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Mitsubishi S6B3, Operation & Maintenance Manual

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Mitsubishi S6B3 Operation & Maintenance Manual Download Page 1

January

 201

1

Pub. No. 99670-101A0

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

OPERATION &
MAINTENANCE MANUAL

1

Summary of Contents for S6B3

Page 1: ...equested to read this Oper ation and Maintenance Manual carefully before operating the engine or conducting inspection and maintenance Never operate the engine or conduct maintenance work with out com...

Page 2: ......

Page 3: ...ntents which are overlapping between the chapters Please read this manual thoroughly before proceeding with operation inspection and maintenance work for correct use and servicing Failure to follow di...

Page 4: ...r use or against infringement of any patent Mitsubishi Heavy Industries Ltd will not be liable for any damages or consequential damages including but not limited to damages or other costs resulting fr...

Page 5: ...these regulations within the warranty period Warranty period Then its warranty period is 5 years or 3000 hours whichever comes first However if your engine warranty period is longer than the emission...

Page 6: ...road engine owner you are responsible for the performance of the required maintenance listed in your owner s manual Mitsubishi Heavy Industries Ltd recommends that you retain all receipts covering mai...

Page 7: ...statement in such writ ten instructions to the effect of repair or replace as necessary shall not reduce the period of warranty coverage Any such part repaired or replaced under the warranty shall be...

Page 8: ...hot air intake system B Intake manifold C Heat riser valve and assembly D Turbocharger supercharger systems E Charged air cooling systems 3 Exhaust gas recirculation EGR system A EGR valve body and ca...

Page 9: ...or devices and mount ing hardware D Pulleys belts and idlers E Emission control information labels F Any other part with the primary purpose of reducing emissions or that can increase emission during...

Page 10: ...be operated maintained and inspected only by qualified persons who have thor ough knowledge of engines and their dangers and who also have received risk avoidance training To prevent an accident do n...

Page 11: ...tions could lead to serious accidents which could result in personal injury or death in the worst case Understand the directions well and handle engines with following directions Indicates an immediat...

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

Page 13: ...ening and Closing Radiator Cap 1 4 Do Not Touch High Pressure Injection Fuel 1 4 Be Careful When Handling Fuel Engine Oil or LLC 1 5 Use Only Specified Fuel Engine Oil and LLC 1 5 Handle LLC Carefully...

Page 14: ...Cautions During Operation 3 14 Inspection During Operation 3 14 Stop 3 15 Emergency Stop 3 15 Inspection After Stopping 3 15 Chapter 4 FUEL Recommended Fuel 4 1 Handling Fuel 4 1 Fuel Specification 4...

Page 15: ...lectrical System 8 23 Starter Inspect 8 24 Alternator Inspect 8 24 Air Starter System 8 25 Air Strainer Drain Water and Clean 8 25 Air Tank Drain Water 8 25 Air Tank Inspect Safety Valve Operation 8 2...

Page 16: ...SSY LLC 6 1 Fig 8 1 Belt and Belt Tension Inspect and Adjust 8 2 Fig 8 2 Damper Check Visually 8 4 Fig 8 3 Damper Temperature Management 8 5 Fig 8 4 Fuel Tank Drain Water 8 6 Fig 8 5 Water Separator D...

Page 17: ...General Purpose Engine 7 9 Table 8 1 Ribbed Belt Tension Force 8 3 Table 8 2 Damper Temperature Management 8 4 Table 8 3 Thermo Label for Temperature Management 8 5 Table 8 4 Specific gravity of elect...

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Page 19: ...Cover Until Engine Cools Do not attempt to open the side cover of the crank case before the engine cools down Wait at least 10 minutes after stopping the engine Opening the cover when the engine is ho...

Page 20: ...e clothing or outfitting is caught by a rotating part serious bodily injuries could result Lockout and Tagout Be sure to lockout and tagout before starting inspec tion and maintenance Lockout and tago...

Page 21: ...ly When mounting generator on the engine use the special hanger of common bed Hangers of engine cannot be used When mounting marine gear on the engine be sure not to apply the load on the hangers of e...

Page 22: ...elds If any of these heat shields have been removed owing to unavoidable circumstances during the work be sure to restore them after the work is completed Be Careful of Opening and Closing Radiator Ca...

Page 23: ...normality Occurs Do Not Add Coolant Immedi ately After a Sudden Stop Due to Overheating If the engine stops suddenly or if you have no choice but stop the engine suddenly due to overheating do not add...

Page 24: ...can cause sparks that may result in an explosion Before servicing electrical components or conducting electric welding set the battery switch to Open OFF position or remove the plug from the negative...

Page 25: ...r balance between fuel injection volume and governor operation or overrunning of the engine which could re sult in a serious accident Perform All Specified Pre oper ation Inspections and Periodic Insp...

Page 26: ...following instructions Never service the air cleaner while the engine is run ning The turbocharger may suck particles of foreign materials into the engine and could result in serious accidents Remove...

Page 27: ...ution labels use a cloth water and soap Do not use cleaning solvents gasoline or other chemicals to prevent the letters from getting blurred or the adhesion from being weakened Replace damaged or frac...

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Page 29: ...ntake inlet Hanger Oil cooler Coolant drain cock Starter Oil drain plug Oil drain plug Oil filter Water pump Fan Bypass oil filter Alternator Coolant drain cock Coolant inlet Front Rear Coolant outlet...

Page 30: ...s located in the fuel control link is moved in the STOP direction the engine stops If the engine continues to operate even after the man ual stop lever is moved in the STOP direction cut off the fuel...

Page 31: ...ully and understand functions of each device Oil Pressure Unit Indicate the oil pressure Fig 2 6 Oil Pressure Unit Thermo Unit Always detect the coolant temperature of engine Fig 2 7 Thermo Unit Revol...

Page 32: ...lues and shapes vary depending on the engine specifications Oil Pressure Switch The oil pressure switch generates an alarm when the engine oil pressure becomes low and reaches the specified pressure F...

Page 33: ...er Indicator If the element is clogged the intake air is decreased and the red signal mark will be displayed The signal indicates only and does not generate an alarm Therefore the periodic visually in...

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Page 35: ...el 7 Refill fuel tank until fuel level gauge indicates FULL level line after checking the contact of float switch Check that the following contents are performed before the engine is operated Failure...

Page 36: ...ection pump by rotating about 1 5 turns 2 Move the priming pump up and down until the fuel flow from the air vent plug is free from air bubbles Push and turn the priming pump clockwise to lock in the...

Page 37: ...es Ltd as the priming pump needs to be changed Fig 3 4 Priming Pump Tightening Method Fig 3 5 Priming Pump Head Packing Never fail to tighten the priming pump to the speci fied angle If the priming pu...

Page 38: ...If the engine oil is low refill the specified engine oil 9 Check the oil pan and other area for oil leaks Re pair the oil leakage if any 10 While pulling the stop lever rotate the crankshaft for appro...

Page 39: ...ge if found 4 When coolant reaches the full level close the cool ant filler securely 5 While pulling the manual stop lever rotate the crankshaft for approx 10 seconds using the starter Stop the operat...

Page 40: ...e level is about 10 to 15 mm 0 39 to 0 59 in above the top of the plates If the electrolyte level is low remove the caps and add distilled water to the proper level Note When adding distilled water ad...

Page 41: ...el engine oil or coolant 3 At 30 minutes after the engine stop check the oil level with the oil level gauge The proper oil level is between the high and low marks on the oil level gauge 4 If the engin...

Page 42: ...dustries Ltd 3 Visually check bolts and nuts for looseness 4 Check the electrical wiring including the starters and alternator 5 Check that valves plugs or cocks are properly po sitioned Fuel feed val...

Page 43: ...3 The proper oil level is between the high and low marks on the oil level gauge If the engine oil goes over the high marks on the oil level gauge open the engine oil drain valve to drain oil If the en...

Page 44: ...ng 2 If the element is clogged the red signal mark will be displayed 3 Immediately clean or replace the air cleaner ele ment when the signal turns red 4 After checking press the bottom on top of the i...

Page 45: ...Tank Air Pressure Check 1 Check the air pressure gauge to see if the air pres sure in the air tank conforms to the standard 2 Open the air pressure gauge valve 3 Check air pressure in the air tank wi...

Page 46: ...ture periodically and check the abnor mality of temperature alteration Note For damper temperature limit and inspection re fer to Damper Inspect 8 4 Fig 3 17 Thermo label of damper If the abnormality...

Page 47: ...ction During Warm up During warm up operation walk around the engine and check for fuel oil coolant or exhaust gas leaks Before starting the engine check to make sure no one is near the engine and tha...

Page 48: ...erate the engine under a light load for break in operation Operating the new engine under heavy load or severe conditions during the break in period can shorten the service life of the engine Do not t...

Page 49: ...while engine parts are hot due to high speed operation can be a cause for heat up of the engine parts and shorten the engine life Before stopping the engine run the engine with the idle speed at low R...

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Page 51: ...ng with fuel in the tank and also gives time for dust and water to separate and settle at the bottom of the tank Before refilling clean the areas around the caps thoroughly and remove the caps from th...

Page 52: ...new type 45 or higher JISK2280 1996 ISO DIS 4264 Kinetic viscosity 2 0 mm2 s 0 0031 in2 s or more at 30 C 86 F 8 0 mm2 s 0 0124 in2 s or more at 30 C 86 F JIS K 2283 2000 ISO 3104 Sulfur content 0 2...

Page 53: ...WS 1 4 kPa 0 0143 kgf cm2 0 2031 psi ISO 12156 1 BDF Biodiesel fuel FAME Fatty Acid Methyl Ester BDF quality shall meet JIS K 2390 or ASTM D 6751 or EN14214 BDF blending of 5 by volume or less is app...

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Page 55: ...clas sification CF or CH 4 When using the CF class engine oil it must be certi fied according to API service classification CF by 2009 and satisfied the following Table 5 1 Recommended Limit of Engine...

Page 56: ...5 ISO 3679 ISO 2719 ISO 2592 Base number Hydrochloric acid method Sulfur contents of fuel 1 0 weight or lower mgKOH g 10 or higher up to 13 JIS K 2501 ISO 3771 ISO 6618 ISO 6619 ISO 7537 0 2 weight or...

Page 57: ...han the legally specified quantities be sure to have the work per formed by a service station operated under the provision of the law When removing oil from the engine or oil can use an oil pump Do no...

Page 58: ...h new oil Table 5 2 Table of engine oil properties Properties Standard Test method Kinetic Viscosity mm2 s in2 s 100 C 212 F 30 or less rate of change from new oil 10 mm2 s 0 155 in2 s or more JIS K 2...

Page 59: ...xidation or sulfurous acid or sulfuric acid derived by the combustion of sul fur content of fuel or the oil becomes contaminated with imperfect combustion products An increase in the acid number will...

Page 60: ...il due to abrasion by which worn parts can be located Water LLC or salt that should not be in engine oil can be detected Engine oil deteriorating conditions by which appropriate engine oil renewal int...

Page 61: ...fication Genuine LLC Mitsubishi Heavy Industries Ltd recommends the use of our genuine long life coolant GLASSY long life coolant Ethylene glycol type and Eco friendly prod uct PG GLASSY long life coo...

Page 62: ...ing malfunctions caused by the use of LLC that does not meet the following specifica tion General Demands of LLC LLC must be a homogeneous liquid without sedi ment When the LLC is diluted to 30 to 60...

Page 63: ...character ASTM D3306 01 30 vol 4 0 ml or less 331 3 vol 150 ml 0 032 gal or less Disappearance of bubble within 5 seconds Hard water adaptability 1 0 or less 50 vol Metallic causticity 88 2 C 190 4 3...

Page 64: ...mg cm2 Copper 0 30 mg cm2 Appearance of the specimen after testing No visible signs of corrosion on the surface excluding the area contacting to spacer However discoloration is acceptable Properties...

Page 65: ...6 5 Chapter 6 COOLANT Storage stability vol 30 vol room temperature 6 Hr 0 3 or less Table 6 2 LLC Specification Property Standard...

Page 66: ...life coolant Ethylene glycol type or PG GLASSY long life coolant Non amine type For determining the accurate LLC concentration refer to the instructions for the LLC used Should coolant or LLC be acci...

Page 67: ...sion than when plain soft water is used This is a typical problem caused by the use of inap propriate LLC Examples of Abnormali ties Caused by LLC Amine Type Pitting of Iron Parts Amines are generally...

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Page 69: ...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...

Page 70: ...r 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 p...

Page 71: ...ed engine Valve Clearance Inspect and Adjust Check valve mechanism at the same time 2 Every 1000 service hours Fuel Filter Replace 8 9 Water Separator Element Replace 1 8 7 Gauze Filter Clean 8 8 Belt...

Page 72: ...bridge guides valve bridges valve springs tappets camshaft thrust plates pistons piston pins connecting rod bolts connecting rod bushings rocker bushings fuel pipe assembly oil pipe assembly 2 Fuel I...

Page 73: ...oil pressure gauge coolant temperature gauge oil temperature gauge exhaust temperature gauge tachometer etc Every month Engine Oil for Mixing of Fuel and Water Inspect 8 14 Fuel Control Link Check 3 9...

Page 74: ...on Bolts Inspect 1 2 Couplings Inspect or Replace 1 2 Fuel system Fuel Tank Drain Water 1 8 6 Water Separator Drain Water 1 8 7 Fuel Injection Nozzle Spray Condition and Spray Pres sure Inspect and Ad...

Page 75: ...Devices Operation Check 1 High coolant temperature low oil pressure overspeeding starting failure water supply failure undervoltage overvoltage overcurrent low coolant level in tank low fuel level in...

Page 76: ...ck and Clean 1 8 18 Rubber Hose Replace 2 Air Cleaner Element Clean Check and Replace 1 8 21 Protective Devices Repair or Replace 1 Oil pressure gauge coolant temperature gauge oil temperature gauge e...

Page 77: ...ilter Alarm Lights 8 12 Governor Oil Filter Change 8 15 Belt and Belt Tension Inspect and Adjust 8 2 Radiator Fins Check and Clean 1 8 18 Exhaust Muffler Drain Water 1 8 19 Air Tank Inspect Safety Val...

Page 78: ...bers 2 Fuel Control Link Ball Joint Inspect 8 10 Damper Inspect 8 4 Air Cleaner Clean 2 Heat Exchanger Wash 2 8000 hours Engine Major Overhaul Disassemble Engine Clean Check and Change Major Parts 2 F...

Page 79: ...for looseness 3 Check the whole engine for leaks of fuel engine oil or coolant If leaks are found repair or contact your local dealer 4 Check that valves plugs or cocks are properly positioned Fuel fe...

Page 80: ...ning bolts of the alternator and ad justing plate 3 Move the alternator to adjust the belt tension 4 After adjusting tighten all retaining bolts of the al ternator and adjusting plate 5 Install the be...

Page 81: ...kgf 15 96 lbf 59 N 6 02 kgf 13 27 lbf 11 191 N 19 48 kgf 42 95 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 40 lbf 12 206 N 21 01 kgf 46 32 lbf 137 N...

Page 82: ...conditions Therefore observe the following suggestions and provide sufficient ventilation for the vibration damper and equipment 1 Make sure the temperature of the outside damper surface does not exce...

Page 83: ...mo label increased identify the abnormality of engine or other cause Then reattach new thermo label and check the change of temperature b If the temperature indication of thermo label comes close to t...

Page 84: ...h particles of foreign material such as dust dirt or water it can cause not only decrease of output but also malfunctions of the fuel system To avoid such a problem drain fuel tank as described below...

Page 85: ...rain fuel in the water separator 4 Close the all drain cocks after draining 5 Replace the element with a new one 6 Fill the water separator with fuel 7 Attach the water separator cover and tighten the...

Page 86: ...feed pump 2 Using a screw driver remove the gauze filter that is fitted inside the eye bolt 3 Soak the gauze filter in the fuel and clean it with a brush 4 After cleaning install the gauze filter int...

Page 87: ...bracket further rotate 3 4 to a full turn 8 After installing the new fuel filter bleed the fuel fil ter Note For bleeding the fuel filter refer to Fuel Filter Bleed Air 3 2 9 Start the engine and run...

Page 88: ...ated in the control link replace the control link when the ball joints have loos ened When installing ball joints be sure to tighten the nuts firmly Fig 8 10 Ball Joints For Looseness Inspect Fig 8 11...

Page 89: ...pressure fuel injection pipe wear If defective replace the high pressure fuel injection pipe with a new one In Every Other Major Overhaul Replace all clamp seats and high pressure fuel injec tion pipe...

Page 90: ...When draining oil or changing the oil filter wear gloves Hot engine oil and parts may cause burns Do not dump waste oil It is forbidden by law For disposal of waste oil consult a dealer of Mitsubishi...

Page 91: ...gauge open the engine oil drain valve to drain oil If the engine oil is low refill the specified engine oil 7 Install the oil filler cap after adding engine oil 8 Check the oil pan and other area for...

Page 92: ...ase contacts the mounting surface of the filter bracket further rotate the center bolt 1 2 to 3 4 turn 88 N m 9 kgf m 65 lbf ft Fig 8 15 Oil Filter and Bypass Oil Filter Replace Engine Oil for Mixing...

Page 93: ...plug after refilling engine oil 8 Operate the priming pump or wing pump to circu late engine oil Check to make sure oil does not leak from filter mounting surface If oil leaks tighten the filter agai...

Page 94: ...rain cocks and plugs and open the coolant drain cocks and plugs to drain the coolant Fig 8 19 Coolant Drain Cock Engine The service life of LLC is 2 years Be sure to change coolant at least once every...

Page 95: ...ng the specified concentration Note Determine the amounts of LLC and water to be added by using the LLC concentration chart For the coolant refer to COOLANT 6 1 For the coolant capacity refer to MAIN...

Page 96: ...the opposite direction of the normal air flow Note If the specification of radiator differs from the contents of this operation manual follow the manufacturer s operation manual Fig 8 21 Radiator fins...

Page 97: ...rbocharger Inspect Exhaust Muffler Drain Water Remove the drain plug and allow water to drain from the exhaust muffler Note If the specification of exhaust muffler differs from the contents of this op...

Page 98: ...will be displayed 3 Immediately clean or replace the air cleaner ele ment when the signal turns red Note a For cleaning of the air cleaner element refer to Air Cleaner Element Clean Check and Replace...

Page 99: ...ner Element Remove Fig 8 26 Air Cleaner Element Clean and Check When handling compressed air wear safety goggles a dust mask a hardhat gloves and other necessary protec tive gear Working without weari...

Page 100: ...r replacing the air cleaner element press the reset button to reset the indicator Note If the specification of air cleaner differs from the contents of this operation manual follow the manufacturer s...

Page 101: ...ittle by little Fig 8 28 Battery Electrolyte Level Inspect Specific Gravity of Battery Electrolyte Check If the specific gravity measured at 20 C 68 F is lower than 1 22 then charge the electrolyte Fi...

Page 102: ...sult a dealer of Mit subishi Heavy Industries Ltd Fig 8 30 Starter Inspect Alternator Inspect Visually check the alternator for damage Remove the belt and turn the pulley by hand to make sure that it...

Page 103: ...r in the tank is drained from drain pipe 2 After water is drained and the air is discharged in the tank tighten the drain valve firmly 3 Loosen the drain handle on the bottom of drain separator Check...

Page 104: ...en the air pressure value in the tank is over the standard Pressure in the air tank 2 94 MPa 30 kgf cm2 427 psi Safety valve operating pressure open 3 14 MPa 32 kgf cm2 455 psi Safety valve operating...

Page 105: ...coat of grease to the terminals and store the battery in a cool and dry room 11 Cover the whole engine Note a Store the engine in a well ventilated and dried indoor area b It is not necessary to drai...

Page 106: ...sure the engine oil pressure rises 13 Conduct a warm up operation for a sufficient duration to fit each part Note For starting the engine refer to Start 3 13 14 Apply load and increase the engine spee...

Page 107: ...hen mounting generator on the engine use the special hanger of common bed Hangers of engine cannot be used When mounting marine gear on the engine be sure not to apply the load on the hangers of engin...

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Page 109: ...embly sequence so that you can reassemble the component in reverse order of disas sembly Cautions Against Contamina tion Dust and foreign materials are the most common cause of rapid wear of parts Whe...

Page 110: ...Electrical system Faulty wire connection Check the DC fuse Check wiring connection between battery starter and starter switch Insufficiently charged battery Check alternator Refer to P8 24 Check and...

Page 111: ...on pipes Check faults and retighten fuel pipes and injection pipes Consult a dealer of Mitsubishi Heavy Industries Ltd Clogged fuel filter Inspect and replace fuel filter Refer to P8 9 Clean gauze fil...

Page 112: ...of Mitsubishi Heavy Industries Ltd Cooling system Overheat overcooled Check fan and heat exchange equipment Check control system Consult a dealer of Mitsubishi Heavy Industries Ltd Inlet and exhaust s...

Page 113: ...lt a dealer of Mitsubishi Heavy Industries Ltd Uneven fuel injection Check ignition noise exhaust smoke temperature Consult a dealer of Mitsubishi Heavy Industries Ltd Faulty fuel injection nozzle Con...

Page 114: ...Industries Ltd Uneven fuel injection Check ignition noise exhaust smoke temperature Consult a dealer of Mitsubishi Heavy Industries Ltd Inlet and exhaust systems Insufficient amount of air Check turb...

Page 115: ...ipes Consult a dealer of Mitsubishi Heavy Industries Ltd Cooling system Overcooled Check fan and heat exchanger Check control system Thermostat Inspect Consult a dealer of Mitsubishi Heavy Industries...

Page 116: ...cosity Analyze oil property Use appropriate engine oil Refer to P5 3 Engine oil temperature is high Check amount of engine oil and lubrication system Refer to P3 9 Check oil cooler and oil thermostat...

Page 117: ...of Mitsubishi Heavy Industries Ltd Table 11 9 Low Engine Oil Pressure Cause Remedies Lubricating system Insufficient amount of engine oil Check amount of engine oil and lubrication system Refer to P3...

Page 118: ...art the engine as described below 1 Return the starter switch to the OFF position 2 Add fuel to the fuel tank For filling fuel tank refer to Fuel Tank Oil Level Check 3 9 3 Bleed air from the fuel sys...

Page 119: ...43 888 1263 mm 64 68 x 34 96 x 49 72 in Dry weight Approx 1550 kg 3417 lb Fuel Diesel fuel Fuel injection pump BOSCH S7S Governor Mechanical mechanical oil pressure or electrical type Fuel filter Pape...

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