Mitsubishi S6R2 Series Manual

January 2011
Pub. No. 99410-12140
The operator and supervisor are requested to read this Oper-
ation and Maintenance Manual carefully before operating the
engine or conducting inspection and maintenance.
Never operate the engine or conduct maintenance work with-
out completely understanding this manual.
OPERATION&
MAINTENANCEMANUAL
1

i
FOREWORD
This operation and maintenance manual contains detailed operation, inspection
and maintenance information for engines from Mitsubishi Heavy Industries, Ltd.
Please be forewarned that there are contents which are overlapping between the
chapters.
Please read this manual thoroughly before proceeding with operation, inspection,
and maintenance work for correct use and servicing.
Failure to follow directions in this manual may result in serious accidents.
Please observe the contents of the controls which are applied in the countries or
areas when using the engines from Mitsubishi Heavy Industries, Ltd.

ii
FOREWORD
LIMITED WARRANTY
If Mitsubishi Heavy Industries, Ltd. examines the returned parts and any failure at manufacturing is found, Mitsubi-
shi Heavy Industries, Ltd. shall repair or exchange the parts.
Mitsubishi Heavy Industries, Ltd.'s warranty is limited to the compensation work of repair or replacement of parts.
The warranty coverage is effective for the original purchaser only. Those to whom ownership is later transferred are
not provided with the warranty. However the warranty coverage is effective for the ultimate purchaser and each sub-
sequent purchaser for emission-related parts.
Mitsubishi Heavy Industries, Ltd. makes no warranties, either expressed or implied,
except as provided in this manual, including, but not limited to, warranties as to market-
ability, merchantability, fitness for a particular purpose or use, or against infringement of
any patent.
Mitsubishi Heavy Industries, Ltd. will not be liable for any damages or consequential
damages, including, but not limited to, damages or other costs resulting from any abuse,
misuse, misapplication of the engine and devices supplied from us.
Mitsubishi Heavy Industries, Ltd. will not be liable for any damages or personal injuries
resulting from any modification, without our written permission, of the engine and
devices supplied from us.
Mitsubishi Heavy Industries, Ltd. will not be liable for any damages or production losses
caused by the use of fuel, engine oil and/or long life coolant (LLC) that we are not recom-
mended.
The owner of the engine is responsible for the performance of the required maintenance
listed in this operation manual.
When performing the maintenance, follow the service manual published by Mitsubishi
Heavy Industries, Ltd.
Mitsubishi Heavy Industries, Ltd. may deny the warranty coverage if the engine or part
has failed due to inadequate or improper maintenance.

iii
FOREWORD
EMISSION WARRANTY
Warranty Coverage
Mitsubishi Heavy Industries, Ltd. warrants to the first owner and each subsequent purchaser of a new non-road die-
sel engine that the emission control system of your engine:
is designed, built and equipped so as to conform at the time of sales with all applicable regulation of the U.S. Envi-
ronmental Protection Agency. If the vehicle in which the engine is installed is registered in the state of California, a
separate California emission regulation also applies.
is free from the defects in material and workmanship which will cause the engine to fail to meet these regulations
within the warranty period.
Warranty Period
Then its warranty period is 5 years or 3000 hours, whichever comes first.
However, if your engine warranty period is longer than the emission warranty period, the emission warranty period
extends to same as the engine warranty period.
Below warranty period shall begin on the date the engine is delivered to the first owner.
Warranted pParts
Mitsubishi Heavy Industries, Ltd. warrants the parts which will increase the emission of pollutants when they
become defective.
The followings are examples.
Inlet/Exhaust manifold
Crankcase ventilation system
Fuel system
Limited Warranty
It conforms to "LIMITED WARRANTY" (page ii).
The following warranty applies to the engines that are approved of the emission regulation of the U.S. Environ-
mental Protection Agency.

iv
FOREWORD
CALIFORNIA EMISSION CONTROL WARRANTY STATE-
MENT YOU WARRANTY RIGHTS AND OBLIGATIONS
The California Air Resources Board (CARB) and Mitsubishi Heavy Industries, Ltd. are pleased to explain the
emission control system warranty on you 2011 or later engine. In California, new heavy-duty off-road engines
must be designed, built, and equipped to meet the State's stringent anti-smog standards. Mitsubishi Heavy
Industries, Ltd. must warrant the emission control system on your engine for the periods of time listed below
provided there has been no abuse, neglect or improper maintenance of your engine.
Your emission control system may include parts such as the fuel-injection system and the air induction system. Also
included may be hoses, belts, connectors and other emission-related assemblies.
Where a warrantable condition exists, Mitsubishi Heavy Industries, Ltd. will repair your heavy-duty off-road engine
at no cost to you including diagnosis, parts, and labor.
Manufacurer's warranty coverage:
The 2011 and later heavy-duty off-road engines are warranted for the warranty period. If any emission-related part
on your engine is defective, the part will be repaired or replaced by Mitsubishi Heavy Industries, Ltd.
Owner's warranty responsiblities
As the heavy-duty off-road engine owner, you are responsible for the performance of the required maintenance
listed in your owner's manual. Mitsubishi Heavy Industries, Ltd. recommends that you retain all receipts covering
maintenance on your heavy-duty off-road engine, but Mitsubishi Heavy Industries, Ltd. can not deny warranty sole-
ly for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.
As the heavy-duty off-road engine owner, you should however be aware that Mitsubishi Heavy Industries, Ltd. may
deny you warranty coverage if your heavy-duty off-road engine or a part has failed due to abuse, neglect, improper
maintenance or unapproved modifications.
Your engine is designed to operate on diesel fuel only. Use of any other fuel may result in your engine no longer
operating in compliance with California's emissions requirements.
You are responsible for initiating the warranty process. The Air Rexources Board suggests that you present your
heavy-duty off-road engine to a Mitsubishi Heavy Industries, Ltd. dealer or distributor dealer as soon as problem
exists. The warranty repairs will be completed by the dealer or distributor as expeditiously as possible.
If you have any questions regarding your warranty rights and responsibilities, you should contact Mitsubishi
Engine North America at 1-630-268-0750.
The following warranty applies to the engines that are approved of the emission regulation of the California Air
Resources Board (CARB).

v
FOREWORD
Warranty coverage
(a) The warranty period shall begin on the date the engine or equipment is delivered to an ultimate purchaser.
(b) Mitsubishi Heavy Industries, Ltd. warrants to the ultimate purchaser and each subsequent purchaser of the en-
gine registered in the state of California that the engine is:
(1) Designed, built and equipped so as to conform with all applicable regulations adopted by the Air Resources
Board.
(2) Free from defects in materials and workmanship which cause the failure of a warranted part to be identical
in all material respects to the parts as described in Mitsubishi Heavy Industries, Ltd.'s application for certifi-
cation for a period of 5 years or 3,000 hours of operation, whichever occurs first. In the absence of a device
to measure hours of use, the engine shall be warranted for a period of 5 years. For all engines rated less
than 19 kW, and for constant-speed engines rated under 37 kW with rated speeds higher than or equal to
3,000 min-1, the period of 2 years or 1,500 hours of operation, whichever occurs first, shall apply. In the ab-
sence of a device to measure hours of use, the engine shall be warranted for a period of 2 years.
(c) The warranty on emission-related parts shall be interpreted as follows:
(1) Any warranted part which is not scheduled for replacement as required maintenance in the written instruc-
tions required by Subsection (e) shall be warranted for the warranty period defined in Subsection (b) (2). If
any such part fails during the period of warranty coverage, it shall be repaired or replaced by Mitsubishi
Heavy Industries, Ltd. according to Subsection (4) below. Any such part repaired or replaced under the war-
ranty shall be warranted for the remaining warranty period.
(2) Any warranted part which is scheduled only for regular inspection in the written instructions required by Sub-
section (e) shall be warranted for the warranty period defined in Subsection (b) (2). A statement in such writ-
ten instructions to the effect of "repair or replace as necessary" shall not reduce the period of warranty
coverage. Any such part repaired or replaced under the warranty shall be warranted for the remaining war-
ranty period.
(3) Any warranted part which is scheduled for replacement as required maintenance in the written instructions
required in Subsection (e) shall be warranted for the period of time prior to the first scheduled replacement
point for that part. If the part fails prior to the first scheduled replacement, the part shall be repaired or re-
placed by Mitsubishi Heavy Industries, Ltd. according to Subsection (4) below. Any such part repaired or
replaced under warranty shall be warranted for the remainder of the period prior to the first scheduled re-
placement point for the part.
(4) Repair or replacement of any warranted part under the warranty provisions shall be performed at no charge
to the owner at a warranty station.
(5) Notwithstanding the provisions of Subsection (4) above, warranty services or repairs shall be provided at all
Mitsubishi Heavy Industries, Ltd. distribution centers that are franchised to service the subject engines.
(6) The owner shall not be charged for diagnostic labor that leads to the determination that a warranted part is
in fact defective, provided that such diagnostic work is performed at a warranty station.
(7) Mitsubishi Heavy Industries, Ltd. shall be liable for damages to other engine components proximately caused
by failure under warranty of any warranted part.
(8) Throughout the engine's warranty period defined in Subsection (b) (2), Mitsubishi Heavy Industries, Ltd. shall
maintain a supply of warranted parts sufficient to meet the expected demand for such parts.
(9) Any replacement part, as defined in Section 1900(b)(13), Title 13, may be used in the performance of any
maintenance or repairs and must be provided without charge to the owner. It is not necessary for replace-
ment parts to be the same brand or by the same manufacturer as the original part sold with the engine.
Such use shall not reduce the warranty obligations of the engine manufacturer.

vi
FOREWORD
(10) Add-on or modified parts, as defined in Section 1900(b)(1) and (b)(10), Title 13, that are not exempted by
the Air Resources Board may not be used. The use of any non-exempted add-on or modified parts shall be
grounds for disallowing a warranty claim made in accordance with this article. The engine manufacturer
shall not be liable under this article to warrant failures of warranted parts caused by the use of a non-
exempted add-on or modified part.
(11) The Air Resources Board may request and, in such case, Mitsubishi Heavy Industries, Ltd. shall provide,
any documents which describe that Mitsubishi Heavy Industries, Ltd.'s warranty procedures or policies.
(d) Warranted parts list.
(1) Fuel metering system
(A) Fuel injection system.
(B) Air/fuel ratio feedback and control system.
(C) Cold start enrichment system.
(2) Air induction system
(A) Controlled hot air intake system.
(B) Intake manifold.
(C) Heat riser valve and assembly.
(D) Turbocharger/supercharger systems.
(E) Charged air cooling systems.
(3) Exhaust gas recirculation (EGR) system
(A) EGR valve body, and carburetor spacer if applicable.
(B) EGR rate feedback and control system.
(4) Air injection system
(A) Air pump or pulse valve.
(B) Valves affecting distribution of flow.
(C) Distribution manifold.
(5) Catalyst or thermal reactor system
(A) Catalytic converter.
(B) Thermal reactor.
(C) Exhaust manifold.
(6) Particulate controls
(A) Traps, filters, precipitators, and any other devices used to capture particulate emissions.
(B) Regenerators, oxidizers, fuel additive devices, and any other device used to regenerate or aid in the
regeneration of the particulate control device.
(C) Control device enclosures and manifolding.
(D) Smoke puff limiters.
(7) Advances oxides of nitrogen (NOx) controls
(A) NOx absorbers.
(B) Lean NOx catalysts.
(C) Selective catalyst reduction.
(D) Reductant (urea/fuel) containers/dispensing systems.
(8) Positive crankcase ventilation (PCV) system
(A) PCV valve.
(B) Oil filler cap

vii
FOREWORD
(9) Miscellaneous items used in above systems
(A) Vacuum, temperature, and time sensitive valves and switches.
(B) Electronic control units, sensors, solenoids, and wiring harnesses.
(C) Hoses, belts, connectors, assemblies, clamps, fittings, tubing, sealing gaskets or devices, and mount-
ing hardware.
(D) Pulleys, belts and idlers.
(E) Emission control information labels.
(F) Any other part with the primary purpose of reducing emissions or that can increase emission during fail-
ure without significantly degrading engine performance.
(e) Mitsubishi Heavy Industries, Ltd. shall furnish with each new engine written instructions for the maintenance and
use of the engine by the owner.
Limited warranty
Refer to "LIMITED WARRANTY" (Page ii).

viii
FOREWORD
IMPORTANT INFORMATION
To avoid the potential hazard, accident prevention
activities must be planned methodically and con-
ducted continually by considering all aspect of
engine operation, maintenance and inspection. All
related personnel, including managers and supervi-
sors, should actively participate, recognize their roles
and organize themselves and their work to ensure a
safe environment.
The foremost safety objective is to prevent accidents
which may result in injury or death, or equipment
damage.
Always observe laws or regulations of the local or
federal/national government.
Mitsubishi Heavy Industries, Ltd. cannot foresee all
potential dangers of the engine, potential danger
resulting from human error and other causes, or dan-
ger caused by a specific environment in which the
engine is used. Since there are many actions that
cannot be performed or must not be performed, it is
impossible 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, maintain-
ing and inspecting the engine.
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 thor-
ough knowledge of engines and their dangers and
who also have received risk avoidance training.
To prevent an accident, do not attempt to carry out
any operation other than those described in this man-
ual, and do not use the engine for any unapproved
purpose.
When the ownership of the engine is transferred, be
sure to provide this manual with the engine to the
new owner. Also inform Mitsubishi Heavy Industries,
Ltd. of the name and address of the new owner of the
engine.
This manual is copyrighted and all rights are
reserved. No part of this manual, including illustra-
tions and technical references, may be photocopied,
translated, or reproduced in any electronic medium
or machine readable form without prior written con-
sent from Mitsubishi Heavy Industries, Ltd.
The contents in this manual are subject to change at
any time without notice for improvement of the
engine.
Pictures or illustrations of the product in this manual
may differ from those of product you have. Please
note that, depending on specifications, items
described in this manual may differ from those on
your engine in shape, or may not be installed on your
engine.
Please contact a dealer of Mitsubishi Heavy Indus-
tries, Ltd. if you need more information or if you have
any questions.
If you lost or damaged this manual, obtain a new
copy at a dealer of Mitsubishi Heavy Industries, Ltd.
as soon as possible.
Mitsubishi Heavy Industries, Ltd. recommends the
engine owner to install an hour meter on the engine
due to monitor correct running intervals and to per-
form the maintenance at the appropriate timing.

ix
FOREWORD
WARNING INDICATION
The following means are used to call the attention of the operators and maintenance personnel to potential dangers
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,
using the following five classifications to indicate the degree of potential hazard.
Failure to follow these directions could lead to serious accidents which could result in personal injury, or death in
the worst case.
Understand the directions well, and handle engines with following directions.
Indicates an immediately hazardous situation which, if not avoided, will result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury.
Indicates a potentially hazardous situation which, if not avoided, may result in property
damage.
Note: Indicates important information or information which is useful for engine operation.

x
FOREWORD
UNITS OF MEASUREMENT
Measurements are based on the International System of Units (SI), and they are converted to the metric system
units in this manual using 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 = 0.75 cmHg
Meter of water:1 kPa = 10.197 cmH2O (cmAq)
Rotation speed:1 min-1 = 1 rpm
Kinetic viscosity:1 mm2/s = 1 cSt
ABBREVIATIONS, STANDARD AND OTHERS
API = American Petroleum Institute
ASTM = American Society for Testing and Materials
ISO = International Organization for Standardization
JIS = Japanese Industrial Standards
LLC = Long Life Coolant
MIL = Military Specifications and Standards
MSDS = Material Safety Data Sheet
SAE = Society of Automotive Engineers

CONTENTS-1
CONTENTS
Chapter 1
BASIC SAFETY PRECAUTIONS
Fire and Explosions.............................1-1
Keep Flames Away.......................................... 1-1
Always Swich the Water Heater ON
(Emergency generator with water heater)........ 1-1
Keep Engine Surrounding Area Tidy and Clean1-1
Ventilation of Engine Room.............................. 1-1
Do Not Open Side Cover Until Engine Cools... 1-1
Care for Fuel, Oil and Exhaust Gas Leakage.. 1-1
Use Explosion-proof Lighting Apparatus.......... 1-1
Prevent Electrical Wires From Short-circuiting. 1-1
Keep Fire Extinguishers and a First-aid Kit
Handy............................................................... 1-1
Stay Clear of All Rotating and Moving
Parts....................................................1-2
Install Protective Covers Around Rotating Parts1-2
Check Work Area for Safety............................. 1-2
Stay Clear of Moving Parts While Engine is
Running............................................................ 1-2
Lockout and Tagout ......................................... 1-2
Keep Engine Stopped During Servicing........... 1-2
Always Restore Engine Turning Tools After Use1-2
Be Careful of Exhaust Fume Poisoning1-3
Operate Engine in a Well-ventilated Area........ 1-3
Protect Ears From Noise.....................1-3
Wear Ear Plugs................................................ 1-3
Be Careful of Falling Down..................1-3
Lift Engine Carefully......................................... 1-3
Do Not Climb Onto the Engine......................... 1-3
Always Prepare Stable Scaffold....................... 1-3
Be Careful of Burns.............................1-4
Do Not Touch the Engine During or Immediately
After Operation................................................. 1-4
Refill Coolant Only After the Coolant Temperature
Dropped ........................................................... 1-4
Be careful of burns when changing oil............. 1-4
Never Remove Heat Shields............................ 1-4
Be Careful of Opening and Closing Radiator
Cap .................................................................. 1-4
Do Not Touch High Pressure Injection Fuel..... 1-4
Be Careful When Handling Fuel,
Engine Oil or LLC................................1-5
Use Only Specified Fuel, Engine Oil and LLC . 1-5
Handle LLC Carefully....................................... 1-5
Proper Disposal of Waste Oil, LLC and Coolant1-5
When Abnormality Occurs...................1-5
Do Not Add Coolant Immediately After a Sudden
Stop Due to Overheating..................................1-5
Stop Operation Immediately If You Notice Any
Unusual Symptoms..........................................1-5
Avoid Immediate Restart After Abnormal Stop.1-5
Avoid Continuous Engine Operation at Low Oil
Pressure...........................................................1-5
If Belt Breaks, Stop Engine Immediately..........1-5
Battery.................................................1-6
Handle the Battery Correctly............................1-6
Other Cautions....................................1-7
Never Modify Engine........................................1-7
Observe Safety Rules at Work Site..................1-7
Work Clothing and Protective Gear..................1-7
Never Break Seals ...........................................1-7
Perform All Specified Pre-operation Inspections
and Periodic Inspections..................................1-7
Break-in the Engine..........................................1-7
Warm-up the Engine Before Use .....................1-7
Never Operate the Engine in an Overloaded
Condition..........................................................1-7
Conduct Cooling Operation Before Stopping the
Engine..............................................................1-8
Do Not Operate Engine Continuously Under Low
Load .................................................................1-8
Protection of the Engine Against Water Entry..1-8
Conduct Proper Maintenance of Air Cleaner....1-8
Use of Tools Optimum for Each Work..............1-8
Avoidance of Prolonged Time of Starter
Operation .........................................................1-8
Do Not Turn Off the Battery Switch During
Operation .........................................................1-8
Cautionary Instructions for Transporting the
Engine..............................................................1-8
Warning Labels...................................1-9
Maintenance of Warning Labels.......................1-9
Chapter 2
NAME OF PARTS
Engine External Diagrams..................2-1
Left Side...........................................................2-1
Right Side.........................................................2-1
Equipment and Instrument..................2-2
Start and Stop Instrument ................................2-2
Instruments ......................................................2-3
Engine Protection Devices..................2-4
Oil Pressure Switch..........................................2-4
Thermo Switch .................................................2-4

CONTENTS
CONTENTS-2
Oil Filter Alarm Switch...................................... 2-4
Revolution Detection Pickup............................ 2-5
Air Cleaner Indicator ........................................ 2-5
Using Turning Gear.............................2-6
Chapter 3
OPERATION
Operational Environment.....................3-1
Preparation for Operating New or
Overhauled Engine..............................3-1
Preparation of Fuel System.............................. 3-1
Preparation of Lubrication System................... 3-4
Preparation of Cooling System ........................ 3-5
Preparation of Electrical System...................... 3-6
Test Operation ................................................. 3-7
Normal Engine Operation....................3-8
Preparations for Operation..................3-8
Engine External - Inspect................................. 3-8
Fuel Tank Oil Level - Check............................. 3-9
Fuel Control Link - Check................................. 3-9
Engine Oil Level - Check.................................. 3-9
Coolant Level - Check.................................... 3-10
Air Cleaner - Check for Clogging ................... 3-10
Air Tank - Drain Water ................................... 3-10
Air Tank Air Pressure - Check........................ 3-11
Temperature of Damper - Check ................... 3-11
Start...................................................3-12
Warming-up Operation......................3-12
Checking Engine Oil Pressure ....................... 3-12
External Inspection During Warm-up............. 3-12
Run....................................................3-13
Cautions During Operation............................. 3-13
Inspection During Operation .......................... 3-13
Stop...................................................3-14
Emergency Stop............................................. 3-14
Inspection After Stopping............................... 3-14
Chapter 4
FUEL
Recommended Fuel............................4-1
Handling Fuel ......................................4-1
Fuel Specification................................4-2
Chapter 5
ENGINE OIL
Recommended Engine Oil..................5-1
Engine Oil Grade ................................5-1
Engine Oil Specification......................5-2
Selection of Oil Viscosity.....................5-3
Handling Engine Oil............................5-3
Service Limits of Engine Oil................5-4
Definition of Properties of Engine Oil..5-5
Kinetic Viscosity ...............................................5-5
Base Number ...................................................5-5
Acid Number ....................................................5-5
Water Content..................................................5-5
Flash Point .......................................................5-5
Insoluble...........................................................5-5
Engine Oil Analysis Service................5-6
Chapter 6
COOLANT
Recommended Water for Coolant ......6-1
Long Life Coolant (LLC)......................6-1
Genuine LLC.......................................6-1
Other Brand LLCs...............................6-2
Standard for Other Brand LLC............6-2
General Demands of LLC ................................6-2
LLC Specification .............................................6-3
Maintenance of LLC............................6-6
Replacement Intervals of LLC..........................6-6
LLC Concentration ...........................................6-6
Importance of LLC ..............................6-7
Characteristics of LLC Additive and
Important Notes ..................................6-7
Examples of Abnormalities Caused by LLC
(Amine Type) ......................................6-7
Pitting of Iron Parts...........................................6-7
Corrosion of Aluminum Parts ...........................6-7
Pitting and Clogging of the Heat Exchange
Equipment........................................................6-7
Chapter 7
MAINTENANCE SCHEDULE
How to Use the Maintenance Schedule7-1
General Definition of Engine...............7-2

CONTENTS-3
CONTENTS
Periodic Maintenance Chart for
Regular Use Engine ............................7-3
Periodic Maintenance Chart for
Emergency Engine..............................7-5
Periodic Maintenance Chart for
General Purpose Engine.....................7-9
Chapter 8
PERIODIC INSPECTION AND
MAINTENANCE PROCEDURES
Basic Engine........................................8-1
Engine External - Inspect................................. 8-1
Belt and Belt Tension - Inspect and Adjust...... 8-2
Damper - Inspect.............................................. 8-4
Fuel System.........................................8-6
Fuel System - Inspect ...................................... 8-6
Fuel Tank - Clean............................................. 8-6
Fuel Tank - Drain Water................................... 8-6
Water Separator - Drain Water ........................ 8-7
Water Separator Element - Replace................ 8-7
Gauze Filter - Clean......................................... 8-8
Fuel Filter - Replace......................................... 8-9
Fuel Control Link Ball Joint - Inspect.............. 8-10
Fuel Pipe - Inspect......................................... 8-11
Lubricating System............................8-12
Engine Oil, Oil Filter and Bypass Oil Filter
- Replace........................................................ 8-12
Engine Oil for Mixing of Fuel and Water
- Inspect ......................................................... 8-14
Governor Oil Filter - Change.......................... 8-15
Oil Pipe - Inspect............................................ 8-15
Cooling System .................................8-16
Coolant - Change........................................... 8-16
Radiator Fins - Check and Clean................... 8-18
Inlet and Exhaust Systems................8-19
Turbocharger - Inspect................................... 8-19
Exhaust Muffler - Drain Water........................ 8-19
Air Cleaner - Check for Clogging ................... 8-20
Air Cleaner Element - Clean, Check and
Replace.......................................................... 8-21
Electrical System...............................8-23
Starter - Inspect.............................................. 8-24
Alternator - Inspect......................................... 8-24
Air Starter System .............................8-25
Air Strainer - Drain Water and Clean ............. 8-25
Air Tank - Drain Water ................................... 8-25
Air Tank - Inspect Safety Valve Operation.....8-26
Chapter 9
LONG-TERM STORAGE
Storing the Engine in an Inoperable
Condition for 3 Months or More ..........9-1
Preparation for Storage....................................9-1
Maintenance During Storage ...........................9-1
Using the Engine After Storage........................9-2
Storing the Engine in an Operable
Condition for 3 Months or More ..........9-2
Operating the Engine for Maintenance ............9-2
Chapter 10
TRANSPORTATION
Lifting the Engine..............................10-1
Chapter 11
TROUBLESHOOTING
General Precautions.........................11-1
Contact a Dealer of Mitsubishi Heavy Industries,
Ltd. for Repair Service ...................................11-1
Considerations Before Work ..........................11-1
Cautions Against Contamination....................11-1
Cautions Regarding Parts Handling...............11-1
Safety Work....................................................11-1
Case of Problems, and Conceivable
Causes and Remedies......................11-2
The Starter Does Not Crank or Cranks Slowly,
Resulting in Start Failure................................11-2
The Starter Cranks, but the Engine Does Not
Start................................................................11-3
Output Decrease............................................11-4
Exhaust Smoke is White or Blue....................11-5
Exhaust Smoke is Black or Charcoal.............11-6
Fuel Consumption is High..............................11-7
Engine Oil Consumption is High ....................11-8
Overheating....................................................11-9
Low Engine Oil Pressure................................11-9
When Fuel has Run Out .................11-10
Chapter 12
MAIN SPECIFICATIONS
Main Specifications...........................12-1

CONTENTS
CONTENTS-4
List of illustrations
Fig. 1-1 Warning labels...................................... 1-9
Fig. 2-1 Engine Left Side View ......................... 2-1
Fig. 2-2 Engine Right Side View ....................... 2-1
Fig. 2-3 Start Switch and Stop Switch .............. 2-2
Fig. 2-4 Manual Stop Lever .............................. 2-2
Fig. 2-5 Stop Solenoid ...................................... 2-2
Fig. 2-6 Oil Pressure Unit ................................. 2-3
Fig. 2-7 Thermo Unit ......................................... 2-3
Fig. 2-8 Revolution Detection Pickup ............... 2-3
Fig. 2-9 Oil Pressure Switch ............................. 2-4
Fig. 2-10 Thermo Switch .................................... 2-4
Fig. 2-11 Oil Filter Alarm Switch ......................... 2-4
Fig. 2-12 Revolution Detection Pickup ............... 2-5
Fig. 2-13 Air Cleaner Indicator ............................ 2-5
Fig. 2-14 Manual Turning Gear Position
(While Engine is Running) ................... 2-6
Fig. 2-15 Manual Turning Gear Position
(When Pushing Shaft in) ..................... 2-6
Fig. 2-16 Turning Gear Position
(When Turning Shaft) .......................... 2-6
Fig. 3-1 Priming Pump - Handle ........................ 3-2
Fig. 3-2 Fuel Filter - Bleed Air............................ 3-2
Fig. 3-3 Fuel Injection Pump - Bleed Air ........... 3-2
Fig. 3-4 Priming Pump Tightening Method ....... 3-3
Fig. 3-5 Priming Pump Head Packing .............. 3-3
Fig. 3-6 Oil Filler and Oil Level Gauge .............. 3-4
Fig. 3-7 Pouring Engine Oil on Valve
Mechanisms and Chamber ................. 3-4
Fig. 3-8 Radiator Cap........................................ 3-5
Fig. 3-9 Coolant Drain Cock (Engine)................ 3-5
Fig. 3-10 Coolant Drain Cock (Water Pump)....... 3-5
Fig. 3-11 Battery Electrolyte Level - Inspect ....... 3-6
Fig. 3-12 Valves for open/closed position
- Check ................................................ 3-8
Fig. 3-13 Fuel Control Link - Check .................... 3-9
Fig. 3-14 Oil Filler and Oil Level Gauge .............. 3-9
Fig. 3-15 Air Cleaner - Check for Clogging ....... 3-10
Fig. 3-16 Air Tank - Drain Water........................ 3-10
Fig. 3-17 Starting Air Tank Air Pressure
- Check............................................... 3-11
Fig. 3-18 Thermo label of damper......................3-11
Fig. 3-19 Manual Stop Lever .............................3-14
Fig. 5-1 Engine Oil Grade...................................5-1
Fig. 5-2 Selection of Oil Viscosity.......................5-3
Fig. 6-1 GLASSY - LLC......................................6-1
Fig. 8-1 Belt and Belt Tension - Inspect and
Adjust ....................................................8-2
Fig. 8-2 Damper - Check Visually.......................8-4
Fig. 8-3 Damper Temperature Management......8-5
Fig. 8-4 Fuel Tank - Drain Water........................8-6
Fig. 8-5 Water Separator - Drain Water..............8-7
Fig. 8-6 Water Separator Element - Replace .....8-7
Fig. 8-7 Gauze Filter - Clean..............................8-8
Fig. 8-8 Fuel Filter - Replace..............................8-9
Fig. 8-9 Fuel Filter ..............................................8-9
Fig. 8-10 Ball Joints For Looseness - Inspect ....8-10
Fig. 8-11 Fuel Control Link - Remove.................8-10
Fig. 8-12 High Pressure Fuel Injection Pipe and
Clamp Seat - Inspect and Replace .....8-11
Fig. 8-13 Low Pressure Fuel Pipe and Clip
- Inspect ..............................................8-11
Fig. 8-14 Oil Filler and Oil Level Gauge .............8-13
Fig. 8-15 Oil Filter and Bypass Oil Filter
- Replace.............................................8-14
Fig. 8-16 Oil Filter...............................................8-14
Fig. 8-17 Governor oil filter - Drain.....................8-15
Fig. 8-18 Governor oil filter - Change.................8-15
Fig. 8-19 Oil Pipe and Clip - Inspect and
Replace...............................................8-15
Fig. 8-20 Radiator Cap.......................................8-16
Fig. 8-21 Coolant Drain Cock (Engine)...............8-16
Fig. 8-22 Coolant Drain Cock (Water Pump)......8-17
Fig. 8-23 Radiator fins - Clean ...........................8-18
Fig. 8-24 Turbocharger - Inspect .......................8-19
Fig. 8-25 Draining Water From the Exhaust
Muffler .................................................8-19
Fig. 8-26 Air Cleaner - Check for Clogging ........8-20
Fig. 8-27 Air Cleaner Element - Remove............8-21
Fig. 8-28 Air Cleaner Element - Clean and
Check..................................................8-21
Fig. 8-29 Air Cleaner - Check for Clogging ........8-22

CONTENTS-5
CONTENTS
Fig. 8-30 Battery Electrolyte Level - Inspect ..... 8-23
Fig. 8-31 Specific Gravity of Battery Electrolyte
- Check............................................... 8-23
Fig. 8-32 Starter - Inspect.................................. 8-24
Fig. 8-33 Alternator - Inspect............................. 8-24
Fig. 8-34 Air Strainer - Drain Water and Clean . 8-25
Fig. 8-35 Air tank - Drain water.......................... 8-25
Fig. 10-1 Hanger................................................ 10-1
Fig. 10-2 Engine's center of gravity
(standard specification) ...................... 10-1
List of tables
Table 3-1 Inspection During Operation..................3-13
Table 4-1 Recommended Fuel................................4-1
Table 4-2 Recommended Limit and Use Limit of
Fuel Property...........................................4-2
Table 5-1 Recommended Limit of Engine Oil
Properties................................................5-2
Table 5-2 Engine Oil Properties...............................5-4
Table 6-1 Water Quality Standards .........................6-1
Table 6-2 LLC Specification.....................................6-3
Table 6-3 Recommended LLC Concentration.........6-6
Table 7-1 Periodic Maintenance Chart for
Regular Use Engine ................................7-3
Table 7-2 Periodic Maintenance Chart for
Emergency Engine..................................7-5
Table 7-3 Periodic Maintenance Chart for
General Purpose Engine.........................7-9
Table 8-1 Ribbed Belt Tension Force......................8-3
Table 8-2 Damper Temperature Management........8-4
Table 8-3 Thermo Label for Temperature
Management............................................8-5
Table 8-4 Specific gravity of electrolyte.................8-23
Table 9-1 Recommended Rust-preventive Oil
and Corrosion Inhibitor............................9-1
Table 11-1 The Starter Does Not Crank or Cranks
Slowly, Resulting in Start Failure...........11-2
Table 11-2 The Starter Cranks, but the Engine
Does Not Start.......................................11-3
Table 11-3 Output Decrease ...................................11-4
Table 11-4 Exhaust Smoke is White or Blue...........11-5
Table 11-5 Exhaust smoke is black or charcoal......11-6
Table 11-6 Fuel Consumption is High .....................11-7
Table 11-7 Engine oil Consumption is High.............11-8
Table 11-8 Overheating...........................................11-9
Table 11-9 Low Engine Oil Pressure.......................11-9
Table 12-1 Main Specifications................................12-1

1-1
Chapter 1 BASIC SAFETY PRECAUTIONS
Fire and Explosions
Keep Flames Away
Do not use flames near the engine (in
the engine room). Fuel gas vapor or
other gas can catch fire and produce
dangerous situations.
Wipe off spilled fuel, oil and LLC
immediately and thoroughly. Spilled fuel, oil and LLC
may ignite and cause a fire.
Store fuel and engine oil in a well-ventilated area.
Make sure that the caps of fuel and engine oil contain-
ers are tightly closed.
Always Swich the Water Heater
ON
(Emergency generator with
water heater)
Always swich the water heater ON (automatic mode)
through a whole year.
If the switch is not ON (automatic mode), each cylin-
der varies considerably in combustion at the starting
up the engine. Unburned fuel may explode in the
exhaust pipe.
Keep Engine Surrounding Area
Tidy and Clean
Do not leave combustible or explosive materials, such
as fuel, engine oil and LLC, near the engine. Such
substances can cause fire or explosion.
Remove dust, dirt and other foreign materials accu-
mulated on the engine and surrounding parts thor-
oughly. Such materials can cause fire or the engine to
overheat. In particular, clean the top surface of the
battery thoroughly. Dust can cause a short-circuit.
Ventilation of Engine Room
Always provide adequate ventilation in the engine
room. Insufficient air in the room can cause an
increase in the engine temperature and a decrease in
the output power and performance. It is highly recom-
mended to calculate the required amount of air supply
to the engine and install an adequate ventilation sys-
tem before installing the engine.
Do Not Open Side Cover Until
Engine Cools
Do not attempt to open the side cover of the crank-
case before the engine cools down. Wait at least 10
minutes after stopping the engine.
Opening the cover when the engine is hot allows fresh
air to flow into the crankcase, which can cause oil mist
to ignite and explode.
Care for Fuel, Oil and Exhaust
Gas Leakage
If any fuel, oil or exhaust gas leaks are found, immedi-
ately stop the engine and take corrective measures to
stop leakage.
Such leakages, if left uncorrected, can cause fuel or
engine oil to reach hot engine surfaces or hot exhaust
gas to contact flammable materials, possibly leading
to personal injury and/or damage to equipment.
Use Explosion-proof Lighting
Apparatus
When inspecting fuel, engine oil, coolant, battery elec-
trolyte, etc., use a flameproof light. An ordinary light-
ing apparatus may ignite gas and cause it to explode.
Prevent Electrical Wires From
Short-circuiting
Avoid inspecting or servicing the electrical system with
the ground cable connected to the battery. Otherwise,
a fire could result from short-circuiting. Be sure to dis-
connect the battery cable from the negative (-) termi-
nal before beginning with the work procedure.
Short-circuits, possibly resulting in fire, may be
caused by a loose terminal or damaged cable/wire.
Inspect the terminals, cables and wires, and repair or
replace the faulty parts before beginning with the ser-
vice procedure.
Keep Fire Extinguishers and a
First-aid Kit Handy
Keep fire extinguishers handy, and
become familiar with their usage.
Keep a first-aid kit at the designated
place where it is easily accessible by
anyone at any time.
Establish response procedures to follow in the event
of fire or accident. Provide an emergency evacuation
route and contact points and means of communication
in case of emergency.

1-2
Chapter 1 BASIC SAFETY PRECAUTIONS
Stay Clear of All Rotating and Moving Parts
Install Protective Covers
Around Rotating Parts
Make sure the protective covers of
the engine are correctly installed.
Repair any damaged or loose covers.
Never remove the covers such as
damper cover, camshaft cover, or
rocker cover that enclose the revolving parts during
operation.
When the engine is coupled to driven equipment, be
sure to provide protective covers over the parts such
as the connecting belts and couplings that are
exposed.
Never remove protective covers.
Check Work Area for Safety
Before starting the engine, make sure no one is near
the engine and tools are not left on or near the engine.
Verbally notify persons within the immediate area
when starting the engine.
When the starter device is posted with a sign that pro-
hibits startup operation, do not operate the engine.
Stay Clear of Moving Parts
While Engine is Running
Stay away from rotating or sliding
parts of the engine while the engine is
running. Put objects, which might be
easily caught by rotating parts, away
from rotating parts.
If any part of the clothing or outfitting is caught by a
rotating part, serious bodily injuries could result.
Lockout and Tagout
Be sure to lockout and tagout before starting inspec-
tion and maintenance.
Lockout and tagout are effective methods of cutting off
machines and equipment from energy sources.
To accomplish the lockout/tagout, remove the starter
switch key, set the battery switch to OFF and attach a
"Do Not Run" or similar caution tag to the starter
switch.
The starter switch key must be kept by the person
who performs inspection and maintenance during the
work.
In the case of pneumatic starting type, close the main
valve of the air tank and post a tag saying "Do Not
Open the Valve" or the like.
Keep Engine Stopped During
Servicing
Be sure to stop the engine before proceeding to
inspection and service procedure. Never attempt to
make adjustments on the engine parts while the
engine is running.
Rotating parts such as belt can entangle your body
and cause serious injuries.
Always Restore Engine Turn-
ing Tools After Use
Be sure to remove all turning tools used during main-
tenance and inspection work. Remember also that the
manual turning gear shaft must be pulled out before
starting the engine.
Starting the engine with the turning tools inserted or
with the turning gear in engagement can lead to not
only engine damage but also personal injuries.