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Mitsubishi S12R Service Manual
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8 INSPECTION AND MAINTENANCE
Mitsubishi Diesel Engine S12R
OPERATION & MAINTENANCE MANUAL
145
Pub. No. 291Y1-40720 Revision: 5
Fig. 8-46 High Pressure Fuel Injection Pipe Clamp - Locatio
n
No.12
Cylinder
No.11
Cylinder
No.10
Cylinder
No.9
Cylinder
No.8
Cylinder
No.7
Cylinder
No.1
Cylinder
No.2
Cylinder
No.3
Cylinder
No.4
Cylinder
No.5
Cylinder
No.6
Cylinder
Front
Front
Position A
Position C
Position B
Position D
Position I
Position E
Position J
Position F
Position H
Position G
Plate
Plate
Plate
Plate
Sheet
Engine Right
Side View
Engine Left
Side View
FF
E
E
A
A
A
A
C
DB
B
B
B
B
B
I
G
HJ
Clamp
Clamp
Plate
Plate
Plate
Plate
Plate
Plate
Plate
Clamp
Clamp
Clamp
Clamp
Clamp
Clamp
Clamp
Sheet
Sheet
Clamp
Sheet
Sheet
Clamp
Clamp
Clamp
Clamp
Plate
Plate
Clamp
Clamp
Plate
Clamp
Clamp
Sheet
Clamp
Clamp
Clamp
Clamp
Clamp
Plate
Plate
Plate
Plate
Plate
Plate
Clamp
144
146
Table of Contents
Foreword
3
General
4
Important Information
4
Intended Purpose and Use
4
General
5
Important Tips for Safety of Work
5
To the User Company
5
About this Manual
6
Fig
6
Fig. 2 Attaching Location of Emission Control Fig
6
Important Tips for Managing Safety of Work
6
Warranty Provisions
7
Emission Warranty
8
Fig
8
Fig. 1-12 Measures in the Event of Fig
8
Contact List
10
Approved Label
11
Emission Control Approved Label
11
Fig. 1 Location of Nameplate
11
Model Name
11
Main Specifications
12
Specifications - Check
12
Table 1 Main Specifications
12
Detailed Specifications
13
Specifications of Engine Body
13
Additional Equipment of Generator
14
Protection Devices Added During Manufacturing the Generator
15
Definition of Intended Persons
16
Fig. 1 Structure of Service Documents
17
Structure of Service Documents
17
Table of Contents
18
Structure of this Manual
18
List of Models
19
Table 1 LIST of MODELS
19
Table 1-1 Types and Meanings of Warning Terms
28
Table 1-2 Meanings of Symbols
29
Fig. 1-1 Warning/Caution Labels and Their Locations (Examples)
30
Matters to be Obeyed and Matters Prohibited
31
Preparation for Emergencies
31
Safety Cautions
31
Precautions for Covers
32
Precautions for Fire Sources
32
Precautions for Protective Gears
32
Precautions Regarding the Environment
32
Precautions for Battery
33
Precautions for Protective Devices
33
Other Precautions
34
Precautions for Auxiliary Facilities of the Generator
34
Precautions for Warning/Caution Labels
34
Operation
35
Fuel
41
Engine Oil
43
Coolant
44
Scheduled Maintenance
44
Inspection and Maintenance
45
Long-Term Storage
53
Transportation
54
Troubleshooting
55
Disposal
56
Fig. 1-2 Oil Pressure Switch
59
Fig. 1-3 Thermo Switch
59
Protective Devices
59
Protective Devices on the Engine
59
Fig. 1-4 Oil Filter Alarm Switch
60
Fig. 1-5 Rotation Detection Pickup
60
Lockout
60
Lockout/Tagout
60
Fig. 1-6 Lockout/Tagout (Example)
61
How to Set the Engine to Zero Energy State
61
Tagout
61
Zero Energy State
61
Working Procedure in Dangerous Areas
62
Works in Dangerous Areas
62
Body Protection
63
Clothing
63
Fig. 1-7 Human Body Protective Gears (Basic)
63
Fig. 1-8 Protective Gears
63
Protective Gears
63
Precautions on Additional Equipment
64
Product-Specific Precautions
64
Surface Temperature
64
Use of Chemicals
64
Water Heater
64
Develop the Action Procedure to Obey in the Event of Emergency
65
Emergency Stop Procedure
65
Fig. 1-9 Emergency Stop Procedure
65
Keep Everyone Informed about the Emergency Stop Procedure
65
Measures in the Event of Emergency
65
Emergency Stopping Devices Installed During Manufacturing the Generator
66
Damaging Disasters
67
Fig. 1-10 Measures in the Event of Personal Injury
67
Fig. 1-11 Measures in the Event of Property
67
Measures in the Event of Personal Injuries Resulting from this Engine
67
Measures in the Event of Property Damaging Disasters
67
Environmental Disaster
68
Fig. 1-13 Measures in the Event of a Fire Disaster
68
Measures in the Event of a Fire Disaster Resulting from this Engine
68
Measures in the Event of Environmental Disaster
68
Fig. 1-14 Measures in the Event of an Earthquake Disaster
69
Measures in the Event of an Earthquake Disaster
69
Education and Training for Safety
70
Fig. 1-16 Education and Training for Safety
70
Occupational Health and Safety Management
70
Operation & Maintenance Manual - Understand and Obey
70
Understand and Obey
70
Dangerous and Hazardous Chemicals
71
Fig. 1-17 Hazardous Chemical Substances
71
Fig. 1-18 Noise
72
Noise
72
Fig. 1-19 Vibration
73
Fig. 1-20 to Maintain Cleanliness and Tidiness
73
To Maintain Cleanliness and Tidiness
73
Vibration
73
Communication with MHIET
74
Fig. 1-21 Fire Hazard
74
Fig. 1-22 Communication with MHIET
74
Risk of Fire
74
Warning/Caution Labels
29
Abbreviations and Standards
20
Unit of Measurement
20
General Information
28
Safety
28
Types and Meanings of Warning Terms
28
Warnings
28
Engine - Outline
75
Names of Parts
75
S12R-Y1Pta, S12R-Y1Pta-2, S12R-Y1Pta-3, S12R-Y1Pta-4
76
S12R-Y1Pta2-1, S12R-Y1Pta2-2
78
S12R-Y2Ptaw, S12R-Y2Ptaw-1
80
Protection System - Location
82
S12R-Y1Pta, S12R-Y1Pta-2, S12R-Y1Pta-3, S12R-Y1Pta-4
83
S12R-Y1Pta2-1, S12R-Y1Pta2-2
84
S12R-Y2Ptaw, S12R-Y2Ptaw-1
85
Starting and Stopping Devices Installed During Manufacturing the Generator
86
Operation
87
Operation - Outline
87
Daily Check
88
Operational Environment - Check
88
Engine Exterior - Check
90
Fuel Tank Oil Level - Check
91
Pre-Operation Check
91
Battery - Check
92
Coolant Level - Check
92
Engine Oil Level - Check
92
Fig. 1-15 Operation & Maintenance Manual
92
Fuel Control Link - Check
92
Air Cleaner - Check for Clogging
93
Damper Temperature - Check
93
Fig. 3-1 Pre-Cleaner - Check for Clogging
93
Pre-Cleaner - Check for Clogging
93
Table 3-1 Limit Temperature of Damper
93
Table 3-2 Checking During Operation
101
Checking after Stopping
102
Maintenance Operation
102
Stopping
102
Air Direct Admission Starting - Check
94
Fig. 3-2 Manual Turning Gear - Check
94
Manual Turning Gear - Check
94
Air Motor Starting - Check
95
Air Direct Admission Starting
96
Engine Start-Up
96
Self Starter Motor Starting
96
Air Motor Starting
97
Fig. 3-3 Air Motor Muffler
97
Warm-Up Operation
98
Operation
99
Checking During Operation
100
Cooling Operation
101
Fuel
103
(Emission Control Approved Model)
103
Diesel Fuel
103
Diesel Fuel
104
Fig. 4-1 ULSD Label
104
Table 4-1 Fuel Properties Table (Emission Control Approved Model)
104
Table 4-2 Fuel Properties Limit Table
104
Table 4-3 Fuel Specifications
104
Fuel - Handling
105
Fuel - Refill
105
Fuel Quality Standard
106
Table 4-4 Fuel Properties Table (1/2)
106
Table 4-5 Fuel Properties Table (2/2)
107
Engine Oil
109
Engine Oil Grade
109
Fig. 5-1 MITSUBISHI DIESEL ENGINE OIL
109
Engine Oil Viscosity
110
Handling Engine Oil
110
Viscosity
110
Coolant
111
Table 6-1 Water Quality Standard
111
Table 6-2 LLC Concentration
113
Fig. 6-1 Freezing Temperature of GLASSY
114
Fig. 6-2 Freezing Temperature of PG GLASSY
114
Fig. 6-3 Tool - Adjust 1
114
LLC Concentration in Coolant - Measure
114
Tool - Adjust
114
Tool - Adjust 2
114
LLC Concentration Measurement 1
115
LLC Concentration Measurement 2
115
Measurement
115
Tool - Adjust 3
115
Tool - Adjust 4
115
Tool - Adjust 5
115
Tool - Adjust 6
115
LLC Concentration Measurement 3
116
LLC Concentration Measurement 4
116
LLC Concentration Measurement 5
116
LLC Concentration Measurement 6
116
Water to be Used
111
Coolant (LLC) - Handling
112
LLC to be Used
112
Coolant - MIX
113
LLC Concentration (Genuine LLC)
113
LLC Concentration in Coolant - Check
113
Maintenance of LLC
113
Replacement Period
113
Table 6-3 Scale Conversion Table
116
Scheduled Maintenance
117
How to Use the Scheduled Maintenance
117
Category of Scheduled Maintenance Chart
118
Rating Definition
119
Table 7-1 MHIET Generator Use Diesel Engine Rating Definition (1/2)
119
Table 7-2 MHIET Generator Use Diesel Engine Rating Definition (2/2)
120
Scheduled Maintenance for EPA Compliant Generator Use Diesel Engine
121
Table 7-3 Maintenance Schedule (1/2)
121
Table 7-4 Maintenance Schedule (2/2)
122
Inspection and Maintenance
123
Inspection and Maintenance - General Information
123
Precautions for General Inspection and Maintenance
124
Inspection and Maintenance - Prepare
125
Inspection and Maintenance - Prepare (with Engine Switched ON)
125
Belt - Check
126
Engine Body - Check
126
Inspection and Maintenance - Prepare (with Engine Switched OFF)
126
Belt Tension - Adjust (Ribbed Belt)
127
Belt Tension - Adjust (V-Belt)
127
Shape of Ribbed Belt
127
Shape of V-Belt
127
Table 8-1 Type of Belt (V-Belt)
127
Table 8-2 Type of Belt (Ribbed Belt)
127
Table 8-3 Ribbed Belt Tensile Force
130
Table 8-5 Types of Thermo Labels
132
Fuel System - Check
133
Fuel Tank - Check and Service
133
Fuel System - Bleed Air
134
Priming Pump
135
Priming Pump - Operation <A-Type
135
Fuel Filter - Bleed Air (1)
136
Fuel Filter - Bleed Air (2)
136
Priming Pump - Operation <A-Type
136
Priming Pump - Operation <B-Type
136
Fuel Injection Pump - Bleed Air 1
137
Fuel Injection Pump - Bleed Air 2
137
Fuel Injection Pump - Bleed Air 3
137
Water Separator - Check and Service
138
Banjo Bolt - Remove
139
Gauze Filter - Clean
139
Gauze Filter - Remove
139
Hose Joint
139
Banjo Bolt - Install
140
Fuel Filter - Replace
140
Fuel Control Link - Check
142
Fuel Pipe - Check
144
Check
146
Engine Oil System - Check
146
Engine Oil - Change
147
Table 8-6 Corresponding Equipment
147
Oil Filter - Replace
151
Bypass Oil Filter - Replace
153
Governor Oil Filter - Replace (Hydraulic Governor Spec)
153
Air Vent Plug - Install
154
Air Vent Plug - Remove
154
Case - Install
154
Drain Plug - Install
154
Element - Install
154
Oil Pipe - Install
154
Clip Attaching Direction
155
Cooling System - Check
155
Oil Pipe - Check
155
Coolant - Change
156
Coolant Drain Cock on Engine Body
156
Coolant Drain Cock on Water Pump
156
Corresponding Devices - Location
156
S12R-Y1PTA - Left-Side View
156
S12R-Y1PTA - Right-Side View
156
Table 8-7 Corresponding Equipment - Location
156
(With Lever)1
157
(Without Lever)
157
Container to Receive Coolant
157
Coolant Drain Cock on Engine Body
157
Coolant Drain Cock on Water Pump
157
Coolant Drain Cock on Engine Body
158
Coolant Drain Cock on Water Pump
158
Container to Receive Tap Water
159
Coolant Drain Cock on Engine Body
159
Coolant Drain Cock on Water Pump
159
Coolant Drain Cock on Engine Body
160
Coolant Drain Cock on Water Pump
160
Container to Receive Tap Water
161
Coolant Drain Cock on Engine Body
161
Cooling System - Bleed Air
163
Radiator Fins - Check and Clean (Radiator Spec)
164
Exhaust Muffler - Drain Water
165
Intake and Exhaust Systems - Check
165
Turbocharger - Check
165
Pre-Cleaner - Check and Service
166
Air Cleaner - Check and Service
167
Damper - Check
131
Damper Temperature - Check
131
Thermo Label - Stick
132
Belt Cover - Remove
128
Belt Tension (Alternator) - Adjust
128
Belt Tension - Adjust (Lock Nut)
128
Belt Tension - Adjust (Retaining Bolt)
128
Belt Tension - Adjust (Turn Buckle)
128
Belt Cover - Install
129
Belt Tension - Adjust (Lock Nut)
129
Belt Tension - Adjust (Retaining Bolt)
129
Front Cover - Install
129
Long-Term Storage
171
10 Transportation
175
11 Troubleshooting
178
Table 11-1 Starter Does Not Crank or Cranks Slowly, Resulting in Starting Failure
180
Table 11-2 Starter Cranks, but Engine Does Not Start
181
Table 11-3 Output Shortage (1/2)
182
Table 11-4 Output Shortage (2/2)
183
Table 11-5 Exhaust Smoke Is White or Blue
184
Table 11-6 Exhaust Smoke Is Black or Dark Grey
185
Table 11-7 Exhaust Smoke Is Black or Dark Grey (2/2)
186
Table 11-8 Excessive Fuel Consumption
187
Table 11-9 Excessive Engine Oil Consumption
188
Table 11-10 Overheating
189
Table 11-11 Engine Oil Pressure Drop
190
Table 11-12 Engine Stops
191
Table 11-13 During Normal Operation, Thermo Switch Activated
192
13 Disposal
194
Table 14-1 Engine Oil Quality Standards (Grade CF SAE 30)
198
Table 14-2 Engine Oil Quality Standards (Grade CF SAE 15W-40)
199
Table 14-3 Engine Oil Quality Standards (Grade CH-4 SAE 15W-40)
200
Table 14-4 Engine Oil Properties
202
Table 14-5 Engine Oil Service Limits for Emergency Use
203
Table 14-6 LLC Specifications (1/3)
205
Table 14-7 LLC Specifications (2/3)
206
Table 14-8 LLC Specifications (3/3)
207
5
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Mitsubishi S12R Specifications
General
Brand
Mitsubishi
Model
S12R
Category
Engine
Language
English
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