Mitsubishi S16R-Y1PTA, S12R-Y1PTA, S6R-Y1PTA Maintance Manual

OPERATION &
MAINTENANCE MANUAL

199405-A0120

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.

October 2009

Pub. No. 99405-A0120

TP-6547 10/09

INTRODUCTION

This operation and maintenance manual contains detailed operation, inspection

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

Please read this manual thoroughly before proceeding with operation, inspection,

and maintenance work for correct use and servicing.

Please observe the contents of the emission controls which are applied in the

countries or areas where the engine is used.

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

i

FOREWORD











LIMITED WARRANTY

Mitsubishi Heavy Industries, Ltd. will repair or replace parts returned to us when we judge that the parts are defec-

tive in material and/or workmanship after conducting inspection.

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, that the warranty coverage is effective for the ultimate purchaser and each

subsequent 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 market-

ability, merchantability, fitness for a particular 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 costs 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 long life coolant (LLC) that we are not recom-

mended.

The owner of the engine is responsible for the performance of the required 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.

ii

FOREWORD

EMISSION WARRANTY

The following warranty applies to the engines that are approved of the emission regulation of the U.S. Environ-

mental Protection Agency.

Warranty coverage

Mitsubishi Heavy Industries, Ltd. warrants to the first owner and each subsequent purchaser of a new non-road die-

sel engine that the emission control system of your engine:

is designed, built and equipped so as to conform at the time of sales with all applicable regulation of the U.S. Envi-

ronmental Protection Agency. If the vehicle in which the engine is installed is registered in the state of California, a

separate California emission regulation also applies.

is free from the defects in material and workmanship which will cause the engine to fail to meet these regulations

within the warranty period.

Warranty period

Then its warranty period is 5 years or 3000 hours, whichever comes first.

However, if your engine warranty period is longer than the emission warranty period, the emission warranty period

extends to same as the engine warranty period.

Below warranty period shall begin on the date the engine is delivered to the first owner.

Warranted parts

Mitsubishi Heavy Industries, Ltd. warrants the parts which will increase the emission of pollutants when they

become defective.

The followings are examples.

Inlet/Exhaust manifold

Crankcase ventilation system

Fuel system

Fuel injection nozzle

Limited warranty

Refer to "Limited warranty" (Page ii).

iii

FOREWORD

CALIFORNIA EMISSION CONTROL WARRANTY STATE-

MENT YOUR WARRANTY RIGHTS AND OBLIGATIONS

The following warranty applies to the engines that are approved of the emission regulation of the California Air

Resources Board (CARB).

The California Air Resources Board (CARB) is pleased to explain the emission control system warranty on

you 2008 or later engine. In California, new heavy-duty off-road engines must be designed, built, and equipped to

meet the State's stringent anti-smog standards. Mitsubishi Heavy Industries, Ltd. must warrant the emission control

system on your engine for the periods of time listed below provided there has been no abuse, neglect or improper

maintenance of your engine.

Your emission control system may include parts such as the fuel-injection system and the air induction system. Also

included may be hoses, belts, connectors and other emission-related assemblies.

Where a warrantable condition exists, Mitsubishi Heavy Industries, Ltd. will repair your heavy-duty off-road engine

at no cost to you including diagnosis, parts, and labor.

Manufacurer's warranty coverage:

The 2008 and later heavy-duty off-road engines are warranted for the warranty period. If any emission-related part

on your engine is defective, the part will be repaired or replaced by Mitsubishi Heavy Industries, Ltd.

Owner's warranty responsibilities:

As the heavy-duty off-road engine owner, you are responsible for the performance of the required maintenance

listed in your owner's manual. Mitsubishi Heavy Industries, Ltd. recommends that you retain all receipts covering

maintenance on your heavy-duty off-road engine, but Mitsubishi Heavy Industries, Ltd. cannot deny warranty

solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.

As the heavy-duty off-road engine owner, you should however be aware that Mitsubishi Heavy Industries, Ltd. may

deny you warranty coverage if your heavy-duty off-road engine or a part has failed due to abuse, neglect, improper

maintenance or unapproved modifications.

Your engine is designed to operate on diesel fuel only. Use of any other fuel may result in your engine no longer

operating in compliance with California's emissions requirements.

You are responsible for initiating the warranty process. The Air Rexources Board suggests that you present your

heavy-duty off-road engine to a Mitsubishi Heavy Industries, Ltd. dealer or distributor dealer as soon as problem

exists. The warranty repairs should be completed by the dealer or distributor as expeditiously as possible.

If you have any questions regarding your warranty rights and responsibilities, you should contact Mitsubishi
Engine North America at 1-630-268-0750.

iv

FOREWORD

Warranty coverage:

(a) The warranty period shall begin on the date the engine or equipment is delivered to an ultimate purchaser.

(b) Mitsubishi Heavy Industries, Ltd. warrants to the ultimate purchaser and each subsequent purchaser of the en-

gine registered in the state of California that the engine is:

(1) Designed, built and equipped so as to conform with all applicable regulations adopted by the Air Resources

Board.

(2) Free from defects in materials and workmanship which cause the failure of a warranted part to be identical

in all material respects to the parts as described in Mitsubishi Heavy Industries, Ltd.'s application for certifi-

cation for a period of 5 years or 3,000 hours of operation, whichever occurs first.In the absence of a device

to measure hours of use, the engine shall be warranted for a period of 5 years. For all engines rated less

than 19 kW, and for constant-speed engines rated under 37 kW with rated speeds higher than or equal to

-1

3,000 min

sence of a device to measure hours of use, the engine shall be warranted for a period of 2 years.

(c) The warranty on emission-related parts shall be interpreted as follows:

(1) Any warranted part which is not scheduled for replacement as required maintenance in the written instruc-

tions required by Subsection (e) shall be warranted for the warranty period defined in Subsection (b) (2). If

any such part fails during the period of warranty coverage, it shall be repaired or replaced by Mitsubishi

Heavy Industries, Ltd. according to Subsection (4) below. Any such part repaired or replaced under the war-

ranty shall be warranted for the remaining warranty period.

(2) Any warranted part which is scheduled only for regular inspection in the written instructions required by Sub-

section (e) shall be warranted for the warranty period defined in Subsection (b) (2). A statement in such writ-

ten instructions to the effect of "repair or replace as necessary" shall not reduce the period of warranty

coverage. Any such part repaired or replaced under the warranty shall be warranted for the remaining war-

ranty period.

(3) Any warranted part which is scheduled for replacement as required maintenance in the written instructions

required in Subsection (e) shall be warranted for the period of time prior to the first scheduled replacement

point for that part. If the part fails prior to the first scheduled replacement, the part shall be repaired or re-

placed by Mitsubishi Heavy Industries, Ltd. according to Subsection (4) below. Any such part repaired or

replaced under warranty shall be warranted for the remainder of the period prior to the first scheduled re-

placement point for the part.

(4) Repair or replacement of any warranted part under the warranty provisions shall be performed at no charge

to the owner at a warranty station.

(5) Notwithstanding the provisions of Subsection (4) above, warranty services or repairs shall be provided at all

Mitsubishi Heavy Industries, Ltd. distribution centers that are franchised to service the subject engines.

(6) The owner shall not be charged for diagnostic labor that leads to the determination that a warranted part is

in fact defective, provided that such diagnostic work is performed at a warranty station.

(7) Mitsubishi Heavy Industries, Ltd. shall be liable for damages to other engine components proximately caused

by failure under warranty of any warranted part.

(8) Throughout the engine's warranty period defined in Subsection (b) (2), Mitsubishi Heavy Industries, Ltd. shall

maintain a supply of warranted parts sufficient to meet the expected demand for such parts.

(9) Any replacement part may be used in the performance of any maintenance or repairs and must be provided

without charge to the owner. Such use shall not reduce the warranty obligations of Mitsubishi Heavy Indus-

tries, Ltd.

, the period of 2 years or 1,500 hours of operation, whichever occurs first, shall apply. In the ab-

v

FOREWORD

(10) Add-on or modified parts that are not exempted by the Air Resources Board may not be used. The use of

any non-exempted add-on or modified parts shall be grounds for disallowing a warranty claim. Mitsubishi

Heavy Industries, Ltd. shall not be liable to warrant failures of warranted parts caused by the use of a non-

exempted add-on or modified part.

(11) The Air Resources Board may request and, in such case, Mitsubishi Heavy Industries, Ltd. shall provide,

any documents which describe that Mitsubishi Heavy Industries, Ltd.'s warranty procedures or policies.

(d) Warranted parts list.

(1) Fuel metering system

(A) Fuel injection system.

(B) Air/fuel ratio feedback and control system.

(C) Cold start enrichment system.

(2) Air induction system

(A) Controlled hot air intake system.

(B) Intake manifold.

(C) Heat riser valve and assembly.

(D) Turbocharger/supercharger systems.

(E) Charged air cooling systems.

(3) Exhaust gas recirculation (EGR) system

(A) EGR valve body, and carburetor spacer if applicable.

(B) EGR rate feedback and control system.

(4) Air injection system

(A) Air pump or pulse valve.

(B) Valves affecting distribution of flow.

(C) Distribution manifold.

(5) Catalyst or thermal reactor system

(A) Catalytic converter.

(B) Thermal reactor.

(C) Exhaust manifold.

(6) Particulate controls

(A) Traps, filters, precipitators, and any other devices used to capture particulate emissions.

(B) Regenerators, oxidizers, fuel additive devices, and any other device used to regenerate or aid in the

regeneration of the particulate control device.

(C) Control device enclosures and manifolding.

(D) Smoke puff limiters.

(7) Advances oxides of nitrogen (NOx) controls

(A) NOx absorbers.

(B) Lean NOx catalysts.

(C) Selective catalyst reduction.

(D) Reductant (urea/fuel) containers/dispensing systems.

(8) Positive crankcase ventilation (PCV) system

(A) PCV valve.

(B) Oil filler cap.

(9) Miscellaneous items used in above systems

(A) Vacuum, temperature, and time sensitive valves and switches.

(B) Electronic control units, sensors, solenoids, and wiring harnesses.

vi

FOREWORD

(C) Hoses, belts, connectors, assemblies, clamps, fittings, tubing, sealing gaskets or devices, and mount-

ing hardware.

(D) Pulleys, belts and idlers.

(E) Emission control information labels.

(F) Any other part with the primary purpose of reducing emissions or that can increase emission during fail-

ure without significantly degrading engine performance.

(e) Mitsubishi Heavy Industries, Ltd. shall furnish with each new engine written instructions for the maintenance and

use of the engine by the owner.

Limited warranty:

Refer to "Limited warranty" (Page ii).

vii

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 danger

resulting from human error and other causes, or dan-

ger 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 directions 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 add safety, caution and operating signs that

describe the original warning label statements in the

native language of the operators.

The engine must be operated, maintained and

inspected only by qualified persons who have 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 provide this manual with the engine to the

new owner. 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.

The contents in this manual are subject to change at

any time without notice for improvement of the

engine.

Pictures or illustrations of the product in this manual

may differ from those of 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 a dealer of Mitsubishi Heavy Indus-

tries, Ltd. if you need more information or if you have

any questions.

If you lost or damaged this manual, obtain a new

copy at a dealer of Mitsubishi Heavy Industries, Ltd.

as soon as possible.

Mitsubishi Heavy Industries, Ltd. recommends the

engine owner to install an hour meter on the engine

due to monitor correct running intervals and to per-

form the maintenance at the appropriate timing.

viii

FOREWORD

WARNING INDICATION

The following means are used to call the attention of the operators and maintenance personnel to potential dangers

of the engine.

Warning statements in the manual

Warning labels affixed on the engine

Warning 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 with 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.

ix

FOREWORD

UNITS OF MEASUREMENT

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

units in this manual using the following conversion rates.

Pressure :1 MPa = 10.197 kgf/cm

Torque:1 N•m = 0.10197 kgf•m

Force:1 N = 0.10197 kgf

Horsepower:1 kW = 1.341 HP = 1.3596 PS

Meter of mercury:1 kPa = 0.75 cmHg

Meter of water:1 kPa = 10.197 cmH

Rotational speed:1 min

Kinetic viscosity:1 mm

-1

= 1 rpm

2

/s = 1 cSt

2

2O (cmAq)

ABBREVIATIONS, STANDARD 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

x

CONTENTS

Chapter 1
BASIC SAFETY PRECAUTIONS

Fire and explosions .............................1-1

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

Care for fuel, oil and exhaust gas leakage....... 1-1

Use explosion-proof lighting apparatus............ 1-1

Prevent electrical wires from short-circuiting.... 1-1

Keep fire extinguishers and first-aid kit handy . 1-1

Stay clear of all rotating and moving

parts ....................................................1-2

Install protective covers around rotating parts . 1-2

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

Stay clear of moving parts while engine is

running ............................................................. 1-2

Lockout and tagout .......................................... 1-2

Keep engine stopped during servicing............. 1-2

Always restore engine turning tools after use .. 1-2

Be careful of exhaust fume poisoning .1-3

Operate engine in a well-ventilated area.......... 1-3

Protect ears from noise .......................1-3

Wear ear plugs................................................. 1-3

Be careful of falling down ....................1-3

Lift engine carefully .......................................... 1-3

Do not climb onto the engine ........................... 1-3

Always prepare stable scaffold ........................ 1-3

Be careful of burns ..............................1-4

Do not touch the engine during or immediately after

operation .......................................................... 1-4

Refill coolant only after the coolant temperature

dropped............................................................ 1-4

Never remove heat shields .............................. 1-4

Do not open the radiator filler cap when the engine

is hot ................................................................ 1-4

Do not touch high pressure injection fuel ......... 1-4

Be careful when handling fuel, engine oil or

LLC......................................................1-5

Use only specified fuel, engine oil and LLC ..... 1-5

Handle LLC carefully........................................ 1-5

Proper disposal of waste oil, LLC and coolant. 1-5

When abnormality occurs....................1-5

Do not add coolant immediately after a sudden stop

due to overheating ........................................... 1-5

Avoid immediate restart after abnormal stop ... 1-5
Avoid continuous engine operation at low oil

pressure ........................................................... 1-5

If belt breaks, stop engine immediately............ 1-5

Service battery .................................... 1-6

Handle the battery correctly ............................. 1-6

Other cautions..................................... 1-7

Never modify engine ........................................ 1-7

Observe safety rules at work site ..................... 1-7

Work clothing and protective gear.................... 1-7

Never break the seals ...................................... 1-7

Perform all specified pre-operation inspections and

periodic inspections.......................................... 1-7

Break-in the engine .......................................... 1-7

Warm-up the engine before use....................... 1-7

Never operate the engine in an overloaded

condition........................................................... 1-7

Conduct cooling operation before stopping the

engine .............................................................. 1-8

Protection of the engine against water entry.... 1-8

Conduct proper maintenance of air cleaner ..... 1-8

Use of tools optimum for each work................. 1-8

Avoidance of prolonged time of starter

operation .......................................................... 1-8

Do not turn off the battery switch during

operation .......................................................... 1-8

Cautionary instructions for transporting the

engine .............................................................. 1-8

Do not operate engine continuously under low

load .................................................................. 1-8

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

Maintenance of warning labels......................... 1-9

Chapter 2
NAME OF PARTS

Engine external diagrams ................... 2-1

Engine front...................................................... 2-1

Engine rear....................................................... 2-1

Left view ........................................................... 2-2

Right view......................................................... 2-2

Equipment and instrument .................. 2-3

Start and stop instrument ................................. 2-3

Instruments ...................................................... 2-3

Engine protection devices................... 2-4

Oil filter alarm switch ........................................ 2-4

Air cleaner indicator ......................................... 2-4

Using turning gear............................... 2-5

CONTENTS-1

CONTENTS

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 of cooling system.......................... 3-5

Preparation of electrical system ....................... 3-6

Test operation .................................................. 3-6

Normal engine operation .....................3-7

Preparations for operation...................3-7

Engine external - Inspect ................................. 3-7

Fuel tank oil level - Check ................................ 3-8

Fuel tank - Drain water..................................... 3-8

Engine oil level - Check.................................... 3-9

Coolant level - Check ..................................... 3-10

Fuel control link - Check................................. 3-10

Air cleaner - Check......................................... 3-11

Temperature of damper - Check .................... 3-11

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

Warm-up operation............................3-12

Checking engine oil pressure......................... 3-12

External inspection during warm-up............... 3-12

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

Cautions when operating ............................... 3-13

Inspection during operation............................ 3-13

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

Emergency stop ............................................. 3-14

Inspection after stopping................................ 3-14

Total base number ........................................... 5-3

Total acid number ............................................ 5-3

Water content................................................... 5-3

Flash point........................................................ 5-3

Insoluble........................................................... 5-3

Service limits of engine oil .................. 5-4

Engine oil analysis service.................. 5-4

Chapter 6
COOLANT

Recommended water for coolant ........ 6-1

Long life coolant (LLC)........................ 6-1

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

Other brand LLCs ............................... 6-2

Standard for other brand LLC ............. 6-2

General demands of LLC ................................. 6-2

LLC specification.............................................. 6-3

Maintenance of LLC............................ 6-5

Replacement intervals of LLC .......................... 6-5

LLC concentration ............................................ 6-5

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

Characteristics of LLC additive and

important notes ................................... 6-6

Examples of abnormalities caused by LLC

(amine type) ........................................ 6-6

Pitting of iron parts ........................................... 6-6

Corrosion of aluminum parts ............................ 6-6

Pitting and clogging of the radiator................... 6-6

Chapter 4
FUEL

Recommended fuel .............................4-1

Handling fuel........................................4-1

Chapter 5
ENGINE OIL

Recommended engine oil....................5-1

Selection of oil viscosity.......................5-1

Handling engine oil..............................5-1

Engine oil performance requirements..5-2
Engine oil deterioration mechanisms...5-2

Definition of properties of engine oil ....5-3

Kinetic viscosity................................................ 5-3

CONTENTS-2

Chapter 7
MAINTENANCE SCHEDULE

How to use the maintenance schedule7-1

General definition of engine ................ 7-1

Periodic maintenance chart for regular use

engine ................................................. 7-2

Periodic maintenance chart for emergency

engine ................................................. 7-4

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

CONTENTS

Damper - Inspect.............................................. 8-3

Fuel system .........................................8-5

Fuel system - Inspect ....................................... 8-5

Fuel tank - Clean.............................................. 8-5

Fuel tank - Drain water..................................... 8-5

Fuel control link ball joint - Inspect ................... 8-6

Gauze filter - Clean .......................................... 8-6

Fuel filter - Replace .......................................... 8-7

Fuel pipe - Inspect............................................ 8-8

Lubricating system...............................8-9

Engine oil, Oil filter and Bypass oil filter -

Replace............................................................ 8-9

Engine oil for mixing of fuel and water -

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

Oil pipe - Inspect ............................................ 8-12

Cooling system..................................8-13

Coolant - Change ........................................... 8-13

Radiator fins - Check and Clean .................... 8-15

Inlet and exhaust systems.................8-16

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

Draining water from the exhaust muffler ........ 8-16

Air cleaner element - Clean, Check and

Replace.......................................................... 8-17

Electrical system................................8-18

Starter - Inspect.............................................. 8-19

Alternator - Inspect......................................... 8-19

Chapter 11
TROUBLESHOOTING

General precautions.......................... 11-1

Contact a dealer of Mitsubishi Heavy Industries, Ltd.

for repair service ............................................ 11-1

Considerations before work ........................... 11-1

Cautions against contamination ..................... 11-1

Cautions regarding parts handling ................. 11-1

Work safety .................................................... 11-1

Troubleshooting ................................ 11-2

The starter does not crank or cranks slowly,

resulting in start failure ................................... 11-2

The starter cranks, but the engine does not

start ................................................................ 11-2

Output decrease............................................. 11-3

Exhaust smoke is white or blue...................... 11-4

Exhaust smoke is black or charcoal............... 11-5

Fuel consumption is high ............................... 11-6

Engine oil consumption is high....................... 11-7

Overheating.................................................... 11-7

Low engine oil pressure ................................. 11-8

When fuel has run out....................... 11-8

Chapter 12
MAIN SPECIFICATIONS

Main specifications............................ 12-1

Chapter 9
LONG-TERM STORAGE

Storing the engine in an inoperable

condition for 3 months or more............9-1

Preparation for storage .................................... 9-1

Maintenance during storage............................. 9-1

Using the engine after storage......................... 9-2

Storing the engine in an operable condition

for 3 months or more ...........................9-2

Operating the engine for maintenance............. 9-2

Chapter 10
TRANSPORTATION

Lifting the engine ...............................10-1

CONTENTS-3

CONTENTS

List of Illustrations

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

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 ................. 2-3

Fig. 2-8 Oil filter alarm switch ............................ 2-4

Fig. 2-9 Air cleaner indicator.............................. 2-4

Fig. 2-10 Turning gear position

(while engine is running) ...................... 2-5

Fig. 2-11 Turning gear position

(when pushing shaft in) ........................ 2-5

Fig. 2-12 Turning gear position

(when turning shaft).............................. 2-5

Fig. 3-1 Priming pump - Handle......................... 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 (Water pump)......... 3-5

Fig. 3-10 Radiator coolant level........................... 3-5

Fig. 3-11 Reserve tank coolant level ................... 3-5

Fig. 3-12 Battery electrolyte level - Inspect ......... 3-6

Fig. 3-13 Valves for open/closed position - Check3-7

Fig. 3-14 Fuel tank - Drain water......................... 3-8

Fig. 3-15 Oil filler and Oil level gauge.................. 3-9

Fig. 3-16 Radiator filler cap ............................... 3-10

Fig. 3-17 Radiator coolant level......................... 3-10

Fig. 3-18 Reserve tank coolant level ................. 3-10

Fig. 3-19 Fuel control link - Check..................... 3-10

Fig. 3-20 Air cleaner - Check............................. 3-11

Fig. 3-21 Thermo label of damper ..................... 3-11

Fig. 3-22 Manual stop lever ............................... 3-14

Fig. 5-1 Recommended engine oil..................... 5-1

Fig. 5-2 Selection of oil viscosity ........................5-1

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

Fig. 8-1 Belt and belt tension - Inspect and Adjust8-

2

Fig. 8-2 Damper - Check visually .......................8-3

Fig. 8-3 Damper temperature management .......8-4

Fig. 8-4 Fuel tank - Drain water..........................8-5

Fig. 8-5 Ball joints for looseness - Inspect..........8-6

Fig. 8-6 Fuel control link - Remove.....................8-6

Fig. 8-7 Gauze filter - Clean ...............................8-6

Fig. 8-8 Fuel filter - Replace ...............................8-7

Fig. 8-9 Fuel filter ...............................................8-7

Fig. 8-10 High pressure fuel injection pipe and

Clamp seat - Inspect .............................8-8

Fig. 8-11 Low pressure fuel pipe and Clip -

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

Fig. 8-12 Oil filler and Oil level gauge ................8-10

Fig. 8-13 Oil filter and Bypass oil filter - Replace8-11

Fig. 8-14 Oil filter ................................................8-11

Fig. 8-15 Oil pipe and Clip - Inspect and Replace8-12

Fig. 8-16 Radiator filler cap ................................8-13

Fig. 8-17 Coolant drain cock (engine) ................8-13

Fig. 8-18 Coolant drain cock (water pump) ........8-14

Fig. 8-19 Radiator coolant level..........................8-14

Fig. 8-20 Reserve tank .......................................8-14

Fig. 8-21 Radiator fins - Clean ...........................8-15

Fig. 8-22 Turbocharger - Inspect........................8-16

Fig. 8-23 Draining water from the exhaust muffler8-16

Fig. 8-24 Air cleaner element - Remove.............8-17

Fig. 8-25 Air cleaner element - Clean and Check8-17

Fig. 8-26 Air cleaner - Check..............................8-17

Fig. 8-27 Battery electrolyte level - Inspect ........8-18

Fig. 8-28 Specific gravity of battery electrolyte -

Check ..................................................8-18

Fig. 8-29 Starter - Inspect...................................8-19

Fig. 8-30 Alternator - Inspect..............................8-19

Fig. 10-1 Hangers...............................................10-1

Fig. 10-2 Engine's center of gravity

(standard specification) .......................10-1

CONTENTS-4

List of Tables

Table 3-1 Standard values at rated speed............ 3-13

Table 4-1 Recommended fuel ................................ 4-1

Table 4-2 Recommended limit and use limit of

fuel property............................................ 4-2

Table 5-1 Engine oil properties............................... 5-4

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

Table 6-2 LLC specification .................................... 6-3

Table 6-3 Recommended LLC concentration ......... 6-5

Table 7-1 Periodic maintenance chart for regular

use engine .............................................. 7-2

Table 7-2 Periodic maintenance chart for emergency

engine..................................................... 7-4

Table 8-1 Thermo label for temperature

management........................................... 8-4

Table 8-2 Specific gravity of electrolyte ................ 8-18

Table 9-1 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................................................. 11-2

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

Table 11-4 Exhaust smoke is white or blue ............ 11-4

Table 11-5 Exhaust smoke is black or charcoal ..... 11-5

Table 11-6 Fuel consumption is high...................... 11-6

Table 11-7 Engine oil consumption is high ............. 11-7

Table 11-8 Overheating .......................................... 11-7

Table 11-9 Low engine oil pressure........................ 11-8

Table 12-1 Main specifications ............................... 12-1

CONTENTS

CONTENTS-5

Chapter 1 BASIC SAFETY PRECAUTIONS

Fire and explosions

Keep flames away

Do not use flames near the engine (in

the engine room). Fuel vapor or other

gas can catch fire and produce dan-

gerous 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.

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 thor-

oughly. Such materials can cause fire or the engine to

overheat. In particular, clean the top surface of the

battery thoroughly. 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.

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 allows fresh

air to flow into the crankcase, which can cause oil mist

to ignite and explode.

Care for fuel, oil and exhaust
gas leakage

If any fuel, oil or exhaust gas leakage is found, imme-

diately take corrective measures to stop it.

Such leakages, if left uncorrected, can cause fuel or

engine oil to reach hot engine surfaces or hot exhaust

gas to contact flammable materials, possibly leading

to personal injury and/or damage to equipment.

Use explosion-proof lighting
apparatus

When inspecting fuel, engine oil, coolant, battery elec-

trolyte, etc., use a flameproof light. An ordinary light-

ing 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 beginning with the work procedure.

Short-circuits, possibly resulting in fire, may be

caused by a loose terminal or damaged cable/wire.

Inspect the terminals, cables and wires, and repair or

replace the faulty parts before beginning with the ser-

vice procedure.

Keep fire extinguishers and
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.

1-1

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.

Never remove the covers protecting

the rotating parts while engine is run-

ning.

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.

Verbally notify persons within the immediate 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 while
engine is running

Do not approach rotating or sliding

parts of the engine while the engine is

running. Keep objects likely to be

caught by rotating parts away from

such parts.

If any part of the clothing or outfitting is caught by a

rotating part, serious bodily injuries could result.

Lockout and tagout

Be sure to lockout and tagout before starting inspec-

tion and maintenance.

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, set the battery switch to OFF and attach a

"Do Not Run" or similar caution tag to the starter

switch.

The starter switch key must be kept by the person

who performs inspection and maintenance during the

work.

Keep engine stopped during
servicing

Be sure to stop the engine before proceeding to

inspection and service procedure. Never attempt to

make adjustments on the engine parts while the

engine is running.

Rotating parts such as belt can entangle your body

and cause serious injuries.

Always restore engine turning
tools after use

Be sure to remove all turning tools used during main-

tenance and inspection work. Remember also that the

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.

1-2

Chapter 1 BASIC SAFETY PRECAUTIONS

Be careful of exhaust
fume poisoning

Operate engine in a well-venti­lated area

Check the exhaust pipes and where

the pipes joint together for gas leaks.

Exhaust gas from the engine contains

carbon monoxide and other harmful

substances. Operating the engine in

an poorly-ventilated area can produce 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.

Be careful of falling down

Lift engine carefully

To lift the engine, use slings capable

of supporting the weight of the

engine.

Attach the wire rope to the hangers

provided on the engine using a cor-

rect sling.

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

anced position by taking the center of gravity of the

engine into consideration.

The hangers equipped with the engine are designed

for lifting the engine only. Be careful not to affect the

hangers by added weight if installing the generator or

marine gear to the engine.

Keep the angle formed by slings attached to hangers

within 60°. 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.

If the wire rope contacts the engine directly, place a

cloth or other soft padding to avoid damage to the

engine and wire rope.

Do not climb onto the engine

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

parts located on the lateral sides.

To work on parts located on the upper section of

engine, use a ladder, stool, etc., that was firmly

secured.

Climbing on the engine may not only damage engine

parts but also cause falling down from the engine and

result in personal injuries.

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 place any unnecessary objects on a work plat-

form.

1-3

Chapter 1 BASIC SAFETY PRECAUTIONS

Be careful of burns

Do not touch the engine during
or immediately after operation

To avoid burns, do not touch the

engine during or immediately after

operation.

A hot engine can cause burns.

To conduct maintenance and inspec-

tion work, wait until the engine has cooled sufficiently

by checking the temperature gauge.

Refill coolant only after the
coolant temperature dropped

Do not add coolant immediately after the engine

stops. Wait until the coolant temperature lowers suffi-

ciently. Adding coolant immediately after the engine

stops 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.

Do not open the radiator filler
cap when the engine is hot

Never open the radiator filler cap while the engine is

running or immediately after the engine is stopped.

When opening the cap, stop the engine and allow the

coolant temperature to lower sufficiently.

When opening the radiator filler cap, open slowly to

discharge the pressure inside the tank. Also to avoid a

risk of getting scalded by steam, wear thick rubber

gloves or wrap a cloth around the cap.

When closing the cap, be sure to tighten securely.

The coolant is hot while engine is running and immedi-

ately 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.

Do not touch high pressure
injection fuel

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

tion pipe, do not touch the fuel.

Fuel in the fuel injection pipes is under high pressure

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

sues and may result gangrene.

1-4

Chapter 1 BASIC SAFETY PRECAUTIONS

Be careful when handling
fuel, engine oil or LLC

Use only specified fuel, engine
oil and LLC

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

handle them carefully.

Use of any other fuel, oil or LLC, or improper handling

may cause various engine problems and malfunc-

tions.

Obtain the MSDS issued by the fuel, oil and LLC sup-

pliers, and follow the directions in the MSDSs for

proper handling.

Handle LLC carefully

When handling LLC, always wear rubber gloves and a

protective face mask. If LLC or cooling water contain-

ing LLC comes into contact with your skin or eyes, or if

it is swallowed, you would suffer from inflammation,

irritation or poisoning.

Should LLC be accidentally swallowed, induce vomit-

ing immediately and seek medical attention. Should

LLC enter your eyes, flush them immediately with

plenty of water and seek medical attention. If LLC

splashes onto your skin or clothing, wash it away

immediately with plenty of water.

Keep flames away from LLC. The LLC can catch

flames, causing a fire. Coolant (containing LLC)

drained from the engine is toxic. Never dispose of

coolant into regular sewage. Abide by the applicable

law and regulations when discarding drained coolant.

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 law and regulations.

When abnormality occurs

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 can damage

parts such as cylinder heads due to a sudden drop of

temperature. Add coolant gradually after the engine

has completely cooled.

Avoid immediate restart after
abnormal stop

If the engine stops abnormally, do not restart the

engine immediately. If the engine stops with an alarm,

check and remedy the cause of the problem before

restarting. Sustained use of the engine without any

remedy could result in serious engine problems.

Avoid continuous engine oper­ation at low oil pressure

If an abnormal engine oil pressure drop is indicated,

stop the engine immediately, and inspect the lubrica-

tion system to locate the cause. Continuous engine

operation with low oil pressure 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. Sustained use of the engine without

any remedy could cause defective charge and cooling

failure, and result in serious engine problems.

1-5

Chapter 1 BASIC SAFETY PRECAUTIONS

Service battery

Handle the battery correctly

Never use flames or allow sparks to

generate near the battery. The bat-

tery releases flammable hydrogen

gas and oxygen gas. Any flames or

sparks in the vicinity could cause an

explosion.

Do not use the battery when the battery electrolyte

level of which is below the "LOWER LEVEL" line. Sus-

tained use of the battery could 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 plugs, 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 cause the loss of sight

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

electrolyte.

Wear protective goggles and rubber gloves when

working with the battery (when adding water, charg-

ing, etc.)

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 the loss of sight if

splashing into the eyes. If it gets into the eyes, imme-

diately flush it away with plenty of clean water, and

seek immediate medical attention.

If the battery electrolyte is accidentally consumed,

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

and seek immediate medical attention.

1-6

Other cautions

Chapter 1 BASIC SAFETY PRECAUTIONS

Never modify engine

Unauthorized modification of the engine will void our

warranty.

Modification of the engine may not only cause engine

damage but also produce personal injuries.

If there is a need to modify the engine, contact a

dealer of Mitsubishi Heavy Industries, Ltd.

Observe safety rules at work
site

Observe the safety rules established at your work-

place when operating and maintaining the engine.

Do not operate the engine if you are feeling ill, inform

your supervisor of your condition. Operation 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.

Work clothing and protective
gear

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

gloves and other protective gear as needed. When

handling compressed air, wear safety goggles, a hard-

hat, gloves and other necessary protective gear.

Works without wearing proper protective gear could

result in serious injuries.

Never break the seals

To ensure proper engine operation, the fuel control

links are sealed to prevent accidental change of the

injection volume and rotation speed settings. Operat-

ing the engine without these seals in place can cause

problems described below, and also invalidates the

warranty.

 Rapid wear of moving and rotating parts

 Engine troubles such as damage and seizure of en-

gine parts

 Increased consumption of fuel and lubricating oil

 Degradation of engine performance due to improper

balance between fuel injection volume and governor

operation or overrunning of the engine which could re-

sult in a serious accident

Perform all specified pre-opera­tion inspections and periodic
inspections

Conduct the pre-operation inspections and periodic

inspections as described in this manual.

Failure to conduct the specified inspections may

cause various engine problems, damage to parts, and

serious accidents.

Break-in the engine

To break-in new engines or overhauled engines, oper-

ate the engine at a speed lower than the rated speed

in a light load condition during the first 50 hours of

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 the engine before use

After starting the engine, run the engine at low idling

speeds for 5 to 10 minutes for warming-up. Start the

work after this operation is completed. Warm-up oper-

ation circulates the lubricant through the engine.

Therefore, individual engine parts are well lubricated

before they are subjected to heavy loads.

Warm-up operation circulates lubricants in the engine

and contributes to a longer service life and economi-

cal operation.

Do not conduct warm-up operation for prolonged

period of time. Prolonged warm-up operation causes

carbon build-up in the cylinders that leads to incom-

plete combustion.

Never operate the engine in an
overloaded condition

If the engine shows an overloaded condition such as

black exhaust smoke, reduce the load immediately to

operate the engine at an appropriate output and load.

Overloading causes not only high fuel consumption

but also excessive carbon deposits inside the engine.

Carbon deposits cause various problems and will

shorten the service life of the engine.

1-7

Chapter 1 BASIC SAFETY PRECAUTIONS

Conduct cooling operation
before stopping the engine

Before stopping the engine, idle the engine in low gear

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.

Protection of the engine against
water entry

Do not allow rainwater, etc. to enter the engine

through the air inlet or exhaust openings.

Do not wash the engine while it is operating. 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

Maintain the engine with air cleaner according to the

following instructions.

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, immediately cover the air

inlet with plastic sheet or similar means to prevent for-

eign materials from entering the engine.

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

tools are damaged, replace them with new tools.

Avoidance of prolonged time of
starter 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 and cause the starter to seize.

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, not only various meters will stop working but

also the alternator may have its diode and transistor

deteriorated.

Cautionary instructions for
transporting the engine

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.

Do not operate engine continu­ously under low load

When operating the engine with a 30 % of rated load

or lower, limit each operation to 10 minutes. Operating

the engine at low load tends to result in unburned fuel,

which can adhere on internal engine parts, and cause

malfunctions and shorten the engine service life.

1-8

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 a dealer of Mitsubishi Heavy Industries, Ltd.

Fig. 1-1 Warning labels

1-9

Chapter 2 NAME OF PARTS

Engine external diagrams

Engine front

Engine rear

Water pump

Coolant outlet

Oil pump

Thermostat

Breather

Oil pan

Fig. 2-1 Engine front view

Turbocharger

Governor actuator

Exhaust gas outlet

a

t

t

i

o

o

n

R

Fig. 2-2 Engine rear view

Turbocharger

Flywheel

2-1

Chapter 2 NAME OF PARTS

Left view

Oil filter
alarm switch

Front hanger

Fan

Front Rear

Damper

Bypass oil filter

Oil filter

Fuel filter

Oil filler

Oil level gauge

Fuel return port

Fuel inlet

Fig. 2-3 Engine left view

Right view

Rear hanger

Air inlet

Manual stop lever

Fuel injection pump

Engine coolant
drain cock

Fuel feed pump

Starter

Air inlet

Stop solenoid

Rear Front

Coolant drain cock

Rear hanger

Fuel feed pump

Front hanger

Alternator

Coolant inlet

Fuel filter

Fig. 2-4 Engine right view

2-2

Equipment and instrument

The installed equipment and shapes differ on the engine type.

Start and stop instrument

Manual stop lever

Use the manual stop lever to shut down the engine in

the event of an emergency. If the starter switch fails to

stop engine operation, use the manual stop lever.

When the manual stop lever, which is located in the

fuel control link, is moved in the "STOP" direction, the

engine stops.

If the engine continues to operate even after the man-

ual stop lever is moved in the "STOP" direction, cut off

the fuel supply to stop the engine.

Stop solenoid

The stop solenoid operates for normal shutdown of

engine operation.

The stop solenoid moves the rack of fuel injection

pump to cut the fuel, and consequently stops the

engine.

The RUN OFF type stop solenoid is equipped in this

engine. Not energized while the engine is running.

Energized by a stop signal to stop the engine.

Chapter 2 NAME OF PARTS

STOP

Fig. 2-5 Manual stop lever

Fig. 2-6 Stop solenoid

Instruments

This section describes about devices which transmit signals to necessary instruments of the engine operation.

Read carefully and understand functions of each device.

Revolution detection pickup

It is installed in the timing gear case, and always

detect engine speed.

Fig. 2-7 Revolution detection pickup

2-3

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 the cause of the problem is unknown, contact a

dealer of Mitsubishi Heavy Industries, Ltd. Protection devices installed on the engine and their types (setting values)

and shapes vary depending on the engine specifications.

Oil filter alarm switch

The oil filter alarm switch generates an alarm when oil

filters become clogged, the difference in pressure

between inlet and outlet of oil and reaches the speci-

fied value.

Oil filter alarm switch

Air cleaner indicator

The air cleaner indicator alarms with its red signal

when air cleaner elements become clogged, the differ-

ence in pressure between front air cleaner and rear air

cleaner, and reaches the specified value. The air

cleaner indicator indicates the signal 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. 2-8 Oil filter alarm switch

Reset button

Signal
(red)

Fig. 2-9 Air cleaner indicator

2-4

Chapter 2 NAME OF PARTS

Using turning gear

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.

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

the shaft groove.

Shaft

Bolt

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

gear.

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.

Make sure the plate is securely installed in the shaft

groove.

Bolt

Fig. 2-10 Turning gear position

(while engine is running)

Fig. 2-11 Turning gear position (when pushing shaft in)

Socket

Plate

Ratchet handle

Fig. 2-12 Turning gear position (when turning shaft)

2-5

Chapter 3 OPERATION

Operational environment

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

problems and will shorten the service life of the engine.

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

opening.

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].

Preparation for operating new or overhauled engine

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

For second operation onward, follow the instructions described in the "Normal engine operation" (3-7).

Preparation of fuel system

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 when filling the fuel tank.

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

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

2. Fill fuel tank with fuel.

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

materials such as dust.

4. Reinstall the drain plug and the fuel feed pipe.

5. Refill fuel tank until fuel level gauge indicates "FULL" level line.

3-1

Chapter 3 OPERATION

Fuel system - Bleed air

When fuel overflow from the air vent plug, wipe thor-

oughly. Spilled fuel causes fire hazard.

After 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.

While feeding fuel with priming pump, bleed air from

the location closest to the fuel tank that are the water

separator, fuel filter, then the fuel injection pump.

Lock the priming pump according to "Priming pump

tightening method".

Fuel filter - Bleed air

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

sealing washers are damaged, replace them with

new ones.

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

turns.

2. Move the priming pump up and down, then feed fu-

el.

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.

[Unlock] [Priming] [Lock]

Turn left

Move up
and down

Fig. 3-1 Priming pump - Handle

Tightening torque

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

Air vent plug

Fig. 3-2 Fuel filter - Bleed air

Hold and
turn right

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 until the fuel

flow from the air vent plug is free from air bubbles.

Push and turn the priming pump clockwise to lock

in the original position when the fuel flows is free

from bubbles.

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

3-2

Air vent plug
15 ± 2 N·m



{1.5 ± 0.2 kgf·m}
[11.0 ± 1.4 lbf·ft]

Priming pump

Fig. 3-3 Fuel injection pump - Bleed air

Priming pump tightening method

Chapter 3 OPERATION

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.

1. Tighten the priming pump firmly by hand, and place

a mark on the priming pump.

2. Use a wrench or another appropriate tool to tighten

the priming pump 90±10°.

3. Check the mounting position of head packing.

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

formation or scratches, consult a dealer of Mit-

subishi Heavy Industries, Ltd., as the priming

pump needs to be changed.

90 ± 10°

Hand-tightening
becomes suddenly
heavy

Head section can be
damaged when
overtightened
(120° or more)

Fig. 3-4 Priming pump tightening method

Head packing

Fig. 3-5 Priming pump head packing

Priming pump

3-3

Chapter 3 OPERATION

Preparation of lubrication system

Engine oil - Refill

Refilling engine oil must be specified level. If the

refilling oil goes over the high marks on the oil level

gauge, engine oil may blow out. And also, the engine

component parts are adversely affected by increas-

ing in oil temperature.

1. Remove the cap from the oil filler.

2. Fill the engine oil pan with 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, and pour engine oil to

the valve mechanism and camshaft oil bath. Pour

engine oil to camshaft oil bath from cylinder head

side.

Oil capacity per cylinder: 0.8 L [0.2 U.S. gal.]

4. Reinstall the rocker covers.

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

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

waste cloth.

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

gauge guide, then pull out the gauge again.

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

marks on the oil level gauge.

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

type.

9. Check the oil pan and other area for oil leaks. Re-

pair the oil leakage if any.

10. While pulling the stop lever, rotate the crankshaft

for approx. 10 seconds to turn on the starter. Stop

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

tion two or three times. Circulate engine oil to each

engine parts.

Note: Prepare for the Cooling system.

11. Check the oil level with the oil level gauge again,

and add oil to the specified level.

Oil level gauge

Improper

H

High

Proper

L

Oil filler

Low

Oil level gauge

Improper

Fig. 3-6 Oil filler and Oil level gauge

Camshaft
oil bath

Fig. 3-7 Pouring engine oil on valve mechanisms and

chamber

3-4

Preparation of cooling system

Coolant - Refill

Chapter 3 OPERATION

Always use the coolant with the same LLC concen-

tration.

1. Make sure the coolant drain cock of engine water

pump are closed securely.

2. Remove the radiator cap, and pour in undiluted

LLC.

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 SPECIFICA-

TIONS" (12-1).

3. Pour in water (soft water with minimal impurities,

such as tap water) slowly to the full level.

Note: For absolute air bleeding, loosen the air vent

plug on the upper section of thermostat.

4. Check the radiator and other parts for coolant

leaks. Repair leakage if found.

5. When coolant reaches the full level, close the radi-

ator tank cap securely.

6. While pulling the stop lever, rotate the crankshaft

for approx. 10 seconds to turn on 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 Cooling system.

7. Check the coolant level in the radiator.

8. If the engine is equipped with a reserve tank, fill the

reserve tank with coolant to the "FULL" level line as

well.

Left side

Coolant

drain cocks

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

Fig. 3-8 Coolant drain cock (Engine)

Coolant
drain cock

Fig. 3-9 Coolant drain cock (Water pump)

Fig. 3-10 Radiator coolant level

Right side

Fig. 3-11 Reserve tank coolant level

3-5

Chapter 3 OPERATION

Preparation of electrical system

Battery - Inspect

If battery electrolyte is spilled on your skin or clothes, flush immediately with plenty of water. If battery electrolyte

get into your eyes, flush them immediately with plenty of water and then get medical attention.

Do not use open flames or other fire hazards near the battery. When handling the battery, be careful of sparks gen-

erated by accidental shorting.

Battery electrolyte level - Inspect

Battery electrolyte evaporates during use and the

electrolyte level gradually decreases. The proper elec-

trolyte surface level is between the LOWER LEVEL

and UPPER LEVEL lines.

For the battery without level lines, the proper electro-

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

in.] above the top of the plates.

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

distilled water to the proper level.

Note: When adding distilled water, pour in carefully.

Fig. 3-12 Battery electrolyte level - Inspect

10 to 15 mm
[0.39 to 0.59 in.]

UPPER LEVEL

LOWER LEVEL

Proper
level

Test operation

To conduct a test operation, follow the procedures below.

Note: For engine operation, refer to "Normal engine operation" (3-7).

Starting and stopping

1. Start the engine.

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

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 filler cap and check the coolant level.

Remove the radiator cap only after the engine has cooled to room temperature. Place a waste cloth over the cap,

and loosen the cap about a half-turn or stand the lever to the upright position to release internal pressure. Never

open the radiator filler cap while the engine is hot, otherwise the steam or hot coolant spurts out and you may be

scald with it.

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 use the coolant with the same LLC concentration.

3-6

Chapter 3 OPERATION

Normal engine operation

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

Should an engine abnormality be observed during operation, stop the engine and correct the problem, or contact a

dealer of Mitsubishi Heavy Industries, Ltd.

Preparations for operation

Always conduct the following inspection before starting the engine.

Engine external - Inspect

Be sure to keep combustible materials away from the engine, especially from the hot engine parts such as exhaust

manifolds, or the battery. Check for fuel and oil leaks. Clean the top surface of the battery.A fire can be caused by

combustible materials placed near hot engine parts. If any abnormality is found, be sure to repair it or contact a

dealer of Mitsubishi Heavy Industries, Ltd.

Inspect the engine exterior as described below.

1. Make sure there is no combustible material near

the engine or battery. Also, check to make sure that

the engine and battery are clean. If combustible

materials or dust are found near the engine or bat-

tery, remove them.

2. Check the whole engine for leaks of fuel, engine oil

or coolant. If leaks are found, repair the leak, or

contact a dealer of Mitsubishi Heavy Industries,

Ltd.

3. Visually check bolts and nuts for looseness.

4. Check the electrical wiring including the starters

and alternator.

5. Make sure the following valves, plugs and cocks

are open or closed properly:

Fuel feed valve: Open

Coolant drain cock (plug): Closed

Oil drain valve: Closed

Air supply valve (air tank): Open

Fig. 3-13 Valves for open/closed position - Check

3-7

Chapter 3 OPERATION

Fuel tank oil level - Check

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

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

Do not remove the strainer when filling the fuel tank.

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

Make sure the fuel tank is full.

If the fuel level is low, refill the tank to the "FULL" level line.

Fuel tank - Drain water

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

fuel completely. Spilled fuel can ignite and cause a fire.

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

Bleeding water procedure described below is a commonly used procedure. Some application may be equipped

with different fuel tank.

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.

1. Prepare the oil pan (capacity of 2 L [0.5 U.S. 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 U.S. gal.].

3. Make sure that water and particles of foreign mate-

rial discharged with fuel. Close the drain cock.

Drain cock

Water

Fig. 3-14 Fuel tank - Drain water

3-8

Engine oil level - Check

Chapter 3 OPERATION

Refilling engine oil must be specified level. If the

refilling oil goes over the high marks on the oil level

gauge, engine oil may blow out.

1. Pull out the oil level gauge and wipe it clean using

a waste cloth.

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

gauge guide, then pull out the gauge again.

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

marks on the oil level gauge.

4. If the oil level is low, remove the oil filler cap and

add engine oil of the specified type to the high lev-

el.

5. Install the oil filler cap after refilling.

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

Oil level gauge

H

High

L

Oil filler

Oil level gauge

Low

Fig. 3-15 Oil filler and Oil level gauge

Improper

Proper

Improper

3-9

Chapter 3 OPERATION

Coolant level - Check

Remove the radiator cap only after the engine has

cooled to room temperature. Place a waste cloth

over the cap, and loosen the cap about a half-turn or

stand the lever to the upright position to release inter-

nal pressure. Never open the radiator filler cap while

the engine is hot, otherwise the steam or hot coolant

spurts out and you may be scald with it.

1. Open the radiator filler cap and check the coolant

level.

2. If the coolant level is low, add coolant to the speci-

fied level.

Always use the coolant with the same LLC concen-

tration.

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 SPECIFICA-

TIONS" (12-1).

3. If a reserve tank is equipped, fill the reserve tank

with coolant up to the "FULL" level line.

Turn the cap about
half a turn

Fig. 3-16 Radiator filler cap

Fig. 3-17 Radiator coolant level

Stand the lever to
the upright position

Fuel control link - Check

Check fuel control link for smooth movement.

Also check ball joint for looseness and play.

3-10

Fig. 3-18 Reserve tank coolant level

Fig. 3-19 Fuel control link - Check

Air cleaner - Check

1. Check the air cleaner indicator for the element

clog.

2. If the element is clogged, the red signal mark is vis-

ible.

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: For cleaning of the air cleaner element, refer to

"Air cleaner element - Clean, Check and Re-

place" (8-17).

Temperature of damper - Check

Damper temperature management by thermo label

It is recommended to use the thermo label for temper-

ature management of the damper. Check the thermo

label before starting engine.

1. Check the thermal part of thermo label is black.

2. Note the highest temperature of thermal part. Note

the temperature periodically, and check the abnor-

mality of temperature alteration.

75ºC [167ºF]<Damper temperature
<80ºC [176ºF]

Chapter 3 OPERATION

Reset button

Signal
(red)

Fig. 3-20 Air cleaner - Check

Thermo label

100 105 110 115 120

75 80 85 90 95

<5E- 100>

<5E- 75>

<5E- 50>

If the abnormality of temperature alteration is found,

consult a dealer of Mitsubishi Heavy Industries, Ltd.

Note: For damper inspection, refer to "Damper - In-

spect" (8-3).

50 55 60 65 70

Fig. 3-21 Thermo label of damper

3-11

Chapter 3 OPERATION

Starting

The starting method changes based on the application and specifications. Start the engine according to the speci-

fied procedure.

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

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

Do not apply a load to the engine at starting. (Disengage the clutch if installed.)

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

starter for more than 10 seconds at a time. When the engine does not start, return the key to "OFF" position and

wait for more than 1 minute before cranking again.

Warm-up operation

Do not approach rotating parts during operation. Entanglement by rotating parts can cause serious injury.

After the engine starts, operate the engine in a no load condition at low idling speed for 5 to 10 minutes to warm up

the engine.

Checking engine oil pressure

During warming-up operation, check if the oil pressure

is in the range of standard value (0.15 MPa {1.53 kgf/

2

cm

} [21.76 psi] or more).

Also, make sure the oil pressure gauge is operating

properly.

Note: The oil pressure gauge may indicate a higher

level than normal level immediately after the en-

gine starts, due to the low oil temperature. The

pressure gradually lowers to the normal level as

the oil temperature rises.

External inspection during
warm-up

Visually check the external view of the engine for

leaks of fuel, engine oil and coolant, or leaks of

exhaust gas from joints.

3-12

Operation

Chapter 3 OPERATION

Cautions when operating

Do not approach rotating parts during operation.

Entanglement by 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. A hot engine can cause burns.

Always provide adequate ventilation in the engine

room. If air supply to the engine room is not sufficient,

the room temperature rises and can affect engine

output and performance.

For the first 50 hours, operate the engine under a

light load for break-in operation. Operating the engine

under heavy load or severe conditions during the

break-in period can shorten the service life of the

engine.

Do not turn the battery switch to OFF when the

engine is running. Turning off the battery switch dur-

ing operation not only stops the instrument opera-

tions but also may deteriorate the alternator diode

and regulator.

Never turn the key to the "START" position during

operation. The starter may be damaged.

When operating the engine with a 30 % of rated load

or lower, 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 after continuous operation for an hour to

prevent causing carbon build-up.

Inspection during operation

Carefully check the exterior of engine such as piping

joints for leaks.

Check for abnormal engine noises or vibrations such

as knocking.

Check the color of exhaust gas from the exhaust muf-

fler.

Check the instruments and gauges for proper opera-

tion and make sure they indicates normal values.

Table 3-1 Standard values at rated speed

Item Standard

Engine oil pressure

Coolant temperature

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

2

{2.96 kgf/cm

tion, or below 0.10 MPa {1.02 kgf/cm

psi] at low idling, stop the engine immediate-

ly.

Be sure to locate the cause of problem and

correct it before restarting the engine.

(b) When the thermo switch is activated in nor-

mal run, idle the engine low for 5 or 6 minutes

to perform the cooling operation before stop-

ping the engine. Be sure to locate the cause

of problem and correct it before restarting the

engine.

} [42.06 psi] in normal opera-

0.49 to 0.64 MPa
{5 to 6.5 kgf/cm

[71 to 92 psi]

70 to 90°C

[158 to 194°F]

2

}

2

} [14.50

3-13

Chapter 3 OPERATION

Stopping

Stopping the engine abruptly while engine parts are hot due to high-speed operation can be a cause for heat up of

the engine parts and shorten the engine life. Before stopping the engine, idle the engine in low for 5 or 6 minutes

to perform cooling operation, and check the engine for abnormalities.

Never accelerate the engine immediately before shutting it down.

Do not restart the engine immediately after abnormal shut down. When the engine stops with alarms, be sure to

locate the cause of the problem and correct the problem before restarting the engine. After restarting the opera-

tion, check the engine for abnormalities again. If the engine has an abnormality, repair it immediately.

Engine stopping method may differ depending on the specifications.

Follow the instructions according to the specifications of the equipment.

Emergency stop

When stopping the engine by pulling the manual

stop lever, continue pulling the lever until the engine

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

To perform the emergency stop, pull the manual stop

lever to the arrow direction. Continue pulling the lever

until the engine stops completely.

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

ual stop lever is pulled, stop fuel supply.

Fig. 3-22 Manual stop lever

STOP

Inspection after stopping

Inspect the engine for leaks of fuel, oil or coolant. If any leak is found, repair the leak or contact a dealer of Mitsubi-

shi Heavy Industries, Ltd.

3-14

Chapter 4 FUEL

Recommended fuel

Use a fuel specified in this manual only. Do not refill the fuel tank more than the specified level, as it may result in

a fire.

Use fuel that meets the values specified in the following Table 4-1 of "Recommended fuel" and Table 4-2 of "Recom-

mended and limit values of fuel property".

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

Note: Please use the fuel that meet the control of the countries or areas where the engine is used, if the control is

applied.

Table 4-1 Recommended fuel

Specification 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

Handling fuel

When using fuel stored in a storage tank, leave it to sit for more than 24 hours so that dust and water can settle at

the bottom. 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.

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

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

or sediment 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.

4-1

Chapter 4 FUEL

Table 4-2 Recommended limit and use limit of fuel property

Properties Recommended limits Use limits Test method

Flash point

50°C [122°F] or higher

(In accordance with the regulation)

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

Distillation

90 % distillate tempera­ture

330 to 380°C [626 to 716°F]

Pour point (PP) 6°C [42.8°F] or lower than ambient temperature

Cloud point (CP) Below ambient temperature

Cold filter plugging point (CFPP) 3 °C [37.4 °F] or lower than ambient temperature

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

Cetane number 45 or higher

Cetane index (new type) 45 or higher

Kinematic viscosity

2.0 mm

8.0 mm

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

2

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

2

1.0 weight % or lower

Sulfur content 0.2 weight % or lower

(Shorten lub. oil change

intervals)

Water content and sediment 0.1 volume % or lower

Ash content 0.01 % by mass or less 0.03 weight % or lower

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

Density at 15 °C [59 °F]

24 hrs at 250 °C
[482 °F]

Caulking

24 hrs at 230 °C
[446 °F]

48 hrs at 180 °C
[356 °F]

0.83 to 0.87 g/cm

75 % carbonization or less 80 % carbonization or less

55 % carbonization or less -

Color change = Copper plate No.3 or less

3

[49.9424

to 54.3123 lb/ft

3

]

0.80 to 0.87 g/cm

[49.9424 to 54.3123 lb/ft3]

Ta r- f re e -

3

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

Polycyclic aromatic content 8 % by volume or less

Asphaltene 0.1 weight % or lower -

Foreign substances
(foreign materials at engine fuel

5.0 mg/liter or less

inlet)

JIS K 2265

:2007

ISO 3769
ISO 2719

JIS K 2254

:1998

ISO 3405

JIS K 2269

:1987

ISO 3016

JIS K 2269

:1987

ISO 3016

JIS K 2288

:2000

IP 309/96

JIS K 2270

:2000

ISO 6615
ISO 10370

JIS K 2280

:1996

ISO 5165

JIS K 2280

:1996

ISO/DIS 4264

JIS K 2283

:2000

ISO 3104

JIS K 2541

:2000

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

JIS K 2275

:1996

ISO 3733

JIS K 2272

:1998

ISO 6245

JIS K 2513

:2000

ISO 2160

JIS K 2249

:1995

ISO 3675

Fed 791B

JIS K 2536

:2003

ISO 3837

JIS B 9931

:2000

ISO 4405

4-2

Table 4-2 Recommended limit and use limit of fuel property

Properties Recommended limits Use limits Test method

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

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

460 µm [0.02 in.] or less

(calculated wear scar diame-

ter at WS 1.4 kPa {0.0143

kgf/cm

2

} [0.2031 psi])

- ISO 12156-1

BDF quality shall meet JIS K 2390, ASTM D 3751 or

EN14214

BDF blending of 5 % by volume or less is approved

Engine applications for prime, or continuous use for stand-by use

Chapter 4 FUEL

JIS K 2390

:2008

EN14214
ASTM-D6751
FAME for mix­ing
ASTM D 6751
EN 14214

Selection
according to
application

4-3

Chapter 5 ENGINE OIL

Recommended engine oil

Use only the engine oils recommended in this manual. Never use other oils.

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.

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.

Selection of oil viscosity

Use the following chart to select the appropriate oil

viscosity according to the ambient temperature.

Excessively high oil viscosity causes power loss and

an abnormal rise of oil temperature, while excessively

low oil viscosity accelerates wear due to inadequate

lubrication, and also causes a decrease in engine out-

put due to leakage of combustion gas.

Fig. 5-1 Recommended engine oil

Temperature

°C [°F]



Engine oil
viscosity

-30 -20 -10 10 20 30 40 500

OIL

Class CF

API Service

Classification

[122][50] [68] [86] [104][-21] [-4] [14] [32]

SAE10W

SAE30

SAE40

SAE15W-40

Fig. 5-2 Selection of oil viscosity

Handling engine 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, securely close the filler cap.

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

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

When handling oil in greater than the legally specified quantities, be sure to have the work performed by a service

station in compliance with the law. When removing oil from the engine or oil can, use an oil pump. Do not suck oil

with the mouth to siphon it.

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 used and follow the instructions of the MSDS.

5-1

Chapter 5 ENGINE OIL

Engine oil performance
requirements

Engine oil requires the following performances.

Excellent dispersion performance (the ability of oil to

disperse sludge in the oil) at high temperature that

prevents engine oil deterioration due to sludge accu-

mulation and soot contamination.

Excellent acid-neutralizing performance that prevents

oxidative degradation due to fuel sulfur content.

Excellent high temperature oxidation stability that en-

dures continuous operation under prolonged high-

load.

Sufficient viscosity concentration to maintain the cold

start performance, and lubrication performance at

high temperature.

Good rust and corrosion resistance to water.

Good foam resistance to prevent the lubricating qual-

ity from lowering due to oxidation.

Engine oil deterioration
mechanisms

Engine oil deteriorates due to natural deterioration

and due to the contamination. The natural deteriora-

tion of oil has two primary causes; one is the degrada-

tion caused by oxidation reaction or thermo

decomposition of base oil and additives, and the other

is the degradation in the performance due to con-

sumption of additives during use.

Contaminants such as fuel and combustion products

(soot, water vapor or oxidation products) that intrude

into oil have critical influence on oil quality. Soot ad-

heres to the oil film of cylinder wall, and is scraped off

the cylinder wall by the piston ring. Such soot increas-

es the rate of insoluble substances in the engine oil

and can cause the wear of piston rings and cylinder

walls.

Abrasion powder in the engine oil also accelerates

deterioration as it can catalyze oxidation reaction.

Dust and dirt entered from outside deteriorate the en-

gine oil as well. Contamination and deterioration pro-

cess accelerates with operation time.

Deterioration products and contaminants in the en-

gine oil, if it is a small amount, are harmless as they

can be dispersed in oil. However, if it is a large

amount, they become harmful. Since such products

and contaminants flow out of the oil pan and start to

accumulate inside the piston and in the oil system,

they eventually lead to serious problems such as pis-

ton ring sticking and bearing scuffing.

Sulfur content in fuel is burned and transformed into

sulfurous acid gas and sulfuric gas that cause corro-

sive wear of cylinders and piston rings. A detergent

additive in the engine oil neutralizes them into harm-

less substances. As the detergent additive is con-

sumed in its role of neutralizing, the engine oil total

base value decreases. A decrease in the total base

value indicates a corresponding decrease in soot dis-

persion ability. As a result, deposits on the pistons in-

crease.

Due to oxygen in the air, oil temperature rise under

high-load continuous operation causes oxidation deg-

radation. As oxidation degradation accelerates, oxi-

dative products are polymerized. The polymerized

oxidative products cause the oil viscosity to increase,

which leads to the generation of sludge and varnish.

As a result, problems such as lubrication failure and

piston ring sticking occur. Also acid substances gen-

erated by oxidation can cause problems like main

bearing corrosion.

5-2

Definition of properties of engine oil

Chapter 5 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 by blow-by gas and deterioration

of oil by its natural aging in crease the kinetic viscosity

and degrade the performance of viscosity, which will

cause the deposition of sludge inside the engine and

oil filter clogging. Contamination of oil by fuel and

sheared molecules of viscosity index improver in oil

decrease the viscosity and degrade the performance

of viscosity, which will cause insufficient lubrication

and friction/wear of engine parts.

Total base number

Total base number (TBN) shows the ability to neutral-

ize acids such as organic acid due to engine oil oxida-

tion, or sulfurous or sulfuric acid due to the sulfur

content of fuel.

Because TBN indicates the amount of dispersant

detergent in oil, it can be used to estimate consump-

tion of basic dispersant detergent. The ability to dis-

perse sludge declines as dispersant detergent is used

up.

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 measured to check the dilution of fuel.

The dilution of fuel reduces oil film, and causes insuffi-

cient lubrication that will cause friction or wear of

engine parts.

Insoluble

Insoluble includes acid products of engine oil, imper-

fect combustion products, sludge or soot, metal abra-

sive particles and dust. Insoluble is an indication of

degradation/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 (using chemical

specialities to stop action of disperse detergent and to

collect the sludge dispersed in oil) by which piston ring

seizure or premature wear can be prevented before it

occurs.

Total acid number

The total 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 combus-

tion of sulfur content of fuel, or the oil becomes con-

taminated with imperfect combustion products.

An increase in the total acid number will result in cor-

rosion or wear of the inner parts of the engine (such

as cylinder liners or metal) due to sulfur content, and

piston ring seizure due to sludge.

5-3

Chapter 5 ENGINE OIL

Service limits of engine oil

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

To determine the timing of engine oil replacement, analyze the used oil, and understand the condition of oil deterio-

ration and oil defacement. It is also required to compare the oil analysis results and the engine analysis results

including inside contamination and wear condition of engine, and to consider the engine operating condition.

The engine oil affects the engine oil quality to use, the engine operating condition and the quality of fuel. Analyze

the used oil, and understand the condition of oil deterioration and oil defacement. To determine the timing of engine

oil replacement, the stabiration of engine is required.

Refer to the following table for the determination of engine oil performance degradation. If any of the following devi-

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

Table 5-1 Engine oil properties

Properties Standard Test method

+3.0 % or less change of new oil

2

mm

Kinetic viscosity

Total base number mgKOH/g

Total acid number mgKOH/g Up to +3.0 of new oil

Water content Vol % 0.2 or less

Flash point (open cup) °C 180 or higher

Pentane insoluble Wt % 0.5 or less ASTM D 893

Pentane insoluble coag­ulated

/s [in2/s]

@100°C [212 °F]

Wt % 3.0 or less ASTM D 893

+30 % or less change of new oil

2.0 or more with hydrochloric acid

1/2 of new oil or more with perchlo-

2

10 mm

/s [0.155 in2/s] or more

-20 % change of new oil

(HCL) method

ric acid (PCA) method

JIS K 2283:2007
ISO 3107
ISO 2909

JIS K 2501
ISO 3771

JIS K 2501
ISO 3771

JIS K 2275
ISO 9029

JIS K 2265
ISO 3769
ISO 2719

:2003

:2003

:1996

:2007

Engine oil analysis service

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

It is a system to understand the availability of the engine oil using in your engine by sampling it with the special sam-

pling tools.

The engine oil analysis service provides the followings:

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, which is necessary when disas-

sembling the engine. It is highly recommended to take advantage of our engine oil analysis service so that you can

learn the engine condition before any malfunction occurs to the engine.

5-4

Chapter 6 COOLANT

Note: In this operation manual, the word "coolant" represents the liquid combined water and LLC.

Recommended water for coolant

Use soft 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.

Table 6-1 Water quality standards

Item

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

Electrical cinductivity
(25°C [77°F])

Total hardness CaCO

M alkalinity CaCO

Chlorine ion Cl

Sulfuric acid ion SO

Total iron Fe ppm < 1.0 < 1.0 Scale formation

Silica SiO

Residue from evaporation - ppm < 250 < 400 Scale formation

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

be below 15 mg/liter.

Chemical

symbol

- mS/m < 25 < 40

3 ppm < 95 < 100 Scale formation

3 ppm < 70 < 150 Scale formation

-

2-

4

2 ppm < 30 < 50 Scale formation

Unit

ppm < 100 < 100 Corrosion and rust

ppm < 50 < 100 Corrosion and rust

Recommend

value

Limit Main adverse effect

Corrosion and rust, scale
formation

Corrosion and rust, scale
formation

Long life coolant (LLC)

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.

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

ene glycol type)" or "PG GLASSY long life coolant (Non-amine type)" as coolant. When using other brand LLCs by

necessity, be sure to use the LLC that meets the specification in Mitsubishi Heavy Industries, Ltd. Mitsubishi heavy

industries, Ltd. disclaim the warranty claim concerning malfunctions caused by the use of LLC that does not meet

the following specification.

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 (Non-amine type)",

which are most appropriate coolant for diesel engine

from Mitsubishi Heavy Industries, Ltd.

Fig. 6-1 GLASSY - LLC

6-1

Chapter 6 COOLANT

Other brand LLCs

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.

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 (Non-amine type)", be sure

to use the LLC which meets specification in 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 only all-season LLC (non-amine type). Do not use

antifreeze alone instead of LLC.

Standard for other brand
LLC

When using other brand LLCs by necessity, be sure to

use the LLC that meets following specification. Mit-

subishi heavy industries, Ltd. disclaim the warranty

claim concerning malfunctions caused by the use of

LLC that does not meet the following specification.

General demands of LLC

 LLC shall be a homogeneous liquid.

 Engine cooling system shall not receive troubles

such as corrosions and precipitation products etc. by

LLC when the LLC is diluted to 30 to 60 % density.

 LLC shall be mixed with other LLC that satisfies this

specification, and shall not separate elements each

other, and shall not decrease the performance each

other.

 LLC shall not allow the container to be corroded, and

shall not has precipitation products etc. even if LLC is

left in the container for 6 months.

 LLC shall not has extraction products etc. even if LLC

is kept in -20 to -25 °C [-4 to -13 °F] .

 The validity term of the quality that provides with this

specification is 2 years after it delivers with the indoor

normal temperature keeping.

6-2

Chapter 6 COOLANT

LLC specification

LLC shall examine according to JIS K2234 section 7 (examination methods), and satisfy this specification. General

matters and the sample to the examination is shown in JIS K2234.

Property Standard

External Not precipitation

Density

Water content Maximum 5.0 weight % (Stock solution)

Frozen temperature

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

pH 7.0 to 11.0 (30 vol %)

Bubbling character
(ASTM D3306-01)

Hard water adaptability 1.0 or less (50 vol %)

Test piece

Metallic causticity
(88±2°C
[190.4±35.6°F],
336±2 Hr,
30 vol % (E.G),
50 vol % (P.G))

Bubbling while examination Not bubbling overflow

Properties of
liquid after the
examination

Table 6-2 LLC specification

Minimum 1.112 g/cm

3

[69.4199 lb/ft3] (20/20
°C) [68/68°F]
(Stock solution)

30 vol % -14.5°C [5.9°F] or less

50 vol % -34.0°C [-29.2°F] or less

30 vol % 4.0 ml [8.79 gal] or less

1/3 vol %

33

Aluminum ±0.30 mg/cm

Cast iron ±0.15 mg/cm

Mass
change

Steel ±0.15 mg/cm

Brass ±0.15 mg/cm

Solder ±0.30 mg/cm

Copper ±0.15 mg/cm

External of test piece after the
examination

150 ml [0.032 gal] or less, Disappearance of
bubble within 5 sec.

2

2

2

2

2

2

Not corrosion on surface excluding between
test piece and spacer. Discoloration is OK.

pH 6.5 to 11.0

pH change ±1.0

Precipitation 0.5 vol % or less

External of liquid

Not remarkable discoloration, separation
and gel.

6-3

Chapter 6 COOLANT

Table 6-2 LLC specification

Property Standard

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

±0.30 mg/cm

Not corrosion on surface excluding between
test piece and spacer. Discoloration is OK.

Circulation metal-

Mass
change

Test piece

External of test piece after the
examination

lic causticity
(98±2°C
[208.4±35.6°F],
1000 Hr,
30 vol %
(E.G)
50 vol %
(P.G)

Properties of
liquid after the
examination

pH 7.0 to 9.0

pH change ±1.0

Pre-alkalinity change ±15 %

Precipitation 1.0 vol % or less

External of liquid

Density
of ion

Fe, Cu, Al, Zn, Pb,
NH4+

Not remarkable discoloration, separation
and gel.

10 ppm or less

Aluminum ±0.60 mg/cm

Cast iron ±0.30 mg/cm

Mass
change

Test piece

Circulation metal­lic causticity

Steel ±0.30 mg/cm

Brass ±0.30 mg/cm

Solder ±0.60 mg/cm

Copper ±0.30 mg/cm

(88±3°C
[190.4±37.4°F],
1000 ± 2 Hr,
30 vol %
(E.G)

Properties of
liquid after the
examination

Condition of
parts

External of test piece after the
examination

pH 6.5 to 11.0

pH change Maximum ±1.0

External of liquid

Pump seal Not trouble while the examination

Inside of pump case and blade Not remarkable corrosion

Not corrosion on surface excluding between
test piece and spacer. Discoloration is OK.

Not remarkable discoloration, separation
and gel.

Tensile strength change -60 to 0 %

Elongation change -40 to +20 %

Silicon

Volume change 0 to +40 %

Hardness change -20 to +10 %

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

Acrylonitrile
butadiene rub­ber

Tensile strength change 0 to +10 %

Elongation change -15 to +15 %

Volume change 0 to +40 %

Hardness change -10 to 0 %

Tensile strength change 0 to +10 %

Ethylene pro-

Elongation change -30 to 0 %

pylene diene
monomer

Volume change 0 to +10 %

Hardness change -10 to 0 %

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

2

2

2

2

2

2

2

6-4

Chapter 6 COOLANT

Maintenance of LLC

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.

Replacement intervals of LLC

Be sure to renew LLC at the intervals specified in the maintenance schedule of this manual.

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

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

years, whichever comes first.

LLC concentration

Keep the LLC concentration of 30 % (GLASSY) and 40 % (PG GLASSY) on any temperature conditions. LLC of

less than 30 % concentration does not provide sufficient corrosion protection. If the LLC concentration is lower than

10 %, it may accelerate corrosion.

When adding coolant, do not add plain water. Always use coolant with the same LLC concentration.

Table 6-3 Recommended LLC concentration

Lowest ambient temperature (°C [°F])

Item Ty pe External

LLC concentration

(%)

Note: (a) If the outside air temperature is -30°C [-22°F] or less, use "GLASSY".

(b) The concentration above is based on Mitsubishi Heavy Industries, Ltd. genuine LLC "GLASSY long life

coolant (Ethylene glycol type)" or "PG GLASSY long life coolant (Non-amine type)".

For determining the accurate LLC concentration, refer to the instructions for the LLC used.

GLASSY Green 30 40 50 60

PG GLASSY Red 40 55 70 -

-10°C [14°F] or
above

-20°C [-4°F] or
above

-30°C [-22°F]
or above

-45°C [-40°F]
or above

6-5

Chapter 6 COOLANT

Importance of LLC

Today's trend is toward smaller and lighter engines

offering 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, the use of LLC that con-

tained the additive to prevent rust is very important.

Characteristics of LLC
additive and important
notes

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 in LLC are not maintained,

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 cause prob-

lems 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 the 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

6-6

Chapter 7 MAINTENANCE SCHEDULE

How to use the 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, make sure to conduct the inspection and maintenance work, regardless of rec-

ommended 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 50 service hours.

Items marked with * in the maintenance schedule require special tools or large equipment. For the servicing of

those items, contact a dealer of Mitsubishi Heavy Industries, Ltd.

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 50 %

load). If the engine cannot be operated under load every month, operate the engine under load (more than 50 %

load) for more than 2 hours once every year.During the engine maintenance operation, check the ease of startup,

oil pressure, and exhaust color and vibration.

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.

7-1

Chapter 7 MAINTENANCE SCHEDULE

Periodic maintenance chart for regular use engine

Table 7-1 Periodic maintenance chart for regular use engine

Refer-

Interval and Service item

Every 50 service hours or
every month

First 50 service hours for
a new or overhauled
engine

Every 250 service hours

First 250 service hours
for a new or overhauled
engine

Every 1000 service hours

Every 1500 service hours Fue injection nozzle - Clean *2

Every 2000 service hours

Every 3000 service hours Fuel injection nozzle - Nozzle tip replacement (Check the spray condition

Every 4000 service hours

Fuel tank - Drain water*1 8-5

Water separator - Drain water*1 *2

Bolts and nuts on the engine - Retighten *2

Engine oil, Oil filter and Bypass oil filter - Replace

It is recommended to check the engine oil characteristics at the same time.
The oil filters must be replaced when the filter alarm lights.

Engine oil, Oil filter and Bypass oil filter - Replace

It is recommended to check the engine oil characteristics at the same time.
The oil filters must be replaced when the filter alarm lights.

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

Fuel filter - Replace 8-7

Water separator - Inspect and Replace*1 *2

Gauze filter - Clean 8-6

Belt and belt tension - Inspect and Adjust 8-2

Fuel tank - Drain water (Replace parts as necessary)*1 8-5

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

Fuel injection timing - Inspect and Adjust *2

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

Fuel pipe - Inspect 8-8

Oil pipe - Inspect 8-12

and adjust the fuel injection pressure after replacement)

Top end of the engine - Overhaul
Remove the cylinder head, and inspect and service the combustion cham­bers.

Turbocharger - Inspect 8-16

Damper - Inspect 8-3

Starter - Inspect 8-19

Protection devices operation - Inspect *2

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

Checking LLC concentration level in the coolant *2

ence
page

8-9

8-9

*2

*2

*2

*2

*2

7-2

Chapter 7 MAINTENANCE SCHEDULE

Table 7-1 Periodic maintenance chart for regular use engine

Interval and Service item

Engine - Major overhaul
Disassemble engine, clean, check and change major parts.
[Parts to be changed]
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 consumable items (gaskets, oil seals, O­rings, etc.)
[In second overhaul, replace the following parts in addition to the parts listed
above]
Cylinder head bolts, valve guides, valve bridge guides, valve bridges, valve

Every 8000 service hours

Every 8000 service hours
or 2 years

As required

*1 It is not a item supplied from Mitsubishi Heavy Industries, Ltd., however, please maintain the part regularly to use

the engine securely and effectively.

*2 Items require special tools or large equipment. For the servicing of those items, contact a dealer of Mitsubishi

Heavy Industries, Ltd.

springs, tappets, camshaft thrust plates, pistons, piston pins, connecting rod
bolts, connecting rod bushings, rocker bushings, fuel pipe assembly, oil pipe
assembly

Fuel injection pump - Inspect and Test (Replace parts as necessary) *2

Governor - Inspect and Test (Replace parts as necessary) *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.

Auxiliary devices operation - Checkt*1
Water heater, oil heater, oil priming pump, fuel transfer pump, governor
motor, etc.

Coolant - Change 8-13

Fuel system - Bleed air*1 3-2

Radiator fins - Check and Clean*1 8-15

Air cleaner element - Clean, Check and Replace*1 8-17

Cleaning the Inside of the Engine Breathers *2

Stop solenoid - Inspect or Replace *2

Couplings - Inspect or Replace*1 *2

Inspecting the vibration-isolating rubber*1 *2

Refer-

ence
page

*2

*2

*2

7-3

Chapter 7 MAINTENANCE SCHEDULE

Periodic maintenance chart for emergency engine

Table 7-2 Periodic maintenance chart for emergency engine

Interval and Service item

Engine external - Inspect (Check for leakage of fuel, oil and coolant) 3-7

Fuel tank oil level - Check*1 3-8

Engine oil level - Check 3-9

Coolant level - Check 3-10

Every week

Every month

Every 6 months

Every 1 year

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.)

Engine oil for mixing of fuel and water - Inspect 8-12

Fuel control link - Check 3-10

Battery electrolyte level - Inspect*1 3-6

Conducting Engine Maintenance Operation (Operate the engine with more
than 50 % 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 8-3

Checking LLC concentration level in the coolant *2

Cleaning the inside of the coolant tank*1 -

Belt and belt tension - Inspect and Adjust 8-2

Bolts and nuts on the engine - Check and Retighten *2

Valve clearance - Inspect and Adjust

Basic engine

Fuel system

Engine
Lubricating sys­tem

(Check valve mechanism at the same time.)

Inspecting the vibration-isolating rubber*1 *2

Foundation bolts - Inspect*1 *2

Couplings - Inspect or Replace*1 *2

Fuel tank - Drain water*1 8-5

Water separator - Drain water*1 *2

Fuel injection nozzle spray condition and Spray pressure

- Inspect and Adjust

Fuel injection timing - Inspect and Adjust *2

Fuel pipe - Inspect 8-8

Oil pipe - Inspect 8-12

Engine oil properties - Analyze *2

Engine oil pressure (Maintenance operation) - Inspect
and Adjust

Refer-

ence

page

-

-

*2

*2

*2

7-4

Chapter 7 MAINTENANCE SCHEDULE

Table 7-2 Periodic maintenance chart for emergency engine

Every 1 year

Every 2 years

Interval and Service item

Water pump - Inspect *2

Solenoid valve and Pressure reducing valve of the cool­ing system - Inspect, Disassemble and Clean*1

Cooling system

Air intake system Air cleaner element - Clean, Check and Replace*1 8-17

Electrical system

Protection devices operation - Inspect*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.

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

Engine oil, Oil filter and Bypass oil filter - Replace

It is recommended to check the engine oil characteristics at the same time.
The oil filters must be replaced when the filter alarm lights.

Fuel filter - Replace 8-7

Water separator - Inspect and Replace*1 *2

Gauze filter - Clean 8-6

Fuel control link ball joint - Inspect

(Replace parts as necessary)

Coolant - Change 8-13

Thermostat - Inspect *2

Turbocharger - Inspect 8-16

Draining water from the exhaust muffler*1 8-16

Strainer (including with/ball tap) of cooling water ­Inspect, Disassemble and Clean*1

Coolant properties (when only soft water is used) ­Inspect (Change coolant according to the analysis
results)

Starter - Inspect 8-19

Alternator - Inspect 8-19

Specific gravity of battery electrolyte - Check*1 8-18

Refer-

ence

page

*2

*2

*2

*2

*2

8-9

8-6

7-5

Chapter 7 MAINTENANCE SCHEDULE

Table 7-2 Periodic maintenance chart for emergency engine

Interval and Service item

Top end of the engine - Overhaul
Remove the cylinder head, and inspect and service the combustion cham­bers.(If the abnormalities of first and second cylinders are found, inspect all
cylinders.)

Checking oil cooler for contamination, clogging and leakage *2

Checking oil pump for discoloration and other external defects *2

Fuel tank - Clean*1 8-5

Every 4 years

Every 8 years

*1 It is not a item supplied from Mitsubishi Heavy Industries, Ltd., however, please maintain the part regularly to use

the engine securely and effectively.

*2 Items require special tools or large equipment. For the servicing of those items, contact a dealer of Mitsubishi

Heavy Industries, Ltd.

Fuel injection pump - Inspect and Test (Replace parts as necessary) *2

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

Radiator fins - Check and Clean*1 8-15

Rubber hose - Replace *2

Air cleaner element - Clean, Check and Replace*1 8-17

Instruments - Repair or Replace*1
Oil pressure gauge, coolant temperature gauge, oil temperature gauge,
exhaust temperature gauge, tachometer

Engine - Major overhaul
Disassemble engine, clean, check and change major parts.

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)

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

Vibration-isolating rubber - Repair or Replace*1 *2

Couplings - Inspect or Replace*1 *2

Governor mortor - Repair or Replace*1 *2

Air ventilation fan of the room - Repair or Replace*1 *2

Stop solenoid - Inspect or Replace *2

Ball tap of water tank - Repair or Replace*1 *2

Other consumables - Replace *2

Refer-

ence

page

*2

*2

*2

*2

7-6

Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Basic engine

Engine external - Inspect

Be sure to keep combustible materials away from the engine, especially from the hot engine parts such as exhaust

manifolds, or the battery. Check for fuel and oil leaks. Clean the top surface of the battery. A fire can be caused by

combustible materials placed near hot engine parts. If any abnormality is found, be sure to repair it or contact a

dealer of Mitsubishi Heavy Industries, Ltd.

Inspect the engine exterior as described below.

1. Make sure there is no combustible material near the engine or battery. Also, check to make sure 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 such components as the starter and alternator for looseness.

3. Check the whole engine for leaks of fuel, engine oil or coolant. If leaks are found, repair or contact a dealer of

Mitsubishi Heavy Industries, Ltd.

4. Make sure the following valves, plugs and cocks are open or closed properly:

Fuel feed valve: Open

Coolant drain cock (plug): Closed

Oil drain valve: Closed

8-1

Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Belt and belt tension - Inspect and Adjust

If defects such as cuts or surface separations are found during inspection, replace the belt.

Keep oil and grease away from the belt. They may cause the belt to slip and shorten the service life.

Excessive belt tension can cause rapid wear of the alternator bearing and shorten the service life of the belt.

Adjust the belt tension accurately by following the procedures below.

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).

Push the belt downward at the midway between pulleys. If the deflection is 10 to 15 mm [0.39 to 0.59 in.], the

tension is correct.

Belt pushing force: Approx. 98 to 147 N {10 to 15 kgf} [22.05 to 33.07 lbf]

If the deflection of belt is not within the standard, adjust the belt tension.

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: That the lower nut on the adjusting rod has left-

hand threads.

4. Turn the adjusting rod to adjust the belt tension.

5. After adjusting deflection, fix the upper and lower

lock nuts.

6. Tighten all retaining bolts of the alternator and ad-

justing plate.

7. Reinstall the belt cover and front cover.

Adjusting rod

Mounting
bolts

Fig. 8-1 Belt and belt tension - Inspect and Adjust

Approx.

10 to 15 mm
[0.39 to

0.59 in.]

8-2

Damper - Inspect

Damper - Check visually

Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

When installing a damper protective cover to the

engine, do not use a cover that encloses the damper.

Installation of a closed cover can cause damper

damage due to heat.

Check the vibration damper for oil leakage, scratches,

deformation, discoloration and peeling of paint. Check

carefully for swelling on the cover (use a scale), oil

leaks from the shim, discoloration and peeling of paint

due to heat.

Note: If defects are found in the damper, contact a

dealer of Mitsubishi Heavy Industries, Ltd.

Silicon
oil

Fig. 8-2 Damper - Check visually

Cover

Damper temperature management

For making damper function well, heat of damper must be dissipated from its surface to prevent excessive damper

heating. Mitsubishi Heavy Industries, Ltd. inspects each engine before shipment to ensure proper operating temper-

ature of the vibration damper. However, the vibration damper temperature varies depending on ambient conditions.

Therefore, observe the following suggestions and provide sufficient ventilation for the vibration damper and equip-

ment.

1. Make sure the temperature of the outside damper surface does not exceed 90 °C [194 °F] when operating the

engine with rated power for an hour.

2. When installing a safety cover to damper, check ventilation carefully and make sure the damper temperature re-

mains below 90 °C [194 °F], with the cover in place.

3. It is recommended to use the thermo label for temperature management.

8-3

Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Thermo label - handle

The white thermal part of thermo label becomes black when reaching the specified value.

Note: The thermal part that becomes black once does not return to white. Therefore, if the engine stops and then the

temperature of damper drops, the thermo label continues indicating the maximum temperature in operation.

1. Attach a thermo label to the periphery or front end of damper.

2. Note the maximum temperature of the thermal part of thermo label when engine stops. Note the temperature pe-

riodically, and check the abnormality of temperature alteration.

Note: (a) When the temperature of thermo label increased, identify the abnormality of engine or other cause. Then,

reattach new thermo label, and check the change of temperature.

(b) If the temperature indication of thermo label comes close to the limit temperature of damper or the abnor-

mality is found in change of temperature, contact a dealer of Mitsubishi Heavy Industries, Ltd.

Table 8-1 Thermo label for temperature management

Parts

name

Thermo

label

100-120

Thermo

label

75-95

Thermo

label

50-70

Parts No.

32522-04211

20 labels set: 32522-04200

32522-04111

20 labels set: 32522-04100

32522-04311

20 labels set: 32522-04300

Temperature

measuring

range

100 to 120°C

[212 to 248°F]

75 to 95°C

[167 to 203°F]

50 to 70°C

[122 to 158°F]

Fig. 8-3 Damper temperature management

Thermo Label

<5E-100>

100 105 110 115 120

<5E-75>

75 80 85 90 95

<5E-50>

50 55 60 65 70

8-4

Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Fuel system

Fuel system - Inspect

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

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

Fuel tank - Clean

Do not remove the strainer when filling the fuel.

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

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

2. Prepare the fuel receiving can, place it 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.

For more information, refer to the operation manual attached to a fuel tank.

5. Add fuel to the fuel tank.

6. Open the fuel feed valve, and bleed air for the fuel system.

Note: For bleeding fuel system, refer to "Fuel system - Bleed air" (3-2).

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.

1. Prepare the oil pan (capacity of 2 L [0.53 U.S. 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 U.S. gal.].

3. Make sure that water and particles of foreign mate-

rial discharged with fuel. Close the drain cock.

Drain cock

Water

Fig. 8-4 Fuel tank - Drain water

8-5

Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Fuel control link ball joint - Inspect

Check ball joint in the fuel control link for play. If the

amount of play is 0.1 mm [0.004 in.] or more, replace

the ball joint with the new one.

0.1 mm

[0.004 in.]

Ball joint

If the sealed ball joints are found loosened, contact a

dealer of Mitsubishi Heavy Industries, Ltd. If the seal

on the ball joint is broken, the warranty is invalidated.

If the ball joints are integrated in the control link,

replace the control link when the ball joints have loos-

ened. When installing ball joints, be sure to tighten the

nuts firmly.

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 eye bolt at the inlet port of fuel feed

pump.

2. Using a screw driver, remove the gauze filter that is

fitted inside the eye bolt.

3. Soak the gauze filter in the fuel, and clean it with a

brush.

4. After cleaning, install the gauze filter into the eye

bolt using a screw driver.

5. Install the eye bolt to the fuel feed pump.

6. Bleed the air from the fuel filter.

Note: For bleeding the fuel filter, refer to "Fuel filter -

Bleed air" (3-2).

0.1 mm

[0.004 in.]

Rod

Lever

Fig. 8-5 Ball joints for looseness - Inspect

Ball joint

Control link

Fig. 8-6 Fuel control link - Remove

Gauze filter

Eye bolt

Fuel feed pump

Fig. 8-7 Gauze filter - Clean

8-6

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. Check new fuel filters for proper seating of the gas-

ket.

Do not use a filter with the dented case. Fillter dam-

age or fule leakage may occur and it can cause fire

hazard.

6. Apply clean fuel to the gasket on the new fuel filter.

7. Install the fuel filter to the filter bracket. When the

gasket contacts the mounting surface of the filter

bracket, further rotate 3/4 to a full turn.

Fig. 8-8 Fuel filter - Replace

Apply fuel to
the gasket.

Do not use a filter wrench to install the fuel filter.

Do not dent or scratch the fuel filter surfaces.

8. After installing the new fuel filter, bleed the fuel fil-

ter.

Note: For bleeding the fuel filter, refer to "Fuel filter -

Bleed air" (3-2).

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

10. Make sure that there is no fuel leak during the en-

gine operation. If fuel leakage 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

8-7

Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Fuel pipe - Inspect

High pressure fuel injection pipe and Clamp seat - Inspect
Visual inspection in every 2000 service

hours

Check clamp seat cracks and high pressure fuel injec-

tion pipe metal contact with clamp. If defective,

replace the clamp seat with a new one. Replace the

high pressure fuel injection pipe with a new one as

needed.

In every major overhaul

Replace clamp seat with a new one. Also, check high

pressure fuel injection pipe metal contact with clamp.

If defective, replace the high pressure fuel injection

pipe with a new one.

In every other major overhaul

Replace all clamp seats and high pressure fuel injec-

tion pipes with new ones.

Fig. 8-10 High pressure fuel injection pipe and Clamp

Clamp plate

Clamp seat

seat - Inspect

Low pressure fuel pipe and Clip - Inspect
Visual inspection in every 2000 service

hours

Loosen clamp fixing bolt and check clip wear and pipe

metal contact with clamp. If defective, replace the pipe

assembly with a new one.

In every other major overhaul

Replace the pipe assembly with a new one.

Clip

Clamp

Fig. 8-11 Low pressure fuel pipe and Clip - Inspect

8-8

Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Lubricating system

Engine oil, Oil filter and Bypass oil filter - Replace

When draining oil or changing the oil filter, wear gloves. Hot engine oil and parts may cause burns.

Do not dump waste oil. It is forbidden by law. For disposal of waste oil, consult a dealer of Mitsubishi Heavy Indus-

tries, Ltd.

Change the engine oil, oil filter and bypass oil filter at the same time.

Also checking and analyzing the oil properties is recommended when changing the engine oil.

Do not reuse the oil filter element, as it is a paper type. When replacing filters, always replace gasket with new

ones.

Engine oil - Drain

After the engine has stopped, drain engine oil from the engine oil drain port.

8-9

Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Engine oil - Refill

Refilling engine oil must be specified level. If the

refilling oil goes over the high marks on the oil level

gauge, engine oil may blow out.

1. Remove the cap from the oil filler.

2. Fill the engine oil pan with 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

waste cloth.

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

gauge guide, then pull out the gauge again.

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

marks on the oil level gauge.

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

type.

7. Check the oil pan and other area for oil leaks. Re-

pair the oil leakage if any.

8. While pulling the stop lever, rotate the crankshaft

for approx. 10 seconds to turn on the starter. Stop

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

tion two or three times. Circulate engine oil to each

engine parts.

Note: Prepare for the Cooling system.

9. Check the oil level with the oil level gauge again,

and add oil to the specified level.

Oil level gauge

H

High

L

Oil filler

Oil level gauge

Low

Fig. 8-12 Oil filler and Oil level gauge

Improper

Proper

Improper

8-10

Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Oil filter and Bypass oil filter - Replace

1. Clean around the oil filters.

2. Prepare drip pans, and place them under oil filters

and a bypass oil filter.

3. Using a filter wrench, remove oil filters and a by-

pass oil filter.

Note: Disconnect the removed oil filters and a bypass

oil filter, and check elements for metal particles.

If metal partivles are found, contact a dealer of

Mitsubishi Heavy Industries, Ltd.

4. Thoroughly wipe off oil on the oil filter mounting

surface of the filter bracket with a cloth.

5. Check the new oil filters and a bypass filter for

proper seating of gasket.

Do not use a filter with the dented case. Fillter dam-

age or oil leakage may occur and it can cause fire

hazard.

Bypass oil filter

Oil filter

Filter wrench

Fig. 8-13 Oil filter and Bypass oil filter - Replace

Oil tray

Apply engine oil
to gasket.

6. Apply clean engine oil to gasket.

7. Install oil filters and a bypass oil filter to the filter

bracket. When the gasket contacts the mounting

surface of the filter bracket, further rotate 3/4 to a

full turn.

Do not use a filter wrench to install the oil filter and

bypass oil filter.

Do not dent or scratch the oil filter surfaces.

Fig. 8-14 Oil filter

8-11

Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Engine oil for mixing of fuel and water - Inspect

If the engine continues to operate with engine oil mixed with fuel or water, the engine oil viscosity decreases and

this can cause serious accidents such as seizing of bearings.

Sample 1 to 2 L [0.26 to 0.53 U.S. gal.] of engine oil, and check for abnormal odor and discoloration to determine

the mixing of fuel and water.

If fuel is mixed with the engine oil, the oil will smell like fuel.

If water is mixed with the engine oil, the oil will be milky white.

If fuel or water is detected in the engine oil, find the cause of the problem, and repair. If the problem cannot be cor-

rected easily, contact a dealer of Mitsubishi Heavy Industries, Ltd.

Oil pipe - Inspect

Oil pipe and Clip - Inspect and Replace
Visual inspection in every 2000 service hours

Loosen clamp fixing bolt and check clip wear and pipe

metal contact with clamp. If defective, replace the pipe

assembly with a new one.

In every other major overhaul

Replace the pipe assembly with a new one.

Clip

Clamp

Fig. 8-15 Oil pipe and Clip - Inspect and Replace

8-12

Cooling system

Coolant - Change

Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Remove the radiator cap only after the engine has

cooled to room temperature. Place a waste cloth over

the cap, and loosen the cap about a half-turn or stand

the lever to the upright position to release internal

pressure. Never open the radiator filler cap while the

engine is hot, otherwise the steam or hot coolant

spurts out and you may be scald with it.

Coolant (containing LLC) drained from the engine is

toxic. Never dispose of coolant into regular sewage.

For disposal of used coolant, consult a dealer of Mit-

subishi Heavy Industries, Ltd. or a industrial waste

disposer.

The service life of LLC is 2 years. Be sure to change

coolant at least once every 2 years.

Coolant - Drain

1. When draining coolant immediately after engine

operation, idle the engine in low gear for 5 to 6 min-

utes to lower the coolant temperature to 70 to 80 °C

[158 to 176 °F].

2. Open the radiator filler cap.

3. Place coolant receiving cans under the drain cocks

and plugs, and open the coolant drain cocks and

plugs to drain the coolant.

Turn the cap about
half a turn

Fig. 8-16 Radiator filler cap

Left side

Coolant

drain cocks

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

Fig. 8-17 Coolant drain cock (engine)

Stand the lever to
the upright position

Right side

8-13

Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Cooling system - Clean

Clean the cooling system when operating the engine

or heat exchange equipment first time, or restarting

the engine after storage with coolant drained.

1. Close coolant drain cocks and plugs.

2. Pour in a cleaning solution (a solution that is non-

corrosive to rubber and metals) in the cooling sys-

tem, and operate the engine at 800 to 900 min

about 15 minutes, then drain the cleaning solution.

3. Close coolant drain cocks and plugs.

4. Pour in fresh water, and operate the engine at 800

-1

to 900 min

Repeat rinsing until the draining water becomes

clear and clean.

for about 10 minutes.

-1

for

Coolant
drain cock

Fig. 8-18 Coolant drain cock (water pump)

Coolant - Refill

Always use the coolant with the same LLC concen-

tration.

1. Close coolant drain cocks and plugs.

2. Remove the radiator filler cap, and pour in undilut-

ed LLC.

Note: Determine the amounts of LLC and water to be

added by using the LLC concentration chart.

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

the coolant capacity, refer to "MAIN SPECIFICA-

TIONS" (12-1).

3. Pour in water (soft water with minimal impurities,

such as tap water) slowly to the full level.

4. Check the radiator and other parts for coolant

leaks. If a coolant leak is found, repair it.

5. When coolant reaches the full level, close the radi-

ator cap securely.

6. While pulling the stop lever, rotate the crankshaft

for approx. 10 seconds to turn on 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 Cooling system.

7. Check the coolant level in the radiator.

If the engine is equipped with a reserve tank, fill the

reserve tank with coolant to the "FULL" level line as

well.

Fig. 8-19 Radiator coolant level

Fig. 8-20 Reserve tank

8-14

Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Radiator fins - Check and Clean

When handling compressed air, wear safety goggles,

a hardhat, gloves and other necessary protective

gear. Works without wearing proper protective gear

could result in serious injuries.

Check the radiator fins for holes and cracks.

To clean the radiator fins, blow compressed air from

the opposite direction of the normal air flow.

Fig. 8-21 Radiator fins - Clean

8-15

Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Inlet and exhaust systems

Turbocharger - Inspect

Check the turbocharger when the engine is cold.

Also, make sure that the compressor wheel is not

rotating before inspecting the turbocharger.

If the color of the exhaust gas is abnormal, also

inspect the turbocharger.

Disconnect the pipe from the air inlet side. Hold the

compressor wheel nut by hand and turn the wheel to

check for looseness or abnormal noise. Replace the

turbocharger if looseness or abnormal noise is found.

Note: When removing and inspecting turbocharger,

contact a dealer of Mitsubishi Heavy Industries,

Ltd.

Fig. 8-22 Turbocharger - Inspect

Draining water from the exhaust muffler

Never touch the exhaust muffler immediately after

the engine stops, as it is extremely hot. To drain

water, wait until the exhaust muffler cools.

Remove the drain plug and allow water to drain from

the exhaust muffler.

Fig. 8-23 Draining water from the exhaust muffler

Drain plug

8-16

Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Air cleaner element - Clean, Check and Replace

When handling compressed air, wear safety goggles, a dust mask, a hardhat, gloves and other necessary protec-

tive gear. Works 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 result in rapid wear of parts, leading to a shorter service

life of the engine. Never knock or hit the air cleaner element.

Cleaning, inspecting and replacing procedure described below is a commonly used procedure. Some application

may be equipped with different air cleaner.

1. Remove the air cleaner cap and wing bolt.

2. Remove the air cleaner element from the body.

2

3. Blow compressed air (0.69 MPa {7 kgf/cm

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 is.

} [100

Wing
bolt

Air cleaner
element

Body

Fig. 8-24 Air cleaner element - Remove

If defects such as cuts, pinholes 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 for new one.

After cleaning or replacing the air cleaner element,

press the reset button to reset the indicator.

Clean

Fig. 8-25 Air cleaner element - Clean and Check

Reset button

Signal
(red)

Fig. 8-26 Air cleaner - Check

Check

8-17

Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Electrical system

Battery - Inspect

If battery electrolyte is spilled on your skin or clothes, flush immediately with plenty of water. If battery electrolyte

get into your eyes, flush them immediately with plenty of water and then get medical attention.

Do not use open flames or other fire hazards near the battery. When handling the battery, be careful of sparks gen-

erated by accidental shorting.

Battery electrolyte level - Inspect

Battery electrolyte evaporates during use and the

electrolyte level gradually decreases. The proper elec-

trolyte surface level is between the LOWER LEVEL

and UPPER LEVEL lines.

For the battery without level lines, the proper electro-

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

in.] above the top of the plates.

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

distilled water to the proper level.

Note: When adding distilled water, pour in carefully.

Specific gravity of battery electrolyte - Check

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

lower than 1.22, then charge the electrolyte.

Table 8-2 Specific gravity of electrolyte

Fig. 8-27 Battery electrolyte level - Inspect

Float

10 to 15 mm
[0.39 to 0.59 in.]

UPPER LEVEL

LOWER LEVEL

Electrolyte
surface

Proper
level

Specific gravity

at 20 °C [68 °F]

Condition Remedy

From 1.26 to 1.28 Fully charged -

From 1.22 to 1.26 Charged Charge

Less than 1.22 Discharged Charge

Electrolyte

Glass tube

Fig. 8-28 Specific gravity of battery electrolyte - Check

8-18

Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES

Starter - Inspect

Visually check the starter for damage.

If the starters are dusty, blow foreign material using

compressed air.

Note: If the starters are defective, consult a dealer of

Mitsubishi Heavy Industries, Ltd.

Alternator - Inspect

Visually check the alternator for damage.

If the starters are dusty, blow foreign material using

compressed air.

Remove the belt, and turn the pulley by hand to make

sure that it rotates smoothly.

Note: If the alternators are defective, consult a dealer

of Mitsubishi Heavy Industries, Ltd.

Starter

Fig. 8-29 Starter - Inspect

Alternator

Fig. 8-30 Alternator - Inspect

8-19

Chapter 9 LONG-TERM STORAGE

If the engine has been left unattended for 3 months or more, the internal engine parts can rust, and that may cause

damage to the engine.

When storing the engine for an extended period of time, be sure to follow the directions below.

Storing the engine in an inoperable condition for 3
months or more

Preparation for storage

1. Drain the engine oil in-use, pour new oil.

2. Prepare a fuel mixture containing 50 % rust-preventive oil (NP-9), and fill the fuel tank with it.

3. Run the engine at low idling speeds for 5 to 10 minutes.

4. Immediately before stopping the engine, spray volatile corrosion inhibitor (VCI) through the inlet port to prevent

rust on the air intake system.

5. With the engine stopped, drain the fuel mixture from the fuel tank.

6. Apply rust-preventive oil (NP-3) liberally on the exposed sections of the machining.

7. Seal the air inlet, exhaust outlet, breather and other openings with an adhesive cloth tape.

8. Loosen the belt.

9. Wrap adhesive cloth tape on the terminals of the starters and alternator, and seal the openings. Cover these sec-

tions with polyethylene sheet or processed polyethylene paper, and place desiccants in the polyethylene covers.

10. Disconnect the cables from the battery terminals, and charge the battery. Clean the terminals, apply a thin coat

of grease to the terminals, and store the battery in a cool and dry room.

11. Cover the whole engine.

Note: (a) Store the engine in a well-ventilated indoor area.

(b) It is not necessary to drain coolant since it contains LLC. (LLC must be specified concentration. For LLC

concentration, refer to "LLC concentration" (6-5).)

(c) Post a sign at an easily noticeable place to warn that the fuel tank must be filled with fuel before operating

the engine for the first time after storage.

Recommended rust-preventive oil and corrosion inhibitor

Table 9-1 Recommended rust-preventive oil and corrosion inhibitor

JIS No. Recommended product Application

NP-3

K2246

NP-9

Z1519 -

Maintenance during storage

Charge the battery once a month. First, check the battery electrolyte for proper level and then charge the battery.

Nippon Oil Corporation
Anti Rust P-1600

Nippon Oil Corporation
Anti Rust P-2400

Ryoukou Kagaku
VCI Diana ND volatile
corrosion inhibitor

Prevention of rust on exposed
machine surfaces

Prevention of rust in fuel system

Prevention of rust in air intake
system

9-1

Chapter 9 LONG-TERM STORAGE

Using the engine after storage

1. Remove the cover from the engine.

2. Connect a fully charged battery.

3. Remove the covers from the starters and alternator.

4. Adjust the tension of belt.

Note: Inspect and adjust V-belt tension. Refer to "Belt and belt tension - Inspect and Adjust" (8-2).

5. Remove sealing tapes from the openings of the engine.

6. Connect pipes.

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

7. Fill the fuel tank with fuel, and bleed the fuel system.

Note: For bleeding fuel system, refer to "Fuel system - Bleed air" (3-2).

8. Inspect the whole engine.

9. Remove the rocker covers, and lubricate the valve mechanisms.

10. While pulling the stop lever, rotate the crankshaft for approx. 10 seconds to turn on the starter. Stop the operation

for 1 minute, then, repeat the operation two or three times.

11. Make sure the engine oil pressure rises.

12. Conduct a warm-up operation for a sufficient duration.

Note: For starting the engine, refer to "Starting" (3-12).

13. Apply load and increase the engine speed to the rated speed.

Storing the engine in an operable condition for 3 months
or more

When the engine is not operated during storage of 3 months or more, internal engine parts can rust and lose oil film.

As a result, the engine can seize when it is started after storage. To prevent such a risk, the engine must be oper-

ated periodically during storage.

Operating the engine for maintenance

Operate the engine for maintenance at least once a month as described below.

1. While pulling the stop lever, rotate the crankshaft for approx. 10 seconds to turn on the starter. Stop the operation

for 1 minute, then, repeat the operation two or three times.

2. Make sure the engine oil pressure rises.

3. Operate the engine about 5 to 10 minutes under no load as the maintenance operation.

Note: For starting the engine, refer to "Starting" (3-12).

9-2

Chapter 10 TRANSPORTATION

Lifting the engine

To lift the engine, use wire ropes, shackles and slings

capable of supporting the weight of the engine.

Attach the wire rope to the hangers provided on the

engine using a correct sling.

Keep the engine balanced during lifting by consider-

ing the engine's center of gravity.

Keep the angle formed by slings attached to hangers

within 60°. 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 the

pipe cover and the insulator near the hangers. To

prevent wire ropes from contacting the engine, use a

cloth or other soft padding.

Rear hanger

Front hanger

Fig. 10-1 Hangers

70 mm

[2.76 in.]

220 mm
[8.66 in.]

The center of gravity

Fig. 10-2 Engine's center of gravity

(standard specification)

10-1

Chapter 11 TROUBLESHOOTING

General precautions

Contact a dealer of Mitsubishi
Heavy Industries, Ltd. for repair
service

Repairing a malfunctioning engine may require special

equipment or involve potentially dangerous work,

except for relatively simple procedures such as the

change and addition of fuel, engine oil and coolant. In

the event of the engine failure, contact a dealer of Mit-

subishi Heavy Industries, Ltd.

Considerations before work

Before troubleshooting, consider possible causes of

the problem and try to find out if the same problem

has occurred in the past.

Check the parts that may be causing the problem in

the most efficient order.

When disassembling a component, pay close atten-

tion to the disassembly sequence so that you can

reassemble the component in reverse order of disas-

sembly.

Cautions against contamination

Dust and foreign materials are the most common

cause of rapid wear of parts.

When disassembling a component, take measures to

prevent dust and foreign materials from entering the

component being disassembled.

Cautions regarding parts han­dling

Handle parts carefully.

When replacing parts, use only genuine parts by refer-

ring to the parts catalogue.

Work safety

Be sure to use wrenches of the correct size. Using a

wrench of the wrong size not only damages nuts but

can also cause the personal injury.

Use correct tools and perform work with utmost cau-

tion.

Be sure to accurately estimate the weight of the part

being dismounted. If the removed part is much heavier

than you have estimated, it may fall down during lifting

and can result in the damage to the parts or personal

injury.

11-1

Chapter 11 TROUBLESHOOTING

Troubleshooting

The starter does not crank or cranks slowly, resulting in start failure

Table 11-1 The starter does not crank or cranks slowly, resulting in start failure

Cause Remedies

Check the DC fuse.

Electrical
system

Faulty wire connection

Insufficiently charged battery

Faulty battery

Check wiring connection between battery, starter and starter

switch

Check alternator. (Refer to P8-19)

Check and adjust belt. (Refer to P8-2)

Check specific gravity of battery electrolyte. (Refer to P8-18)

Charge battery

Change battery.

Lubricating
system

Basic engine

Faulty starter or starter relay

Oil viscosity too high Use appropriate engine oil. (Refer to P5-1)

Excessive oil

Rapid wear of sliding parts, or
locked

Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Check amount of engine oil and lubrication system. (Refer to P3-

9)

Consult a dealer of Mitsubishi Heavy Industries, Ltd.

The starter cranks, but the engine does not start

Table 11-2 The starter cranks, but the engine does not start

Cause Remedies

Run out of fuel, blocked pipe

Improper fuel property

Fuel leakage in fuel pipes and
injection pipes.

Fuel system

Clogged fuel filter

Faulty fuel feed pump Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Faulty fuel injection pump

Faulty fuel injection nozzle Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Air intake
system

Control
system

Basic engine Low compression pressure Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Insufficient amount of air

Faulty governor

Inspect fuel tank, supply fuel, bleed air. (Refer to P8-5)

Check fuel pipes, valves.

Use appropriate fuel. (Refer to P4-1)

Remove dust, water impurities. (Refer to P8-5)

Check faults and retighten fuel pipes and injection pipes.

Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Inspect and replace fuel filter. (Refer to P8-7)

Clean gauze filter. (Refer to P8-6)

Check the rack movementx

Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Clean, inspect and replace air cleaner element. (Refer to P8-17)

Check the linkage operation. (Refer to P3-10)

Consult a dealer of Mitsubishi Heavy Industries, Ltd.

11-2

Output decrease

Cause Remedies

Improper fuel property Use appropriate fuel. (Refer to P4-1)

Clogged fuel filter

Faulty fuel feed pump Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Faulty fuel injection pump Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Fuel system

Cooling
system

Inlet and
exhaust
systems

Basic engine

Control
system

Faulty fuel injection nozzle Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Faulty fuel injection timing

Improper amount of injected fuel

Overheat, overcooled

Insufficient amount of air

Increase resistance of exhaust air.

Low compression pressure Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Faulty valve timing Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Rapid wear of sliding parts Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Faulty governor control

Chapter 11 TROUBLESHOOTING

Table 11-3 Output decrease

Inspect and replace fuel filter. (Refer to P8-7)

Clean gauze filter. (Refer to P8-6)

Check fuel injection pump couplings.

Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Check fuel injection pump rack stroke.

Check left and right bank.

Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Check fan and heat exchanger.

Check control system.

Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Check turbocharger. (Refer to P8-16)

Clean, inspect and replace air cleaner element. (Refer to P8-

17)

Check intake air pressure and leakage of intake air.

Check intake air temperature and ventilation device.

Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Check turbocharger. (Refer to P8-16)

Check exhaust pipes and silencer.

Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Consult a dealer of Mitsubishi Heavy Industries, Ltd.

11-3

Chapter 11 TROUBLESHOOTING

Exhaust smoke is white or blue

Table 11-4 Exhaust smoke is white or blue

Cause Remedies

Improper fuel property Check cetane index, and use appropriate fuel. (Refer to P4-1)

Faulty fuel injection timing

Fuel system

Lubricating
system

Cooling
system

Basic engine

Faulty fuel injection nozzle Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Uneven fuel injection

Incorrect fuel injection timing Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Combustion of engine oil

Overcooled

Faulty valve timing Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Low compression pressure Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Check fuel injection pump couplings.

Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Check ignition noise, exhaust smoke temperature, left and

right bank balance.

Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Check amount of engine oil and lubrication system. (Refer to

P3-9)

Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Check radiator. (Refer to P8-15)

Check control system.

Thermostat - Inspect

Consult a dealer of Mitsubishi Heavy Industries, Ltd.

11-4

Exhaust smoke is black or charcoal

Table 11-5 Exhaust smoke is black or charcoal

Cause Remedies

Improper fuel property Use appropriate fuel. (Refer to P4-1)

Faulty fuel feed pump Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Faulty fuel injection pump Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Faulty fuel injection nozzle Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Fuel system

Inlet and
exhaust
systems

Basic engine

Control
system

Faulty fuel injection timing

Uneven fuel injection

Insufficient amount of air

Increase resistance of exhaust air.

Low compression pressure Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Faulty valve timing Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Rapid wear of sliding parts Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Increase in load

Check fuel injection pump couplings.

Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Check exhaust smoke temperature, left and right bank bal-

ance.

Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Check turbocharger. (Refer to P8-16)

Clean, inspect and replace air cleaner element. (Refer to P8-

17)

Check intake air pressure and leakage of intake air.

Check intake air temperature and ventilation device.

Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Check turbocharger. (Refer to P8-16)

Check exhaust pipes and silencer.

Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Check control system and governor controller.

Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Chapter 11 TROUBLESHOOTING

11-5

Chapter 11 TROUBLESHOOTING

Fuel consumption is high

Table 11-6 Fuel consumption is high

Cause Remedies

Faulty fuel injection nozzle Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Faulty fuel injection timing

Fuel system

Cooling
system

Inlet and
exhaust
systems

Basic engine

Improper fuel property Use appropriate fuel. (Refer to P4-1)

Fuel leakage in fuel pipes and
injection pipes.

Overcooled

Insufficient amount of air

Increase resistance of exhaust air.

Low compression pressure Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Faulty valve timing Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Rapid wear of sliding parts Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Check fuel injection pump couplings.

Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Check faults and retighten fuel pipes and injection pipes.

Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Check radiator. (Refer to P8-15)

Check control system.

Thermostat - Inspect

Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Check turbocharger. (Refer to P8-16)

Clean, inspect and replace air cleaner element. (Refer to P8-

17)

Check intake air pressure and leakage of intake air.

Check intake air temperature and ventilation device.

Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Check turbocharger. (Refer to P8-16)

Check exhaust pipes and silencer.

Consult a dealer of Mitsubishi Heavy Industries, Ltd.

11-6

Chapter 11 TROUBLESHOOTING

Engine oil consumption is high

Table 11-7 Engine oil consumption is high

Cause Remedies

Fuel system Faulty fuel injection timing

Oil leakage to the outside of engine

Lubricating
system

Cooling
system

Inlet and
exhaust
systems

Basic engine Wear of sliding parts Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Control
system

Engine oil viscosity too low Use appropriate oil viscosity. (Refer to P5-1)

Engine oil temperature is high.

Overheating

Spread oil to intake part

Wear of valve operating system Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Increase in load

Check fuel injection pump couplings.

Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Check oil leakage.

Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Check amount of engine oil and lubrication system. (Refer to

P3-9)

Check oil cooler and oil thermostat

Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Check radiator. (Refer to P8-15)

Check control system.

Thermostat - Inspect

Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Check oil leakage to the turbocharger.

Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Check control system and governor controller.

Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Overheating

Table 11-8 Overheating

Cause Remedies

Low coolant level

Cooling
system

Control
system

Basic engine Rapid wear of sliding parts Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Faulty water pump operation Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Faulty thermostat operation Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Faulty radiator operation

Increase in load

Check coolant leakage

Check coolant level. (Refer to P3-10)

Check and clean radiator and radiator filler cap. (Refer to P8-

15)

Check fuel injection pump rack stroke.

Check control system and governor controller.

Consult a dealer of Mitsubishi Heavy Industries, Ltd.

11-7

Chapter 11 TROUBLESHOOTING

Low engine oil pressure

Cause Remedies

Insufficient amount of engine oil

Faulty engine oil property
(viscosity)

Lubricating
system

Control
system

Basic engine

Oil temperature too high

Oil filter clogged

Faulty oil pump operation Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Faulty relief valve operation Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Faulty pressure unit operation

Increase in load

Rapid wear of sliding parts Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Increase clearance of sliding part. Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Table 11-9 Low engine oil pressure

Check amount of engine oil and lubrication system. (Refer to

P3-9)

Analyze oil property. Use appropriate engine oil. (Refer to P5-

1)

Check coolant system.

Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Inspect and replace oil filter and bypass oil filter. (Refer to P8-

9)

Check control system and wire.

Consult a dealer of Mitsubishi Heavy Industries, Ltd.

Check control system and governor controller.

Consult a dealer of Mitsubishi Heavy Industries, Ltd.

When fuel has run out

When fuel runs out while engine is running and the engine has stopped, restart the engine as described below.

1. Return the starter switch to the "OFF" position.

2. Add fuel to the fuel tank.

For filling fuel tank, refer to "Fuel tank oil level - Check" (3-8).

3. Bleed air from the fuel system.

For bleeding fuel system, refer to "Fuel system - Bleed air" (3-2).

4. Restart the engine.

For starting the engine, refer to "Starting" (3-12).

11-8

Chapter 12 MAIN SPECIFICATIONS

Main specifications

Table 12-1 Main specifications

Item Specifications

Engine model S16R-Y1PTA-1 S16R-Y1PTA-2

Type Water-cooled 4-stroke cycle, turbocharged with air cooler

No. of cylinders - arrange­ment

Cylinder bore × stroke ø170 × 180 mm [6.69 × 7.09 in.]

Displacement 65.37 L [3989.73 cu. in.]

Conbustion type Direct injection system

Compression ratio 13.5 : 1 15.0 : 1

Firing order 1 - 9 - 6 - 14 - 2 - 10 - 4 - 12 - 8 - 16 - 3 - 11 - 7 - 15 - 5 - 13

Direction of rotation Counterclockwise as viewed from flywheel side

Dimensions (L x W x H)

Dry weight Approx. 6200 kg [13669 lb.]

Fuel Diesel fuel

Fuel injection pump Mitsubishi PS8A × 2

Fuel filter Paper-element type (spin-on type)

Fuel injection nozzle Hole type

Initial fuel injection pres­sure

Lubrication method Forced circulation (pressure feed by oil pump)

Lubrication oil Class CF oil (API service classification)

Engine oil capacity

Oil filter Paper-element type (with bypass oil filter, spin-on type)

Oil cooler Water cooled multi-plate (built-in crankcase)

Cooling method Forced water cooling

Coolant capacity Approx. 170 L [26.42 U.S. gal.] (in engine only)

Starting system Electric motor starting

Starter 24V DC - 7.5 kW × 2

Alternator 24 V DC - 30 A

Turbocharger Mitsubishi TD10L x 4

Note: The specification above are subject to change without prior notice.

Approx. 3223 x 1360 x 1810 mm

[126.89 x 53.54 x 71.26 in.]

34.32 MPa {350 kgf/cm

Oil pan: Approx. 200 L [52.84 U.S. gal.],

Whole engine: Approx. 230 L [60.77 U.S. gal.]

16-V

Approx. 3223 x 1455 x 1810 mm

[126.89 x 53.54 x 71.26 in.]

2

} [4978 psi]

12-1

TP-6547 10/09