Mitsubishi S12A2-PTA2 Operation & Maintenance Manual Download | Manualshive

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January

201

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Pub. No. 99265-37110

The operator and supervisor are requested to read this Oper-
ation and Maintenance Manual carefully before operating the
engine or conducting inspection and maintenance.
Never operate the engine or conduct maintenance work with-
out completely understanding this manual.

OPERATION &
MAINTENANCE MANUAL

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Summary of Contents for S12A2-PTA2

Page 1: ...requested to read this Oper ation and Maintenance Manual carefully before operating the engine or conducting inspection and maintenance Never operate the engine or conduct maintenance work with out completely understanding this manual OPERATION MAINTENANCE MANUAL 1 ...

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Page 3: ...ontents which are overlapping between the chapters 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 Please observe the contents of the controls which are applied in the countries or areas when using the engines from Mitsubishi Heavy Industries...

Page 4: ...t 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 writt...

Page 5: ... these regulations within the warranty period Warranty 3eriod 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 3arts Mit...

Page 6: ... 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 can not deny warranty sole ly for the lack of receipts or for your failure to ensure the performance of all scheduled m...

Page 7: ...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 f...

Page 8: ... 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 the...

Page 9: ...s 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...

Page 10: ...t 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 provid...

Page 11: ...ctions 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 ...

Page 12: ... kW 1 341 HP 1 3596 PS Meter of mercury 1 kPa 0 75 cmHg Meter of water 1 kPa 10 197 cmH2O cmAq Rotation speed 1 min 1 1 rpm Kinetic viscosity 1 mm2 s 1 cSt 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 Specifica...

Page 13: ...ion 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 Coolant1 5 When Abnormality Occurs 1 5 Do Not Add Coolant Immediately After a Sudden Stop Due to Overheating 1 5 Stop Operation Immediately If You Notice Any Unusual Symptoms 1 5 Avoid Immediate Restart After Abnormal Stop 1 5...

Page 14: ...on 4 2 Chapter 5 ENGINE OIL Recommended Engine Oil 5 1 Engine Oil Grade 5 1 Engine Oil Specification 5 2 Selection of Oil Viscosity 5 3 Handling Engine Oil 5 3 Service Limits of Engine Oil 5 4 Definition of Properties of Engine Oil 5 5 Kinetic Viscosity 5 5 Base Number 5 5 Acid Number 5 5 Water Content 5 5 Flash Point 5 5 Insoluble 5 5 Engine Oil Analysis Service 5 6 Chapter 6 COOLANT Recommended ...

Page 15: ...apter 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...

Page 16: ...op Lever 3 14 Fig 5 1 Engine Oil Grade 5 1 Fig 5 2 Selection of Oil Viscosity 5 3 Fig 6 1 GLASSY LLC 6 1 Fig 8 1 Adjusting the Belt Tension 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 Gauze Filter Clean 8 6 Fig 8 6 Fuel Filters Wire element Type Drain Water 8 7 Fig 8 7 Inside of Fuel Filters Wire element Type Clean 8 7 F...

Page 17: ...gency Engine 7 4 Table 8 1 Inspect belt tension deflection 8 2 Table 8 2 Thermo Label for Temperature Management 8 4 Table 8 3 Specific gravity of electrolyte 8 19 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 3 Table 11 3 Out...

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Page 19: ... 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 leaks are found immedi ately stop...

Page 20: ...caught by rotating parts away from rotating 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 starte...

Page 21: ...h the engine are designed for lifting the engine only When mounting generator on the engine use the special hanger of common bed Hangers of engine cannot be used 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 ...

Page 22: ...ields If any of these heat shields have been removed owing to unavoidable circumstances during the work be sure to restore them after the work is completed Be Careful of Opening and Closing Radiator Cap Never open the radiator cap while the engine is run ning or immediately after the engine is stopped To open the cap stop the engine and allow the coolant temperature to lower sufficiently To open t...

Page 23: ...bnormality Occurs Do Not Add Coolant Immedi ately 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 Stop...

Page 24: ...p 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 swallow the ...

Page 25: ...er 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 oper ation 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 s...

Page 26: ...cally The pre cleaner clogging can cause insufficient intake air or increasing in the exhaust temperature Never service the pre cleaner during operation The turbocharger may suck particles of foreign materials into the engine and could result in serious accidents When removing pre cleaner be sure to shut out for eign materials attached to pre cleaner After removing the pre cleaner immediately cove...

Page 27: ...or 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 n...

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Page 29: ...AME OF PARTS Engine External Diagrams Front Face Fig 2 1 Engine Front View Rear Face Fig 2 2 Engine Rear View Coolant outlet Oil pump Fuel inlet port Fuel return port Air inlet Rotational direction Flywheel Air inlet ...

Page 30: ...il level gauge Oil filler Coolant inlet Alternator Front Rear Fuel feed pump Fuel injection pump Starter Manual stop lever Water pump Coolant drain cock Stop solenoid Aftercooler Bypass oil filter Oil filter Oil filter alarm switch Fan Secondary fuel filter Fuel injection pump Fuel feed pump Rear Front Oil pan Exhaust gas outlet Engine coolant drain cock Aftercooler ...

Page 31: ...e even after the man ual stop lever is moved in the STOP direction cut off the fuel supply to stop the engine Fig 2 5 Manual Stop Lever 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 ON type stop solenoid is equipped in this engine Energized while the ...

Page 32: ... instruments of the engine operation Read carefully and understand functions of each device Oil Pressure Unit Indicate the oil pressure Fig 2 7 Oil Pressure Unit Revolution Detection Pickup It is installed in the timing gear case and always detect engine speed Fig 2 8 Revolution Detection Pickup Oil pressure unit ...

Page 33: ...rrective measures If the cause of the problem is unknown contact a dealer of Mitsubishi Heavy Industries Ltd Oil Pressure Switch When the engine oil pressure decreases and reaches to 0 3 MPa 3 1 kgf cm2 43 51 psi the contact becomes ON Fig 2 9 Oil Pressure Switch Oil Filter Alarm Switch The contact will turn ON when oil filters become clogged the difference in pressure between inlet and outlet of ...

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Page 35: ...uel 7 Refill fuel tank until fuel level gauge indicates FULL level line after checking the contact of float switch 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 openi...

Page 36: ... the air vent plug of 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 Fig 3 3 Fuel Filter Bleed Air When fuel overflow from the air vent plug wipe thor oughly Spilled fuel causes fire hazard After bleeding lock the priming pump ...

Page 37: ...ck 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 Fig 3 5 Priming Pump Tightening Method Fig 3 6 Priming Pump Head Packing Air vent plug Priming pump Fuel injection pumps are located on the both banks of engine Never fail to tighten the prim...

Page 38: ... If the engine oil is low refill the specified engine oil 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 Star...

Page 39: ...le pulling the manual stop lever crank the en gine for approx 10 seconds using the starter Stop the operation for approx 1 minute then repeat the operation two or three times to bleed the cooling system Note Prepare for the engine oil system 6 Check the coolant level in the radiator 7 If the engine is equipped with a reserve tank fill the reserve tank with coolant to the FULL level line as well Fi...

Page 40: ...ce 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 add little by little Fig 3 12 Battery Electrolyte Level Inspect If battery electrolyte is spilled on your skin or clothes flush immediately with plenty of water If battery electrolyte get into your eye...

Page 41: ... engine oil from the oil filler Be sure to use the engine oil of the same brand and type 5 Open the radiator cap and check the coolant level 6 If the coolant level is low add coolant to the specified level If a reserve tank is equipped fill the reserve tank with coolant up to the FULL level line Always switch the water heater ON automatic mode through a whole year If the switch is not ON automatic...

Page 42: ...subishi Heavy Industries Ltd 3 Visually check bolts and nuts for looseness 4 Check the electrical wiring including the starters and alternator 5 Check that valves plugs or cocks are properly po sitioned Fuel feed valve Open Coolant drain cock valve Closed Engine oil drain plug Closed Fig 3 13 Valves for Open Closed Position Check Should an engine abnormality be observed during operation stop the e...

Page 43: ...l spring Then relax your grip on the lever little by little check that the manual stop lever returns to the no fuel injec tion position smoothly Also check ball joint for looseness and play Fig 3 14 Fuel Control Link 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 re...

Page 44: ...the high marks on the oil level gauge open the engine oil drain valve to drain oil If the engine oil is low refill the specified engine oil 4 Install the oil filler cap after adding engine oil 5 Check the oil pan and other area for oil leaks Fig 3 15 Oil Filler and Oil Level Gauge Refilling engine oil must be specified level If the refilling oil goes over the high marks on the oil level gauge engi...

Page 45: ...he 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 Note For damper temperature limit and inspection re fer to Damper Inspect 8 3 Fig 3 16 Thermo label of damper Always use the coolant having the same concentration If the abnormality of temperature alteration is found consult ...

Page 46: ...alk around the engine and check for fuel oil coolant or exhaust gas leaks 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 Continuous operation of the starter will drain the battery power and cause the starter to s...

Page 47: ...perate the engine under a light load for break in operation Operating the new 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 OFF when the engine is running Turning off the battery switch during oper ation not only stops the instrument operations but also may deteriorate the alternator diode and regul...

Page 48: ... 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 run the engine with the idle speed at low Rpms for 5 or 6 minutes to cool the engine and check the engine for abnormalities Never accelerate the engine immediately before shutting it down Do not restart the engine immediately after abnormal s...

Page 49: ...ing 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 u...

Page 50: ...x new type 45 or higher JISK2280 1996 ISO DIS 4264 Kinetic viscosity 2 0 mm2 s 0 0031 in2 s or more at 30 C 86 F 8 0 mm2 s 0 0124 in2 s or more at 30 C 86 F JIS K 2283 2000 ISO 3104 Sulfur content 0 2 weight or lower 1 0 weight or lower Shorten lub oil change intervals JIS K 2541 2000 The content should be as low as the die sel fuel ISO 4260 ISO 8754 Water content and sediment 0 1 volume or lower ...

Page 51: ...at WS 1 4 kPa 0 0143 kgf cm2 0 2031 psi ISO 12156 1 BDF Biodiesel fuel FAME Fatty Acid Methyl Ester BDF quality shall meet JIS K 2390 or ASTM D 6751 or EN14214 BDF blending of 5 by volume or less is approved JIS K 2390 2008 FAME for mixing ASTM D 6751 EN 14214 Engine applications for regular prime use Regular for emergency use Emergency Selection according to application Table 4 2 Recommended Limi...

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Page 53: ...e clas sification CF or CH 4 When using the CF class engine oil it must be certi fied according to API service classification CF by 2009 and satisfied the following Table 5 1 Recommended limit of engine oil property When using the CH 4 class engine oil the sulfur con tent of fuel must be 0 2 weight or lower Fig 5 1 Engine Oil Grade Use the engine oils recommended in this manual only Never use oil ...

Page 54: ...K 2265 ISO 3679 ISO 2719 ISO 2592 Base number Hydrochloric acid method Sulfur contents of fuel 1 0 weight or lower mgKOH g 10 or higher up to 13 JIS K 2501 ISO 3771 ISO 6618 ISO 6619 ISO 7537 0 2 weight or lower 8 or higher up to 13 Perchloric acid method Sulfur contents of fuel 1 0 weight or lower mgKOH g 13 or higher up to 16 0 2 weight or lower 11 or higher up to 16 Acid number mgKOH g 1 5 to 2...

Page 55: ...the legally specified quantities be sure to have the work per formed by a service station operated under the provision of the law When removing oil from the engine or oil can use an oil pump Do not suck oil using you mouth and a pipe Be sure to close the cap on the oil can after use Keep oil in a well ventilated place and out of direct sunlight Be sure to obtain the MSDS of the engine oil and foll...

Page 56: ...th new oil Table 5 2 Table of engine oil properties Properties Standard Test method Kinetic Viscosity mm2 s in2 s 100 C 212 F 30 or less rate of change from new oil 10 mm2 s 0 155 in2 s or more JIS K 2283 2007 ISO 3107 ISO 2909 30 or less rate of change from new oil 20 or less rate of change from new oil Base number mgKOH g 2 0 or more with hydrochloric acid HCL method 1 2 of new oil or more with ...

Page 57: ...oxidation or sulfurous acid or sulfuric acid derived by the combustion of sul fur content of fuel or the oil becomes contaminated with imperfect combustion products An increase in the acid number will result in corrosion or wear of the inner parts of the engine such as cylin der liners or metal due to sulfur content and piston ring seizure due to sludge Water Content Water in oil promotes corrosio...

Page 58: ...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 s...

Page 59: ...ification Genuine LLC Mitsubishi Heavy Industries Ltd recommends the use of our genuine long life coolant GLASSY long life coolant Ethylene glycol type and Eco friendly prod uct PG GLASSY long life coolant propylene glycol type which are most appropriate coolant for Mitsubi shi diesel engines Be sure to use our Genuine LLC Fig 6 1 GLASSY LLC Table 6 1 Water Quality Standards Item Chemical symbol U...

Page 60: ...ning malfunctions caused by the use of LLC that does not meet the following specifica tion General Demands of LLC LLC must be a homogeneous liquid without sedi ment When the LLC is diluted to 30 to 60 density the LLC shall not cause troubles such as corrosion and precip itation deposits in the engine cooling system LLC shall be mixed with other LLC that satisfies this specification and shall not s...

Page 61: ...g character ASTM D3306 01 30 vol 4 0 ml or less 331 3 vol 150 ml 0 032 gal or less Disappearance of bubble within 5 seconds Hard water adaptability 1 0 or less 50 vol Metallic causticity 88 2 C 190 4 35 6 F 336 2 Hr 30 vol E G 50 vol P G Metalspecimen Mass change Aluminum 0 30 mg cm2 Cast iron 0 15 mg cm2 Steel 0 15 mg cm2 Brass 0 15 mg cm2 Solder 0 30 mg cm2 Copper 0 15 mg cm2 Appearance of the s...

Page 62: ...0 mg cm2 Copper 0 30 mg cm2 Appearance of the specimen after testing No visible signs of corrosion on the surface excluding the area contacting to spacer However discoloration is acceptable Properties of liquid after the test pH 6 5 to 11 0 pH change Maximum 1 0 Appearance of liquid No remarkable discoloration separation and gel generation Condition of parts Pump seal Free from any malfunction liq...

Page 63: ...6 5 Chapter 6 COOLANT Storage stability vol 30 vol room temperature 6 Hr 0 3 or less Table 6 2 LLC Specification Property Standard ...

Page 64: ...g 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 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 cool...

Page 65: ... 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 Abnormali ties 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 iro...

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Page 67: ...iodic 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 d...

Page 68: ...uled engine Valve Clearance Inspect and Adjust Check valve mechanism at the same time 2 Every 1000 service hours Inside of Fuel Filters Wire element Type Clean 8 7 Fuel Filter Replace 8 8 Water Separator Inspect and Replace 1 Gauze Filter Clean 8 6 Belt and Belt Tension Inspect and Adjust 8 2 Every 2000 hours Fuel Tank Drain Water Replace parts as necessary 1 8 5 Valve Clearance Inspect and Adjust...

Page 69: ... guides valve bridge guides valve bridges valve springs tappets camshaft thrust plates pistons piston pins connecting rod bolts connecting rod bushings rocker bushings fuel pipe assembly oil pipe assembly 2 Fuel Injection Pump Inspect and Test Replace parts as necessary 2 Governor Inspect and Test Replace parts as necessary 2 Protective Devices Repair or Replace 1 High coolant temperature low oil ...

Page 70: ...ion oil pressure gauge coolant temperature gauge oil temperature gauge exhaust temperature gauge tachometer etc Every month Engine Oil for Mixing of Fuel and Water Inspect 8 14 Clean Fuel Filter Wire element Type Turn Handle One or Two Times Fuel Control Link Check 3 9 Battery Electrolyte Level Inspect 1 3 6 Operating the Engine for Maintenance more than 50 load for 15 to 30 minutes Check for ease...

Page 71: ...ng system Water Pump Inspect 2 Solenoid Valve and Pressure Reducing Valve of the Cool ing system Inspect disassemble and clean 1 2 Strainer Including with ball tap of Cooling Water Inspect Disisassemble and clean 1 2 Coolant Properties when only soft water is used Inspect change coolant according to the analysis results 2 Electrical system Starter Inspect 8 20 Alternator Inspect 8 20 Specific Grav...

Page 72: ...Engine Overhaul Remove the cylinder head and inspect and service the combustion cham bers If the abnormalities of first and second cylinders are found inspect all cylin ders 2 Checking Oil Cooler for Contamination Ogging and Leakage 2 Checking Oil Pump for Discoloration and Other External Defects 2 Fuel Tank Clean 1 8 5 Fuel Injection Pump Inspect and Test Replace parts as necessary 2 Governor Ins...

Page 73: ...l Injection Nzzle Nozzle tip Replacement check the spray condition and adjust the fuel injection pressure after replacement 2 Rubber parts and O rings Replace 2 Unit Seal and Oil Seal of Water Pump Replace 2 Turbocharger Disassemble and Inspect 2 Aftercooler Disassemble and Clean 2 Vibration isolating Rubber Repair or Replace 1 2 Couplings Repair or Replace 1 2 Governor Motor Repair or Replace 1 2...

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Page 75: ...n 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 and dried 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 6 c Post a sign at an easily noticeable place to warn that the fuel tank must be...

Page 76: ... sure the engine oil pressure rises 13 Conduct a warm up operation for a sufficient duration to fit each part Note For starting the engine refer to Start 3 12 14 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 fi...

Page 77: ... with the engine is designed for lifting the engine only When mounting marine gear on the engine be sure not to apply the load on the hangers of engine only 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 af...

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Page 79: ...sembly sequence so that you can reassemble the component in reverse order of disas sembly Cautions Against Contamina tion 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 Han dling Handle parts carefully When replacing...

Page 80: ...s Electrical system Faulty wire connection Check the DC fuse Check wiring connection between battery starter and starter switch Insufficiently charged battery Check alternator Refer to P8 20 Check and adjust belt Refer to P8 2 Faulty battery Check specific gravity of battery electrolyte Refer to P8 19 Charge battery Change battery Faulty starter or starter relay Consult a dealer of Mitsubishi Heav...

Page 81: ...jection pipes Check faults and retighten fuel pipes and injection pipes Consult a dealer of Mitsubishi Heavy Industries Ltd Clogged fuel filter Inspect and replace fuel filter Refer to P8 8 Clean gauze filter Refer to P8 6 Faulty fuel feed pump Consult a dealer of Mitsubishi Heavy Industries Ltd Faulty fuel injection pump Check fuel injection pump rack stroke Consult a dealer of Mitsubishi Heavy I...

Page 82: ...t of injected fuel Consult a dealer of Mitsubishi Heavy Industries Ltd Cooling system Overheat overcooled Check fan and radiator Refer to P8 17 Check control system Consult a dealer of Mitsubishi Heavy Industries Ltd Inlet and Exhaust systems Insufficient amount of air Check turbocharger Refer to P8 18 Clean inspect and replace pre cleaner Refer to P8 18 Check intake air pressure and leakage of in...

Page 83: ...njection nozzle Consult a dealer of Mitsubishi Heavy Industries Ltd Uneven fuel injection Check ignition noise exhaust smoke temperature left and right bank balance Consult a dealer of Mitsubishi Heavy Industries Ltd Incorrect fuel injection timing Consult a dealer of Mitsubishi Heavy Industries Ltd Lubricating system Combustion of engine oil Check amount of engine oil and lubrication system Refer...

Page 84: ...stries Ltd Uneven fuel injection Check exhaust smoke temperature left and right bank bal ance Consult a dealer of Mitsubishi Heavy Industries Ltd Inlet and exhaust systems Insufficient amount of air Check turbocharger Refer to P8 18 Clean inspect and replace pre cleaner Refer to P8 18 Check intake air pressure and leakage of intake air Check intake air temperature and ventilation device Consult a ...

Page 85: ...tion pipes Consult a dealer of Mitsubishi Heavy Industries Ltd Cooling system Overcooled Check radiator Refer to P8 17 Check control system Thermostat Inspect Consult a dealer of Mitsubishi Heavy Industries Ltd Inlet and exhaust systems Insufficient amount of air Check turbocharger Refer to P8 18 Clean inspect and replace pre cleaner Refer to P8 18 Check intake air pressure and leakage of intake a...

Page 86: ...too low Use appropriate oil viscosity Refer to P5 3 Engine oil temperature is high Check amount of engine oil and lubrication system Refer to P3 10 Check oil cooler and oil thermostat Consult a dealer of Mitsubishi Heavy Industries Ltd Cooling system Overheating Check radiator Refer to P8 17 Check control system Thermostat Inspect Consult a dealer of Mitsubishi Heavy Industries Ltd Inlet and exhau...

Page 87: ...Consult a dealer of Mitsubishi Heavy Industries Ltd Basic engine Rapid wear of sliding parts Consult a dealer of Mitsubishi Heavy Industries Ltd Table 11 9 Low Engine Oil Pressure Cause Remedies Lubricating system Insufficient amount of engine oil Check amount of engine oil and lubrication system Refer to P3 10 Faulty engine oil property viscosity Analyze oil property Use appropriate engine oil Re...

Page 88: ...tart 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 9 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 Start 3 12 ...

Page 89: ... is installed Approx 1541 7 x 1504 2 x 2163 5 mm 60 697 x 59 220 x 85 177 in Dry weight Approx 2920 kg 6437 lb in engine only Fuel Diesel fuel Fuel injection pump BOSCH P type x 2 Governor Electric motor starting Fuel filter Paper element type Fuel injection nozzle Hole type Fuel injection starting pressure 29 4 MPa 299 8 kgf cm2 4264 psi Lubrication method Forced circulation pressure feed by oil ...

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