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7 SCHEDULED MAINTENANCE

Mitsubishi Diesel Engine S16R & S16R2 OPERATION & MAINTENANCE MANUAL

129

Pub. No. K29001-00320 Revision: 1

*1: If the part is not supplied from Shanghai MHI Engine co., Ltd. (SME), service the part following the

supplier's operation manual.

*2: Service intervals vary depending on the use conditions. For details, see the rating definition

.

Table 7-10 Scheduled Maintenance for Emergency Use Engine (5/5)

Inspection and
Maintenance Period Service Items

Reference
Page

Service period

Every 8 years*2

• Engine - Major Overhaul

(Disassemble the engine, and then clean, check, and replace major
parts.)

• Damper - Replace
• Oil Pump - Repair or Replace
• Fuel Injection Nozzle Tip, Spacer, and Nozzle Spring - Replace

(Check the spray condition and adjust the fuel injection pressure after
the replacement.)

• Rubber Parts and O-rings - Replace
• Water Pump Unit Seal and Oil Seal - Replace
• Turbocharger - Disassemble and Inspect
• Air Cooler - Disassemble and Clean
• Vibration-isolating Rubber - Repair or Replace *1
• Couplings - Repair or Replace *1
• Governor Motor - Repair or Replace *1
• Indoor Ventilation Fan - Repair or Replace *1
• Stop Solenoid - Check or Replace
• Ball Tap of Water Tank - Repair or Replace *1
• Other Consumable Parts - Replace

(Contact your
SME dealer)

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Summary of Contents for S16R

Page 1: ...duction Read this Operation Maintenance Manual and conduct the engine operation inspection and maintenance only after sufficiently understanding the description Please keep this Operation Maintenance Manual with the generator related manuals at a suitable place for quick reference when needed CAUTION Issued July 2018 Pub No K29001 00320 Revision 1 ...

Page 2: ...Engine S16R S16R2 OPERATION MAINTENANCE MANUAL 2 Pub No K29001 00320 Revision 1 Company names or product names described this Operation Maintenance Manual are generally trademarks or registered trademarks of each company ...

Page 3: ...Manual describes information and basic points required to use the Mitsubishi Diesel Engine hereinafter called the engine correctly and effectively Please read this manual before using the engine In addition operation inspection and maintenance of the engine must be limited to the persons who understand the contents of this manual sufficiently ...

Page 4: ...nt and other local municipalities When disposing this engine follow the method defined by the national government or other local municipalities When discarding fuel engine oil or coolant follow the method defined by the national government or other local municipalities The devices covered by the recycle law and those for which recycling requirements are stipulated shall be disposed in accordance w...

Page 5: ...he devices and facilities outside the scope of our supply refer to the corresponding manual of the generator and the supplier s operation manual and obey the descriptions Electrical instruments must be inspected or maintained by a person who has received education and training for handling and avoiding risks about the electrical instruments on the machine in addition to general knowledge needed fo...

Page 6: ...ine Always consider environmental protection Shanghai MHI Engine co Ltd SME shall accept no responsibility for loss or injury resulting from not observing instructions in this manual or not paying attention to commonly required precautions when operating inspecting or maintaining this engine About This Manual This manual is intended for native speakers of the language in which the manual is writte...

Page 7: ...the warranty 4 We may deny the warranty coverage regardless of the warranty period if fault or damage has been caused to the engine by any reason mentioned below Fault or damage caused by operation or maintenance deviated from the instructions or cautions described in this manual Fault or damage caused by being repaired or modified by other than us SME dealer or by illegal act Fault or damage caus...

Page 8: ...ishi Diesel Engine S16R S16R2 OPERATION MAINTENANCE MANUAL 8 Pub No K29001 00320 Revision 1 CONTACT LIST China China Shanghai MHI Engine co Ltd SME 2630 Jun Gong Road Shanghai China TEL 86 21 6065 2943 FAX 86 21 6065 2323 ...

Page 9: ...K Page 10 Location of Nameplate The name plate is located on the lateral side of the engine and indicates the following information Serial number Manufactured date Model name Rated output Rated speed Engine top view Fig 1 Location of Nameplate 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 N PLQ LVSODFHPHQW 0RGHO 2UGHU 1R 6HULDO 1R ᵪ ਧ ර ਧ ᧂ䟿䇒 ਧ 仍 ᇊ ӗᰕᵏ 0 DWH LFHQVHG E 0 768 6 9 1 8675 6 7 5DWHG RXWSXW L...

Page 10: ...L 4876 53 cu in Combustion system Direct injection system Compression ratio 13 5 1 14 0 1 14 5 1 15 0 1 14 0 1 Firing order 1 9 6 14 2 10 4 12 8 16 3 11 7 15 5 13 Direction of rotation Counterclockwise as viewed from flywheel side Damper Double damper damper with spacer Triple damper with spacer Fuel injection pump PS8 type Fuel injection nozzle Hall type Fuel injection starting pressure 34 3 MPa ...

Page 11: ... name Serial number Manufacturing date Dimensions L x W x H mm x mm x mm Dry weight kg Purpose and intended use Continuous use engine Emergency use engine Rated output kW Rated speed min 1 Generator frequency Hz Installation situation Stationary Cubicle bonnet type Starting system Self Starter Motor Starting Air Direct Admission Starting Air Motor Starting Fuel Diesel fuel Priming pump type Type A...

Page 12: ...g system Expansion tank Metal Fan Resin Fan Radiator Reserve tank Heat exchanger Water heater Air Intake System Air cleaner Silencer pre cleaner Air heater Exhaust system Flue piping external smoke equipment Muffler silencer Air starter system Air tank Air compressor Air filter Air motor Electrical system Control panel operation panel instrument panel Battery Battery switch Protection devices Oil ...

Page 13: ...6R2 OPERATION MAINTENANCE MANUAL 13 Pub No K29001 00320 Revision 1 Protection Devices Added During Manufacturing the Generator Please compile the information about the protection devices added during manufacturing the generator and attach it on this page ...

Page 14: ...intenance in addition to operation works The operator is allowed to bring this engine to an emergency stop when he she has found critical situation Before working the operator must read the Safety Manual and this manual thoroughly to understand the special features of this engine and all the details of works sufficiently Customers Means the user company supervisor and operator mentioned above Serv...

Page 15: ... Layout Plan Installation Construction Selection of Equipment and Capacity Operation Daily Check Scheduled Maintenance Troubleshooting Parts Replacemant Inspection Repair Overhaul Running in Adjustment Start up Warm up Operation Operation Cooling Operation Stopping Maintenance Operation Test Run of the generator equipment Commissioning Test Related Service Document Performance Check Transportation...

Page 16: ...RE OF THIS MANUAL This manual is constructed as follows 1 SAFETY 26 2 ENGINE OUTLINE 73 3 OPERATION 88 4 FUEL 104 5 ENGINE OIL 109 6 COOLANT 111 7 SCHEDULED MAINTENANCE 118 8 INSPECTION AND MAINTENANCE 131 9 LONG TERM STORAGE 180 10 TRANSPORTATION 184 11 TROUBLESHOOTING 187 12 AFTER SALES SERVICE 201 13 DISPOSAL 202 14 APPENDIX 205 ...

Page 17: ...the models conforming to the exhaust gas standards see corresponding items Table 1 List of Models Model name intended use Supercharging method Cooling method S16R PTA C Generaor Turbocharging Aftercooler PTA2 C Generaor Turbocharging Aftercooler PTAA2 C Generaor Turbocharging Air to air intercooler S16R2 Long stroke type PTAW C Generaor Turbocharging Dualline cooling system Jacket cooling air cool...

Page 18: ...e 1 N 0 10197kgf Horsepower 1 kW 1 341 HP 1 3596 PS Pressure meter of mercury 1 kPa 0 75 cmHg Pressure meter of water 1 kPa 10 197 cmH2O cmAq Rotating speed 1 min 1 1 rpm Kinetic viscosity 1 mm2 s 1 cSt ABBREVIATIONS AND STANDARDS API American Petroleum Institute ASTM American Society for Testing and Materials ISO International Organization for Standardization JIS Japanese Industrial Standards LLC...

Page 19: ...UAL 16 LIST OF MODELS 17 UNIT OF MEASUREMENT 18 ABBREVIATIONS AND STANDARDS 18 1 SAFETY General Information 26 Warnings 26 Types and Meanings of Warning Terms 26 Warning Labels 27 Matters to be Obeyed and Matters Prohibited 29 Safety Cautions 29 Preparation for Emergencies 29 Precautions for Covers 30 Precautions for Fire Sources 30 Precautions Regarding the Environment 30 Precautions for Personal...

Page 20: ...lth and Safety Management 68 Operation Maintenance Manual Understand and Obey 68 Education and Training for Safety 68 Dangerous and Hazardous Chemicals 69 Noise 70 Vibration 71 To Maintain Cleanliness and Tidiness 71 Risk of Fire 72 Communication with SME 72 2 ENGINE OUTLINE Names of Parts 73 S16R PTA C 74 S16R PTA2 C 76 S16R PTAA2 C 78 S16R2 PTAW C 80 Protection System Location 82 S16R PTA C 83 S...

Page 21: ... Inspection and Maintenance General Information 131 Precautions for General Inspection and Maintenance 132 Inspection and Maintenance Prepare 133 Inspection and Maintenance Prepare with Engine Switched ON 133 Inspection and Maintenance Prepare with Engine Switched OFF 134 Engine Body Check 134 Belt Check 134 Belt Tension Alternator Adjust 136 Damper Check 139 Damper Temperature Check 139 Fuel Syst...

Page 22: ...es Not Crank or Cranks Slowly Resulting in Starting Failure 189 Starter Cranks but Engine Does Not Start 190 Output Shortage 191 Exhaust Smoke is White or Blue 192 Exhaust Smoke is Black or Dark Grey 193 Excessive Fuel Consumption 195 Excessive Engine Oil Consumption 196 Overheating 197 Engine Oil Pressure Drop 198 Engine Stops 199 During Normal Operation Thermo Switch Activated 200 12 AFTER SALES...

Page 23: ...l Adjust 3 115 Fig 6 6 Tool Adjust 4 115 Fig 6 7 Tool Adjust 5 115 Fig 6 8 Tool Adjust 6 115 Fig 6 9 LLC concentration measurement 1 116 Fig 6 10 LLC concentration measurement 2 116 Fig 6 11 LLC concentration measurement 3 116 Fig 6 12 LLC concentration measurement 4 116 Fig 6 13 LLC concentration measurement 5 116 Fig 6 14 LLC concentration measurement 6 117 Fig 8 1 Belt Tension Adjust V belt 135...

Page 24: ...Install 162 Fig 8 73 Drain Plug Install 162 Fig 8 74 Air Vent Plug Remove 162 Fig 8 75 Air Vent Plug Install 162 Fig 8 76 Clip Attaching Direction 163 Fig 8 77 Oil Pipe Check 163 Fig 8 78 S16R PTA C Right Side View 164 Fig 8 79 S16R PTA C Left Side View 164 Fig 8 80 Coolant Drain Cock on Engine Body 164 Fig 8 81 Coolant Drain Cock on Water Pump 165 Fig 8 82 Container to Receive Coolant 165 Fig 8 8...

Page 25: ...enance for Emergency Use Engine 1 5 125 Table 7 7 Scheduled Maintenance for Emergency Use Engine 2 5 126 Table 7 8 Scheduled Maintenance for Emergency Use Engine 3 5 127 Table 7 9 Scheduled Maintenance for Emergency Use Engine 4 5 128 Table 7 10 Scheduled Maintenance for Emergency Use Engine 5 5 129 Table 7 11 Scheduled Maintenance for Air Direct Admission Starting 130 Table 7 12 Scheduled Mainten...

Page 26: ...ed in Types and Meanings of Warning Terms Page 26 and their text are described in this Operation Maintenance Manual Understand and obey the details of warnings for each operation In addition to Matters to be Obeyed and Matters Prohibited Page 29 these warnings present important information for each operation Types and Meanings of Warning Terms Marking description Warning labels and warning texts i...

Page 27: ...s Examples Examples of locations of the warning labels are indicated on the next page Before using the engine check the locations of the warning labels since they differ according to the specifications of the devices and the construction work carried out by the generator suppliers Table 1 2 Meanings of symbols Mark Meanings Indicates prohibition of a danger ous action Indicates an operating instru...

Page 28: ...ator Radiator Fan Belt cover Shaft bracket Radiator Cap Exhaust manifold Rocker cover Exhaust manifold Generator Silencer Fuel filter Alternator cover Equipment board Grounding Terminal box Fuel injection pump cover Fuel filter Fuel inlet Splash of hot water may cause burns Do not open the cap when hot Risk of entanglement Read the OMM before operation and operate safely Never place your hand or f...

Page 29: ...eness could cause improper operation that could result in accidents or damage to the devices Prepare fire fighting equipments and fire extinguishers If you are obliged to prepare fire extinguishers by various laws and regulations be sure to place them In case of a fire delay in fire suppression will result in expansion of damage To extinguish engine fire it is recommended to use an ABC dry powder ...

Page 30: ...Do not use flames near the engine They could cause a fire When working with flammable substances such as fuel engine oil coolant LLC grease rust preventive oil anti corrosive agent etc use explosion proof lighting equipment without fire Otherwise they could catch fire and cause an explosion Do not operate the engine in a poorly ventilated place Otherwise it could cause carbon monoxide intoxication...

Page 31: ...lace the battery with a new one Do not short the battery terminals with a tool or other metal objects A short circuit may cause explosion fire electric shock or fusing of the terminals When working with the battery obey the manufacturer s operation manual or SDS If you accidentally swallow battery fluid rinse your mouth with plenty of water and then drink lots of water and seek immediate medical a...

Page 32: ...ning label from your SME dealer and attach it to the new part Never cut the seal of the fuel control link If you cut the seal damage to the engine or deterioration in the exhaust gas properties could occur In case that the seal is cut warranty will become invalid Never peel off the label at the fuel inlet or other labels that are not allowed to remove Doing so may be against the law or regulations...

Page 33: ...lt Make sure that no foreign particles get into the air inlet They could cause damage to the turbocharger and lead to serious problems in the engine Make sure that there is no contamination of water into the fuel engine oil air inlet and exhaust systems and combustion chambers Flue explosion deterioration in the exhaust gas properties or damage to the devices could result Make sure that there is n...

Page 34: ...ngine check the battery and cable terminals for corrosion In addition check the connections for looseness Defective contact or short circuit could cause damage to the devices Be sure to perform the pre operation check and scheduled maintenance as instructed in this Operation Maintenance Manual Failure to perform the pre operation check and scheduled maintenance may cause various engine problems an...

Page 35: ...tery terminals Otherwise sparks could occur and cause a fire or an explosion Do not touch battery terminal with a wet hand There are possibilities to get an electric shock When checking and servicing the battery wear suitable personal protective equipment such as protective eyeglasses rubber gloves working clothes with long sleeves and long trousers If battery fluid comes into contact with your ey...

Page 36: ...chamber Otherwise water hammering could cause damage to the engine inner parts and a serious accident Before starting the engine make sure there is no one in the vicinity of the engine Otherwise he she may be caught in the rotating parts and get seriously injured or suffer noise induced hearing loss Stay away from rotating parts during operation Otherwise you may get caught in the rotating parts a...

Page 37: ...operate the engine at no load or low load for a prolonged period of time Otherwise it could cause deterioration in the exhaust gas properties Do not operate the engine at a load exceeding the specified value or for a prolonged period of time Otherwise the main bearing or connecting rod bearing could seize The thermal load could increase excessively and will cause piston scuffing Otherwise the cran...

Page 38: ...e specified level the engine stopping device may work due to the increased exhaust temperature and stop the engine suddenly The thermal load could increase excessively and will cause piston scuffing If the intake air temperature cannot be kept at the specified level reconsider the operating conditions and operating time Keep the engine oil and coolant temperatures at the specified level If the eng...

Page 39: ...r the pipelines over the period recommended by the manufacturer with new fuel Otherwise deterioration in the components may cause clogged pipe lines which could result in starting failure Do not discard waste oil into sewerage river lake or other similar places Be sure to discard waste oil in accordance with the applicable laws and regulations Do not store fuel in a poorly ventilated place Otherwi...

Page 40: ...exceeds the limit the engine oil must not be used Otherwise seizure of the sliding parts may occur which could cause serious damage to the devices Use the genuine engine oil specified in this Operation Maintenance Manual Otherwise seizure of bearings breakage of a valve sticking of a piston ring seizure between a ring and a cylinder premature wear of bearings and sliding parts may occur which coul...

Page 41: ...rer s SDS If engine oil gets in your eyes it will cause pain and lead to sight loss at the worst Do not breathe in vaporized engine oil Otherwise it could be hazardous to your health When storing engine oil in the container be sure to close the cap Otherwise vaporized engine oil may build up which could cause an explosion or a fire on exposure to a flame When you add water to coolant use only the ...

Page 42: ...Failure to perform the pre operation check and scheduled maintenance may cause various engine problems and breakage to parts which may result in serious accidents Before starting the engine pull out the manual turning gear shaft Starting the engine while the turning gear is engaged with the ring gear could result in serious personal injury or destruction of the engine Before inspecting and maintai...

Page 43: ... lead to environmental pollution If you violate rules you may be subject to penalties Make sure that dripped oil parts tools or other things are not left on the floor around the engine Always maintain cleanliness and tidiness Otherwise a tumbling accident may occur Wear proper personal protective equipment for the work Watch your step during inspection and maintenance work Otherwise a tumbling acc...

Page 44: ...eration Otherwise you may get caught in the rotating parts and seriously injured Keep the belt for the crankshaft pulley or alternator free from oil and grease Otherwise a slip could occur which will shorten the service life of the belt Check each belt status tension damage and the like of the crankshaft pulley or alternator If the belt has been stretched the battery cannot be cahrged and DC power...

Page 45: ...d fuel will overflow from the container and may run to outside of the facility The fuel drained into the container shall be discarded in accordance with the local laws and regulations as well as the manufacturer s SDS When draining water from the fuel tank always use a container which is suitable for the water quantity Otherwise the drained water will overflow from the container and may run to out...

Page 46: ...se a genuine fuel filter If a non genuine filter is used deterioration in the exhaust gas properties and damage to the devices could occur due to insufficient air intake Faults or damages caused by using non genuine parts will be outside the scope of the warranty Do not use a fuel filter with a scratch or dent Otherwise damage to the filter or fuel leak may occur which could cause a fire or enviro...

Page 47: ...ner O ring Sustained use of the engine without any remedy could cause seizure of the crankshaft and lead to serious damage to the devices Be sure to install the oil filler cap after engine oil is refilled Otherwise seizure due to insufficient oil or environmental pollution due to engine oil running out from the facility may occur Make sure that engine oil is not leaking from the oil pan When check...

Page 48: ...or dent Otherwise damage to the filter or oil leak may occur which could cause a fire or environmental pollution due to fuel running to outside of the facility Do not use a filter wrench when installing the oil filter It may cause a dent or damage to the oil filter When replacing the oil filter set the gasket into the groove properly Otherwise engine oil leak could occur which could cause a fire o...

Page 49: ...he blade mounting portion If there is looseness in the blade mounting portion the blades may break Since replacing a blade requires balancing do not replace a single blade by yourself When replacing a single blade be sure to ask SME dealer When cleaning the blades do not use acid and alkaline solutions There is a risk of blade deterioration Do not use a high pressure washer to clean the blades The...

Page 50: ...sure that the pre cleaner is free from clogging Insufficient intake air could result in loss of power incomplete combustion exhaust gas temperature rise and overspeed of the turbocharger Make sure that the air cleaner is free from clogging Insufficient intake air could result in loss of power incomplete combustion exhaust gas temperature rise and overspeed of the turbocharger Do not short the batt...

Page 51: ... from the starting air tank Otherwise water could enter the air motor when starting the engine Keep away from fire when working with flammable substances such as volatile corrosion inhibitor or rust preventive oil They may cause a fire Keep away from fire when working with flammable substances such as grease They may cause a fire When handling grease obey the manufacturer s SDS If the engine is st...

Page 52: ...tations When handling grease obey the manufacturer s SDS Do not short the battery terminals Otherwise sparks could occur and cause a fire or an explosion When checking and servicing the battery wear suitable personal protective equipment such as protective eyeglasses rubber gloves working clothes with long sleeves and long trousers If battery fluid comes into contact with your eyes or skin it may ...

Page 53: ... personnel injury or damage to the devices may occur Lift the slings while keeping the angle formed by the slings attached to the hangers within 60 If the angle is too large excessive weight will be imposed on the hanger which could cause damage to the hanger Before inspecting and maintaining the engine read this Operation Maintenance Manual thoroughly to understand the construction and the requir...

Page 54: ... not enter into them Otherwise the devices could be damaged Do not discard waste oil into sewerage river lake or other similar places Be sure to discard waste oil in accordance with the applicable laws and regulations Keep away from fire when working with flammable substances such as fuel They may cause a fire When working with fuel wear suitable personal protective equipment such as protective ma...

Page 55: ...uld lead to environmental pollution If you violate rules you may be subject to penalties Do not discard coolant LLC into sewerage river lake or other similar places Be sure to discard coolant LLC in accordance with the applicable laws and regulations Keep away from fire when working with flammable substances such as coolant LLC They may cause a fire When handling coolant LLC always wear suitable p...

Page 56: ...es working clothes with long sleeves and long trousers If battery fluid comes into contact with your eyes or skin it may result in sight loss or burns In case that you have to discard the engine body contact your SME dealer You must deal with it as a special industrial waste in accordance with the laws and regulations of the national government and other local municipalities Asbestos was used in t...

Page 57: ...hods and procedures while taking advantage of the permanently installed protection devices Never deactivate the protection devices The location of the protection devices varies depending on the specification of the engine Refer to Protection System Location Page 82 Equipped or not equipped type setting value and figure of each protection device vary depending on the equipment and specifications Ch...

Page 58: ...ty when the operators enter the dangerous area for maintenance work such as replacing parts Shut off all the power source and set to Zero Energy State Zero Energy State Page 59 Lock up the power source so that the other operators will not be able to switch on the power source The operator in charge must hold the key so that other operators will not be able to open the lock Tagout Tagout is to atta...

Page 59: ...e relay of the generator OFF etc For engines with the air direct admission starting or air motor starting system conduct the following operation in addition 5 Bleed air trapped in the air starter system starting air tank starting air compressor to release the residual pressure Working Procedure in Dangerous Areas Works in Dangerous Areas When you need to enter a dangerous area for example to solve...

Page 60: ...een completed 5 Start up the engine by the normal operation procedure Body Protection When working on this engine obey the requirements below in order to protect the operator Clothing Fig 1 7 Clothing Be sure to wear the appropriate protective clothing to work Wear tight clothing and fasten cuffs firmly Proper work clothing is valuable protection against electrical shock If you work while wearing ...

Page 61: ...Safety belt when working at the high position Product specific Precautions Use of Chemicals This engine uses fuel diesel fuel engine oil coolant LLC grease and anti corrosive agent If these come into contact with your eyes or skin they may cause skin burns or abnormal sight sight loss at the worst To prevent an accident take measures given below When handling wear proper personal protective equipm...

Page 62: ...he suitable tools and equipment required for rescue work Keep Everyone Informed about the Emergency Stop Procedure Compile the information about the protection devices fuel engine oil pipings of the cooling and Inlet exhaust system installed during manufacturing the generator and attach it on the next page Also ensure that their locations and function are instructed to and understand by the operat...

Page 63: ... this engine in the direction of stopping and hold this position Fig 1 9 Emergency Stop Procedure The location of the manual stop lever varies depending on the specification of the engine Refer to Protection System Location Page 82 3 After the engine has stopped completely release the manual stop lever When stopping the engine by pulling the manual stop lever keep pulling the lever until the engin...

Page 64: ...ANCE MANUAL 64 Pub No K29001 00320 Revision 1 Emergency Stopping Devices Installed During Manufacturing the Generator The user company must compile the information about the emergency stopping devices installed during manufacturing the generator and attach it here ...

Page 65: ...ealer CONTACT LIST Page 8 as soon as possible Measures in the Event of Property Damaging Disasters If the engine has been damaged due to a wrong handling during operation act in accordance with the procedure shown below Fig 1 11 Measures in the Event of Property Damaging Disasters 1 Contact your SME dealer CONTACT LIST Page 8 immediately If the engine has been damaged exact damage situation cannot...

Page 66: ...during operation act in accordance with the following procedure Fig 1 13 Measures in the Event of a Fire Disaster 1 The operator who has found a fire must inform the other people around him of it aloud immediately 2 If there is any injured persons take them to a safety place and perform proper emergency medical procedures 3 Call the fire department 4 Use a fire extinguisher which is suitable for t...

Page 67: ...ance with the following procedure Fig 1 14 Measures in the Event of an Earthquake Disaster 1 If there is any injured persons take them to a safety place and perform proper emergency medical procedures 2 The user company or supervisor must lead all the operators to a safe place in accordance with the company rules 3 After confirming that there is not a possibility of earthquake recurrence check the...

Page 68: ...stand the details described in this Operation Maintenance Manual and conduct the training to prevent risks at the actual engine Fig 1 15 Operation Maintenance Manual Understand and Obey Education and Training for Safety Safety skills of the personnel can be improved by teaching as with skills of the other works Be sure to include the points concerning safety in your education and training The safe...

Page 69: ... procedures c Stick labels on to the containers of dangerous and hazardous materials and handle them according to the manufacturer s instruction Keep the chemicals from hot places spark of flame and store them in a dry and cool environment d Before handling dangerous and hazardous materials check the manufacturer s SDS and follow their handling procedures e When handling dangerous and hazardous ma...

Page 70: ...e The noise level near the engine exceeds 85 dB during operation Therefore do not stay in a dangerous area without wearing earplugs hearing personal protective equipment for a long time Preparation of facilities such as a cubicle bonnet is recommended Fig 1 18 Noise For the noise level refer to the factory test results statement held by the generator supplier Noise Level during Operation The actua...

Page 71: ...1 19 Vibration For the vibration level refer to the factory test results statement held by the generator supplier To Maintain Cleanliness and Tidiness Without keeping in mind to maintain cleanliness and tidiness you are in danger of stumbling over an obstacle or falling over In addition maintaining cleanliness and tidiness has a significant influence on the operations Sufficiently maintaining clea...

Page 72: ...ydrants and replace them with new ones periodically If the insulation of an electrical wiring is damaged repair or replace it immediately To prevent a fire due to old and deteriorated wiring check and replace deteriorated wiring Control build up of static electricity In addition to these always conduct the measures for preventing a fire Fig 1 21 Risk of Fire Communication with SME Please inform SM...

Page 73: ...s and the location of protection devices The descriptions are based on the standard data of an engine built as a unit which may become altered depending on the specifications of your devices or the construction work made by the generator supplier Names of Parts Refer to the pages corresponding your engine type S16R PTA C 74 S16R PTA2 C 76 S16R PTAA2 C 78 S16R2 PTAW C 80 ...

Page 74: ...w No Name No Name Engine body 1 Damper Cooling system 9 Coolant outlet 2 Flywheel 10 Thermostat case Fuel system 3 Governor actuator 11 Water pump Lubrication system 4 Breather Inlet and exhaust systems 12 Intake port 5 Bypass oil filter 13 Turbocharger 6 Oil pan 14 Exhaust outlet 7 Engine oil drain port 8 Oil pump 13 12 13 14 12 2 3 7 9 10 9 10 4 1 11 8 7 6 5 ...

Page 75: ...ger Lubrication system 11 Oil filler 2 Rear hanger 12 Oil level gauge 3 Cylinder head 13 Oil filter 4 Manual turning gear 14 Oil cooler Fuel system 5 Fuel injection pump Cooling system 15 Coolant inlet 6 Priming pump 16 Coolant drain cock Fuel feed pump Starting system 17 Starter 7 Fuel filter Electrical system 18 Alternator 8 Fuel control link 9 Fuel inlet 10 Fuel return port 1 2 5 8 16 17 6 10 9...

Page 76: ...w No Name No Name Engine body 1 Damper Cooling system 9 Coolant outlet 2 Flywheel 10 Thermostat case Fuel system 3 Governor actuator 11 Water pump Lubrication system 4 Breather Inlet and exhaust systems 12 Intake port 5 Bypass oil filter 13 Turbocharger 6 Oil pan 14 Exhaust outlet 7 Engine oil drain port 8 Oil pump 13 12 13 14 12 2 3 7 9 10 9 10 4 1 11 8 7 6 5 ...

Page 77: ...ger Lubrication system 11 Oil filler 2 Rear hanger 12 Oil level gauge 3 Cylinder head 13 Oil filter 4 Manual turning gear 14 Oil cooler Fuel system 5 Fuel injection pump Cooling system 15 Coolant inlet 6 Priming pump 16 Coolant drain cock Fuel feed pump Starting system 17 Starter 7 Fuel filter Electrical system 18 Alternator 8 Fuel control link 9 Fuel inlet 10 Fuel return port 1 2 5 8 16 17 6 10 9...

Page 78: ...eater 2 Flywheel 10 Coolant drain cock Fuel system 3 Governor actuator 11 Water pump Lubrication system 4 Breather 12 Thermostat case 5 Bypass oil filter 13 Coolant outlet 6 Oil pan Inlet and exhaust systems 14 Intake port 7 Engine oil drain port from air cooler 8 Oil pump 15 Intake air outlet to air cooler 16 Intake port 17 Turbocharger 18 Exhaust outlet 13 13 16 16 17 17 1 6 12 11 12 8 7 5 10 10...

Page 79: ...body 1 Front hanger Lubrication system 11 Oil filler 2 Rear hanger 12 Oil level gauge 3 Cylinder head 13 Oil filter 4 Manual turning gear 14 Oil cooler Fuel system 5 Fuel injection pump Cooling system 15 Coolant inlet 6 Priming pump Starting system 16 Starter Fuel feed pump Electrical system 17 Alternator 7 Fuel filter 8 Fuel control link 9 Fuel inlet 10 Fuel return port 1 2 5 8 16 6 12 11 7 13 14...

Page 80: ...4 2 3 6 No Name No Name Engine body 1 Damper Cooling system 8 Engine coolant outlet 2 Flywheel 9 Thermostat case Fuel system 3 Governor actuator 10 Water pump Lubrication system 4 Bypass oil filter 11 Air cooler coolant outlet 5 Oil pan 12 Thermostat case 6 Engine oil drain port for air cooler 7 Oil pump 13 Water pump for air cooler Inlet and exhaust systems 14 Intake port 15 Turbocharger 16 Exhau...

Page 81: ...11 Breather 2 Rear hanger 12 Oil filler 3 Cylinder head 13 Oil level gauge 4 Manual turning gear 14 Oil filter Fuel system 5 Fuel injection pump 15 Oil cooler 6 Priming pump Cooling system 16 Engine coolant inlet Fuel feed pump 17 Air cooler coolant inlet 7 Fuel filter 18 Engine coolant drain 8 Fuel control link cock 9 Fuel inlet Starting system 19 Starter 10 Fuel return port Electrical system 20 ...

Page 82: ...i Diesel Engine S16R S16R2 OPERATION MAINTENANCE MANUAL 82 Pub No K29001 00320 Revision 1 Protection System Location Refer to the pages corresponding your engine type S16R PTA C 83 S16R PTA2 C 84 S16R PTAA2 C 85 S16R2 PTAW C 86 ...

Page 83: ...S16R2 OPERATION MAINTENANCE MANUAL 83 Pub No K29001 00320 Revision 1 S16R PTA C Right Side View Left Side View 2 No Name No Name 1 Oil pressure switch 4 Rotation detection pickup 2 Thermo switch 5 Manual stop lever 3 Oil filter alarm switch 5 4 3 1 ...

Page 84: ...S16R2 OPERATION MAINTENANCE MANUAL 84 Pub No K29001 00320 Revision 1 S16R PTA2 C Right Side View Left Side View 2 No Name No Name 1 Oil pressure switch 4 Rotation detection pickup 2 Thermo switch 5 Manual stop lever 3 Oil filter alarm switch 5 4 3 1 ...

Page 85: ...16R2 OPERATION MAINTENANCE MANUAL 85 Pub No K29001 00320 Revision 1 S16R PTAA2 C Right Side View Left Side View 2 No Name No Name 1 Oil pressure switch 4 Rotation detection pickup 2 Thermo switch 5 Manual stop lever 3 Oil filter alarm switch 5 4 3 1 ...

Page 86: ...16R2 OPERATION MAINTENANCE MANUAL 86 Pub No K29001 00320 Revision 1 S16R2 PTAW C Right Side View Left Side View 2 No Name No Name 1 Oil pressure switch 4 Rotation detection pickup 2 Thermo switch 5 Manual stop lever 3 Oil filter alarm switch 3 1 5 4 ...

Page 87: ...ing and stopping devices as well as operation panels installed during manufacturing the generator and attach it below Also ensure that their locations and function are instructed to and understand by the operators in addition to the details of the Safety Manual Please compile the information about the starting and stopping devices as well as operation panels installed during manufacturing the gene...

Page 88: ...el Check Fuel Control Link Check Engine Oil Level Check Coolant Level Check Battery Check Pre cleaner Check for Clogging Air Cleaner Check for Clogging Damper Temperature Check Manual Turning Gear Check Air Direct Admission Starting Check Air Motor Starting Check 3 Engine Start up Self Starter Motor Starting Air Direct Admission Starting Air Motor Starting 4 Warm up Operation 5 Operation Checking ...

Page 89: ...fuel engine oil coolant LLC grease rust preventive oil and anti corrosive agent They could cause a fire Do not place flammable substances such as fuel and engine oil around the engine They could cause a fire Make sure that there is no water especially seawater or rain water seeped in the air intake and exhaust ports Piston scuffing contact of the piston with the cylinder inner wall and damage to t...

Page 90: ...r CONTACT LIST Page 8 Make sure the following measures are taken a Air intake port Prevent inrush of water especially sea water and rainwater Prevent contamination by foreign materials b Rotating parts Prevent contamination by foreign materials Prevent contact with human body install a protective cover c Hot parts Prevent contact with human body confirm warning labels d Electrical system Prevent a...

Page 91: ...e open Coolant drain cock plug closed Engine oil drain valve closed Make sure that any accumulation of flammables fuel leaks engine oil leaks moisture etc are not found around the hot parts of the engine exhaust manifold and the battery They could cause a fire Make sure that a coolant leak from any part of the engine is not found Coolant will flow out Make sure that the open close conditions of th...

Page 92: ...ntrol Link Check Page 150 Engine Oil Level Check Refer to Engine Oil Level Check Page 92 When handling engine oil refer to 5 ENGINE OIL Page 109 Be sure to perform the pre operation check and scheduled maintenance as instructed in this Operation Maintenance Manual Failure to perform the pre operation check and scheduled maintenance may cause various engine problems and breakage to parts which may ...

Page 93: ...ould cause corrosion of the radiator or heat exchanger If LLC concentration is high it may cause damage to the devices or overheat due to the seized engine parts Do not open the radiator cap or coolant tank cap while the engine is hot Otherwise you could get burns by steam or water splashing out Tighten the drain cock on the water pump properly Insufficient tightening may cause a coolant leak When...

Page 94: ... again Damper Temperature Check Page 139 A thermo label is attached as a guide It is recommended to measure the temperature while operating the engine with a noncontact thermometer thermo gun and to control and record it accordingly If the detected temperature comes close to the limit temperature of the damper as shown in the table below or if there is any abnormal change of temperature contact yo...

Page 95: ... compressor The starting air compressor may be outside the scope of our supply For the details refer to such a document as the specification sheet prepared by the generator manufacturer If it is not supplied by SME follow the instructions in the supplier s operation manual Air Filter Check Check the air filter The air filter may be outside the scope of our supply For the details refer to such a do...

Page 96: ...t supplied by SME follow the instructions in the supplier s operation manual Air Filter Check Check the air filter The air filter may be outside the scope of our supply For the details refer to such a document as the specification sheet prepared by the generator manufacturer If it is not supplied by SME follow the instructions in the supplier s operation manual Reducing Valve Check Check the reduc...

Page 97: ...g Devices Installed during Manufacturing the Generator Page 87 to start the engine Do not apply load to the engine at startup Otherwise the devices could be damaged Do not use the starter continuously for 10 seconds or longer In case that the engine does not start after three consecutive trials contact your SME dealer Otherwise flue explosion due to the accumulation of unburnt fuel or burn damage ...

Page 98: ...not start after three consecutive trials contact your SME dealer CONTACT LIST Page 8 4 After the engine has started close the main valve of starting air tank Air Motor Starting A general starting procedure is as follows The starting air tank and starting system may be outside the scope of our supply For the details refer to such a document as the specification sheet prepared by the generator manuf...

Page 99: ... dealer CONTACT LIST Page 8 Stay away from rotating parts during operation Otherwise you may get caught in the rotating parts and seriously injured Do not apply excessive load when the engine is cold Otherwise it could cause a failure If the engine is driven at an idle speed in the low load range for a prolonged period of time unburnt fuel may accumulate in the flue and explode When operating at l...

Page 100: ... in the alternator Never turn the key to the START position during operation Otherwise the starter could be damaged Do not remove the protective covers during operation If you are caught in rotating parts you could be seriously injured Do not perform the inspection and maintenance work during operation Unexpected activation of the devices could cause serious personal injury or damage to the device...

Page 101: ... engine oil pressure drop is observed stop the engine immediately and check the engine oil system to locate the cause Sustained use of the engine without any remedy could cause seizure of the bearings and lead to serious damage to the devices If the cause of problem cannot be located contact your SME dealer If a belt breaks stop the engine immediately and replace the belt Sustained use of the engi...

Page 102: ... 6 minutes at an idle speed Table 3 2 Checking During Operation Check item Criteria Reference Value Warning indicator in struments Lighting numerical value normality Engine speed frequency No large fluctuation Breather mist volume To be normal Exhaust color To be normal Damper temperature For continuous use 90 C 194 F or lower For emergency use 100 C 212 F or lower Engine oil pressure 0 39 MPa 3 9...

Page 103: ...Law etc is obliged according to the generator set application The method of inspection and maintenance and maintenance operation differs according to the device Contact the device supplier Once a Week Operate the engine for 5 to 10 minutes at no load and check the following points Startability exhaust color Abnormal vibration noise and odor Indication of various instruments oil pressure gauge wate...

Page 104: ...or manufacturers Otherwise damage to the fuel supply pump or deterioration in the exhaust gas properties may occur Do not use fuel after the recommended storage expiration date Otherwise incomplete combustion may occur which could result in flue explosion or deterioration in the exhaust gas properties Use only the fuel that meets our fuel quality standards specified in this Operation Maintenance M...

Page 105: ... laws and regulations Do not store fuel in a poorly ventilated place Otherwise vaporized fuel may build up which could cause an explosion or a fire on exposure to a flame Before handling fuel remove static electricity Otherwise the fuel could be ignited Ground the fuel tank When working with fuel wear suitable personal protective equipment such as protective mask protective eyeglasses rubber glove...

Page 106: ...bient temperature by 3 C 5 4 F or more JIS K 2288 2000 ISO 3015 Carbon residue content 10 residual oil 0 4 weight or lower 1 0 weight or lower JIS K 2270 2000 ISO 6615 ISO 10370 Cetane number 45 or higher 1 45 or higher 2 JIS K 2280 1996 Cetane Index New method 45 or higher 45 or higher ISO 5165 ISO DIS 4264 Kinetic viscosity 2 0 mm2 s or higher at 30 C 86 F 8 0 mm2 s or lower at 50 C 122 F 2 0 mm...

Page 107: ...up to load input is to be 40 seconds Operating the engine at no load or low load load factor 25 or less for a prolonged period of time is avoided 3 If the sulfer content of using fuel is higher than 0 2 weight use the specified engine oil 5 ENGINE OIL Page 109 Table 4 3 Fuel Properties Table 2 2 Item Recommended limit Service limit Remark Coking 250 C 482 F 24 Hr Carbonization 75 or less Carboniza...

Page 108: ...sider and take necessary treatment such as Antioxidation at high temperature Prevention from fuel solidification at low temperature Prevention from growth of microbe Removal of moisture For details refer to Technical Information For Engine warranty coverage refer to Limited Warranty conditions in this manual 5 Disregarding the value in could result in serious accident ...

Page 109: ... must be 0 2 weight or less Refer to the Engine Oil Properties table in this Operation Maintenance Manual and even if one item exceeds the limit the engine oil must not be used Otherwise seizure of the sliding parts may occur which could cause serious damage to the devices Use the genuine engine oil specified in this Operation Maintenance Manual Otherwise seizure of bearings breakage of a valve st...

Page 110: ... Do not operate the engine with fuel or water mixed in the engine oil Otherwise viscosity of engine oil could decrease which could cause seizure of the bearings or other serious accidents Do not store engine oil in a poorly ventilated place Otherwise vaporized engine oil may build up which could cause an explosion or a fire on exposure to a flame SAE10W SAE30 SAE40 SAE15W 40 Temperature C F Engine...

Page 111: ...the recommended values however up to the limit value is acceptable When you add water to coolant use only the water that meets the water quality standard specified in this Operation Maintenance Manual Otherwise premature corrosion or overheating in the engine parts may occur Table 6 1 Water Quality Standard pH 25 C 77 F Electrical conductivity mS m Total hard ness M alkalinity Chlorine ion Sulphat...

Page 112: ...eezing of cooling water Do not use antifreeze alone instead of LLC For details refer to Examples of Abnormalities Caused by LLC Amine Type Page 213 Coolant LLC Handling Use the genuine LLC specified in this Operation Maintenance Manual Otherwise the devices could be damaged Keep away from fire when working with flammable substances such as coolant LLC They may cause a fire Wipe off spilled flammab...

Page 113: ...ially contrasting density of the LLC concentration may occur which could interfere with the sufficient anticorrosion and cooling properties 3 Prepare a vessel for mixing and pour in water Water to Be Used Page 111 4 In accordance with the LLC concentration checked in Step 1 add LLC LLC to Be Used Page 112 5 Check the LLC concentration in mixed coolant LLC Concentration in Coolant Measure Page 114 ...

Page 114: ...Fig 6 1 Freezing Temperature of GLASSY Fig 6 2 Freezing Temperature of PG GLASSY When using the other LLC follow the instruction manual of LLC to be used LLC Concentration in Coolant Measure To measure the LLC concentration the following tool is required Tool Coolant tester When using other tools follow the instruction manual attached to the tool to be used Tool Adjust 1 Place 1 or 2 drops of dist...

Page 115: ...e eye piece Rotate the eyepiece to either side to focus Fig 6 6 Tool Adjust 4 5 Confirm the boundary line of blue color aligns with the 0 on the scale If it does not align rotate the scale adjusting screw by using a scale adjusting tool and let it align Fig 6 7 Tool Adjust 5 6 Wipe the surface of the prism and daylight plate with water soaked soft facial tissue Fig 6 8 Tool Adjust 6 60 1 35 1 30 1...

Page 116: ...l not enter it Fig 6 11 LLC concentration measurement 3 4 Read the scale through the eye piece Rotate the eyepiece to either side to focus Fig 6 12 LLC concentration measurement 4 5 Read the scale at the position where the blue boundary line comes across Fig 6 13 LLC concentration measurement 5 How to read the Scale The scale of the coolant tester is for the ethylene glycol type When measuring a p...

Page 117: ...hi Diesel Engine S16R S16R2 OPERATION MAINTENANCE MANUAL 117 Pub No K29001 00320 Revision 1 6 Wipe the surface of the prism and daylight plate with water soaked soft facial tissue Fig 6 14 LLC concentration measurement 6 ...

Page 118: ...s temperature Abnormal vibration Fuel leaks Engine oil leaks Exhaust gas leaks Appropriate service intervals vary with usage and operating conditions as well as conditions of fuel oil and coolant Check the results and shorten the interval as necessary Be sure to check the items which are included in the applicable interval and shorter intervals For example in the 2000 hour maintenance also check t...

Page 119: ...ated in terms of the annual operating time Refer to the rating definition Rating Definition Page 120 to check the interval of overhauls Scheduled Maintenance for Continuous Use Engine For the continuous use engine perform the scheduled maintenance in accordance with the Scheduled Maintenance for Continuous Use Engines Scheduled Maintenance for Emergency Use Engine For the emergency use engine perf...

Page 120: ...Time Overload operation Rack set Not possible E 5 Not possible E 10 E Definition Applications where there standby output continu ous operation request of 300hr or lower Typically example For Data center Rated power of an emer gency generator that sup plies power in case of a failure of main power source or commercial power Regular power source of which the operating hour is limited to the short pe...

Page 121: ...th no runtime limitation when the operation is loaded to N demand for the engine generator set This document may be changed without prior notification Table 7 2 SME Generator Use Diesel Engine Rating Definition 2 2 Symbol DCC C D Name of rating Data center Continuous 7 Continuous Overload operation Rack set Not possible P 5 6 Not possible C Not possible D Definition For generator in Data center ap...

Page 122: ...tor Drain Water 1 145 First 50 service hours for a new or overhauled engine Bolts and Nuts on the Engine Retighten 91 Engine Oil Oil Filter and Bypass Oil Filter Replace 2 3 159 161 161 Engine Oil Analysis Recommended Every 250 service hours Engine Oil Oil Filter and Bypass Oil Filter Replace 2 3 159 161 161 Engine Oil Analysis Recommended First 250 service hours for a new or overhauled engine Val...

Page 123: ...bocharger Check 174 Damper Check 139 Starter Check 177 Unit Seal and Oil Seal of Water Pump Replace Protection System Check 8 Contact your SME dealer Resin Fan Inspection Blade Inspection Cleaning Bolt Looseness Check and Tightening 173 LLC Concentration in Coolant Check 114 Every 8000 service hours 1 Engine Major Overhaul Disassemble the engine and then clean check and replace major parts At the ...

Page 124: ...st plates pistons piston pins connecting rod bolts rocker bushings fuel injection pipe assembly oil pipe assembly Fuel Injection Pump Inspect and Test Replace parts as needed Protective Devices Repair and Replace 1 High coolant temperature low oil pressure overspeeding starting stall cooling water supply fault undervoltage overvoltage overcurrent low coolant level in tank low fuel level in tank lo...

Page 125: ...e the engine at no load for 5 to 10 minutes Check startability 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 and others 103 Every month Ingress of Fuel and Water In Engine Oil Check 8 Contact your SME dealer Fuel Control Link Check 150 Battery Elect...

Page 126: ...uel Tank Drain Water 1 141 Water Separator Drain Water 1 145 Fuel Injection Nozzle Spray Condition and Injection Pressure Inspect and Adjust Fuel Injection Timing Check and Adjust 8 Contact your SME dealer Fuel Pipe Check 152 Lubrication system Oil Pipe Check 163 Engine Oil Properties Analyze Engine Oil Pressure Maintenance Operation Check and Adjust 8 Contact your SME dealer Cooling system Water ...

Page 127: ...n Air Distribution Valve Check Air Compressor Belt Tension Check 8 Contact your SME dealer Protection System Check 1 High coolant temperature low oil pressure overspeeding start stalling cooling water supply fault undervoltage overvoltage overcurrent low coolant level in tank low fuel level in tank low air pressure in tank and others Auxiliary Devices Check 1 Engine control devices fuel transfer p...

Page 128: ...bers Inspect the cylinder No 1 and 2 If any abnormality is found inspect all the cylinders Oil Cooler Check Contamination Clogging and Leak Oil Pump Check Discoloration and Other External Defects 8 Contact your SME dealer Governor Oil Filter Replace 161 Fuel Tank Clean 1 141 Fuel Injection Pump Inspect and Test Replace parts as needed 8 Contact your SME dealer Governor Inspect and Test Replace par...

Page 129: ...8 years 2 Engine Major Overhaul Disassemble the engine and then clean check and replace major parts Damper Replace Oil Pump Repair or Replace Fuel Injection Nozzle Tip Spacer and Nozzle Spring Replace Check the spray condition and adjust the fuel injection pressure after the replacement Rubber Parts and O rings Replace Water Pump Unit Seal and Oil Seal Replace Turbocharger Disassemble and Inspect ...

Page 130: ...em of the air motor starting perform the scheduled maintenance in accordance with the table below Table 7 11 Scheduled Maintenance for Air Direct Admission Starting Inspection and Maintenance Period Service Items Reference Page Before Starting Starting Air Tank Check 95 Starting Air Compressor Check Air Filter Check Starting Valve Check Table 7 12 Scheduled Maintenance for Air Motor Starting Inspe...

Page 131: ...r Water Separator Check and Service Gauze Filter Clean Fuel Filter Replace Fuel Control Link Check Fuel Pipe Check Engine Oil System Check Engine Oil Change Oil Filter Replace Bypass Oil Filter Replace Governor Oil Filter Replace Hydraulic governor spec Oil Pipe Check Cooling System Check Coolant Change Cooling System Bleed Air Radiator Fins Check and Clean Radiator Spec Resin Fan Inspection Speci...

Page 132: ...mediately after the engine is stopped Otherwise you could get burned by hot engine oil or coolant splashing out Do not touch any part of the engine other than the manual stop lever during or immediately after operation and immediately after stopping If you touch you could get burned by heat Before starting the inspection and maintenance work make sure that the engine is cooled down Only the genuin...

Page 133: ...The floor could be extremely slippery due to spilt oil Thoroughly wipe off oil on the floor and the sole of your shoes Install a stable scaffold as required Cover the disconnected pipes or joints and their openings properly so that dusts or other foreign objects will not enter into them Otherwise the devices may be damaged The engine must be inspected and maintained only by qualified persons who h...

Page 134: ...r the corresponding manual of the generator and the supplier s operation manual Belt Check Check each belt for the crankshaft pulley or alternator in the engine Be sure to lockout tagout before starting inspection and maintenance work Unexpected startup of the engine could cause serious personal injury or damage to the devices Be sure to establish zero energy state before starting inspection and m...

Page 135: ...just V belt Fig 8 2 Shape of V belt Fig 8 3 Belt Tension Adjust Ribbed Belt Fig 8 4 Shape of Ribbed Belt Tool Gauge 10 mm 0 39 in wide Table 8 1 Type of Belt V belt Type of Belt Standard value V belt When the center of the belt span is pressed with a force of approx 98 N 9 99 kgf 22 03 lbf to 147N 14 99 kgf 33 05 lbf the deflec tion of the belt must be 10 to 15 mm 0 39 to 0 59 in 10 to 15 mm 0 39 ...

Page 136: ...r lock nut 3 has a left hand thread Tool Wrench Fig 8 7 Belt Tension Adjust Lock Nut 4 Turn the turn buckle 4 of the adjusting bolt to adjust the belt tension Fig 8 8 Belt Tension Adjust Turn Buckle Stay away from rotating parts during operation Otherwise you may get caught in the rotating parts and seriously injured Adjust the belt tension properly in accordance with the procedures recommended by...

Page 137: ...right hand thread The lower lock nut 3 has a left hand thread Tool Wrench Fig 8 9 Belt Tension Adjust Lock Nut 6 Tighten the retaining bolts 1 of the alternator and the adjusting rod which were loosened in Step 2 Tool Wrench Fig 8 10 Belt Tension Adjust Retaining Bolt 7 Install the belt cover of the alternator which was removed in Step 1 Fig 8 11 Belt Cover Install 8 Install the front cover Fig 8 ...

Page 138: ...gf 39 57 lbf 118 N 12 03 kgf 26 53 lbf 88 N 8 97 kgf 19 78 lbf 71 N 7 24 kgf 15 96 lbf 59 N 6 02 kgf 13 26 lbf 11 191 N 19 48 kgf 42 94 lbf 127 N 12 95 kgf 28 55 lbf 96 N 9 79 kgf 21 58 lbf 76 N 7 75 kgf 17 09 lbf 64 N 6 53 kgf 14 39 lbf 12 206 N 21 01 kgf 46 31 lbf 137N 13 97 kgf 30 80 lbf 103 N 10 50 kgf 23 16 lbf 82 N 8 36 kgf 18 43 lbf 69 N 7 04 kgf 15 51 lbf When retightened 3 51 N 5 20 kgf 1...

Page 139: ...t be dissipated from its surface to prevent excessive heating Be sure to obey the instructions below Make sure the temperature of the damper outside surface does not exceed the temperature described in the following table when operating the engine at the rated power output When installing a protective cover to the damper provide adequate ventilation so that the damper temperature does not exceed t...

Page 140: ...an touch 2 Stick a thermo label 1 onto the outer face of the damper Avoid the stamped marking Fig 8 14 Thermo Label Stick 3 Operate the engine at the rated load for about an hour 4 Operate the stop switch Starting and Stopping Devices Installed during Manufacturing the Generator Page 87 of the generator to turn off the engine 5 Check the heat sensitive area of the thermo label and record the highe...

Page 141: ...roughly with a waste cloth They may cause a fire When discarding a waste cloth used to wipe off combustible material put it into a lidded can and obey the Waste Management and Public Cleansing Act to handle it as a special industrial waste It may cause a fire It could lead to environmental pollution If you violate rules you may be subject to penalties Tighten the fuel supply valve to the engine fi...

Page 142: ...e of our supply refer the corresponding manual of the generator and the supplier s operation manual Priming Pump Operate There are two different types A type and B type of priming pumps For the location of the priming pumps refer to 2 ENGINE OUTLINE Page 73 A type 1 Loosen the priming pump cap 1 by turning it counterclockwise The cap 1 is released and the cap 1 is raised Fig 8 15 Priming Pump Oper...

Page 143: ...mality such as deformation or scratches Fig 8 19 Priming Pump Operation A type If the head packing has an abnormality such as deformation or scratches the priming pump must be replaced Contact your SME dealer CONTACT LIST Page 8 B type 1 Move the handle up and down Fuel is discharged Fig 8 20 Priming Pump Operation B type There is not a locking mechanism Water Separator Bleed Air Bleed air from th...

Page 144: ...aste cloth 4 Tighten the air vent plug of the fuel filter by turning it clockwise Tool Torque wrench Tightening torque 7 8 to 9 8 N m 0 80 to 1 00 kgf m 5 75 to 7 23 lbf ft Fig 8 22 Fuel Filter Bleed Air 2 Fuel Injection Pump Bleed Air Bleed air from the fuel injection pump For the location of the fuel injection pump refer to 2 ENGINE OUTLINE Page 73 1 Loosen the air vent plug of the fuel filter b...

Page 145: ...r Separator Element Replace 1 Replace the water separator element 2 After the new fuel filter element is installed bleed air from the fuel system Fuel System Bleed Air Page 142 When draining water from the water separator always use a container which is suitable for the water quantity Otherwise the drained water will overflow from the container and may run to outside of the facility The water drai...

Page 146: ...Banjo Bolt Remove 2 Remove the gauze filter that is fitted inside the banjo bolt Tool Flat blade screwdriver Fig 8 27 Gauze Filter Remove 3 Soak the gauze filter into fresh fuel oil in the container and wash it with a soft brush or others Replace the gauze filter with a new one if it has a break or deformation 4 After cleaning install the gauze filter into the banjo bolt Tool Flat blade screwdrive...

Page 147: ... installation procedure described in this Operation Maintenance Manual Use a genuine fuel filter If a non genuine filter is used deterioration in the exhaust gas properties and damage to the devices could occur due to insufficient air intake Faults or damages caused by using non genuine parts will be outside the scope of the warranty Do not use a fuel filter with a scratch or dent Otherwise damage...

Page 148: ... 8 31 Container to Receive Fuel The customer is required to prepare the container 3 Remove the fuel filter Tool Filter wrench Fig 8 32 Fuel Filter Remove Remove it slowly so that fuel will not spill 4 Wipe off fuel on the fuel filter installing surface of the filter bracket with a waste cloth Fig 8 33 Fuel Filter Installing Surface Clean 5 Prepare a new fuel filter 1 Check that the gasket is prope...

Page 149: ...r Fuel Filter Bleed Air Page 144 8 Check the fuel control link Fuel Control Link Check Page 150 9 Operate the start switch of the generator Starting and Stopping Devices Installed during Manufacturing the Generator Page 87 to start the engine 10 Operate the engine at an idle speed for several minutes 11 Operate Starting and Stopping Devices Installed during Manufacturing the Generator Page 87 the ...

Page 150: ...ies depending on the specification of the engine Refer to Protection System Location Page 82 3 Decrease the pushing pressure little by little and check the manual stop lever for smooth returning to the previous position Fig 8 39 Manual Stop Lever Check If the lever cannot be returned back smoothly contact your SME dealer CONTACT LIST Page 8 Never cut the seal of the fuel control link If you cut th...

Page 151: ...e Page 151 If the sealing is defective contact your SME dealer CONTACT LIST Page 8 Ball Joint Replace If the ball joint is integrated with the control link replace the assembly 1 Remove the nut or lock nut which fixes the ball joint Tool Wrench Fig 8 41 Ball Joint Remove 2 Ball Joint and Washer Remove The lock nut does not have a washer Fig 8 42 Ball Joint and Washer Remove 3 Install the new ball ...

Page 152: ... SME dealer CONTACT LIST Page 8 2 Install the clamp for the high pressure fuel injection pipe at the previous position Fig 8 45 High Pressure Fuel Injection Pipe Clamp Location Page 153 Check the clamp for the high pressure fuel injection pipe for looseness If looseness or play is detected at the clamp for the high pressure fuel injection pipe damage to the pipe may occur which could cause a fire ...

Page 153: ...inder No 1 Cylinder No 2 Cylinder No 3 Cylinder No 4 Cylinder No 5 Cylinder No 6 Cylinder No 7 Cylinder No 8 Cylinder Front Front Plate Plate Plate Plate Plate Plate Plate Plate Plate Plate Plate Plate Plate Plate Plate Clamp Clamp Clamp Clamp Clamp Clamp Clamp Clamp Clamp Clamp Clamp Clamp Clamp Clamp Clamp Sheet Sheet Sheet Engine Right Side View Engine Left Side View C E C A B A A A D E F G D E...

Page 154: ...ct your SME dealer CONTACT LIST Page 8 Engine Oil System Check When handling engine oil refer to 5 ENGINE OIL Page 109 Devices and equipment outside the scope of our supply are included in the facility For the details refer to such a document as the specification sheet prepared by the generator supplier For the devices and equipment outside the scope of our supply refer the corresponding manual of...

Page 155: ...iner 3 Drain engine oil from the oil pan drain port 4 Discard engine oil in the container in Step 2 properly Engine Oil Check 1 Extract 1 to 2 L 0 26 to 0 53 US gal of engine oil from the oil pan 2 Check for odor and discoloration to determine if the oil is contaminated with fuel or water If fuel is mixed the oil will smell like fuel If water is mixed the engine oil becomes milky If the engine oil...

Page 156: ...to engine oil running out from the facility may occur Make sure that engine oil is not leaking from the oil pan When checking the engine oil level wear protective glasses to prevent engine oil from getting in your eyes If engine oil gets in your eyes it will cause pain and lead to sight loss at the worst Refill engine oil enough to raise the level to within the specified range between the highest ...

Page 157: ... Oil Bath 6 Install the rocker covers onto all the cylinder heads Tool Wrench Fig 8 55 Rocker Cover Install Engine Oil Level Check After filling engine oil check and adjust the engine oil level 1 Check the specified level of the engine oil SPECIFICATIONS CHECK Page 10 2 Pull out the oil level gauge 1 slowly and wipe off the engine oil with a waste cloth Fig 8 56 Engine Oil Level Check 3 Insert the...

Page 158: ...ck that the oil pan drain port is closed 7 Check the engine oil system including the oil pan for leak of engine oil If a leak is found contact your SME dealer CONTACT LIST Page 8 Engine Adjust after Oil Change After changing engine oil operate the engine as follows 1 Pull the manual stop lever in the direction to stop and hold the position and crank the engine for approx 10 seconds using the start...

Page 159: ...uine parts will be outside the scope of the warranty If paint or other matter is adhering around the sealing surface remove them before assembling If paint or other matter is stuck on the sealing surface fuel could leak through the gap which could cause a fire If engine oil spills out while removing the oil filter wipe off with a waste cloth Otherwise it may cause a fire or environmental pollution...

Page 160: ...te cloth Fig 8 63 Oil Filter Installing Surface Clean 5 Prepare a new oil filter 1 Check that the gasket is properly seated in the groove 2 Apply clethe engine oil to the gasket Fig 8 64 Oil Filter Gasket 6 Install the oil filter in Step 5 on the filter bracket When the oil filter gasket comes in contact with the installing surface of the filter bracket further tighten the oil filter by 3 4 to a f...

Page 161: ... receive spilled oil and place it under the governor oil filter The customer is required to prepare the container 3 Drain engine oil in the governor oil filter Tool Wrench 1 Loosen the air vent plug 1 2 Remove the drain plug 2 Engine oil is drained Fig 8 66 Engine Oil Drain 4 Remove the oil pipe 3 from center bolt Tool Wrench Fig 8 67 Oil Pipe Remove 5 Remove the center bolt 4 The case 5 can be re...

Page 162: ...ket Fix it by tightening the center bolt 4 Tool Wrench Fig 8 71 Case Install 9 Install the oil pipe 3 was removed in Step 4 Tool Wrench Fig 8 72 Oil pipe Install 10 Install the drain plug 2 which was removed in Step 3 Tool Wrench Fig 8 73 Drain Plug Install 11 Remove the air vent plug 1 Tool Ring spanner Fig 8 74 Air Vent Plug Remove 12 After filling the filter with engine oil install the air vent...

Page 163: ...rator supplier For the devices and equipment outside the scope of our supply refer the corresponding manual of the generator and the supplier s operation manual 1 1 1 3 3 3 2 2 2 R R R 1 4 Do not continue to operate the engine with engine oil mixed in coolant Otherwise cooling fault may occur which could cause damage to the engine Do not open the radiator cap or coolant tank cap while the engine i...

Page 164: ...PTA C Left Side View Coolant Change Coolant Drain When draining coolant immediately after engine operation run the engine at low idle for 5 to 6 minutes and check that the coolant becomes to the room temperature 1 Prepare a container for receiving drained coolant and place it under the coolant drain cock on the engine body The customer is required to prepare the container 2 Slightly open the coola...

Page 165: ...drain cock on the water pump Fig 8 82 Container to Receive Coolant The customer is required to prepare the container 5 Slightly open the coolant drain cock 2 on the water pump Fig 8 83 Coolant Drain Cock on Water Pump 6 Slightly open the coolant filler port to release pressure If the radiator cap has a pressure release lever move the lever upward to release pressure Fig 8 84 Radiator Cap Pressure ...

Page 166: ... Fig 8 87 Coolant Drain Cock on Water Pump Cooling System Clean When using the engine or radiator for the first time or after a long term storage clean the cooling system 1 Close the coolant drain cock 1 and 2 on the engine body and water pump Fig 8 88 Coolant Drain Cock on Engine Body Fig 8 89 Coolant Drain Cock on Water Pump 1 2 When handling cleaning solution for washing the cooling system obey...

Page 167: ...are a container for receiving drained coolant and place it under the coolant drain cock on the engine body The customer is required to prepare the container 7 Connect a clear plastic tube 3 to the coolant drain cock 2 on the water pump and fix with a band Fig 8 90 Coolant Drain Cock on Water Pump Prepare a plastic tube 5 mm 0 20 in in diameter approx 1 m 39 97 in long and a band 8 Prepare a contai...

Page 168: ...coolant filler cap 2 Operate the start switch of the generator Starting and Stopping Devices Installed during Manufacturing the Generator Page 87 to start the engine 3 Operate the engine at the rated speed for about 10 minutes 4 Operate the stop switch of the generator Starting and Stopping Devices Installed during Manufacturing the Generator Page 87 to turn off the engine 5 Prepare a container fo...

Page 169: ... and water pump The tap water poured in Step 1 will be drained Fig 8 98 Coolant Drain Cock on Engine Body Fig 8 99 Coolant Drain Cock on Water Pump 9 Close the coolant drain cock 1 and 2 on the engine body and water pump Fig 8 100 Coolant Drain Cock on Engine Body Fig 8 101 Coolant Drain Cock on Water Pump 10 Discard tap water in the container in Step 5 and Step 7 properly 11 Repeat Step 1 to 10 u...

Page 170: ...ified quantity of coolant For the specified quantity of coolant refer to SPECIFICATIONS CHECK Page 10 For mixing coolant refer to Coolant Mix Page 113 Refill slowly to prevent air included in the coolant 4 Wait approx 30 minutes untill the coolant to circulate all parts of the coolant system then check the coolant quantity again 5 Check the heat exchanger and other part in the coolant system for c...

Page 171: ...otection System Location Page 82 2 Pause for about 1 minute 3 Repeat the operation of Step 1 and 2 for 2 or 3 times Coolant will reach each part 4 Slightly loosen the air vent plug at the engine coolant outlet pipe and bleed air For the location of the air vent plug refer to such a document as the corresponding manual of the generator 5 After checking that air has been bled tighten the air vent pl...

Page 172: ... same side as air flow of radiator front side Fig 8 106 Radiator fin Clean If you wash in reverser order dust may be pushed into the fins and cause damage Avoid excessive high pressure steam more than 0 28 MPa 2 86 kgf cm2 40 61 psi and pressurized water as they will damage the fins 4 Clean the surface of the radiator fins until you can see the light from the opposite side If dust or dirt remains ...

Page 173: ... 75 lbf ft Fig 8 107 Blade mounting portion Blade Cleaning 1 Use a neutral solution to clean the blade surface 2 Wait for it to dry Check that there are no flaws cracks or discoloration on the surface of blades If you operate the engine with a defective blade the blade may break Check that there is no play in the blade mounting portion If there is play in the blade mounting portion the blades may ...

Page 174: ...ge If discoloration or damage is detected contact your SME dealer CONTACT LIST Page 8 Exhaust Muffler Drain Water Be sure to drain the exhaust muffler The exhaust muffler is outside the scope of our supply For the details refer to the corresponding manual of the generator and the supplier s operation manual Before checking the turbocharger make sure that the engine has cooled down to normal temper...

Page 175: ...detergent Fig 8 111 Pre cleaner Clean 1 3 Rinse the pre cleaner with fresh water Discard the rinsed water properly Fig 8 112 Pre cleaner Clean 2 Do not check maintain or remove the pre cleaner during operation Otherwise dust or other foreign particles may enter the engine which could accelerate wear of the parts or cause damage to the devices including the turbocharger Take care that parts will no...

Page 176: ... and Service Check the air cleaner for clogging and clean the air cleaner element The air cleaner may be outside the scope of our supply For the details refer to such a document as the specification sheet prepared by the generator manufacturer If it is not supplied by SME follow the instructions in the supplier s operation manual Air Cleaner Check for Clogging Check the air cleaner for clogging Ai...

Page 177: ...73 Fig 8 115 Starter Check Self Starter Motor Starting Visually check the starter Check for damage If the starter is damaged or defective contact your SME dealer CONTACT LIST Page 8 Do not short the battery terminals Otherwise sparks could occur and cause a fire or an explosion Do not touch battery terminal with a wet hand There are possibilities to get an electric shock When checking and servicin...

Page 178: ...Water and Clean The starting air strainer may be outside the scope of our supply For the details refer to such a document as the specification sheet prepared by the generator manufacturer If it is not supplied by SME follow the instructions in the supplier s operation manual 1 Close the main valve of the starting air tank The air supply stops 2 While cranking the engine lightly bleed air remaining...

Page 179: ...k and check the operation of the safety valve The starting air tank may be outside the scope of our supply For the details refer to such a document as the specification sheet prepared by the generator manufacturer If it is not supplied by SME follow the instructions in the supplier s operation manual If the safety valve is defective contact your SME dealer CONTACT LIST Page 8 Starting Air Motor Ch...

Page 180: ...e rusted which could cause damage to the devices Follow the storage procedure described in this Operation Maintenance Manual Use volatile corrosion inhibitor and rust preventive oil recommended by us If a product other than the recommendation is used the internal engine parts may be rusted due to insufficient anti rust effect Use new immediately after opened desiccant If you use a product which ha...

Page 181: ...ine is completely consumed refill the fuel mixture into the fuel tank or switch the fuel pipes to feed the fuel mixture into the engine 5 Operate the start switch of the generator Starting and Stopping Devices Installed during Manufacturing the Generator Page 87 to start the engine 6 Close the fuel valve Air Intake System Spray volatile corrosion inhibitor while cranking the engine for 2 times or ...

Page 182: ...ve the cover that has been placed over the entire engine 2 Remove the adhesive cloth tape from around the terminals of the starter and alternator 3 Adjust the tension of each belt on the crank pulley or alternator Belt Tension Alternator Adjust Page 136 4 Remove the adhesive cloth tape from around the air inlet exhaust outlet breather and other openings 5 Connect each piping of the fuel system and...

Page 183: ... 10 seconds using the starter Fig 9 4 Restart after Storing The location of the manual stop lever varies depending on the specification of the engine Refer to Protection System Location Page 82 2 Pause for about 1 minute 3 Repeat the operation of Step 1 and 2 for 2 or 3 times 4 After starting the engine check that the engine oil pressure rises with a pressure gauge 5 Conduct a warm up operation Wa...

Page 184: ...se if the wire breaks the engine may fall down which could cause serious personal injury The engine must be lifted only by an operator who is qualified for a crane and slinging works and also well skilled Otherwise the engine may fall by an operation error which could cause serious personal injury or damage to the devices To lift the engine take the mass of the engine and that of water remained in...

Page 185: ... generator and the supplier s operation manual 1 Drain fuel engine oil and coolant from the engine 2 Disconnect the wiring and pipings from the engine 3 Remove pipe covers and insulators located near the hangers 4 Hook the slings on the hangers For the location of the hangers refer to ENGINE OUTLINE Page 73 5 Release the lockings between the engine and the common bed 6 Lift up the engine by using ...

Page 186: ...4 in 822 mm 32 36 in 768 mm 30 24 in 752 mm 29 61 in 502 mm 19 76 in 502 mm 19 76 in 722 mm 28 43 in 722 mm 28 43 in 220 mm 8 66 in 220 mm 8 66 in 395 mm 15 55 in 395 mm 15 55 in 698 mm 27 48 in 892 mm 35 12 in Right Side View Engine Front View Left Side View Crankshaft Center Center of Gravity Center of Gravity Center of Gravity Hanger Center 30 mm 1 18 in 30 mm 1 18 in 799 mm 31 46 in 822 mm 32 ...

Page 187: ...ssly you may hurt your back or get injured by dropping the part Make sure that dripped oil parts tools or other things are not left on the floor around the engine Always maintain cleanliness and tidiness Otherwise a tumbling accident may occur Wear proper personal protective equipment for the work Make sure that the tools to be used are not damaged Using a damaged tool or a wrong size tool may cau...

Page 188: ...he engine take measures to prevent dust and foreign materials from entering Parts Handling Handle parts carefully When replacing use genuine parts Safety Working Practices Use correct tools and perform work with the utmost care If you misjudge the weight you may damage the part by dropping it or get injured How to Troubleshoot In general problems can be divided into 3 types a Machine related probl...

Page 189: ...ks slowly resulting in starting failure Problem Cause Remedies Reference Page Starter does not crank or cranks slowly resulting in starting failure Electrical System Faulty wire connec tion insufficient ca pacity Check fuse Check wiring connection between battery starter and starter switch Battery charge fault Alternator Check 178 Check and adjust the belt 134 136 Capacity degrada tion of the batt...

Page 190: ...l injection pipe Check defects of high pressure fuel injection pipe 152 Contact your SME dealer 8 Clogged fuel filter Check and replace fuel filter 147 Gauze Filter Clean 146 Change to fuel suitable for the ambient temperature 104 Fuel feed pump malfunction Contact your SME dealer 8 Fuel injection pump malfunction Check fuel injection pump rack stroke Contact your SME dealer 8 Fuel injection noz z...

Page 191: ...Clogged fuel filter Check and replace fuel filter 147 Gauze Filter Clean 146 Change to fuel suitable for the ambient temperature 104 Fuel feed pump malfunction Contact your SME dealer 8 Cooling System Overheating Refer to the items of overheating 197 Overcooling Check fan and heat exchanger Check control system Contact your SME dealer 8 Inlet and Exhaust Systems Insufficient amount of intake air T...

Page 192: ...uel System Improper fuel prop erties Check cetane index 106 Change with appropriate fuel 104 Faulty fuel injection timing Not good Check fuel injection pump drive coupling Contact your SME dealer 8 Uneven fuel injec tion volume Check ignition sound exhaust temperature and the balance between left and right banks Contact your SME dealer 8 Fuel injection noz zle malfunction Contact your SME dealer 8...

Page 193: ...e coupling Contact your SME dealer 8 Uneven fuel injec tion volume Check ignition sound exhaust temperature and the balance between left and right banks Contact your SME dealer 8 Lubrication System Combustion of en gine oil Check engine oil properties Engine Oil Level Check 157 Contact your SME dealer 8 Inlet and Exhaust Systems Insufficient amount of intake air Turbocharger Check 174 Clean check ...

Page 194: ...t Smoke is Black or Dark Grey 2 2 Problem Cause Remedies Reference Page Exhaust Smoke is Black or Dark Grey Control System Excessive load Check control system and governor controller Check boost compensator Contact your SME dealer 8 Engine Body Compression pressure drop Contact your SME dealer 8 Faulty valve timing Wear of sliding parts ...

Page 195: ...52 Fuel leaks from high pressure fuel injection pipe Check defects of high pressure fuel injection pipe 152 Contact your SME dealer 8 Cooling System Overcooling Check fan and heat exchanger Check control system Check thermostat Contact your SME dealer 8 Inlet and Exhaust Systems Insufficient amount of intake air Turbocharger Check 174 Clean check and replace pre cleaner 175 Clean check and replace...

Page 196: ...ulty engine oil property viscosity Analyze engine oil properties Change with the engine oil of proper viscosity 206 Excessive engine oil temperature Engine Oil Level Check Check lubrication system Check oil cooler and oil thermostat 157 Contact your SME dealer 8 Cooling System Overheating Refer to the items of overheating 197 Inlet and Exhaust Systems Oil entry to the air supply chamber Check oil ...

Page 197: ...oolant leakage Coolant Level Check Excessive LLC concentration Check LLC concentration 113 Water pump mal function Contact your SME dealer 8 Thermostat mal function Contact your SME dealer 8 Heat exchanger malfunction Check and clean heat exchanger Control System Excessive load Check fuel injection pump rack stroke Check control system and governor controller Contact your SME dealer 8 Engine Body ...

Page 198: ...es Change with the engine oil of proper viscosity 206 Excessive engine oil temperature Cooling system Check Contact your SME dealer 8 Clogged oil filter Check and replace oil filter and bypass oil filter 159 161 Oil pump malfunc tion Contact your SME dealer 8 Relief valve mal function Contact your SME dealer 8 Control System Oil pressure gauge malfunction Check control system and wiring Contact yo...

Page 199: ...edies Reference Page Engine Stops Run out of fuel Restart the engine in the following order 1 Turn the start switch to the ON position 2 Fill the fuel tank with fuel 3 Bleed air from the fuel system Fuel System Bleed Air Page 142 4 Operate the start switch of the generator Starting and Stopping Devices Installed during Manufacturing the Generator Page 87 to start the engine ...

Page 200: ... Normal Opera tion Thermo Switch Ac tivated Coolant temperature raised Restart the engine in the following order 1 Operate the engine at low idle speed to cool down immediately 2 Stop the engine 3 Check the coolant level 4 Check the ambient temperature 5 Bleed air from the cooling system 6 Check the radiator fan and fan belt 7 Check the coolant temperature 8 If no fault has been found restart the ...

Page 201: ...ir which reached its supply period will be terminated for supply However according to the scale of the demand and the production situation of the supplier it may be supplied In addition reproduction at your cost may be considered When Requesting Repair If you cannot restore the engine to normal operating condition in spite that the cause has been identified according to 11 TROUBLESHOOTING Page 187...

Page 202: ...sed to wipe off combustible material put it into a lidded can and obey the Waste Management and Public Cleansing Act to handle it as a special industrial waste It may cause a fire It could lead to environmental pollution If you violate rules you may be subject to penalties Do not discard waste oil into sewerage river lake or other similar places Be sure to discard waste oil in accordance with the ...

Page 203: ...strial waste It may cause a fire It could lead to environmental pollution If you violate rules you may be subject to penalties Do not discard waste oil into sewerage river lake or other similar places Be sure to discard waste oil in accordance with the applicable laws and regulations Keep away from fire when working with flammable substances such as volatile corrosion inhibitor or rust preventive ...

Page 204: ...ment and other local municipalities Asbestos was used in the parts of the engines that were manufactured in 2005 or earlier Therefore when discarding them obey the Waste Management and Public Cleansing Act If you violate rules you may be subject to penalties While discarding the engine body be sure to wear the appropriate personal protective equipment Without wearing or not properly wearing person...

Page 205: ...r than the genuine ones use the engine oil which meets Engine Oil Quality Standards Page 206 Do not mix and use engine oil of different types and or manufacturers In addition conduct the oil analysis earlier than the normal change interval and check the change interval If you use the engine oil which does not meet Engine Oil Quality Standards Page 206 for fault caused by the engine oil the warrant...

Page 206: ...3 100 C 212 F 13 5 to 15 5 Viscosity index JIS K 2283 Flash point C F 225 to 250 437 to 482 JIS K 2265 Base Num ber Hydrochloric acid method Sulfur content in fuel 1 0 weight or lower mgKOH g 10 or higher up to 13 JIS K 2501 0 2 weight or lower 8 or higher up to 13 Perchloric acid method 1 0 weight or lower 13 or higher up to 16 0 2 weight or lower 11 or higher up to 16 Acid Number mgKOH g 1 5 to ...

Page 207: ...ect combustion products An increase in the acid number will result in corrosion or wear of the inner parts of the engine such as cylinder liner and bearing due to sulfur content and the piston ring seizure due to sludge Water Content Water in oil promotes corrosion wear and decreases lubricity in sliding parts Flash Point The flash point is lowered by contamination with fuel Flash point is used to...

Page 208: ...the upper limit Table 14 2 Engine Oil Properties Properties Standard value Test standard Kinetic viscosity mm2 s 100 C Continuous use 30 or less rate of change from new oil 10 mm2 s or more JIS K 2283 2007 ISO 3107 ISO 2909 Emergency use 30 or less of the change rate from new oil 20 or less rate of change from new oil For portable 30 or less of the change rate from new oil 15 or less rate of chang...

Page 209: ...ng life coolant that prevent freezing of cooling water Do not use antifreeze alone instead of LLC Requirements for LLC LLC must be a homogeneous liquid without sediment When the LLC is diluted to 30 to 60 density the LLC must not cause any problems such as corrosion and precipitation deposits in the engine cooling system LLC must be mixed well with other non amine type LLC that meets this requirem...

Page 210: ...solu tion 150 ml or less defoaming time 5 sec or less Hard water compatibility 1 0 or less 50 volumetric water solution Corrosive to metal 88 2 C 190 4 3 6 F 336 2 Hr 30 volumetric wa ter solution eth ylene glycol 50 volumetric water solution propylene glycol Metallic 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 1...

Page 211: ... No significant discoloration No sig nificant changes such as separation and gel generation Ion con centration Iron copper alumi num zinc lead and ammonium ion 10 ppm or less Circulating corro sion 88 3 C 190 4 5 4 F 1000 2 Hr 30 vol umetric water solution ethylene glycol Metallic test piece Mass change Aluminum 0 60 mg cm2 Cast iron 0 30 mg cm2 Steel 0 30 mg cm2 Brass 0 30 mg cm2 Solder 0 60 mg c...

Page 212: ...er Tensile strength change rate 60 to 0 Elongation change rate 40 to 20 Volume change rate 0 to 40 Hardness change rate 20 to 10 Nitryl rubber Tensile strength change rate 0 to 10 Elongation change rate 15 to 15 Volume change rate 0 to 40 Hardness change rate 10 to 0 Ethylene pro pylene diene monomer Tensile strength change rate 0 to 10 Elongation change rate 30 to 0 Volume change rate 0 to 10 Har...

Page 213: ...n generates more severe corrosion than when plain soft water is used This is a typical problem caused by the use of inappropriate LLC Examples of Abnormalities Caused by LLC Amine Type Corrosion of Iron Parts Amines are generally effective in suppressing the rusting of ferrous metals but they are said to cause problems for copper parts If copper corrosion occurs in the cooling system due to loweri...

Page 214: ...tle Pub No OPERATION MAINTENANCE MANUAL K29001 00320 Mitsubishi Diesel Engine S16R S16R2 Revision History Revision Issued Description March 2018 First edition issued 1 July 2018 S16R2 PTAW C description of resin fan added ...

Page 215: ......

Page 216: ...Shanghai MHI Engine co Ltd Issued July 2018 Pub No K29001 00320 Address 2630 Jun Gong Road Shanghai China Tel 86 21 60652943 Fax 86 21 60652323 Http www sme sh cn ...

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