OPERATION & MAINTENANCE MANUAL MITSUBISHI DIESEL ENGINE SIZA2-PTA2-S NOTE The operator and supervisor are requested to read this Ope 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 November 2005 MITSUBISHI HEAVY INDUSTRIFOREWORD This operation and maintenance manual contains detailed operation, inspection and maintenance information of the Mitsubishi Engines. Please read this manual thoroughly before proceeding with operation, inspaction, and maintenance ‘work for correct use and servicing Failure to follow directions in this manual may result in serious accidents, Pub.No.99260-24100FOREWORD. Limited warranty ‘The manufacturer will repair or replace parts returned to the manufacturer when the manufacturer judges that the parts are defective in material andlor workmanship after conducting inspection. ‘The manufacturer's warranty is limited to the compensation work of repair or replacement of parts. ‘The coverage of the warranty is effective to the original purchaser only. Those who are transferred the ownership are not provided with the warranty. “The manufacturer makes no warranties, elther expressed or implied, excapt as provided in this ‘manual, including, but not limited to, warranties as to marketability, merchantabily, fitness for @ particular purpose or use, or against infringement of any patent. + The manufacturer will not be liable for any damages or consequential damages, including, but ‘ot limited to, damages or other costs resulting from any abuse, misuse, misapplication of the engine and devices supplied by the manutacturer. ‘+ The manutacturer will not be liable tor any damages or personal injuries resulting trom 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 (LLC) that are not recommended by the manufacturer.FOREWORD Important information ‘+ To avoid potential hazard, accident prevention activ- ities must be planned methodically and conducted ‘continually by considering all aspects of engine ‘operation, maintenance and inspection Everyone including managers and supervisors should actively participate, recognize one's role and ‘organize oneself and one's work to ensure a safe ‘environment + The foremost safety objective is to prevent acci- dents which may result in injury or death, or equip- ment damage. + Always observe laws or regulations by the local or federal/national government. + The manufacturer cannot foresee all potential dan- ger of the engine, potential danger resulting from. human error and others, or danger caused by a spe~ cific environment in which the engine is used. ‘Since thore are many actions that cannot be por- formed or must not be performed, it's impossible to indicate every caution in this manual or on warning labels. As such, itis extremely important to follow directions in this manual and also to take general safety measures when operating, maintaining 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 origi- ral 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 danger and also who have received risk aversion training, To provent an accident, do not attempt to carry out any operation other than those described in this ‘manual, or do not use the engine for any unap- proved 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 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 ilustra- tions and technical reference may be reproduced, photocopied, translated, or reproduced in any elec- tronic medium or machine readable form without prior written consent from the menufacturer. The contents inthis manual are subject to change at any time without notice for improvement of the engine. Pictures or illustrations of the engine in this manual may defer from those of your e Please note that, depending on sgecifcations, items described in this manual may differ from those on your engine in shape, of may not be installed on your engine. Please contact your Mitsubishi dealer it you need ‘more information or if you have any questions. If you lost or damaged this manual, obtain a new copy at your Mitsubishi dealer as soon as possible.FOREWORD Warnings The folowing two means are used to call the attention of the operators and maintenance persomel to potential dan- gers of the engine. *+ Warning statements in the manual * Warning labeis 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 inury, or death in the worst case. BUN tes or pzarsous station wn, tnt avoided wil rutin death rss TER 125228 potoraty hazardous situation which, not avoided, cou result death or serious injury Indicates a potentially hazardous situation which, if not avoided, may result in minor or CAUTION moderate injury. Indicates a potentially hazardous situation which, if not avoided, can result in property CAUTION omage Note: Indicates important information or information which is useful for engine operation.FOREWORD Units of measurement Measurements are based on the Intemational System of Units (SI), and they are converted to the metric system units in this manual using the folowing conversion rates. + Pressure: 1 MPa = 10,197 kgtlemn® + Torque: 1 Nm = 0.10197 kgtm * Force: 1 N = 0.10197 kgf + Horsepower: 1 KW = 1.341 HP = 1.3596 PS + Meter of mercury: 1 kPa = 0.75 omHg * Meter of water: 1 KPa = 10.197 cmH0 (omAg) * Engine speed: 1 min’ = 1 pm Abbreviations, standards and others + API_= American Petroleum Institute ‘+ ASTM = American Society for Testing and Materials + JIS = Japanese Industrial Standards ‘+ MIL = Miltary Specifications and Standards (U.S.) ‘+ MSDS = Material Safety Data Sheet + SAE = Society of Automotive Engineers (U.S.) *+ LLC = Long Life CoolantCONTENTS Chapter 1 BASIC SAFETY PRECAUTIONS Warning fire and explosion st Keep flames avy. 4 Keep engine and surrounding area clean and clear. 1-1 over open crankcase when engine is het. Mt Check for fuel, ol and exhaust gas leaks 1 Use lameproo ight, 4 Do not short electical wires. 4 Koop ft extinguishers and first-aid kit handy... 11 Warning stay clear of all rotating and moving parts... 1-2 Install protective covers around rotating PARE aon. 12 Check work area for safety 12 Watch out for rotating and moving parts while engine is in OPETALION sn 12 Lock out and tag out 12 ‘Always stop engine before inspection and maintenance. =) Always remove tuning tools fom the ENGINE. on 12 Warning be careful of bums seed Do not touch engine during operation or immediately ater operation nnn 13 Do not open radiator filer cap when the engine is hott-3 ‘Add coolant only after coolant temperature is lowered -2 Do not remove heat protection covers 13 Warming be careful of exhaust fume poisoning. -3 Perform engine operation in a well-ventilated area. 1-3 Waming protect ears from noises........1-3 Wear earmut 13 Warning be careful when iting engine 1-4 Lift engine carefully 14 Do not climb onto engine. 14 ‘Always prepare secure platform. 14 Caution be careful of handling engine oil and LLC 1-4 Use only specified fuel, engine oil and coolant (LLC) 1-4 Handle LLC carefully vvosnonnse Yoh Properly dispose of drained oil and LLC. 14 Caution service battery 1-5 Handle battery carefully. 15 Caution when abnormality occurs 1-5 I engine overheats, conduct cootng operation before stopping engine : +5 Itengine stops due to abnormality, exercise caution when restarting 16 engine oi pressure dope, stop engin immediat-5 1 V-belt breaks, stop engine immediately 15 Caution other cautions. Never modify engine, Never break seals. ss Peroum al specie pre-aperation inspections and Periodic inspections. 16 Perform engine breakin vo ene Warm up engine befor® US arn 16 Never operate engine under overload conditon..18 ‘Conduct cooling operation before stopping engine 1-6 Do not splash water on engine 16 Conduct proper maintenance of air cleaner or pre-cleaner COboerve safety ues at workplace Wear proper work clothes and protective gear. Use appropriate tools for maintenance work Do not operate starter for prolonged time. Do not tum off battery switch while engine is operating Cautions concerning transportation. Caution about warning labels. Maintain and inspect waming label Chapter 2 NAME OF PARTS. Engine extemal view. Left view. Right view a) Equipment and instrument . 22 Manual sip lever snd 2 Stop solenoid se BB Instruments 22 Thormo unit 22 Ol preSSU16 UM ssn 23 Revolution pickup se BB Engine protection devices. sr BB Ci fiter alarm switch, son Aiccleaner indicator 28 CONTENTS-1CONTENTS en Chapter 3 OPERATION Preparation for operating new or overhauled engine a4 Preparation of fuel system. 34 Filing fuel tank 3H Bleeding fuel system 32 Bleeding fuel fiter 2 32 Fuel injection pump. ewe) Priming pump cap tightening method. 38 Preparation of lubrication system. 34 Filing engine with engine ol. a4 Preparation of cooling system. one 85 Filling cooling system with coolant 35 Checking battery. Checking battery electrolyte level Checking specific gravity of battery electrolyte... 3-6 Test operation... 37 Starting and stopping. 37 Inspection 37 Normal engine operation Preparations for operation (pre-start inspection). 38 External inspection . 38 ‘Checking uel tank of level scene 88 Checking engine oi level. so 38 Checking coolant eval su 340 Checking air cleaner 40 Starting ant Warming-up operation... 31 Checking engine oll pressure ant Extomal inspection during warming-up. on Operation O12 Inspection during operation. 342 SHOPPING nnnnninsnnnninninnnnnnnenn SAB Emergency stop 343 Inspection atter stopping. 343 Chapter 4 FUEL Recommended fuel 41 Handling fuel. At CONTENTS-2 Chapter 5 ENGINE OIL Properties of engine oil and their influence on engine performance 54 Main properties of engine oil 51 Dispersibilty.. a 54 ‘Acid neutralization ability... 54 Viscosity Recommended engine oil Selection of oil viscosity... Genuine engine oil.. Engine oil in the market .. Handling engine oil 53 Service limits of engine oi... 5d Definition of properties of engine oil....5-4 54 5-2 5-2 52 5-3 Viscosity. 54 Total base number: 54 Total acid number 54 Water. 54 Flash point... 54 Insolubles.... se 54 Engine oil analysis service... 55 How to order engine oil sampling tool set... 5-5 Chapter 6 COOLANT AND LLC Recommended coolant. Long life coolant (LLC) Genuine LLC... LLC in the market. Maintenance of LLC... Replacement intervals of LLC. LLC concentration Importance of LLC. Characteristics of LLC additive and important notes: eee eed) Examples of abnormalities caused by LLC... 6-3 Ping on irom parts. 63 Corrosion of aluminum pats.n.rannninnnnnnennn6D Piting and clogging of radiator... 63CONTENTS: Chapter 7 PERIODIC MAINTENANCE CHART How to use periodic maintenance chart7-1 Periodic maintenance chart... TA Periodic maintenance chart for regular use engine .. 7-1 Petiodic maintenance chart for emergency engine ..7-1 Periodic maintenance chart for gener Definition of regular use engine, emergency engine use engine. 7-1 and generaluse engine .n.nnnnnnvnnnnnes 7, Regular use engine. 72 Emergency engine. 72 Gonoral-use engine 72 Periodic maintenance chart for regular use engine. 73 Periodic maintenance chart for emergency engine. TS Periodic maintenance chart for general-use power supply engine. 78 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Engine body periodic inspection and maintenance, 81 Visual inspection 84 Checking V-belt and adusting bet tension. 8-2 Checking V-belt 22 Adjusting bet tension (tan side). 22 Adjusting bet tension (water pump side) 22 Adjusting bet tension (aerator side). a2 Checking damper 83 Visual checking of damper o 23 Damper temperature management 83 Fuel system periodic inspection and maintenance... 84 Draining fuel tank 84 Checking fuel control linkage ball joints... 8-4 Changing fue! filter ..acnsnenn 85 Lubricating system periodic inspection and maintenance... 86 Changing engine cil, oil fiters and bypass oil filter... 86 86 Draining engine oi Changing ol fiters and bypass oll flter un 8-7 Refilling engine oil 1 8B Checking engine oll for mixing of fuel and water8-8 Cooling system periodic inspection and maintenance 8-9 Changing coolant 89 Draining coolant 89 Cleaning cooling system... 8-10 Refilling coolant.. 810 Checking and cleaning radiator fins connec 8-14 Inlet exhaust system periodic inspection and maintenance .. 8-12 Checking turbocharger. e12 Draining water from exhaust muftler 8412 Cleaning, checking, and replacing pre-cleaner8-13 Cleaning, checking, replacing air cleaner element etd Electrical systom period Inspection and maintenance 8-15 Checking starter BAS Checking alternator nn... B15 Checking battery .ansnmnnnnnnnennne B16 Checking battery electrolyte level 216 Checking specific gravity of battery electrolyt,...8-16 Chapter 9 LONG-TERM STORAGE Long-term storage. 29-4 Storing engine in non-operable condition for 3 months or more... 24 Preparation for storage ot Recommended rust-preventive ol and corrosion IAIDHOF orn a 94 Maintenance during storage. a Using engine after storage vn.nnnnnnnnsnne 92 Storing engine in operable condition for 3 months or more.. 9-2 Operating engine for maintenance purpose...9-2 CONTENTS-3CONTENTS: Chapter 10 Fig.2-9 Air cleaner indicator. a nS TRANSPORTATION Fig-1 How to use priming pump 32 Lifting engine carefully. 10-4 Fig32 Bleeding fue! fier 32 Fig.3-3. Fuel injection pump. 33 Chapter 11 Fig.3-4 Priming pump cap tightening method ..-.3+3 TROUBLESHOOTING Fig.-6 Priming pump cap packing. 33 General precautions . at Fig3-6 Oil filer and ol evel gage 34 Contact your mitsubishi dealer for repair Fig3-7_ Pouring engine ollon valve mechanisms and service . ot chamber. 34 Consideration before work. 14 Coolant drain cock on the engine.....ns.98 Cautions against contamination 144 Fig.3-9 Coolant drain cock on the water pump ....35 Cautions regarding parts handling. W4 Fig 3-10 Radiator coolant level 36 Work satety.. 114 Fig.-11 Coolant level in reserve tank. 36 How to troubleshoot... 11-2 Fig3+12Checking battery electrolyte level... 36 Starters do not erank or crank slow, resulting in Fig.3-13Checking specie gravity of electroyte....3-6 stan failure 111-2 Fig3-140ii filler and oil evel 990 39 Starters crank, but engine does not start. 14-2 FigS-18Radiator c4P 310 Other problems and countermeasures11-3 _Fig3-16Radiator coolant level... 210 Engine output is low 1-3 Fig3-17 Reserve tank coolant level 8-10 Exhaust smoke is white or blue 111-3 Fig3-48Checking air cleaner ssn 10 Exhaust smoke is black or dark gray 11-4 Fig.3-19Manual stop lever. G8 Fuel consumption is high . 11-4 Fig.4-1 recommended tue comes Engine oil consumption is high... 11-4 Fig4.2. Recommended fuel according to Engine overheats. M5 sic temperature. at Engine oil pressure is faulty. 11-5 FigS-1 Recommended engine oil 52 When fuel has run out. 11-5 Fig52 Recommended oil viscosity according to air temperature. sen Chapter 12 Fig.5-3 Jukoil cojera.new mariner 52 MAIN SPECIFICATIONS Fig 5-4 Engine oil sampling tool set 55 Main specifications 124 Fig6-1 GLASSY -LLC. 6-4 Fig.8-1 Inspecting camp. BA List of Illustrations Fig8-2 Adjusting V-bott tension 82 Fig:1-1 Warning labels 4-8 Fig8-3 Checking damper. 83 Fig21 Lett view.. aa Fig8-4 Damper temperature management. 88 Fig.2-2 Right view. Det Fig8-5. Draining water from fuel tank 24 Fig.23. Manual stop lever. 2.2 FI98-6 Inspecting fuel control linkage for looseness8-4 Fig.2-4 Stop solenoid 2.2 FIQ®-7 Removing fuel conto linkage... Fig.2-5 Thermo unit 2.2 Fig&-8 Changing fuel fiters 85 Fig.2-6 Pressure unt. 23 Fig89 Fuelfiter 85 Fig.2-7. Revolution pickup... 2.4 Fig8-100iIfiters and bypass oi fiter a7 Fig2-8 Oilfiter alarm switch os 23 Fig8-110ifiter.. a7 CONTENTS-4CONTENTS Fig.8-1200 filler and oil level gage. snes BB Table 9-1 Recommended rust-preventive Fig.8-13Radiator cap, neue BD oil and corrosion inhibitor. 94 Fig.8-14Draining coolant (engine main parts)... 9 Table 11-1 Startars do not crank or crank slowly, Fig.8-15Draining coolant (water pump side) 89 resulting in start failure 142 Fig. 8-16 Radiator ocean ato Table 11-2 Starters crank, but engine does not start11-2 Fig.8-17Reserve tank. ato Table 11-3 Engine output i 10W rm 113 Fig 8-18Claaning radiator fins an Table 11-4 Exhaust smoke ie white or blue. 113 Fig 8-19 Checking turbocharger. 812 Table 11-5 Exhaust smoke is black or dark gray....11-4 Fig.8-20Draining water from exhaust muffle... 812 ‘Table 11-6 Fuol consumption is high 114 Fig.8-21 Cleaning pre-cleaner. 813 Table 11-7 Engine oil consumption is high 114 Fig.8-22 Removing air cleaner element ate Table 11-8 Engine overheats. 115 Fig 8-23 Cleaning air cleaner element a4 ‘Table 11-9 Engine pill pressure is fauty 115 Fig.8-24 Checking air cleaner element. ane Table 12-1 Main specifications. 124 Fig.8-25 Air cleaner indicator aad Fig.8-26 Checking starter. one BAB: Fig.8-27 Checking alternator 845 Fig 8-28 Checking battery electrolyte level 816 Fig.8-29Checking specific gravity of electrolyte... 616 Fig. 10-1 Hangers for iting (left S166) oro nnsnnns WHT Fig.10-2 Hangers for iting (right side) se TO List of Tables Table 3-1 Specific gravity of electrolyte 36 Table 9-2 Standard values at rated Sp20d conn. S12 Table 4-1 Recommended fuel eee Table 4-2 Recommended and limit values of fuel property 42 Table §-1 Service limit for engine oll properties... 5-4 Table 6-2 Engine oll sampling tool sets. 55 Table 6-1 Wator quality standard... nnnssnsnn 64 Table 6-2 Recommended LLC concentration (for reference only) 62 Table 7-1. Periodic maintenance chart for regular use engine. 73 Table 7-2 Periodic maintenance cha for emergency engine snnnne 7S Table 7-8 Periodic maintenance chart for general-use engine sn 78 Table 8-1 Thermo label for temperature Management.rnnnnnnsnsennnnnnen 88 Table 8-2 Specific gravity of electrolyte 816 CONTENTS-5Chapter 1 BASIC SAFETY PRECAUTIONS A Warning fire and explosion Keep flames away Store fueland engine oil in a well- ventilated designated area. Make sure thatthe caps of fuel and engine oil containers are tightly closed Do not use flames, do not smoke, ‘or do not work near heater or other fie hazards where {uel or ol is handled or when cleaning solvent is being used for washing parts Wipe of spied fuel, il and LLC immediately and thoroughly. Spilled fuel, ol and LLC may ignite and cause a fire Keep engine and surrounding area clean and clear Keep the engine and the surrounding area tree of dust, dirt and foreign materials, as they may easily ignte and cause a fire or may cause engine overheat. Clean the top surface ofthe battery after performing maintenance work. Dust onthe battery may ignite and cause a snort-ircuit The engine must be installed at least 1 m [3.3 ft] away from structures and other ‘equipment to avoid possible fre hazards due to engine heat Never open crankcase when engine is hot It the cover is opened while the engine is stil hot, fresh air enters crankcase and ol mist can ignite due to engine heat and may result in the explosion ofthe tengine, Naver open the engine crankcase cover while the engine is hot. Wat at least 10 minutes after the engine has stopped. Open the cover after the engine becomes coo Check for fuel, oil and exhaust gas leaks Inspect fuel, oil and exhaust pipes regularly for dam. ‘age and loose. Ifa fuel, ol and exhaust gas leak is found, repair the leakage immediately. Spilled fuel or cil on a hot surface of the engine, or exhaust gas dis- charged directly to a combustible material may cause a fire and result in personal injury and/or damage to equipment Use flameproof light When inspecting uel, engine oil, coolant, battery elee- trolte, etc, use a flameproat light. An ordinary light, i it accidentally broken, may ignite and cause an explo- sion, Do not short electrical wires Before inspecting or servicing any electrical compo- nent, disconnect the ground cable from the (-) nega~ tive battery terminal to prevent a short-circuit and a risk of fire, Loose terminals or damaged cables/wires can cause a short-circuit that may result in fire. Before operating the engine, inspect the cables and wires, and repair or replace if necessary. Keep fire extingt handy Koop fire extinguishers handy, and be familiarized with their usage Koop first-od kis at the desig- nated place with easy access by anyone at anytime Establish response procedures to follow in the event of fire or accident. Provide emer- gency evacuation route and contact points and means of communication in case of emergency. hers and first-aid kit(Chapter 1 BASIC SAFETY PRECAUTIONS. A Warning stay clear of all rotating and moving parts Install protective covers around rotat- ing parts Make sure the protective covers of the engine are correctly installed. Repair any damaged or loose cov- ‘ers. When the engine is coupled to the radiator or other equipment, install protective covers around the ‘exposed connecting belt and coupling. Never remove protective covers of rotating parts such as the damper cover, camshaft cover or rocker cover while the engine is operating, Check work area for safety Before stating the engine, check to make sure that no ane is near the engine, no tools are left behind on the floor or on the engine. Verbally notty persons around the engine or in the work area when stating the engine. When the starter device is posted witha sign that pro hibits startup operation, de not operate the engine, Watch out for rotating and moving parts while engine is in operation Do not touch or come close to rotating and moving parts (output shat, flywheel, fan belts and pul leys) ofthe engine while the engine is running, Keep lappy and loose objects away from rotating pars to avoid entanglement. Entanglement of your body oF tools in rotating and ‘moving parts will result in serious injury Lock out and tag out Before starting inspection or maintenance work, be ‘sure to lock out and tag out the engine. Lockout and tagout are effective methods of cutting off machines ‘and equipment from energy sources. To lock out and tag out, pull out the key from the starter switch, turn off the battery switch, and post a “Do Not Operate" tag on the starter switch. The starter key switch should be kept by the person performing the inspection and maintenance. For the air starter system, close the main valve ofthe air tank, and post a "Do Not Open the Valve" tag Always stop engine before inspection and maintenance Be sure to stop the engine before proceeding with inspection and maintenance work. Never attempt to adjust the engine parts while the engine is running. ‘Attempting any work on running engine can cause @ severe accident. Always remove turning tools from the engine Be sure to remove all turning tools used during main- tenance and inspection work. f the engine is started with turing tools or gears left on the engine, it can cause a severe accident and result in not only engine damage but also personal injury or death.A Warning be careful of burns Do not touch engine during operation or immediately after oper Do not touch any parts of the engine during operation or immedi- ately after operation to avoid bburns.To conduct maintenance and inspection work, wait until the ‘engine have cooled sufficiently by checking the temperature gage. i, Do not open radiator filler cap when the engine is hot Never open the radiator filer cap while the engine is running or immediately after the engine is stopped. The engine coolant s hot during engine operation and immediately after operation. if the radiator filer cap is ‘opened when the coolant is at operating temperature, steam and hot coolant may blow out and result in burns. When opening the cap, stop the engine and allow the coolant temperature to lower sufficiently Gover the cap with a cloth or use thick rubber glove, and then slowly open the cap. When closing the cap, be sure to tighten securely, ‘Add coolant only after coolant tempera- ture is lowered Do not add coolant immediately ater the engine stops. Wit until the coolant temperature lowers suff ciently to avoid a risk of burns. Do not remove heat protection covers ‘The high-temperature exhaust components are installed with heat protection covers. Do not remove these heat protection covers. Ifthe covers must be removed during inspection and maintenance work, be sure to reinstall them after the inspection and mainte- nance work is completed. Chapter 1 BASIC SAFETY PRECAUTIONS A Warning be careful of exhaust fume poisoning Perform engine operation in a well-ven- tilated area Exhaust gas from the engine con- tains carbon monoxide and other toxic substances. Do not operate the engine in an enclosed area {inside a warehouse, tunnel, etc.) or in an area where all sides are blocked, as exhaust gas is hazardous. If the engine ‘must be operated in an enclosed area, discharge the exhaust gas to the outside and provide adequate ven- tilation. Connect exhaust duct to the exhaust pipe to discharge exhaust gas to the outside, and make sure exhaust gas does not leak from the duct joints. Make sure the exhaust gas is not discharged directly to sur- rounding buildings, plants or living passersby. A Warning protect ears from noises Wear earmutft Be sure to wear earmuff or ear- plugs when entering the engine room. The earmulff or earplugs can be quite useful to protect ears from various engine noises.(Ghapter 1 BASIC SAFETY PRECAUTIONS. A Warning be careful when lifting engine ift engine carefully Toll the engine, use slings capa- bile of supporing the weight of the tengine. Attach appropriate slings to the hangers onthe engine. Keep the engine balanced during lifting by considering the center of ravi ofthe engine. Keep the angle formed by slings attached to hangers within 60°. If the angle exceeds this limit, excessive load is imposed on the hangers and may damage the hangers and result ina serious accident If slings come in contact wit the engine, lace @ cloth or other soft padding o avoid damage to the engine and slings Do not climb onto engine Never climb onto the engine. To work on parts located (on the upper part ofthe engine, use a ladder, stand, or other stable platform. Climbing on the engine may not only damage engine parts but also cause parts to fall of and result in per- sonal injury Always prepare secure platform Use a stable work platform to stand on when working on the Upper part ofthe engine and other hard-to-reach places, Stancing on a feoble stand or pants box may resultin personal injury. Do not put ‘obstacles onthe platform. A Caution be careful of handling engine oil and LLC Use only specified fuel, engine oil and coolant (LLC) Use fuel, oll and LLC specified in this manual, and handle them carefully. Use of any other fuel, oil or LLC, and improper handing may cause various ‘engine problems and malfunctions. Obtain the MSDSs issued by the fuel, cil and LLC suppliers, and follow the directions in the MSDS for proper handling Handle LLC carefully ‘Wear safety mask and rubber gloves when handling LLC. Avoid contact with skin and eyes to prevent per- ‘sonal injury. FLUC is accidentally swallowed, induce voriting immediately and seek medical attention at once. IFLLC enter eyes, flush immediately with plenty of water and seek medical attention at once. If LLC is. spilled on skin or clothes, wash immediately with plenty of water. Keep flammable materials away from LLC to prevent a tisk offre. Never use open flames or generate ‘sparks near LLC, as they can cause a fire, Coolant containing LLG is a hazardous material. For disposal of the coolant, observe applicable law or reg- Ulations, or contact your Mitsubishi dealer. Properly dispose of drained oil and LLC Do not discharge engine oil, used cleaning ol oF LLC into conventional sewage Prepare crip pan or other containers to receive ol and LLC drained from the engine. De not discharge them ddrectyin the ground. For disposal of used oil and LLC, observe applicable law or rogulations, or contact your Mitsubishi dealerA\ Caution service battery Handle battery carefully + Batteries release flammable hydrogen gas and oxygen. Never use open flames or gen- erate sparks near the battory since open flames or sparks can cause an explosion Do not use the battery when the fluid surface is lower than the minimum required level. Using a bat. ‘ery witha low electrolyte level may result in an explosion Do not shor the battery terminals witha tool or other metal object When disconnecting battery cables, remove the cable from the (-) negative terminal first. When reconnecting cables, attach the cable to the (+) pos- itive terminal frst. Charge the battery in a well-ventilated aroa, with all filing hole plugs removed + Make sure the cable clamps are securely installed on the battery terminals. A loose cable clamp can cause sparks that may result in an explosion Before servicing electrical components or conduct- ing electric welding, set the battory switch to the OFF} position or cisconnect the cable trom the (-) negative battery terminal to cut off the electical cur- rent Batery electrolyte contains dilute sulfuric acid Careless handing ofthe batery may result in oss of sight and burns, Wear safety goggles and rubber gloves when work: ing withthe battery (filing of fuid, charging, etc.) Wf battery electroyte is spilled on skin or clothes, wash immediately with lots of water. Then, use soap to clean thoroughly I battery electrolyte enters eyes, flush immediately With lots of fresh water and seek medical attention at If battery electrolyte is accidentally swallowed, gar- le with plenty of water, and then drink lots of water. Seek medical attention at once. (Chapter 1 BASIC SAFETY PRECAUTIONS, A\ Caution when abnor- mality occurs Hf engine overheats, conduct cooling operation before stopping engine Ifthe engine overheats, do not stop the engine imme- diately, Abrupt stopping of an overheated engine may cause the coolant temperature to ise and resutin seizing ofthe engine. I the engine overheats, operate the engine at low idling speed (cooling operation), and stop the engine ater the coolant temperature lowers sulfciently. Do nat add coolant immeciately after stop ping the engine, Adding coolant to a hot engine may cause damage to the cylinder head due to sudden change in temperature. Add coolant gradually after the engine cools tothe room temperature Hf engine stops due to abnormality, exercise caution when restarting Ifthe engine stops due to an abnormality, do not restart the engine immediately the engine stops with an alarm, check and correct the cause ofthe problem before restarting. Operating the engine without cor- recting the problem may result in serious engine prob- tems. If engine oil pressure drops, stop engine immediately Ifthe engine oil pressure decreases, stop the engine immediately, and inspect the lubricating systam including the oil level and pump. Operating the engine with low ol pressure may cause seizing of bearings and other parts If V-belt breaks, stop engine immedi- ately It V-belt breaks, stop the engine immediately. Contin- Led operation ofthe engine without V-belt in place causes an engine overheating and could be result in bums due to blowout of steam from reserve tank or radiator.Chapter 1 BASIC SAFETY PRECAUTIONS A\ Caution other cautions Never modify engine Unauthorized modification of the engine wil void the ‘manufacturer's warranty. Modification ofthe engine may not only cause engine damage but may resultin perscnal injury as well. f there is a need to modify the engine, contact your Mitsubishi dealer. Never break seals ‘To ersure proper engine operation, the fuel control links are sealed to prevent accidental change of the injection volume and rotation speed settings. Operat- ing the engine without these seals in place can cause problems described below, and also invalidates the warranty, ‘+ Rapid wear of sliding and rotating parts ‘+ Engine damage such as seizing of engine parts ‘+ Considerably increased consumption of fuel and lubsicating oil + Degradation of engine performance due to improper balance between fusl injection volume and governor ‘operation or overtun of engine which will be result in ‘serous accident, Perform all specified pre-operation inspections and periodic inspections ‘Conduct the pre-operation inspections and periodic inspections as described inthis manual. Failure to ‘conduct the specified inspections may cause various ‘engine problems, damage to pars, and serious acci- dents, Perform engine break-in To break in a new engine, operate the engine at a speed lower than rated speed under light load during the fist 80 hours of operation. Operating a new engine under heavy load of severe concstions during the breakin period wil shorten the service life of the engine. Warm up engine before use ‘When starting auxiliary devices such as water heater ‘and engine oil priming pump is not installed, let the ‘engine idle for § to 10 minutes before operating the ‘engine for work. Warm-up operation circulates lubri- canis in the engine and contributes to a longer service life and economical operation. Do not conduct warm- up operation for prolonged period of time. Prolonged \warm-up operation causes carbon build-up in the cyl- inders that lead to incomplete combustion. Never operate engine under overload condition Ifthe engine shows an overload condition such as back exhaust smoke, reduce the load immediately to operate the engine at appropriate output and load. Overioading causes not only high fuel consumption but also excessive carbon deposits inside the engine. Carbon deposits cause various problems and will shorten the service life of the engine. Conduct cooling operation before stop- ping engine Before stopping the engine, lett idle at low speed for 5 10.6 minutes to cool down, Stopping the engine immediately after hightoad operation will eause engine pars to heat up and shorten the service life of the engine. During cooling operation, check the engine for abnormalities. Do not splash water on engine Do not allow water such as rain to enter the engine through the air inlet or exhaust openings. Do not wash the engine while itis in operation, as the water enters the engine. If the engine is started with water inside the combustion chambers, water hammering occurs ‘and damages the engine, and may result in serious accidents,Conduct proper maintenance of air cleaner or pre-cleaner ‘The major cause of abnormal wear on engine parts is duo to the dus from intake air. Wom parts result in an increase of oll consumption, decrease of output, and starting ifcuties. Conduet maintenance ofthe air cleaner or pre-cleaner as described below to ensure optimum ai tering performance, + Do not conduct maintenance of the ar cleaner or pre-cleaner while the engine is in operation. Without the air cleaneripre-cleaner, the turbocharger can suck foreign particles into the engine and it could resul in serious accidents When removing the air cleanerpre-cleaner, use care to prevent dust rapped in the ar cleaner trom entering the engine. Ifthe air cleaner is equipped witha dust indicator, conduct maintenance whenever the clog warning sign appears. While servicing the air cleaner, do not allow dust to enter the air cleaner and do net dam- age of deform the element Observe safety rules at workplace Observe the safety rules established at your work: place when operating and maintaining the engine, Do not operate the engine if you are feeling il. Operation of the engine with reduced awareness may cause improper operations that could result in accidents. In such a case, inform your supervisor of your condition. When working in @ team of two or more persons, use specified hand signals to communicate among the workers Wear proper work clothes and protec- /e gear Wear a hardhat, face shield, safety shoes, dust pro- teotve mack, gloves and other protective gear as needed. When handling compressed air, wear safety goggles, ‘a harchat, gloves and other necessary protective gears. Without the proper protective gear, the com- prossed alr may cause personal injury. CChaptor 1 BASIC SAFETY PRECAUTIONS Use appropriate tools for maintenance work Use appropriate tools according tothe type of mainte= nance work, and use them correctly. Wa tool is damaged, replace with a new one. Do not operate starter for prolonged time Do not use the starter for more than 10 seconds at a time. tthe engine does not stat, wat for at least 30 ‘seconds before cranking again. Continuous operation of the starter will cause the bat- tory to discharge as wel as the starter to seize. Do not turn off battery switch while engine is operating Do not tum of the battery switch while the engine is in operation “Turning the battery switch off while the engine isin ‘operation causes the operation of instruments to stop, and may deteriorate the alternator ciode and regula: tor. Cautions concerning transportation ‘When transporting the engine using a truck, consider the engine weight, width and height to ensure safety Abide by the pertinent laws and regulations.(Chopter 1 BASIC SAFETY PRECAUTIONS. A\ Caution about warning labels Maintain and inspect warning labels Make sure all warming labels are legible. IF the description andlor ilustration on a warning labels legible, clean or replace the label To clean warning labels, use a cloth, water and soap. Do not use solvents, gasoline or ather chemicals to clean warning labels, as chemicals may cause the labels to pee! of. It warning labels are damaged or missing, install new labels. if part ofthe engine with warning labels replaced with a new pat, also instal the new waming label to the new par. To obtain replacement warning labels, contact your Mitsubishi dealer. TURNING CAN, AOTATING ARTS CAUSE SEVERE CAN CRUSE SEVERE PERSONAL INURY. PERSOYAL INUIRY. OL wisT 15. FLAMWABLE AND EXPLOSIVE. BE SURE No DANGER 0_NOT OPEN AROUND MOVING PARTS + KEP AWAY FFOW ROTATING BEFORE TURNING. INSPECTION COVER Foweeet Keep TuANING Device WITHIN 10. MINUTES + D0 NOT oFeRATE warkout Of BAR IN OFF Pos AFTER ENGINE STOP. POWER COVER SiON" WHEN NOT IN USE. ACAUTION A CAUTION) (RIG) ¥ HIGH PLACE MAY| 4 VOLTAGE MAY CAUSE Mo. SE FALLING ELECTRIC sHoc. e BE CAREFUL WHERE YoU STEP ON SCAFFOLD. ‘TURN OF ones exon HEME OW MAW TENAC. © oo aot roustany era ndPuck WHA POWER OX So. oF mas ‘oor orERATE m4 0008 0 0 Ny fu cs KAR no PROTECTIVE COVE O°. 93 i Monnaie) . © cer. oF oT Lu soko nana frac 0 Nor PUT ANY IMPROPER MATERIALS ON ENGINE AND Scarrolb 2@ [ERS TR chow 2A ea, A CAUTION SCT TI, HERR is wo TOE et Wor SUREACES, AIRY SADR at nc a | (CAUTION a aL HT Sea Figi~1 Warming labels,Chapter 2 NAME OF PARTS Engine external view The external views shown below are the standard type of engine. ‘The exterral view changes based on the type and attachments. Left view Water outlet Turbocharger ‘Thermostat, me jAir cooler Fan. ° Fuelnjocton pump Fue food pu Front 5 HAL EP] -coverer ‘Atorato? n ter dan og Q tater out fite” P cer tite? (wire-element type) Oil level gage Fuel return pipe joint Stop slenad ua net pie ot Fae Lottvow Esato outa an take rine Trennstt Ar coe : : coon — = Bypass ol iter 2 a o/ « Damper Fue! injection pump eran Fuel food pune ‘ters at tot RTE] Fig2-2 Right view 2-1(Chaptor 2 NAME OF PARTS Equipment and instrument Manual stop lever Use the manual stop lever to shut down the engine in the event of anemergency. Ifthe state switch fais to stop engine operation, use the manuel stop lever. When the lever is moved in the [STOP] direction, the engine stops operation. Ifthe engine centinues a operation even alter the ‘manual stop lever is operated, cutoff the fuel supply to stop the engne, Stop solenoid “The stop solencid operates for normal shutdown of engine operaticn. The stop solenoid moves the rack of ‘the fue injection pump to stop fue injection, thus shut- ting down the engine operation. The "RUN-ON' type solenoid sets the start switch to the “OFF* position by de-energizng the stop solenoid and pushing the rod out by intemal spring power Which makes the rack ofthe fue injection pump move to the non-injeton direction Instruments This section describes about devices which transmit signals to necessary instruments of the engine in operation, Please read carefully and understand functions of each device, Thermo unit ‘The thermo unit detects the temperature of engine coolant Fig2-4 Stop solenoid Operating temperature range: 50 to 120°C [122 to 248°F] Fig2-8 Thermo unit‘Chapter 2 NAME OF PARTS Oil pressure unit The ol pressure unit detects the engine cil pressure. Revolution pickup The revolution pickup i installed inthe timing gear case to detect the engine speed Engine protection devices Oil filter alarm switch The oil fiter alarm switch activates the alarm system ‘when the ol fter is clogged, The switch is activated when the difference of pres- sures measured at before and after oil fiter reaches, the limit When the alarm sign is given, immediately replace the oll fiter with a new fiter. Also renew the engine ol Air cleaner indicator ‘When the air cleaner element is clogged and the det- erence of pressures measured at before and after air cleaner becomes abnormally high, the air cleaner indi- caator shows a red sign. Immediately clean the ele- ‘ment or replace with a new element when the red sign appears. After cleaning or replacing the air cleaner, press the bottom on the top of the indicator to reset the alarm signal. When serving the air cleaner, use care to prevent dust from entering the air cleaner. Also do not damage nor distort the element. Fig2-6 Pressure unit Fig2-7 Revolution pickup Cl fiter alarm stich Fig2-8 Oilfiter alarm switch Button Signal Fig2-9 Alrcleaner indicatorChapter 3 OPERATION Preparation for operating new or overhauled engine Betore proceeding with operation ofa new ot overhauled engine, conduct the inspections described inthis section For secord operation onward, follow the instructions described in the "Normal engine operation” (38) Preparation of fuel system ACAUTION ‘When handing fuel, do not use open flames or heaters. Wipe off any spilled fuel completely. Spilled fuel is highly flammable and can cause a tre CAUTION Domnot remove the strainer when filing the fuel tank. Use the fuel specified in FUEL” (4-1), Filling fuel tank 1. Make sure the insides of the fuel tank and fuel pipes are thoroughly clean. 9. Fill fuel tank with fuel. }. Remove the fuel feed pipe and the drain plug from the fuel inlet of engine, and check the discharged fuel for for- ‘ign particies such as dust |. Reinstall the drain plug and the fuel feed pipe. 5. Refill fuel tank until fuel level gage indicates "FULL." er geChopter 3 OPERATION Bleeding fuel system ‘When fuel overflow from the air vent plug, wipe thor- ‘oughly with a cloth. Spilled fuel isa fire hazard. Alter bleeding, lock the priming pump cap securely. If ‘not locked tightly, the priming pump can be damaged, causing fuel leakage that may lead to a fire. ‘To lock the priming pump cap, follow the procedure described on the following page. CAUTION Do nat close all air vont plugs before locking the prim ing pump cap, as the priming pump cap will not return to the original position due to internal pressure. Bleed air at fuel fiers and then atthe fuel injection pump. Bleeding from upstream to downstream makes the job ettective. Bleeding fuel filter CAUTION Tair vent plugs, thread portion of bracket, or sealing Washers are damaged, replace then with new ones. 1, Loosen the air vent plug on the fuel fitter intake for the loft bank cylinder about 1.5 turns. ‘Turn the priming pump cap counterclockwise to Unlock, and prime the fuel filter. ‘When the fue! from the air vent lug becomes free {rom air bubbles, stop priming and tighten the air vent plug to the specified torque. Loosen the air vent plug on the fuel fiter outlet for the left bank cylinder about 1.5 turns, and bleed as described above, = © no [Unlock] [Prime] Lock) “Tum counterclockwise wile esuna Fig3-1 How to use priming pump Air vent plug Tightening torque 7.8 109.8Nm (0.810 1.0 kgf m) Fig3-2 Bleeding fue! fiterFuel injection pump 1. Loosen the ar vent cock on the fuel injection pump about 1.5 tums, 2. Move the priming pump cap up and down until the fuel flow from the air vent cock is free from air bub- bles, Push and tur the priming pump cap clock: wise to lock inthe original position when the fuel flows is fee from bubbles. 3. Tighten te air vent lug on the fuel injection pump. 4. Repeat the same procedure to fuel injection pump on the other side. Priming pump cap tightening method A CAUTION ‘ever fal to Tghien the priming pump cap tothe spec: ified angle (90210°). If the priming pump cap is not firmly tightened, internal thread will be worn due to engine vibration, resulting in sudden ejection of the cap to cause fuel low-out. Orit the priming pump cap is excessively tightoned (tumed 120° or more), the head of the priming pump can be damaged. 1, Finger tighten the priming pump cap 2. Mark this postion on the cap to facilitate the folow- ing stops: 3. Tighten the cap further by 9010" with a wrench, Note that the cap will be tightened by 70 to 90° with full foree of hand atthe above step 1. 4. Make sure the head packing isnot protruding, Note: If the head packing is protruding, loosen the priming pump cap. Check the packing for dam- ago and retighton the cap. If damaged, consult your Mitsubishi dealer. Chapter 3 OPERATION Ar vent plug Postion whore _S0#10" hand-ghtening becomes suddenly heawy Fig3-4 Priming pump cap tightening method Head packing Fig3-5 Priming pump cap packingChaptor 3 OPERATION Preparation of lubrication system Filling engine with engine oil 1. Remove the cap from the ol ile. 2. Fillengine with the specitied engine oll tothe spec- ified level Note: For engine oll, refer to “ENGINE OIL" (5-1) For engine oil capacity, refer to "MAIN SPECIFI- CATIONS" (12-1). Rlomove the rocker covers of all the cylinders. Lubricate the valve mechanisms and fil the cam- shaft oil bath with engine oi from the cylinder head Oil capacity per cylinder: 800em? |. Reinstall the rocker covers 5. Check the oil evel of ol pan as described below: = Pul out the oil level gage and wipe itclean with a loth = Reinsor the oil level gage all the way inthe ot level guide and then pull out again = The oi levels correct fit is between maximum ‘and minimum level mack. ~ Add the specified engine oil itis lower the mini- mum level mark. ‘Check the oil pan and other pats for cl leaks. Repair the oll leakage if any. Shut off fuel and crank the engine with the starter for 10 seconds to circulate oil throughout the engine. After 1 minuto of rest period, start cranking ‘again to circulate oil throughout the engine for another 10 seconds. Check the oil level wth the olf level gage again, and ada oll it necessary x CAUTION ‘Tocrank the engine, shutoff the fuel supply tothe ‘engine and operate the starters. When conducting the ‘above cranking operation, also check the items to be inspected for the cooling system by cranking, 2 B Oillevel gage Fig3-6 Oilfiler and oil level gage Camshaft ol batty Fig3-7 Pouring engine oil on valve mechanisms and ‘chamberPreparation of cooling system Filling cooling system with coolant 1. Make sure the drain cocks on the engine and water pump are securely tightened. 2. Remove the radiator cap, and fil the radiator tank with undiluted LLC. Note: Determine the quantities of LLC based on the coolant capacity and the LLC concentration chart For the coolant, refer to “COOLANT AND LLC co For the coolant capacity, refer to “MAIN SPECI- FICATIONS" (12-1). 3. Pour in water (soft water wth minimal impurities, ‘such as tap water) slowly to the full level. Note: For absolut air bleeding, loosen the air vent cock on the upper section of thermostat when adding water. |. Check the radiator and other pars for coolant leaks. Repair leakage if found 5. Insal the radiator cap securely . Shut off fuel and crank the engine with the starter for 10 seconds. After about 1 minute of rest period, stat cracking again for another 10 seconds to bleed air from the water pump. = on x CAUTION engine and operate the starters, When conducting the above eranking operation, also check the items to be inapected forthe lubricating system by cranking '8. Check the coolant level inthe radiator, 9. When a reserve tank is equipped, fil the reserve ‘tank with the coolant to the [FULL] level. Chaptor 3 OPERATION ‘Amount of coolant — (engine body): Approx 1001. Figi-@ Coolant drain cock on the water pump CAUTION ‘iways use the coolant with the same LLC concentra- tion for refilling Fig3-11 Coolant level in reserve tank(Chapter 3 OPERATION Checking battery x ee TE ‘lush immediately with plenty of water. I battery electrolyte enters eyes, flush them immediately with lots of fresh water and seek medical attention at once. Do not use open flames or cher fre hazards near the battory. When handling the battery, be careful of sparks generated by accidental short- ing. For other cautions in handling the battery, refer to “Caution service battery” (1 Checking battery electrolyte level Battery electrolyte evaporates during use and the uid level gradually decreases. The correct fluid surface level is between the LOWER LEVEL and UPPER LEVEL tines, For the battery without level ines, the correct fluid surface level is about 10 to 15 mm [0.394 to 0,591 in.] above the top of the plates. If the fluid level slow, remove the caps and add distiled water to the proper level. Note: When adding cstiled water, pour in carefully. Checking specific gravity of battery electrolyte Check the specific gravity ofthe electrolyte. I the spe- cific gravity measured at 20°C [68°F] is lower than. 1.22, then charge the battery Table 3-1 Specific gravity of electrolyte ‘Specie graviy at T pice etc Condition | Remedy ). AOt016 mm ELEGTROUTTE SURFACE “From 12610128 | Fully charged] = earn Framnaaioras [chess | Grane [ — ee Geese cians} Fig3-13 Checking specific gravity of electrolyte‘chapter 3 OPERATION Test operation To conduct a test operation, follow the procedures below. Note: For engine operation, refer to "Normal engine operation’ (2-8) Starting and stopping 1, Star the engine. 2. Operate the engine at low iding speed under no load for 5 to 10 minutes for a warm-up operation 3. Stop the engine. Inspection Leave the engine ve stopped for about 30 minutes. During this period, check the engine and surrounding area for leaks of fuel, engine oil or coolant. ‘A130 minutes after the engine stop, check the oil level with the oil level gauge. It the oll evel is low, add engine oil rom the ol ile Be sure fo use the engine ol of the same brand and type. (Open the radiator cap, and check the coolant level ACAUTION Flomove The radiator cap only after the engine Is cooled tothe room temperature. Place a cloth over the cap, and loosen the cap about.a hal-tum to release internal pressure. Opening the radiator cap while the engine is hot causes steam and hot coolant to splash out that may resultin skin burns, 6. ifthe coolant levelis low, add coolant tothe specified level. 7. When a reserve tenk is equipped, add coolant to the [FULL] level ‘CAUTION. ‘Aways use the coolant with the same LLG concentration for refling:Chepter 3 OPERATION Normal engine operation This section of the manual covers the procedures for the engine operation in normal condition. ACAUTION any engine abnormally 1s observed during operation, slop the engine and correct ihe problem, or conlacl your Mitsubishi dealer. Preparations for operation (pre-start inspection) Before starting the engine, always conduct the following inspection. External inspection ACAUTION Be sure to Keep combustible materials away from the engine, especially from the hol engine paris such as exhaust ‘manifolds, or the battery. Check for fuel and oil leaks. Clean the top of battery with a wet cloth before starting engine, as dust on the battery can easily ignite. If any abnormality is found, be sure to repair or contact your Mitsub- {shi dealer. 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 dust are found near the engine or battery, remove them. . Check the electrical wiring to such components as starters and alternator for loose, CCheck the entire engine for leaks of fuel, engine oll and coolant. If leaks are found, repair the leak, or contact your Mitsubishi dealer. 4, Make sure the following valves, plugs and cocks are open or closed properiy Fuel feed valve: Open Coolant drain cock (plug): Closed Oil drain valve: Closed(Chapter 3 OPERATION Checking fuel tank oil level When working around fuel, make sure there are no open flames, heaters or other fire hazards. Wipe off any spilled fuel completely. Spilled fue! can ignite and cause a fire, CAUTION Donot remove the strainer when filing the fuel tank. Use fuel specitiod in "FUEL" (4-1) Make sure the fuel tank is full. If the fuel level is low, refill the tank to the “FULL” level Checking engine oil level 41. Pullout the oil level gauge and wipe it with a cloth 2. Insert ine oil evel gauge fully into the oi level gauge guide, then pull out the gauge again 3, The cctret ol level is between the MAXIMUM and MINIMUM marks on the oil level gauge. 4, Ifthe ol evel is low, remove the oi filer cap and ‘add engine ol ofthe specified type to the MAXI- MUM bevel. 5. Install the oil filer cap after a rfl Oilevel gage 6. Checkthe oil pan and other parts for ol leaks. Fig3-14 Oil filler and oil level gage(Chapter 3 OPERATION Checking coolant level Remove the radiator cap only after the engine is cooled to the room temperature. Place a cloth over the ‘cap, and loosen the cap about a halt-ur or stand the lever to the upright position to release internal pres- ‘sure, Opening the radiator cap while the engine Is hot ‘causes steam and hot coolant to splay out that may result in skin burs. 1. Open the radiator cap and check the coolant level 2. If the coolant level is low, add coolant to the speci- fied level. ‘CAUTION ‘Riways use the coolant with the same LLC concentra tion, Note: Determine the quantities of LLC based on the coolant capacity and the LLC concentration chart. For the coolant, refer to “COOLANT AND LLC" (6-1). For the coolant capacity, refer to "MAIN SPECIFICATIONS" (12-1) 3. Ita reserve tank is equipped, fil the reserve tank with coolant up to the [FULL line level Checking air cleaner 1. Check the alr cleaner indicator for the element clog. Ifthe element is clogged, the red signal mark is, Visible. Immediately clean or replace the air cleaner ele- ‘ment when the signal tums red Note: For cleaning of the air cleaner element, refer to “Cleaning, checking, replacing air cleaner ele- ment" (8-14). p » 3-10 Tum cap about Stand the lever to half a turn upright position Fig3-15 Radiator cap Fig3-17 Reserve tank coolant level Button Signal Fig3-18 Checking air cleanerChapter 3 OPERATION Starting ‘The starting method changes based on application and specitications. Start the engine according to the specified procedure. Before starting the engine, check to make sure no one is near the engine and tools are not left on or near the ‘engine. In loud voice, notify people in the area when starting the engine. CAUTION ‘Donat apply load to the engine at starting. (Dsen- gage the clutch if installed.) Warming-up operat Do not approach rotating parts during operation, Entanglement by rotating parts can cause serious injury. CAUTION Da nat conduct warm-up operation Tor prolonged period of ime. Prolonged warm-up operation causes carbon buildup in the cylinders that leads to incomplete combustion, Do not turn the battery switch to OFF. Turing off the battery switch while the engine is in warm-up opera- ‘ion not only stops the instrument operations but also may deteriorates the alternator diode and regulator. Never turn the Key to START position during warm-up operation, as it damages starter. During warming-up operation, do not operate the ‘engine under overload (if overloaded, the black smoke is exhausted). Operating the engine under overload not only inereases fuel consumption but also genet- atos oxcossivo carbon doposits inside the engine hich considerably shorten the engine service fe. ‘Alter the engine starts, operate the engine under no Toad at low idling speed for 5 to 10 minutes to warm up. Checking engine oil pressure During warming-up operation, check i the oll pressure isin the range of standard value. ‘Also, make sure the oil pressure gage is operating Properly. Note: The oi! pressure gage may indicate higher level ‘than normal level immediately after the engine starts, due to the low ol temperature. The pres- sure gradually lowers to the normal level as the «il temperature rises. External inspection during warming-up Visually check the extemal view ofthe engine for leaks of fuel, engine ol and coolant, or leaks of exhaust gas from joints. 3-11Chepter 3 OPERATION Operation Bo not approach rotating parts during operation, Entanglement by rotating parts can cause serious injury. A CAUTION Do nat toush any hot part ofthe engine Such as ‘exhaust pipes during operation or immediately ater shut down. A hot engine can cause bums, CAUTION ‘Aways provide adequate ventilation in he engine room. If air supply to the engine room is not sufficient, the room temperature rises and can affect engine out put and performance. For the first 50 hours, operate the engine under light load at lower speed than the normal operation for break-in operation. (Operating the engine under heavy load or severe con- ditions during the break-in period can shorten the ser- vice life of the engine. Do not turn the battory switch to OFF when the engine is in operation, Tuming off the battery switch during ‘operation not only stops the battery charge but also causes malfunctioning of instruments and deteriorates the alternator diode and regulator. Never turn the key to the START position during oper- ation. The starter may be damaged, ‘After the warm-up operation, start applying load to the engine. Inspection during operation Careluly check the exterior of engine such as piping joins for leaks Check for abnormal engine noises or vibrations such ‘8 knocking ‘Check the color of exhaust gas from the exhaust mut- flr. Note: For abnormal exhaust gas conditions, refer to ‘Other problems and countermeasures" (11-3). Check the instruments and gages for proper operation and make sure they indicates normal values. Table 3-2 Standard values at rated speed Tem ‘Standard valve 0.49 10 0.64 MPa Engine oll pressure gage (5 to 6.5 kat/om?) [71 to 82 psi] 70 10 80°C Coolant temperature Resear Note ee wscosty lubrication, and also causes a decrease in engine out- put due to leakage of combustion gas. ig5-2 Recommended oil viscosity according to air temperature Genuine engine oi Mitsubishi Heavy Industries, Ld. offers the best suited oil, which yielded from many tests, to Misubishi ce- sel engines. We highly recommend the use of our genuine engine ol, For land use engine, “JUKCOIL Cojera 1540 or 15-90" and for marine engine, “JUKOIL New Mariner 15W-40 or 15W-20" are aval able Fig5-3 Jukoll cojera,new marinerChapter 5 ENGINE OL Engine oil in the market Mitsubishi Hoavy Industries, Ltd, does not warrant the engine if olin the market are used. ‘The quality and performance of commercially available os as well as their components variations are inthe respon- sibilty of engine ol suppliers. Before purchasing commercial lls, be sure to discuss the suitability of engin ol wth the oil supplier. Handling engine oil Before filing engne with engine ol, stop the engine and make sure there are no open flames and other firenazards near the engine, Leaked or spilled oll on hot surfaces or electrical components can cause a fre. Wipe off ary spilled oilimmediately and thoroughly. After filing, securely close the filer cap, CAUTION aver mix dierent brands of engine oll Mixing diferent brands of engine oll may cause a chemical reaction by additives in the engine oll that could degrade the engine oil quality. ‘When handling ol of more than the legally specified quantities, be sure to have the work performed by a service sta- tion in compliance with the legal regulations. ‘When removing oil from the engine or oil can, use an oil pump. Do not suck ol with the mouth to siphon. Be sure to close the cap on the oll 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 oll used and follow the instructions of the MsDs.Chaptor § ENGINE OlL Service limits of engine oil Engine oil degrades by the use and by lapse of time, Be sure to renew engine oil if a property exceeds the limit Table 5-1 Service limit for engine oil properties Propertie ‘Senice int Tost Method Viscosity €st@1006 | Within +30 and -15% of new oll TIS K2283 2.0 or more with hydrochloric acid (HGL) method) “Total base number mAKONG | 1/2 of new ai or more with perchloric acid (PCA) method | “'S K2501 Total acid number [_makonig | Upto +80 of new ol “IS K2501 Water content Vol% | 0.2 orless JIS K2501 Flash point (open cup) °C __| 180 ormore IK K2275 entane insolubles orless come aie Pentane insoluble wi% | oSork Fella Pentane insolubles coagu- an ‘Comply with lated M% | 30ork ASTM D883 Definition of properties of engine oil Viscosity Viscosity isa basic physical propery of engine and Considered as the most important aspect of ol wien evaluating Contamination of ol by blow-by gas and deterioration of cil by its natural aging degrade the performance of viscosity that will cause the deposition of sludge in the interval engine and ol fiter clogging. Contamination of oil by fuel and sheared molecules of viscosity index improver in oil also dograde tho performance of vis- cosity that will ause insufficient lubrication and frc- tion/wear of engine pars Total base number ‘Total base number (TBN) shows the ability to neutral- ize acids such as organic acid due to the engine oil cxidation, oF sulfurous acid or sufurie acid due to sul fur content of fuel Because TBN inicates the amount of dispersant Getergent in ol it can be used to estimate consump- tion of basic depereant detergent. The ability to dis- perse sludge declines as dispersant detergent is being used up. Total acid number Total acid number in oil increases as the organic acid is being derived by the engine ol! oxidation, or sufu- ‘ous acid or sulfuric acid derived by the combustion of sullur content of ful, othe ols be contaminated with imperfect combustion products. The increase of total 5-4 ‘acid number will result in corrosion or wear of inner parts of engine (such as cylinder liner or metals) derived by sulfur content, and piston ring seizure by sludge, Water Water in oil promotes corrosion/wear, and decreases lubricity in sliding parts. Flash point Flash points lowered by contamination by fuels Flash pointis measured to check the dilution of fuel. ‘The dilution of fuel reduces ol fim, and causes insut- cient lubrication that will cause friction or wear of engine parts. Insolubles Insolubles include acid products of engine ol, impor- fect combustion products, sludge or soot, metal abra sive particles and dust. Insoluble are an indication of ‘or degradation/contamination of oi Dispersant detergent, which is one of adelitives in engine oil, absorbs sludge particles, and disperses them as fine particles ino Total insolubles density and remaining dispersibilty can be obtained by measuring insolubles and coagu- lated insolubles (using chemical specialities to stop action of disperse detergent and to collet the sludge ispersed in ol) and by which, piston ring seizure or premature wear can be prevented before occurring,‘chapter 5 ENGINE OlL Engine oil analysis service Fora long term sorvce life of engine, Mitsubishi Heavy Industries, Ltd. offers an engine oil analysis service. The service includes special ol sampling tools, the sample oll analysis and the result data. The engine ol analysis service provides the following information: ~The quantity of fine metal powder in engine oil due to abrasion, by which worn pars can be located Water, LLC, or salt that should not bein engine ol can be detected. Engine ol deteriorating conditions, with that, appropriate engine oll renewal intervals, operating conditions, proper inspection and maintenance schedule can be planned Tho engine oil analysis service can diagnose the intemal colton of an engine, which used to require engine dis- assembly. tis highly recommended to take advantage of our engine ol analysis service as you can lear the {engine condition before any maifunctions are appeared on the engine How to order engine oil sampling tool set The oil sampling pump is reusable, but oll sampling botle and suction pipe must be replaced each time. For replac- ing tools, order them through the regular part supply system. The analysis fee s included inthe price of the sam- pling bottle. Therefore, if you sample the oil in other botles, you will nt receive our analysis service. Also, note that ‘optional analysis requires addition charge. Table 5-2 Engin ol sarong tol eats bien Partna Remarks (it sampling pump ae | Sons ota 6281-10100 | ping pump, pes sarin st Bling pur, 17 canon: 6 poies Oitsample Incas ston pes bottle set 96291-00098 | ang oll | sample data ana Ot samping bot Brcampng bolle scan, 6 bottos oes sueton pipes and analyzing data of sampio ol Figi-a Engine o sapling ool satChapter 6 COOLANT AND LLC Recommended coolant Use soft water (e.g. ‘ap water) for the engine cooling system. The water quality must meet the requirements in the Table below. Basicaly, the water qualty should be within the recommended value, however, within limits accept- able. Table 6-1 Water quality standards Shee 2 = on Unit ‘Umit L : formation pH (25°C [77°F]) ~ - 651085 ° Elta carci - | msm <25 <40 ° ° Total hardness aco | ppm <5 =i00 - [0 Malkalinity CaCO: ppm <70 <150 - | oO Chlorine fon ci pom <100| <100 ° - Sulfur aca on sot | ppm <0 | o.1mm {0.004in { a T Rod Ss Lever Fig8-6 Inspecting fuel control linkage for looseness: Ball joint ‘Control linkage [Pe Fig8-7 Removing fuel control inkage‘Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES, Changing fuel filter When handling fuet, make sure there are no open flames or other fire hazards near the engine. Wipe off any spilled fuel completely. Spilled fuel can ignite and cause a fre. Clean the area around the fuel fits. Place a drip pan under the fuel filters. Using a fiter wrench, remove the fuel fiters. Wipe off fuel on the fuel fiter cartridge mounting surface ofthe fiter bracket with a cloth, Check new fue! filters for proper seating of the gas- kets. Do not use the fiter that has dent on its case. Itmay damage the fiter, or may cause a fuel leak, Which could result in a fire during operation. 6. Apply clean fuel to the gaskets on new fue! fiters. 7. Install fuel fers. When the gasket contacts the mounting surface on the filter bracket, further rotate 3/4 to a full turn, CAUTION ‘Donot use the fiter wrench for the installation of fuel filters. Do not dent or scratch the fuel fiter surfaces. 8. Affor installing the new fuel fiter, bleed the fuel fi- ter. Note: For bleeding fue! fiter, refer to “Bleeding fuel system" (3-2) 9. Start the engine and let it dle for several minutes. 10.Check the fue! filter mounting sections for fuel leakage. If fuel leakage is found, loosen the fuel fil- ter and check the gaskets for damage. If there is no gasket damage, retighten the fuel fiter. Apply fuel to gasket Fig8-9 Fuel fiter(Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Lubricating system periodic inspection and mainte- nance Changing engine oil, oil filters and bypass oil filter A CAUTION ‘Todrain of or change ol fiters, wear gloves. Hot engine oll and paris can cause bums. CAUTION Disposal of discharged oll is legally restricted. Contact your Mitsubishi dealer for he disposal of waste oll ‘When changing engine oll, renew oil fters and bypass oil fiter. Also itis recommended to conduct an analysis of engine cil properties at the time of engine oil change. Never wash and reuse oil fiters, as their elements are paper type. ‘When replacing fiters, always replace gaskets with new ones. Draining engine oil After the engine has stopped, drain engine oil from the engine ol drain port Note: A sucking-up draining should be avoided 8-6‘chapter & PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Changing oil filters and bypass oil filter ht cd ‘not use the fiter that has dent on iis case. It may damage the filter, or may cause an cil leak, which could result in a fre during operation ‘CAUTION ‘Donot use the filter wrench to install fiters. Use hands: to prevent fiters from damaging, 11. Clean the area around the ol fiters. 2. Place a drip pan under oil fiters and a bypass oil filter 3. Using a fiter wrench, remove oil fiters and a bypass oil fiter. Note: Disassemble the removed oil fter and bypass oil fiter and check elements for metal particles. metal particles are found, contact your Mitsub- {shi dealer. Change oi fiters and a bypass oil filer whenever the filter alarm turns on 4. Wipe off oll on the oil filter mounting surface of the fiter bracket with a cloth, '5. Check new oil fiters and a bypass fiter for proper seating of the gaskets. 6. Apply clean engine oil to the gaskets on new oil fi ters and a bypass cil fter. 7. Install oi filters and a bypass ol fiter. When the ‘gasket contacts the mounting surface of the filter bracket, further rotate $/4 to a full tum. Fig8-10 Oil filers and bypass oil filer ‘Apply engine oll to packing Figé-11 Ol fiter(Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Refilling engine oil CAUTION ‘To crank the engine, shut off the fuel supply to the engine and operate the starters. 1. Reinstall the drain plug. 2, Remove the oll filer cap. 3. Fill the engine oil pan with specified engine oil to the specified level Note: For engine oll, refer to "ENGINE OIL" (6-1) . For engine oll capacity refer to “MAIN SPECIFI- Gis CATIONS" (12-1). a 4, Check the oil level in the oil pan as follows: Fig8-12 Olfiler and oll level gage Pullout the oll level gauge and wipe it with a cloth, Insert the ol level gauge fly into the ci level gauge guide, then pul the gauge out again, The oi level should be between the MAXIMUM and MINI- MUM marks onthe oil evel gauge 5. Ifthe ol levels low, add engine ol ofthe specitiod type. . Check the ol pan and other pats for ol leakage. Repair any oil leakage found 7. Shut off the fue supply and crank the engine for bout 10 seconds or loss using the starters, and wait for about + minute 8. Perform the above cranking operation again to cir culate oil inthe engine 9. Check the ol level with the ol level gauge again, and add ol othe specified level ° Checking engine oil for mixing of fuel and water A CAUTION I ihe engine continues to operate with engine oll with mixed with fuel or water, the engine oll viscosity deceases and this can cause serious accidents such as seizing of bearings ‘Sample 1 to 2 L [0.26 to 0.83 U. S. gal] of engine oil, and check for abnormal odor and discoloration to determine the mixing of fuel and water. If fue! is mixed with the engine oil, the oil smells like fuct. I water is mixed with the engine oil, the color of oll turns to milky white. It fuel andor water is mixed with the engine oll, locate and correct the cause of i, or if correction of the cause Is di ficult, contact your Mitsubishi dealer.8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Cooling system periodic inspection and maintenance Changing coolant ‘To remove the radiator cap, wait until the engine is, cooled to the room temperature, Place a cloth over the cap, and loosen the cap about a halt-tur or stand the lever to upright position to release intemal pressure. pening the radiator cap while the engine is hot causes steam and hot coolant to blow out and can result in skin bums. Coolant containing LLC drained from the engine is toxic. Never dispose of coolant into regular sewage. For disposal of used coolant, consult ‘your Mitsubishi dealer. Stand the lever to ‘upright position Tum cap about half turn ‘CAUTION ‘The service Ife of LLC is 2 years. Be sure To renew coolant at least once every 2 years. Draining coolant 1. When draining coolant immediately after engine ‘operation let the engine idle at low idling speod for 5 0 6 minutes to lower the coolant temperature to 70 to 80°C [158 to 176°F]. . Open the racator cap Place coolant receiving cans under the drain cocks Con the engine, and open the drain cocks to drain coolant er ‘Amount of coolant (engine body): Approx 1001. Fig8=15 Draining coolant (weter pump side) 8-9(Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Cleaning cooling system 1. Close drain cocks and plugs. 2. Pour in a cleaning solution (non-corrosive solution to rubber and motals) in the cooling system, and operate the engine at 800 to 900 min" for about 15 minutes, then drain the cleaning solution. 3. Close drain cocks and plugs. 4. Pour in fresh water, and operate the engine at 200 0 900 min* for about 10 minutes. Repeat rinsing Until the draining water becomes clear and clean, Refilling coolant 1, Make sure drain cocks and plugs are closed tightly. 2. Remove radiator cap, and pour in undiluted LLC. Note: Determine the amounts of LLC and water to be added by using the LLC concentration chart. For coolant, refer to "COOLANT AND LLC" (6-1), For coolant capacity, refer to "MAIN SPECIFI- CATIONS* (12-1) 3. Pour in water (soft water with minimal impurities, ‘such as tap water) slowly to the full level |. Check radiator and other parts for coolant leakage. If coolant leakage is found, repair it ;. When coolant reaches the full level, close the radi- ator cap securely |. Shut off the fuel supply and crank the engine for about 10 seconds or less using the starters. Wait for about 1 minute, then repeat the above cranking ‘operation again to remove air from the water pump. CAUTION ‘To crank the engine, shut off the fuel supply to the engine and operate the starters, Fig8-17 Reserve tank 7. Check the coolant level in the radiator. Ha reserve tank is equipped, fil the reserve tank with coolant to the full Ievel as well CAUTION ‘When adding coolant, use the coolant having the same LLC concentration as the coolant already in the radiator.Checking and cleaning radiator fins heck radiator fins for holes and cracks. To clean radi ator fins, blow compressed air from the opposite direc- tion to the normal airflow, ter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES ce Fig8-18 Cleaning radiator fins 8-11+ 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Inlet exhaust system periodic inspection and mainte- nance Checking turbocharger A CAUTION ‘Gheck turbocharger when engine is cold. Also make sure the compressor whe! is not rotating when checking turbocharger. ‘CAUTION iT ihe color of exhaust gas is abnormal, also conduct ingpections of the turbocharger. Disconnect the pipe from the air inlet side, Hold the compressor wheel nut by hand and turn the wheel to check for loose and abnormal noise. Replace the bearings if loose or abnormal noise is found. Note: For replacement of the bearing, consult your Mitsubishi dealer. Draining water from exhaust muffler A CAUTION ‘Never touch the exhaust muffler immediately after the engine stops, as itis extremely hot. To drain water, wait until the exhaust muffler becomes coo. Remove the drain plug and allow water to drain from the exhaust muff cy 12 Compressor wheel nut Fig8-18 Checking turbocharger ‘ Drain plug Fig8-20 Draining water from exhaust muffier(Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Cleaning, checking, and replac- ing pre-cleaner ‘A CAUTION ever service the pre-cleaner while the engine is run ning. Servicing the pre-cleaner while the engne is in ‘operation can cause foreign particles to enter the ‘engine and result in rapid wear of parts which leads a shorter service life of engine, ‘The pre-cleaner is equipped to the silencer of the tur- bocharger to remove dust from intake alr andkeep the ‘engine clean for optimum performance. Be sure to clean the pre-cleaner as described below. 1. Remove the pre-cleaner from the silencer, and hhand-wash the pre-cleaner with a mild detergent. . Rinse the pre-cleaner with fresh water. . After drying thoroughly, check the pre-cleaner for defects. If defects are found, replace the pre- cleaner with new one. Ater cleaning, checking or replacement, reinstall the pre-cleaner. a S V2 Rinse) wy] install (oy) Fig8-21 Cleaning pre-cleaner 8-13Chanter @ PERIODIC INSPECTION AND MAINTENANCE PROCEDURES: Cleaning, checking, replacing air cleaner element ‘A CAUTION Never service the air cleaner while the engine Is run- ning. Servicing the air cleaner while the engine isin ‘operation can cause foreign particles to enter the engine and resut in rapid wear of parts that leads to a shorter service life of engine. Never knock or hit the element. When using compressed air, wear protective gear such as safety glasses, hard hat and gloves. Working without protective gear can result in a severe personal Injury. |. Remove the alr cleaner cap or wing nut. . Remove the alr cleaner element from the body. - Blow compressed air (0.69 MPa (7 kgfiom?) [100 Psi] or lower) onto the inside surface of the ele- ment to remove dust and other contaminants. J. To remove dust stuck on the element, blow dry ‘compressed air onto the outside surface from a distance. Blow compressed air on the inside sur- face toward outside along the pleats, Then, blow ‘compressed air on the outside and inside surface again. 3. After cleaning, place a light bulb to illuminate inside the element to check for defects such as cots, pinholes or a local wear. . If defects are found, replace the air cleaner ele- ment with a new one. After cleaning, checking or replacing the air cleaner element, reinstall the air cleaner element to the body, ° ~ CAUTION ‘Fdeects such as cuts, pinholes or a local wear are found in the element or if the air cleaner indicator ‘shows red sign soon after the cleaned element is installed, replace the filter element with new element. Reset the indicator by pressing the reset button after the clean or new element is installed when the indica- tor shows a red sign, Wing nut Fig8-22 Removing alr cleaner element Fig8-24 Checking air cleaner element Button Signal Fig8-25 Air cleaner indicator(Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Electrical system periodic inspection and maintenance Checking starter Visually check the starter for damage. It the starter are dusty, blow off dust using com- pressed air Note: If defects are found in the starter, contact your Mitsub shi dealer. Visually check the alternator for damage. {tthe altemacor is dusty, blow off dust using com- pressed air. Remove V-balt, and turn the pulley with hands to make sute itrotates smoothly Note: If defects are found in the alternator, contact your Mitsubishi dealer. ‘alternator Figi-27 Checking altemator 8-15(Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES. Checking battery If battery electrolyte is spilled on your skin, flush immediately with plenty of water. If battery electrolyte enters the ‘eyes, flush them immediately with lots of fresh water and seek medical attention at once. Do not use open flames or ‘other fre hazards near the battery. When handling the battery, be careful of sparks generated by accidental short- ing. For other cautions in handling the battery, refer to "Caution service battery” (1-5) Checking battery electrolyte level Battery electrolyte evaporates during use and the fluid level gradually decreases. The correct fui surface level is between the LOWER LEVEL and UPPER, LEVEL lines. For the battery witout level lines, the correct uid surface level is about 10 to 15 mm [0.994 100.591 in. above the top ofthe plates. If the fuid level is low, remove the caps and add cistiled water to the proper level Note: When adding cstiled water, pour in carefully Checking specific gravity of battery electrolyte Check the specific gravity of the elecroyt. If the epe- cific gravity measured at 20°C [38°F] is lower than 1.22, then charge the battery Table 8-2 Specific gravity of electro ‘Specific gravity at 20°C (68F) Condition | Remedy 101015 mm [0.394 t9 0501 in} eectaS. ine disss Tus, Fron 12610 1.28 | Fuly ranged |= ea From12210126 | Charged | Charge | Tees tan 122] Bachaged 1] Change Tigi-00 Checking spocic raviy of locranae 8-16Chapter 9 LONG-TERM STORAGE Long-term storage The folowing describes how to store the engine in a non-operable condition for three months or more and in an operable condition for three months of mor. ifthe engine has been left unattended for three ‘months or more, he intemal engine pets can rust that ‘may cause damage tothe engine. When string the engine for an extended period of time, be sure to fol- low the directions below. Storing engine in non- operable condition for 3 months or more Preparation for storage 1. Drain engine oil, and pour in rust-preventive ol (NP-10-2) into the engine. 2. Prepare a fuel mixture containing 50% rustpre- vntive oil (NP-8), and fil the fuel tank with it ‘8. Operate the engine at a speed of 800 to 1000 min (idling) for 5 to 10 minutes under no load. 4, Immediately before stopping the engine, spray vol atile corrosion inhibitor (V.C.) through the inlet port to prevent rust on the air intake system, 5. With the engine stopped, dain the fuel mixture from the fuel tank. 6. Apply rust preventive oil (NP-3) liberally on the exposed sections of the machining 7. Seal ar inlet, exhaust outlet, breather and other openings with an adhesive cloth tape . Loosen V-belt 9. Wrap adhesive cloth tape on the terminals ofthe starts and alternator, and seal the openings. Cover these sections with polyethyiene sheet or processed polyethylane paper, and place desic- cants in the polyethylene covers. 10.Disconnect cables from the battery terminals, and charge the battery. Clean the terminals, apply @ thin coat of grease tothe terminals, and store the battery ina cool and dry room. 11.Cover the entire engine » Note a) Store the engine in a well-ventilated indoor area. (b) No need to drain coolant since it contains LLC. (Add LLCto increase the concentration between 30 and 60%.) (c) Posta sign at an easily noticeable place to war that the rust-preventive oil in the engine must be replaced with engine oil, and the fuel tank must be filled with fuel before ‘operating the engine, (@) Anew engine oil can substitute for rust-pre- ventive oll (NP-10-2), Recommended rust-preventive oil and corrosion inhibitor Table 8-1 Recommended rust-preventive oil and corrosion inhibitor Facarmended IS Na en Applicaton | Prvention of ton Nppen Oi Corporation oo peed Ani ust?-1400 | exPD8ed furaces 12248 | pg | Nippon OL Corporation | Frevenvon Ant Punt P-2400 | OON = as Prevention 2 | Nepen i Corperain | of rst on NP+0-2 | ‘anti Rust P-230 lubricating system Ryouiou Kagatar | Prevention WelDana otras on are ‘volatile corrosion inhi air intake tor system Maintenance during storage ‘Charge the battery once a month First, check the battory eectolyte for corect level and thon charge the battery.