Mitsubishi S6B Operation & Maintenance Manual
OPERATION &
MAINTENANCE MANUAL
199670-14110
The operator and supervisor are requested to read this Operation and Maintenance Manual carefully before operating the
engine or conducting inspection and maintenance.
Never operate the engine or conduct maintenance work without completely understanding this manual.
March 2009
Pub. No. 99670-14110
FOREWORD
This operation and maintenance manual contains detailed operation, inspection
and maintenance information for Mitsubishi engines.
Please read this manual thoroughly before proceeding with operation, inspection,
and maintenance work for correct use and servicing.
Failure to follow directions in this manual may result in serious accidents.
i
FOREWORD
LIMITED WARRANTY
The manufacturer will repair or replace parts returned to the manufacturer when the manufacturer judges that the
parts are defective in material and/or workmanship after conducting inspection.
The manufacturer'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.
The manufacturer makes no warranties, either expressed or implied, except as provided
in this manual, including, but not limited to, warranties as to marketability, merchantability, fitness for a particular purpose or use, or against infringement of any patent.
The manufacturer will not be liable for any damages or consequential damages, includ-
ing, but not limited to, damages or other costs resulting from any abuse, misuse, misapplication of the engine and devices supplied by the manufacturer.
The manufacturer will not be liable for any damages or personal injuries resulting from
any modification, without the manufacturer's written permission, of the engine and
devices supplied by the manufacturer.
The manufacturer will not be liable for any damages or production losses caused by the
use of fuel, engine oil and/or long life coolant (LLC) that are not recommended by the
manufacturer.
The owner of the engine is responsible for the perf orm ance of the required maintenance
listed in this operation manual.
The manufacturer may deny the warranty coverage if the engine or part has failed due to
inadequate or improper maintenance.
ii
Important information
FOREWORD
To avoid the potential hazard, accident prevention
activities must be planned methodically and conducted continually by considering all aspect of
engine operation, maintenance and inspection. All
related personnel, including managers and supervisors, 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.
The manufacturer cannot foresee all potential dan-
gers of the engine, potential danger resulting from
human error and other causes, or danger caused by
a specific environment in which the engine is used.
Since there are many actions that cannot be performed or must not be performed, it is impossible to
indicate every caution in this manual or on warning
labels. As such, it is extremely important to follow
directions in this manual and also to take general
safety measures when operating, maintaining and
inspecting the engine.
This manual has been prepared for people whose
native language is English. When the engine is used
by individuals whose native language is not English,
the customer is requested to provide thorough safety
guidance to the operators. Also add safety, caution
and operating signs that describe the original warning label statements in the native language of the
operators.
The engine must be operated, maintained and
inspected only by qualified persons who have thorough knowledge of engines and their 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 manual, 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 the manufacturer 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 illustrations and technical references, may be reproduced,
photocopied, translated, or reproduced in any electronic medium or machine readable form without
prior written consent from the manufacturer.
The contents in this manual are subject to change 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 your Mitsubishi dealer if you need
more information or if you have any questions.
If you lost or damaged this manual, obtain a new
copy at your Mitsubishi dealer as soon as possible.
Mitsubishi Heavy Industries recommends the engine
owner to install an hour meter on the engine due to
monitor correct service intervals and to perform the
maintenance at the proper timing.
iii
FOREWORD
W arning indication
The following two means are used to call the attention of the operators and main tenance 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.
Indicates a highly 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.
iv
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
Engine speed :1 min
Kinetic viscosity: 1 mm
-1
= 1 rpm
2
/s = 1 cSt
2
2O(cmAq)
Abbreviations, standards and others
API = American Petroleum Institute
ASTM = American Society for Testing and Materials
ISO = International Organization for Standardization
JIS = Japanese Industrial Standards
LLC = Long Life Coolant
MIL = Military Specifications and Standards
MSDS = Material Safety Data Sheet
SAE = Society of Automotive Engineers
v
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 a 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 during engine
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 the engine in a well-ventilated area....1-3
Be careful of falling..............................1-3
Lift engine carefully.......................................... 1-3
Do not climb onto the engine ........................... 1-3
Always prepare stable scaffold .... ... ... .... ... ... ... . 1-3
Protect ears from noise .......................1-4
Wear ear plugs................................................. 1-4
Be careful of burn injuries....................1-4
Do not touch the engine during or immediately
after operation.................................................. 1-4
Add 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
long-life coolant (LLC)...................................... 1-5
Handle LLC (long life coolant) carefully ........... 1-5
Proper disposal of waste oil, LLC and
coolant ............................................................. 1-5
If any anomaly 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 V-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 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
Properly maintain the air cleaner and
pre-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
Chapter 2
NAME OF PARTS
Engine external diagrams...................2-1
Left view...........................................................2-1
Right view.........................................................2-1
Equipment and instrument..................2-2
Start and stop instrument................................. 2-2
Instruments ......................................................2-3
Engine protection devices...................2-4
Oil pressure switch........ .... ... ... ... .... ... ... ... ... .... .. 2-4
Thermo switch.................................................. 2-4
Oil filter alarm switch...................................... .. 2-4
Overrun detection pickup .................................2-5
Air cleaner indicator ................................ ... .... .. 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.................................................. 3-7
Normal engine operation.....................3-8
Preparations for operation...................3-8
Engine external - Inspect ................................. 3-8
Fuel tank oil level - Check................................ 3-9
Engine oil level - Check.................................... 3-9
Coolant level - Check..................................... 3-10
Fuel control link - Check................................. 3-10
Air tank - Drain water ... .................................. 3-11
Air tank air pressure - Check.......................... 3-11
Air cleaner - Check......................................... 3-11
Temperature of damper - Check.................... 3-12
Starting..............................................3-13
Warming-up operation.......................3-13
Checking engine oil pressure......................... 3-13
External inspection during warm-up ... .... ... ... .. 3-13
Operation...........................................3-14
Cautions when operating ............................... 3-14
Inspection during operation............................ 3-14
Stopping ............................................3-15
Emergency stop............................................. 3-15
Inspection after stopping................................ 3-15
Chapter 4
FUEL
Recommended fuel .............................4-1
Handling fuel........................................4-1
Chapter 5
ENGINE OIL
Recommended engine oil....................5-1
Handling engine oil..............................5-1
Properties of engine oil and its
influence on engine performance........5-2
Main properties of engine oil ...............5-2
Detergent dispersibility..................................... 5-2
Viscosity...........................................................5-2
Selection of oil viscosity......................5-3
Definition of properties of engine oil....5-4
Viscosity...........................................................5-4
Total base number ........................................... 5-4
Total acid number ............................................5-4
Water content................................................... 5-4
Flash point........................................................5-4
Insoluble...........................................................5-4
Service limits of engine oil ..................5-5
Engine oil analysis service..................5-5
How to order engine oil sampling tool set ........5-6
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 .....................................................6-6
Pitting of iron parts ........................................... 6-6
Corrosion of aluminum parts............................ 6-6
Pitting and clogging of the radiator...................6-6
Chapter 7
MAINTENANCE SCHEDULE
How to use the maintenance
schedule..............................................7-1
General Definition of Regular-Use
Engine, Emergency Engine and
General-Purpose Engine ....................7-2
Periodic maintenance chart for regular
use engine ..........................................7-3
CONTENTS-2
CONTENTS
Periodic maintenance chart for
emergency engine...............................7-5
Periodic maintenance chart for
general purpose engine.......................7-9
Chapter 8
PERIODIC INSPECTION AND
MAINTENANCE PROCEDURES
Engine mechanical..............................8-1
Engine external - Inspect ................................. 8-1
V-belt and belt tension - Inspect and Adjust.....8-2
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 linkage ball joint - Inspect.............8-6
Water separator - Inspect................................. 8-7
Gauze filter - Clean...................................... ... . 8-7
Fuel filter - Replace.......................................... 8-8
Fuel pipe - Inspect............................................ 8-9
Lubricating system.............................8-10
Engine oil, Oil filter and Bypass oil filter
- Replace....................................................... 8-10
Engine Oil for Mixing of Fuel and Water
- Inspect ........................................................ 8-11
Governor oil filter - Replace ........................... 8-12
Oil pipe - Inspect.................................... ........ 8-12
Cooling system..................................8-13
Coolant - Change........................................... 8-13
Radiator fins - Check and Clean.................... 8-14
Inlet and exhaust systems.................8-15
Turbocharger - Inspect................................... 8-15
Draining water from the exhaust muffler........ 8-15
Pre-cleaner - Clean, Inspect and Replace.....8-16
Air cleaner element - Clean, Check and
Replace.......................................................... 8-17
Electrical system................................8-18
Starter - Inspect.............................................. 8-19
Alternator - Inspect......................................... 8-19
Air starter system...............................8-20
Air strainer - Drain water and Clean............... 8-20
Air tank - Drain water ... .................................. 8-20
Air tank - Inspect safety valve operation........ 8-20
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
Chapter 11
TROUBLESHOOTING
General precautions..........................11-1
Contact your Mitsubishi dealer for repair s
ervice..............................................................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....................................................11-8
Low engine oil pressure ................................. 11-8
When fuel has run out.......................11-8
Chapter 12
MAIN SPECIFICATIONS
Main specifications............................12-1
CONTENTS-3
CONTENTS
List of illustrations
Fig. 2-1 Engine left view........................................... 2-1
Fig. 2-2 Engine right view......................................... 2-1
Fig. 2-3 Start switch and stop switch........................ 2-2
Fig. 2-4 Manual stop lever.................................. ...... 2-2
Fig. 2-5 Stop solenoid .............................................. 2-2
Fig. 2-6 Oil pressure unit.......................................... 2-3
Fig. 2-7 Thermo unit.................................................2-3
Fig. 2-8 Revolution detection pickup........................ 2-3
Fig. 2-9 Oil pressure switch...................................... 2-4
Fig. 2-10Thermo switch............................................ 2-4
Fig. 2-11Oil filter alarm switch..................................2-4
Fig. 2-12Overrun detection pickup............................2-5
Fig. 2-13Air cleaner indicator.................................... 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 cap 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 Radiator coolant level..................................3-5
Fig. 3-10Reserve tank coolant level ................... ...... 3-5
Fig. 3-11Battery electrolyte level - Inspect................ 3-6
Fig. 3-12Specific gravity of battery electrolyte
- Check................................... .................... 3-6
Fig. 3-13Valves for open/closed position - Check .... 3-8
Fig. 3-14Oil filler and oil level gauge......................... 3-9
Fig. 3-15Radiator cap............................................. 3-10
Fig. 3-16Radiator coolant level............................... 3-10
Fig. 3-17Reserve tank coolant level ................... .... 3-10
Fig. 3-18Fuel control link - Check........................... 3-10
Fig. 3-19Air tank - Drain water................................ 3-11
Fig. 3-20Air tank air pressure - Check.................... 3-11
Fig. 3-21Air cleaner - Check................................... 3-11
Fig. 3-22Thermo label of damper ........................... 3-12
Fig. 3-23Manual stop lever ..................................... 3-15
Fig. 4-1 Recommended fuel..................................... 4-1
Fig. 4-2 Recommended fuel according to ambient
temperature..................................................4-1
Fig. 5-1 Recommended engine oil ............................5-1
Fig. 5-2 Selection of oil viscosity...............................5-3
Fig. 5-3 Engine oil sampling tool set .........................5-6
Fig. 6-1 GLASSY - LLC.............................................6-1
Fig. 8-1 V-belt and belt tension
- Inspect and Adjust ....................................8-2
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 Fuel control linkage for looseness
- Inspect ................................................. ... ..8-6
Fig. 8-6 Fuel control linkage - Remove .....................8-6
Fig. 8-7 Water separator - Drain water......................8-7
Fig. 8-8 Water separator element - Replace .............8-7
Fig. 8-9 Gauze filter - Clean................................. ... ..8-7
Fig. 8-10Fuel filter - Replace.....................................8-8
Fig. 8-11Fuel filter......................................................8-8
Fig. 8-12High pressure fuel injection pipe and
Clamp seat - Inspect and Replace...............8-9
Fig. 8-13Low pressure fuel pipe and Clip
- Inspect and Replace.................................8-9
Fig. 8-14Oil filler and oil level gauge........................8-10
Fig. 8-15Oil filter and bypass oil filter - Replace......8-11
Fig. 8-16Governor oil filter - Replace.......................8-12
Fig. 8-17Oil pipe and Clip - Inspect and Replace....8-12
Fig. 8-18Radiator cap.......................... ....................8-13
Fig. 8-19Coolant drain cock (engine).......................8-13
Fig. 8-20Radiator coolant level................................8-14
Fig. 8-21Reserve tank .............................................8-14
Fig. 8-22Radiator fins - Clean..................................8-14
Fig. 8-23Turbocharger - Inspect..............................8-15
Fig. 8-24Draining water from the exhaust muffler....8-15
Fig. 8-25Pre-cleaner - Clean ...................................8-16
Fig. 8-26Air cleaner element - Remove...................8-17
Fig. 8-27Air cleaner element - Clean and Check.....8-17
Fig. 8-28Air cleaner - Check....................................8-17
Fig. 8-29Battery electrolyte level - Inspect...............8-18
Fig. 8-30Specific gravity of battery electrolyte
- Check................................................... ...8-18
CONTENTS-4
CONTENTS
Fig. 8-31Starter - Inspect........................................8-19
Fig. 8-32Alternator - Inspect................................... 8-19
Fig. 8-33Air strainer - Drain water and Clean ......... 8-20
Fig. 8-34Air tank - Drain water................................ 8-20
Fig. 10-1Lifting hanger............................................ 10-1
Fig. 10-2Engine's center of gravity ......................... 10-1
List of tables
Table 3-1 Specific gravity of electrolyte.................. 3-6
Table 3-2 Standard values at rated speed............ 3-14
Table 4-1 Recommended fuel ................................ 4-1
Table 4-2 Recommended and limit values of fuel
property .................................................. 4-2
Table 5-1 Engine oil properties............................... 5-5
Table 5-2 Engine oil sampling tool set.................... 5-6
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............................. 7-3
Table 12-1 Main specifications ................................12-1
Table 7-2 Periodic maintenance chart
for emergency engine............................. 7-5
Table 7-3 Periodic maintenance chart
for general purpose engine..................... 7-9
Table 8-1 Damper temperature management ........ 8-3
Table 8-2 Thermo label for temperature
management........................................... 8-4
Table 8-3 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 .......................................... 11-8
Table 11-9 Low engine oil pressure........................ 11-8
CONTENTS-5
Chapter 1 BASIC SAFETY PRECAUTIONS
Fire and explosions
Keep flames away
Do not use flames near the engine
and in the engine room. Fuel vapor or
other gas can catch fire and produce
dangerous 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 designated area. Make sure that the caps of fuel and
engine oil containers 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 accumulated on the engine and surrounding parts thoroughly. 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.
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 recommended to calculate the required amount of air supply
to the engine and install an adequate ventilation system before installing the engine.
Do not open side cover until engine cools
Do not attempt to open the side cover of the crankcase 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, immediately 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 electrolyte, etc., use a flameproof light. An ordinary lighting apparatus may ignite gas and cause it to explode.
Prevent electrical wires from short-circuiting
Avoid inspecting or servicing the electrical system with
the ground cable connected to the battery. Otherwise,
a fire could result from short-circuiting. Be sure to disconnect the battery cable from the negative (-) terminal 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 service procedure.
Keep fire extinguishers and a first-aid kit handy
Keep fire extinguishers handy, and
become familiar with their usage.
Keep a first-aid kit at the designated
place where it is easily accessible by
anyone at any time.
Establish response procedures to follow in the event
of fire or accident. Provide an emergency evacuation
route and contact points and means of communication
in case of emergency.
1-1
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 such as
damper cover, camshaft cover, or
rocker cover that enclose the revolving parts during
operation.
When the engine is coupled to driven equipment, be
sure to provide protective covers over the parts such
as the connecting belts and couplings that are
exposed.
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 prohibits startup operation, do not operate the engine.
Stay clear of moving parts during engine running
Do not approach rotating or sliding
parts of the engine when the engine
is in operation. 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 inspection 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 maintenance and inspection work. Remember also that the
turning gear must be returned to the operating condition 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 the engine in a wellventilated 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 ill-ventilated area can produce gas poisoning.
Be careful of falling
Lift engine carefully
To lift the engine, use slings capable
of supporting the weight of the
engine.
Attach the wire rope to the lifting
hangers provided on the engine using
a correct sling.
During lifting process, keep the engine in a well-balanced position by taking the center of gravity of the
engine into consideration.
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 platform.
1-3
Chapter 1 BASIC SAFETY PRECAUTIONS
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 burn injuries
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 inspection work, wait until the engine has cooled sufficiently
by checking the temperature gauge.
Add coolant only after the coolant temperature dropped
Do not add coolant immediately after the engine
stops. Wait until the coolant temperature lowers sufficiently to avoid a risk of burns.
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 engine coolant is hot during engine operation and
immediately after operation. If the radiator filler 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 injection 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 tissues and may result gangrene.
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.
1-4
Chapter 1 BASIC SAFETY PRECAUTIONS
Be careful when handling fuel, engine oil or LLC
Use only specified fuel, engine oil and long-life coolant (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 malfunctions.
Obtain the MSDS issued by the fuel, oil and LLC suppliers, and follow the directions in the MSDSs for
proper handling.
Handle LLC (long life coolant) carefully
When handling LLC, always wear rubber gloves and a
protective face mask. If LLC or cooling water containing 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 vomiting 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 regulations.
Dispose of waste oil, LLC and coolant and other environmentally hazardous waste in accordance with the
applicable law and regulations.
If any anomaly 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 lubrication system to locate the cause. Continuous engine
operation with low oil pressure could cause bearings
and other parts to seize.
If V-belt breaks, stop engine immediately
If the V-belt breaks, stop the engine immediately and
replace the V-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 battery releases flammable hydrogen
gas and oxygen gas. Any flames or
sparks in the vicinity could cause an
explosion.
Do not use the battery the fluid level of which is low-
ered below the lower limit line. Sustained use of the
battery could result in an explosion.
Do not short the battery terminals with a tool or other
metal object.
When disconnecting battery cables, always remove
the cable from the negative (-) terminal first. When reconnecting cables, attach the cable to the positive (+)
terminal first.
Charge the battery in a well-ventilated area, with all
filling hole plugs removed.
Make sure the cable clamps are securely installed on
the battery terminals. A loose cable clamp can cause
sparks that may result in an explosion.
Before servicing electrical components or conducting
electric welding, set the battery switch to the [Open/
OFF] position or disconnect the cable from the negative (-) battery terminal to cut off the electrical current.
Electrolyte (battery fluid) contains dilute sulfuric acid.
Careless handling of the battery can lead to the loss
of sight and/or skin burns. Also, keep the battery fluid
off the mouth.
Wear protective goggles and rubber gloves when
working with the battery (when adding water, charging, etc.)
If electrolyte is spilled onto the skin or clothing, imme-
diately wash it away with lots of water. Use soap to
thoroughly clean.
The battery fluid can cause blindness if splashing into
the eyes. If it gets into the eyes, immediately flush it
away with plenty of clean fresh water, and seek immediate medical attention.
If the battery fluid is accidentally swallowed, 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 the
manufacturer's 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 your
Mitsubishi dealer.
Observe safety rules at work site
Observe the safety rules established at your workplace 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 workers.
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 hardhat, gloves and other necessary protective gear.
Works without wearing proper protective gear could
result in serious injuries.
Never break seals
To ensure proper engine operation, the fuel control
links are sealed to prevent accidental change of the
injection volume and rotation speed settings. Operating the engine without these seals in place can cause
problems described below, and also invalidates the
warranty.
Rapid wear of sliding and rotating parts
Engine damage such as seizing of engine parts
Considerably increased consumption of fuel and lu-
bricating oil
Degradation of engine performance due to improper
balance between fuel injection volume and governor
operation or overrunning of the engine which could
result 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, operate 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 operation 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 economical 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 incomplete 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, let it idle at low speed for
5 to 6 minutes to cool down.
Stopping the engine immediately after high-load operation will cause engine parts to heat up and shorten
the service life of the engine.
During cooling operation, check the engine for abnormalities.
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.
Properly maintain the air cleaner and pre-cleaner
The major cause of abnormal wear on engine parts is
dust from intake air. Worn parts produce many problems such as an increase of oil consumption,
decrease of output, and starting difficulties. For effective removal of dust from intake air, maintain the air
cleaner or pre-cleaner according to the following
instructions.
Do not maintain the air cleaner or pre-cleaner while
the engine is operating. Operating the engine without
the air cleaner can suck particles of foreign matter into
the engine and could result in serious accidents.
Remove the air cleaner/pre-cleaner slowly to prevent
dust accumulated on the element from falling off. After
removing the air cleaner or pre-cleaner, immediately
cover the opening (inlet port of air cleaner; port in
body for pre-cleaner) with plastic sheet or similar
means to prevent dust from entering the engine.
If the engine is equipped with a dust indicator, con-
duct maintenance when the clog warning sign appears.
Use of tools optimum for each work
Always keep in mind to select most appropriate tools
for the work to be performed and use them correctly. If
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 battery 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 2 NAME OF PARTS
Engine external diagrams
Left view
Water outlet pipe
Water pump
Right view
Front
Fan
Oil cooler
Name plate
Exhaust outlet
Bypass oil filter
Fig. 2-1 Engine left view
Turbocharger
Air intake inlet
Rear
Starter
Oil filter
Breather, oil filler
Fuel injection pump
Fuel feed pump
Rear Front
Coolant drain cock
Oil pan
Oil level gauge
Fuel return port
Air cooler
Thermostat
Governor
Stop solenoid
Alternator
Damper
Fuel filter
Fuel inlet
Fig. 2-2 Engine right view
2-1
Chapter 2 NAME OF PARTS
Equipment and instrument
The installed equipment and shapes differ on the engine type.
Start and stop instrument
Start switch
When the start switch on the operation panel is
pressed, starting system is operated and cranks the
engine.
Stop switch
When the stop switch on the operation panel is
pressed, the stop solenoid operates and moves the
control shaft of the fuel injection pump to the no-injection position to shut down the engine operation.
Manual stop lever
Use the manual stop lever to shut down the engine in
the event of an emergency. If the stop 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 manual stop lever is moved in the STOP position, 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. Two types of stop solenoids are
available.
RUN OFF type
Not energized while the engine is running. Energized
by a stop signal to stop the engine.
RUN ON type
Energized while the engine is running, and de-energized to stop the engine.
STOPSTART
(Example)
Fig. 2-3 Start switch and stop switch
STOP
Fig. 2-4 Manual stop lever
Stop solenoid
Fig. 2-5 Stop solenoid
2-2
Instruments
This section describes about devices which transmit
signals to necessary instruments of the engine in
operation. Read carefully and understand functions of
each device.
Oil pressure unit
Always detect the oil pressure.
Thermo unit
Always detect the coolant temperature of engine.
Chapter 2 NAME OF PARTS
Oil pressure unit
Fig. 2-6 Oil pressure unit
Thermo unit
Revolution detection pickup
It is installed in the timing gear case, and always
detect engine speed.
Fig. 2-7 Thermo unit
Fig. 2-8 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, examine the cause of the abnormality, and
take corrective measures. If the cause of the problem
is unknown, contact a Mitsubishi dealer. Protection
devices installed on the engine and their types (setting
values) and shapes vary depending on the engine
specifications.
Oil pressure switch
The oil pressure switch generates an alarm when the
engine oil pressure becomes low and reaches the
specified pressure.
Oil pressure switch
Thermo switch
The thermo switch activates the alarm system when
the coolant temperature reaches the specified value.
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 reaches the specified
value.
Fig. 2-9 Oil pressure switch
Thermo switch
Fig. 2-10 Thermo switch
2-4
Oil filter
alarm switch
Fig. 2-11 Oil filter alarm switch
Overrun detection pickup
The overrun detection pickup generates an alarm
when the engine speed becomes high and reaches
the specified engine speed.
Air cleaner indicator
The air cleaner indicator alarms with its red signal
when air cleaner elements become clogged, the difference in pressure between inlet and outlet of air
cleaner reaches the specified value. The signal indicates only, and does not generate an alarm. Therefore, the periodic visually inspection is needed.
Press the reset button on the top of air cleaner indicator and restore the signal after cleaned the air cleaner
indicator or replaced with a new one.
Chapter 2 NAME OF PARTS
Fig. 2-12 Overrun detection pickup
Reset button
Signal
(red)
Fig. 2-13 Air cleaner indicator
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 substances to the air inlet
opening.
Prevent from entering foreign substances 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 or overhauled engine, conduct the inspections described in this section.
For second operation onward, follow the instructions described in the "Normal engine operation" (3-8).
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
particles such as dust.
4. Reinstall the drain plug and the fuel feed pipe.
5. Refill fuel tank until fuel level gauge indicates "FULL".
3-1
Chapter 3 OPERATION
Fuel system - Bleed air
When fuel overflow from the air vent plug, wipe thoroughly. Spilled fuel causes fire hazard.
After bleeding, lock the priming pump cap 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 is the water
separator, fuel filter, then the fuel injection pump.
Lock the priming pump cap according to "Priming
pump cap tightening method".
[Unlock] [Prime]
Turn counterclockwise
Fig. 3-1 Priming pump - Handle
Move cap up
and down
[Lock]
Turn clockwise
while pressing
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 cap up and down, then
feed fuel.
3. When the fuel from the air vent plug becomes free
from air bubbles, stop priming and tighten the air
vent plug to the specified torque.
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 cap up and down until the
fuel flow from the air vent plug is free from air bubbles. Push and turn the priming pump cap clockwise to lock in the original position when the fuel
flows are free from bubbles.
3. Tighten the air vent plug on the fuel injection pump.
Air vent plug
Tightening torque
8.8 ± 1 N·m
{0.9 ± 0.1 kgf·m}
[6.4 ± 0.7 lbf·ft]
Fig. 3-2 Fuel filter - Bleed air
Air vent
plug
Priming pump
3-2
Fig. 3-3 Fuel injection pump - Bleed air
Loading...