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('#41(#(+4'
6 * ' 4 ' + 5 ( ' # 4 1 ( # ( + 4 '
#
#
241*+$+6+10
241*+$+6+10
2.'#5'&1016$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 coolantinlet
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
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