Mitsubishi S12R-T2MPTK Operation & Maintenance Manual
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Mitsubishi S12R-T2MPTK Operation & Maintenance Manual

Mitsubishi S12R-T2MPTK Operation & Maintenance Manual

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OPERATION &
MAINTENANCE MANUAL
Issued: September 2012
Pub. No. 291T1-00120
CAUTION
●Read this Operation & Maintenance Manual, and
conduct the engine operation, inspection and
maintenance only after sufficiently understanding
the description.
●Please keep this Operation & Maintenance Manual
with related manuals at a suitable place for quick
reference when needed.

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  • Page 1 OPERATION & MAINTENANCE MANUAL Issued: September 2012 Pub. No. 291T1-00120 CAUTION ●Read this Operation & Maintenance Manual, and conduct the engine operation, inspection and maintenance only after sufficiently understanding the description. ●Please keep this Operation & Maintenance Manual with related manuals at a suitable place for quick reference when needed.
  • Page 3 INTRODUCTION This operation and maintenance manual contains detailed operation, inspection and maintenance information for engines from Mitsubishi Heavy Industries Engine & Turbocharger, Ltd. Please be noticed that some contents are repeated among chapters for better understanding. Please read and understand this manual before proceeding with operation, inspection, and maintenance work.
  • Page 4 Limited Warranty Mitsubishi Heavy Industries Engine & Turbocharger, Ltd. will repair or replace the product, which returned to us during the warranty period, when we judge that the product or a part of the products is defective in material and/or workmanship after conduct-ing inspection.
  • Page 5 Mitsubishi Heavy Industries Engine & Turbocharger, or machine readable form without prior written con- sent from Mitsubishi Heavy Industries Engine & Ltd. cannot foresee all potential dangers of the Turbocharger, Ltd. engine, potential dangers resulting from human error and other causes, or a danger caused by a specific For improvement of the engine, the contents in this...
  • Page 6 FOREWORD Warning Indication The following signs and symbols are used to call attention of the operators and maintenance personnel to potential dangers of the engine. Warning Statements in This Manual Warning Labels Affixed on the Engine Warning Statements The warning statements in this manual describe potential danger in operating, inspecting or maintaining the engine, using the following five classifications to indicate the degree of potential hazard.
  • Page 7 FOREWORD Units of Measurment Measurements are based on the International System of Units (SI), and they are converted to the metric system units in this manual. Conversion rates are as follows: Pressure: 1 MPa = 10.197 kgf/cm Torque: 1 N•m = 0.10197 kgf•m Force: 1 N = 0.10197 kgf Horsepower: 1 kW = 1.341 HP = 1.3596 PS Rotation speed: 1 min...
  • Page 8 FOREWORD Regulation for the Prevention of Air Pollution From Ships Engine International Air Pollution Prevention Certificate and Technical File The engine you have purchased is provided with "Engine International Air Pollution Certificate" (EIAPP-certificate) which proves the NOx regulation compliance of MARPOL 73/78 Annex VI, regulation for the Prevention of Air Pollu- tion from Ships, and "Technical File."...

  • Page 9: Table Of Contents

    CONTENTS Chapter 1 Stop Engine Immediately When Engine Oil Pressure is Dropped ........1-5 BASIC SAFETY PRECAUTIONS If Belt Breaks, Stop Engine Immediately ..1-5 Fire and Explosions Prevention...1-1 Battery..........1-5 Keep Flames Away .......... 1-1 Handle Battery Correctly ........1-5 Keep Engine Surrounding Area Tidy and Clean ..
  • Page 10 CONTENTS Chapter 5 About Stop Panel.........2-9 ENGINE OIL Using Manual Turning Gear ....2-10 Recommended Engine Oil ....5-1 Chapter 3 Engine Oil Grade ........ 5-1 Engine Oil Specifications ....5-2 OPERATION Selection of Oil Viscosity..... 5-3 Preparation for Operation of New or Handling Engine Oil ......
  • Page 11 TROUBLESHOOTING Damper - Inspect..........8-3 General Precautions ......11-1 Cold Weather Operations......... 8-4 Contact a Dealer of Mitsubishi Heavy Industries Fuel System.........8-5 Engine & Turbocharger, Ltd. for Repair Service 11-1 Fuel System - Inspect ........8-5 Considerations Before Proceeding with Fuel Tank - Clean..........
  • Page 12 CONTENTS List of Illustration Fig. 3-16 No Fuel Injection Position ....3-11 Fig. 1-1 Warning Labels ........1-8 Fig. 3-17 Oil Filler and Oil Level Gauge .....3-12 Fig. 2-1 Engine Front View ........ 2-1 Fig. 3-18 Coolant Expansion Tank Cap .....3-13 Fig.
  • Page 13 CONTENTS List of Table Fig. 8-20 Oil Filter - Replace While Engine is Running ..........8-15 Table 2-1 Instrument Panel ........2-7 Fig. 8-21 Governor Oil Filter - Change ....8-17 Table 2-2 About Stop Panel........2-9 Fig. 8-22 Coolant Expansion Tank Cap..... 8-18 Table 4-1 Recommended Fuel ........4-1 Fig.

  • Page 15: Basic Safety Precautions Fire And Explosions Prevention

    Chapter 1 BASIC SAFETY PRECAUTIONS Fire and Explosions Prevention Keep Flames Away Watch Out for Fuel, Oil and Do not use flames near the engine (in Exhaust Gas Leaks the engine room). Fuel gas vapor or If any fuel, oil or exhaust gas leak is found, immedi- other gas can catch fire and produces ately stop the engine.

  • Page 16: Stay Clear Of All Rotating And Moving Parts

    Chapter 1 BASIC SAFETY PRECAUTIONS Stay Clear of All Rotating and Moving Parts Install Protective Covers Lockout and Tagout Around Rotating Parts Be sure to lockout/tagout before starting inspection Make sure the protective covers and maintenance work. attached to the engine rotating parts Lockout and tagout are effective methods of cutting off are correctly installed.

  • Page 17: Exhaust Fume Poisoning Prevention

    Chapter 1 BASIC SAFETY PRECAUTIONS Exhaust Fume Poisoning Falling Down Prevention Prevention Lift Engine Carefully To lift the engine, use slings capable Operate Engine in a Well-Venti- of supporting the weight of the lated Area engine. Check exhaust pipes and pipe joints Hitch proper slings to the hangers for gas leaks.

  • Page 18: Burn Prevention

    Chapter 1 BASIC SAFETY PRECAUTIONS Burn Prevention Be Careful of Burns When Changing Oil Before draining oil or changing oil filters, wear leather Do Not Touch the Engine Dur- gloves or be sure to check the engine temperature. If ing or Immediately After Opera- hot oil or parts touch your skin, it can cause burns.

  • Page 19: If Problem Occurs

    Chapter 1 BASIC SAFETY PRECAUTIONS If Problem Occurs Battery Stop Operation Immediately If Handle Battery Correctly You Notice Any Unusual Symp- Never use flames or allow sparks toms near the battery. The battery Stop the operation immediately if you notice any releases flammable hydrogen gas unusual noise, odor or vibration during operation.

  • Page 20: Other Cautions

    Chapter 1 BASIC SAFETY PRECAUTIONS Other Cautions Never Modify Engine Perform All Specified Pre-oper- ation Inspections and Periodic Unauthorized modification of the engine will void your Inspections warranty. Conduct pre-operation inspections and periodic Modification of the engine may not only cause dam- age to the engine but also may result in personal inspections as instructed in this manual.

  • Page 21: Never Operate The Engine Under Overload

    Chapter 1 BASIC SAFETY PRECAUTIONS Never Operate the Engine Avoid Prolonged Starting Oper- Under Overload ation If overload symptoms such as black exhaust smoke is Do not use the starter for more than 10 seconds at a observed, reduce the load immediately and assure the time.

  • Page 22: Warning Labels

    Chapter 1 BASIC SAFETY PRECAUTIONS Warning Labels Maintenance of Warning Labels Make sure all warning/caution labels are legible. Clean or replace the warning/caution labels when the description and/or illustration are not clear to read. For cleaning the warning/caution labels, use a cloth, water and soap. Do not use cleaning solvents, gasoline or other chemicals to prevent the letters from getting blurred or the adhesion from being weakened.

  • Page 23: Name Of Parts

    Chapter 2 NAME OF PARTS Engine External Views Front View Sea water drain cock Heat exchanger Sea water outlet Water pmup Sea water inlet Water pump drain cock Front P.T.O pulley Oil pump Oil pan Fig. 2-1 Engine Front View Rear View Exhaust gas outlet Turbocharger...

  • Page 24: Left View

    Chapter 2 NAME OF PARTS Left View Fuel injection pump Front hanger Fuel filter Rear hanger Seawater inlet Governor oil filter (Emergency) Manual stop lever Seawater Governor pump Rear Front Speed control knob Coolant drain cock (Crankcase behind Oil cooler fuel injection pump accessory drive) Relief valve...

  • Page 25: Equipment And Instruments

    Chapter 2 NAME OF PARTS Equipment and Instruments The installed equipment and shapes vary with specifications. Speed Control Knob You can adjust the engine speed in the engine room. Turn the knob for fine adjustment of rotating speed. High-speed Button rotation Turn the knob counterclockwise for high-speed rota- Turn clockwise...

  • Page 26: Stop Solenoid

    Chapter 2 NAME OF PARTS Stop Solenoid The stop solenoid is used for normal shutdown of engine operation. The stop solenoid moves the rack of the fuel injection pump to stop fuel injection, thus shutting down the engine. Stop solenoid Fig.

  • Page 27: Transmitters To Instruments

    Chapter 2 NAME OF PARTS Transmitters to Instruments This section describes about devices which transmit signals to instruments for operation. Read carefully and under- stand functions of each device. Oil Pressure Unit Detects the oil pressure. Oil pressure unit Fig. 2-9 Oil Pressure Unit Revolution Detection Pickup Located on the timing gear case, and detects engine Revolution detection pickup...

  • Page 28: Engine Protection Devices

    Chapter 2 NAME OF PARTS Engine Protection Devices Oil Pressure Switch There are two oil pressure switches, the one activates a alarm and the other stops the engine when engine oil pressure has dropped and reached the set pres- Oil pressure switch sure.

  • Page 29: Instrument Panel

    Chapter 2 NAME OF PARTS Instrument Panel kg/cm kg/cm X100RPM HEAT START STARTER SWI T CH Fig. 2-14 Instrument Panel Table 2-1 Instrument Panel Name Function Manifold pressure Indicates manifold air pressure in the engine. gauge Indicates the temperature of the engine coolant (freshwater). Coolant tempera- (Sandard temperature at rated speed: 70 to 80°C [158 to 176°F]) ture gauge...
  • Page 30 Chapter 2 NAME OF PARTS Table 2-1 Instrument Panel Name Function When the warning buzzer goes off, turn this switch "OFF" to stop the buzzer. Always Buzzer stop switch keep this switch in "ON" position during operation. Illumination switch Turn this switch "ON" to illuminate gauges. Press this button to stop the engine.

  • Page 31: About Stop Panel

    Chapter 2 NAME OF PARTS About Stop Panel ENGINE ALARM PANEL HIGH OVER F. O. TRIP SOURCE WATER SPEED LEAX CANCEL TEMP PRESS SOURCE ENGINE STOP RESET BELL STOP TRIP CANCEL ALRARM TEST Fig. 2-15 Stop Panel Table 2-2 About Stop Panel Name Function SOURCE light...

  • Page 32: Using Manual Turning Gear

    Chapter 2 NAME OF PARTS Using Manual Turning Gear Before starting the engine, make sure that the turning gear is pulled out. Starting the engine with the turning gear pushed-in not only damages the ring gear but also may result in personal injury. 1.

  • Page 33: Preparation For Operation Of New Or Overhauled Engine

    Chapter 3 OPERATION Preparation for Operation of New or Overhauled Engine Before proceeding with operation of a new or overhauled engine, conduct the inspections described in this section. Note that, for second operation onward, follow the instructions described in the "Normal Engine Operation"...

  • Page 34: Fig. 3-3 Bleeding Air From Oil-Water Separator Fig

    Chapter 3 OPERATION Oil-Water Separator - Bleed Air For Suction Type 1. Loosen air vent plug of oil-water separator. Air vent plug Manual 2. Close valve A on the piping and open valves B and wing pump C located front and behind the manual wing pump. 3.

  • Page 35: Fig. 3-5 Fuel Injection Pump - Bleed Air

    Chapter 3 OPERATION Fuel Injection Pump - Bleed Air 1. Loosen the air vent plug on the fuel injection pump Air vent plug by rotating about 1.5 turns. 15 ± 2 N·m 2. Move the priming pump up and down. When the {1.53 ±...

  • Page 36: Preparation Of Lubrication System

    Chapter 3 OPERATION Preparation of Lubrication System Engine Oil - Filling Oil level gauge Refill the engine with the specified engine oil to the Oil filler specified level. If the oil level is higher than the max- Improper imum mark on the level gauge, engine oil may blow High out during operation.

  • Page 37: Preparation Of Cooling System

    Chapter 3 OPERATION Preparation of Cooling System Coolant Expansion Tank Cap - Open/Close 1/4 turn to reliese Never open the coolant expansion tank cap during pressure. the operation or immediately after stopping. Stop the engine and, after coolant has sufficiently cooled down, open the cap.

  • Page 38: Fig. 3-10 Coolant Drain Cock (Engine Body)

    Chapter 3 OPERATION Coolant - Refill Left side Right side When adding coolant, use the same LLC concentra- tion coolant that is currently in the cooling system. 1. Close the coolant drain cocks of engin and water pump securely. Coolant 2.

  • Page 39: Preparation Of Electrical System

    Chapter 3 OPERATION Preparation of Electrical System Battery - Check Never use flames or allow sparks near the battery. The battery releases flammable hydrogen gas and oxygen gas. Any flames or sparks in the vicinity of battery could cause an explosion. Do not use the battery when the battery electrolyte level is below the "LOWER LEVEL"...

  • Page 40: Test Operation

    Chapter 3 OPERATION Test Operation To conduct a test operation, follow the procedures below. Note: For engine operation, refer to "Normal Engine Operation" (3-9). Starting and Stopping 1. Start the engine. 2. Operate the engine at a low idling speed under no load for 5 to 10 minutes for warm-up. 3.

  • Page 41: Normal Engine Operation

    Chapter 3 OPERATION Normal Engine Operation This section covers the procedures for the engine operation in normal condition. If the engine abnormality is observed during operation, stop the engine and correct the problem, or contact a dealer of MHIET. Preparations for Operation Always conduct daily pre-start inspection before starting the engine for the day.

  • Page 42: Fuel Tank Oil Level - Check

    Chapter 3 OPERATION Fuel Tank Oil Level - Check When handling fuel, make sure there are no open flames, heaters or other fire hazards. Wipe off any spilled fuel completely. Spilled fuel can be ignited and cause a fire. Do not remove the strainer during fuel tank filling. For the fuel to be used, refer to "FUEL"...

  • Page 43: Fuel Control Link - Check

    Chapter 3 OPERATION Fuel Control Link - Check Check the fuel control link for smooth movement. Push the manual stop lever to the fuel increase direc- Manual stop lever Rack cancel spring tion, check the movement of the rack cancel spring. Then loosen your grip on the lever little by little, mak- ing sure the manual stop lever returns to the no fuel injection position smoothly.

  • Page 44: Engine Oil Level - Check

    Chapter 3 OPERATION Engine Oil Level - Check Oil level gauge Refill the engine with oil to the specified level. If the Oil filler oil level is higher than the maximum mark on the Improper level gauge, engine oil may blow out during opera- High tion.

  • Page 45: Coolant Level - Check

    Chapter 3 OPERATION Coolant Level - Check 1/4 turn to reliese Never open the coolant expansion tank cap during pressure. the operation or immediately after stopping. Stop the engine and after coolant has sufficiently cooled down, open the cap. When opening the coolant expansion tank cap, raise the lever to the upright position to release internal pressure.

  • Page 46: Warning Indicator Light - Operation Check

    Chapter 3 OPERATION Warning Indicator Light - Operation Check 1. Turn the starter switch to the "ON" position. 2. Turn the light test switch to "ON" position. 3. Make sure the lights come on. If any of the lights kg/cm kg/cm X100RPM does not come on, check the light bulbs, etc.

  • Page 47: Starting-Up

    Chapter 3 OPERATION Starting-up Cautions When Starting Before starting the engine, make sure no one is near the engine and that no tools are left on or near the engine. Alert people in the area when starting the engine. Continuous operation of the starter will drain the battery power or cause the starter to seize. Do not use the starter for more than 10 seconds at a time.

  • Page 48: Starting Procedures

    Chapter 3 OPERATION Starting Procedures 1. Open the Kingston valve. 2. Turn the battery switch to the "ON" position. 3. Place the speed control lever in the low idle posi- tion and place the direction lever in the neutral po- sition.

  • Page 49: Warm-Up Operation

    Chapter 3 OPERATION Warm-up Operation Stay away from rotating parts during operation. If you are caught in rotating parts, you can be seriously injured or killed. Do not conduct warm-up operation for a prolonged period of time. Carbon deposits form in the cylinder, which may result in incomplete combustion.

  • Page 50: Operation

    Chapter 3 OPERATION Operation Cautions During Operation Operate the Clutch Carefully Pay Attention to Exhaust Color When shifting (operating clutch) between neutral and If the exhaust gas shows an abnormal color, there is forward, and between neutral and reverse, make a problem in the engine.

  • Page 51: Stopping

    Chapter 3 OPERATION Stopping Cautions When Stopping Do not stop the engine abruptly during high-speed operation or while engine is hot. Otherwise, the engine life will be shortened. Except in a case of emergency, operate the engine in low idle for 5 to 6 minutes to cool the engine befor stopping.

  • Page 53: Recommended Fuel

    Chapter 4 FUEL Recommended Fuel Use the fuel specified in this manual. Also, do not refill the fuel tank more than the specified level. It could lead a fire. Use a fuel that meets the requirements in the following Table 4-1 of "Parameter Entity References" Table 4-2 of "Recommended limit and use limit of fuel property"...

  • Page 54: Fuel Specifications

    Chapter 4 FUEL Fuel Specifications Use a fuel which meets the requirements specified in the table below. Table 4-2 Recommended limit and use limit of fuel property Item Recommended limit Use limit Test method JIS K 2265 :2007 50°C [122°F] or higher Flash point ISO 3769 (In accordance with the regulation)
  • Page 55 Chapter 4 FUEL Table 4-2 Recommended limit and use limit of fuel property Item Recommended limit Use limit Test method Fine foreign substances JIS B 9931 :2000 5.0 mg/liter or less (foreign substances at fuel inlet) ISO 4405 Lubricity: MWSD (Measured mean 460 μm [0.02 in.] or less Wear Scar Diameter) by HFRR (calculated wear scar diame-...

  • Page 57: Engine Oil

    Chapter 5 ENGINE OIL Recommended Engine Oil Use the engine oil recommended in this manual only. Do not use any other oil. The use of inappropriate or inferior oils will result in sticking of piston rings, seizure between piston and cylinder, or premature wear of bearings and moving parts, and significantly shortens the service life of the engine.

  • Page 58: Engine Oil Specifications

    Chapter 5 ENGINE OIL Engine Oil Specifications Use engine oil that meets the requirements specified in the table below. Table 5-1 Table of Recommended Limit of Engine Oil Properties Item Unit Recommended limit Test method API/JASO Grade CF *1 SAE viscosity 15W-40 JIS K 2580 Color ASTM...

  • Page 59: Selection Of Oil Viscosity

    Chapter 5 ENGINE OIL Table 5-1 Table of Recommended Limit of Engine Oil Properties Item Unit Recommended limit Test method 10/0 Bubbling test JIS K 2518 30/0 ISO 6247 10/0 300°C 140 or lower [572 °F] Panel coking test FED791-3462 325°C 300 or lower [617 °F]...

  • Page 60: Handling Engine Oil

    Chapter 5 ENGINE OIL Handling Engine Oil Before filling the engine with engine oil, stop the engine and make sure there are no open flames and other fire hazards near the engine. Leaked or spilled oil on hot surfaces or electrical components can cause a fire. Wipe off any spilled oil immediately and thoroughly.

  • Page 61: Definition Of Properties Of Engine Oil

    Chapter 5 ENGINE OIL Definition of Properties of Engine Oil Kinetic viscosity Water content Kinetic viscosity is a basic physical property of engine Water in oil promotes corrosion/wear, and decreases oil and is considered as the most important aspect lubricity in sliding parts. when evaluating oil.

  • Page 62: Engine Oil Analysis Service

    Chapter 5 ENGINE OIL Engine Oil Analysis Service For a long productive service life of engine, it is recommended to get an engine oil analysis service. By this service, the engine oil is extracted from the engine using a sampling tool and the sampled oil is analyzed to determine whether the oil being used is acceptable or not for the use.

  • Page 63: Recommended Water For Coolant

    Be sure to use Mitsubishi Heavy Industries Engine & Turbocharger, Ltd. genuine long life coolant (LLC), "GLASSY long life coolant (ethyl-ene glycol type)" or "PG GLASSY long life coolant (propylene glycol type)." When using an LLC other than Mitsubishi Heavy Industries Engine &...

  • Page 64: General Quality Requirements For Llc

    Never mix genuine MHIET LLC with other brand of the LLC that meets the requirements below. LLCs. Mixing with other brand of LLCs degrades Mitsubishi Heavy Industries Engine & Turbocharger, the performance of genuine MHIET LLC. Ltd. disclaims the warranty claim for defects caused...

  • Page 65: Llc Quality Requirements

    Chapter 6 COOLANT LLC Quality Requirements LLC shall be tested according to JIS K2234, Section 7 "Test method", and satisfy the requirements. General matters and specimen sampling method shall comply with JIS K2234. Table 6-2 LLC Quality Requirements Property Standard Appearance No precipitation Minimum 1.112 g [0.039225 oz.]/cm...
  • Page 66 Chapter 6 COOLANT Table 6-2 LLC Quality Requirements Property Standard Aluminum, Cast Mass iron, Steel, Brass, ±0.30 mg/cm change Solder, Copper Metal specimen No visible signs of corrosion on the surface Appearance of the specimen excluding the area in contact with the Circulation metal- after testing spacer.
  • Page 67 Chapter 6 COOLANT Table 6-2 LLC Quality Requirements Property Standard Tensile strength change -60 to 0 % Elongation change -40 to +20 % Silicon Volume change 0 to +40 % Hardness change -20 to +10 % Tensile strength change 0 to +10 % Rubber adapt- ability Acrylonitrile...

  • Page 68: Maintenance Of Llc

    Chapter 6 COOLANT Maintenance of LLC Should coolant or LLC be accidentally swallowed, induce vomiting immediately and seek medical attention. If LLC should enter eyes, flush immediately with plenty of water and seek medical attention. LLC is toxic. Never dispose of coolant containing LLC drained from engine into regular sewage. For disposal of used coolant, consult LLC distributor.

  • Page 69: Llc Concentration (Glassy

    Chapter 6 COOLANT LLC concentration (GLASSY, PG GLASSY) 1. To prevent cavitations of water pump and cylinder liners, LLC concentration must be at least 30% for GLASSY (ethylene glycol) and 40% for PG GLASSY (propylene glycol) by volume under any temperature conditions throughout the year.

  • Page 70: Importance Of Llc

    Chapter 6 COOLANT Importance of LLC Examples of Abnormali- ties Caused by LLC Today's trend is smaller and lighter engines that can offer greater output, lower fuel consumption and lower (Amine Type) exhaust emission levels. Pitting of Iron Parts Conditions to which engine coolant is subjected, therefore, are becoming severer due to longer operat- Amines are generally effective in suppressing the rust- ing hours, higher coolant temperature and higher cool-...

  • Page 71: Maintenance Schedule How To Use Maintenance Schedule

    Chapter 7 MAINTENANCE SCHEDULE How to Use Maintenance Schedule Periodic inspection not only extends the service life of the engine but also serves to ensure safe operation. Be sure to conduct inspections and maintenance according to the maintenance schedule. Observe the standard service intervals given in the maintenance schedule. However, if you notice any abnormalities such as abnormal noise, black exhaust smoke, white exhaust smoke, extremely high temperature of exhaust gas, abnormal vibration, and fuel, oil or exhaust gas leakage, be sure to conduct the inspection and maintenance work, regardless of recommended service intervals in the "Maintenance schedule."...

  • Page 72: Maintenance Schedule

    Chapter 7 MAINTENANCE SCHEDULE MAINTENANCE SCHEDULE Table 7-1 MAINTENANCE SCHEDULE Inspection and Mainte- Service items Page nance Intervals Engine Oil and Oil Filter - Replace 8-12 First 100 hours of oper- Fuel Filter - Replace ation Valve Clearance - Inspect and Adjust (Only once) Engine External - Inspect (Bolts, Nuts, Common Bed Bolts - Retightening)
  • Page 73 Chapter 7 MAINTENANCE SCHEDULE Table 7-1 MAINTENANCE SCHEDULE Inspection and Mainte- Service items Page nance Intervals Includes service items for every 100, 250, 500, 1000 and 2000 service hours. Cylinder Head - Disassembly and Inspect Engine Overhaul Valve Mechanism - Inspect Cylinder Liner Inside Surface - Inspect Belt - Repalce Damper - Inspect...
  • Page 74 Chapter 7 MAINTENANCE SCHEDULE Table 7-1 MAINTENANCE SCHEDULE Inspection and Mainte- Service items Page nance Intervals Includes service items for every 100, 250, 500, 1000, 2000 and 4000 service hours. Piston - Inspect Crankshaft - Inspect Main Bearing - Replace Thrust Plate - Replace Connecting Rod Bearing - Replace Camshaft Bushing - Inspect...

  • Page 75: Periodic Inspection And Maintenance Procedures

    Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Engine Proper Engine External - Inspect Check external parts of the engine, particularly hot parts (exhaust manifold, etc.) and battery unit for any accumu- lation of flammable material. Also check for leaks of fluids such as fuel and engine oil. Remove dust from the top surface of the battery.

  • Page 76: Belt And Belt Tension - Inspect And Adjust

    Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Belt and Belt Tension - Inspect and Adjust If defects such as cuts or surface separations are found during inspection, replace the belt. Belts must be free from grease and oils. Grease and oils cause belts to slip and shorten their service life. Excessive belt tension can cause rapid wear to the alternator bearing and shorten the service life of the belt.

  • Page 77: Damper - Inspect

    Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Damper - Inspect Damper - Check Visually Cover The protective cover for the damper should not be air-tight. Installation of a closed cover can cause damage to the damper due to heat. Visually check the damper for scratches, silicon oil Silicon leaks, and paint discoloration or peeling.

  • Page 78: Cold Weather Operations

    Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Cold Weather Operations Coolant In cold weather, engine oil gets thicker and the coolant can freeze. As a result, the engine fails to start, or the cylinder heads and heat exchanger may be damaged. Never open the coolant expansion tank cap during To prevent such problems, follow the instructions the operation or immediately after stopping.

  • Page 79: Fuel System

    Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Fuel System Fuel System - Inspect When handling fuel, make sure there are no open flames or other fire hazards near the engine. Wipe off any spilled fuel completely. Spilled fuel can be ignited and cause a fire. Fuel Tank - Clean For the fuel to be used, refer to "FUEL"...

  • Page 80: Oil-Water Separator - Drain Water

    Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Oil-Water Separator - Drain Water From water drain valve, fuel is discharged together with water. Wipe off any spilled fuel completely. 1. Turn the 3-way cock of oil-water separator to the 3-way valve Air vent plug "drain"...

  • Page 81: Gauze Filter - Clean

    Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Gauze Filter - Clean If the gauze filter is clogged, the fuel supply becomes insufficient, resulting in decrease in power output or engine stall. Gauze filter 1. Remove the union bolt at the inlet port of fuel feed pump.

  • Page 82: Fuel Filter - Replace

    Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Fuel Filter - Replace 1. Clean the area around the fuel filters. 2. Place a tray under the fuel filters. Air vent plug Filter bracket 3. Using a filter wrench, remove the fuel filters. Tightening torque 4.

  • Page 83: Fuel Filter - Replace While Engine Is Running

    Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Fuel Filter - Replace While Engine is Running If the engine has to be operated continuously, you can replace fuel filters while the engine is running by turning the switchover cock located between the fuel filters. Note: (a) In general, the engine must be stopped when replacing fuel filters.

  • Page 84: Fuel Control Link Ball Joint - Inspect

    Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Fuel Control Link Ball Joint - Inspect Check ball joint in the fuel control link for looseness or 0.1 mm sluggish movement. If the amount of looseness is 0.1 [0.004 in.] Ball joint mm [0.004 in.] or more, replace the ball joint with the new one.

  • Page 85: Fuel Pipe - Inspect

    Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Fuel Pipe - Inspect High Pressure Fuel Injection Pipe and Clamp Seat - Inspect and Replace Visual Inspection Check clamp seat for cracks and wear. Check high pressure fuel injection pipe for wear. If defective, replace the clamp seat with a new one.

  • Page 86: Lubrication System

    Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Lubrication System Engine Oil and Oil Filter - Replace Before draining engine oil, make sure the oil has cooled. When draining oil or replacing oil filters, be sure to wear gloves. Hot engine oil and parts can cause burns. Do not dump waste oil.
  • Page 87 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Engine Oil - Filling Oil level gauge Refill the engine with the specified engine oil to the Oil filler specified level. If the oil level is higher than the maxi- Improper mum mark on the level gauge, engine oil may blow High out during operation.
  • Page 88 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Oil Filter - Change If filter case is dented, do not use the filter. Filter may be damaged during operation, which could result in a fire due to oil leaks. Hand tighten oil filters. Do not use a filter wrench. Be careful not to dent or scratch oil filter surfaces.
  • Page 89 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Oil Filter - Replace While Engine is Running If the engine cannot be stopped when oil filter change Filter interval has been reached, the oil filter can be Operating replacement position replaced while the engine is running by turning the position switchover cock located between the oil filters.

  • Page 90: Fuel And Water Ingress In Engine Oil - Inspect

    If fuel or water is mixed with the engine oil, find the cause and repair. If you cannot repair, contact a dealer of Mitsubishi Heavy Industries Engine & Turbocharger, Ltd. If the coolant enters the engine oil during operation, moisture vapor is discharged from the breather. In such case, locate the fuel or water leak, and repair properly.

  • Page 91: Governor Oil Filter - Change

    Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Governor Oil Filter - Change When draining oil or replacing oil filters, be sure to Element wear gloves. Hot engine oil and parts can cause burns. 1. Prepare a tray and place it under the governor oil Case filter.

  • Page 92: Cooling System

    Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Cooling System Coolant (Fresh Water) - Change When a coolant mixed with the LLC recommended by our company is used, replace coolant every 8000 hours or 2 years, whichever comes first. Coolant Expansion Tank Cap - Open/Close 1/4 turn to reliese Never open the coolant expansion tank cap during pressure.
  • Page 93 Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Cooling System - Clean Wash the cooling system before operating the engine for the first time, or starting the engine after it has been in storage under coolant drained condition. 1. Close coolant drain cocks and plugs. 2.

  • Page 94: Draining Sea Water

    Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Draining Sea Water When the ambient temperature drops below 0°C [32°F], the seawater used to cool the engine can freeze and cause serious problems such as seawater pump damage. To prevent such problems, drain the seawater after engine operation by following the pro- cedures below.

  • Page 95: Seawater Pump Impeller - Inspect

    Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Seawater Pump Impeller - Inspect When installing the impeller, pay attention to the orientation of impeller blades. The impeller may be broken if it is incorrectly installed. 1. Remove the seawater pump cover. 2.

  • Page 96: Seawater Strainer Mesh Filter - Clean And Replace

    Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Seawater Strainer Mesh Filter - Clean and Replace Hexagon cap nut Air vent Pay attention to the orientation of strainer mesh filter -ring -ring (Seal washer) when installing. (Correns Corporation) Top cover Piping shall be free from deformation and stress. Center bolt -ring Do not drop or lay any objects on the seawater...

  • Page 97: Inlet And Exhaust Systems

    Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Inlet and Exhaust Systems Turbocharger - Inspect Inspect the turbocharger when the engine is cold. Also, make sure that the compressor wheel is not rotating. The turbocharger inspection should be also con- ducted if the color of the exhaust gas is abnormal. Disconnect the pipe on the inlet side.

  • Page 98: Electrical System

    Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Electrical System Battery - Check Never use flames or allow sparks near the battery. The battery releases flammable hydrogen gas and oxygen gas. Any flames or sparks in the vicinity of battery could cause an explosion. Do not use the battery when the battery electrolyte level is below the "LOWER LEVEL"...

  • Page 99: Table 8-1 Specific Gravity Of Electrolyte

    Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Specific Gravity of Battery Electrolyte - Check If the specific gravity measured at 20 °C [68 °F] is Float lower than 1.22, charge the battery. Electrolyte Table 8-1 Specific Gravity of Electrolyte surface Specific gravity Conditions Remedy...

  • Page 100: Starter - Inspect

    Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Starter - Inspect Visually inspect the starter and ring gear for damage. Note: If the starter is defective, contact a dealer of Starter MHIET. Fig. 8-35 Starter - Inspect Alternator - Inspect Visually inspect the alternator for damage. Remove the belt and turn the pulley by hand to check if it rotates smoothly.

  • Page 101: Long-Term Storage

    Chapter 9 LONG-TERM STORAGE If the engine is not in use for more than 3 months, the internal engine parts can rust, and it may cause damage to the engine. For long term engine storage, be sure to follow the instructions below. Storing Engine in an Inoperable Condition for 3 Months up to 1 Year Preparation for Storage...

  • Page 102: When Using Engine After Storage

    Chapter 9 LONG-TERM STORAGE When Using Engine After Storage 1. Remove the cover that has been placed over the entire engine. 2. Connect a fully charged battery. 3. Remove the cover from the starter and alternator. 4. Adjust the belt tension. Note: Refer to "Belt and Belt Tension - Inspect and Adjust"...

  • Page 103: Lifting Engine

    Chapter 10 TRANSPORTATION Lifting Engine Front hanger Rear hanger To lift the engine, use wire ropes, shackles and slings capable of supporting the weight of the engine. Hitch slings to the hangers provided on the engine to lift the engine. Consider the engine's center of gravity and maintain the balance during lifting.

  • Page 105: Troubleshooting

    Chapter 11 TROUBLESHOOTING General Precautions Contact a Dealer of MHIET for Cautions Against Contamina- Repair Service tion Dust and foreign materials are the most common Except for relatively simple maintenance work such as cause of rapid wear of parts. changes and refilling of fuel, engine oil and coolant, the repair work of the engine that has malfunctioned When disassembling a component, take measures to may require special equipment or involves dangerous...

  • Page 106: Troubleshooting

    Chapter 11 TROUBLESHOOTING Troubleshooting Tends to Overheat. Remove the coolant expansion tank cap only after the engine has cooled down sufficiently. To open the coolant expansion tank cap, open slowly to release pressure. Do not open the coolant expansion tank cap while the engine is hot to avoid burns due to hot steam and water.

  • Page 107: Problems, Probable Causes And Solutions

    Chapter 11 TROUBLESHOOTING Problems, Probable Causes and Solutions The Starter Does not Crank or Cranks Slowly, Resulting in Start Fail- Table 11-2 The Starter Does not Crank or Cranks Slowly, Resulting in Start Failure Causes Solutions Check fuse. Faulty wire connection Check wiring connection of each relay between battery, starter and starter switch.

  • Page 108: Starter Cranks, But Engine Does Not Start

    Chapter 11 TROUBLESHOOTING Starter Cranks, but Engine Does Not Start Table 11-3 Starter Cranks, but Engine Does Not Start Causes Solutions Inspect fuel tank, refill fuel, bleed air. (Refer to P3-2) Run out of fuel, blocked pipe Check fuel pipes and valves. Use appropriate fuel.

  • Page 109: Insufficient Output

    Chapter 11 TROUBLESHOOTING Insufficient Output Table 11-4 Insufficient Output Causes Solutions Improper fuel properties Use appropriate fuel. (Refer to P4-1) Inspect and replace fuel filter. (Refer to P8-8) Clogged fuel filter Clean gauze filter. (Refer to P8-7) Contact your MHIET dealer. Fuel feed pump malfunction Contact your MHIET dealer.

  • Page 110: Exhaust Smoke Is White Or Blue

    Chapter 11 TROUBLESHOOTING Exhaust Smoke is White or Blue Table 11-5 Exhaust Smoke is White or Blue Causes Solutions Check cetane index, and use appropriate fuel. Improper fuel properties (Refer to P4-1) Check fuel injection pump couplings. Faulty fuel injection timing Contact your MHIET dealer.

  • Page 111: Exhaust Smoke Is Black Or Charcoal

    Chapter 11 TROUBLESHOOTING Exhaust Smoke is Black or Charcoal Table 11-6 Exhaust Smoke is Black or Charcoal Causes Solutions Improper fuel properties Use appropriate fuel. (Refer to P4-1) Contact your MHIET dealer. Fuel feed pump malfunction Contact your MHIET dealer. Fuel injection pump malfuction Contact your MHIET dealer.

  • Page 112: Excessive Fuel Consumption

    Chapter 11 TROUBLESHOOTING Excessive Fuel Consumption Table 11-7 Excessive Fuel Consumption Causes Solutions Contact your MHIET dealer. Fuel injection nozzle malfunction Check fuel injection pump couplings. Faulty fuel injection timing Contact your MHIET dealer. Fuel system Improper fuel properties Use appropriate fuel. (Refer to P4-1) Check fuel lines and injection pipes for damage, and Fuel leaks from fuel line or injec-...

  • Page 113: Excessive Engine Oil Consumption

    Chapter 11 TROUBLESHOOTING Excessive Engine Oil Consumption Table 11-8 Excessive Engine Oil Consumption Causes Solutions Check fuel injection pump couplings. Fuel system Faulty fuel injection timing Contact your MHIET dealer. Check oil leaks. Oil leaking on outside engine Contact your MHIET dealer. Engine oil viscosity too low Use appropriate oil viscosity.

  • Page 114: Engine Oil Pressure Drop

    Chapter 11 TROUBLESHOOTING Engine Oil Pressure Drop Table 11-10 Engine Oil Pressure Drop Causes Solutions Low engine oil level Check engine oil level. (Refer to P3-12) Analyze oil property. Use appropriate engine oil. Faulty engine oil property (viscosity) (Refer to P5-3) Cooling System - Check Lubricating Oil temperature too high...

  • Page 115: Main Specifications

    Chapter 12 MAIN SPECIFICATIONS Main Specifications Table 12-1 Main Specifications Item Specifications Engine model S12R-T2MPTK 1210 kW {1645 PS} / 1800 min (Light Duty) Rated output 1040 kW {1414 PS} / 1650 min (Midium Duty) 940 kW {1278 PS} / 1600 min...
  • Page 117 Chapter 13 ELECTRICAL WIRING DIAGRAM Fig. 13-1 Electrical Wiring Diagram 13-1...
  • Page 118 Chapter 13 ELECTRICAL WIRING DIAGRAM Fig. 13-2 Electrical Wiring Diagram 13-2...
  • Page 120 Revision History Revision History Mitsubishi Marine Engine S12R-T2MPTK Title OPERATION & MAINTENANCE MANUAL Pub. No. 291T1-00120 Revision Issued Description September 2012 First edition issued. Changed the document number, cover Pub. No. 99245-31100 (issued in June 2018 September 2012) and issued it as a new publication.
  • Page 121 OPERATION & MAINTENANCE MANUAL Issued in September 2012 Pub. No. 291T1-00120 Issued by Mitsubishi Heavy Industries Engine & Turbocharger, Ltd. 3000, Tana, Chuo-ku, Sagamihara, Kanagawa, 252-5293, Japan Edited by MHI Sagami High-tech LTD. Printed and bound by Fuji Xerox Service Link Co., Ltd.
  • Page 122 Printed in Japan Copyright © 2018 MITSUBISHI HEAVY INDUSTRIES ENGINE & TURBOCHARGER, LTD. All Rights Reserved.

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