Mitsubishi S12U Operation & Maintenance Manual Download

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CONTENTS

CONTENTS-4

Inspection of Engine Oil for Mixing of Fuel and

Water.............................................................. 6-11

Analysis of Engine Oil Properties................... 6-12

Engine Oil Sampling Tool Sets and Ordering

Procedure ............................................................... 6-12

Cooling System .................................6-13

Checking LLC Concentration ......................... 6-13

Inspection and Replacement of Zinc Rods .... 6-13

Changing Coolant .......................................... 6-14

Draining Coolant ..................................................... 6-14
Cleaning the Cooling System ................................. 6-14
Pouring coolant....................................................... 6-15

Inlet and Exhaust Systems................6-16

Inspection and Draining Water of Exhaust Pipes

and Exhaust Muffler ....................................... 6-16

Draining Water From Air Cooler Chamber and

Inspection for Water Leakage ........................ 6-16

Cleaning, Inspection and Changing

Pre-Cleaner.................................................... 6-16

Cleaning, Inspecting and Changing Air Cleaner

Element.......................................................... 6-17

Air Starter System .............................6-18

Draining Water and Cleaning Air Starter

Strainer........................................................... 6-18

Draining Water from Air Starter Compressor . 6-18

Chapter 7

LONG-TERM STORAGE

Storing Engine in Non-Operable Condition for More

Than 3 Months ................................................. 7-1

Preparation for Storage ............................................ 7-1
Maintenance during Storage..................................... 7-1
Using Engine after Storage....................................... 7-1

Storing Engine in Operable Condition for More Than

3 Months .......................................................... 7-2

Operating Engine for Maintenance Purposes........... 7-2

Chapter 8

TRANSPORTATION

Lifting Engine Carefully .................................... 8-1

TROUBLESHOOTING

General Precautions ........................... 9-1

Contact a Mitsubishi Dealer for Repair

Service ............................................................. 9-1

Examination before Work................................. 9-1

Notes Regarding Contamination ...................... 9-1

Notes Regarding Parts Handling...................... 9-1

Work Safety...................................................... 9-1

Conditions Required for Proper Engine

Operation ......................................................... 9-2

Troubleshooting .................................. 9-3

Engine Turns, But It Does Not Start................. 9-3

Engine Does Not Turn...................................... 9-5

Engine Output is Low.................................................9-6

Engine Knocks ................................................. 9-7

Engine Produces Large Amount of Smoke While in

Operation ......................................................... 9-8

Engine Operates at High Speed and Does Not

Stop.................................................................. 9-8

Malfunction of Lubricating System ................... 9-9

Chapter 10

MAIN SPECIFICATIONS

Main Specifications ........................... 10-1

List of Illustrations

fig.1-1 Warning for flywheel entanglement..............1-9

fig.1-2 Warning for moving parts .............................1-9

fig.1-3 Warning for oil mist ......................................1-9

fig.1-4 Caution for footing........................................1-9

fig.1-5 Caution for electric shock.............................1-9

fig.1-6 Warning for rotating parts.............................1-9

fig.1-7 Caution for burns .........................................1-9

fig.1-8 Warning for rotating parts.............................1-9

fig.1-9 Caution for referring to manual ....................1-9

fig.1-10 Caution for burns .........................................1-9

fig.2-1 S12U engine left view ..................................2-1

fig.2-2 S12U engine right view ................................2-1

fig.2-3 S16U engine left view ..................................2-2

fig.2-4 S16U engine right view ................................2-2

fig.2-5 Start switch and stop switch.........................2-3

Chapter 9

Summary of Contents for S12U

Page 1: ...tor 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 October 2003 October 2003 99080 20120 99080 20120 ...

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Page 3: ...pection and maintenance of the Mitsubishi Engines Please read this manual carefully to understand the operation inspection and maintenance procedures in order to use the engine properly Failure to follow directions in this manual can lead to serious accidents 99080 20120 ...

Page 4: ...pt as provided in this manual includ ing without limitation thereof 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 including without limitation thereof damages or other costs resulting from any abuse misuse misapplication of the engine and devic...

Page 5: ...horough 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 danger and also received danger avoidance training To prevent occurrence of an accident do not ...

Page 6: ... potential hazard Failure to follow these directions can lead to serious accidents which can result in personal injury or death in the worst case Indicates a highly hazardous situation which if not avoided can result in death or serious injury Indicates a potentially hazardous situation which if not avoided can result in death or serious injury Indicates a potentially hazardous situation which if ...

Page 7: ...SAE Society of Automotive Engineers U S LLC Long Life Coolant Units of Measurement Measurements are based on the International System of Units SI and they are converted to the metric sys tem units in this manual based on the following conversion rates Pressure 1 MPa 10 197 kgf cm2 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 7 cmHg Me...

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Page 9: ...arefully 1 4 Do not climb onto engine 1 4 Always watch your footing 1 4 Caution Be Careful of Handling Fuel Engine Oil and LLC 1 4 Use only specified fuel engine oil and coolant LLC 1 4 Handle LLC carefully 1 4 Properly dispose of drained oil and LLC 1 4 Caution Service Battery 1 5 Handle battery carefully 1 5 Caution When Abnormality Occurs 1 5 If engine overheats conduct cooling operation before...

Page 10: ...specific gravity of electrolyte 3 6 Checking loosened wire 3 6 Checking Valves for Open Closed Position 3 7 Test Operation 3 7 Normal Engine Operation 3 8 Preparations for Operation Pre Start Inspection 3 8 External Inspection 3 8 Cleaning Fuel Filters Wire Element Type 3 8 Checking Fuel Level in Tank 3 9 Draining Water from Fuel Tank 3 9 Checking Engine Oil Level 3 9 Checking Coolant Level 3 10 I...

Page 11: ...finition of emergency engine 5 2 General definition of general purpose engine 5 2 Periodic Maintenance Chart for Engine in Regular Use 5 3 Periodic Maintenance Chart for Emergency Engine 5 8 Periodic Maintenance Chart for General Purpose Power Supply Engine 5 13 Chapter 6 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Fuel System 6 1 Draining Water from Fuel Filters Wire Element Type 6 1 Draining ...

Page 12: ...for Maintenance Purposes 7 2 Chapter 8 TRANSPORTATION Lifting Engine Carefully 8 1 TROUBLESHOOTING General Precautions 9 1 Contact a Mitsubishi Dealer for Repair Service 9 1 Examination before Work 9 1 Notes Regarding Contamination 9 1 Notes Regarding Parts Handling 9 1 Work Safety 9 1 Conditions Required for Proper Engine Operation 9 2 Troubleshooting 9 3 Engine Turns But It Does Not Start 9 3 En...

Page 13: ...1 Draining water from fuel filter wire element type 6 1 fig 6 2 Draining water from fuel filter center bolt type 6 1 fig 6 3 Draining water from fuel tank 6 2 fig 6 4 Cleaning inside of fuel filter wire element type 6 2 fig 6 5 Changing fuel filters center bolt type 6 3 fig 6 6 Fuel filter switchover handle 6 4 fig 6 7 Changing fuel filters cartridge type 6 4 fig 6 8 Fuel filter switchover handle ...

Page 14: ...ergency engine 5 8 Table 5 3 Periodic maintenance chart for general purpose power supply engine 5 13 Table 6 1 Engine oil sampling tool sets 6 12 Table 7 1 Recommended rust preventive oil and corrosion inhibitor 7 1 Table 9 1 Conditions required for proper engine operation 9 2 Table 9 2 Engine turns but it does not start 9 3 Table 9 3 Engine does not turn 9 5 Table 9 4 Engine output is low 9 6 Tab...

Page 15: ... it may lead to the explosion of the engine Never open the engine crankcase cover before the engine becomes cool wait at least 10 minutes after the engine stops Check for fuel oil and exhaust gas leaks Inspect fuel oil and exhaust pipes regularly for damage and looseness If a fuel oil and exhaust gas leak is found repair the leakage immediately Fuel or oil spilled on a hot surface of the engine an...

Page 16: ...an be easily entangled by rotating parts away from the engine If your body or tool contacts rotating and moving parts serious injury may occur as a result Lock out and Tag out Be sure to lock out and tag out before starting inspection and maintenance Lockout and tagout are effective methods of cutting off machines and equipment from energy sources To lock out and tag out pull out the key from the ...

Page 17: ... engine stops Wait until the coolant temperature lowers sufficiently to prevent burns Do not dismount heat protection covers The high temperature exhaust components are installed with heat protection covers Do not dis mount these heat protection covers If they must be removed during inspection and maintenance be sure to reinstall them after completing the inspec tion and maintenance Warning Be Car...

Page 18: ...ine Oil and LLC Use only specified fuel engine oil and coolant LLC Use fuel oil and LLC specified in this manual and handle them carefully Use of any other fuel oil or LLC and improper han dling may cause various engine problems and mal functions Obtain the MSDSs issued by the fuel oil and LLC suppliers and follow the directions on the MSDSs for proper handling Handle LLC carefully Wear safety mas...

Page 19: ...water Then use soap to clean thoroughly If electrolyte enters eyes flush immediately with lots of fresh water and see a physician as soon as possible Should you accidentally swallow electrolyte gar gle with plenty of water then drink lots of water Consult a physician immediately Caution When Abnor mality Occurs If engine overheats conduct cool ing operation before stopping engine If the engine ove...

Page 20: ...en the service life of the engine Warm up engine before use If the auxiliary devices for the starter water heater engine oil priming pump etc are not installed let the engine idle for 5 to 10 minutes before using the engine for work 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 an extende...

Page 21: ...er work clothes and protective gear Wear the work clothes specified by your workplace Wear a hardhat face shield safety shoes dust pro tective mask gloves and other protective gear as needed When handling compressed air wear safety gog gles hardhat gloves and other necessary protec tive gear Compressed air may cause personal injury when not wearing the proper protective gear Use appropriate tools ...

Page 22: ...ace the label To clean warning labels use a cloth water and soap Do not use solvents gasoline or other chemi cals to clean warning labels Cleaning with chemi cals may cause the labels to peel off If warning labels are damaged or missing replace with new labels If a part of the engine with warning label is replaced with new part also attach new warning label to the new part To obtain replacement wa...

Page 23: ...ment fig 1 2 Warning for moving parts fig 1 3 Warning for oil mist fig 1 4 Caution for footing fig 1 5 Caution for electric shock fig 1 6 Warning for rotating parts fig 1 7 Caution for burns fig 1 8 Warning for rotating parts fig 1 9 Caution for referring to manual fig 1 10 Caution for burns ...

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Page 25: ...eaner Air cooler Pipe cover Oil filler Bypass oil filter Oil level gage Breather Fuel filter center bolt type Governor Governor oil filter Fuel feed pump Fuel priming pump Fuel filter wire element type Crankcase side cover Timing gear case Fuel injection pump Distributor Air starter main pipe Fuel injection pipe Cylinder head Oil pump Front gear case Low temoerature water pump Front Rear Nameplate...

Page 26: ...r center bolt type Fuel priming pump Fuel feed pump Governor oil filter Governor Coolant drain cock Cylinder head Oil level gage Front gear case Fuel injection pipe Fuel injection pump Low temperature water pump Oil filler Breather Damper Damper cover Air starter main pipe Silencer Turbocharger Pre cleaner Front Rear Nameplate Pipe cover fig 2 4 S16U engine right view ...

Page 27: ...ion Start Lever The start lever is provided on the air starter pipe When the lever is moved toward the OPEN posi tion air flows and cranks the engine Once the engine starts return the lever to the CLOSE posi tion immediately Manual Stop Lever Use the manual stop lever to shut down the engine in the event of an emergency If the stop button is not working use the manual stop lever The lever is insta...

Page 28: ...his indicates the engine oil pressure Oil Temperature Gage This indicates the engine oil temperature Jacket Coolant Temperature Gage This indicates coolant temperature inside of the crankcase Oil Cooler Coolant Temperature Gage This indicates coolant temperature in the oil cooler Air Cooler Coolant Temperature Gage This indicates coolant temperature in the air cooler Jacket Coolant Pressure Gage T...

Page 29: ... to an engine malfunction or other reason Oil Filter Clog Alarm The oil filter clog detector generates a warning when the oil filter becomes clogged and causes an abnormally large pressure difference between before and after the oil filter When it generates an alarm replace it with a new filter immediately and change engine oil as well Overspeed Alarm The overspeed alarm device generates a warning...

Page 30: ...etaining bolt 2 Move the turning gear fully to engage the ring gear and tighten the bolt 3 Turn the shaft using the socket wrench and the rachet handle 4 After turning move the turning gear disengage the turning gear with the ring gear and tighten the retain ing bolt Make sure the lock pin is securely inserted fig 2 9 Preparation for turning fig 2 10 Turning Shaft Socket Rachet handle fig 2 11 Loc...

Page 31: ...flames near the engine Wipe any spilled fuel completely Spilled fuel can ignite and cause fire Do not remove the strainer when filling the fuel tank Use fuel specified in Fuel 4 2 Pouring fuel 1 Make sure the insides of the fuel tank and fuel pipes are clean 2 Pour fuel into the fuel tank 3 Remove the fuel feed pipe and drain plug from the fuel inlet of the engine and check the discharged fuel for...

Page 32: ...ent type by rotating about 1 5 turns 2 Loosen the priming pump cap by turning counter clockwise and move it back and forth 3 When there are no air bubbles in the fuel flowing from the air vent plug tighten the air vent plug to the specified torque Bleeding Air from Fuel Filters Center Bolt Type Replace to a new part if there is a damage on the air vent plug thread area of bracket or sealing washer...

Page 33: ... cap back and forth repeatedly When there are no air bubbles in the fuel flowing from the air vent cock press the priming pump cap and turn the cap clockwise to lock 3 Tighten the air vent cock on the fuel feed pipe Tighten the priming cap before closing the air vent plug Closing all air vent plugs before the priming pump cap disalllows the priming pump cap from returning to the original position ...

Page 34: ... pan and other parts for oil leaks Repair any oil leakage found 5 Operate the engine oil priming pump to circulate oil in the engine 6 Remove the rocker cover and make sure that oil is supplied to the valve mechanisms 7 Stop the priming pump After about 30 minutes add engine oil until the oil level reaches the Maximum line on the oil level gage 8 Reinstall the cap on the oil filler fig 3 8 Oil fil...

Page 35: ...ds 6 Wait for about 1 minute then repeat the above cranking operation twice to remove air from the water pump 7 Check the level gage on the coolant tank to make sure there is sufficient coolant surface level at about the center of the level gage If the coolant level is low add coolant 8 Start the engine and operate it under light load until the thermostat opens the valve to allow soft water and LL...

Page 36: ...0 to 15 mm 0 394 to 0 591 in above the top edges of the plate If the fluid level is lower remove the caps and add distilled water to the proper level Note When pouring fresh electrolyte pour the fluid carefully Checking specific gravity of electrolyte Check the specific gravity of the electrolyte If the spe cific gravity measured at 20 C 68 F is lower than 1 22 then charge the battery Checking loo...

Page 37: ... 10 minutes 4 Stop the engine Leave the engine for about 30 minutes While waiting check the engine exterior for leakage of fuel engine oil coolant and exhaust gas After 30 minutes check the engine oil level and coolant level If they are low add engine oil or coolant to the specified level 5 Operate the engine under no load and at low idling speed for 5 minutes 6 Operate the engine under no load an...

Page 38: ...Inspect the engine exterior as described below 1 Make sure there is no combustible material near the engine or battery Also check to make sure the engine and battery are clean If combustible materials or waste are found near the engine or battery remove them 2 Check the entire engine for leakage of fuel engine oil coolant If leaks are found repair leakage or contact a Mitsubishi dealer 3 Visually ...

Page 39: ...n water from the fuel tank by following proce dures below 1 Place a fuel receiving tray capacity 2 L 0 53 U S gal or more under the drain cock on the fuel tank 2 Open the drain cock on the fuel tank and drain at least 1 to 2 L 0 26 to 0 53 U S gal of fuel 3 Make sure water and dust particles were drained together with fuel then close the drain cock Checking Engine Oil Level 1 Pull out the oil leve...

Page 40: ...e same LLC concen tration Never add plain water Note a Determine the amounts of LLC and water to be poured by using the LLC concentra tion chart b Regarding coolant refer to Coolant 4 6 Inspection of Air Cleaner Indicator 1 Check the air cleaner indicator for the element clog 2 If the element clogs the red signal mark is visi ble 3 Immediately clean or replace the air cleaner ele ment when the sig...

Page 41: ...mulated water from the tank Note The amount of drained water can vary depending on the relative humidity and air consumption 3 Close the drain valve handle after draining water 4 Open the starting air handles slowly Inspection of Air Tank Air Pressure Check the air pressure gage to see if the air pres sure in the air tank conforms to the standard Air tank internal pressure standard 2 94 MPa 30 kgf...

Page 42: ...iate opera tion However be sure to check all items on the inspection and maintenance chart Do not operate the engine under excessive load indicated by discharge of black smoke during a warm up operation Operating the engine under excessive load not only consumes fuel unnecessar ily but also causes incomplete combustion which can result in carbon deposits and shorten the engine service life Conduct...

Page 43: ... the amount or color Check to make sure the instruments and gages indicate normal values Note a When the oil pressure drops below 0 29 MPa 3 kgf cm2 42 7 psi in normal oper ation or below 0 10 MPa 1 kgf cm2 14 2 psi at minimum speed with no load stop the engine immediately Before restarting the engine check and correct the cause of the problem b When the high temperature alarm switch is activated ...

Page 44: ...oblem before restarting the engine Continuing engine operation without correcting the problem can result in a serious accident For stopping the engine follow the instructions since stopping procedure varies depending upon the models and its installed equipment Emergency Stop When stopping the engine by pulling the speed con trol lever continue pulling the lever until the engine stops completely If...

Page 45: ...enty of water and seek medical attention LLC is a potent alkaline solution Do not drink or allow it to enter your eyes Always wear protective gear Wear protective gear such as a hardhat face shield work clothes safety shoes dust protective mask etc Be sure to wear protective goggles and other pro tective devices when handling compressed air Compressed air can cause personal injury if han dled care...

Page 46: ...ch work day This prevents water from mixing with fuel in the tank and gives time for dust and water to separate and settle at the bottom of the tank Before removing the caps from the drum and tank clean the areas around the caps thoroughly Also clean your hands and the hose used for refueling When a hand operated pump is used be careful not to pump water or sediment accumulated at the bottom of th...

Page 47: ... in2 or lower 40 C 104 F 16 0 mm 2 s 0 0248 in 2 or lower 30 C 86 F Sulfur content 0 2 weight or lower 1 0 weight or lower JISK25410 05 weight same as diesel fuel is rec ommended Water and sediment 0 1 volume or lower JIS K2275 Ash 0 03 weight or lower JIS K2272 Copper plate corrosion 100 C 212 F 3 hrs No 3 or lower No 3 or lower ASTM No 3 JIS K2513 Discoloration No 3 Specific gravity 15 C 59 F 0 ...

Page 48: ...d moving parts thus shortening the engine life It can also result in the sticking of piston rings and seizing of pistons in the cylinders thus causing major damage Selection of Oil Viscosity Use the following chart to select the appropriate oil viscosity according to the ambient temperature Excessively high oil viscosity causes power loss and an abnormal rise of oil temperature while excessively l...

Page 49: ...of engine oil may cause a chemical reaction by the additives in the engine oil that could degrade the engine oil quality If oil of more than the legally specified amount must be handled be sure to have the work performed by a ser vice station in compliance with the legal regulations Use an oil pump to remove oil from the engine or oil can Do not use a hose to siphon with the mouth Be sure to close...

Page 50: ...f LLC should enter eyes flush immediately with plenty of water and seek medical attention Be sure to use long life coolant LLC as coolant because it prevents not only freezing of coolant but also rusting of the cooling system Use an all season non amine type LLC Table 4 3 Water quality standards Item Chemical symbol Unit Recommended Limit Main adverse effect Corrosion and rust Scale formation pH 2...

Page 51: ...urpose engine In an emer gency engine replace coolant every 2 years LLC concentration When determining the LLC concentration provide a margin of 5 C 41 F below the expected lowest temperature in your region Maintain the LLC con centration between 30 and 60 throughout the year LLC of less than 30 concentration does not pro vide sufficient corrosion protection If the LLC con centration is as low as ...

Page 52: ...in more corro sion than when plain soft water is used This prob lem is often caused by the use of inappropriate LLC Examples of Abnormalities Caused by LLC Pitting on iron parts Amines are generally effective in suppressing the rusting of ferrous metals but they are said to cause problems for copper parts Dissolved copper copper corrosion in the cooling system deposits on iron parts and copper dep...

Page 53: ... well as quality of fuel and oil in use When replacing filters use genuine Mitsubishi parts Do not wash and reuse cartridge type filters Always use new filters When filters are changed inspect the removed fil ters for metal particles If metal particles are found consult a Mitsubishi dealer Electrical Parts Do not splash water on electrical parts Water can cause electrical leakage and short circuit...

Page 54: ...ezing of cooling water and rusting of the engine cooling system Note Regarding coolant refer to Coolant 4 6 Battery Never use flames near the battery and be care ful to handle battery since flames can cause an explosion If electrolyte is spilled on skin or clothes wash immediately with lots of water If electrolyte gets into your eyes flush immediately with lots of fresh water and consult a physici...

Page 55: ...erform all daily inspection and maintenance items in an accordance with the following 3 categories Periodic maintenance chart for regular use engine When the engine is used as a regular use engine perform the periodic inspection and maintenance in accordance with the Periodic Maintenance Chart for Engine in Regular Use Periodic maintenance chart for emer gency engine When the engine is used as an ...

Page 56: ...r supply An engine operated under a fluctuating load throughout a day for supplying rated electric power in lieu of commercial power General definition of emergency engine An engine used for emergency power generation such as main power supply and commercial power supply General definition of general purpose engine An engine used for a purpose other than power generation for example to drive a pum...

Page 57: ...ge function 3 13 Air cooler Inspect water leakage from air cooler chamber and drain water 6 16 Every 500 service hours Fuel filters Drain water 6 1 Fuel control linkage Inspect ball joints bolts and nuts for looseness and smooth movement 6 6 Engine oil Inspect engine oil for mixing of fuel and water 6 11 Analyze engine oil properties according to engine oil analysis service 6 12 Change 6 7 Oil fil...

Page 58: ...ervices hours or 2 years whichever comes first Fuel system accumulator Refill with nitrogen gas Every 6000 service hours Camshafts and tappets Inspect Crankcase Inspect inside remove the side cover for inspec tion Water pump Change oil seals unit seals and other expend able parts Damper Check temperature with thermo label and check for silicon oil leakage Turbocharger Inspection of shaft and wheel...

Page 59: ...ushings valve springs tappet rollers tappet roller bushing tappet shafts tappet guides tappet guide set screws Inspect Stem seal Change Safety valve Inspect and change expendable parts Cylinder liners Inspect and clean Pistons Inspect including overhaul and clean Piston rings Change Connecting rods Inspect bolts inspect Magnaflux serrations change big end bearing shells and inspect small end bushi...

Page 60: ...ng system Water pump Change bearings Coolant pipes Change O rings Inlet and exhaust systems Turbocharger Remove carbon deposits and change seal rings bearings and expendable parts Air cooler Clean element Air cooler cover Change gaskets Air inlet pipes Change O rings Exhaust pipes Change gaskets bolts and nuts Exhaust duct Change V clamps Air starter system Starting valve Inspect lap and change O ...

Page 61: ...ufacturer Timing gear and front gear All shafts Inspect Rear idler gear Inspect and change assemblies including bush ings Change front idler bearing camshaft roller bearing front seal rear seal front gear case gasket and rear gear case gasket Fuel system Fuel injection nozzles Change nozzle holder assemblies Fuel injection pump Change plunger assembly and delivery valve Fuel feed pump trochoid typ...

Page 62: ...ge 3 10 Air cooler Inspect water leakage from air cooler cham ber and drain water 6 16 Air starter tank Inspect air pressure 3 11 Every month Conducting maintenance operation Operate the engine under load at 50 or more for 15 to 30 minutes Inspect starting property exhaust color abnormal vibrations abnormal sounds abnormal odors Inspect displayed value of each gage such as oil pressure gage water ...

Page 63: ... clearance with the flywheel attach ment of foreign items on the tip mounting nut tightness an open circuit and connector disconnection Fuel tank Drain water 6 2 Fuel injection nozzles Change nozzle tips and adjust pressure Fuel injection timing Inspect and adjust Coolant Inspect LLC concentration 6 13 Exhaust pipes and exhaust muffler Inspect and drain water 6 16 Pre cleaner Clean 6 16 Air cleane...

Page 64: ...Cylinder head gas ket Change cylinder head gaskets Valve guides valve rotator valve cotter pushrods rocker arm bush ings valve springs tappet rollers tappet brush tappet shafts tappet guides tappet guide set screws Inspect Stem seal Change Safety valve Inspect and change expendable parts Cylinder liners Inspect and clean Crankcase Inspect inside remove the side cover for inspection Pistons Inspect...

Page 65: ...ain clean and change expendable parts Inlet and exhaust valves and valve seats Inspect regrind and lap Valve guides valve rotators valve cot ters pushrods rocker arm bush ings valve springs tappet rollers tap pet roller bushings tappet shafts tap pet guides and tap pet guide set screws Inspect Stem seal Change Copper tubes and copper tube O rings Change Safety valves Inspect and change expendable ...

Page 66: ...s and gaskets Cooling System Water pump Change oil seals unit seals expendable parts and bearings Coolant pipes Change O rings Inlet and exhaust systems Air cooler cover Change gaskets Air inlet pipes Change O rings Exhaust pipes Change gaskets bolts and nuts Exhaust duct Change seal rings gaskets and V clamps Air starter system Air pipes Change gaskets Air tank Inspect safety valve operation Gove...

Page 67: ... 1 month whichever comes first Fuel filters Drain water 6 1 Fuel control linkage Inspect ball joints bolts and nuts for looseness and smooth movement 6 6 Engine oil Inspect engine oil for mixing of fuel and water 6 11 Exhaust pipes and exhaust muffler Inspect and drain water 6 16 Air starter compressor Drain water 6 19 After 500 services hours or 6 months whichever comes first Zinc rod Inspect and...

Page 68: ...hafts and tappets Inspect Crankcase Inspect inside remove the side cover for inspec tion Water pump Change oil seals unit seals and other expend able parts Damper Check temperature with thermo label and check for silicon oil leakage Turbocharger Inspection of shaft and wheel for smooth rotation and thrust for looseness Inspection of pipe clamps of fuel lines oil lines instrument pipes and starting...

Page 69: ...ker arm bushings valve springs tappet rollers tappet roller bushings tappet shafts tappet guides tappet guide set screws Inspect Stem seal Change Safety valve Inspect and change expendable parts Cylinder liners Inspect and clean Pistons Inspect including overhaul and clean Piston rings Change Connecting rods Inspect bolts inspect Magnaflux serrations change big end bearing shells and inspect small...

Page 70: ...ent Regulator valve Disassemble and maintain Oil pipes Change O rings and gaskets Cooling system Oil pipes Change bearings Coolant pipes Change O rings Inlet and exhaust systems Turbocharger Remove carbon deposits and change seal rings expendable parts and bearings Air cooler Clean element Air cooler cover Change gasket Air inlet pipes Change O rings Exhaust pipes Change gaskets bolts and nuts Exh...

Page 71: ...anufacturer Timing gear and front gear All shafts Inspect Rear idler gear Inspect and change rear idler gear assemblies including bushings Change front idler bearing camshaft roller bearing front seal rear seal front gear case gasket and rear gear case gasket Fuel system Fuel injection nozzles Change nozzle holder assemblies Fuel injection pump Change plunger assembly and delivery valve Fuel feed ...

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Page 73: ... Refer to Bleeding Fuel System 3 2 for the pro cedure for releasing air from the fuel system Draining Water from Fuel Filters Center Bolt Type Before handling fuel make sure there is no flame or heat source in the area Wipe spilled fuel thoroughly Spilled fuel can cause a fire Check for damage of the center bolt drain plug threaded section and the sealing washer If any damage are found replace wit...

Page 74: ...andling fuel make sure there is no flame or heat source in the area Wipe spilled fuel thoroughly Spilled fuel can cause a fire Check for damage of the filter case the drain plug threaded section and the sealing washer if any damage are found replace with the new one 1 Close the fuel feed valve to cut off the fuel supply to the engine 2 Place a container under the fuel filter to receive drained fue...

Page 75: ...ealing washers 6 Remove the center bolt and disassemble the fuel filter unit 7 Clean the inside surface of the case and O ring groove 8 Wipe off fuel from element mounting surface of the bracket and external O ring seal surface with a cloth 9 Use the O rings provided in a new filter element kit to replace old parts 10 Reassemble the fuel filter unit 11 Tighten the center bolt to 63 7 4 9 N m 6 5 0...

Page 76: ...a fuel receiving tray under the fuel filters 4 Set the filter handle to the Left Close Right Open 5 Using the filter wrench remove 2 fuel filters from left side 6 Apply clean fuel to the gasket on the new fuel fil ters 7 Install the fuel filters When the gasket contacts the mounting surface on filter bracket further rotate 3 4 to a full turn 8 Set the fuel filter handle to the Left Close Right Ope...

Page 77: ...EN 8 Loosen the air vent plug of the left side fuel filter 9 When the fuel flows from the air vent plug no longer contains air bubbles tighten the air vent plug 10 Return the handle to the Left OPEN Right CLOSE 11 Using the filter wrench remove 2 right fuel filters 12 Apply clean fuel to the gasket on the new fuel fil ters 13 Install the fuel filters When the gasket contacts the mounting surface o...

Page 78: ...looseness If the amount of looseness is more than 0 1 mm 0 004 in consult a Mitsubishi dealer to replace the ball joints Never break a seal of fuel control link to replace the ball joints If the seal on the ball joint is broken the warranty may be invalidated fig 6 10 Inspection of the ball joints for looseness Ball joint Rod Lever 0 1 mm 0 004 in 0 1 mm 0 004 in ...

Page 79: ... the gasket if any damage are found replace it with the new one 1 Clean the area around the oil filters 2 Remove the center bolts and the gaskets and remove the cases and elements 3 Remove the packing from the bracket Note Disassemble the removed elemenets to see if they have collected metal particles If there are metal particles on the elements consult your Mitsubishi dealer 4 By using a clean cl...

Page 80: ...oil can leak from switcho vwe lever 1 Clean the surrounding area of the oil filters 2 Place a container under the oil filters to receive drained oil 3 Remove the cover from the oil filter switchover cock 4 Turn the switchover cock to have pin position Left Close Right Open 5 Refer to Changing Oil Filters S12U 6 7 for the procedure for changing 3 new sets of left oil filter elements 6 Turn the swit...

Page 81: ...o replace the oil filters while the engine is in operation be sure to run the engine under no load low idling and rated speed If the oil filter is replaced during the engine is in high speed operation oil can leak from switcho vwe lever 1 Clean the surrounding area of the oil filters 2 Turn the oil filter tightening handle for an angle of 90 to 180 degrees in the counterclockwise direc tion Remove...

Page 82: ...he oil filter mounting surface on the filter bracket with a cloth 5 Check the new bypass oil filter for proper seat ing of the packing 6 Apply clean engine oil to the packing 7 Install the bypass oil filter to the filter bracket When the packing contacts the mounting sur face on the filter bracket further rotate 3 4 to a full turn Do not use the filter wrench for the installation of fil ters to pr...

Page 83: ...lter 1 Start the engine and let it idle for several minutes 2 Check the oil filter for engine oil leakage If any leakage are found remove and reassemble making sure that there are no scratches on the packing then reinstall or reassemble the filter Inspection of Engine Oil for Mixing of Fuel and Water If the engine continues to operate with engine oil mixed with fuel or water the engine oil viscosi...

Page 84: ...alysis service is designed to diagnose the internal condition of an engine which previously required engine disassembly It is highly recommended to take advantage of our engine oil analysis service so you can understand your engine condition before the engine manifests abnormalities or malfunctions Engine Oil Sampling Tool Sets and Ordering Procedure The oil sampling pump is reusable but a new oil...

Page 85: ...refer to Coolant 4 6 Inspection and Replacement of Zinc Rods Zinc rods zinc electrodes are installed at various sec tions of the sea water passage to prevent corrosion caused by sea water 1 Remove each zinc rod and remove deposits scale from the surface 2 If the zinc rod has worn to half the original size replace it with a new zinc rod If the zinc rod is larger than half the original size reinstal...

Page 86: ... 2 Prepare a container to receive drained coolant 3 Open the drain cocks on the engine low temper ature water pump high temperature water pump coolant pipe and expansion tank to drain coolant Cleaning the Cooling System 1 Close the drain cocks or plug 2 Pour a cleaning solution non corrosive solution to rubber and metals in the cooling system and operate the engine with low idling for about 10 min...

Page 87: ... the engine for about 10 seconds 6 Wait for about 1 minute then repeat the above cranking operation twice to remove air from the water pump 7 Check the level gage on the coolant tank to make sure there is sufficient coolant surface level at about the center of the level gage If the coolant level is low add coolant 8 Start the engine and operate it under light load until the thermostat opens the va...

Page 88: ...f this happens contact a Mitsubishi dealer Cleaning Inspection and Changing Pre Cleaner Do not service the air cleaner while the engine is running Maintenance of the air cleaner while the engine is in operation can cause dust to enter the engine and result in rapid wear of parts leading to a shorter service life Remove dust from the inlet side of the pre cleaner installed to the silencer of the tu...

Page 89: ... on the element blow dry compressed air onto the outside surface from a distance Blow compressed air on the inside surface toward outside along the net pattern Then blow compressed air on the outside and inside surface again 5 After cleaning place a light bulb in the element to check for damage pinholes and worn sec tions 6 If any breakage are found replace the air cleaner element with the new one...

Page 90: ... air to dry 5 Reinatall the air strainer as it is 6 Open the air starter handle slowly Draining Water from Air Starter Compressor 1 Check the starter valve handle of the air strainer tank 2 Remove the drain plug and drain water from the air strainer compressor 3 Install the drain plug after draining water 4 Open the starter valve handle of the air starter tank slowly Note The air compressor model ...

Page 91: ...long life coolant Add long life coolant to increase the concentration between 30 and 60 c Post a sign at an easily noticeable location to warn that the rust preventive oil in the engine must be replaced with engine oil and the fuel tank must be filled with fuel before operating the engine d New engine oil may be used in place of rust preventive oil NP 10 2 Maintenance during Storage Charge the bat...

Page 92: ...orage Operating Engine for Maintenance Pur poses Operate the engine for maintenance purposes at least once a month by following the directions below 1 With no fuel supplied to the engine press the engine stop button to shut off fuel injection operate the air starters three times for 10 sec onds at intervals of about 1 minute and check the engine oil pressure gage to make sure the oil pressure incr...

Page 93: ... engine s center of gravity Keep the angle formed by slings attached to hangers within 60 If the angle exceeds this limit excessive load is applied on the hang ers and may damage the hangers Attach wire ropes to the hanger after remov ing the pipe cover and the insulator near the hanger for lifting To prevent wire ropes from contacting the engine place a cloth or other soft padding to prevent dama...

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Page 95: ...lose attention to the disassembly sequence so that you can reassemble the component efficiently Notes Regarding Contamination Dust and foreign particles are the most common cause of rapid wear of parts When disassembling a component take measures to prevent dust and foreign particles from entering the component being disassembled Notes Regarding Parts Handling Handle parts carefully When replacing...

Page 96: ... Affecting locations Complete compression of air Affected by cylinder liners pistons piston rings exhaust valves inlet valves and their related parts Appropriate quantity of fuel injected in proper spray pattern and at correct timing Affected by fuel injection pump fuel injection noz zles governor and their related parts Appropriate air volume Affected by air cleaner turbocharger air cooler and th...

Page 97: ...ct two way delivery valve and disas semble and clean e Broken plunger spring Disassemble and repair or replace if defective B Engine emits small amount of exhaust smoke Check the cause of insuffi cient injected fuel Check all items in A 1 and 2 b and also check items at right a Fuel lever does not open fully Check relation of movement with fuel lever and disassemble and repair if defec tive b Seiz...

Page 98: ...f necessary 3 Insufficient compression pressure cylinder internal temperature does not reach igni tion temperature a Inadequate rotation speed If starting air pressure is low increase pressure If engine oil viscosity is high heat oil or change oil to one with appropriate viscos ity Repair if there are other abnormalities b Inlet exhaust valve not contacting valve seat properly Disassemble and repa...

Page 99: ...eck air tank pressure and increase pressure if low B Malfunction of mechanical engine parts a Seizing of moving parts in engine Disassemble and inspect pistons con necting rods crankshaft camshaft bush ings of timing gear and others inlet and exhaust valves etc and repair b Deviation of timing due to incorrect engine assembly Pistons are hitting valves Disassemble and repair c Viscosity of engine ...

Page 100: ...alve not contacting valve seat properly Disassemble and correct by lapping valve in valve seat or replace if necessary c Broken inlet exhaust valve spring Disassemble and repair or replace if nec essary d Leaking of compression pressure due to worn cylinders or sticking of piston rings Disassemble and repair or replace if nec essary 3 Poor fuel condition water in fuel Open drain cock and check fue...

Page 101: ...e engine does not knock severely and emits bluish white exhaust smoke Engine oil rising above pistons a Oil level too high in crankcase Discharge oil to appropriate level b Worn piston rings or sticking of piston rings resulting in inade quate scraping of oil Check crankcase breather pipe for gas leak and replace if there are defective parts c Excessive clearance between cylinder and piston Check ...

Page 102: ...ne emits excessive black exhaust smoke 1 Minor knocking a Injection timing too retarded Refer to C 1 in Table 9 2 2 Other a Excessive amount of injected fuel Check if fuel injection pump rack set screw or bolt is loose and repair b Fuel injection not uniform Inspect and repair or replace as described in C 2 in Table 9 4 c Improper spray of fuel by fuel injection nozzles Inspect and repair or repla...

Page 103: ...sassemble clean replace f Defective oil pressure gage Disconnect oil pressure gage pipe If oil pours out replace oil pressure gage B Oil pressure drops gradually dur ing operation a Clogged oil filter element Disassemble clean replace b Engine oil viscosity too low Oil temperature rises and causes oil pressure to drop Change oil to one with higher viscosity c Abnormally high oil tempera ture Engin...

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Page 105: ... 45195 Fuel Diesel fuel refer to 4 3 Fuel Use Limit Property Guideline Fuel injection pump Bosh unit pump Governor WOODWARD UG8L UG8D hydaulic governor WOODWARD EG10P electrohydraulic governor or TOHO SEISAKUSHO SG4080C electric governor Fuel filter Wire element type primary and paper element type secondary Fuel injection nozzle Hole type Lubricating system Forced circulation type pressure feed by...

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Mitsubishi S12U, Operation & Maintenance Manual

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