Operation Maintenance Manual S12U S16U Oct.2003 1

October 2003
OPERATION &
MAINTENANCE MANUAL
OPERATION&MAINTENANCE MANUAL
NOTE
The operator and supervisor are requested to read this
Operation and Maintenance Manual carefully before
operating the engine or conducting inspection and
maintenance.
Never operate the engine or conduct maintenance work
without completely understanding this manual.
October 2003
Pub.No. 99080-20120
Printed in Japan Pub.No. 99080-20120

INTRODUCTION
This manual contains information for operation, inspection and maintenance of the Mitsubishi Engines.
Please read this manual carefully to understand the operation, inspection and maintenance procedures in
order to use the engine properly.
Failure to follow directions in this manual can lead to serious accidents.
Pub.No. 99080-20120
INTRODUCTION
Limited Warranty
The manufacturer, at its option, will repair or replace any parts returned intact to the manufacturer only when
the manufacturer, upon inspection, determines to be defective in material and/or workmanship.
The foregoing shall constitute the limited warranty provided by the manufacturer.
The manufacturer will provide the limited warranty only to the user with whom the manufacturer concludes the
original contract, and shall not provide the limited warranty to a user to whom the ownership of the product
may be transferred.
• The manufacturer makes no warranties, either express or implied, except as provided in this manual, includ-
ing without limitation thereof, warranties as to marketability, merchantability, fitness for a particular purpose
or use, or against infringement of any patent.
• The manufacturer will not be liable for any damages or consequential damages, including without limitation
thereof, damages or other costs resulting from any abuse, misuse, misapplication of the engine and devices
supplied by the manufacturer.
• The manufacturer will not be liable for any damages or personal injuries resulting from any modification,
without the manufacturer's written permission, of the engine and devices supplied by the manufacturer.
• The manufacturer will not be liable for any damages or production losses caused by the use of fuel, engine
oil and/or long life coolant that are not recommended by the manufacturer.
INTRODUCTION
Important Information
the name and address of the new owner of the
• To avoid potential hazard, accident prevention engine.
activities must be planned methodically and con- • This manual is copyrighted and all rights are
ducted continually by considering all aspects of reserved. The drawings and technical reference,
engine operation, maintenance and inspection. including this manual, may not, in whole or in
Everyone including managers and supervisors part, be duplicated, photocopied, translated, or
should actively participate, recognize one's role reproduced in any electronic medium or machine
and organize oneself and one's work to ensure a readable form without prior written consent from
safe environment. the manufacturer.
• The foremost safety objective is to prevent acci- • The contents in this manual are subject to change
dents which could result in injury or death, or without notice for improvement of the engine.
damage equipment. • Your engine may differ from the photographs and
• Observe all related federal/national and local figures in this manual.
codes and regulations to reduce the possibility of Please note that, depending on specifications,
personal injury. items described in this manual may differ from
• The manufacturer cannot foresee all potential those on your engine in shape, or may not be
danger of the engine, potential danger resulting installed on your engine.
from human error and others, or danger caused • If you need more detailed information or have
by a specific environment in which the engine is questions, contact a Mitsubishi dealer.
used. • If this manual is misplaced, obtain a new copy
Since there are many actions that cannot be per- from a Mitsubishi dealer as soon as possible.
formed or must not be performed, it is not possi-
ble to indicate every caution in this manual or on
warning labels. As such, it is extremely important
to follow directions in this manual and also to take
general safety measures when operating, main-
taining and inspecting the engine.
• This manual has been prepared for people whose
native language is English. When the engine is
used by individuals whose native language is not
English, the customer is requested to provide
thorough safety guidance to the operators. Also
add safety, caution and operating signs that
describe the original warning label statements in
the native language of the operators.
• The engine must be operated, maintained and
inspected only by qualified persons who have
thorough knowledge of engines and their danger
and also received danger avoidance training.
• To prevent occurrence of an accident, do not
attempt to carry out any operation other than
those described in this manual, or to use the
engine for any unapproved purpose.
• When the ownership of the engine is transferred,
be sure to provide this manual with the engine to
the new owner. Also inform the manufacturer of
INTRODUCTION
Warnings
The following two methods are used to call the attention of the operators and maintenance personnel to the
potential danger of the engine.
• Warning statements in the manual
• Warning labels affixed on the engine
Warning Statements
The warning statements in this manual describe potential danger in operating, inspecting or maintaining the
engine by using the following five classifications to indicate the degree of potential hazard. Failure to follow
these directions can lead to serious accidents which can result in personal injury, or death in the worst case.
Indicates a highly hazardous situation which, if not avoided, can result in
death or serious injury.
Indicates a potentially hazardous situation which, if not avoided, can result
in death or serious injury.
in minor or moderate injury.
in property damage.
Note Indicates important information or information which is useful for engine

operation.
INTRODUCTION
Explanation of Terms
Abbreviations, Standards and Others
• API = American Petroleum Institute
• ASTM = American Society for Testing and Materials
• JIS = Japanese Industrial Standards
• MIL = Military Specifications and Standards (U.S.)
• MSDS = Material Safety Data Sheet
• SAE = Society of Automotive Engineers (U.S.)
• LLC = Long Life Coolant
Units of Measurement
Measurements are based on the International System of Units (SI), and they are converted to the metric sys-
tem units in this manual based on the following conversion rates.
• Pressure: 1 MPa = 10.197 kgf/cm2

• Torque: 1 N⋅m = 0.10197 kgf⋅m
• Force: 1 N = 0.10197 kgf
• Horsepower: 1 kW = 1.341 HP = 1.3596 PS
• Meter of mercury: 1 kPa = 0.7 cmHg
• Meter of water: 1 kPa = 10.197 cmH2O (cmAq)
• Engine speed: 1 min-1 = 1 rpm
CONTENTS
Chapter 1 Engine Oil and LLC............................. 1-4

BASIC SAFETY PRECAUTIONS Use only specified fuel, engine oil and coolant
Warning Fire and Explosion ...............1-1 (LLC).............................................................. 1-4
Keep flames away............................................ 1-1 Handle LLC carefully ........................................ 1-4
Keep engine and surrounding area clean ........ 1-1 Properly dispose of drained oil and LLC .......... 1-4
Never open crankcase until engine cools ........ 1-1 Caution Service Battery ..................... 1-5
Check for fuel, oil and exhaust gas leaks......... 1-1 Handle battery carefully ................................... 1-5
Use flameproof light ......................................... 1-1 Caution When Abnormality Occurs.... 1-5
Do not short electrical wires ............................. 1-1 If engine overheats, conduct cooling operation
Keep fire extinguishers and first-aid kit before stopping engine..................................... 1-5
nearby .............................................................. 1-1 If engine stops due to abnormality, exercise caution
Warning Stay Clear of All Rotating and when restarting................................................. 1-5

Moving Parts........................................1-2 If engine oil pressure drops, stop engine
Install protective covers on rotating parts......... 1-2 immediately ...................................................... 1-5
Check surrounding area for safety ................... 1-2 Caution Other Cautions ..................... 1-6
Stay clear of all rotating and moving parts while Never modify engine ........................................ 1-6
engine is operating........................................... 1-2 Never break seals ............................................ 1-6
Lock out and Tag out ....................................... 1-2 Perform all specified pre-operation inspections and
Always stop engine before inspection and periodic inspections.......................................... 1-6
maintenance..................................................... 1-2 Perform engine break-in................................... 1-6
Always return turning tools to original Warm up engine before use ............................. 1-6
position............................................................. 1-2 Never operate engine under overload
Warning Be Careful of Burns..............1-3 condition ........................................................... 1-6
Do not touch engine during operation or Conduct cooling operation before stopping
immediately after operation.............................. 1-3 engine .............................................................. 1-6
Open radiator filler cap carefully ...................... 1-3 Do not splash water on engine......................... 1-6
Add coolant only after coolant temperature Conduct proper maintenance of air cleaner/pre-
drops ................................................................ 1-3 cleaner ............................................................. 1-7
Do not dismount heat protection covers........... 1-3 Observe safety rules at workplace ................... 1-7
Warning Be Careful of Exhaust Fume Wear proper work clothes and protective gear. 1-7
Poisoning.............................................1-3 Use appropriate tools for maintenance work.... 1-7
Perform engine operation in a well-ventilated Cautions concerning transportation ................. 1-7
site ................................................................... 1-3 Do not operate engine continuously under low
Warning Protect Ears from Noises .....1-3 load .................................................................. 1-7
Wear earplugs.................................................. 1-3 Ventilate the engine room sufficiently .............. 1-7
Warning Be Careful When Lifting Do not touch high-pressure injection fuel ......... 1-7
Engine .................................................1-4 Caution About Warning Labels .......... 1-8
Lifting engine carefully ..................................... 1-4 Maintain and inspect warning labels ................ 1-8
Do not climb onto engine ................................. 1-4 Warning labels ................................................. 1-9
Always watch your footing................................ 1-4
Caution Be Careful of Handling Fuel,
CONTENTS-1
CONTENTS
Chapter 2
NAME OF PARTS Checking Battery.............................................. 3-6
Engine External Diagrams...................2-1 Electrolyte level..........................................................3-6
S12U Left View ................................................ 2-1 Checking specific gravity of electrolyte......................3-6
S12U Right View .............................................. 2-1 Checking loosened wire ................................... 3-6
S16U Left View ................................................ 2-2 Checking Valves for Open/Closed Position...... 3-7
S16U Right View ............................................. 2-2 Test Operation ................................................. 3-7
Equipment and Instrument ..................2-3 Normal Engine Operation ................... 3-8
Starting and Shutdown Devices ....................... 2-3 Preparations for Operation
Start Switch ............................................................. 2-3
(Pre-Start Inspection) ....................................... 3-8
Stop Switch ............................................................. 2-3
External Inspection ....................................................3-8
Start Lever ................................................................ 2-3
Manual Stop Lever.................................................... 2-3 Cleaning Fuel Filters (Wire-Element Type)................3-8
Instruments..........................................2-4 Checking Fuel Level in Tank .....................................3-9
Tachometer............................................................... 2-4 Draining Water from Fuel Tank..................................3-9
Hour Meter................................................................ 2-4 Checking Engine Oil Level.........................................3-9
Oil Pressure Gage .................................................... 2-4 Checking Coolant Level...........................................3-10
Oil Temperature Gage .............................................. 2-4 Inspection of Air Cleaner Indicator...........................3-10
Jacket Coolant Temperature Gage........................... 2-4 Draining Water from Air Starter Tank ......................3-11
Oil Cooler Coolant Temperature Gage ..................... 2-4 Inspection of Air Tank Air Pressure .........................3-11
Air Cooler Coolant Temperature Gage ..................... 2-4
Starting.............................................. 3-12
Jacket Coolant Pressure Gage................................. 2-4
Warming-up Operation ................................... 3-12
Oil Cooler Coolant Pressure Gage ........................... 2-4
Inspection of Oil Pressure........................................3-12
Air Cooler Coolant Pressure Gage ........................... 2-4
External Inspection during Warming-up...................3-12
Exhaust Temperature Gage ..................................... 2-4
Operation ....................................................... 3-13
Fuel Pressure Gage.................................................. 2-4
Inspection During Operation ....................................3-13
Inlet Pressure Gage.................................................. 2-4
Stopping ......................................................... 3-14
Engine Protection Devices ..................2-5
Low Oil Pressure Alarm ............................................ 2-5 Emergency Stop............................................. 3-14
High Coolant Temperature Alarm ............................. 2-5 Inspection After Stopping ............................... 3-14
Oil Filter Clog Alarm.................................................. 2-5
Overspeed Alarm...................................................... 2-5 Chapter 4
Using Turning Gear .............................2-6 MAINTENANCE
Chapter 3 Cautions Concerning Maintenance..... 4-1
Stop the engine before checking or adding fuel, oil or
OPERATION
coolant. ......................................................................4-1
Preparation for Operation of New or
Handle electrolyte carefully........................................4-1
Overhauled Engine..............................3-1
Handle LLC carefully. ................................................4-1
Fuel System ..................................................... 3-1
Always wear protective gear......................................4-1
Pouring fuel............................................................... 3-1
Use recommended fuel, engine oil and coolant.........4-1
Bleeding Fuel System............................................... 3-2
Perform all specified pre-start inspections and periodic
Bleeding Air from Fuel Filters
inspections.................................................................4-1
(Wire-Element Type)................................................. 3-2
Use only genuine Mitsubishi parts. ............................4-1
Bleeding Air from Fuel Feed Pipe............................. 3-3
Fuel ..................................................... 4-2
Lubricating System........................................... 3-4
Recommended Fuel ......................................... 4-2
Pouring engine oil ..................................................... 3-4
Handling Fuel ................................................... 4-2
Cooling System ................................................ 3-5
Engine Oil ........................................... 4-4
Pouring coolant......................................................... 3-5
Recommended Engine Oil ............................... 4-4
Electrical Systems............................................ 3-6
CONTENTS-2
CONTENTS
Selection of Oil Viscosity .......................................... 4-4 General definition of emergency engine ....................5-2
Handling Engine Oil ......................................... 4-5 General definition of general-purpose engine............5-2
Coolant ................................................4-6 Periodic Maintenance Chart for Engine in

Recommended Coolant ................................... 4-6 Regular Use ........................................ 5-3
Long Life Coolant (LLC) ................................... 4-6 Periodic Maintenance Chart for
Recommended LLC ......................................... 4-7 Emergency Engine.............................. 5-8
Features and Performance of Recommended Periodic Maintenance Chart for General-
LLC .................................................................. 4-7 Purpose Power Supply Engine ......... 5-13
Maintenance of LLC ......................................... 4-7
Replacement timing of LLC ...................................... 4-7 Chapter 6
LLC concentration..................................................... 4-7 PERIODIC INSPECTION AND
Importance of LLC............................................ 4-8 MAINTENANCE PROCEDURES
Characteristics of LLC Additive and Important Fuel System ........................................ 6-1
Notes................................................................ 4-8 Draining Water from Fuel Filters
Examples of Abnormalities Caused by LLC..... 4-8 (Wire-Element Type)..................................................6-1

Draining Water from Fuel Filters
Pitting on iron parts................................................... 4-8
(Center-Bolt Type) .....................................................6-1
Corrosion of aluminum parts..................................... 4-8
Draining Water from Fuel Tank..................................6-2
Pitting and clogging of radiator ................................. 4-8
Cleaning inside of Fuel Filters
Filters...................................................4-9
(Wire-Element Type)..................................................6-2
Electrical Parts.....................................4-9
Changing Fuel Filters (Center-Bolt Type)......... 6-3
Cautions in Operating Engine in Cold
Changing Fuel Filters (Cartridge Type) ............ 6-4
Weather Season................................4-10
Changing Fuel Filters with Engine Stop.....................6-4
Fuel ................................................................ 4-10
Changing Fuel Filters while Engine in
Engine Oil....................................................... 4-10
Operation...................................................................6-5
Coolant........................................................... 4-10
Inspection of Fuel Control Linkage Ball
Battery............................................................ 4-10
Joints ................................................................ 6-6
Maintenance After Cold Season .................... 4-10
Lubricating System ............................. 6-7
Changing Engine Oil, Oil Filters and Bypass Oil
Chapter 5 Filter ................................................................. 6-7
PERIODIC MAINTENANCE CHART Draining Engine Oil....................................................6-7
How to Use Periodic Maintenance Changing Oil Filters (S12U).......................................6-7
Chart....................................................5-1 Changing Oil Filters (Swithover Type)

Periodic Maintenance Chart............................. 5-1 (S12U) .............................................................. 6-8
Periodic maintenance chart for regular-use Changing Oil Filters with Engine Stop .......................6-8
engine ....................................................................... 5-1 Changing Oil Filters While Engine in Operation ........6-8
Periodic maintenance chart for emergency Changing Oil Filters (Swithover Type)
engine ....................................................................... 5-1 (S16U) .............................................................. 6-9
Periodic maintenance chart for general-purpose Changing Oil Filters with Engine Stop .......................6-9
engine ....................................................................... 5-1 Changing Oil Filters While Engine in Operation ........6-9
General Definition of Regular-Use Engine, Changing Bypass Oil Filter ......................................6-10
Emergency Engine and General-Purpose Pouring Engine Oil...................................................6-11
Engine .............................................................. 5-2 Inspection of Engine Oil Leakage After Replacing
General definition of regular-use engine................... 5-2 Oil Filter .......................................................... 6-11
CONTENTS-3
CONTENTS
Chapter 9
Inspection of Engine Oil for Mixing of Fuel and
TROUBLESHOOTING
Water.............................................................. 6-11
General Precautions ........................... 9-1
Analysis of Engine Oil Properties................... 6-12 Contact a Mitsubishi Dealer for Repair
Engine Oil Sampling Tool Sets and Ordering Service ............................................................. 9-1
Procedure ............................................................... 6-12
Examination before Work ................................. 9-1
Cooling System .................................6-13 Notes Regarding Contamination ...................... 9-1
Checking LLC Concentration ......................... 6-13
Notes Regarding Parts Handling...................... 9-1
Inspection and Replacement of Zinc Rods .... 6-13
Work Safety...................................................... 9-1
Changing Coolant .......................................... 6-14
Conditions Required for Proper Engine
Draining Coolant ..................................................... 6-14
Operation ......................................................... 9-2
Cleaning the Cooling System ................................. 6-14
Pouring coolant....................................................... 6-15 Troubleshooting .................................. 9-3
Engine Turns, But It Does Not Start ................. 9-3
Inlet and Exhaust Systems ................6-16
Inspection and Draining Water of Exhaust Pipes Engine Does Not Turn...................................... 9-5
and Exhaust Muffler ....................................... 6-16 Engine Output is Low.................................................9-6

Engine Knocks ................................................. 9-7
Draining Water From Air Cooler Chamber and
Engine Produces Large Amount of Smoke While in
Inspection for Water Leakage ........................ 6-16
Operation ......................................................... 9-8
Cleaning, Inspection and Changing
Engine Operates at High Speed and Does Not
Pre-Cleaner.................................................... 6-16
Stop .................................................................. 9-8
Cleaning, Inspecting and Changing Air Cleaner
Malfunction of Lubricating System ................... 9-9
Element .......................................................... 6-17
Air Starter System .............................6-18
Draining Water and Cleaning Air Starter Chapter 10
Strainer........................................................... 6-18 MAIN SPECIFICATIONS
Draining Water from Air Starter Compressor . 6-18 Main Specifications ........................... 10-1
Chapter 7
LONG-TERM STORAGE List of Illustrations
Storing Engine in Non-Operable Condition for More fig.1-1 Warning for flywheel entanglement..............1-9
Than 3 Months ................................................. 7-1 fig.1-2 Warning for moving parts .............................1-9
Preparation for Storage ............................................ 7-1 fig.1-3 Warning for oil mist ......................................1-9
Maintenance during Storage..................................... 7-1 fig.1-4 Caution for footing........................................1-9
Using Engine after Storage....................................... 7-1 fig.1-5 Caution for electric shock.............................1-9
Storing Engine in Operable Condition for More Than fig.1-6 Warning for rotating parts.............................1-9
3 Months .......................................................... 7-2 fig.1-7 Caution for burns .........................................1-9
Operating Engine for Maintenance Purposes........... 7-2 fig.1-8 Warning for rotating parts.............................1-9
fig.1-9 Caution for referring to manual ....................1-9
Chapter 8 fig.1-10 Caution for burns .........................................1-9
TRANSPORTATION fig.2-1 S12U engine left view ..................................2-1
Lifting Engine Carefully .................................... 8-1 fig.2-2 S12U engine right view ................................2-1
fig.2-3 S16U engine left view ..................................2-2
fig.2-4 S16U engine right view ................................2-2
fig.2-5 Start switch and stop switch.........................2-3
CONTENTS-4
CONTENTS
fig.2-6 Start lever.................................................... 2-3 fig.6-2 Draining water from fuel filter
fig.2-7 Manual stop lever........................................ 2-3 (center-bolt type) ..........................................6-1
fig.2-8 Air cleaner indicator .................................... 2-5 fig.6-3 Draining water from fuel tank .......................6-2
fig.2-9 Preparation for turning ................................ 2-6 fig.6-4 Cleaning inside of fuel filter
fig.2-10 Turning ........................................................ 2-6 (wire-element) type) .....................................6-2
fig.2-11 Locking turning gear.................................... 2-6 fig.6-5 Changing fuel filters (center-bolt type) .........6-3
fig.3-1 Priming pump operating method ................. 3-2 fig.6-6 Fuel filter switchover handle.........................6-4
fig.3-2 Bleeing air from fuel filters fig.6-7 Changing fuel filters (cartridge type) ............6-4
(wire-element type) ..................................... 3-2 fig.6-8 Fuel filter switchover handle.........................6-5
fig.3-3 Bleeding air from fuel filters fig.6-9 Changing fuel filters (cartridge type) ............6-5
(center-bolt type) ......................................... 3-2 fig.6-10 Inspection of the ball joints for
fig.3-4 Bleeding air from fuel filters looseness .....................................................6-6
(cartridge-type)............................................ 3-3 fig.6-11 Changing oil filter element (S12U) ...............6-7
fig.3-5 Fuel filter switchover cock ........................... 3-3 fig.6-12 Inspection of oil filter ....................................6-7
fig.3-6 Bleeding air from fuel feed pipe (1) ............. 3-3 fig.6-13 Changing oil filters (switchover type)........ 6-8
fig.3-7 Bleeding air from fuel feed pipe (2) ............. 3-3 fig.6-14 Changing oil filter elements..........................6-9
fig.3-8 Oil filler and oil level gage ........................... 3-4 fig.6-15 Oil filter switchover handle ...........................6-9
fig.3-9 Engine oil priming pump.............................. 3-4 fig.6-16 Changing bypass oil filters .........................6-10
fig.3-10 Coolant drain cock on the engine................ 3-5 fig.6-17 Inspection of bypass oil filter ......................6-10
fig.3-11 Coolant drain cock on the water pump........ 3-5 fig.6-18 Bypass oil filter ...........................................6-10
fig.3-12 Water tank coolant level.............................. 3-5 fig.6-19 Oil filler and level gage...............................6-11
fig.3-13 Inspecting electrolyte level .......................... 3-6 fig.6-20 Engine oil priming pump.............................6-11
fig.3-14 Inspecting specific gravity of electrolyte...... 3-6 fig.6-21 Engine oil sampling tool sets......................6-12
fig.3-15 Checking valves for open/closed fig.6-22 Zinc rod good/bad ......................................6-13
position........................................................ 3-7 fig.6-23 Coolant drain cock (on engine) ..................6-14
fig.3-16 Checking valves for open/closed position ... 3-8 fig.6-24 Coolant drain cock (on water pump) ..........6-14
fig.3-17 Cleaning fuel filter (wire-element type)........ 3-8 fig.6-25 Coolant drain cock on the engine...............6-15
fig.3-18 Draining water from fuel tank ...................... 3-9 fig.6-26 Coolant drain cock on the water pump.......6-15
fig.3-19 Oil filler and oil level gage ........................... 3-9 fig.6-27 Water tank coolant level.............................6-15
fig.3-20 Checking coolant level .............................. 3-10 fig.6-28 Inspection and raining water of exhaust pipes
fig.3-21 Air cleaner indicator .................................. 3-10 and exhaust muffler ...................................6-16
fig.3-22 Draining water from air starter tank........... 3-11 fig.6-29 Coolant drain cock on air cooler
fig.3-23 Inspection of air tank air pressure ............. 3-11 chamber .....................................................6-16
fig.3-24 Stop button................................................ 3-14 fig.6-30 Cleaning pre-cleaner..................................6-16
fig.3-25 Manual stop lever...................................... 3-14 fig.6-31 Removal of air cleaner element .................6-17
fig.4-1 Recommended fuel ..................................... 4-2 fig.6-32 Cleaning air cleaner element .....................6-17
fig.4-2 Recommended fuel according to air fig.6-33 Inspecting air cleaner element ...................6-17
temperature................................................. 4-2 fig.6-34 Air cleaner indicator ...................................6-17
fig.4-3 Recommended oil viscosity according to air fig.6-35 Air starter strainer.......................................6-18
temperature................................................. 4-4 fig.6-36 Air starter compressor................................6-18
fig.6-1 Draining water from fuel filter fig.8-1 Hangers for lifting .........................................8-1
(wire-element type) ..................................... 6-1 fig.8-2 Lifting the engine..........................................8-1
CONTENTS-5
CONTENTS
List of Tables
Table 3-1 Specific gravity of electrolyte .................. 3-6
Table 3-2 Data for rated speed............................. 3-13
Table 4-1 Recomended Fuel .................................. 4-2
Table 4-2 Fuel Use Limit Property Guideline .......... 4-3
Table 4-3 Water quality standards.......................... 4-6
Table 4-4 Recommended brands of LLC................ 4-7
Table 4-5 Recommended LLC concentration (for
reference only)........................................ 4-7
Table 5-1 Periodic maintenance chart for engine in
regular use.............................................. 5-3
Table 5-2 Periodic maintenance chart for emergency
engine..................................................... 5-8
Table 5-3 Periodic maintenance chart for general-
purpose power supply engine............... 5-13
Table 6-1 Engine oil sampling tool sets ................ 6-12
Table 7-1 Recommended rust-preventive
oil and corrosion inhibitor........................ 7-1
Table 9-1 Conditions required for proper engine
operation................................................. 9-2
Table 9-2 Engine turns, but it does not start ........... 9-3
Table 9-3 Engine does not turn .............................. 9-5
Table 9-4 Engine output is low ............................... 9-6
Table 9-5 Engine knocks ........................................ 9-7
Table 9-6 Engine produces large amount of smoke while
in operation............................................. 9-8
Table 9-7 Engine operates at high speed and does not
stop......................................................... 9-8
Table 9-8 Malfunction of lubrication system ........... 9-9
Table 10-1 Main specifications table ...................... 10-1
CONTENTS-6
Chapter 1
BASIC SAFETY PRECAUTIONS
Warning Fire and Explosion
Keep flames away Check for fuel, oil and exhaust
Store fuel and engine oil in a gas leaks
well-ventilated area. Inspect fuel, oil and exhaust pipes regularly for
Make sure that the caps of fuel damage and looseness. If a fuel, oil and exhaust
and engine oil containers are gas leak is found, repair the leakage immediately.
tightly closed, and store them in Fuel or oil spilled on a hot surface of the engine,
the designated site. and exhaust gas blown onto a combustible material
Do not use flames or smoke where fuel or oil is may cause fire and result in personal injury and/or
handled or cleaning solvent is used for washing damage to equipment.
parts.
Spilled fuel, oil and LLC should be wiped immedi- Use flameproof light
ately and thoroughly. Spilled fuel, oil and LLC can When inspecting fuel, engine oil, coolant, battery
ignite and cause fire. electrolyte, etc., use a flameproof light. An ordinary
light may ignite and cause an explosion.
Keep engine and surrounding
area clean Do not short electrical wires
Do not store combustible (such as fuel, engine oil Before inspecting or servicing any electrical compo-
and LLC), explosive or dangerous materials near nent, disconnect the ground cable from the nega-
the engine. Those substances can cause a fire or tive (-) battery terminal to prevent short-circuit and
explosion. fire.
Keep the engine and the surrounding area free of Loose terminals or damaged cables/wires can
dust, dirt and foreign materials, since they can cause a short-circuit that may result in fire. Before
cause fire or the engine to overheat. operating the engine, inspect the cables and wires,
Clean the top surface of the battery after perform- and repair or replace if necessary.
ing maintenance work. Dust on the battery may
cause a short-circuit. Keep fire extinguishers and first-
The engine must be used at least 1 m [3.3 ft.] away
aid kit nearby
from buildings and other equipment to prevent pos-
Keep fire extinguishers nearby,
sible fire caused by engine heat.
and be familiarized with their
usage.
Never open crankcase until Keep a first-aid kit at the desig-
engine cools nated place, and make sure it is
If the cover is opened while the engine is still hot, easily accessible at anytime.
fresh air comes into crankcase and oil mist can be Establish response procedures to follow in the
ignited by engine heat, then it may lead to the event of fire or accident, and post information con-
explosion of the engine. cerning emergency contact locations and their con-
Never open the engine crankcase cover before the tact methods.
engine becomes cool, wait at least 10 minutes after
the engine stops.
1-1
Chapter 1 BASIC SAFETY PRECAUTIONS
Warning Stay Clear of All Rotating and Moving Parts

Install protective covers on rotat- Lock out and Tag out
ing parts Be sure to lock out and tag out before starting
Make sure the protective covers of inspection and maintenance.
the engine are correctly installed. Lockout and tagout are effective methods of cutting
Repair any damaged or loose covers. off machines and equipment from energy sources.
When the engine is coupled to other To lock out and tag out, pull out the key from the
equipment or the radiator, install pro- starter switch, turn off the battery switch, and post a
tective covers on the exposed connecting belt and tag on the starter switch indicating “Do Not Oper-
coupling. ate.” The starter key switch should be kept by the
Never remove protective covers for rotating parts person performing the inspection and maintenance.
such as the damper cover, camshaft cover or For the air starter system, close the main valve of
rocker cover while the engine is operating. the air tank, and post a tag indicating “Do Not Open
the Valve.”
Check surrounding area for safety

Before starting the engine, check to make sure no Always stop engine before
one is near the engine and tools are not left on or inspection and maintenance
near the engine. Verbally notify persons within the Be sure to stop the engine before conducting
immediate area when starting the engine. inspection and maintenance. Never attempt to
When the starter device is posted with a sign that adjust the engine parts while the engine is running.
prohibits startup operation, do not operate the Conducting inspection and maintenance on an
engine. operating engine can result in a serious accident of
entanglement by rotating parts.
Stay clear of all rotating and mov-
ing parts while engine is operat- Always return turning tools to
ing original position
Do not approach rotating and moving Be sure to remove all turning tools used during
parts of the engine while the engine is maintenance and inspection.
in operation. Starting the engine with the turning tools inserted or
Rotating parts can entangle your turning gears engaged may not only cause engine
body or tools and result in serious damage but personal injury as well.
injury.
Keep items that can be easily entangled by rotating
parts away from the engine.
If your body or tool contacts rotating and moving
parts, serious injury may occur as a result.
1-2
Warning Be Careful of Warning Be Careful of

Burns Exhaust Fume Poisoning
Do not touch engine during oper- Perform engine operation in a
ation or immediately after opera- well-ventilated site
tion Exhaust gas from the engine
Do not touch the main and exhaust contains carbon monoxide and
parts of the engine during operation other harmful substances.
or immediately after operation to Do not operate the engine in an
prevent burns. enclosed area (inside a ware-
To conduct maintenance and house, tunnel, etc.) or in a site where all sides are
inspection, wait until the engine cools sufficiently as blocked, since exhaust fumes can cause gas poi-
indicated with the temperature gage. soning.
If the engine must be operated in an enclosed area,
Open radiator filler cap carefully discharge the exhaust gas to the outside and pro-
Never open the radiator filler cap while the engine vide adequate ventilation.
is operating or immediately after it is stopped. Connect an exhaust duct to the exhaust pipe to
The engine coolant is hot during engine operation lead exhaust gas to the outside, and make sure
and immediately after operation. If the radiator filler exhaust gas does not leak from the duct joints.
cap is opened when the coolant is at operating tem- Make sure the exhaust gas does not blow in the
perature, steam and hot coolant may blow out, direction of plants or animals.
causing skin burns as a result.
When opening the cap, stop the engine and allow
the coolant temperature to drop sufficiently. Cover
Warning Protect Ears
the cap with a cloth or use thick rubber glove, and from Noises
then slowly open the cap.
When closing the cap, be sure to tighten securely. Wear earplugs
Be sure to wear earplugs when
Add coolant only after coolant entering into the engine room.
temperature drops The earplugs can be quite use-
Do not add coolant immediately after the engine ful to protect ears from various
stops. Wait until the coolant temperature lowers engine noises.
sufficiently to prevent burns.
Do not dismount heat protection

covers
The high-temperature exhaust components are
installed with heat protection covers. Do not dis-
mount these heat protection covers. If they must be
removed during inspection and maintenance, be
sure to reinstall them after completing the inspec-
tion and maintenance.
1-3
Warning Be Careful Caution Be Careful of

When Lifting Engine Handling Fuel, Engine Oil
and LLC
Lifting engine carefully
To lift the engine, use slings capa- Use only specified fuel, engine oil
ble of supporting the weight of the
and coolant (LLC)
engine.
Use fuel, oil and LLC specified in this manual, and
Attach appropriate slings to the
handle them carefully.
hangers on the engine.
Use of any other fuel, oil or LLC, and improper han-
Keep the engine balanced during lifting by consid-
dling may cause various engine problems and mal-
ering the center of gravity of the engine.
functions.
Keep the angle formed by slings attached to hang-
Obtain the MSDSs issued by the fuel, oil and LLC
ers within 60°. If the angle exceeds this limit, exces-
suppliers, and follow the directions on the MSDSs
sive load is applied on the hangers and may
for proper handling.
damage the hangers.
If wire ropes contact the engine, place a cloth or
other soft padding to prevent damage to the engine
Handle LLC carefully
Wear safety mask and rubber gloves when han-
and wire ropes.
dling LLC. Avoid contact with skin and eyes to pre-
vent personal injury.
Do not climb onto engine Should LLC be accidentally swallowed, induce
Never climb onto the engine.
vomiting immediately and seek medical attention.
To work on parts located on the upper section, use
Should LLC enter eyes, flush immediately with
a ladder, stand, etc.
plenty of water and seek medical attention. If LLC is
Climbing on the engine can not only damage entire
spilled on skin or clothes, wash immediately with lot
parts, but also cause parts to fall off and result in
of water.
injury.
Keep flammable materials away from LLC to pre-
vent fire. Never use flames or generate sparks near
Always watch your footing LLC since flames or sparks can cause fire.
Use a stable work platform to Drained LLC is harmful. Do not dispose of into con-
stand on when working on the ventional sewage. Contact a Mitsubishi dealer for
upper part of the engine and the disposal of drained LLC.
other hard-to-reach places.
Standing on a decrepit stand or
Properly dispose of drained oil
parts box may result in personal injury.
and LLC
Do not put obstacles on the stand.
Do not dispose of engine oil, used cleaning oil or
LLC into conventional sewage.
Prepare drip pan or other containers to receive oil
and LLC drained from the engine. Do not drain
them directly onto the ground.
For disposal of drained oil and LLC, consult a Mit-
subishi dealer.
1-4
Caution Service Bat- Caution When Abnor-

tery mality Occurs
Handle battery carefully If engine overheats, conduct cool-
• Batteries release flammable ing operation before stopping
hydrogen gas and oxygen. engine
Never use flames or generate If the engine overheats, do not stop the engine
sparks near the battery since immediately. Abrupt stopping of an overheated
flames or sparks can cause engine may cause the coolant temperature to rise,
an explosion. resulting in seizing of the engine. If the engine over-
• Do not use the battery when the fluid surface is heats, operate the engine at low idling speed (cool-
lower than the minimum required level. Using a ing operation), and stop the engine after the coolant
battery with a low electrolyte level can result in an temperature lowers sufficiently.
explosion. Do not add coolant immediately after stopping the
• Do not short the battery terminals with a tool or engine. Adding coolant to a hot engine may cause
other metal object. damage to the cylinder head from sudden change
• When disconnecting battery cables, remove the in temperature. Add coolant gradually after the
cable from the negative (-) terminal first. When engine cools to room temperature.
reconnecting cables, attach the cable to the posi-
tive (+) terminal first.
If engine stops due to abnormal-
• Charge the battery in a well-ventilated area, with
ity, exercise caution when restart-
all filling hole plugs removed.
• Make sure the cable clamps are securely
ing
If the engine stops due to an abnormality, do not
installed on the battery terminals. A loose cable
restart the engine immediately. If the engine stops
clamp can cause sparks that may result in an
with an alarm, check and correct the cause of the
explosion.
problem before restarting. Operating the engine
• Before servicing electrical components or con-
without correcting the problem may result in serious
ducting electric welding, set the battery switch to
engine problems.
the [OFF] position or disconnect the cable from
the negative (-) battery terminal to cut off the
electrical current. If engine oil pressure drops, stop
• Electrolyte contains dilute sulfuric acid. Careless engine immediately
handling of the battery can cause loss of sight If the engine oil pressure decreases, stop the
and burns. engine immediately, and inspect the lubricating sys-
• Wear safety goggles and rubber gloves when tem including the oil level and pump. Operating the
working with the battery (replenishment of fluid, engine with low oil pressure may cause seizing of
charging, etc.) bearings and other parts.
• If electrolyte is spilled on skin or clothes, wash
immediately with lots of water. Then, use soap to
clean thoroughly.
• If electrolyte enters eyes, flush immediately with
lots of fresh water and see a physician as soon as
possible.
• Should you accidentally swallow electrolyte, gar-
gle with plenty of water, then drink lots of water.
Consult a physician immediately.
1-5
Caution Other Cautions

Never modify engine Warm up engine before use
Unauthorized modification of the engine will void If the auxiliary devices for the starter (water heater,
the maker's warranty. engine oil priming pump etc.) are not installed, let
Modification of the engine may not only cause the engine idle for 5 to 10 minutes before using the
engine damage but may result in personal injury as engine for work.
well. Warm-up operation circulates lubricants in the
If there is a need to modify the engine, please con- engine and contributes to a longer service life and
tact a Mitsubishi dealer. economical operation.
Do not conduct warm-up operation for an extended
Never break seals period of time. Prolonged warm-up operation
To ensure proper engine operation, the fuel control causes carbon build-up in the cylinders that leads
links are attached with seals that prevent accidental to incomplete combustion.
change of the injection volume and rotation speed
settings. Operating the engine without these seals Never operate engine under over-
in place can result in the following problems, and load condition
also invalidates the warranty. If the engine shows an overload condition such as
• Rapid wear of moving and rotating parts the emmision of exhaust smoke, decrease the load
• Engine damage such as seizing of engine parts immediately so that the engine operates at appro-
• Increased consumption of fuel and lubricating oil priate output and load.
• Degradation of engine performance due to Overloading the engine causes not only high fuel
improper balance between fuel injection volume consumption but also excessive carbon deposits
and governor operation. inside the engine. Carbon deposits cause various
problems and can shorten the service life of the
Perform all specified pre-opera- engine.
tion inspections and periodic
inspections Conduct cooling operation before
Conduct the pre-operation inspections and periodic stopping engine
inspections as described in this manual. Before stopping the engine, let it idle at low speed
Failure to conduct the specified inspections may for 5 to 6 minutes to cool.
cause various engine problems and damage to Stopping the engine immediately after high-speed
parts, as well as serious accidents. operation can cause engine parts to heat up and
shorten the service life of the engine.
Perform engine break-in During cooling operation, check the engine for
Break in a new engine by operating it with a light abnormalities.
load and at a speed lower than normal during the
first 50 hours of operation. Do not splash water on engine
Operating a new engine under high load or severe Do not allow rainwater, etc., to enter the engine
conditions during the break-in period can shorten through the air inlet or exhaust openings.
the service life of the engine. Do not wash the engine while it is in operation,
since the engine may suck in the cleaning fluid
(water). If the engine is started with water inside the
combustion chambers, water hammer action can
damage the engine and result in serious accidents.
1-6
Conduct proper maintenance of Use appropriate tools for mainte-

air cleaner/pre-cleaner nance work
The major cause of abnormal wear on engine parts Use appropriate tools according to the type of
is dust entering with intake air. Worn parts result in maintenance work, and use them correctly.
an increase of oil consumption, decrease of output, If tools are damaged, replace with new tools.
and starting difficulties. Conduct maintenance of
the air cleaner/pre-cleaner according to the follow- Cautions concerning transporta-
ing directions to ensure optimum air filtering perfor- tion
mance. When transporting the engine using a truck, con-
• Do not conduct maintenance of the air cleaner/ sider the engine weight, width and height to ensure
pre-cleaner while the engine is operating. safety. Abide by the pertinent laws and regulations.
Without the air cleaner/pre-cleaner in place, the
turbocharger can suck foreign particles into the
Do not operate engine continu-
engine, decrease the load immediately so that
the engine operates at appropriate output and
ously under low load
When operating the engine with a 30 % load or
load.
lower, limit each operation to 10 minutes. Operating
• When removing the air cleaner, do not allow dust
the engine under low load tends to result in
attached on the air cleaner/pre-cleaner to enter
unburned fuel, which can adhere on internal engine
into the engine.
parts to cause malfunctions and shorten the engine
• If equipped with a dust indicator, conduct mainte-
service life.
nance only when the clog warning sign appears.
While servicing the air cleaer/pre-cleaner, do not
let dust enter into the air cleaner/pre-cleaner, Ventilate the engine room suffi-
damage or deform the element. ciently
Be sure to provide sufficient ventilation in the
Observe safety rules at workplace engine room. Insufficient air in the room can cause
Observe the safety rules established at your work- the engine temperature to rise and the output
place when operating and maintaining the engine. power and performance to lower.
Do not operate the engine if you are feeling ill. It is highly recommended to calculate the required
Operation of the engine with reduced awareness amount of air supply to the engine and install an
may cause accidental operations that may result in appropriate ventilation system before installing an
accidents. In such case, you should inform your engine.
supervisor of your condition.
When working in a team of two or more persons, Do not touch high-pressure injec-
use specified hand signals to communicate among tion fuel
the workers. Should injected fuel leak from a fuel injection pipe,
do not touch the spurting fuel.
Wear proper work clothes and Fuel in the fuel injection pipes is under high pres-
protective gear sure. Touching high-pressure fuel can cause the
Wear the work clothes specified by your workplace. fuel to penetrate the skin and result in gangrene.
Wear a hardhat, face shield, safety shoes, dust pro-
tective mask, gloves and other protective gear as
needed.
When handling compressed air, wear safety gog-
gles, hardhat, gloves and other necessary protec-
tive gear. Compressed air may cause personal
injury when not wearing the proper protective gear.
1-7
Caution About Warning Labels

Maintain and inspect warning
labels
Make sure all warning labels are legible.
If the description and/or illustration on a warning
label cannot be seen clearly, clean or replace the
label.
To clean warning labels, use a cloth, water and
soap. Do not use solvents, gasoline or other chemi-
cals to clean warning labels. Cleaning with chemi-
cals may cause the labels to peel off.
If warning labels are damaged or missing, replace
with new labels.
If a part of the engine with warning label is replaced
with new part, also attach new warning label to the
new part.
To obtain replacement warning labels, contact a
Mitsubishi dealer.
1-8
Warning labels
fig.1-1 Warning for flywheel fig.1-2 Warning for moving parts fig.1-3 Warning for oil mist
entanglement
fig.1-4 Caution for footing fig.1-5 Caution for electric shock fig.1-6 Warning for rotating parts
fig.1-7 Caution for burns
fig.1-8 Warning for rotating parts
fig.1-9 Caution for referring to manual
fig.1-10 Caution for burns
1-9
Chapter 2
NAME OF PARTS
Engine External Diagrams
The external diagram is for standard type of S12U/S16U engine.
The installed equipment and shapes differ on the engine type.
S12U Left View
Turbocharger
Silencer, pre-cleaner
Pipe cover
Cylinder head Air cooler
Fuel filter
Fuel injection pipe
(center-bolt type)
Fuel injection pump Air cooler chamber
water drain cock
Air starter main pipe
Governor
Distributor
Governor oil filter
Rear
Front
Fuel feed pump
Breather
Oil level gage Fuel priming pump
Low temoerature Fuel filter
water pump (wire-element type)
Oil pump Timing gear case
Front gear case Oil filler Crankcase side cover
Nameplate Bypass oil filter
fig.2-1 S12U engine left view
S12U Right View

%

$ "

!

#

!"

&'$

#

fig.2-2 S12U engine right view
2-1
Chapter 2 NAME OF PARTS
S16U Left View
Fuel injection pipe
Turbocharger Fuel injection pump

Pipe cover
Silencer Cylinder head

Fuel filter
Pre-cleaner
(center-bolt type)
Air starter Coolant drain cock
main pipe Governor
Damper cover
Rear
Front Governor oil filter
Damper
Breather Fuel feed pump
Oil filler Fuel priming pump

Low temperature
water pump Fuel filter
(wire-element type)
Front gear case
Nameplate Crankcase side cover
Oil level gage Bypass oil filter
fig.2-3 S16U engine left view
S16U Right View

!

"

#
!

#$% &
%

fig.2-4 S16U engine right view
2-2
Equipment and Instrument

Starting and Shutdown Devices
The shape and type of the starting and shutdown devices may vary from those described below depending on
the engine specifications.
Start Switch
When the start switch on the operation panel is START STOP
pressed, starting air is supplied to the air starter
system and cranks the engine.
Stop Switch
When the stop switch on the operation panel is
pressed, the shutdown cylinder operates and
moves the control shaft of the fuel injection pump to
the no-injection position to shut down the engine
fig.2-5 Start switch and stop switch
operation.
Start Lever
The start lever is provided on the air starter pipe.
When the lever is moved toward the OPEN posi-
tion, air flows and cranks the engine. Once the
engine starts, return the lever to the CLOSE posi- Start lever
tion immediately.
OPEN
CLOSE
From air starter tank

fig.2-6 Start lever
Manual Stop Lever

Use the manual stop lever to shut down the engine

in the event of an emergency.

If the stop button is not working, use the manual
stop lever. The lever is installed to the fuel control
link and when the lever is moved in the STOP
direction, the engine stops operation.
Should the engine continue operating even after
the manual stop lever is operated, cut off the fuel
supply to stop the engine.
fig.2-7 Manual stop lever
2-3
Instruments
The instruments indicate the internal conditions of Oil Cooler Coolant Pressure Gage
the engine in operation. In normal operation, record This indicates the coolant pressure in the oil cooler.
the numerical values indicated on the instruments
at regular intervals. If the numerical value is far dif-
Air Cooler Coolant Pressure Gage
ferent from that in normal operation, the indications
This indicates the coolant pressure in the air cooler.
of the instruments allow prompt judgment of engine
problems.
The instrument shape (round, square) and indica-
Exhaust Temperature Gage
tion type (analog, digital) can vary depending on This indicates the temperature of exhaust gas at
the engine specifications. the cylinder outlets or turbocharger inlet or outlet.
Tachometer Fuel Pressure Gage

This indicates the engine revolutions per minute This indicates the pressure of fuel supplied to the
(rpm). fuel injection pump by the fuel feed pump.
Note: The tachometer may have a built-in hour
meter. Inlet Pressure Gage
This indicates the pressure of inlet supplied to the
Hour Meter air cooler.
This indicator shows cumulative engine operating
hours.
Use the meter indication as a guigeline for deter-
mining the need for regular inspection and servic-
ing.
Oil Pressure Gage

This indicates the engine oil pressure.
Oil Temperature Gage

This indicates the engine oil temperature.
Jacket Coolant Temperature Gage

This indicates coolant temperature inside of the
crankcase.
Oil Cooler Coolant Temperature Gage

This indicates coolant temperature in the oil cooler.
Air Cooler Coolant Temperature Gage

This indicates coolant temperature in the air cooler.
Jacket Coolant Pressure Gage

This indicates the pressure of coolant in the crank-
case, cylinder heads and other parts.
2-4
Engine Protection Devices

The engine protection devices activate an alarm when an abnormality occurs in the engine in order to protect
the engine and prevent serious problems and accidents. When a protection device is activated, stop the
engine, examine the cause of the abnormality, and take corrective measures.
If the cause of the problem is unknown, contact a Mitsubishi dealer.
Protection devices installed on the engine and their types (setting values) and shapes vary depending on the
engine specifications. The following describes the typical protection devices installed in a Mitsubishi engine.
Low Oil Pressure Alarm

The oil pressure switch activates an alarm when the engine oil pressure drops to an abnormally low level.
High Coolant Temperature Alarm

The high coolant temperature alarm device generates a warning or stops the engine when the coolant tem-
perature rises to an abnormally high level due to an engine malfunction or other reason.
Oil Filter Clog Alarm

The oil filter clog detector generates a warning when the oil filter becomes clogged and causes an abnormally
large pressure difference between before and after the oil filter. When it generates an alarm, replace it with a
new filter immediately and change engine oil, as well.
Overspeed Alarm
The overspeed alarm device generates a warning and stops the engine operation when the engine speed
starts operating at abnormally high speed due to an engine malfunction or other reason.
Air Cleaner Clog Alarm (Air Cleaner Indicator)

A red signal appears as a warning when the air cleaner
element becomes clogged and causes an abnormally
large pressure difference between before and after the
air cleaner. When a red signal appears, clean the air
cleaner element immediately or replace it with a new
element.
After the element is cleaned or replaced, press the
reset button located at the upper part of the indicator to
cancel the red signal.
Signal
While serving the air cleaner, do not enter dust into the
Reset button
air cleaner or damage the element. fig.2-8 Air cleaner indicator
2-5
Using Turning Gear
Before starting the engine, return (pull out) the turning gear to the original position. Starting the engine with the
turning gear pushed in not only damages the ring gear but also may result in personal injury.
1 Untighten the retaining bolt.
2 Move the turning gear fully to engage the ring gear
and tighten the bolt.
Turning gear
shaft
Retaining bolt
fig.2-9 Preparation for turning

3 Turn the shaft using the socket wrench and the
rachet handle.
Rachet handle
Socket
Shaft
fig.2-10 Turning
4 After turning, move the turning gear, disengage the
turning gear with the ring gear and tighten the retain-
ing bolt.
Shaft
Make sure the lock pin is securely inserted.
Retaining bolt
fig.2-11 Locking turning gear
2-6
Chapter 3
OPERATION
Preparation for Operation of New or Overhauled Engine
Before operating a new or overhauled engine, do the following inspection. For second operation onward, do
the following normal operation outlined on page 3-8 "Normal Engine Operation".
Fuel System
When handling fuel, make sure there are no flames near the engine.
Wipe any spilled fuel completely. Spilled fuel can ignite and cause fire.
Do not remove the strainer when filling the fuel tank.

Use fuel specified in "Fuel" (4-2).
Pouring fuel
1 Make sure the insides of the fuel tank and fuel pipes are clean.
2 Pour fuel into the fuel tank.
3 Remove the fuel feed pipe and drain plug from the fuel inlet of the engine, and check the discharged fuel
for dust particles.
4 Reinstall the drain plug and fuel feed pipe.
5 Add fuel until the fuel level gage indicates "FULL."
3-1
Chapter 3 OPERATION
Bleeding Fuel System
When fuel overflows from the air vent plug, wipe

[Unlock]
thoroughly with a cloth. Spilled fuel is a fire haz- Turn counterclockwise
ard.
After bleeding, lock the priming pump cap
securely. If the cap is not locked tightly, the
priming pump can be damaged, causing fuel [Priming]
Move back and force [Lock]
leakage that may lead to a fire. Priming pump cap Press the cap
and turn clockwise
fig.3-1 Priming pump operating method

Closing all air vent plugs before locking the priming
pump cap disallows the priming pump cap from
returning to the original position due to internal pres-
sure.
Bleed air from the location closest to the fuel tank
that are the fuel filter (wire-element type), fuel filter
(center-bolt type), then the fuel feed pipe.

(Wire-Element Type)
Replace to a new part if there is a damage on the air

vent plug, thread area of bracket or sealing washer. Bracket
1 Loosen the air vent plug on the fuel filter (wire-
element type) by rotating about 1.5 turns.
2 Loosen the priming pump cap by turning counter- Air vent plug and
clockwise and move it back and forth. sealing washer
3 When there are no air bubbles in the fuel flowing

from the air vent plug, tighten the air vent plug to
the specified torque.
fig.3-2 Bleeing air from fuel filters
Bleeding Air from Fuel Filters (wire-element type)
(Center-Bolt Type)
Air vent plug and Air vent plug and

Replace to a new part if there is a damage on the air sealing washer sealing washer
vent plug, thread area of bracket or sealing washer.
1 Loosen the air vent plug on the fuel filter (center-
bolt type) by rotating about 1.5 turns.
2 Move its priming pump cap back and forth.
3 When there are no air bubbles in the fuel flowing
from the air vent plug, tighten the air vent plug to
the specified torque.
fig.3-3 Bleeding air from fuel filters
(center-bolt type)
3-2
Chapter 3 OPERATION

Right side air vent plug
(Cartridge-Type) and sealing washer
1 Set the handle of the fuel filters (cartridge-type)
Bracket
to the "Left - Open, Right - Bleed position, and
loosen the right-side air vent plug by rotating it Handle
about 1.5 turns.
2 Move the priming pump cap back and forth. Left side
air vent plug and
When the fuel flowing from the right-side air vent sealing washer
plug no longer contains air bubbles, tighten the
Left side fuel filters Right side fuel filters
air vent plug.
3 Set the handle to the "Right - Open, Left - Bleed fig.3-4 Bleeding air from fuel filters (cartridge-type)
position, and open the left-side air vent plug.
Right side Left side
4 Move the priming pump cap back and forth. bleeding position bleeding position
When the fuel flowing from the left side air vent
plug no longer contains air bubbles, tighten the
air vent plug.
5 Return the handle to the normal position.
Left side filter

Replace to a new part if there is a damage on the Normal position replacement position
(Fuel flows through (Fuel flows through
air vent plug, thread area of bracket or sealing left side fuel filters only.) right-side fuel filter only)
washer. fig.3-5 Fuel filter switchover cock
Bleeding Air from Fuel Feed Pipe

1 Loosen the air vent cock on the fuel feed pipe by
rotating about 1.5 turns.
2 Move the priming pump cap back and forth
repeatedly. When there are no air bubbles in the
fuel flowing from the air vent cock, press the
priming pump cap and turn the cap clockwise to
lock.
3 Tighten the air vent cock on the fuel feed pipe. Air vent cock Fuel feed pipe
fig.3-6 Bleeding air from fuel feed pipe (1)
Tighten the priming cap before closing the air vent

plug.
Closing all air vent plugs before the priming pump
cap disalllows the priming pump cap from returning
to the original position due to internal pressure.
When fuel overflows from the air vent plug, wipe
throughly with a cloth. Spilled fuel causes fire haz-
ard.
Air vent cock

Fuel feed pipe
fig.3-7 Bleeding air from fuel feed pipe (2)
3-3
Chapter 3 OPERATION
Lubricating System
Pouring engine oil
Oil filler
1 Remove the cap from the oil filler.
2 Pour engine oil of the specified type.
Specified engine oil:Class CD or CF Oil level gage
(API Service Classification)
Engine oil capacity (oil pan)
S12U: approx. 450 L [118.88 U. S. gal.]
S16U: approx. 600 L [158.50 U. S. gal.]
Note: Regarding engine oil, refer to "Engine Oil" (4-
4).
fig.3-8 Oil filler and oil level gage
3 Check the oil level with the oil level gage.
If the automatic oil feeder is installed, check if it
works normally.
The oil level should be between the MAXIMUM
and MINIMUM marks on the oil level gage.
If the oil level is low, add specified type of engine
oil.
Engine oil
4 Check the oil pan and other parts for oil leaks. priming pump
Repair any oil leakage found.
5 Operate the engine oil priming pump to circulate
oil in the engine.
6 Remove the rocker cover, and make sure that oil fig.3-9 Engine oil priming pump
is supplied to the valve mechanisms.
7 Stop the priming pump. After about 30 minutes,
add engine oil until the oil level reaches the Maximum line on the oil level gage.
8 Reinstall the cap on the oil filler.
3-4
Chapter 3 OPERATION
Cooling System
Pouring coolant
1 Make sure the drain cocks on the engine and
water pump are closed firmly.
2 Remove the cap from the water supply inlet of
the coolant tank, and pour undiluted LLC.
Note:(a) Determine the amounts of LLC and water
to be poured by using the LLC concentra-
tion chart.
(b) Regarding coolant, refer to "Coolant" (4-6).
Coolant capacity (engine only)

S12U: approx. 520 L [137.37 U. S. gal] fig.3-10 Coolant drain cock on the engine
S16U: approx. 700 L [184.92 U. S. gal]
3 Pour soft water with minimal impurities slowly to

the full level.
4 When coolant reaches the full level securely,
close the water supply inlet cap of the coolant
tank.
5 To release air from the water pump and coolant
pipes, pull the manual stop lever fully to the
STOP position and hold it in that position to keep
the fuel injection pump in no-injection condition, Coolant drain cocks
then supply starting air and crank the engine for
fig.3-11 Coolant drain cock on the water pump
about 10 seconds.
6 Wait for about 1 minute, then repeat the above
Water supply inlet
cranking operation twice to remove air from the
water pump.
7 Check the level gage on the coolant tank to make Fluid level gage
sure there is sufficient coolant (surface level at
about the center of the level gage). If the coolant
level is low, add coolant.
8 Start the engine, and operate it under light load
until the thermostat opens the valve to allow soft
water and LLC to mix thoroughly.
fig.3-12 Water tank coolant level
9 Stop the engine, check the level gage on the
coolant tank again. If the coolant level is low, add
coolant (so that the surface level rises to about
the center of the level gage).
Note: Always add coolant having the same LLC con-
centration.
10 Check the pipe joint and other parts for coolant
leaks.
3-5
Chapter 3 OPERATION
Electrical Systems
Checking Battery
If electrolyte is spilled on the eyes, skin or clothes, wash immediately with plenty of water. If electrolyte enters
the eyes, flush immediately with lots of fresh water and see a physician.
Do not use flames near the battery. When handling the battery, be careful of sparks generated by accidental
shorting.
Regarding other cautions in handling the battery, refer to "Caution Service Battery" (1-5).
Electrolyte level
Electrolyte evaporates during use and the fluid level
gradually decreases. The fluid surface should be 10 to15 mm
between the LOWER LEVEL and UPPER LEVEL lines. (0.394 to 0.591 in.)
If there are no level lines on the battery, make sure that Proper
R L EV E L level
UPP E
the fluid surface is about 10 to 15 mm [0.394 to 0.591 R
L EV E L
L OW E
in.] above the top edges of the plate. If the fluid level is
lower, remove the caps and add distilled water to the
proper level.
Note: When pouring fresh electrolyte, pour the fluid
fig.3-13 Inspecting electrolyte level
carefully.
Checking specific gravity of electrolyte

Check the specific gravity of the electrolyte. If the spe-
Float
cific gravity measured at 20 °C [68 °F] is lower than Electrolyte
1.22, then charge the battery. level
Table 3-1 Specific gravity of electrolyte

Electrolyte
Specific gravity
Condition Remedy
at 20°C [68°F] Glass pipe
From 1.26 to Fully
-
1.28 charged
From 1.22 to
Charged Charge fig.3-14 Inspecting specific gravity of electrolyte
1.26
Less than 1.22 Discharged Charge
Checking loosened wire

Check the faulty wire connection for other parts of the
electrical system and the battery terminal.
3-6
Chapter 3 OPERATION
Checking Valves for Open/Closed

Position
Make sure the following valves, plugs and cocks
are open or closed properly.
• Fuel feed valve: Open
• Coolant drain cock (coolant tank): Closed
• Coolant drain cock (engine): Closed
• Coolant drain cock (water pump): Closed
• Oil drain valve: Closed
• Air supply valve (air tank): Open
fig.3-15 Checking valves for open/closed position
Test Operation
To conduct a test operation, follow the procedures below.
Note: Refer to "Normal Engine Operation" (3-8) to operate the engine.
1 To circulate engine oil throughout the engine, pull the manual stop lever fully to the STOP position and hold
it in that position to keep the fuel injection pump in no-injection condition, then supply starting air and crank
the engine for about 10 seconds.
Then, wait for about one minute, and repeat the above process twice to fully circulate engine oil.
2 Start the engine.
3 Operate the engine under no load and at low idling speed for 10 minutes.
4 Stop the engine.
Leave the engine for about 30 minutes. While waiting, check the engine exterior for leakage of fuel, engine
oil, coolant and exhaust gas.
After 30 minutes, check the engine oil level and coolant level. If they are low, add engine oil or coolant to
the specified level.
5 Operate the engine under no load and at low idling speed for 5 minutes.
6 Operate the engine under no load and at rated speed for 5 minutes.
7 Operate the engine under 25% rated load and at rated speed for 30 minutes. (In the case of a main marine
engine, apply load according to a cube curve.)
10 Operate the engine under 100% rated load and at rated speed for 60 minutes. (In the case of a main
marine engine, apply load according to a cube curve.)
11 Stop the engine.
3-7
Chapter 3 OPERATION
Normal Engine Operation

The following describes the procedures for operating the engine in normal operating condition.
Should an engine abnormality be observed during operation, stop the engine and correct the problem, or con-
tact a Mitsubishi dealer.
Preparations for Operation (Pre-Start Inspection)

Always conduct the following inspection before starting the engine.
External Inspection
A fire can be caused by combustible materials placed near hot engine parts (exhaust manifolds and other
exhaust gas passages) or battery, fuel leaks, and oil leaks. Check the engine exterior carefully. If an abnor-
mality is found, be sure to repair or contact a Mitsubishi dealer.
Before starting the engine, clean the top surface of the battery with wet cloth.
Inspect the engine exterior as described below.
1 Make sure there is no combustible material near the engine or battery. Also, check to make sure the
engine and battery are clean.
If combustible materials or waste are found near the engine or battery, remove them.
2 Check the entire engine for leakage of fuel, engine oil coolant. If leaks are found, repair leakage or contact
a Mitsubishi dealer.
3 Visually check for loose bolts and nuts.
4 Check the electrical wiring including the starters and
alternator.
5 Make sure the following valves, plugs and cocks are
open or closed properly:
Fuel feed valve...................... Open
Coolant drain cock (plug) ...... Closed
Oil drain valve ....................... Closed
Air supply valve (air tank)...... Open
fig.3-16 Checking valves for open/closed position
Cleaning Fuel Filters (Wire-Element Type)
Rotate the handle of the fuel filter (wire-element) 1 or 2
turns in the direcion of the arrow (clockwise) to clean
the element inside the filter.
fig.3-17 Cleaning fuel filter (wire-element type)
3-8
Chapter 3 OPERATION
Checking Fuel Level in Tank
When handling fuel, make sure there are no flames near the engine.

Check the fuel level if it is full.

If the fuel level is low, add fuel to FULL level in the level gage.
Draining Water from Fuel Tank
When handling fuel, make sure there are no flames or heat source in the area.

Fuel mixed with water and/or dust not only reduces the
output but can also cause malfunctions of the fuel sys-
tem. Drain water from the fuel tank by following proce-
dures below.
1 Place a fuel receiving tray (capacity: 2 L [0.53 U. S.
gal] or more) under the drain cock on the fuel tank. Drain cock
2 Open the drain cock on the fuel tank, and drain at
least 1 to 2 L [0.26 to 0.53 U. S. gal] of fuel.
3 Make sure water and dust particles were drained
together with fuel, then close the drain cock. fig.3-18 Draining water from fuel tank
Checking Engine Oil Level Oil filler

1 Pull out the oil level gage and wipe it with a cloth.
2 Insert the oil level gage fully into the oil level gage
guide, then pull out the gage again. Oil level gage
3 The oil level should be between the MAXIMUM and

MINIMUM marks on the oil level gage.
4 If the oil level is low, remove the oil filter cap and add
engine oil of the specified type to the MAXIMUM
level.
5 Securely tighten the oil filler cap after adding the fig.3-19 Oil filler and oil level gage
engine oil.
6 Check the oil pan and other parts for oil leakage.
3-9
Chapter 3 OPERATION
Checking Coolant Level

Water supply inlet
Never check the coolant level while the engine

Fluid level gage
is in operation or immediately after it is stopped
but wait until the coolant temperature drops
sufficiently. If not, hot water blow out, causing
skin burns as a result.
Check if the coolant level is appropriate in the cool-

ant tank (at around center of the level gage). If the fig.3-20 Checking coolant level
coolant level is low, add coolant to the specified
level.
Always add coolant having the same LLC concen-

tration. Never add plain water.
Note:(a) Determine the amounts of LLC and water
to be poured by using the LLC concentra-
tion chart.
Inspection of Air Cleaner Indicator

1 Check the air cleaner indicator for the element
clog.
2 If the element clogs, the red signal mark is visi-
ble.
3 Immediately clean or replace the air cleaner ele-
ment when the signal turns red.
Note: Regarding cleaning of the air cleaner ele- Signal
ment, refer to "Cleaning, Inspecting and Reset button
Changing Air Cleaner Element" (6-18). fig.3-21 Air cleaner indicator
3-10
Chapter 3 OPERATION
Draining Water from Air Starter Tank Starting

air handles
Slowly open the starting air handle of the air tank. If

the handle is opened quickly, the engine can start
abruptly and cause an unexpected accident.
1 Close the starting air handle of the air tank.
2 Open the drain valve handle located under the Drain valve
drain valve on the front side of the tank to drain handle
accumulated water from the tank.

fig.3-22 Draining water from air starter tank
Note: The amount of drained water can vary
depending on the relative humidity and air
consumption.
3 Close the drain valve handle after draining water.
4 Open the starting air handles slowly.
Inspection of Air Tank Air Pressure

Check the air pressure gage to see if the air pres- Air pressure
sure in the air tank conforms to the standard. gages
Air tank internal pressure standard:
2.94 MPa (30 kgf/cm2) [426 psi]
fig.3-23 Inspection of air tank air pressure
3-11
Chapter 3 OPERATION
Starting
The starting method varies depending on the appli- Do not operate the engine under excessive load
cation and specifications. Start the engine accord- (indicated by discharge of black smoke) during a
ing to the specified procedure. warm-up operation. Operating the engine under
excessive load not only consumes fuel unnecessar-
ily, but also causes incomplete combustion, which
Before starting the engine, check to make sure
can result in carbon deposits and shorten the
no one is near the engine and tools are not left
engine service life.
on or near the engine. In loud voice, notify peo-
ple in the area when starting the engine. Conduct a warm-up operation according to the
ambient temperature.
When the air temperature is lower than 5 oC [41 oF],
Never load the engine at starting time. (Disengage operate the engine under no load and at low idling
the clutch if it is installed.) speed for 5 to 10 minutes.
1 Check to make sure the air tank internal pres- When the air temperature is higher than 5 oC [41
o
sure is 2.94 MPa (30 kgf/cm2) [426 psi]. F], operate the engine under no load and at low
2 Open the air tank main valve. idling speed for at least 20 seconds.
3 Set the start lever to OPEN or press the Start The above guidelines for warm-up operation do not
button to start the engine. apply when the engine is equipped with an auxiliary
After confirming the engine startup, set the start starting device (water heater, engine oil priming
lever to CLOSE and close the air tank main pump, etc.).
valve.
In the case of automatic startup, keep the air Inspection of Oil Pressure
tank main valve open. During warming-up operation, check if the oil pres-
If the engine does not start, wait for 2 minutes, sure is in the range of standard value.
then set the air tank pressure to the specified Also, make sure the oil pressure gage is operating
level and start the engine again. properly.
Note: If the engine fails to start after three attempts, Oil pressure standard value during warming-up:
contact a Mitsubishi dealer. 0.20 to 0.39 MPa (2.0 to 4.0 kgf/cm2) [29 to 56.56
psi] (at low idling)
Warming-up Operation Note: The oil pressure gage indicates higher pres-
sure than normal immediately after the
Do not approach rotating parts while in opera- engine starts since the oil temperature is low.
tion. This does not denote an abnormality. The
Entanglement by rotating parts can cause seri- pressure gradually lowers to the normal level
ous injury. as the oil temperature rises.
External Inspection during Warming-up

Do not conduct warm-up operation for an extended Check the external view of the engine to make sure
period of time. there is no fuel, oil, cooling water or exhaust gas
Prolonged warm-up operation causes carbon leakage from joints.
buildup in the cylinders that leads to incomplete
combustion.
Emergency engines do not require a warm-up
operation since they start up for immediate opera-
tion. However, be sure to check all items on the
inspection and maintenance chart.
3-12
Chapter 3 OPERATION
Operation
Check to make sure the instruments and gages
indicate normal values.
Do not approach rotating parts while in opera- Table 3-2 Data for rated speed
tion. Entanglement by rotating parts can cause Item Standard value
serious injury. No load, 0.20 to 0.39 MPa
low idling (2.0 to 4.0 kgf/cm2)
Engine oil speed [29 to 56.56 psi]
Do not touch any part of the engine while it is oper- pressure 0.39 to0.69 MPa
Rated
ating or immediately after it is shut down. A hot (4.0 to 7.0 kgf/cm2)
speed
[56.56 to 100.08 psi]
engine can cause burns.
Engine oil 70 to 100 °C
temperature [158 to 212 °F]
0.05 to 0.34 MPa
Provide adequate ventilation in the engine room. If Jacket coolant
(0.5 to 3.5 kgf/cm2)
pressure
air supplied to the engine room is restricted, the [7.25 to 49.31 psi]
room temperature increases and can affect engine Jacket coolant 65 to 85 °C
output and performance. temperature [149 to 185 °F]
During the first 50 hours of operation, break-in the 0.05 to 0.34 MPa
Oil cooler/air cooler
engine by operating it with light load and at lower (0.5 to 3.5 kgf/cm2)
coolant pressure
[7.25 to 49.31 psi]
speed than normal.
Oil cooler/air cooler 30 to 85 °C
Operating the engine under high load or severe coolant temperature [86 to 185 °F]
conditions during the break-in period can shorten Cylinder 250 to 650 °C
the service life of the engine. Exhaust outlets [482 to 1202 °F]
After the warm-up operation, start operating the tempera- Turbo-
ture 250 to 600 °C
engine with load. charger
[482 to 1112 °F]
outlet
Inspection During Operation Note:(a) When the oil pressure drops below 0.29
Check for leakages. MPa (3 kgf/cm2) [42.7 psi] in normal oper-

Inspect the exterior of the engine to make sure ation, or below 0.10 MPa (1 kgf/cm2) [14.2
there is no leakage from joints. psi] at minimum speed with no load, stop
Check to make sure the engine does not produce the engine immediately. Before restarting
abnormal noise or vibrations. the engine, check and correct the cause of
Inspect the engine for abnormal operating sound the problem.
and vibrations such as knocking. (b) When the high temperature alarm switch
Check to make sure the exhaust gas is normal is activated in normal operation, change
color. the engine operation immediately to no-
Check the color of the exhaust gas discharged from load idling condition until the engine tem-
the exhaust pipe. perature decreases to normal operating
Note: Regarding abnormal exhaust gas conditions, level. Then, operate the engine for
refer to "Engine Produces Large Amount of another 5 or 6 minutes for cooling before
Smoke While in Operation" (9-8). stopping the engine.
Check to make sure that the mist discharged from Before restarting the engine, check and
the breather is not abnormal in the amount or color. correct the cause of the problem.
If the above inspection finds an abnormality, stop
the engine immediately, correct all problems, and
restart the engine. If the engine cannot be repaired,
contact a Mitsubishi dealer.
3-13
Chapter 3 OPERATION
Stopping
Stopping the engine abruptly while engine parts are hot due to high-speed operation can be a cause for heat
up of the engine parts and shorten the service life of the engine. Before stopping the engine, let it operate at
low idle speed for 5 to 6 minutes to cool down operation. Stopping the engine immediately after high-speed
operation can cause engine parts to be heated up and result in bad effects.
During cooling operation, check the engine for abnormalities.
Do not accelerate the engine prior to shutting it down.
Do not restart the engine immediately after it shuts down due to an abnormality. If an alarm is generated when
the engine stops, locate the cause of the problem and correct the problem before restarting the engine.
Continuing engine operation without correcting the problem can result in a serious accident.
For stopping the engine, follow the instructions
since stopping procedure varies depending upon START STOP
the models and its installed equipment.
fig.3-24 Stop button
Emergency Stop

When stopping the engine by pulling the speed con-
trol lever, continue pulling the lever until the engine
stops completely. If not, the engine may start again
To stop the engine with emergency lever, pull the
manual lever to the arrow direction and continue
pulling the lever until the engine stops completely.
Note: If the operation of the manual stop lever fails
to shut down the engine, cut off the fuel sup- fig.3-25 Manual stop lever
ply.
Inspection After Stopping

Inspect the engine parts to make sure there is no fuel, oil or coolant leakage. If a fuel or oil leak is found, repair
the leakage or contact a Mitsubishi dealer.
3-14
Chapter 4
MAINTENANCE
Cautions Concerning Maintenance
Stop the engine before checking or Always wear protective gear.
adding fuel, oil or coolant.
Wear protective gear such as a hardhat, face
Be sure to stop the engine before checking and shield, work clothes, safety shoes, dust protective
adding fuel, engine oil or coolant. mask, etc.
Make sure the coolant temperature is suffi- Be sure to wear protective goggles and other pro-
ciently low before checking coolant. Do not tective devices when handling compressed air.
check coolant immediately after the engine Compressed air can cause personal injury if han-
stops. dled carelessly.
Do not attempt to adjust the parts while the
engine is operating. Use recommended fuel, engine oil and
Failure to follow the above directions may coolant.
cause fire, skins burns or entanglement by
rotating parts.
Use fuel, engine oil and coolant specified in this
Handle electrolyte carefully. manual, and handle them with utmost caution.
When adding engine oil, use oil of the same brand.
Do not mix oils of different brands.
Should electrolyte enter eyes or contact the skin or
clothes, flush immediately with plenty of water. Perform all specified pre-start inspec-
Should electrolyte enter eyes, wash immediately
tions and periodic inspections.
with water and seek medical attention.
Handle LLC carefully. Conduct the pre-start inspection and periodic

inspection as specified in this manual.
Failure to conduct pre-start inspections and peri-
Should LLC be accidentally swallowed, induce odic inspections may cause various engine prob-
vomiting immediately and seek medical attention. lems and damage to parts as well as serious
Should LLC enter eyes, flush immediately with accidents.
plenty of water and seek medical attention.
LLC is a potent alkaline solution. Do not drink or
Use only genuine Mitsubishi parts.
allow it to enter your eyes.
When replacing new parts, use only genuine Mit-

subishi parts.
To obtain new parts, contact a Mitsubishi dealer.
4-1
Chapter 4 MAINTENANCE
Fuel
Recommended Fuel
Use commercially available diesel fuel (JIS K2204).
Note: Some Class-A heavy oils are unsuitable for Diesel fuel
use in the Mitsubishi diesel engine. Use fuel
that meets the Use Limit Property Guideline In
for Diesel Fuel. If the engine is continuously Compliance
used for many hours, refer to the recom- with
mended use limit. JIS K2204
fig.4-1 Recommended fuel

It is necessary to use fuel that has a pour point suit-
able for the ambient temperature. Choose the fuel
Tempe-
type from the chart on the right. rature
C [ F]
[-21] [-4] [14] [32] [50] [68] [86] [104]
Special No. 3
Table 4-1 Recommended Fuel
Diesel oil No. 3
Standard Classification
No. 2
JIS K2204 TYPE 1, TYPE 2, TYPE 3
No. 1
ASTM D975 No. 1-D, No. 2-D Special No. 1
BS 2869 CLASS-A1, CLASS A-2
DIN 51601 DIESEL-FUEL
ISO 8217 DMX-CLASS fig.4-2 Recommended fuel according to air
temperature
Handling Fuel
When using fuel kept in a storage tank, allow it to sit
for more than 24 hours so dust and water can settle at the bottom. Then, use clean fuel from the upper layer.
Fill the fuel tank or service tank after each work day. This prevents water from mixing with fuel in the tank and
gives time for dust and water to separate and settle at the bottom of the tank.
Before removing the caps from the drum and tank, clean the areas around the caps thoroughly. Also clean
your hands and the hose used for refueling. When a hand-operated pump is used, be careful not to pump
water or sediment accumulated at the bottom of the storage tank.
Be sure to pour fuel through a strainer. Use of a clean, lint-free cheesecloth is recommended.
4-2
Table 4-2 Fuel Use Limit Property Guideline

Property Recommend use limit Current use limit Remarks
JIS K2204, 2205
Diesel fuel: 50°C or higher
Flash point As stipulated by regulation
Class-A heavy oil: 60 °C [140
°F] or higher
First distillation 170 °C [338 °F] or
170 °C [338 °F] or higher
point higher
Distillation JIS K2254
90% distillation 330 to 380 °C 330 to 380 °C
point [626 to 716 °F] [626 to 716 °F]
More than 6°C [10.8 °F] below ambient tempera-
Pour point
ture JIS K2269
Cloud point Below ambient temperature
Carbon residue (10% residual
0.4 weight % or lower 1.0 weight % or lower JIS K2270
oil)
Cetane number 45 or higher
Cetane index (new) 45 or higher JIS K2280-1996
2 2
2.0 mm /s [0.0031 in ] or higher (30 °C [86 °F])
8.0 mm2/s [0.0124 in2] or lower (50 °C [122 °F])
Kinetic viscosity
10.5 mm2/s [0.0163 in2] or lower (40 °C [104 °F])
2 2
16.0 mm /s [0.0248 in ] or lower (30 °C [86 °F])
JISK25410.05 weight %
Sulfur content 0.2 weight % or lower 1.0 weight % or lower (same as diesel fuel) is rec-
ommended.
Water and sediment 0.1 volume % or lower JIS K2275
Ash 0.03 weight % or lower JIS K2272
ASTM - No.3
Copper plate corrosion
No.3 or lower No.3 or lower JIS K2513 - Discoloration
(100°C [212°F], 3 hrs.)
No.3
Specific gravity (15°C [59°F]) 0.83 to 0.87 0.80 to 0.87
Should not be carbonized
more than 75% at 250 °C
[482 °F] Fed791B (U.S.)
Should not be carbon-
Should not be evapo- 250 °C [482 °F] X 24Hr
Coking test ized 100% at 250 °C
rated more than 55% at 230 °C [446 °F] X 24Hr
[482 °F]
230 °C [446 °F] 180 °C [356 °F] X 48Hr
Should not be turn to tar
at 180 °C [356 °F]
Aromatics content JIS K 2536
38 weight % or lower 38 weight % or lower
(HPLC method) Total of aromatic content
Asphaltene 0.1 weight % or lower 0.1 weight % or lower ICP analysis (U.K.)
JIS B9931
Particulate contaminant 5.0 mg/l or lower 5.0 mg/l or lower Including foreign substance in
the fuel pipe lines
4-3
Engine Oil
Recommended Engine Oil
Use class CD (recommended) and CF engine oils. Class CE and CF-4 engine oils are designed for diesel fuel
with a sulfur content of less than 0.5% and less than 0.2%, respectively. Since the sulfur content of most
Class-A heavy oil exceeds 0.5%, do not use Class CE or CF-4 engine oil when using Class-A heavy oil as
fuel.
Use of improper or inferior oil can cause excessive wear of bearings and moving parts, thus shortening the
engine life. It can also result in the sticking of piston rings and seizing of pistons in the cylinders, thus causing
major damage.
Selection of Oil Viscosity

Use the following chart to select the appropriate oil

viscosity according to the ambient temperature.
# # # # # $%# %$##
Excessively high oil viscosity causes power loss
and an abnormal rise of oil temperature, while

excessively low oil viscosity results in inadequate ! "

lubrication and leakage of combustion gas that

cause increased wear and reduced output.
Recommended oil viscosity is SAE 15W-40 for all
seasons.
fig.4-3 Recommended oil viscosity according to air
temperature
4-4
Handling Engine Oil
Before pouring engine oil into the engine, stop the engine and make sure there are no flames near the engine.
Oil leaked or spilled onto hot surfaces or electrical components can cause a fire. Wipe any spilled oil immedi-
ately and thoroughly.
After pouring engine oil, close filler cap surely.
Never mix different brands of engine oil. Mixing different brands of engine oil may cause a chemical reaction
by the additives in the engine oil that could degrade the engine oil quality.
If oil of more than the legally specified amount must be handled, be sure to have the work performed by a ser-
vice station in compliance with the legal regulations.
Use an oil pump to remove oil from the engine or oil can. Do not use a hose to siphon with the mouth.
Be sure to close the cap on the oil can after use.
Keep oil in a well-ventilated place and out of direct sunlight.
Be sure to obtain the MSDS (material safety data sheet) of the engine oil used and follow the instructions.
4-5
Coolant
Recommended Coolant
Water used in the engine cooling system must be soft water. The water quality must meet the following
requirements.
Water quality should meet with recommended limit, however, within limit is acceptable.
Table 4-3 Water quality standards

Main adverse effect
Chemical
Item Unit Recommended Limit Corrosion Scale
symbol
and rust formation
pH (25°C [77°F]) - - 6.5 to 8.5 6.5 to 8.5 O O
Electrical conductiv-
- µ /cm <250 <400 O O
ity (25°C [77°F])
Total hardness CaCO3 ppm < 95 < 100 - O
M alkalinity CaCO3 ppm < 70 < 150 - O
-
Chlorine ion Cl ppm < 100 < 100 O -
4-
Sulfuric acid ion SO2 ppm < 50 < 100 O -
Total iron Fe ppm < 1.0 < 1.0 - O
Silica SiO2 ppm - < 50 - O
Residue from evap-
- ppm < 250 < 400 - O
oration
Note: Figures in parentheses are the standard value. In addition to the items specified above, turbidity is spec-
ified to be below 15 mg/liter.
Long Life Coolant (LLC)
Should LLC be accidentally swallowed, induce vomiting immediately and seek medical attention.
If LLC should enter eyes, flush immediately with plenty of water and seek medical attention.
Be sure to use long life coolant (LLC) as coolant, because it prevents not only freezing of coolant but also
rusting of the cooling system.
Use an all-season, non-amine type LLC.
4-6
Recommended LLC Maintenance of LLC

Recommended brands of LLC are shown in the
chart below.
Coolant (containing LLC) drained from an engine is
toxic, and must not be disposed of into regular sew-
Table 4-4 Recommended brands of LLC
age.
Manufacturer Brand
For disposal of used coolant, consult a Mitsubishi
Nippon Oil Corporation Super Coolant X
dealer.
Mitsubishi Fuso Truck & Fuso Diesel Long Life
Bus Corporation Coolant
TEXACO Code 7998 Replacement timing of LLC
When a coolant mixed with the LLC recommended
Note: When using an LLC other than the above, fre- by our company is used, replace coolamt every
quent inspections are required since the ser- 12000 hours or 2 years, whichever comes first, in a
vice life may be shorter. regular-use or general-purpose engine. In an emer-
gency engine, replace coolant every 2 years.
Features and Performance of Rec-
ommended LLC LLC concentration
• Use LLC with no amine content. When determining the LLC concentration, provide a
• Use LLC with no silicate or borate. margin of 5°C [41°F] below the expected lowest
• Use LLC that is close to neutral on the pH scale temperature in your region. Maintain the LLC con-
and slightly alkaline. centration between 30 and 60% throughout the
• Use LLC that contains balanced chemical addi- year.
tives as substitutes for amines. LLC of less than 30% concentration does not pro-
• Use LLC that offers long life (with 30% LLC con- vide sufficient corrosion protection. If the LLC con-
centration and service life of more than 1 year). centration is as low as several percent, it may
promote corrosion.
LLC of more than 60% concentration can adversely
affect its freeze protection characteristic and cause
the engine to overheat easily.
When adding coolant without changing all coolant,
do not add plain water. Always use coolant having
the same LLC concentration.
Table 4-5 Recommended LLC concentration (for

reference only)
Lowest
up to up to up to up to
ambient
-15 -24 -36 -43
temperature
[5] [-11] [-32] [-45]
(°C [°F])
LLC concentra-
30 40 50 55
tion (%)
Note: For determining the accurate LLC concentra-

tion, refer to the instructions for the LLC used.
4-7
Importance of LLC Examples of Abnormalities

Today's trend is toward smaller and more light- Caused by LLC
weight engines offering greater output, lower fuel
consumption and lower exhaust emission level. Pitting on iron parts
Conditions to which engine coolant is subjected are
Amines are generally effective in suppressing the
becoming severer due to longer operating hours,
rusting of ferrous metals, but they are said to cause
higher coolant temperature and higher coolant cir-
problems for copper parts.
culating speed.
Dissolved copper (copper corrosion) in the cooling
Many different materials (such as steel, aluminum,
system deposits on iron parts, and copper deposits
copper, solder and rubber) are used in the cooling
produce galvanic or local-cell action, thus corroding
system, and they are also subjected to the severe
and pitting iron that has a higher ionizing tendency.
conditions described above.
These materials differ in ionizing tendency, and this
Corrosion of aluminum parts
difference promotes corrosion through the medium
of engine coolant. Silicate is highly effective in protecting aluminum
To prevent the above problem, it is necessary to against rusting. However, it is unstable in a solution
use LLC (long life coolant). in which pH is 9 or lower, and can turn to gel and
precipitate in the solution. For this reason, the pH is
usually specified to be about 10 to ensure a high
Characteristics of LLC Additive
alkaline level.
and Important Notes This means, after silicate is used up, the high alka-
LLC contains several chemicals in such proportions
linity causes chemical attacks on aluminum. To pre-
as to produce chemical reactions that suppress
vent this problem, proper maintenance of the
corrosion (ionization) of engine parts in contact with
coolant is required.
the coolant.
(Example)
LLC loses its effectiveness after many months of
Rapid wear of mechanical seals in the water pump
use.
due to secondary effects of silicate gel formed.
Moreover, if the chemicals are not well propor-
Corrosion of aluminum parts after silicate is con-
tioned to match the metals used in the cooling sys-
sumed.
tem, certain chemicals in the LLC become rapidly
used up and result in dissolving of metals.
Pitting and clogging of radiator
Moreover, other corrosion preventing chemicals
As LLC's general performance deteriorates or
react with dissolving metals and further accelerate
when its concentration in the coolant is too low, its
corrosion. This condition can result in more corro-
anti-corrosion performance lowers and results in
sion than when plain soft water is used. This prob-
the corrosion of metals.
lem is often caused by the use of inappropriate
Brass and solder tend to corrode faster than other
LLC.
metals, and corrosion of these metals is said to
cause water leakage and clogs.
(Example)
Holes and clogs in radiator
4-8
Filters
Filters remove impurities such as dust particles
from fuel, engine oil and air starter system. While it
is important to use clean fuel, engine oil and air
supply, filters must be changed regularly to ensure
maximum engine performance and extend the ser-
vice life of the engine.
Refer to "PERIODIC MAINTENANCE CHART" (5-
1) for the procedure for changing filters. The inter-
val of changing filters can be shortened depending
on the usage and operating conditions as well as
quality of fuel and oil in use.
When replacing filters, use genuine Mitsubishi
parts.
Do not wash and reuse cartridge-type filters.
Always use new filters.
When filters are changed, inspect the removed fil-
ters for metal particles. If metal particles are found,
consult a Mitsubishi dealer.
Electrical Parts
Do not splash water on electrical parts. Water can
cause electrical leakage and short-circuiting, result-
ing in equipment damage. Wet electrical parts can
also cause electric shock.
When cleaning the engine, keep water away from
electrical parts.
If malfunctioning of electrical parts is suspected,
consult a Mitsubishi dealer.
Also, do not use disassembled or reassembled
electrical parts.
4-9
Cautions in Operating Engine in Cold Weather Season

When the ambient temperature is low, fuel and
engine oil become thick and coolant can freeze, Battery
thus making it difficult to start the engine or causing
damage to the cylinder heads. To prevent these
Never use flames near the battery, and be care-
problems, observe the following directions.
ful to handle battery since flames can cause an
explosion.
Fuel
When handling fuel, make sure there are no If electrolyte is spilled on skin or clothes, wash
flames near engine. immediately with lots of water. If electrolyte gets
Wipe any spilled fuel completely. Spilled fuel into your eyes, flush immediately with lots of fresh
can ignite and cause fire. water and consult a physician as soon as possible.
For other cautions to handle battery, refer to "Cau-
Use appropriate fuel according to the ambient tem-
tion Service Battery" (1-5)
perature.
Note: Regarding fuel, refer to "Fuel" (4-2). When the ambient temperature drops to a very low
level, the charging rate becomes low even if the
specific gravity of electrolyte remains the same.
Engine Oil
Therefore, in a cold area the battery may not pro-
Replace engine oil suitable to the ambient tempera-
vide sufficient power to start the engine immedi-
ture.
ately. Furthermore, electrolyte becomes easier to
Note: Regarding engine oil, refer to "Engine Oil" (4-
freeze when its specific gravity is low. Therefore, it
4).
is recommended to additionally charge the battery
to increase the specific gravity of electrolyte and
Coolant the charging rate.
Note: For the inspection of specific gravity of elec-
Remove the radiator cap only after the engine cools trolyte, refer to "Checking specific gravity of
to room temperature. Place a cloth over the cap, electrolyte" (3-6).
and turn the cap about a half turn to release pres-
sure. Opening the radiator cap while the engine is Maintenance After Cold Season
hot causes steam and hot coolant to blow out, After a cold season ends, change fuel, engine oil
resulting in skin burns. and coolant to those suitable for the outside tem-
Freezing of coolant due to cold temperatures can perature in accordance with the specifications
damage the crankcase. Be sure to use all-season described in this manual.
long life coolant that prevent freezing of cooling
water and rusting of the engine cooling system.
Note: Regarding coolant, refer to "Coolant" (4-6).
4-10
Chapter 5
PERIODIC MAINTENANCE CHART
How to Use Periodic Maintenance Chart
Periodic inspection not only extends the service life Periodic maintenance chart for emer-
of the engine but also serves to ensure safe opera-
gency engine
tion. Be sure to conduct inspections and mainte-
When the engine is used as an emergency engine,
nance according to the periodic maintenance chart.
perform the periodic inspection and maintenance in
The maintenance chart shows the standard service
accordance with the "Periodic Maintenance Chart
intervals. Whenever you notice the abnormalities
for Emergency Engine".
mentioned below, make sure the service must be
Due to the nature of application, an emergency
performed to the defective part of the engine,
engine is subject to demanding operating condi-
regardless recommended service intervals in the
tions such as a quick startup and immediate supply
“Periodic Maintenence Chart”; abnormal noise,
of power. In addition, it must operate reliably in the
black exhaust smoke, white exhaust smoke, abnor-
event of an emergency. Therefore, be sure to per-
mally high temperature of exhaust gas, abnormal
form the daily inspection and also conduct the fol-
vibration in engine, fuel, oil or exhaust gas leakage.
lowing operation for maintenance purposes.
Note: Appropriate service intervals vary depending
on the usage and operating conditions as well
Once every week: Operate the engine under no
as consumption of fuel, oil and coolant.
load (for 3 to 5 minutes).
Check the operating record of the engine to
(When operating the engine for the adjustment of
determine the most appropriate service inter-
peripheral devices, limit the operating time to 10
vals. (Feel free to consult a Mitsubishi dealer
minutes.)
regarding service intervals.)
Once every month: Operate the engine under load
(for 15 to 30 minutes with more than 1/2 load).
Perform service items listed under the service inter-
If the engine cannot be operated under load every
val. Service items with shorter intervals should also
month, operate the engine under load (more than 1/
be included in the longer interval service.
2 load) for more than 2 hours.
Items marked with ½ in the maintenance chart
During the engine maintenance operation, check
require special tools or large equipment. For the
the ease of startup, oil pressure, and exhaust color
servicing of these items, consult a Mitsubishi
and vibration.
dealer.
Periodic maintenance chart for general-

Periodic Maintenance Chart
Appropriate service intervals vary depending on the purpose engine
engine specifications. Perform all daily inspection If the engine is used for different purposes other
and maintenance items in an accordance with the than the above usage, do maintenance according
following 3 categories. to the “Periodic Maintenance Chart for General-
Purpose Power Supply Engine”.
Periodic maintenance chart for regular-
use engine
When the engine is used as a regular use engine,
perform the periodic inspection and maintenance in
accordance with the "Periodic Maintenance Chart
for Engine in Regular Use".
5-1
Chapter 5 PERIODIC MAINTENANCE CHART
General Definition of Regular-Use

Engine, Emergency Engine and
General-Purpose Engine
General definition of regular-use engine

An engine operated with a constant base load for
the purpose of generating electric power, which is
used independently or in combination with commer-
cial power supply.
An engine operated under a fluctuating load
throughout a day for supplying rated electric power
in lieu of commercial power.
General definition of emergency engine

An engine used for emergency power generation
such as main power supply and commercial power
supply.
General definition of general-purpose

engine
An engine used for a purpose other than power
generation - for example, to drive a pump, as the
main engine for a ship, and for an industrial vehicle
- and operated under constant or cylically varying
load and speed.
5-2
Periodic Maintenance Chart for Engine in Regular Use

Table 5-1 Periodic maintenance chart for engine in regular use (1 / 5)
Service Service item Service contents Page
interval
Every day Inspect leakage and looseness of bolts and nuts.
External 3-8
Retighten bolts and nuts.
Fuel tank Inspect fuel level and drain water. 3-9
Fuel filters (wire-element) Clean inside of the filter by using handle. 3-8
Inspect oil level and add oil by using oil level
Engine oil 3-9
gage. Inspect level regulator operation.
Inspect coolant level and add coolant by using
Coolant 3-10
fluid level gage.
Air cleaner Inspect air cleaner indicator for element clog. 3-10
Air starter tank Inspect air pressure and drain water. 3-11
Check operating period, performance record,
Operating condition 3-13
sound, vibration and gage function.
Inspect water leakage from air cooler chamber
Air cooler 6-16
and drain water.
Every 500 Fuel filters Drain water. 6-1
service Inspect ball joints, bolts and nuts for looseness
hours Fuel control linkage 6-6
and smooth movement.
Inspect engine oil for mixing of fuel and water. 6-11
Analyze engine oil properties
Engine oil 6-12
(according to engine oil analysis service)
Change. 6-7
Oil filter and bypass oil filter Change. 6-7
Exhaust pipes and exhaust
Inspect and drain water. 6-16
muffler
Air starter compressor Drain water. 6-18
Zinc rod Inspect and change. 6-13
First 1500 Inspect and adjust (also inspect inside of rocker
Valve clearance ½
service chamber).
hours Camshafts and tappets Inspect. ½
Retighten air cooler cover mounting bolt (Also
Air cooler cover after first 1500 service hours from gasket ½
replacement).
Every 1500 Fuel filters Change. 6-3
service Coolant Inspect LLC concentration. 6-14
hours
Pre-cleaner Clean. 6-16
Air cleaner element Clean and inspect. 6-17
Air starter strainer Drain water and clean. 6-18
5-3

interval
Every 3000 Inspect and adjust (also inspect inside of rocker
Valve clearance ½
service chamber).
hours Fuel injection nozzles Change nozzle tipes and adjust pressure. ½
Fuel filters (wire-element) Disassemble and clean inside. 6-1
Inspect and clean mist separator, and change
Breather ½
expendable parts.
Governor oil filter Change. ½
Pre-cleaner Change. 6-17
Air cleaner element Change. 6-18
Inspect clearance with the flywheel, attachment
of foreign items on the tip, mounting nut tight-
Magnetic pickup ½
ness, an open-circuit and connector disconnec-
tion.
After 3000
services
hours or 2
Fuel system accumulator Refill with nitrogen gas. ½
years,
whichever
comes first
Every 6000 Camshafts and tappets Inspect. ½
service Inspect inside (remove the side cover for inspec-
hours Crankcase
tion).
Change oil seals, unit seals and other expend-
Water pump
able parts.
Check temperature with thermo label and check
Damper
for silicon oil leakage.
Inspection of shaft and wheel smooth rotation
Turbocharger
and thrust for looseness.
Inspection of pipe clamps of
Inspection of interference and wear, and repair
fuel lines, oil lines, instrument
rubber tape.
pipes and starting air pipes
After 12000
service
hours or 2
Coolant Change. 6-13
years,
whichever
comes first
5-4

interval
Every 12000 Overhaul of top end of engine (remove the cylinder heads for inspection and main- ½
service tenance.)
hours Disassemble and maintain, clean and change expendable parts.
Valve seat Inspect, regrind and lap.
Cylinder head
Change.
gasket
Copper tubes Change copper tubes and O-rings.
Inlet and
Inspect, regrind and lap.
exhaust valves
Valve guides,
Cylinder valve rotator,
heads and valve cotter,
valve mech- pushrods,
anisms rocker arm
bushings, valve
springs, tappet Inspect.
rollers, tappet
roller bushing,
tappet shafts,
tappet guides,
tappet guide
set screws.
Stem seal Change.
Safety valve Inspect and change expendable parts.
Cylinder liners Inspect and clean.
Pistons Inspect including overhaul and clean.
Piston rings Change.
Inspect bolts, inspect Magnaflux serrations,
Connecting rods change big-end bearing shells and inspect small-
end bushings.
Crankshaft Inspect and adjust deflection.
Analyze silicon oil properties and change thermo
Damper
label.
Front gear and timing gear Inspect gear teeth.
5-5

interval
Every 12000 Fuel control ½
Change ball joints and ball bearings.
service linkage
hours Fuel injection Disassembe and maintain, and change deflec-
pump tors and O-rings.
Fuel feed pump Change oil seals and O-rings.
Fuel injection
Change.
pipes
Fuel system
Fuel injection
Inspect and adjust.
timing
Fuel pressure
Inspect.
regulator valve
Fuel system
Change.
accumulator
Fuel pipes Change O-rings and sealing washers.
Oil pump Change bushings.
Lubricating Oil cooler Inspect and clean element.
system Regulator valve Disassemble and maintain.
Oil pipes Change O-rings and gaskets.
Cooling Water pump Change bearings.
system Coolant pipes Change O-rings.
Remove carbon deposits and change seal rings,
Turbocharger
bearings and expendable parts.
Inlet and Air cooler Clean element.
exhaust Air cooler cover Change gaskets.
systems Air inlet pipes Change O-rings.
Exhaust pipes Change gaskets, bolts and nuts.
Exhaust duct Change V-clamps.
Starting valve Inspect, lap and change O-rings and gaskets.
Air starter Air pipes Change gaskets.
system Air tank Inspect safety valve operation.
Distributor Change valve, shaft, bushings, pins and gaskets.
Increasing cool-
ant tempera-
ture,
Protection decreasing oil
Inspect operation.
device pressure, over-
speed and
emergency
stop device
Flexible hoses Change.
5-6

interval
Every 24000 Major overhaul (complete disassembly and inspection) ½
service Change all O-rings, gaskets and seals.
hours Change inlet and exhaust valves, valve seats, valve guides, valve
Cylinder rotators and valve cotters.
heads and
valve mech- Inspect and change pushrods, rocker arm bushings, valve springs,
anisms tappet rollers, tappet roller bushings, tappet shafts, tappet guides
and tappet guide set screws.
Cylinder liners Change.
Inspect caps and bolts, and change main bear-
Main bearings
ings.
Inspect and change (in 2nd 24000-service-hour-
Cam bushings
interval inspection and maintenance).
Disassemble and inspect piston crown, and
Pistons
change O-rings.
Connecting rods Change bolts and small-end bushings.
Crankshaft Inspect journals and pins, and change slingers.
Change (in 2nd 24000-service-hour-interval
Damper
inspection and maintenance).
Disassemble and maintain (by spring coupling
Spring coupling
manufacturer).
All shafts Inspect.
Timing gear Inspect and change assemblies (including bush-
Rear idler gear
and front ings).
gear Change front idler bearing, camshaft roller bearing, front seal, rear
seal, front gear case gasket and rear gear case gasket.
Fuel injection
Change nozzle holder assemblies.
nozzles
Fuel injection
Change plunger assembly and delivery valve.
Fuel system pump
Fuel feed pump
Change pump assembly.
(trochoid type)
Regulator valve Change.
Oil pump Change safety valve and spring.
Oil thermostat Change.
Lubricating
system Oil pan Clean and change gasket.
Engine oil regu-
Inspect and change.
lator valve
Water pump Change shaft and impeller.
Cooling
system Coolant ther-
Change.
mostat
Change element (in 2nd 24000-hour-interval
Inlet and Air cooler
exhaust
Exhaust pipes Inspect and change bellows.
systems
Exhaust duct Change seal rings.
Disassemble and maintain (by governor manu-
Actuator
facturer).
Governor
Governor case Change bearings, O-rings and gaskets.
Control shaft Change oil seals.
5-7
Periodic Maintenance Chart for Emergency Engine

Table 5-2 Periodic maintenance chart for emergency engine (1 / 5)
interval
Every week Operate the engine under no load for 3 to 5
minutes.
Inspect starting property, exhaust color,
abnormal vibrations, abnormal sounds and
Conducting maintenance operation abnormal odors. 3-13
Inspect displayed value of each gage (such
as oil pressure gage, water temperature
gage, oil temperature gage, exhaust tem-
perature and rotating speed gage).
Inspect leakage and looseness of bolts and
External 3-8
nuts. Retighten bolts and nuts.
Fuel tank Inspect fuel level. 3-9
Engine oil 3-9
Inspect coolant level and coolant oil by
Coolant 3-10
using fluid level gage.
Inspect water leakage from air cooler cham-
Air cooler 6-16
ber and drain water.
Air starter tank Inspect air pressure. 3-11
Every month Operate the engine under load (at 50 % or
more) for 15 to 30 minutes.
abnormal vibrations, abnormal sounds,
perature, rotating speed gage).
Fuel filter (wire-element) Clean inside of the filter by using handle. 6-2
Inspect ball joints, bolts and nuts for loose-
Fuel control linkage 6-6
ness and smooth movement.
Inspect engine oil for mixing of fuel and
Engine oil 6-11
water.
Inspect air cleaner indicator for element
Air cleaner 3-10
clog.
Pre-cleaner Inspect for clog. -
Air starter tank Drain water. 3-11
Every 6 Fuel filter
Drain water. 6-1
months (wire-element and center-bolt)
After 6
months or
500 service
hours,
whichever
comes first
5-8

interval
After 1 year
or 500 ser-
Analyze engine oil properties.
vice hours, Engine oil 6-12
(according to engine oil analysis service)
whichever
comes first
Every year Operate the engine under no load for 2
hours (more than 1/2 load).
abnormal vibrations, abnormal sounds and
perature and rotating speed gage).
Inspect and adjust (also inspect inside of
Valve clearance ½
rocker chamber).
Camshaft and tappets Inspect. ½
Check temperature with thermo label and
Damper ½
check for silicon oil leakage.
Inspect clearance with the flywheel, attach-
ment of foreign items on the tip, mounting
Magnetic pickup ½
nut tightness, an open-circuit and connector
disconnection.
Fuel tank Drain water. 6-2
Fuel injection nozzles Change nozzle tips and adjust pressure. ½
Fuel injection timing Inspect and adjust. ½
Coolant Inspect LLC concentration. 6-13
Exhaust pipes and exhaust muffler Inspect and drain water. 6-16
Air cleaner element Clean and inspect. 6-17
Increasing coolant
temperature,
Protection decreasing oil pres-
Inspect operation. ½
device sure, overspeed
and emergency
stop device
After 2 years Engine oil Change. 6-7
or 500 ser-
vice hours,
whichever Oil filter and bypass oil filter Change. 6-7
comes first
After 2 years Fuel filters
Change. 6-3
or 1500 ser- (center-bolt and cartridge)
vice hours,
whichever Fuel filter (wire-element) Clean inside. 6-2
comes first
5-9

interval
Every 2 Inspection of shaft for smooth rotation and
Turbocharger ½
years and wheel thrust for looseness.
Coolant thermostat Inspect. ½
Inspect, lap and change O-rings and gas-
Starting valve ½
kets.
Inspect valve, shafts, bushings and pins,
Distributor ½
and change gaskets.
Air starter strainer Drain water and clean. 6-18
Every 4 Overhaul of top end of engine ½
years Disassemble one cylinder, and inspect cylinder head, piston and connecting rod. If
abnormalities are found, disassemble all cylinders for inspection.
Disassemble and maintain, clean and change expendable parts.
Inlet and exhaust
valves
Cylinder head gas-
Change cylinder head gaskets.
ket
Valve guides,
valve rotator,
Cylinder valve cotter,
heads and pushrods,
valve mech- rocker arm bush-
anisms ings,
valve springs, Inspect.
tappet rollers,
tappet brush,
tappet shafts,
tappet guides,
tappet guide set
screws
Stem seal Change.
Inspect inside(remove the side cover for
Crankcase
inspection).
Piston rings Inspect.
Connecting rods change big-end bearing shells and inspect
small-end bushings.
Inspect and adjust deflection, and inspect
Crankshaft
journals and pins.
Analyze silicon oil properties and change
Damper
thermo label.
Inspection of pipe clamps of fuel
Inspection of interference and wear, and
lines, oil lines, instrument pipes
repair rubber tape.
and starting air pipes
5-10

interval
Every 4 Fuel injection ½
Change nozzle tips and adjust pressure.
years nozzles
Fuel system Disassemble, maintain, adjust and change
Fuel injection pump
O-rings.
Fuel tank Clean inside.
Oil pump Inspect discoloration and external.
Oil cooler Inspect and clean element.
Lubricating
system Clean mist separator and change expend-
Breather
able parts.
Governor oil filter Change.
Cooling
Coolant thermostat Change.
system
Remove carbons, change seal rings and
Turbocharger
Inlet and change expendable parts.
exhaust Air cooler Disassemble and clean element.
systems Pre-cleaner Change. 6-16
Air cleaner element Change. 6-17
years Change all O-rings, gaskets and seals.
Disassemble and maintain, clean and change expendable parts.
Inlet and exhaust
valves and valve Inspect, regrind and lap.
seats
Valve guides, valve
rotators, valve cot-
ters, pushrods,
Cylinder rocker arm bush-
heads and ings, valve springs,
valve mech- tappet rollers, tap- Inspect.
anisms pet roller bushings,
tappet shafts, tap-
pet guides and tap-
pet guide set
screws
Stem seal Change.
Copper tubes and
Change.
copper tube O-rings
Safety valves Inspect and change expendable parts.
Cylinder liners Inspect, clean and change O-rings.
Inspect main bearing caps, bolts and main
Main bearings
bearings, and inspect thrust plate.
Cam bushings Inspect.
Connecting rods change big-end bearing shells and inspect
small-end bushings.
Inspect gear teeth, bearings and shafts.
Front gear and timing gear Change front seal, rear seal, front gear
case gasket and rear gear case gasket.
5-11

interval
Every 8 Fuel regulator valve Inspect. ½
years Fuel pipes Change O-rings and sealing washers.
Fuel control linkage Change ball joints and ball bearings.
Fuel system Fuel system accu-
Change.
mulator
Fuel injection pipes Inspect.
Oil pump Disassemble and maintain.
Oil thermostat Inspect.
Lubricating
system Engine oil regulator
Disassemble and maintain.
valve
Change oil seals, unit seals, expendable
Cooling Water pump
parts and bearings.
System
Coolant pipes Change O-rings.
Air cooler cover Change gaskets.
Inlet and Air inlet pipes Change O-rings.
exhaust
systems Exhaust pipes Change gaskets, bolts and nuts.
Exhaust duct Change seal rings, gaskets and V-clamps.
Disassemble and maintain (by governor
Actuator
manufacturer).
Governor
5-12
Periodic Maintenance Chart for General-Purpose Power

Supply Engine
Table 5-3 Periodic maintenance chart for general-purpose power supply engine (1 / 5)
interval
Every day Inspect leakage and looseness of bolts and nuts.
External 3-8
Retighten bolts and nuts.
Fuel tank Inspect fuel level and drain water. 3-9
Fuel filters (wire-element) Clean inside of the filter by using handle. 3-8
Engine oil 3-9
Inspect coolant level and add coolant by using
Coolant 3-10
fluid level gage.
Air cleaner Inspect air cleaner indicator for element clog. 3-10
Air starter tank Inspect air pressure and drain water. 3-11
Check operating period, performance record,
Operating condition 3-13
sound, vibration and gage function.
Inspect water leakage from air cooler chamber
Air cooler 6-18
and drain water.
After 500 Fuel filters Drain water. 6-1
services Inspect ball joints, bolts and nuts for looseness
hours or 1 Fuel control linkage 6-6
and smooth movement.
month,
Engine oil Inspect engine oil for mixing of fuel and water. 6-11
whichever
comes first Exhaust pipes and exhaust
Inspect and drain water. 6-16
muffler
After 500
services
hours or 6
months,
whichever
comes first
After 500 Change. 6-7
services Engine oil Analyze engine oil properties
hours or 1 6-12
(according to engine oil analysis service).
year, which-
ever comes Oil filter and bypass oil filter Change. 6-7
first
After first Inspect and adjust (also inspect inside of rocker ½
Valve clearance
1500 ser- chamber).
vices hours Camshaft and tappets Inspect. ½
or 1 year,
Retighten air cooler cover mounting bolt (Also ½
whichever
Air cooler cover after first 1500 service hours or first 1 year,
comes first
whichever comes first from gasket replacement).
After 1500 Fuel filters Change. 6-4
services Coolant Inspect LLC concentration. 6-13
hours or 1
year, which-
ever comes Air cleaner element Clean and inspect. 6-18
first Air starter strainer Drain water and clean. 6-19
5-13
interval
Every 3000 Inspect and adjust (also inspect inside of rocker
Valve clearance ½
service chamber).
hours Inspect and change nozzle tipes and adjust pres-
Fuel injection nozzles ½
sure.
After 3000 Fuel filter (wire-element) Clean inside. 6-3
services Inspect and clean mist separator, and change
hours or 2 Breather ½
expendable parts.
years,
Governor oil filter Change. ½
whichever
comes first Air cleaner element Change. 6-17
Pre-cleaner Change. 6-18
Inspect clearance with the flywheel, attachment ½
of foreign items on the tip, mounting nut tight-
Magnetic pickup
ness, an open-circuit and connector disconnec-
tion.
After 6000 Camshafts and tappets Inspect. ½
services Inspect inside (remove the side cover for inspec-
hours or 4 Crankcase
tion).
years,
Change oil seals, unit seals and other expend-
whichever Water pump
able parts.
comes first
Check temperature with thermo label and check
Damper
for silicon oil leakage.
Inspection of shaft and wheel for smooth rotation
Turbocharger
and thrust for looseness.
Inspection of pipe clamps of
Inspection of interference and wear, and repair
fuel lines, oil lines, instrument
rubber tape.
pipes and starting air pipes
Increasing cool-
ant tempera-
ture,
Protection decreasing oil
Inspect operation.
device pressure, over-
speed and
emergency
stop device
After 12000 ½
service Flexible hoses Change.
hours or 4
years,
whichever Fuel system accumlator Change.
comes first
After 12000
service
hours or 2
years,
whichever
comes first
5-14
interval
After 12000 Overhaul of top end of engine (remove the cylinder heads for inspection and main- ½
service tenance.)
hours or 8 Disassemble and maintain, clean and change expendable parts.
years,
whichever
comes first Inlet and
exhaust valves
Cylinder head
Change.
gasket
Copper tubes Change copper tubes and O-rings.
Valve guides,
Cylinder valve rotator,
heads and valve cotter,
valve mech- pushrods,
anisms rocker arm
bushings, valve
springs, tappet Inspect.
rollers, tappet
roller bushings,
tappet shafts,
tappet guides,
tappet guide
set screws.
Stem seal Change.
Connecting rods change big-end bearing shells and inspect small-
end bushings.
Crankshaft Inspect and adjust deflection.
Analyze silicon oil properties and change thermo
Damper
label.
Front gear and timing gear Inspect gear teeth.
5-15
interval
After 12000 Fuel control ½
Change ball joints and ball bearings.
service linkage
hours or 8 Fuel injection Disassemble and maintain, and change deflec-
years, pump tors and O-rings.
whichever
comes first
Fuel injection
Change.
pipes
Fuel system
Fuel injection
Inspect and adjust.
timing
Fuel pressure
Inspect.
regulator valve
Fuel system
Change.
accumulator
Fuel pipes Change O-rings and sealing washers.
Oil pump Change bushings.
Lubricating Oil cooler Inspect and clean element.
system Regulator valve Disassemble and maintain.
Cooling Oil pipes Change bearings.
system Coolant pipes Change O-rings.
Remove carbon deposits and change seal rings,
Turbocharger
expendable parts and bearings.
Inlet and Air cooler Clean element.
exhaust Air cooler cover Change gasket.
systems Air inlet pipes Change O-rings.
Exhaust pipes Change gaskets, bolts and nuts.
Exhaust duct Change V-clamps.
Starting valve Inspect, lap and change O-rings and gaskets.
Distributor Change valve, shaft, bushings, pins and gaskets.
5-16
interval
service Change all O-rings, gaskets and seals.
hours Cylinder Change inlet and exhaust valves, valve seats, valve guides, valve
Heads and rotators and valve cotters.
Valve Inspect and change pushrods, rocker arm bushings, valve springs,
Mecha- tappet rollers, tappet roller bushings, tappet shafts, tappet guides
nisms and tappet guide set screws.
Cylinder liners Change.
Inspect main bearing caps and bolts, and change
Main bearing
main bearings.
Inspect and change (in 2nd 24000-service-hour-
Cam bushings
Disassemble and inspect piston crown, and
Pistons
change O-rings.
Change connecting rod bolts and small-end
Connecting rods
bushings.
Crankshaft Inspect journals and pins, and change slingers.
Change (in 2nd 24000-service-hour-interval
Damper
Disassemble and maintain (by spring coupling
Spring coupling
manufacturer).
All shafts Inspect.
Timing gear Inspect and change rear idler gear assemblies
Rear idler gear
and front (including bushings).
gear Change front idler bearing, camshaft roller bearing, front seal, rear
seal, front gear case gasket and rear gear case gasket.
Fuel injection
Change nozzle holder assemblies.
nozzles
Fuel injection
Fuel system Change plunger assembly and delivery valve.
pump
Fuel feed pump Change pump assembly.
Regulator valve Change.
Oil pump Change safety valve and spring.
Oil thermostat Change.
Lubricating
system Oil pan Clean and change gasket.
Engine oil regu-
Inspect and change.
lator valve
Water pump Change shaft and impeller.
Cooling
system Coolant ther-
Change.
mostat
Change element (in 2nd 24000-service--hour-
Inlet and Air cooler
exhaust
Exhaust pipes Inspect and change bellows.
systems
Exhaust duct Change seal rings.
Disassemble and maintain (by governor manu-
Actuator
facturer).
Governor
5-17
Chapter 6
PERIODIC INSPECTION AND MAINTE-
NANCE PROCEDURES
Fuel System
Draining Water from Fuel Filters (Wire-Element Type)
Before handling fuel, make sure there is no flame or heat source in the area.
Wipe spilled fuel thoroughly. Spilled fuel can cause a fire.
Check for damage of threaded section of the filter case, the drain plug and the sealing washer, if any damage
are found, replace with the new one.
1 Close the fuel feed valve to cut off the fuel supply to
the engine. Handle
2 Place a container under the fuel filter to receive
drained fuel.
3 Turn the handle at the top of the fuel filter to remove
dust and other particles from the element. Filter case
4 Remove the drain plug and the sealing washer to dis-
charge sediment from the filter. Sealing washer
5 Reinstall the drain plug and the sealing washer.
Drain plug
6 Bleed air from the fuel system.
Note: Refer to "Bleeding Fuel System" (3-2) for the pro- fig.6-1 Draining water from fuel filter (wire-element type)
cedure for releasing air from the fuel system.
Draining Water from Fuel Filters (Center-Bolt Type)
Check for damage of the center bolt, drain plug threaded section and the sealing washer. If any damage are
found, replace with the new one.
the engine.
drained fuel.
3 Remove the drain plug and the sealing washer to dis-
charge sediment from the filter.
4 Reinstall the drain plug and the sealing washer.
5 Bleed air from the fuel system. Center bolt,
Sealing washer,
Note: Refer to "Bleeding Fuel System" (3-2) for the pro-
Drain plug
cedure for releasing air from the fuel system.
fig.6-2 Draining water from fuel filter (center-bolt type)
6-1
Chapter 6 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES
Draining Water from Fuel Tank

Fuel mixed with water and/or dust not only reduces

the output but can also cause malfunctions of the
fuel system. Drain water from the fuel tank by fol-
lowing procedures below.
1 Place a fuel receiving tray (capacity: 2 L [0.53 U.
S. gal] or more) under the drain cock on the fuel
tank. Drain cock
2 Open the drain cock on the fuel tank, and drain
at least 1 to 2 L [0.26 to 0.53 U. S. gal] of fuel.
3 Make sure water and dust particles were
drained together with fuel, then close the drain fig.6-3 Draining water from fuel tank
cock.
Cleaning inside of Fuel Filters (Wire-Element Type)
Check for damage of the filter case, the drain plug threaded section and the sealing washer, if any damage
are found, replace with the new one.
the engine. Mounting bolt
Wire element
drained fuel.
3 Drain fuel by removing the drain plug and the sealing
washer.
4 Remove the filter case by loosening the mounting
Filter case
bolt at the top of the filter.
5 Remove dust and other particles from the element
Drain plug Sealing washer
using the soft brush with diesel fuel.
6 Also clean inside of the case. fig.6-4 Cleaning inside of fuel filter (wire-element)
7 Reinstall the drain plug, the sealing washer and the
filter case to the original position.
8 Bleed air from the fuel system.
Note: Refer to "Bleeding Fuel System" (3-2) for the procedure for releasing air from the fuel system.
6-2
Changing Fuel Filters (Center-Bolt Type)
The fuel filter (center-bolt type) uses a paper element. It cannot be cleaned for reuse.
When installing a new element, be careful not to damage the element.
Check the threaded sections of the air vent plugs, the bracket, the drain plugs, the center bolts and the seal-
ing washers. If the threads are damaged, replace the damaged part.
1 Close the fuel supply valve to the engine.
2 Clean the area around the fuel filters. Air vent plugs
Sealing washers
3 Place a fuel receiving tray under the fuel filters. Bracket
4 Remove the drain plug and the sealing washers Case O-ring
to discharge fuel from the filter.
Element Element kit
5 After fuel is drained, reinstall the drain plug and O-ring
the sealing washers. Washer
Retainer
6 Remove the center bolt, and disassemble the Center-bolt
fuel filter unit. Sealing washer
Drain plug
7 Clean the inside surface of the case and O-ring
groove. fig.6-5 Changing fuel filters (center-bolt type)
8 Wipe off fuel from element mounting surface of
the bracket and external O-ring seal surface with
a cloth.
9 Use the O-rings provided in a new filter element kit to replace old parts.
10 Reassemble the fuel filter unit.
11 Tighten the center bolt to 63.7±4.9 N·m (6.5±0.5 kgf·m) [46.98±3.61 lbf·ft].
12 After replacing the fuel filter, open the fuel supply valve to the engine, then bleed air from the fuel system.
Note: Regarding bleeding of the fuel system, refer to "Bleeding Fuel System" (3-2).
13 Start the engine and let it idle for several minutes.
14 Check the fuel filter mounting sections for fuel leakage. If fuel leakage is found, disassemble the fuel filter
and check the O-rings for damage. If there is no gasket damage, reassemble the fuel filter.
6-3
Changing Fuel Filters (Cartridge Type)
This fuel filter (cartridge type) uses a paper element. It cannot be cleaned for reuse.
The fuel filter cartridges must be installed by hand, and caution should be exercised to prevent denting or
scratching the cartridge surfaces. Do not use a filter wrench for installation.
Check the threaded sections of the air vent plugs, bracket and sealing washers. If the threads are damaged,
replace the damaged part.
Changing Fuel Filters with Engine Stop
1 Close the fuel supply valve to the engine.
2 Clean the area around the fuel filters.

3 Place a fuel receiving tray under the fuel filters.

4 Set the filter handle to the “Left-Close, Right-

Open”.
5 Using the filter wrench, remove 2 fuel filters from
left side.
6 Apply clean fuel to the gasket on the new fuel fil-
ters.
7 Install the fuel filters. When the gasket contacts

the mounting surface on filter bracket, further fig.6-6 Fuel filter switchover handle
rotate 3/4 to a full turn.
8 Set the fuel filter handle to the “Left-Close,

Right-Open”, then take same measures stated in
5 to 7 and replace 2 fuel filters from right side.
9 After replacing the filters, open the fuel feed

valve to the engine, then bleed air from the fuel

system.
Note: Regarding bleeding of the fuel system, refer
to "Bleeding Fuel System" (3-2).
10 Start the engine and let it idle for several min-

utes. fig.6-7 Changing fuel filters (cartridge type)

11 Check each fuel filter for fuel leaks. If fuel leaks
from a filter, remove the filter and check the gas-
ket for scratches or other abnormalities, then
reinstall the filter.
6-4
Changing Fuel Filters while Engine in Operation
To replace the fuel filters while the engine is in operation, be sure to run the engine under no load low idling
and at rated speed.
If the fuel filter is replaced during the engine is in high-speed operation, fuel can leak from the switchover
lever.
1 Clean the area around the fuel filters.

2 Place a fuel receiving tray under the fuel filters.

3 Set the fuel filter handle to the "“Left-CLOSE,

Right-OPEN”.

4 Using a filter wrench, remove 2 fuel filters either
from left side or right side.
5 Coat the gaskets of new fuel filters with clean
fuel.
6 Mount the new fuel filters to the bracket.
Tighten each filter until it contacts the bracket,

the further tighten 3/4 to 1 turn by hand. fig.6-8 Fuel filter switchover handle
7 Set the handle to the “Left-AIR PURGE, Right-
OPEN”.

8 Loosen the air vent plug of the left side fuel filter.

9 When the fuel flows from the air vent plug no
longer contains air bubbles, tighten the air vent

plug.

10 Return the handle to the "Left-OPEN, Right-
CLOSE”.

11 Using the filter wrench, remove 2 right fuel filters.

12 Apply clean fuel to the gasket on the new fuel fil-

fig.6-9 Changing fuel filters (cartridge type)
ters.
13 Install the fuel filters. When the gasket contacts
the mounting surface on filter bracket, further rotate 3/4 to full turn.
14 Set the fuel filter handle to the “Right-AIR PURGE, Left-OPEN” position.
15 Loosen the air vent plug of the right side fuel filter.
16 When the fuel flows from the air vent plug no longer contains air bubbles, tighten the air vwnt plug.
17 Return the handle to the NORMAL position.
18 Start the engine, and let it under no load low idling for several minutes.
19 Check each fuel filter for fuel leaks. If fuel leaks from a filter, loosen the filter and check the gasket for
scratches or other abnormalities.
6-5
Inspection of Fuel Control Link-

age Ball Joints 0.1 mm [0.004 in.] Ball joint
Check the ball joints in the fuel control linkage for
looseness. 0.1 mm
If the amount of looseness is more than 0.1 mm [0.004 in.]
[0.004 in.], consult a Mitsubishi dealer to replace
the ball joints. Rod
Lever
Never break a seal of fuel control link to replace the
ball joints. fig.6-10 Inspection of the ball joints for looseness
If the seal on the ball joint is broken, the warranty
may be invalidated.
6-6
Lubricating System
Changing Engine Oil, Oil Filters and Bypass Oil Filter
To drain oil or change oil filters, wear gloves. Hot engine oil and parts may cause burns.
When changing engine oil, change the oil filters and bypass oil filter at the same time.
It is recommended to analyze engine oil properties at the same time.
Also change the oil filters whenever the filter alarm turns on.
The oil filters use paper elements. Never clean and reuse them. When replacing the filters, be sure to install
new packings.
Draining Engine Oil

To ensure thorough drainage, drain engine oil from the oil pan while it is still warm at 30 to 40 °C [86 to 104 °F]
after engine operation.
Be sure to suck out the engine oil when draining.

S12U: approx. 450 L [118.88 U. S. gal.]
S16U: approx. 600 L [158.50 U. S. gal.]
Changing Oil Filters (S12U)
Inspect the damage of the drain plug and filter bracket threaded sections, the center bolt and the gasket, if
any damage are found, replace it with the new one.
1 Clean the area around the oil filters.
2 Remove the center bolts and the gaskets, and Center bolt
remove the cases and elements. Gasket
3 Remove the packing from the bracket. Case
Note: Disassemble the removed elemenets to see if
Element
they have collected metal particles. If there
are metal particles on the elements, consult Packing
your Mitsubishi dealer. Set spring
4 By using a clean cloth, wipe off oil from the filter Spring
Drain plug Bracket retainer
bracket surface and inside the groove of packing
that contacts the oil filter mounting sections. fig.6-11 Changing oil filter element (S12U)
5 Mount a packing provided in a new element kit
into each grovve on the bracket.
6 Install the element, and set the spring retainer
and set spring on top of each element.
7 Install each case and the gaskets of the center
bolts, then tighten the center bolt to 83.4±4.9
N··m (8.5±0.5 kgf·m) [61.51±3.61 lbf·ft].
fig.6-12 Inspection of oil filter
6-7
Changing Oil Filters (Swithover Type) (S12U)
Inspect the damage of the drain plug and filter bracket threaded sections, the center bolt and the gasket, if
any damage are found, replace it with the new one.
Changing Oil Filters with Engine Stop

Refer to "Changing Fuel Filters (Center-Bolt Type)" (6-3) for the procedure for changing oil filter element.
Changing Oil Filters While Engine in Operation
To replace the oil filters while the engine is in operation, be sure to run the engine under no load low idling and
rated speed. If the oil filter is replaced during the engine is in high-speed operation, oil can leak from switcho-
vwe lever.
1 Clean the surrounding area of the oil filters.
2 Place a container under the oil filters to receive Left side oil filters
drained oil.
3 Remove the cover from the oil filter switchover
cock.
4 Turn the switchover cock to have pin position
“Left-Close, Right-Open”.
5 Refer to "Changing Oil Filters (S12U)" (6-7) for Right side oil filters
the procedure for changing 3 new sets of left oil
filter elements.
6 Turn the switchover cock to have pin position
“Right-Close, Left-Open”.
7 Refer to "Changing Oil Filters (S12U)" (6-7) for
the procedure for changing 3 new sets of right
oil filter elements.
8 Return the switchover cock pin to the NORMAL Left-CLOSE, "NORMAL Right-CLOSE,
Right-OPEN position" Left-OPEN
position and reinstall the cover to the switchover Open both sides
of oil filter
cock.
fig.6-13 Changing oil filters (switchover type)
6-8
Changing Oil Filters (Swithover Type) (S16U)

Changing Oil Filters with Engine Stop
Nut Bolt
2 Open the air vent valves on the filter covers to
Cover
release the internal pressure of the oil filters.
O-ring
3 Open the drain valve located located below the Spindle
Wing nut
filter body to discharge engine oil from the oil fil-
Washer
ters.
4 Remove the bolts and nuts, and dismount the fil- Element
ter covers. Body
5 Remove the filter bodies, wing nuts and wash- Drain valve
Packing
ers, and dismount the oil filter elements.
Note: Open the removed elements to see if they fig.6-14 Changing oil filter elements
have collected metal particles. If metal parti-
cles are found on the elements, consult your
Mitsubishi dealer.
6 By using a clean cloth, wipe off oil from the oil filter mounting surfaces and O-ring mounting surfaces of the
filter bodies.
7 Install the packings provided in a new element kit securely into the grooves on the filter bodies.
8 Install the elements, packings and washers, and secure them in place by tightening the wing nuts.
9 Install the filter covers to the filter bodies with the bolts and nuts.
10 Close the air vent valves and drain plug.
Changing Oil Filters While Engine in Operation
To replace the oil filters while the engine is in operation, be sure to run the engine under no load low idling and
rated speed. If the oil filter is replaced during the engine is in high-speed operation, oil can leak from switcho-
vwe lever.
2 Turn the oil filter tightening handle for an angle of Switchover handle
"Both Right and Left Filters in Use"
90 to 180 degrees in the counterclockwise direc- Tightening handle
Left side oil filter
tion.Remove the cover from the oil filter switcho- Right side oil filter
ver cock. "Left side "Right side
CLOSE" CLOSE"
3 Move the switchover handle to the "Left-STOP" position position
or "Right-STOP" position. Stopper hole
Note: When the switchover handle is operated, the
Drain valve
stopper located on the back side of the handle
Drain valve
enters the stopper hole on the flange to secure
the handle in place. fig.6-15 Oil filter switchover handle
4 Change the element and packing in the oil filter
on the side selected by the switchover handle.
5 Change the element and packing in the other oil
filter by following the same procedure.
6 Return the switchover handle to the "Both Right and Left Filters in Use" position (center position), and turn
the oil filter tightening handle to the right to tighten.
6-9
Changing Bypass Oil Filter

1 Clean the area around the oil filters.
2 Place an oil-receiving tray under the bypass oil
filter.
3 Using the provided filter wrench, remove each Apply engine oil
bypass oil filter.
Bypass oil filters

fig.6-16 Changing bypass oil filters
Note: Check the filter elements in the removed oil

filter for metal particles. If metal particles are
found, consult a Mitsubishi dealer.
4 Wipe oil from the oil filter mounting surface on
the filter bracket with a cloth.
5 Check the new bypass oil filter for proper seat-
ing of the packing.
6 Apply clean engine oil to the packing.
7 Install the bypass oil filter to the filter bracket.
When the packing contacts the mounting sur-
fig.6-17 Inspection of bypass oil filter
face on the filter bracket, further rotate 3/4 to a
full turn.
Apply clean engine oil
to packing
Do not use the filter wrench for the installation of fil-

ters to prevent filters from deformation.
fig.6-18 Bypass oil filter
6-10
Pouring Engine Oil

1 Remove the cap from the oil filler.
Oil filler
2 Pour designated engine oil to the specified level.
Specified engine oil Class CD or CF Oil level gage
(API Service Classification)
Specified engine oil capacity (oil pan)
S12U: approx. 450 L [118.88 U. S. gal]
S16U: approx. 600 L [158.50 U. S. gal]
Note: Regarding engine oil, refer to "Engine Oil" (4-4).

3 Check the oil level with the oil level gage.
If the automatic oil feeder is installed, check if it fig.6-19 Oil filler and level gage
works normally.
The oil level should be between the MAXIMUM and
MINIMUM marks on the oil level gage.
If the oil level is low, add specified type of engine oil.
4 Check the oil pan and other parts for engine oil
leaks. Repair any oil leakage found.

5 Operate the engine oil priming pump to circulate oil

in the engine.
6 Remove the rocker cover, and make sure that oil is
supplied to the valve mechanisms, and install the
rocker cover. fig.6-20 Engine oil priming pump
7 Stop the priming pump. After about 30 minutes, add engine oil until the oil level reaches the MAXIMUM
line on the oil level gage.
8 Reinstall the cap on the oil filler.
Inspection of Engine Oil Leakage After Replacing Oil Filter

1 Start the engine, and let it idle for several minutes.
2 Check the oil filter for engine oil leakage. If any leakage are found, remove and reassemble, making sure
that there are no scratches on the packing, then reinstall or reassemble the filter.
Inspection of Engine Oil for Mixing of Fuel and Water
If the engine continues to operate with engine oil mixed with fuel or water, the engine oil viscosity decreases
and this can cause serious accidents such as seizing of bearings.
Sample 1 to 2 L [0.26 to 0.53 U. S. gal] of engine oil, and check for abnormal odor and discoloration to deter-
mine the mixing of fuel and water.
If fuel is mixed with the engine oil, the oil will smell like fuel.
If water is mixed with the engine oil, the oil will be milky white.
If fuel or water is detected in the engine oil, find the cause of the problem, and repair. If the problem cannot be
corrected easily, contact a Mitsubishi dealer.
6-11
Analysis of Engine Oil Properties

For many years of trouble-free engine operation, Mitsubishi offers engine oil analysis service. This service
provides detailed information of your engine condition by analyzing a sample of engine oil collected from
your engine with special oil sampling tools.
The engine oil analysis service can provide the following information:
• It can detect the amount of extremely fine metal powder in engine oil which could result from friction. This
information helps you to locate abnormally worn internal engine parts.
• It can detect water, LLC or salt in the engine oil, which should not be contained in the engine oil.
• It can provide the information of engine oil degradation. This information helps you to arrange proper oper-
ating conditions and maintenance and to plan the most appropriate oil change intervals.
The engine oil analysis service is designed to diagnose the internal condition of an engine, which previously
required engine disassembly. It is highly recommended to take advantage of our engine oil analysis service
so you can understand your engine condition before the engine manifests abnormalities or malfunctions.
Engine Oil Sampling Tool Sets and Ordering Procedure

Table 6-1 Engine oil sampling tool sets
Product
name
Part no. Remarks Oil sampling pump
Engine oil Contains oil sam-
sampling 36291-19100 pling pump, pipes
set and bottles
1 carton: 6 bottles
Oil sample Includes suction
36291-00098
bottle set pipes and oil sam-
ple data labels.
Oil sampling bottle
The oil sampling pump is reusable, but a new oil
sample bottle and new suction pipe must be used fig.6-21 Engine oil sampling tool sets
each time.
Order an engine oil sampling tool set through the regular parts ordering channel. The analysis fee is included
in the price of the sample oil bottle. Note that an oil sample will not be analyzed unless it is contained in the
specified oil sample bottle.
There will be an additional charge for the analysis of optional items.
6-12
Cooling System
Checking LLC Concentration
Check the LLC concentration in the coolant by using an optical hydrometer for battery fluid and antifreeze.
Regarding LLC concentration, refer to "Coolant" (4-6).
Inspection and Replacement of Zinc Rods

Zinc rods (zinc electrodes) are installed at various sec-
tions of the sea water passage to prevent corrosion
Good Bad
caused by sea water.
1 Remove each zinc rod and remove deposits (scale)
from the surface.
2 If the zinc rod has worn to half the original size,
replace it with a new zinc rod. If the zinc rod is larger
than half the original size, reinstall it.
fig.6-22 Zinc rod good/bad
6-13
Changing Coolant
Coolant (containing LLC) drained from an engine is toxic, and must not be disposed of into regular sewage.
For disposal of used coolant, consult a Mitsubishi dealer.
When a coolant mixed with the LLC recommended by our company is used, replace coolamt every 12000
hours or 2 years, whichever comes first, in a regular-use or general-purpose engine. In an emergency engine,
replace coolant every 2 years.
Draining Coolant
1 Allow the coolant temperature to lower to 30 to
40 °C [86 to 104 °F].
2 Prepare a container to receive drained coolant.

3 Open the drain cocks on the engine, low-temper-
ature water pump, high-temperature water
pump, coolant pipe and expansion tank to drain
coolant. fig.6-23 Coolant drain cock (on engine)
Coolant drain cocks
fig.6-24 Coolant drain cock (on water pump)
Cleaning the Cooling System

1 Close the drain cocks or plug.
2 Pour a cleaning solution (non-corrosive solution to rubber and metals) in the cooling system, and operate
the engine with low idling for about 10 minutes, stop the engine, then drain the cleaning solution.
3 Close the drain cocks or plugs.
4 Pour fresh water, and operate the engine with low idling for about 10 minutes.
Continue flushing the cooling system in the above manner until the draining water is clear.
6-14
Pouring coolant
1 Make sure the drain cocks on the engine and
water pump are closed firmly.
2 Remove the cap from the water supply inlet of the
coolant tank, and pour undiluted LLC.
Note:(a) Determine the amounts of LLC and water to
be poured by using the LLC concentration
chart.
Coolant capacity (engine only)

S12U: approx. 520 L [137.37 U. S. gal]
S16U: approx. 700 L [184.92 U. S. gal]
3 Pour soft water with minimal impurities slowly to

the full level. fig.6-25 Coolant drain cock on the engine
4 When coolant reaches the full level securely, close
the water supply inlet cap of the coolant tank.
5 To release air from the water pump and coolant
pipes, pull the manual stop lever fully to the STOP
position and hold it in that position to keep the fuel
injection pump in no-injection condition, then sup-
ply starting air and crank the engine for about 10
seconds.
6 Wait for about 1 minute, then repeat the above
Coolant drain cocks
cranking operation twice to remove air from the
water pump. fig.6-26 Coolant drain cock on the water pump
7 Check the level gage on the coolant tank to make
sure there is sufficient coolant (surface level at Water supply inlet
about the center of the level gage). If the coolant
level is low, add coolant. Fluid level gage
8 Start the engine, and operate it under light load
until the thermostat opens the valve to allow soft
water and LLC to mix thoroughly.
9 Stop the engine, check the level gage on the cool-
ant tank. If the coolant level is low, add coolant to
the center of the fluid level gage.
Note: Always add coolant having the same LLC con- fig.6-27 Water tank coolant level
centration.
10 Check the pipe joint and other parts for coolant
leaks.
6-15
Inlet and Exhaust Systems

Inspection and Draining Water of

Exhaust Pipes and Exhaust Muf-
fler
Check the exhaust pipes and muffler for damage
and cracks. If they are damaged or cracked, con-
tact a Mitsubishi dealer.
Remove the drain plug and allow water to drain
from the exhaust muffler. Be sure to reinstall the
drain plug after draining water.
fig.6-28 Inspection and raining water of exhaust
pipes and exhaust muffler
Draining Water From Air Cooler

Chamber and Inspection for Water
Leakage Water drain cock
Loosen the water drain cock on the air cooler on air cooler
chamber to drain condensed water from the air chamber
cooler chamber, and also check the air cooler for air
leaks.
Be sure to close the drain cock after draining con-
densed water or checking water leakage.
If a large amount of water is discharged from the fig.6-29 Water drain cock on air cooler chamber
water drain cock, there may be water leaks in the (S12U)
air cooler or water pipes. If this happens, contact a
Mitsubishi dealer.
Cleaning, Inspection and Changing Pre-Cleaner
Do not service the air cleaner while the engine is

running. Maintenance of the air cleaner while the
engine is in operation can cause dust to enter the
engine and result in rapid wear of parts, leading to a
shorter service life.
Remove dust from the inlet side of the pre-cleaner
installed to the silencer of the turbocharger. Be sure

to keep the pre-cleaner clean to ensure optimum

engine performance.
fig.6-30 Cleaning pre-cleaner
1 Remove the pre-cleaner from the silencer, and
hand-wash the pre-cleaner with a mild detergent.
2 Rinse the pre-cleaner with clean water.
3 After drying thoroughly, inspect the pre-cleaner for cracks and damage.
If the pre-cleaner is cracked or damaged, replace it with a new part.
4 After cleaning, inspecting or changing the pre-cleaner, reinstall it to the silencer.
6-16
Cleaning, Inspecting and Chang-

ing Air Cleaner Element
When handling compressed air, wear safety gog-

gles, hardhat, gloves and other necessary protec-
tive gear. Compressed air may cause personal
injury when not wearing the proper protective gear.
Do not service the air cleaner while the engine is
running. Maintenance of the air cleaner while the
engine is in operation can cause dust to enter the fig.6-31 Removal of air cleaner element
engine and result in rapid wear of parts, leading to a
shorter service life.
Never knock or hit the element.
1 Remove the air cleaner cap or the wing nut.
2 Pull out the air cleaner element from the body.
3 Blow compressed air (0.69 MPa (7 kgf/cm2) [100

psi] or lower) onto the inside surface of the ele-
ment to remove dust and other contaminants.
4 To remove dust stuck on the element, blow dry
compressed air onto the outside surface from a
fig.6-32 Cleaning air cleaner element
distance.
Blow compressed air on the inside surface
toward outside along the net pattern.
Then, blow compressed air on the outside and
inside surface again.
5 After cleaning, place a light bulb in the element
to check for damage, pinholes and worn sec-
tions.
6 If any breakage are found, replace the air
cleaner element with the new one.
7 Reinstall the air cleaner element after cleaning,
fig.6-33 Inspecting air cleaner element
inspecting or replacing the air cleaner element.
If abnormalities such as damage, pinholes and thin

sections are found in the element or if the air
cleaner indicator shows red sign soon after the
cleaned element is installed, install a new filter ele-
ment in the air cleaner.
If the indicator shows a red sign, after the clean ele-
ment is installed, reset the indicator by pressing the Signal
reset button. Reset button
fig.6-34 Air cleaner indicator
6-17
Air Starter System

Draining Water and Cleaning Air
Starter Strainer
1 Close the starter valve handle of the air starter Air starter Air starter
tank. inlet outlet
2 Remove the drain plug of air starter strainer and
drain water from the air strainer.
3 Remove the cap and remove the filter from the
cap. Filter Cap
4 Clean the filter with diesel fuel, then blow com- Spring
Packing Plug
pressed air to dry.
fig.6-35 Air starter strainer
5 Reinatall the air strainer as it is.
6 Open the air starter handle slowly.
Draining Water from Air Starter

Compressor
1 Check the starter valve handle of the air strainer
tank.
2 Remove the drain plug and drain water from the
air strainer compressor.
3 Install the drain plug after draining water.
4 Open the starter valve handle of the air starter Drain plug
tank slowly.
Note: The air compressor model and shape differ on
fig.6-36 Air starter compressor
the type of the engine.
6-17
Chapter 7
LONG-TERM STORAGE
The following describes the method to store the (d) New engine oil may be used in place of
engine in a non-operable condition for more than rust-preventive oil (NP-10-2).
three months and the method for storing the engine
in an operable condition for more than three Table 7-1 Recommended rust-preventive
months. oil and corrosion inhibitor
If the engine is not properly prepared for a long- Recommended
JIS No. Application
product
term storage of more than three months, internal
Prevention of
engine parts can rust and become damaged. Be Nippon Oil Corpo- rust on
sure to follow the directions below when storing the NP-3 ration exposed
Anti Rust P-1400 machine sur-
engine for an extended period of time. faces
Nippon Oil Corpo- Prevention of
K2246
NP-9 ration rust on fuel
Storing Engine in Non-Operable Anti Rust P-2100 system
Condition for More Than 3 Months Nippon Oil Corpo-
Prevention of
rust on lubri-
Preparation for Storage NP-10-2 ration
cating sys-
Anti Rust P-230
1 Drain engine oil, and pour rust-preventive oil tem
(NP-10-2) into the engine. Ryoukou Kagaku Prevention of

V.C.I.Diana rust on air
2 Prepare a fuel mixture containing 50% rust-pre- Z1519 - volatile corrosion intake sys-
ventive oil (NP-9), and pour it into the fuel tank. inhibitor tem
3 Operate the engine at a speed of 500 to 600

min-1 (idling) for 5 to 10 minutes under no load. Maintenance during Storage
4 Immediately before stopping the engine, spray Charge the battery once a month.
volatile corrosion inhibitor (V.C.I.) through the After checking proper electrolyte level in the bat-
inlet side to prevent rust on the air intake sys- tery, charge the battery.
tem.
5 With the engine not in operation, drain the fuel Using Engine after Storage
mixture from the fuel tank. 1 Remove the cover from the engine.
6 Apply rust-preventive oil (NP-3) liberally on the 2 Remove sealing tapes from the openings of the
exposed sections of the machine. engine.
7 Seal air inlet, exhaust outlet, breather and other 3 Drain rust-preventive oil, and pour appropriate
openings with adhesive cloth tape. engine oil.
8 Cover the entire engine. Note: Regarding engine oil, refer to "Engine Oil" (4-
Note:(a) Store the engine in a well-ventilated indoor 4).
location. 4 Prepare the engine for operation by following
(b) Coolant does not need to be drained since the directions in "Preparation for Operation of
it contains long life coolant. (Add long life New or Overhauled Engine" (3-1).
coolant to increase the concentration 5 Start the engine.
between 30 and 60%.) Note: With regaes to starting the engine, refer to
(c) Post a sign at an easily noticeable location "Normal Engine Operation" (3-8).
to warn that the rust-preventive oil in the 6 Conduct a warm-up operation to circulate oil
engine must be replaced with engine oil throughout the engine.
and the fuel tank must be filled with fuel 7 Apply load and increase the engine speed to the
before operating the engine. rated speed.
7-1
Chapter 7 LONG-TERM STORAGE
Storing Engine in Operable Con-

dition for More Than 3 Months
When the engine is not operated during storage of
more than three months, internal engine parts can
rust and lose oil film. As a result, the engine can
seize when it is started after storage. To prevent
this, the engine must be operated periodically for
maintenance purposes during storage.
Operating Engine for Maintenance Pur-

poses
Operate the engine for maintenance purposes at
least once a month by following the directions
below.
1 With no fuel supplied to the engine (press the
engine stop button to shut off fuel injection),
operate the air starters three times for 10 sec-
onds at intervals of about 1 minute and check
the engine oil pressure gage to make sure the
oil pressure increases.
2 After the engine starts, operate under no load
for 5 to 10 minutes.
Note: Regarding operation of the engine, refer to
"Preparations for Operation (Pre-Start Inspec-
tion)" (3-8).
7-2
Chapter 8
TRANSPORTATION
Lifting Engine Carefully
To lift the engine, use wire ropes, shackles

and slings capable of supporting the weight
of the engine.
Attach slings to the hangers provided on the
engine to lift the engine.
Keep the engine balanced during lifting by
considering the engine's center of gravity.
Keep the angle formed by slings attached to
hangers within 60°. If the angle exceeds this
fig.8-1 Hangers for lifting
limit, excessive load is applied on the hang-
ers and may damage the hangers.
Attach wire ropes to the hanger after remov-
ing the pipe cover and the insulator near the
hanger for lifting.
To prevent wire ropes from contacting the
engine, place a cloth or other soft padding to
prevent damage to the engine and wire
ropes.
fig.8-2 Lifting the engine
8-1
Chapter 9
TROUBLESHOOTING
General Precautions
Contact a Mitsubishi Dealer for Notes Regarding Parts Handling
Repair Service Handle parts carefully.
Repairing a malfunctioning engine may require When replacing parts, use only genuine parts by
special equipment or potentially dangerous work, referring to the parts catalog.
except for relatively simple procedures such as the
change and addition of fuel, engine oil and coolant. Work Safety
In the event of the engine generates a malfunction, Be sure to use wrenches of correct size. Using a
contact a Mitsubishi dealer. wrench of a wrong size not only damages nuts but
can also cause personal injury.
Examination before Work Use correct tools and perform work with utmost
Before troubleshooting, examine possible causes caution.
of the problem and try to see if the same problem Be sure to estimate the weight of the part being dis-
has occurred in the past. mounted. If the removed part is too heavy, it may
Check the parts that may be causing the problem in fall during lifting, causing damage to the part as well
the most efficient order. as personal injury.
When disassembling a component, pay close
attention to the disassembly sequence so that you
can reassemble the component efficiently.
Notes Regarding Contamination

Dust and foreign particles are the most common
cause of rapid wear of parts.
When disassembling a component, take measures
to prevent dust and foreign particles from entering
the component being disassembled.
9-1
Chapter 9 TROUBLESHOOTING
Conditions Required for Proper Engine Operation

The following table shows the conditions required for proper engine operation, and the locations that affect
those conditions.
Table 9-1 Conditions required for proper engine operation
Required condition Affecting locations
Affected by cylinder liners, pistons, piston rings,
Complete compression of air
exhaust valves, inlet valves, and their related parts
Appropriate quantity of fuel injected in proper spray Affected by fuel injection pump, fuel injection noz-
pattern and at correct timing zles, governor, and their related parts
Affected by air cleaner, turbocharger, air cooler, and
Appropriate air volume
their related parts
Affected by bearing adjustment and engine lubricat-
All bearings in good condition
ing system
Affected by engine oil circulated inside and outside
Proper circulation of engine oil and coolant and
engine, coolant circulating parts, oil pump, water
proper temperature control
pump, etc
If any of the above conditions is not met, the engine can manifest problems such as output decrease, lack of
smoothness in operation, inability to run at low speed, excessive vibrations, and other general engine
problems.
9-2
Troubleshooting
Engine Turns, But It Does Not Start
Table 9-2 Engine turns, but it does not start (1 / 2)
Problem Cause Remedy
(1) No fuel supplied to fuel injection pump
Bleed air from fuel filter and fuel feed
pipes, and inspect each part for damage
a Air trapped in fuel supply system
and air leaks. Disassemble and repair, if
necessary.
b Empty daily fuel tank Add fuel.
Disassemble and clean, or replace ele-
c Clogged fuel filter
ment.
d Clogged fuel feed pipe Clean inside of pipe.
e Fuel not supplied due to malfunction of Disassemble and inspect, or replace fuel
A fuel feed pump or drive unit feed pump or drive unit.
Engine emits
hardly any (2) Fuel supplied to fuel injection pumps
exhaust smoke. a Loose fuel injection pipe If loosened, tighten.
Inspect control link. If there is a fuel lever
b Seized or damaged parts in fuel injection
linkage problem, disassemble and repair.
pump
Remove cam chamber cover, and operate
Malfunction of fuel lever
by hand. If parts are defective, disassem-
Control rack does not move
ble and repair, or replace.
c Seized plunger Replace, if defective.
Inspect two-way delivery valve, and disas-
d Clogged two-way delivery valve
semble and clean.
Disassemble and repair, or replace if
e Broken plunger spring
defective.
Check relation of movement with fuel
a Fuel lever does not open fully lever, and disassemble and repair if defec-
tive.
Check for uneven movement, and disas-
b Seized tappet in fuel injection pump
semble and repair, or replace.
B c Worn tappet roller or camshaft in fuel
Engine emits injection pump (reduced amount of Replace, if worn.
small amount of injected fuel)
exhaust smoke. d Seized or worn plunger in fuel injection
(Check the Check for uneven movement, and disas-
pump, worn broken plunger spring
cause of insuffi- semble and repair, or replace.
(reduced amount of injected fuel)
cient injected
fuel. e Loose tightening screw of control rack of
Tighten screw.
Check all items fuel injection pump
in A-(1) and (2)- f Defective oil sealing performance of
b, and also two-way delivery valve, or broken two- Disassemble and repair, or replace.
check items at way delivery valve spring
right.) Use fuel with viscousity suitable for ambi-
g Fuel viscosity too high to allow smooth
ent temperature. If fuel quality is improper,
flow
change fuel.
h Large amount of fuel leaks from fuel Check leak-off pipe for amount of fuel
injection nozzles, and insufficient leaks, check with nozzle tester, and
injected fuel replace defective parts if necessary.
9-3
Table 9-2 Engine turns, but it does not start (2 / 2)

(1) Improper fuel injection timing
Inspect camshaft drive section, and adjust
a Malfunction of camshaft drive
fuel injection timing correctly.
b Deviation of fuel ignition timing due to
worn fuel injection pump tappet roller or Replace if worn.
camshaft cam
(2) Poor spray condition of fuel injection nozzles
a Sticking of needle valve in fuel injection Check with nozzle tester, and disassemble
nozzle, or improper valve seat sealing and repair, or replace.
Using nozzle tester, adjust adjustment
b Fuel injection nozzle valve opening
screw so that fuel is injected at specified
pressure is low
valve opening pressure.
c Damaged or broken nozzle spring Replace if damaged.
Clean mounting surfaces of nozzle and
d Large amount of fuel leaks from nozzle
C holder. Replace if necessary.
Engine emits (3) Insufficient compression pressure (cylinder internal temperature does not reach igni-
large amount of tion temperature)
exhaust smoke.
If starting air pressure is low, increase
(Check the
pressure.
cause of igni-
If engine oil viscosity is high, heat oil or
tion failure a Inadequate rotation speed
change oil to one with appropriate viscos-
despite suffi-
ity.
cient amount of
Repair if there are other abnormalities.
injected fuel.)
b Inlet/exhaust valve not contacting valve Disassemble and repair by lapping valve
seat properly in valve seat, or replace if necessary.
Check for sticking of valve and valve
guide, incorrect tappet assembly, and
c Valve remaining open
valve clearance, and correct abnormalities
if necessary.
d Leaking of compression pressure due to
Disassemble and repair, or replace if nec-
worn cylinder liners or sticking of piston
essary.
rings
Check for gas leaks, and tighten cylinder
e Leaking of compression pressure from
cover properly. Repair gas seal surface or
cylinder cover
replace gas seal ring, if necessary.
(4) Inappropriate fuel
Drain fuel and check. Change to higher-
a Inappropriate fuel or water in fuel
quality fuel, if necessary.
9-4
Engine Does Not Turn

Table 9-3 Engine does not turn
A Inspect starting valve, and repair or
a Malfunction of starting valve
Malfunction of replace.
starting air sys- Check air tank pressure, and increase
tem. b Starting air pressure lower than specified
pressure if low.
Disassemble and inspect pistons, con-
necting rods, crankshaft, camshaft, bush-
a Seizing of moving parts in engine
ings of timing gear and others, inlet and
B exhaust valves, etc., and repair.
Malfunction of
b Deviation of timing due to incorrect
mechanical
engine assembly Disassemble and repair.
engine parts
Pistons are hitting valves
c Viscosity of engine oil too high, or clotted
Change oil to one with lower viscosity.
oil
9-5
Engine Output is Low

Table 9-4 Engine output is low
(1) Tendency of engine moving parts toward seizing
Check abnormal heating of parts listed in
a Tendency toward seizing due to insuffi-
A B-a in Table 9-3, and repair defective
cient clearances of engine parts
Engine emits parts.
small amount of Check oil level, oil pressure and oil viscos-
exhaust. ity, and add, adjust or replace oil, and also
(Engine output b Inadequate lubrication
clean lubricating system if there is oil clog-
and speed are ging.
inadequate due
to insufficient (2) Insufficient amount of fuel supply
injected fuel.) a Clogged fuel system or loose pipe Clean or replace. (Refer to A in Table 9-2.)
b Malfunction of fuel supply or injection
Clean or replace. (Refer to B in Table 9-2.)
system
(1) Engine knocking and excessive white smoke when engine is cold
Injection timing too advanced Correct. (Refer to C-(1) in Table 9-2.)
(2) Poor combustion due to low compression pressure
Check for valve, valve guide sticking and
a Valve remaining open.
valve clearances, and repair.
B
Engine emits b Inlet/exhaust valve not contacting valve Disassemble and correct by lapping valve
excessive white seat properly in valve seat, or replace if necessary.
exhaust smoke. Disassemble and repair, or replace if nec-
c Broken inlet/exhaust valve spring
essary.
d Leaking of compression pressure due to Disassemble and repair, or replace if nec-
worn cylinders or sticking of piston rings. essary.
Open drain cock and check fuel. Drain
(3) Poor fuel condition (water in fuel)
water or change fuel.
(1) Fuel injection timing too retarded Correct. (Refer to C-(1) in Table 9-2.)
(2) Uneven fuel injection among cylinders
(Poor combustion condition, unstable rotation with knocking)
a One or more worn tappet rollers or cams
on camshaft in fuel injection pumps Replace if worn.
causing deviation of fuel injection timing
b One or more plunger springs seized,
Disassemble, repair or replace.
worn or broken
C
(3) Poor spray condition of some fuel
Engine emits
injection nozzles
excessive black
(Exhaust temperature of cylinders with Refer to C-(2) in Table 9-2.
exhaust smoke.
poor fuel spray condition may become
high.)
(4) Poor combustion due to insufficient inlet
a Malfunction of turbocharger (damage of Disassemble and repair, or replace if nec-
vanes, seizing of bearing, etc.) essary.
b Malfunction of inlet/exhaust valve Refer to B-(2) in Table 9-4.
Disassemble and clean, or replace if nec-
c Air cleaner clogged with dust
essary.
9-6
Engine Knocks
Table 9-5 Engine knocks
A
Engine knocks slightly and emits Fuel injection timing too retarded Refer to C-(1) in Table 9-2.
black exhaust smoke.
B
Fuel injection timing is too
Knocking is severe, and exhaust Refer to C-(1) in Table 9-2.
advanced
smoke is white.
Uneven fuel injection among cylinders
C a Excessive fuel injection in some
Refer to C-(2)-a in Table 9-2.
Knocking is severe in certain cyl- cylinders
inders. b Fuel injection timing too
Refer to C-(2)-b in Table 9-2.
advanced in some cylinders
D Improper spray of fuel by fuel injection nozzles
Ignition retardation occurs and
results in simultaneous ignition to Fuel is not sprayed in proper con-
Refer to C-(2) in Table 9-2.
cause severe knocking. dition in some cylinders.
E Low engine compression
Ignition retardation occurs fre-
quently and results in simulta- Amount of intake air is low in
neous ignition to cause severe Refer to C-(3) in Table 9-2.
some cylinders.
knocking.
Engine oil rising above pistons
F a Oil level too high in crankcase Discharge oil to appropriate level.
Injection of fuel generates knock-
b Worn piston rings or sticking of Check crankcase breather pipe
ing, and engine emits large
piston rings, resulting in inade- for gas leak, and replace if there
amount of black or gray exhaust
quate scraping of oil are defective parts.
smoke.
When oil does not rise, engine Check crankcase breather pipe
c Excessive clearance between
does not knock severely and for gas leak, and replace if neces-
cylinder and piston
emits bluish white exhaust sary.
smoke. Change to high-quality oil with
d Engine oil viscosity too low
higher viscosity.
a Excessive connecting rod bear-
Disassemble and inspect, and
ing clearance, or bearing metal
repair or replace if necessary.
flaking.
G
Abnormal noise produced when b Loose connecting rod cap tight- Disassemble and inspect, and
injection is stopped suddenly and ening bolts repair or replace if necessary.
engine is allowed to rotate by Check crankcase breather pipe
inertia c Excessive clearance between
for gas leak, and replace if neces-
(engine mechanical failure) cylinder and piston
sary.
d Piston hitting foreign item fallen
Disassemble and inspect.
inside cylinder
H
Low compression temperature
Operate engine until it warms up
and retarded ignition cause Engine too cold
before increasing engine speed.
severe knocking, especially after
engine starts in cold weather.
9-7
Engine Produces Large Amount of Smoke While in Operation

Table 9-6 Engine produces large amount of smoke while in operation
(1) Severe knocking
Fuel injection timing too
Refer to C-(1) in Table 9-2.
advanced
(2) Knocking produced only in cylinders with insufficient compression
Low engine compression Refer to C-(3) in Table 9-2.
(3) Improper fuel
Open drain cock and check.
a Water contained in fuel
A Remove water or change fuel.
Engine emits excessive white (4) Other
exhaust smoke. a Large amount engine oil rising Inspect and repair or replace as
above pistons described in F in Table 9-5.
Inspect temperature regulator,
b Engine too cold, resulting in
and adjust it properly to prevent
poor combustion
overcooling.
Unburned oil is trapped in
c Engine operating too long with exhaust pipe. White smoke stops
no load after engine is operated under
load.
(1) Minor knocking
a Injection timing too retarded Refer to C-(1) in Table 9-2.
(2) Other
Check if fuel injection pump rack
a Excessive amount of injected
set screw or bolt is loose, and
fuel
repair.
B
Engine emits excessive black Inspect, and repair or replace as
b Fuel injection not uniform
exhaust smoke. described in C-(2) in Table 9-4.
c Improper spray of fuel by fuel Inspect, and repair or replace as
injection nozzles described in C-(2) in Table 9-4.
Inspect, and repair or replace as
d Low engine compression
described in C-(2) in Table 9-4.
e Large amount engine oil rising Inspect and repair or replace as
above pistons described in F in Table 9-5.
Engine Operates at High Speed and Does Not Stop

Table 9-7 Engine operates at high speed and does not stop
Link between fuel increase/
decrease lever and governor fail- Check if link returns without
ing to return smoothly to original catching, and repair if necessary.
Fuel injection pump does not set position
to no-injection condition. Repair if rack does not move in
a Loose control link lever
connection with governor lever.
b Sticking of rack disallowing its Check rack for smoothness, and
return to original position disassemble and repair.
9-8
Malfunction of Lubricating System

Table 9-8 Malfunction of lubrication system
Check oil level gage, and add oil
a Engine oil level too low
if level is low.
b Engine oil viscosity too high for
smooth pumping of oil Change oil to one with appropri-
(Especially when temperature ate viscosity.
is low)
Remove pipe from pump dis-
charge side, and check oil dis-
A c Clogged oil pump suction side
charge. If no oil is discharged,
Oil pressure does not rise imme- or strainer screen
disassemble, clean and repair, or
diately after startup. replace.
Repair or replace defective parts,
d Malfunction of regulator valve such as broken valve spring and
seized valve.
e Clogged oil filter element Disassemble, clean, replace.
Disconnect oil pressure gage
f Defective oil pressure gage pipe. If oil pours out, replace oil
pressure gage.
a Clogged oil filter element Disassemble, clean, replace.
Oil temperature rises and causes
b Engine oil viscosity too low oil pressure to drop. Change oil to
B one with higher viscosity.
Oil pressure drops gradually dur- Engine is overheated. Do not
ing operation. c Abnormally high oil tempera-
operate engine until oil tempera-
ture
ture is low.
d Tendency toward bearing seiz-
Disassemble, repair.
ing
a Damage bearing causing
C Disassemble and repair.
increased oil leaks
Oil pressure abruptly drops dur-
ing operation and remains there. b Cracking in engine oil pas- Check for leaks, and repair or
sage, or oil leakage from joint replace defective parts.
D
Engine oil level too low, causing Check oil level gage, and add oil
Oil pressure fluctuates suddenly
air to mix into oil if level is low.
during operation.
9-9
Chapter 10
MAIN SPECIFICATIONS
Main Specifications
Table 10-1 Main specifications table
Engine model S12U S16U
Type Water-cooled, 4-stroke cycle, turbocharged diesel, air cooler
Number of cylinders,
12-V 16-V
arrangement
Bore×stroke (mm [in.]) 240×260 [9.45×10.2]
Total displacement
141.1 [37.27] 188.2 [49.72]
(L [U. S. gal])
Combustion type Direct injection
Compression ratio 13.5:1
1-9-6-14-2-10-4-12
Firing order 1-12-5-8-3-10-6-7-2-11-4-9
-8-16-3-11-7-15-5-13
Counterclockwise as viewed from flywheel or clockwise
Rotating direction
(reverse rotation by option)
Dimensions 3520×1842×2374 4586×1710×2490
(L×W×H (mm) [in.]) [139×72.5×93.5] [181×67.3×98]
Dry weight (kg [lb.]) Approx. 15500 [34172] Approx. 20500 [45195]
Fuel Diesel fuel (refer to 4-3 "Fuel Use Limit Property Guideline")
Fuel injection pump Bosh unit pump
WOODWARD UG8L, UG8D hydaulic governor,
Governor WOODWARD EG10P electrohydraulic governor or
TOHO SEISAKUSHO SG4080C electric governor
Fuel filter Wire-element type (primary) and paper-element type (secondary)
Fuel injection nozzle Hole type
Lubricating system Forced circulation type (pressure feed by oil pump)
Lubrication oil (oil pan) Class CD or CF oil (API service classification)
Approx. 450 [118.88] Approx. 600 [158.50]
(L [U. S. gal])
Oil filter Paper-element type
Oil cooler Water cooled multi-plate
Cooling system Force water cooling by centrifugal pump
Cooling water capacity
Approx. 520 [137.37] Approx. 700 [184.92]
(L [U. S. gal])
Water pump Centrifugal volute type
Starting system Air-compression direct entry type
Turbocharger Mitsubishi TD24×2 Mitsubishi TD18×4
10-1

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What is the purpose of this manual?

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What safety precautions are emphasized in the manual?

October 2003

Printed in Japan Pub.No. 99080-20120

Failure to follow directions in this manual can lead to serious accidents.

Indicates a highly hazardous situation which, if not avoided, can result in

death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, can result

in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, can result

in minor or moderate injury.

Indicates a potentially hazardous situation which, if not avoided, can result

Note Indicates important information or information which is useful for engine

• Pressure: 1 MPa = 10.197 kgf/cm2

Chapter 1 Engine Oil and LLC............................. 1-4

Warning Stay Clear of All Rotating and when restarting................................................. 1-5

Coolant ................................................4-6 Periodic Maintenance Chart for Engine in

Examples of Abnormalities Caused by LLC..... 4-8 (Wire-Element Type)..................................................6-1

Chart....................................................5-1 Changing Oil Filters (Swithover Type)

and Exhaust Muffler ....................................... 6-16 Engine Output is Low.................................................9-6

Warning Stay Clear of All Rotating and Moving Parts

Check surrounding area for safety

Warning Be Careful of Warning Be Careful of

Do not dismount heat protection

Warning Be Careful Caution Be Careful of

Caution Service Bat- Caution When Abnor-

Caution Other Cautions

Conduct proper maintenance of Use appropriate tools for mainte-

Caution About Warning Labels

fig.1-7 Caution for burns

fig.1-8 Warning for rotating parts

fig.1-9 Caution for referring to manual

fig.1-10 Caution for burns

fig.2-1 S12U engine left view

S12U Right View

S16U Left View

Fuel injection pipe

Turbocharger Fuel injection pump

Silencer Cylinder head

Oil filler Fuel priming pump

fig.2-3 S16U engine left view

S16U Right View

   

fig.2-4 S16U engine right view

Equipment and Instrument

From air starter tank

Manual Stop Lever

Tachometer Fuel Pressure Gage

Oil Pressure Gage

Oil Temperature Gage

Jacket Coolant Temperature Gage

Oil Cooler Coolant Temperature Gage

Air Cooler Coolant Temperature Gage

Jacket Coolant Pressure Gage

Engine Protection Devices

Low Oil Pressure Alarm

High Coolant Temperature Alarm

Oil Filter Clog Alarm

Excessively high oil viscosity causes power loss

and an abnormal rise of oil temperature, while

lubrication and leakage of combustion gas that