Mitsubishi S12R-Y1PTA Operation & Maintenance Manual Download Page 26

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2-1

Chapter 2 NAME OF PARTS

Engine external diagrams

Engine front

Fig. 2-1 Engine front view

Engine rear

Fig. 2-2 Engine rear view

Oil pan

Water pump

Coolant outlet

Oil pump

Breather

Thermostat

Flywheel

Governor actuator

Turbocharger

Exhaust gas outlet

Rotation

Summary of Contents for S12R-Y1PTA

Page 1: ... 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 199405 A0120 TP 6547 10 09 ...

Page 2: ... 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 ...

Page 3: ...pose 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 modificat...

Page 4: ...egulations 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 ...

Page 5: ...r 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 h...

Page 6: ...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 ma...

Page 7: ...tems 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 an...

Page 8: ...ormation 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 ...

Page 9: ...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 10: ...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 11: ... kW 1 341 HP 1 3596 PS Meter of mercury 1 kPa 0 75 cmHg Meter of water 1 kPa 10 197 cmH2O cmAq Rotational 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 Specifi...

Page 12: ...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 t...

Page 13: ... 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 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...

Page 14: ...onths 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 a dealer of Mitsubishi Heavy Industries Ltd for repair service 11 1 ...

Page 15: ...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 ...

Page 16: ...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...

Page 17: ...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 ...

Page 18: ...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...

Page 19: ... 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...

Page 20: ...ng 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 ins...

Page 21: ...nd 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 over heating If the engine stops suddenly or if you h...

Page 22: ...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 co...

Page 23: ... 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 opera tion 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 ser...

Page 24: ... 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...

Page 25: ...aution 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...

Page 26: ...external diagrams Engine front Fig 2 1 Engine front view Engine rear Fig 2 2 Engine rear view Oil pan Water pump Coolant outlet Oil pump Breather Thermostat Flywheel Governor actuator Turbocharger Turbocharger Exhaust gas outlet Rotation ...

Page 27: ...ual stop lever Starter Fuel return port Oil level gauge Oil filler Oil filter Bypass oil filter Fuel feed pump Engine coolant drain cock Air inlet Fuel inlet Damper Oil filter alarm switch Front hanger Fan Rear hanger Rear Front Rear hanger Front hanger Alternator Coolant inlet Fuel filter Fuel feed pump Coolant drain cock Air inlet Stop solenoid ...

Page 28: ...t 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 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 ...

Page 29: ... 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 Fig 2 8 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 reach...

Page 30: ...and a ratchet handle turn the shaft 4 After turning pull out the shaft insert the plate in the shaft groove and tighten the bolts Fig 2 12 Turning gear position when turning shaft Before starting the engine make sure that the turning gear is pulled out in the original position Starting the engine with the turning gear pushed in not only damages the ring gear but also may result in personal injury ...

Page 31: ...rain plug and the fuel feed pipe 5 Refill fuel tank until fuel level gauge indicates FULL level line 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 fro...

Page 32: ...ating 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 Fig 3 3 Fuel injection pump Bleed air When fuel overflow from the air vent plug wipe thor oughly Spilled...

Page 33: ...ndustries Ltd as the priming pump needs to be changed Fig 3 4 Priming pump tightening method Fig 3 5 Priming pump head packing Never fail to tighten the priming pump to the speci fied angle If the priming pump is not firmly tightened internal thread will be worn due to engine vibration resulting in sudden ejection of the cap to cause fuel flow out Or if the priming pump is excessively tight ened t...

Page 34: ...en 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 engi...

Page 35: ...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 r...

Page 36: ...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 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 cool...

Page 37: ... 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 Should an engine abnormality be observed during operati...

Page 38: ...e that water and particles of foreign mate rial discharged with fuel Close the drain cock Fig 3 14 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 tank For fuel to be used refer to FUEL 4 1 When working around...

Page 39: ...il 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 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 engine oil may blow out H...

Page 40: ...g 3 17 Radiator coolant level Fig 3 18 Reserve tank coolant level Fuel control link Check Check fuel control link for smooth movement Also check ball joint for looseness and play Fig 3 19 Fuel control link 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 positio...

Page 41: ...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 Note For damper inspection refer to Damper In s...

Page 42: ...essure 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 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...

Page 43: ... 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 i...

Page 44: ... 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 abno...

Page 45: ...xing 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 ...

Page 46: ...r 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 JIS K 2275 1996 ISO 3733 Ash content 0 01 by mass or less 0 03 weight or lower JIS K 2272 199...

Page 47: ...iodiesel fuel FAME Fatty Acid Methyl Ester BDF quality shall meet JIS K 2390 ASTM D 3751 or EN14214 BDF blending of 5 by volume or less is approved JISK2390 2008 EN14214 ASTM D6751 FAME for mix ing ASTM D 6751 EN 14214 Engine applications for prime or continuous use for stand by use Selection according to application Table 4 2 Recommended limit and use limit of fuel property Properties Recommended...

Page 48: ...rmed 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 Use only the engine oils recommended in...

Page 49: ... 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 harmles...

Page 50: ...ng 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 Water co...

Page 51: ...il 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 s...

Page 52: ...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 Table 6 1 Water quality standards...

Page 53: ...ncerning 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...

Page 54: ...o 11 0 30 vol Bubbling character ASTM D3306 01 30 vol 4 0 ml 8 79 gal or less 331 3 vol 150 ml 0 032 gal or less Disappearance of bubble within 5 sec 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 Test piece 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 ...

Page 55: ...pper 0 30 mg cm2 External of test piece after the examination Not corrosion on surface excluding between test piece and spacer Discoloration is OK Properties of liquid after the examination pH 6 5 to 11 0 pH change Maximum 1 0 External of liquid Not remarkable discoloration separation and gel Condition of parts Pump seal Not trouble while the examination Inside of pump case and blade Not remarkabl...

Page 56: ...ant 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 coolant contain...

Page 57: ...es 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 i...

Page 58: ...ular 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 Engin...

Page 59: ...Check valve mechanism at the same time 2 Every 1000 service hours 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 Every 1500 service hours Fue injection nozzle Clean 2 Every 2000 service hours Fuel tank Drain water Replace parts as necessary 1 8 5 Valve clearance Inspect and Adjust Check valve mechanism at the same...

Page 60: ...ve 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 oi...

Page 61: ... 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 Every 6 months Checking LLC concentration level in the coolant 2 ...

Page 62: ...supply failure undervoltage overvoltage overcurrent low coolant level in tank low fuel level in tank etc 2 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 prim ing pump etc 2 Every 2 years Engine oil Oil filter and Bypass oil filter Replace It is recommended to check the...

Page 63: ... 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 2 Every 8 years Engine Major overhaul Disassemble engine clean check and change major parts 2 Damper Replace 2 Oil pump Repair or Replace 2 Fuel injection nozzle Nozzle tip replacemen...

Page 64: ... 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 Be sure to keep combustible materials away from the engine especially from the hot engine parts such as exhaust m...

Page 65: ...usting 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 Fig 8 1 Belt and belt tension Insp...

Page 66: ... 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 wi...

Page 67: ...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 Fig 8 3 Damper temperature manageme...

Page 68: ...uel 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 ...

Page 69: ...ng 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 ...

Page 70: ...surface of the filter bracket further rotate 3 4 to a full turn 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 ...

Page 71: ...ssure 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 seat Inspect Low pressure fuel pipe and Clip Inspect Visual inspection in every 2000 service hours Loosen clamp fi...

Page 72: ... 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...

Page 73: ... 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 ...

Page 74: ...nting surface of the filter bracket with a cloth 5 Check the new oil filters and a bypass filter for proper seating of 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 Fig 8 13 Oil filter and Bypass oil filter Replace Fig 8 14 Oil filter...

Page 75: ...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 assem...

Page 76: ...h 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 de...

Page 77: ...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 t...

Page 78: ...oles 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 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 ...

Page 79: ...tsubishi Heavy Industries Ltd Fig 8 22 Turbocharger Inspect Draining water from the exhaust muffler Remove the drain plug and allow water to drain from the exhaust muffler Fig 8 23 Draining water from the exhaust muffler 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 abnor...

Page 80: ... the air cleaner element press the reset button to reset the indicator Fig 8 24 Air cleaner element Remove Fig 8 25 Air cleaner element Clean and Check Fig 8 26 Air cleaner Check 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 cleane...

Page 81: ...ravity of battery electrolyte Check If the specific gravity measured at 20 C 68 F is lower than 1 22 then charge the electrolyte Fig 8 28 Specific gravity of battery electrolyte Check 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...

Page 82: ...onsult a dealer of Mitsubishi Heavy Industries Ltd Fig 8 29 Starter Inspect 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 Fig 8 30 Alternator Ins...

Page 83: ...rease 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 bef...

Page 84: ... 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 ...

Page 85: ...ced 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 c...

Page 86: ...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 han dling Handle parts carefully When r...

Page 87: ...es Ltd Table 11 2 The starter cranks but the engine does not start Cause Remedies Fuel system Run out of fuel blocked pipe Inspect fuel tank supply fuel bleed air Refer to P8 5 Check fuel pipes valves Improper fuel property Use appropriate fuel Refer to P4 1 Remove dust water impurities Refer to P8 5 Fuel leakage in fuel pipes and injection pipes Check faults and retighten fuel pipes and injection...

Page 88: ...y Industries Ltd Cooling system Overheat overcooled Check fan and heat exchanger Check control system Consult a dealer of Mitsubishi Heavy Industries Ltd Inlet and exhaust systems Insufficient amount of air 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 d...

Page 89: ...haust 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 to P3 9 Consult a dealer of Mitsubishi Heavy Industries Ltd Cooling system Overcooled Check radiator Refer to P8...

Page 90: ...subishi Heavy Industries Ltd Inlet and exhaust systems Insufficient amount of air 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 Increase resistance of exhaust air Check turbocharger Refer to P8 1...

Page 91: ...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 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 Incr...

Page 92: ...take part Check oil leakage to the turbocharger Consult a dealer of Mitsubishi Heavy Industries Ltd Wear of valve operating system Consult a dealer of Mitsubishi Heavy Industries Ltd Basic engine Wear of sliding parts Consult a dealer of Mitsubishi Heavy Industries Ltd Control system Increase in load Check control system and governor controller Consult a dealer of Mitsubishi Heavy Industries Ltd T...

Page 93: ... engine oil property viscosity Analyze oil property Use appropriate engine oil Refer to P5 1 Oil temperature too high Check coolant system Consult a dealer of Mitsubishi Heavy Industries Ltd Oil filter clogged Inspect and replace oil filter and bypass oil filter Refer to P8 9 Faulty oil pump operation Consult a dealer of Mitsubishi Heavy Industries Ltd Faulty relief valve operation Consult a deale...

Page 94: ...54 x 71 26 in Approx 3223 x 1455 x 1810 mm 126 89 x 53 54 x 71 26 in 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 pres sure 34 32 MPa 350 kgf cm2 4978 psi Lubrication method Forced circulation pressure feed by oil pump Lubrication oil Class CF oil API serv...

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Page 96: ...TP 6547 10 09 ...

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Mitsubishi S12R-Y1PTA, Operation & Maintenance Manual

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