to lock.

3. Tighten the air vent plug on the fuel injection pump.

Fig. 3-3 Fuel Injection Pump - Bleed Air

When fuel overflows from the air vent plug, wipe

thoroughly with a cloth. Spilled fuel can cause a fire.

After air bleeding, lock the priming pump securely. If

the cap is not locked tightly, the priming pump can be

damaged, causing a fuel leak that could lead to a

fire.

[Unlock] [Prime] [Lock]

Turn counterclockwise

Move cap up
and down

Turn clockwise
while pressing

If air vent plugs, the thread portion of the bracket, or

sealing washers are damaged, replace them with

new ones.

Air vent plug

Tightening torque

8.8 ± 1 N·m
{0.9 ± 0.1 kgf·m}
[6.4 ± 0.7 lbf·ft]

Air vent plug
15 ± 2 N·m
{1.53 ± 0.20 kgf·m}
[11.06 ± 1.48 lbf·ft]

3-3

Chapter 3 OPERATION

Priming Pump Tightening Method

1. Gently tighten the priming pump by hand, and

make a mark indicating the seating position.

2. Using a wrench or another appropriate tool, further

tighten the priming pump by 90±10°.

3. Check the mounting position of head packing.

Note: If the head packing has abnormality such as de-

formation or scratches, the priming pump should

be replaced. Consult a dealer of Mitsubishi

Heavy Industries, Ltd. for replacement of the

priming pump.

Fig. 3-4 Priming Pump Tightening Method

Fig. 3-5 Priming Pump Head Packing

Never fail to tighten the priming pump to the speci-

fied angle. If the priming pump is not firmly tightened,

internal thread will be worn due to engine vibration,

resulting in sudden ejection of the cap to cause fuel

flow-out. Or if the priming pump is excessively tight-

ened, the head of the priming pump can be dam-

aged.

Position where
the sheet has
been seated.

Head section can be
damaged when
overtightened

90 ±10°

Head packing

3-4

Chapter 3 OPERATION

Preparation of Lubrication System

Engine Oil - Filling

1. Remove the oil filler cap.

2. Add the specified engine oil to the specified level.

Note: For engine oil, refer to "ENGINE OIL" (5-1). For

engine oil capacity, refer to "MAIN SPECIFICA-

TIONS" (12-1).

3. Remove the rocker cover of every cylinder, and

pour engine oil to the valve mechanism and cam-

shaft oil bath.Pour engine oil to the camshaft oil

bath from cylinder head side.

Oil capacity per cylinder: 0.8 L [0.21 U.S. gal.]

4. Reinstall the rocker covers.

5. Check the oil level in oil pan as follows:

6. Pull out the oil level gauge and wipe it clean with a

cloth.

7. Insert the oil level gauge fully into the oil level

gauge guide and then pull it out again.

8. The oil level should be between the maximum and

minimum marks on the oil level gauge.If the oil lev-

el is low, add the specified engine oil.

9. Check the oil pan, etc., for oil leaks.Repair if there

is oil leak.

10. With the stop knob placed in pulled position, rotate

the engine with starter for approx. 10 seconds to

circulate oil to the whole engine. Stop the rotation

for 1 minute, then, repeat the rotation two or three

times to circulate the engine oil to each engine

parts.

Note: Also perform the Preparation of Cooling System

described below.

11. Start the engine and run at a no-load and low-idling

condition for 5 to 10 minutes.

12. Stop the engine, and after 30 minutes or more has

elapsed, check the oil level with the oil level gauge

again and add oil to the specified level.

For details, refer to"Test Operation" (3-9).

Fig. 3-6 Oil Filler and Oil Level Gauge

Fig. 3-7 Pouring Engine Oil on Valve Mechanisms and

Chamber

Refill the engine with the specified engine oil to the

specified level.If the oil level is higher than the maxi-

mum mark on the level gauge, engine oil may blow

out during operation.Also, the increase of oil temper-

ature could adversely affect engine components.

H

L

Oil filler

Oil level gauge

Oil level gauge

High

Low

Improper

Improper

Proper

Camshaft
oil bath

3-5

Chapter 3 OPERATION

Preparation for Cooling System

Coolant - Refill (Engine)

Note: If the specification of radiator differs from the

contents of this operation manual, follow the

manufacturer's operation manual.

1. Make sure coolant drain cocks are closed securely.

2. Remove the radiator cap, and add a mixture of wa-

ter and LLC of the specified concentration to the

specified level.

Note: (a) Determine the quantities of LLC based on the

coolant capacity and the LLC concentration

chart.

For the coolant, refer to "COOLANT" (6-1).

For the coolant capacity, refer to "MAIN

SPECIFICATIONS" (12-1).

(b) For absolute air bleeding, loosen the air vent

plug.

3. Check the radiator and other parts for coolant

leaks. Repair leakage if found.

4. When coolant reaches the specified level, close the

radiator cap securely.

5. With the manual stop lever placed in the pulled po-

sition, crank the engine for approx 10 seconds us-

ing the starter. Stop cranking for 1 minute, then,

repeat the cranking two or three times to bleed the

cooling system.

Note: Prepare for the lubricating system and refilling

the coolant to the Air Cooler.

6. Check the coolant level in the radiator.

Fig. 3-8 Coolant Drain Cock (Engine)

Fig. 3-9 Coolant Drain Cock

(Engine water pump)

Fig. 3-10 Air Vent Plug (Engine Cooling System)

When adding coolant, use the same LLC concentra-

tion coolant that is currently in the cooling system.

Coolant

drain cocks

Left side

Right side

The coolant drain cocks located in the crankcase
(behind the each fuel injection pump
accessory drive unit respectively).

Coolant
drain cock

Air vent plug

3-6

Chapter 3 OPERATION

Coolant - Refill (Air Cooler)

Note: If the specification of radiator differs from the

contents of this operation manual, follow the

manufacturer's operation manual.

1. Make sure coolant drain cocks are closed securely.

2. Remove the radiator and add a mixture of water

and coolant having the specified concentration.

Note: (a) Determine the quantities of LLC based on the

coolant capacity and the LLC concentration

chart.

For the coolant, refer to "COOLANT" (6-1).

For the coolant capacity, refer to "MAIN

SPECIFICATIONS" (12-1).

(b) For absolute air bleeding, loosen the air vent

plug.

3. Check the radiator and other parts for coolant

leaks. Repair leakage if found.

4. When coolant reaches the full level, close the cool-

ant filler securely.

5. While pulling the manual stop lever, crank the en-

gine for approx 10 seconds using the starter. Stop

the operation for 1 minute, then, repeat the opera-

tion two or three times to bleed the cooling system.

Note: Prepare for the lubricating system and refilling

the coolant to the engine.

6. Check the coolant level in the radiator.

Fig. 3-11 Coolant Drain Cock (Air Cooler)

Fig. 3-12 Coolant Drain Cock

(Air Cooler water pump)

Always use the coolant having the same concentra-

tion.

Coolant drain cock

Air vent plug

Air vent cocks

3-7

Chapter 3 OPERATION

Preparation of Electrical System

Battery - Check

Note: If the specification of battery differs from those of this operation manual, follow the manufacturer's operation

manual.

Battery Electrolyte Level - Inspect

The battery electrolyte evaporates in the use, and the

electrolyte level gradually decreases. The proper elec-

trolyte level is between the LOWER LEVEL and

UPPER LEVEL marks.

For the battery without level marks, the proper electro-

lyte surface level is about 10 to 15 mm [0.39 to 0.59

in.] above the top of the polar plates.

If the electrolyte level is low, remove the caps and add

distilled water to the proper level.

Note: When adding distilled water, add little by little.

Fig. 3-13 Battery Electrolyte Level - Inspect

Never use flames or allow sparks near the battery. The battery releases flammable hydrogen gas and oxygen gas.

Any flames or sparks in the vicinity could cause an explosion.

Do not use the battery when the battery electrolyte level is below the "LOWER LEVEL" mark. Continual use may

result in an explosion.

Do not short the battery terminals with a tool or other metal object.

When removing battery, always remove the plug from the negative (-) terminal first. When connecting battery,

always connect the plug to the positive (+) terminal first.

Remove all battery cables, then charge the battery in a well ventilated area.

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 conducting electric welding, set the battery switch to [Open/OFF] posi-

tion or remove the plug from the negative (-) terminal to cut off the electrical current.

Electrolyte (battery electrolyte) contains dilute sulfuric acid.Careless handling of the battery can lead to loss of

sight and/or skin burns. Also, do not swallow the battery electrolyte.

Wear protective goggles and rubber gloves when working with the battery (e.g. when adding water or charging

battery).

If battery electrolyte is spilled onto the skin or clothing, immediately wash it away with lots of water. Use soap to

thoroughly clean.

The battery electrolyte can cause blindness if splashing into the eyes.If it gets into your eyes, immediately flush it

away with plenty of clean water, and seek immediate medical attention.

If you accidentally swallow battery electrolyte, gargle with plenty of water and then drink lots of water, and seek

immediate medical attention.

If the battery does not fully recover after 24 hours charging or more, do not use the battery.

UPPER LEVEL

LOWER LEVEL

10 to 15 mm
[0.39 to 0.59 in.]

Proper

3-8

Chapter 3 OPERATION

Specific Gravity of Battery Electrolyte - Check

If the specific gravity measured at 20°C [68°F] is lower

than 1.22, charge the battery.

Fig. 3-14 Specific Gravity of Battery Electrolyte -

Check

Table 3-1 Specific Gravity of Electrolyte

Specific gravity

at 20°C [68°F]

Conditions Remedy

From 1.26 to 1.28 Fully charged -

From 1.22 to 1.26

Partially
charged

Charge

Less than 1.22 Discharged Charge

Float

Electrolyte
surface

Electrolyte

Glass tube

3-9

Chapter 3 OPERATION

Test Operation

To conduct a test operation, follow the procedures below.

Before starting the engine, switch the water heater ON (automatic mode) and keep the coolant temperature prop-

erly.(Emergency generator with water heater)

Note: For engine operation, refer to "Normal Engine Operation" (3-10).

Starting and Stopping

1. Start the engine.

2. Operate the engine at a low idling speed under no load for 5 to 10 minutes for warm-up.

3. Stop the engine.

Inspection

1. Leave the engine be stopped for about 30 minutes.

2. During this period, check the engine and surrounding area for leaks of fuel, engine oil or coolant.

3. At 30 minutes after the engine stop, check the oil level with the oil level gauge.

4. If the oil level is low, add engine oil from the oil filler. Be sure to use the engine oil of the same brand and type.

5. Open the radiator cap and check the coolant level.

6. If the coolant level is low, add coolant to the specified level.

If the engine is equipped with a reserve tank, fill the reserve tank with coolant to the "FULL" level line as well.

Always switch the water heater ON (automatic mode) through a whole year.

If the switch is not ON (automatic mode), each cylinder varies considerably in combustion and abundant white

exhaust gas generates at the starting up the engine. Unburned fuel may explode in the exhaust pipe. (Emergency

generator with water heater)

Never open the radiator cap while the engine is running or immediately after the generator set is stopped. Stop the

engine and open the cap after the coolant temperature lowers sufficiently.

Place a waste cloth over the radiator cap, and loosen the cap about a 1/4 turn or stand the lever to the upright

position to release internal pressure.

The coolant is hot while engine is running and immediately after the engine stops. If the cap is opened when the

coolant is at operating temperature, steam and hot coolant may blow out and result in burns. To avoid a risk of get-

ting scalded by steam, wear thick rubber gloves or wrap a cloth around the cap.

When closing the radiator cap, be sure to tighten securely.

Always use the coolant having the same concentration.

3-10

Chapter 3 OPERATION

Normal Engine Operation

This section of the manual covers the procedures for the engine operation in normal condition.

Preparations for Operation

Always conduct daily pre-start inspection before starting the engine for the day.

Engine External - Inspect

Inspect the engine exterior as instructed below.

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

and battery are clean. If combustible materials or dust are found near the engine or battery, remove them.

2. Check the electrical wiring for components such as the starter and alternator for looseness.

3. Make sure that the turning tool is pulled out in it's original position.

4. Make sure fluids, such as fuel, oil and coolant, are not leaking from the engine. If a leak is found, repair the leak,

or contact your local dealer.

5. Make sure the following valves, plugs or cocks are properly positioned.

Fuel feed valve: Open

Coolant drain cock (plug): Closed

Engine oil drain valve: Closed

Fuel Tank Oil Level - Check

Make sure that the fuel tank is filled to the specified level.

If the fuel level is low, add fuel to the "FULL" level.

Note: If the specification of fuel tank differs from the contents of this operation manual, follow the fuel tank manufac-

turer's operation manual.

If the engine abnormality is observed during operation, stop the engine and correct the problem, or contact your

local dealer.

Check external parts of the engine, particularly hot part (exhaust manifold, etc.) and battery unit for any accumula-

tion of flammables, fuel leaks, and engine oil leaks, etc. Remove dust from the top surface of the battery. If some-

thing goes wrong with the hot parts, it may cause a fire. If any abnormality is found, be sure to repair it or contact

your local dealer.

When handling fuel, make sure there are no open flames, heaters or other fire hazards.

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

Do not remove the strainer during fuel tank filling.

If fuel level is above the low alarm mark where float switch is equipped, the float switch may be broken. Check and

correct the problem.

For fuel to be used, refer to "FUEL" (4-1).

3-11

Chapter 3 OPERATION

Fuel Tank - Drain Water

If fuel gets mixed with particles of foreign material

such as dust, dirt, or water, it can cause not only

decrease of output but also malfunctions of the fuel

system. To avoid such a problem, drain fuel tank as

described below.

Note: If the specification of fuel tank differs from the

contents of this operation manual, follow the fuel

tank manufacturer's operation manual.

1. Place the oil pan (capacity of 2 liters [0.5 US gal] or

more) under the drain cock of fuel tank.

2. Open the drain cock of fuel tank and drain fuel at

least 1 to 2 liters [0.3 to 0.5 US gal].

3. After checking that there is no water or foreign ob-

ject in the drained fuel, close the drain cock.

Fig. 3-15 Fuel Tank - Drain Water

Fuel Control Link - Check

Check fuel control link for smooth movement.

Push the manual stop lever to the fuel increase direc-

tion, check the movement of the rack cancel spring.

Then loosen your grip on the lever little by little, mak-

ing sure the manual stop lever returns to the no fuel

injection position smoothly.

Also check all ball joints for looseness and play.

Fig. 3-16 Check Fuel Control Link

When handling fuel, make sure there are no open flames, heaters or other fire hazards. Wipe off any spilled fuel

completely. Spilled fuel can ignite and cause a fire.

Do not remove the strainer when filling the fuel. For fuel to be used, refer to "FUEL" (4-1).

The following is a common procedure to drain water from fuel tanks, although the fuel tank actually installed may

exactly the same.

Drain cock

Water

Rack cancel spring

Manual stop lever

Ball joint

3-12

Chapter 3 OPERATION

Engine Oil Level - Check

1. Stop the engine and leave it for 30 minutes or

more.

2. Pull out the oil level gauge and wipe oil off the oil

level gauge using a clean waste cloth.

3. Insert the oil level gauge fully into the oil level

gauge guide and then pull it out again.

4. The proper oil level is between the high and low

marks on the oil level gauge. If the engine oil level

is higher than the high mark on the oil level gauge,

drain the oil. If the oil level is low, add the specified

engine oil.

5. Install the oil filler cap after engine oil has been re-

filled.

6. Check the oil pan and other area for oil leaks.

Fig. 3-17 Oil Filler and Oil Level Gauge

Coolant Level - Check

If the coolant level is low, add coolant to the specified level.

Note: Determine the quantities of LLC based on the coolant capacity and the LLC concentration chart.

For the coolant, refer to "COOLANT" (6-1). For the coolant capacity, refer to "MAIN SPECIFICATIONS" (12-1).

Always add engine oil to the specified level. If the oil

level is higher than the maximum mark on the level

gauge, engine oil may blow out during operation.

Also, the increase of oil temperature may adversely

affect engine components.

When adding engine oil, always use the same

engine oil.

H

L

Oil filler

Oil level gauge

Oil level gauge

High

Low

Improper

Improper

Proper

When adding coolant, use the same LLC concentration coolant that is currently in the cooling system.

3-13

Chapter 3 OPERATION

Air Cleaner - Check for Clogging

1. Check the air cleaner indicator for the element

clogging.

2. If the element is clogged, the red signal mark will

be displayed.

3. Immediately clean or replace the air cleaner ele-

ment when the signal turns red.

4. After checking, press the bottom on top of the indi-

cator to re-set the alarm signal.

Note: (a) For cleaning of the air cleaner element, refer

to "Air Cleaner Element - Clean, Check and

Replace" (8-22).

(b) If the specification of air cleaner differs from

the contents of this operation manual, follow

the manufacturer's operation manual.

Fig. 3-18 Air Cleaner - Check for Clogging

Temperature of Damper - Check

Damper Temperature Control by Thermo Label

Use of thermo label is recommenced for damper tem-

perature control. Check the thermo label before start-

ing engine as instructed below.

1. Ensure the heat-sensitive part of thermo label is

black.

2. Record the highest temperature of heat-sensitive

part. Record the temperature periodically, by which

you can check the abnormality of temperature al-

teration.

Note: For damper temperature limit and damper in-

spection, refer to "Damper - Inspect" (8-5).

Fig. 3-19 Thermo Label of Damper

Reset button

Signal
(red)

If the abnormality of temperature alteration is found,

consult a dealer of Mitsubishi Heavy Industries, Ltd.

75 80 85 90 95

100 105 110 115 120

50 55 60 65 70

Thermo label

ࠨ࡯ࡕ࡜ࡌ࡞

ࠨ࡯ࡕ࡜ࡌ࡞

ࠨ࡯ࡕ࡜ࡌ࡞

5E-75

5E-100

5E-50

5E-75

5E-100

5E-50

5E-75

5E-100

5E-50

5E-75

5E-100

5E-50

(Display example)
When thermal part of the thermo label is
black until 80, it indicates that the maximum
temperature of damper during operating is
from 80°C [176°F] to 85°C [185°F].

3-14

Chapter 3 OPERATION

Starting-up

Warm-up Operation

Warm-up the engine at low idle speed until the coolant temperature reaches approx. 50°C [122°F].

Engine Oil Pressure - Check

During warm-up operation, check if the oil pressure is in the range of standard value (0.3 MPa {3.1 kgf/cm2} [21 psi]

or more).

Also, make sure the oil pressure gauge functions properly.

External Inspection During Warm-up

Visually inspect the engine for external damage, abnormal noise, odor, vibration and exhaust gas color, then inspect

for fuel, engine oil and coolant or exhaust gas leaks from joints during warm-up operation.

Before starting the engine, make sure no one is near the engine and that tools are not left on or near the engine. In

a loud voice, notify people in the area when starting the engine.

Do not apply load to the engine when starting.

Continuous operation of the starter will drain the battery power or cause the starter to seize. Do not use the starter

for more than 10 seconds at a time. When the engine does not start, wait for more than 1 minute before cranking

again.

Stay away from rotating parts during operation. If you are caught in rotating parts, you can be seriously injured or

killed.

3-15

Chapter 3 OPERATION

Operation

Cautions During Operation

Inspection During Operation

Carefully check the exterior of engine such as piping

joints for leaks during operation.

Check engine for abnormal noise, odor or vibration

during warmimg-up operation.

Check the exhaust gas color from the exhaust muffler.

Check the instruments and gauges for proper opera-

tion and make sure they indicates normal values.

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

{3 kgf/cm

2

} [42.7 psi] in normal operation, or

below 0.1 MPa {1 kgf/cm

2

} [14.2 psi] at low

idling, stop the engine immediately.

Be sure to locate the cause of problem and

correct it before restarting the engine.

(b) When the thermo switch is activated during

normal operation, run the engine with the idle

speed at low Rpm for 5 or 6 minutes to cool

the engine before stopping the engine. Be

sure to locate the cause of problem and cor-

rect it before restarting the engine.

Stay away from rotating parts during operation.

Entanglement in rotating parts can cause serious

injury.

Do not touch any hot part of the engine such as

exhaust pipes during operation or immediately after

shut down. You may get burned.

Always provide adequate ventilation in the engine

room. If air ventilation in the engine room is not suffi-

cient, the room temperature rises and can affect

engine output and performance.

For the first 50 hours of a new or overhauled engine,

operate the engine under a light load for break-in

operation. Do not operate the new engine under

heavy load or severe conditions during the break-in

period, as it will shorten the service life of the engine.

Do not turn the battery switch OFF during operation.If

the battery switch is turned off during operation, it will

not only stops various functions of instruments but

also may deteriorate the alternator diode and transis-

tor.

Never turn the key to the "START" position during

operation. It may cause damage to the starter.

When operating the engine with a 30 % of rated load

or lower, limit each operation to an hour. Prolonged

warm-up operation causes carbon accumulation in

the cylinders that leads to incomplete combustion.

Operate the engine with a 30 % of rated load or more

for over 5 minutes to prevent carbon accumulation

when one hour continuous operation has been con-

ducted.

Pay attention to the generated voltage of generator

set.

Table 3-2 Standard values at rated speed

Item Standard

Engine oil pressure

0.49 to 0.64 MPa
{5 to 6.5 kgf/cm

2

}

[71 to 92 psi]

Coolant
tempera­ture

Basic engine
cooling system

70 to 90°C

[158 to 194°F]

Air Cooler
cooling system

40 to 70°C

[104 to 158°F]

3-16

Chapter 3 OPERATION

Stopping

Engine stopping method varies depending on the specifications.

To stop the engine, follow the proper instructions for each machine.

Emergency Stop

To perform an emergency stop, pull the manual stop

lever fully to the stop direction (arrow). Keep pulling

the manual lever until the engine stops completely.

Note: When the engine does not stop even if the man-

ual stop lever is pulled, cut fuel supply.

Fig. 3-20 Manual Stop Lever

Inspection After Stopping

Inspect the engine for fluid leaks such as fuel, oil or coolant. If any leak is found, repair the leak or contact a your

local dealer.

Stopping the engine abruptly during high-speed operation or while engine is hot will shorten the engine life. Before

stopping the engine, run the engine with the idle speed at low Rpm for 5 or 6 minutes to cool the engine, and

check the engine for abnormalities.

Do not race the engine immediately before shutting it down.

If the engine stops abnormally, do not restart the engine immediately. When the engine stops with alarms, be sure

to locate the cause of the problem and correct the problem before starting the engine again. After restarting the

operation, check the engine for abnormalities again. If an abnormality is detected, repair it immediately.

When stopping the engine by pulling the manual

stop lever, keep pulling the lever until the engine

stops completely. If not, the engine may start again.

STOP

4-1

Chapter 4 FUEL

Recommended Fuel

Use fuel that meets the values specified in the following "Recommended Fuel" (4-1) and "Recommended Limit and

Use Limit of Fuel Property" (4-2)

It is necessary to use fuel that has a pour point suitable for the ambient temperature.

Note: Please use the fuel that meets the regulations of the countries or areas where the engine is used, if the regu-

lations are applied.

Handling Fuel

When using fuel that is stored in a storage tank, leave it for more than 24 hours to settle dust and water at the bot-

tom and drain them. Then, use the upper clean fuel.

Fill up the fuel tank or service tank after each operation.

This prevents water from mixing with fuel in the tank and also gives time for dust and water to separate and settle at

the bottom of the tank.

When refilling, clean the areas around the caps of drum and tank thoroughly before removing the caps. Also clean

your hands and the hose before refueling. When using a hand-operated pump, be careful not to pump water or sed-

iment accumulated at the bottom of the storage tank.

Be sure to use a strainer when filling fuel tank. For a complete filtration, it is recommended to use a clean lint-free

cloth together with the strainer.

Use the fuel specified in this manual only. And, do not refill the fuel tank more than the specified level. It could lead

a fire.

Table 4-1 Recommended Fuel

Specifications Classification

ISO 8217 DMX-CLASS

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

BS 2869 CLASS A1, CLASS A2

DIN 51601 DIESEL-FUEL

JIS K2204 TYPE1, TYPE2, TYPE3

EN 590 DIESEL-FUEL

4-2

Chapter 4 FUEL

Fuel Specification

Use fuel which meets the requirements specified in the table below.

Table 4-2 Recommended Limit and Use Limit of Fuel Property

Item Recommended limit Use limit Test method

Flash point

50°C [122°F] or higher

(In accordance with the regulation)

JIS K 2265

:2007

ISO 3769
ISO 2719

Distillation

Initial boiling point 170°C [338°F] or higher

JIS K 2254

:1998

ISO 3405

90 % distillate
temperature

330 to 380°C [626 to 716°F]

Pour point (PP) Lower than ambient temperature by 6°C [43°F] or more

JIS K 2269

:1987

ISO 3016

Cloud point (CP) Below ambient temperature

JIS K 2269

:1987

ISO 3015

Cold filter plugging point (CFPP) Lower than ambient temperature by 3°C [37°F] or more

JIS K 2288

:2000

IP 309/96

Carbon residue (10 % residual oil) 0.4 weight % or lower 1.0 weight % or lower

JIS K 2270

:2000

ISO 6615
ISO 10370

Cetane number 45 or higher

JIS K 2280

:1996

ISO 5165

Cetane index (new type) 45 or higher

JIS K 2280

:1996

ISO/DIS 4264

Kinetic viscosity

2.0 mm

2

/s [0.0031 in2/s] or more at 30°C [86°F]

8.0 mm

2

/s [0.0124 in2/s] or more at 30°C [86°F]

JIS K 2283

:2000

ISO 3104

Sulfur content 0.2 weight % or lower

1.0 weight % or lower

(Shorten lub. oil change

intervals)

JIS K 2541

:2000

(The content
should be as
low as the die­sel fuel.)
ISO 4260
ISO 8754

Water content and sediment 0.1 volume % or lower

JIS K 2275

:1996

ISO 3733

Ash content 0.01 weight % or lower 0.03 weight % or lower

JIS K 2272

:1998

ISO 6245

Copper corrosion
(3 hrs at 50°C [122°F])

Discoloration = Copper plate No.3 or less

JIS K 2513

:2000

ISO 2160

Density at 15°C [59°F]

0.83 to 0.87 g/cm

3

[49.9424 to 54.3123 lb/ft

3

]

0.80 to 0.87 g/cm

3

[49.9424 to 54.3123 lb/ft

3

]

JIS K 2249

:1995

ISO 3675

Caulking

24 hrs at 250°C
[482°F]

75 % carbonization or less 80 % carbonization or less

Fed 791B

24 hrs at 230°C
[356°F]

55 % carbonization or less -

48 hrs at 180°C
[356°F]

Ta r- f re e -

Aromatics substances (by HPLC) 38 % by volume or less

JIS K 2536

:2003

ISO 3837

Polycyclic aromatic content 8 volume % or lower

Asphaltene 0.1 weight % or lower -

4-3

Chapter 4 FUEL

Foreign substances
(foreign materials at engine fuel
inlet)

5.0 mg/liter or less

JIS B 9931

:2000

ISO 4405

Lubricity: MWSD (Measured mean
Wear Scar Diameter) by HFRR
wear test at 60°C [140°F] fuel
temperature

460 μm [0.02 in.] or less

(calculated wear scar

diameter at WS 1.4 kPa

{0.0143 kgf/cm

2

}

[0.2031 psi])

- ISO 12156-1

BDF: Biodiesel fuel
(FAME: Fatty Acid Methyl Ester)

BDF quality shall meet JIS K 2390,

ASTM D 6751 or EN14214.

BDF blending of 5 % by volume or less is approved.

JIS K
2390

:2008

(Standard for
FAME)
ASTM D 6751
EN 14214

Engine applications

For engines operated under
a high load for a long period

(e.c. continuous use)

For engines operated under
a low load for a short period

of time

(e.c. stand-by use)

Selection
according to
applications

Table 4-2 Recommended Limit and Use Limit of Fuel Property

Item Recommended limit Use limit Test method

5-1

Chapter 5 ENGINE OIL

Recommended Engine Oil

Engine Oil Grade

Many oil standards, which are established through

special engine tests, are available to determine the

quality of oil depending on the engines to which they

will be applied and on operating conditions. Among

those standards, API (American Petroleum Institute)

service classifications are mostly used to classify

engine oils. SAE specifies the viscosity only, while the

API service classification indicates the quality level of

engine oil.

For engine lubrication oil, please use API service clas-

sification CF or CH-4.

When using the CF class engine oil, it must be certi-

fied according to API service classification CF by 2009

and satisfied the following "Table of Recommended

Limit of Engine Oil Properties" (5-2).

When using the CH-4 class engine oil, the sulfur con-

tent of fuel must be 0.2 weight % or lower.

Fig. 5-1 Engine Oil Grade

Use the engine oil recommended in this manual only. Never use oil other than that specified in this manual.

The use of inappropriate or inferior oils will result in sticking of piston rings, seizure between piston and cylinder, or

premature wear of bearings and moving parts, and significantly shortens the service life of the engine.

OILOIL

Class CH-4

API Service

Classification

API Service

Classification

Class CF

5-2

Chapter 5 ENGINE OIL

Engine Oil Specifications

Use engine oil that meets the requirements specified in the table below.

Table 5-1 Table of Recommended Limit of Engine Oil Properties

Item Unit Recommended limit Test method

API/JASO CF class *1 -

SAE viscosity - 15W-40 -

Color ASTM - L4.0

JIS K 2580

ISO 2049

Density 15°C [59°F] g/cm

3

0.87 to 0.90

JIS K 2249

ISO 3675

ISO3838

ISO 649-4

ISO 91-1

Kinetic viscosity

40°C [104°F]

mm

2

/s

100 to 110 JIS K 2283

ISO 3107
ISO 2904

100°C [212°F] 13.5 to 15.5

Viscosity - -

JIS K 2283

ISO 3107
ISO 2904

Flash point °C [°F]

225 to 250

[437 to 482]

JIS K 2265

ISO 3679
ISO 2719
ISO 2592

Base
Number

Hydrochloric
acid method

Sulfur contents
of fuel

1.0 weight %
or lower

mgKOH/g

10 or higher

(up to 13)

JIS K 2501

ISO 3771
ISO 6618
ISO 6619
ISO 7537

0.2 weight %
or lower

8 or higher

(up to 13)

Perchloric
acid method

Sulfur contents
of fuel

1.0 weight %
or lower

mgKOH/g

13 or higher

(up to 16)

0.2 weight %
or lower

11 or higher

(up to 16)

Acid number mgKOH/g 1.5 to 2.0

JIS K 2501

ISO 3771
ISO 6618
ISO 6619
ISO 7537

Sulfur content % 0.5 or less

JIS K 2541

ISO 4260
ISO 8754

Sulfuric acid ash % 2.0 or lower

JIS K 2272

ISO 3987
ISO 6245

Carbon residue content % 2.0 or lower

JIS K 2270

ISO 10370

ISO 6615

High temperature shear viscosity 150°C [302°F] mPa•S 3.7 or higher JPI-5S-36-91

Pour point °C [°F] -25 [-13] or lower

JIS K 2269

ISO 3015
ISO 3016

5-3

Chapter 5 ENGINE OIL

*1 API CF grade oil certified in 2009 or before.

*2 Temperature of test I (24°C [75.2°F]), Temperature of test II (93.5°C [200.3°F]), Temperature of test III (24°C

[75.2°F] after 93.5°C [200.3°F])

*3 Temperature of aluminum panel: 300°C [572°F] and 325°C [617°F], Temperature of engine oil: 100°C [212°F],

Splatter time: 15 seconds

Downtime: 45 seconds, Test time: 8 hours, the properties are the weight of solid product.

Selection of Oil Viscosity

Use the chart on the right 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 accelerates wear due to inadequate

lubrication, and also causes a decrease in engine out-

put.

Fig. 5-2 Selection of Oil Viscosity

Bubbling test *2

I

mL

10/0

JIS K 2518

ISO 6247

II 30/0

III 10/0

Panel caulking test *3

300°C

[572°F]

mg

140 or lower

FED791-3462

325°C

[617°F]

300 or lower

Table 5-1 Table of Recommended Limit of Engine Oil Properties

Item Unit Recommended limit Test method



SAE10W

SAE30

SAE40

SAE15W-40

Temperature

°C [°F]

Engine oil

viscosity

-30

[-21]

-20
[-4]

-10

[14]

10

[50]20[68]30[86]40[104]50[122]

0

[32]

5-4

Chapter 5 ENGINE OIL

Handling Engine Oil

When handling a large amount of engine oil more than the legally specified quantities, be sure to have the work per-

formed by a service station operated under the provision of the law. When removing oil from the engine or oil can,

use an oil pump. Do not siphon oil using a pipe and your 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 of the engine oil and follow the instructions of the MSDS.

Service Limits of Engine Oil

Engine oil degrades through the use and by lapse of time.

The quality of engine oil and the operating condition of the engine have influence on deterioration of the engine oil.

Change the engine oil in accordance with "MAINTENANCE SCHEDULE" (7-1).However, only if the operating load

is stable and engine oil analysis result allows, oil replacement interval may be changed.

Refer to the following table for the determination of engine oil performance. If any of the following properties

exceeds the limit, replace the engine oil with new oil.

Before filling the engine with engine oil, stop the engine and make sure there are no open flames and other fire

hazards near the engine. Leaked or spilled oil on hot surfaces or electrical components can cause a fire. Wipe off

any spilled oil immediately and thoroughly. After filling oil, securely close the filler cap.

Table 5-2 Table of Engine Oil Properties

Properties Standard Test method

Kinetic viscosity

mm

2

/s @100°C

[212 °F]

Continuous

and general

machinery

use

+30 % or less rate of change from

new oil

10 mm

2

/s [0.155 in2/s] or more

JIS K 2283

:2007

ISO 3107
ISO 2909

Emergency

use

+30 % or less rate of change from

new oil

-20 % or less rate of change from
new oil

Base Number mgKOH/g

2.0 or more with hydrochloric acid (HCL) method
1/2 of new oil or more with perchloric acid (PCA)
method

JIS K 2501

:2003

ISO 3771

Acid number mgKOH/g

+3.0 of new oil or less JIS K 2501

:2003

ISO 3771

Water content Vol %

0.2 or less JIS K 2275

:1996

ISO 9029

Flash Point (Open
Cup)

°C

180 [356] or higher JIS K 2265

:2007

ISO 3769
ISO 2719

Pentane Insoluble Wt %

0.5 or less Compliant to ASTM D
893

Pentane Insoluble
Coagulated

Wt %

3.0 or less Compliant to ASTM D
893

5-5

Chapter 5 ENGINE OIL

Definition of Properties of Engine Oil

Kinetic Viscosity

Kinetic viscosity is a basic physical property of engine oil and is considered as the most important aspect when

evaluating oil.

Contamination of oil due to blow-by gas and deterioration of oil or its natural aging increases the kinetic viscosity

and degrades the performance of viscosity, which will cause the deposition of sludge inside the engine and oil filter

clogging. Contamination of oil due to fuel and sheared molecules of viscosity index improver in oil decreases the

viscosity and degrade the performance of viscosity, which will cause insufficient lubrication and friction/wear of

engine parts.

Base Number

Base number shows the ability to neutralize acids such as organic acid due to engine oil oxidation, or sulfurous or

sulfuric acid due to the sulfur content of fuel.

Because base number indicates the amount of dispersant detergent in oil, it can be used to estimate consumption

of basic dispersant detergent. The ability to disperse sludge declines as dispersant detergent is used up.

Acid Number

The acid number in oil increases as the organic acid is being derived by the engine oil oxidation, or sulfurous acid or

sulfuric acid derived by the combustion of sulfur content of fuel, or the oil becomes contaminated with imperfect

combustion products.

An increase in the acid number will result in corrosion or wear of the inner parts of the engine (such as cylinder lin-

ers or metal) due to sulfur content, and piston ring seizure due to sludge.

5-6

Chapter 5 ENGINE OIL

Water Content

Water in oil promotes corrosion/wear, and decreases

lubricity in sliding parts.

Flash Point

The flash point is lowered by contamination with fuels.

Flash point is used to check the dilution of fuel. The

dilution of fuel reduces oil film, and causes insufficient

lubrication that will cause friction or wear of engine

parts.

Insoluble

Insoluble include acid products of engine oil, imperfect

combustion products, sludge or soot, metal abrasive

particles and dust. Insoluble is an indication of degra-

dation/contamination of oil.

Dispersant detergent, which is an additive in engine

oil, absorbs sludge particles, and disperses them as

fine particles in oil. Total insoluble density and remain-

ing dispersibility can be obtained by measuring insolu-

ble and coagulated insoluble (chemical specialties

which stop action of disperse detergent and collect the

sludge dispersed in oil) to understand engine oil con-

tamination level, and thereby, piston ring seizure or

premature wear can be prevented before it occurs.

5-7

Chapter 5 ENGINE OIL

Engine Oil Analysis Service

For a long productive service life of engine, it is recommended to have an engine oil analysis service.

The sample oil is taken from the engine using dedicated sampling tool and the oil is analyzed whether it is appropri-

ate for the use.

The following date is obtained by the engine oil analysis service.

The quantity of fine metal powder in engine oil due to abrasion, by which worn parts can be located.

Water, LLC or salt that should not be in engine oil can be detected.

Engine oil deteriorating conditions, by which appropriate engine oil renewal intervals, operating conditions, proper

inspection and maintenance schedule can be planned.

The engine oil analysis service can diagnose the internal condition of the engine without disassembling the engine.

It is highly recommended to take advantage of our engine oil analysis service so that you can find the engine condi-

tion before any malfunction occurs to the engine.

6-1

Chapter 6 COOLANT

Note: In this operation manual, the word "coolant" represents a mixture of water and LLC.

Recommended Water for Coolant

Use soft water (such as tap water) for the engine cooling system. The water quality must meet the requirements in

the table below. Basically, the water quality should be within the recommended value, however, up to the limit is

acceptable.

Note: Other than those above, turbidity must be below 15 mg/liter.

Long Life Coolant (LLC)

Be sure to use Mitsubishi Heavy Industries, Ltd. genuine long life coolant (LLC), "GLASSY long life coolant (ethyl-

ene glycol type)" or "PG GLASSY long life coolant (propylene glycol type)." If you have to use other brand LLCs, be

sure to use the non-amine type LLC that meets the requirements by Mitsubishi Heavy Industries, Ltd.

Mitsubishi heavy industries, Ltd. disclaims the warranty claims about malfunctions due to the use of LLC that does

not meet our requirements.

Genuine LLC

Mitsubishi Heavy Industries, Ltd. recommends the use

of our genuine long life coolant "GLASSY long life

coolant (Ethylene glycol type)", and Eco-friendly prod-

uct "PG GLASSY long life coolant (propylene glycol

type)", which are most appropriate coolant for Mitsubi-

shi diesel engines. Be sure to use our Genuine LLC.

Fig. 6-1 GLASSY - LLC

Table 6-1 Water quality standards

Item

Chemical

symbol

Unit

Recommend

value

Limit Main adverse effect

pH (25 °C [77 °F]) - - 6.5 to 8.0 6.5 to 8.5

Corrosion and rust, scale
formation

Electrical conductivity
(25°C [77°F])

- mS/m < 25 < 40

Corrosion and rust, scale
formation

Total hardness CaCO

3 ppm < 95 < 100 Scale formation

M alkalinity CaCO

3 ppm < 70 < 150 Scale formation

Chlorine ion Cl

-

ppm < 100 < 100 Corrosion and rust

Sulfuric acid ion SO

4

2-

ppm < 50 < 100 Corrosion and rust

Total iron Fe ppm < 1.0 < 1.0 Scale formation

Silica SiO

2 ppm < 30 < 50 Scale formation

Residue from evaporation - ppm < 250 < 400 Scale formation

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

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

6-2

Chapter 6 COOLANT

Other Brand LLCs

When using LLC other than Mitsubishi Heavy Indus-

tries, Ltd. genuine long life coolant (LLC) "GLASSY

long life coolant (Ethylene glycol type)" or "PG

GLASSY long life coolant (propylene glycol type)", be

sure to use the LLC which meets the requirements by

Mitsubishi Heavy Industries, Ltd.

The quality and performance of commercially avail-

able LLCs as well as their component variations are

the responsibility of LLC suppliers.

Before purchasing commercial LLC, be sure to dis-

cuss the suitability of LLC with the LLC supplier.

Use all-season LLC (non-amine type) only. Do not use

antifreeze alone instead of LLC.

Requirements for Other
Brand LLC

If you have to use other brand LLCs, be sure to use

the LLC that meets the requirements below. Mitsubi-

shi heavy industries, Ltd. disclaims the warranty claim

concerning malfunctions caused by the use of LLC

that does not meet our requirements.

General Quality Requirements
for LLC

 LLC must be a homogeneous liquid without sedi-

ment.

 When the LLC is diluted to 30 to 60% density, the LLC

shall not cause any problems such as corrosion and

precipitation deposits in the engine cooling system.

 LLC shall be mixed well with other non-amine type

LLC that meets this requirement and shall not sepa-

rate elements included in the each product, and shall

not decrease the performance of both products.

 LLC shall not corrode the container and shall not pro-

duce a precipitate when LLC is left in the container for

6 months.

 LLC shall be free from any abnormalities such as pre-

cipitates when kept at -20 to -25°C [-4 to -13°F] tem-

perature.

 The validity period for the quality requirements for

products specified herein shall be 2 years after the de-

livery, provided that they are stored under indoor nor-

mal temperature.

Never mix Mitsubishi Heavy Industries, Ltd. genuine

LLC with other brand LLCs. Mixing with other brand

LLCs degrades the performance of the Mitsubishi

Heavy Industries, Ltd. genuine LLC.

6-3

Chapter 6 COOLANT

LLC Quality Requirements

LLC shall be tested according to JIS K2234, Section 7 "Test method", and satisfy the requirements. General mat-

ters and specimen sampling method shall comply with JIS K2234.

Table 6-2 LLC Quality Requirements

Property Standard

Appearance No precipitation

Density

Minimum 1.112 g/cm

3

[69.4199 lb/ft

3

] (20/20 °C) [68/68 °F]

(Stock solution)

Water content Maximum 5.0 weight % (Stock solution)

Frozen temperature

30 vol % Maximum -14.5°C [5.9°F]

50 vol % Maximum -34.0°C [-29.2°F]

Boiling temperature 155°C [311°F] or higher (Stock solution)

pH 7.0 to 11.0 (30 vol %)

Bubbling character
(ASTM D3306-01)

30 vol % 4.0 ml or less

33

1/3 vol %

150 ml [0.032 gal] or less, disappearance of
bubble within 5 seconds.

Hard water adaptability 1.0 or less (50 vol %)

Metallic causticity
(88 ± 2°C
[190 ± 3.60°F],
336 ± 2 Hr,
30 vol % (E.G),
50 vol % (P.G)

Metal speci­men

Mass
change

Aluminum ±0.30 mg/cm

2

Cast iron ±0.15 mg/cm

2

Steel ±0.15 mg/cm

2

Brass ±0.15 mg/cm

2

Solder ±0.30 mg/cm

2

Copper ±0.15 mg/cm

2

Appearance of the specimen
after testing

No visible signs of corrosion on the surface
excluding the area contacted to the spacer.
However, discoloration is acceptable.

Bubbling during the test No bubbles overflowing

Properties of
liquid after
testing

pH 6.5 to 11.0

pH change ±1.0

Precipitation 0.5 vol % or less

Appearance of liquid

No remarkable discoloration, separation
and gel generation.

6-4

Chapter 6 COOLANT

Circulation metal­lic causticity
(98 ± 2°C
[208 ± 3.60°F],
1000 Hr,
30 vol %
(E.G)
50 vol %
(P.G)

Metal speci­men

Mass
change

Aluminum, Cast
iron, Steel, Brass,
Solder, Copper

±0.30 mg/cm

2

Appearance of the specimen
after testing

No visible signs of corrosion on the surface
excluding the area contacted to the spacer.
However, discoloration is acceptable.

Properties of
liquid after
testing

pH 7.0 to 9.0

pH change ±1.0

Pre-alkalinity change ±15 %

Precipitation 1.0 vol % or less

Appearance of liquid

No remarkable discoloration, separation
and gel generation.

Density
of ion

Fe, Cu, Al, Zn, Pb,
NH

4

+

10 ppm or less

Circulation metal­lic causticity
(88 ± 3°C
[190 ± 5.40°F],
1000 ± 2 Hr,
30 vol %
(E.G)

Metal speci­men

Mass
change

Aluminum ±0.60 mg/cm

2

Cast iron ±0.30 mg/cm

2

Steel ±0.30 mg/cm

2

Brass ±0.30 mg/cm

2

Solder ±0.60 mg/cm

2

Copper ±0.30 mg/cm

2

Appearance of the specimen
after testing

No visible signs of corrosion on the surface
excluding the area contacted to the spacer.
However, discoloration is acceptable.

Properties of
liquid after
testing

pH 6.5 to 11.0

pH change Maximum ±1.0

Appearance of liquid

No remarkable discoloration, separation
and gel generation.

Condition of
parts

Pump seals

Free from any malfunction, liquid leak and
abnormal noise during operation.

Pump case inner surfaces and
blades

Free from remarkable corrosion

Table 6-2 LLC Quality Requirements

Property Standard

6-5

Chapter 6 COOLANT

Rubber adapt­ability
(30 vol %
water solution,
115°C [239°F],
360 Hr)

Silicon

Tensile strength change -60 to 0 %

Elongation change -40 to +20 %

Volume change 0 to +40 %

Hardness change -20 to +10 %

Acrylonitrile
butadiene
rubber

Tensile strength change 0 to +10 %

Elongation change -15 to +15 %

Volume change 0 to +40 %

Hardness change -10 to 0 %

Ethylene
propylene
diene monomer

Tensile strength change 0 to +10 %

Elongation change -30 to 0 %

Volume change 0 to +10 %

Hardness change -10 to 0 %

Storage stability vol % (30 vol %, room temperature, 6 Hr) 0.3 or less

Table 6-2 LLC Quality Requirements

Property Standard

6-6

Chapter 6 COOLANT

Maintenance of LLC

Replacement Intervals of LLC

When a coolant mixed with the LLC recommended by our company is used, replace coolant every 8000 hours or 2

years, whichever comes first for continuous use and general power-source engine. For standby engine, replace

coolant once every 2 years.

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

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

LLC is toxic. Never dispose of coolant containing LLC drained from engine into regular sewage. For disposal of

used coolant, consult LLC distributor.

Be sure to renew LLC (coolant) at the intervals specified in this manual.

Failure to renew LLC may cause malfunctions due to performance degradation of preventing rust and cavitations.

6-7

Chapter 6 COOLANT

LLC Concentration (GLASSY, PG GLASSY)

1. To prevent cavitations of water pump and cylinder liners, LLC concentration must be at least 30% for GLASSY

(ethylene glycol) and 40% for PG GLASSY (propylene glycol) by volume under any temperature conditions

throughout the year.

2. Coolant anti-freeze concentration for the engine is determined by the ambient minimum temperature throughout

the year. Be sure to observe the coolant anti-freeze concentration range given in the table below.

3. Concentration must be 60% at a maximum for GLASSY (ethylene glycol) and 85% for PG GLASSY (propylene

glycol). If concentration is higher than that, it can lead to a risk of adverse effects. For example, anti-freeze per-

formance will decrease. Or coolant temperature will rise due to the decrease in specific heat.

4. Coolant temperature will increase by approx. 1.5°C [34.7°F] for 60% concentration of GLASSY (ethylene glycol)

and approx 3°C [37.4°F] for 85% concentration of PG GLASSY (propylene glycol). Check heat exchanger capac-

ity of the cooling system to avoid overheating.

Fig. 6-2 Coolant Freezing Temperature (GLASSY, PG GLASSY)

Table 6-3 Recommended LLC Concentration

Ambient temperature to -10°C

[14°F]

to -20°C

[-4°F]

to -30°C

[-22°F]

to -45°C

[-49°F]

LLC Con­centration

GLASSY (ethylene glycol) 30% 40% 50% 60%

PG GLASSY (propylene glycol) 40% 55% 70% 85%

40

50 60 70 80 90 100

10

20 30 40 50 60070

0

Lower limit of
concentration

Lower limit of
concentration

Freezing Temperature (ºC [ºF])

Concentration (Volume %)

Concentration (Volume %)

Freezing Temperature vs. GLASSY Concentration

Freezing Temperature vs. PG GLASSY Concentration

Freezing Temperature (ºC [ºF])

0

[32]

-10

[14]

-20
[-4]

-30

[-22]

-40

[-40]

-50

[-58]

-60

[-76]

0

[32]

-10

[14]

-20
[-4]

-30

[-22]

-40

[-40]

-50

[-58]

-60

[-76]

6-8

Chapter 6 COOLANT

Importance of LLC

Today's trend is smaller and lighter engines that can

offer greater output, lower fuel consumption and lower

exhaust emission levels.

Conditions to which engine coolant is subjected,

therefore, are becoming severer due to longer operat-

ing hours, higher coolant temperature and higher cool-

ant circulating speed.

Many different materials such as steel, aluminum,

copper, solder and rubber are used in the cooling sys-

tem, and they are also subjected to the severe condi-

tions described above. Those materials have different

ionization characteristics, and this difference acceler-

ates corrosion through the medium of engine coolant.

To prevent such a problem, it is necessary to use the

LLC having the additive that prevents rust.

Characteristics of LLC
Additive and Points to
Remember

LLC contains several chemicals in such proportions

as to produce chemical reactions that suppress corro-

sion (ionization) of engine parts in contact with the

coolant. LLC loses its effectiveness by hours of use as

well as lapse of time.

Moreover, if the chemicals are not well proportioned to

match the metals used in the cooling system, certain

chemicals in the LLC become rapidly used up and

result in dissolution of metals instead of protecting

metals from corrosion. Consequently, other corrosion

preventing chemicals react with dissolving metals and

accelerate corrosion. This condition generates more

severe corrosion than when plain soft water is used.

This is a typical problem caused by the use of inap-

propriate LLC.

Examples of Abnormali­ties Caused by LLC
(Amine Type)

Pitting of Iron Parts

Amines are generally effective in suppressing the rust-

ing of ferrous metals, but they are said to become cor-

rosion promoter for copper parts.

Dissolved copper (copper corrosion) in the cooling

system deposits on iron parts and the copper deposits

cause corrosion and then pitting on iron parts that

have a high ionization characteristics due to galvanic

or local-cell action.

Corrosion of Aluminum Parts

Silicate is highly effective in protecting aluminum

against rusting. However, it is unstable in a solution in

which the pH is 9 or lower, and can turn to gel and pre-

cipitate in the solution. For this reason, the pH is usu-

ally specified to be about 10 to ensure a high alkaline

level.

This means, after silicate is used up, the high alkalinity

causes chemical attacks on aluminum. To prevent this

problem, proper maintenance of the coolant is

required. For case example, rapid wear of mechanical

seals in the water pump due to secondary effects of

silicate gel formed. Corrosion of aluminum parts after

silicate is consumed.

Pitting and Clogging of Radia­tor

When LLC deteriorates or when its concentration in

the coolant is too low, the anti-corrosion performance

of LLC lowers and results in the corrosion of metals.

Brass and solder tend to corrode faster than other

metals, and corrosion of these metals is said to cause

water leakage and clogs. Example: Holes and clogs in

radiator.

7-1

Chapter 7 MAINTENANCE SCHEDULE

How to Use Maintenance Schedule

Periodic inspection not only extends the service life of the engine but also serves to ensure safe operation. Be sure

to conduct inspections and maintenance according to the maintenance schedule.

The maintenance schedule shows the standard service intervals. If you notice any abnormalities such as abnormal

noise, black exhaust smoke, white exhaust smoke, extremely high temperature of exhaust gas, abnormal vibration,

and fuel, oil or exhaust gas leakage, be sure to conduct the inspection and maintenance work, regardless of recom-

mended service intervals in the "Maintenance schedule."

Note: Appropriate service intervals vary depending on the usage and operating conditions as well as consumption

of fuel, oil and coolant. Check the operating record of the engine to determine the most appropriate service

intervals. (Feel free to consult a dealer of Mitsubishi Heavy Industries, Ltd. regarding service intervals.)

Service the items at multiples of the original requirement. For example, at 1000 service hours, also service those

items listed under every 250 service hours and every 500 service hours.

Periodic Maintenance Chart

Appropriate service intervals vary depending on the engine specifications. Perform all daily inspection and mainte-

nance items in an accordance with the following 3 categories.

Periodic Maintenance Chart for Regular Use Engine

When the engine is used as a regular use engine, perform the periodic inspection and maintenance in accordance

with the "Periodic Maintenance Chart for Engine in Regular Use".

Periodic Maintenance Chart for Emergency Engine

When the engine is used as an emergency engine, perform the periodic inspection and maintenance in accordance

with the "Periodic Maintenance Chart for Emergency Engine". Due to the nature of application, an engine for emer-

gency use is subject to demanding operating conditions such as a quick startup and immediate supply of power. In

addition, it must operate reliably in the event of an emergency. Therefore, be sure to perform the daily inspection

and also conduct the following operation for maintenance purposes. Once every week: Operate the engine under

no load (for 3 to 5 minutes). (When operating the engine for 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 for general purpose engine

If the engine is used for different purposes other than the above usage, do maintenance according to the "Periodic

Maintenance Chart for General-Purpose Power Supply Engine".

7-2

Chapter 7 MAINTENANCE SCHEDULE

General Definition of Engine

General Definition of Regular Use Engine

An engine operated with a constant base load for the purpose of generating electric power, which is used indepen-

dently or in combination with commercial power supply. An engine operated under a fluctuating load throughout a

day for supplying rated electric power in lieu of commercial power.

General Definition of Emergency Engine

An engine used for emergency power generation such as main power supply and commercial power supply.

General Definition of General-purpose Engine

An engine used for a purpose other than power generation - for example, to drive a pump, as the main engine for a

ship, and for an industrial vehicle - and operated under constant or cyclically varying load and speed.

7-3

Chapter 7 MAINTENANCE SCHEDULE

Periodic Maintenance Chart for Regular (Prime) Use
Engine

Table 7-1 Periodic Maintenance Chart for Continuous Use Engine

Inspection and maintenance intervals and items inspected/maintained

Refer-

ence
page

Every 50 service hours or
every month

Fuel Tank - Drain Water *1 8-7

Water Separator - Drain Water *1 *2

First 50 service hours for
a new or overhauled
engine

Bolts and Nuts on the Engine Exterior - Retighten *2

Engine Oil, Oil Filter and Bypass Oil Filter - Replace

Engine oil analysis is also recommended at the same time.
The oil filters must also be replaced when the filter alarm light is turned on.

8-13

Every 250 service hours

Engine Oil, Oil Filter and Bypass Oil Filter - Replace

Engine oil analysis is also recommended at the same time.
The oil filters must be also replaced when the filter alarm lamp is turned on.

8-13

First 250 service hours
for a new or overhauled
engine

Valve Clearance - Inspect and Adjust
(Check valve mechanism at the same time.)

*2

Every 1000 service hours

Fuel Filter - Replace 8-10

Water Separator - Inspect and Replace *1 *2

Belt and Belt Tension - Inspect and Adjust 8-2

Gauze Filter - Clean 8-9

Every 2000 hours

Fuel Tank - Drain Water (Replace Parts As Needed) *1 8-7

Valve Clearance - Inspect and Adjust
(Check valve mechanism at the same time.)

*2

Fuel Injection Timing - Inspect and Adjust *2

Checking Movement of the Rack (during operation) of the fuel injection
pump (including the governor)

*2

Fuel Pipe - Inspect 8-12

Oil Pipe - Inspect 8-16

Fuel Injection Nozzle - Nozzle Tip Replacement (Check the spray condition
and adjust the fuel injection pressure after replacement)

*2

Every 4000 service hours

Top-End Engine - Overhaul
Remove the cylinder head, and perform inspection and maintenance around
the combustion chamber.

*2

Turbocharger - Inspect 8-21

Damper - Inspect 8-5

Starter - Inspect 8-26

Protection System - Inspect *2

Unit Seal and Oil Seal of water pump - Replace *2

LLC Concentration Level in the Coolant - Check *2

7-4

Chapter 7 MAINTENANCE SCHEDULE

*1 If it is not a item supplied from Mitsubishi Heavy Industries, maintain the part following the manufacture's opera-

tion manual as required.

*2 Items require special tools or large scale maintenance. For maintenance of those items, contact your local

dealer.

Every 8000 hours

Engine - Major Overhaul
Disassemble the engine, then clean, check and change major parts.
[Parts to be changed at major overhaul.]
Inlet and exhaust valves, inlet and exhaust valve seats, valve rotators, valve
cotters, rocker arm adjusting screws, valve push rods, bridge caps, camshaft
bushings, camshaft expansion plugs, main bearings, cylinder liners, main
bearing cap bolts and washers, piston rings, connecting rod bearings,
damper, crankcase thrust plate and exhaust pipe flexible joint consumable
items (gaskets, oil seals, O-rings, etc.)
<At second overhaul, replace the following parts in addition to the parts
listed above>
Cylinder head bolts, valve guides, valve bridge guides, valve bridges, valve
springs, tappets, camshaft thrust plates, pistons, piston pins, connecting rod
bolts, connecting rod bushings, rocker bushings, fuel pipe assembly, oil pipe
assembly

*2

Fuel Injection Pump - Inspect and Test (Replace parts as needed) *2

Governor - Inspect and Test (Replace parts as needed) *2

Protective Devices - Repair or Replace *1
High coolant temperature, low oil pressure, overspeeding, starting failure,
water supply failure, undervoltage, overvoltage, overcurrent, low coolant
level in tank, low fuel level in tank, etc.

*2

Auxiliary Devices Operation - Check *1
Water heater, oil heater, oil priming pump, fuel transfer pump, governor
motor, etc.

*2

Every 8000 hours
or every 2 years

Coolant - Change 8-17

As required

Fuel Filter - Bleed Air *1 3-2

Radiator Fins - Check and Clean *1 *2

Air Cleaner Element - Clean, Check and Replace *1 8-23

Pre-cleaner - Clean, Inspect and Replace *1 8-21

Exhaust Muffler - Drain Water *1 -

Inside of Engine Breather - Clean *2

Stop Solenoid - Inspect or Replace *2

Couplings - Inspect or Replace *1 *2

Vibration-isolating Rubber - Inspect *1 *2

Table 7-1 Periodic Maintenance Chart for Continuous Use Engine

Inspection and maintenance intervals and items inspected/maintained

Refer-

ence
page

7-5

Chapter 7 MAINTENANCE SCHEDULE

Periodic Maintenance Chart for Emergency Engine

Table 7-2 Periodic Maintenance Chart for Emergency Engine

Inspection and maintenance intervals and items inspected/maintained

Refer-

ence
page

Every week

Engine External - Inspect (Check for leakage of fuel, oil and coolant) 3-10

Fuel Tank Oil Level - Check *1 3-10

Engine Oil Level - Check 3-12

Coolant Level - Check 3-12

Water Leakage of Air Cooler - Inspect -

Operating the engine for maintenance (operate the engine under no load for
5 to 10 minutes)
Check for ease of starting, color of exhaust smoke, abnormal vibration,
abnormal noise, abnormal smell and gauge indication (oil pressure gauge,
coolant temperature gauge, oil temperature gauge, exhaust temperature
gauge, tachometer, etc.)

-

Every month

Fuel and Water Ingress In Engine Oil - Inspect 8-16

Fuel Control Link - Check 3-11

Battery Electrolyte Level - Inspect*1 3-7

Conducting Engine Maintenance Operation (Operate the engine with more
than 1/2 load for 15 to 30 minutes)
Check for ease of starting, color of exhaust smoke, abnormal vibration,
abnormal noise, abnormal smell and gauge indication (oil pressure gauge,
coolant temperature gauge, oil temperature gauge, exhaust temperature
gauge, tachometer, etc.)
Check fuel injection pump and governor rack movement

-

Damper - Inspect 8-5

Every 6 months

LLC Concentration - Check *2

Inside of Coolant Tank - Clean *1 -

7-6

Chapter 7 MAINTENANCE SCHEDULE

Every year

Engine Proper

Belt and Belt Tension - Inspect and Adjust 8-2

Bolts and Nuts on the Engine Exterior - Check and
Retighten

*2

Valve Clearance - Inspect and Adjust
(Check valve mechanism at the same time.)

*2

Vibration-isolating Rubber - Inspect *1 *2

Foundation Bolts - Inspect *1 *2

Couplings - Inspect or Replace *1 *2

Fuel system

Fuel Tank - Drain Water *1 8-7

Water Separator - Drain Water *1 *2

Fuel Injection Nozzle Spray Condition and Spray Pres­sure - Inspect and Adjust

*2

Fuel Injection Timing - Inspect and Adjust *2

Fuel Pipe - Inspect 8-12

Lubrication Sys­tem

Oil Pipe - Inspect 8-16

Engine Oil Properties - Analyze *2

Engine Oil Pressure (Maintenance Operation) - Inspect
and Adjust

*2

Cooling System

water pump - Inspect *2

Solenoid Valve and Pressure Reducing Valve of Cooling
System - Inspect, Disassemble and Clean *1

*2

Strainer (Including With Ball Tap) of Cooling Water ­Inspect, Disassemble and Clean *1

*2

Coolant Properties (When Only Soft Water is Used) ­Inspect (Change Coolant Based on Analysis Results)

*2

Air intake system

Air Cleaner Element - Clean, Check and Replace *1 8-22

Pre-cleaner - Clean, Inspect and Replace *1 8-21

Every year

Electrical System

Starter - Inspect 8-26

Alternator - Inspect 8-26

Specific Gravity of Battery Electrolyte - Check *1 3-8

Auxiliary Devices Operation - Check *1
High coolant temperature, low oil pressure, overspeeding, starting failure,
water supply failure, undervoltage, overvoltage, overcurrent, low coolant
level in tank, low fuel level in tank, etc.

*2

Auxiliary Devices Operation - Check *1
Engine control devices, fuel transfer pump, governor motor, room ventilating
fan, solenoid, storage pump, water tank ball tap, water heater, oil heater, oil
priming pump, etc.

*2

Table 7-2 Periodic Maintenance Chart for Emergency Engine

Inspection and maintenance intervals and items inspected/maintained

Refer-

ence
page

7-7

Chapter 7 MAINTENANCE SCHEDULE

Every 2 years

Engine Oil, Oil Filter and Bypass Oil Filter - Replace

Engine oil analysis is also recommended at the same time.
The oil filters must be also replaced when the filter alarm lamp is turned on.

8-13

Fuel Filter - Replace 8-10

Water Separator - Inspect and Replace *1 *2

Gauze Filter - Clean 8-9

Fuel Control Link Ball Joint - Inspect

(Replace parts as needed)

8-11

Coolant - Change 8-17

Inspect thermostat. *2

Turbocharger - Inspect 8-21

Exhaust Muffler - Drain water *1 -

Every 4 years

Top-End Engine - Overhaul
Remove the cylinder head, and perform inspection and maintenance around
the combustion chamber. (If the abnormalities of first and second cylinders
are found, inspect all cylinders.)

*2

Oil Cooler Contamination, Clogging and Leakage - Check *2

Oil Pump Discoloration and Other External Defects - Check *2

Fuel Tank - Clean *1 8-7

Fuel Injection Pump - Inspect and Test (Replace parts as needed) *2

Governor - Inspect and Test (Replace parts as needed) *2

Radiator Fins - Check and Clean *1 *2

Rubber Hose - Replace *2

Protective Devices - Repair or Replace *1
Oil pressure gauge, coolant temperature gauge, oil temperature gauge,
exhaust temperature gauge, tachometer

*2

Every 8 years

Engine - Major Overhaul
Disassemble the engine, then clean, check and change major parts.

*2

Damper - Replace *2

Oil Pump - Repair or Replace *2

Fuel Injection Nozzle - Nozzle Tip Replacement (Check the spray condition
and adjust the fuel injection pressure after replacement)

*2

Rubber Parts and O-rings - Replace *2

Unit Seal and Oil Seal of water pump - Replace *2

Turbocharger - Disassemble and Inspect *2

Air Cooler - Disassemble and Clean *2

Table 7-2 Periodic Maintenance Chart for Emergency Engine

Inspection and maintenance intervals and items inspected/maintained

Refer-

ence
page

7-8

Chapter 7 MAINTENANCE SCHEDULE

*1 If it is not an item supplied by MHI, service the part following the manufacture's operation manual as required.

*2 Items require special tools or large scale maintenance. For maintenance of those items, contact your local

dealer.

Every 8 years

Vibration-isolating Rubber - Repair or Replace *1 *2

Couplings - Repair or Replace *1 *2

Protective Devices - Repair or Replace *1 *2

Protective Devices - Repair or Replace *1 *2

Stop Solenoid - Inspect or Replace *2

Ball Tap of Water Tank - Repair or Replace *1 *2

Other Consumable Parts - Replace *2

Table 7-2 Periodic Maintenance Chart for Emergency Engine

Inspection and maintenance intervals and items inspected/maintained

Refer-

ence
page

8-1

Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Basic Engine

Engine External - Inspect

Inspect the engine exterior as instructed below.

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

and battery are clean. If combustible materials or dust are found near the engine or battery, remove them.

2. Check the electrical wiring for components such as the starter and alternator for looseness.

3. Make sure that the turning tool is pulled out in it's original position.

4. Make sure fluids, such as fuel, oil and coolant, are not leaking from the engine. If a leak is found, repair the leak,

or contact your local dealer.

5. Make sure the following valves, plugs or cocks are properly positioned.

Fuel feed valve: Open

Coolant drain cock (plug): Closed

Engine oil drain valve: Closed

Check external parts of the engine, particularly hot part (exhaust manifold, etc.) and battery unit for any accumula-

tion of flammables, fuel leaks, and engine oil leaks, etc. Remove dust from the top surface of the battery. If some-

thing goes wrong with the hot parts, it may cause a fire. If any abnormality is found, be sure to repair it or contact

your local dealer.

8-2

Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Belt and Belt Tension - Inspect and Adjust

Belt - Inspect

1. Inspect the belt visually for separation or damage. If any abnormality is found, replace the belt with a new one.

2. Inspect belt tension (deflection). Refer to "Ribbed Belt Tension Force" (8-3)., adjust the pressing force if it is not

average level when pushing the belt downward till 15 mm at the midway between pulleys with gauge.

Belt Tension (Alternator Side) - Adjust

1. Remove the belt cover.

2. Loosen all retaining bolts of the alternator and ad-

justing rod.

3. Loosen the upper and lower lock nuts on the ad-

justing rod.

Note: The lower nut on the adjusting rod has left-hand

threads.

4. Turn the adjusting rod to adjust the belt tension.

5. After tension adjustment, tighten the upper and

lower lock nuts.

6. Tighten all retaining bolts of the alternator and ad-

justing rod.

7. Reinstall the belt cover and front cover.

Fig. 8-1 Belt Tension (Alternator Side) - Adjust

Belt Tension (Air Cooler Water Pump Side) - Adjust

1. Loosen all the slide plate retaining bolts of tension

pulley bracket.

2. Loosen the lock nut of Air Cooler water pump ad-

justing bolt.

3. Turn the adjusting bolt to adjust the belt tension.

4. After adjusting deflection, fix lock nuts of adjusting

bolt.

5. Tighten all slide plate retaining bolts of Air Cooler

water pump tension pulley bracket.

Fig. 8-2 Belt Tension (Air Cooler water pump Side) -

Adjust

If defects such as cuts or surface separations are found during inspection, replace the belt.

Belts must be free from grease and oils. Grease and oils cause belts to slip and shorten their service life.

Excessive belt tension can cause rapid wear of the alternator bearing and shorten the service life of the belt.

Adjust the belt tension properly by following the procedures below.

Adjusting rod
Lock nut
(left-hand thread)

Lock nut
(right-hand thread)

Fixing bolt

Width Approx.

10 mm [0.39 in.]

Gauge

Pressing
force

15 mm [0.59 in.]

Ribbed belt

Thrust force

Gauge

15 mm

[0.59 in.]

Gauge width
approx. 10 mm [0.39 in.]

Fixing bolt

Lock nut

Lock nut

Fixing bolt

8-3

Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Table 8-1 Ribbed Belt Tension Force

Item

Num-

ber of

ribs

Belt direct distance (mm)

Up to 300

300 or more

Up to 400

400 or more

Up to 500

500 or more

Up to 600

600 or more

New

3

74 N {7.55 kgf }

[16.64 lbf]

49 N {5.00 kgf }

[11.02 lbf]

37 N {3.77 kgf }

[8.31 lbf]

29 N {2.96 kgf }

[6.53 lbf]

25 N {2.55 kgf }

[5.62 lbf]

4

88 N {8.97 kgf }

[19.78 lbf]

59 N {6.02 kgf }

[13.27 lbf]

44 N {4.49 kgf }

[9.90 lbf]

35 N {3.57 kgf }

[7.87 lbf]

29 N {2.96 kgf }

[6.53 lbf]

5

103 N {10.50 kgf }

[23.15 lbf]

69 N {7.04 kgf }

[15.52 lbf]

51 N {5.20 kgf }

[11.46 lbf]

41 N {4.18 kgf }

[9.22 lbf]

34 N {3.47 kgf }

[7.65 lbf]

6

118 N {12.03 kgf }

[26.52 lbf]

79 N {8.06 kgf }

[17.77 lbf]

59 N {6.02 kgf }

[13.27 lbf]

47 N {4.79 kgf }

[10.56 lbf]

39 N {3.98 kgf }

[8.77 lbf]

7

132 N {13.46 kgf }

[29.67 lbf]

88 N {8.97 kgf }

[19.78 lbf]

66 N {6.73 kgf }

[14.84 lbf]

53 N {5.40 kgf }

[11.90 lbf]

44 N {4.49 kgf }

[9.90 lbf]

8

147 N {14.99 kgf }

[33.05 lbf]

98 N {9.99 kgf}

[22.02 lbf]

74 N {7.55 kgf }

[16.64 lbf]

59 N {6.02 kgf }

[13.27 lbf]

49 N {5.00 kgf }

[11.02 lbf]

9

162 N {16.52 kgf }

[36.42 lbf]

108 N {11.01 kgf }

[24.27 lbf]

81 N {8.26 kgf }

[18.21 lbf]

65 N {6.63 kgf }

[14.62 lbf]

54 N {5.51 kgf }

[12.15 lbf]

10

176 N {17.95 kgf }

[39.57 lbf]

118 N {12.03 kgf }

[26.52 lbf]

88 N {8.97 kgf }

[19.78 lbf]

71 N {7.24 kgf }

[15.96 lbf]

59 N {6.02 kgf }

[13.27 lbf]

11

191 N {19.48 kgf }

[42.95 lbf]

127 N {12.95 kgf }

[28.55 lbf]

96 N {9.79 kgf }

[21.58 lbf]

76 N {7.75 kgf }

[17.09 lbf]

64 N {6.53 kgf }

[14.40 lbf]

12

206 N {21.01 kgf }

[46.32 lbf]

137 N {13.97 kgf }

[30.80 lbf]

103 N {10.50 kgf }

[23.15 lbf]

82 N {8.36 kgf }

[18.43 lbf]

69 N {7.04 kgf }

[15.52 lbf]

8-4

Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

The pressing force when pressing the belt downward till 15 mm [0.59 in.] at the midway of the belt direct distance.

Reused

3

51 N {5.20 kgf }

[11.46 lbf]

34 N {3.47 kgf }

[7.65 lbf]

26 N {2.65 kgf }

[5.84 lbf]

21 N} {2.14 kgf }

[4.72 lbf]

17 N {1.73 kgf }

[3.81 lbf]

4

62 N {6.32 kgf }

[13.93 lbf]

41 N {4.18 kgf }

[9.22 lbf]

31 N {3.16 kgf }

[6.97 lbf]

25 N {2.55 kgf }

[5.62 lbf]

21 N {2.14 kgf }

[4.72 lbf]

5

72 N {7.34 kgf }

[16.18 lbf]

48 N {4.89 kgf }

[10.78 lbf]

36 N {3.67 kgf }

[8.09 lbf]

29 N {2.96 kgf }

[6.53 lbf]

24 N {2.45 kgf }

[5.40 lbf]

6

82 N {8.36 kgf }

[18.43 lbf]

55 N {5.61 kgf }

[12.37 lbf]

41 N {4.18 kgf }

[9.22 lbf]

33 N {3.37 kgf }

[7.43 lbf]

27 N {2.75 kgf }

[6.06 lbf]

7

93 N {9.48 kgf}

[20.90 lbf]

62 N {6.32 kgf }

[13.93 lbf]

46 N {4.69 kgf }

[10.34 lbf]

37 N {3.77 kgf }

[8.31 lbf]

31 N {3.16 kgf }

[6.97 lbf]

8

103 N {10.50 kgf }

[23.15 lbf]

69 N {7.04 kgf }

[15.52 lbf]

51 N {5.20 kgf }

[11.46 lbf]

41 N {4.18 kgf }

[9.22 lbf]

34 N {3.47 kgf }

[7.65 lbf]

9

113 N {11.52 kgf }

[25.40 lbf]

75 N {7.65 kgf }

[16.87 lbf]

57 N {5.81 kgf }

[12.81 lbf]

45 N {4.59 kgf }

[10.12 lbf]

38 N {3.87 kgf }

[8.54 lbf]

10

123 N {12.54 kgf }

[27.65 lbf]

82 N {8.36 kgf }

[18.43 lbf]

62 N {6.32 kgf }

[13.93 lbf]

49 N {5.00 kgf }

[11.02 lbf]

41 N {4.18 kgf }

[9.22 lbf]

11

134 N {13.66 kgf }

[30.12 lbf]

89 N {9.08 kgf }

[20.02 lbf]

67 N {6.83 kgf }

[15.06 lbf]

54 N {5.51 kgf }

[12.15 lbf]

45 N {4.59 kgf }

[10.12 lbf]

12

144 N {14.68 kgf }

[32.36 lbf]

96 N {9.79 kgf }

[21.58 lbf]

72 N {7.34 kgf }

[16.18 lbf]

58 N {5.91 kgf }

[13.03 lbf]

48 N {4.89 kgf }

[10.78 lbf]

Table 8-1 Ribbed Belt Tension Force

Item

Num-

ber of

ribs

Belt direct distance (mm)

Up to 300

300 or more

Up to 400

400 or more

Up to 500

500 or more

Up to 600

600 or more

8-5

Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Damper - Inspect

Damper - Check Visually

Check the damper for oil leaks, scratches, deforma-

tions such as bulges of the cover (check with a scale

attached), and discoloration or peeling of paint due to

heat. Check carefully for bulges in the cover (use a

scale) and check for oil leaks from the shim, discolor-

ation and peeling of paint due to heat.

Note: If any defects are found in the damper, contact

your local dealer.

Fig. 8-3 Damper - Check Visually

Damper Temperature Control

To ensure the proper function of damper, heat must be dissipated from its surface to prevent excessive heating. Mit-

subishi Heavy Industries, Ltd. inspects each engine before shipment to make sure that the temperature of damper

does not excessively rise. However, the damper temperature varies depending on ambient conditions. Therefore,

make sure to provide sufficient ventilation for damper by following the instructions below.

1. Make sure the temperature of the damper outer surface does not exceed 90 °C [194 °F] when operating the en-

gine with rated power for an hour.

2. When installing a protective cover to damper, provide adequate ventilation so that the damper temperature re-

mains below 90 °C [194 °F].

3. We recommend the use of thermo label for temperature control.

The protective cover for the damper should not be

air-tight.

The damper deteriorates or slows down the perfor-

mance by heat, which may cause serious engine

problems.

Silicon oil

Cover

8-6

Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Thermo Label - Use

When the thermo label reaches a specified temperature, the white heat-sensitive area turns into black.

Note: Once the heat-sensitive area turns its color, it will never return to the original color again.Therefore, if the en-

gine is stopped, thereby dropping the temperature of damper, the thermo label still indicates the highest tem-

perature when engine was running.

1. Attach the thermo label to the damper outer circumference or front end near the outside diameter.

2. Record the highest temperature by checking the thermo label heat-sensitive area when engine is not running.Re-

cord the temperature periodically so that you can tell if there is any abnormal temperature change.

Note: (a) When the increase in thermo label temperature is observed, look for the abnormality of engine or other

causes. Then, replace the thermo label with new one, and check the temperature change again.

(b) If the temperature indication of thermo label comes close to the limit temperature of damper, or if there is

any abnormal temperature changes, contact your local dealer.

(c) For damper temperature limit, refer to "Damper - Inspect" (8-5).

Fig. 8-4 Damper Temperature Control

Table 8-2 Types of Thermo Labels

Parts name Part No.

Measurable

temperature

range

Thermo Label

100-120

32522-04211
(20 labels set:
32522-04200)

100 to 120°C

Thermo Label

75-95

32522-04111
(20 labels set:
32522-04100)

75 to 95°C

Thermo Label

50-70

32522-04311
(20 labels set:
32522-04300)

50 to 70°C

<5E-75>

75 80 85 90 95

<5E-100>

100 105 110 115 120

<5E-50>

50 55 60 65 70

Thermo Label

8-7

Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Fuel System

Fuel System - Inspect

Fuel Tank - Clean

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

2. Place a fuel container under the drain cock.

3. Drain all fuel in the tank from drain cock on the bottom of fuel tank.

4. Clean the inside of fuel tank.

5. Add fuel to the fuel tank.

6. Open the fuel feed valve of the engine.

Note: If the specification of fuel tank differs from the contents of this operation manual, follow the fuel tank manufac-

turer's operation manual.

Fuel Tank - Drain Water

If fuel gets mixed with foreign material particles such

as dust, dirt, or water, it can cause not only decrease

of output but also malfunctions of the fuel system. To

avoid such a problem, drain fuel tank as instructed

below.

1. Place a fuel container (capacity of 2 L [0.5 US gal.]

or more) under the drain cock of fuel tank.

2. Open the drain cock of fuel tank and drain fuel at

least 1 to 2 L [0.3 to 0.5 US gal].

3. After making sure water and foreign material parti-

cles has been discharged with fuel, close the drain

cock.

Note: If the specification of fuel tank differs from the

contents of this operation manual, follow the fuel

tank manufacturer's operation manual.

Fig. 8-5 Fuel Tank - Drain Water

When handling fuel, make sure there are no open flames or other fire hazards near the engine.

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

For fuel to be used, refer to"FUEL" (4-1).

Drain cock

Water

8-8

Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Oil-water Separator - Drain Water

1. Prepare a plate, and place it under the drain cock

of water separator.

2. Open the drain cock, and drain water in the water

separator.

3. Close the all drain cocks after draining.

Note: If the specification of water separator differs from

the contents of this operation manual, follow the

manufacturer's operation manual.

Fig. 8-6 Water Separator - Drain Water

Oil-water Separator Element - Replace

1. Close the inlet cock and outlet cock.

2. Turn the T-handle, and remove the water separator

cover.

3. Open the drain cock, and drain fuel in the water

separator.

4. Close the all drain cocks after draining.

5. Replace the element with a new one.

6. Fill the water separator with fuel.

7. Attach the water separator cover, and tighten the T-

handle.

8. Open the inlet cock and outlet cock.

9. After replacing the element, open the fuel feed

valve to the engine, then bleed air from the fuel

system.

Note: (a) For bleeding fuel system, refer to "Fuel Filter

- Bleed Air" (3-2).

(b) If the specification of water separator differs

from the contents of this operation manual,

follow the manufacturer's operation manual.

Fig. 8-7 Water Separator Element - Replace

Inlet cock

Outlet cock

Drain cock

Open the inlet valve slowly to prevent overflowing fuel. Wrap a cloth around the water separator before the fuel

may spill.

Element

Inlet cock

Drain cock

Outlet cock

8-9

Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Gauze Filter - Clean

If the gauze filter is clogged, the fuel supply becomes

insufficient, resulting in decrease in power output or

engine stall.

1. Remove the union bolt at the inlet port of fuel feed

pump.

2. Using a screw driver, remove the gauze filter that is

fitted inside the union bolt.

3. Soak the gauze filter in the fuel, and clean it with a

brush.

4. After cleaning, install the gauze filter into the union

bolt using a screw driver.

5. Install the union bolt to the fuel feed pump.

6. Bleed air from the fuel filter.

Note: For bleeding the fuel filter, refer to "Fuel Filter -

Bleed Air" (3-2).

Fig. 8-8 Gauze Filter - Clean

Gauze filter

Fuel feed pump

Eye bolt

8-10

Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Fuel Filter - Replace

1. Clean the area around the fuel filters.

2. Prepare a drip pan, and place it under the fuel fil-

ters.

3. Using a filter wrench, remove the fuel filters.

4. Wipe off fuel on the fuel filter cartridge mounting

surface of the filter bracket with a waste cloth.

5. Prepare new fuel filter, and make sure that gasket

is properly seated in the groove.

6. Apply clean fuel to the gasket of the new fuel filter.

7. Install the fuel filter to the filter bracket. When the

gasket comes in contact with the mounting surface

of the filter bracket, further rotate 3/4 to a full turn.

8. After the new fuel filter has been installed, bleed

the fuel filter.

Note: For bleeding the fuel filter, refer to "Fuel Filter -

Bleed Air" (3-2).

9. Start the engine and run at idle speed for several

minutes.

10. Make sure that there is no fuel leak during engine

operation. If the leak is found, loosen the fuel filter

and check the gaskets for damage. If there is no

damage, retighten the fuel filter.

Fig. 8-9 Fuel Filter - Replace

Fig. 8-10 Fuel Filter

If filter case is dented, do not use the filter. Such filter

may be damaged during operation, leading to fuel

leaks, and eventually may result in a fire.

Hand tighten fuel filters. Do not tighten with a filter

wrench.

Be careful not to dent or scratch the fuel filter sur-

faces.

Apply fuel to
the gasket.

8-11

Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Fuel Control Link Ball Joint - Inspect

Check ball joint in the fuel control link for looseness or

sluggish movement. If the amount of looseness is 0.1

mm [0.004 in.] or more, replace the ball joint with the

new one.

If the ball joints are integrated with the control link,

replace the control link assembly. When installing ball

joints, be sure to tighten the nuts firmly.

Fig. 8-11 Ball Joints Looseness - Inspect

Fig. 8-12 Fuel Control Link - Remove

If the sealed ball joints are found loosened, contact

your local dealer. If the seal on the ball joint is bro-

ken, the engine is no longer covered under warranty.

Ball joint

Rod

Lever

0.1 mm

[0.004 in.]

0.1 mm

[0.004 in.]

Ball joint

Control link

8-12

Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Fuel Pipe - Inspect

High Pressure Fuel Injection Pipe and Clamp Seat - Inspect and Replace
Visual Inspection

Check clamp seat for cracks and wear. Check high

pressure fuel injection pipe for wear. If defective,

replace the clamp seat with a new one. Replace the

high pressure fuel injection pipe with a new one if

needed.

During Every Major Overhaul

Replace clamp seat with a new one. Also, check high

pressure fuel injection pipe for wear. If defective,

replace the high pressure fuel injection pipe with a

new one.

During Every Other Major Overhaul

Replace all high pressure fuel injection pipes with new

ones.

Fig. 8-13 High Pressure Fuel Injection Pipe and

Clamp Seat - Inspect and Replace

Low Pressure Fuel Pipe and Clip - Inspect
Visual Inspection During Overhaul

Loosen clamp retaining bolts and check for clip wear

and metal contact between pipe and clamp. If defec-

tive, replace the pipe assembly with a new one.

During Every Other Major Overhaul

Replace the pipe assembly with a new one.

Fig. 8-14 Low Pressure Fuel Pipe and Clip - Inspect

Clamp plate

Clamp seat

Clamp

8-13

Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Lubrication System

Engine Oil, Oil Filter and Bypass Oil Filter - Replace

Engine Oil - Drain

Drain engine oil from the drain port of oil pan after stopping the engine.

Before draining engine oil, make sure the oil has cooled.

When draining oil or replacing oil filters, be sure to wear gloves. You can get burned if you touch the hot engine oil

or parts.

Do not dump waste oil. It is forbidden by law. For disposal of waste oil, consult a dealer of Mitsubishi Heavy Indus-

tries, Ltd.

Engine oil, oil filter and bypass oil filter should be changed at the same time.

Also engine oil analysis is recommended when changing engine oil.

Do not reuse oil filter elements, as it is a paper type. When replacing filters, always replace gasket with new ones.

8-14

Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Oil Filter and Bypass Oil Filter - Replace

1. Clean the area around oil filters.

2. Prepare drip pans, and place them under oil filters

and bypass oil filter.

3. Using a filter wrench, remove oil filters and bypass

oil filter.

4. Thoroughly wipe off oil on the oil filter mounting

surface of the filter bracket with a cloth.

5. Check new oil filters and bypass filter to make sure

the gasket is properly seated in the groove.

6. Apply clean engine oil to gasket.

7. Install oil filters and bypass oil filter to the filter

bracket. When the gasket comes in contact with

the mounting surface of the filter bracket, further ro-

tate 3/4 to a full turn.

Fig. 8-15 Oil Filter and Bypass Oil Filter - Replace

Fig. 8-16 Oil Filter

If filter case is dented, do not use the filter. It can

damage the filter during operation, and may result in

a fire due to oil leaks.

Do not use a filter wrench to install the oil filter and

bypass oil filter. Tighten the filters by hand.

Be careful not to dent or scratch oil filter surfaces.

Bypass
oil filter

Filter bracket

Oil filter

Oil filter

Filter

Container

Apply engine oil
to gasket.

8-15

Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Engine Oil - Refill

1. Remove the oil filler cap.

2. Fill the engine oil pan with the specified engine oil

to the specified level.

Note: For engine oil, refer to "ENGINE OIL" (5-1). For

engine oil capacity, refer to "MAIN SPECIFICA-

TIONS" (12-1).

3. Check the oil level in the oil pan as follows:

4. Pull out the oil level gauge and wipe it clean with a

cloth.

5. Insert the oil level gauge fully into the oil level

gauge guide and then pull it out again.

6. The proper oil level is between the high and low

marks on the oil level gauge.

If the engine oil level is higher than the high mark

on the oil level gauge, drain engine oil by opening

drain valve. If the engine oil level is low, add the

specified engine oil.

7. Install the oil filler cap after adding engine oil.

8. Check the oil pan and other area for oil leaks. Re-

pair if there is oil leak.

9. With the manual stop lever placed in pulled posi-

tion, rotate the engine with starter for approx. 10

seconds to circulate oil to the whole engine. Stop

the rotation for 1 minute, then, repeat the rotation

two or three times to circulate the engine oil to each

engine parts.

Note: Also perform the procedures described under

Preparation for Cooling System.

10. Check the oil level with the oil level gauge again,

and add oil to the specified level.

Fig. 8-17 Oil Filler and Oil Level Gauge

Always refill with specified quantity of engine oil. If

the oil level is higher than the maximum mark on the

level gauge, engine oil may blow out during opera-

tion. Also, the increase of oil temperature could

adversely affect engine components.

H

L

Oil filler

Oil level gauge

Oil level gauge

High

Low

Improper

Improper

Proper

8-16

Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Fuel and Water Ingress In Engine Oil - Inspect

Sample 1 to 2 Liters [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, oil may turn milky white in color.

If fuel or water mixture is found in the engine oil, find the cause and repair. If you cannot repair, contact your local

dealer.

If the coolant enters the engine oil during operation, moisture vapor is discharged from the breather. In such case,

locate the fuel or water leak, and repair properly.

Note: If oil leaks from oil cooler, oil will float in water in the freshwater tank. Also, LLC that is not miscible with oil will

accumulate at the bottom of oil pan.

Oil Pipe - Inspect

Oil Pipe and Clip - Inspect and Replace
Visual Inspection at Overhaul

Loosen clamp fixing bolt and check clips and pipes for

wear. If defective, replace the pipe assembly with a

new one.

During Every Other Major Overhaul

Replace the pipe assembly with a new one.

Fig. 8-18 Oil Pipe and Clip - Inspect and Replace

If the engine operation is continued with fuel or water mixed in the engine oil, the engine oil viscosity will decrease

and this can cause serious accidents such as bearing seizure.

Clamp

8-17

Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Cooling System

Coolant - Change

Radiator Cap - Open/Close

Note: If the specification of radiator cap differs from the

contents of this operation manual, follow the

manufacturer's operation manual.

Fig. 8-19 radiator Cap

Do not dump the coolant (containing LLC) drained from the engine.

Such a way of disposal is strictly prohibited by laws and regulations.

Abide by the applicable law and regulations when discarding drained coolant.

When a coolant mixed with the LLC recommended by our company is used, replace coolant every 8000 hours or

2 years, whichever comes first for continuous use engine and general purpose engine. For emergency use

engine, replace coolant once every 2 years.

Never open the radiator cap during the operation or

immediately after the stop. Stop the engine and open

the cap after the coolant temperature lowers suffi-

ciently.

Place a waste cloth over the radiator cap, and loosen

the cap about a quarter-turn or stand the lever to the

upright position to release internal pressure.

The coolant is hot while engine is running and imme-

diately after the engine stops. If the cap is opened

when the coolant is at an operating temperature,

steam and hot coolant may blow out and result in

burns. To avoid a risk of getting scalded by steam,

wear thick rubber gloves or wrap a cloth around the

cap.

When fastening the radiator cap, be sure to tighten

securely.

Turn the cap about
1/4 turn to reliese
pressure.

Stand the lever to
the upright position
to reliese pressure.

8-18

Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Coolant - Drain

1. To drain coolant immediately after engine opera-

tion, run the engine at low idle for 5 to 6 minutes to

lower the coolant temperature to 70 to 80 °C [158

to 176 °F].

2. Open the coolant inlet.

3. Place coolant receiving cans under the drain cocks

and plugs, and open the coolant drain cocks and

plugs to drain the coolant.

Fig. 8-20 Coolant Drain Cock (Engine)

Cooling System - Clean

1. Close coolant drain cocks and plugs.

2. Pour a cleaning solution (a solution that is non-cor-

rosive to rubber and metals) into the cooling sys-

tem, and operate the engine at 800 to 900 min

-1

for

about 15 minutes, then drain the cleaning solution.

3. Close coolant drain cocks and plugs.

4. Add fresh water and operate the engine at 800 to

900 min

-1

for about 10 minutes.

Repeat the above rinsing steps until the draining

water becomes clear and clean.

Fig. 8-21 Coolant Drain Cock (water pump)

Coolant

drain cocks

Left side

Right side

The coolant drain cocks located in the crankcase
(behind the each fuel injection pump
accessory drive unit respectively).

Wash the cooling system before operating the

engine for the first time, or starting the engine after it

has been in storage under coolant drained condition.

Coolant
drain cock

8-19

Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Coolant - Refill (Engine)

Note: If the specification of radiator differs from the

contents of this operation manual, follow the

manufacturer's operation manual.

1. Make sure coolant drain cocks are closed securely.

2. Remove the radiator cap, and add a mixture of wa-

ter and LLC of the specified concentration to the

specified level.

Note: (a) Determine the quantities of LLC based on the

coolant capacity and the LLC concentration

chart.

For the coolant, refer to"COOLANT" (6-1).

For the coolant capacity, refer to "MAIN

SPECIFICATIONS" (12-1).

(b) For absolute air bleeding, loosen the air vent

plug.

3. Check the radiator and other parts for coolant

leaks. Repair leakage if found.

4. When coolant reaches the specified level, close the

radiator cap securely.

5. With the manual stop lever placed in the pulled po-

sition, crank the engine for approx 10 seconds us-

ing the starter. Stop cranking for 1 minute, then,

repeat the cranking two or three times to bleed the

cooling system.

Note: Prepare for the lubricating system and refilling

the coolant to the Air Cooler.

6. Check the coolant level in the radiator.

Fig. 8-22 Coolant Drain Cock (Engine)

Fig. 8-23 Coolant Drain Cock

(Engine water pump)

Fig. 8-24 Air Vent Plug (Engine Cooling System)

When adding coolant, use the same LLC concentra-

tion coolant that is currently in the cooling system.

Coolant

drain cocks

Left side

Right side

The coolant drain cocks located in the crankcase
(behind the each fuel injection pump
accessory drive unit respectively).

Coolant
drain cock

Air vent plug

8-20

Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Coolant - Refill (Air Cooler)

Note: If the specification of radiator differs from the

contents of this operation manual, follow the

manufacturer's operation manual.

1. Make sure coolant drain cocks are closed securely.

2. Remove the radiator and add a mixture of water

and coolant having the specified concentration.

Note: (a) Determine the quantities of LLC based on the

coolant capacity and the LLC concentration

chart.

For the coolant, refer to "COOLANT" (6-1).

For the coolant capacity, refer to "MAIN

SPECIFICATIONS" (12-1).

(b) For absolute air bleeding, loosen the air vent

plug.

3. Check the radiator and other parts for coolant

leaks. Repair leakage if found.

4. When coolant reaches the full level, close the cool-

ant filler securely.

5. While pulling the manual stop lever, crank the en-

gine for approx 10 seconds using the starter. Stop

the operation for 1 minute, then, repeat the opera-

tion two or three times to bleed the cooling system.

Note: Prepare for the lubricating system and refilling

the coolant to the engine.

6. Check the coolant level in the radiator.

Fig. 8-25 Coolant Drain Cock (Air Cooler)

Fig. 8-26 Coolant Drain Cock

(Air Cooler water pump)

Always use the coolant having the same concentra-

tion.

Coolant drain cock

Air vent plug

Air vent cocks

8-21

Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Inlet and Exhaust Systems

Turbocharger - Inspect

Disconnect the pipe on the inlet side. Hold the com-

pressor wheel nut by hand and move in the axis direc-

tion and from right to left and up and down to check

looseness. Turn the wheel to check if it rotates

smoothly. Replace if there is looseness or the wheel

does not rotate smoothly.

Note: When the inspection requires the removal of tur-

bocharger, contact your local dealer.

Also check the compressor wheel fins for discol-

oration and breaks, and check for rubbing be-

tween compressor wheel and housing.

Fig. 8-27 Turbocharger - Inspect

Pre-cleaner - Clean, Inspect and Replace

The pre-cleaner, which is attached to the silencer of

the turbocharger, prevents foreign materials from

entering the engine and keeps the engine clean for

optimum performance. Always keep it clean as

instructed below.

1. Remove the pre-cleaner from the silencer, and

hand-wash the pre-cleaner with a mild detergent.

2. Rinse the pre-cleaner with fresh water.

3. After drying thoroughly, inspect the pre-cleaner for

damage such as breaks. If breaks or etc. are found,

replace the pre-cleaner with a new one.

4. After cleaning, inspection or replacement, install

the pre-cleaner to the silencer.

Fig. 8-28 Pre-cleaner - Clean

Inspect the turbocharger when the engine is cold.

Also, make sure that the compressor wheel is not

rotating.

The turbocharger inspection should be also con-

ducted if the color of the exhaust gas is abnormal.

Never remove pre-cleaners during engine operation

for cleaning or overhauling. If dust and dirt enter the

engine, it will cause rapid wear of parts, shortening

the service life of the engine.

Water

(Wash)

(Dry)

Install

(Rinse)

Mild
detergent

8-22

Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Air Cleaner Element - Clean, Check and Replace

When handling compressed air, wear safety goggles, a dust mask, a hardhat, gloves and other necessary protec-

tive gears. Working without wearing proper protective gear could result in serious injuries.

Never service the air cleaner while the engine is running. Servicing the pre-cleaner while the engine is running can

cause particles of foreign material to enter the engine and it results in rapid wear of parts, leading to a shorter ser-

vice life of the engine. Never tap or hit the air cleaner element.

And also, do not wash the air cleaner element.

If defects such as a cut, pinhole or local wear are found in the element, or if the air cleaner indicator shows a red

sign soon after the cleaned element is installed, change it with a new one. Remove the air cleaner slowly to pre-

vent foreign materials accumulated on the element from falling off.

After removing the air cleaner, immediately cover the air inlet with plastic sheet or similar means to prevent foreign

materials from entering the engine.

8-23

Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

1. Remove the air cleaner cap or wing bolt.

2. Remove the air cleaner element from the body.

3. Blow compressed air (0.69 MPa {7 kgf/cm

2

} [100

psi] or lower) onto the inside surface of the element

to remove foreign materials.

4. To remove dust stuck on the air cleaner element,

blow dry compressed air onto the outside surface

from a distance.

Blow compressed air on the inside surface toward

the outside along the pleats. Then, blow com-

pressed air on the outside and inside surface

again.

5. After cleaning, hold the air cleaner element near a

light bulb to illuminate the inside, to check for de-

fects such as cuts, pinholes or local wear.

6. If any defect is found, replace the air cleaner ele-

ment with a new one.

7. Reassemble the air cleaner element as it was.

8. After cleaning or replacing the air cleaner element,

press the reset button to reset the indicator.

Note: If the specification of air cleaner differs from the

contents of this operation manual, follow the

manufacturer's operation manual.

Fig. 8-29 Air Cleaner Element - Remove

Fig. 8-30 Air Cleaner Element - Clean and Check

Fig. 8-31 Air Cleaner - Check for Clogging

Air cleaner
element

Body

Wing
bolt

Clean Check

Reset button

Signal
(red)

8-24

Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Electrical System

Battery - Check

Note: If the specification of battery differs from those of this operation manual, follow the manufacturer's operation

manual.

Battery Electrolyte Level - Inspect

The battery electrolyte evaporates in the use, and the

electrolyte level gradually decreases. The proper elec-

trolyte level is between the LOWER LEVEL and

UPPER LEVEL marks.

For the battery without level marks, the proper electro-

lyte surface level is about 10 to 15 mm [0.39 to 0.59

in.] above the top of the polar plates.

If the electrolyte level is low, remove the caps and add

distilled water to the proper level.

Note: When adding distilled water, add little by little.

Fig. 8-32 Battery Electrolyte Level - Inspect

Never use flames or allow sparks near the battery. The battery releases flammable hydrogen gas and oxygen gas.

Any flames or sparks in the vicinity could cause an explosion.

Do not use the battery when the battery electrolyte level is below the "LOWER LEVEL" mark. Continual use may

result in an explosion.

Do not short the battery terminals with a tool or other metal object.

When removing battery, always remove the plug from the negative (-) terminal first. When connecting battery,

always connect the plug to the positive (+) terminal first.

Remove all battery cables, then charge the battery in a well ventilated area.

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 conducting electric welding, set the battery switch to [Open/OFF] posi-

tion or remove the plug from the negative (-) terminal to cut off the electrical current.

Electrolyte (battery electrolyte) contains dilute sulfuric acid.Careless handling of the battery can lead to loss of

sight and/or skin burns. Also, do not swallow the battery electrolyte.

Wear protective goggles and rubber gloves when working with the battery (e.g. when adding water or charging

battery).

If battery electrolyte is spilled onto the skin or clothing, immediately wash it away with lots of water. Use soap to

thoroughly clean.

The battery electrolyte can cause blindness if splashing into the eyes.If it gets into your eyes, immediately flush it

away with plenty of clean water, and seek immediate medical attention.

If you accidentally swallow battery electrolyte, gargle with plenty of water and then drink lots of water, and seek

immediate medical attention.

If the battery does not fully recover after 24 hours charging or more, do not use the battery.

UPPER LEVEL

LOWER LEVEL

10 to 15 mm
[0.39 to 0.59 in.]

Proper