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Japan Mitsubishi Diesel Engine Generator Maintenance Manual
Documented content and usage
This maintenance manual is divided into chapters to explain the specifications, maintenance standards, commissioning methods, and disassembly, testing, adjustment, and assembly of the diesel engine of our company.
The main contents of each chapter are recorded in the general catalog. In addition, sub-tables of each chapter are listed on the first page of each chapter.
For operation and periodic maintenance, please refer to the operation manual. For the order of components and spare parts, please refer to the parts manual. For the Mitsubishi R16 diesel engine
Please refer to various technical education materials for structure and function.
When inquiries are needed, please confirm the model of Mitsubishi R16 diesel engine and the manufacturing number of Mitsubishi R16 diesel engine in advance, and provide it to the maintenance service department.
(1) The search numbers of the component names in the figure and in this article are listed in the order of disassembly of the unit.
(2) The tests performed during the disintegration operation are described in a rectangular frame in the disintegration diagram.
(3) The maintenance standards for maintenance operations are described in the corresponding descriptions in this document, as well as in the list in Chapter 2 of this manual.
(4) The parts where Mitsubishi R16 diesel engine oil needs to be applied when tightening bolts are indicated by "wet". The parts that are not indicated are treated as normal tightening methods.
(5) In this article, precautions regarding safety and other aspects are specifically indicated by the following marks.
Indicates a dangerous situation that, if not avoided, could result in a serious personal injury or death.
Indicates a potentially hazardous situation that, if not avoided, could result in a serious personal injury or death.
Indicates a potentially hazardous situation that, if not avoided, may result in minor injuries or moderate accidents.
Indicates a potentially dangerous situation where, if not avoided, a unit damage accident may occur. Emphasizes important matters and indicates useful information for operation and maintenance.
Risk of fire and explosion
Open flames are strictly prohibited
Do not use open flames around the Mitsubishi R16 diesel engine (in the engine room). It is the cause of fire and is very dangerous. The spilled fuel, Mitsubishi R16 diesel engine oil or LLC must be completely wiped clean. Fires caused by fuel, Mitsubishi R16 diesel engine lubricating oil or coolant can cause a fire which is very dangerous. When storing fuel oil and lubricating oil for Mitsubishi R16 diesel engines, the storage space should be well ventilated and the oil tank cap should be fully tightened.
Mitsubishi R16 diesel engines should be cleaned up and rectified. Fuels, lubricants, LLC and other flammable materials, gunpowder and other dangerous materials should not be placed around Mitsubishi R16 diesel engines. Risk of fire or explosion. In addition, it is necessary to remove the dust, dirt and foreign matter on or around the Mitsubishi R16 diesel engine. This is also the cause of fire or overheating of Mitsubishi R16 diesel engine. Remove dust from the battery especially after maintenance. This dust can cause a short circuit in the battery. In order to prevent fire during operation, the generator set must be kept at a distance of more than 1 m from buildings and other equipment when in use.
The inspection cover on the side must be opened after the temperature of the Mitsubishi R16 diesel engine has fallen to normal temperature. Wait at least 10 minutes for the Mitsubishi R16 diesel engine to cool down to room temperature before opening the side cover of the crankcase of the Mitsubishi R16 diesel engine. When the Mitsubishi R16 diesel engine is in an overheated state, the lubricant oil mist gas may ignite when fresh air flows into the crankcase of the Mitsubishi R16 diesel engine.
Pay attention to the leakage of fuel, lubricating oil or exhaust gas. When leakage of fuel, lubricating oil or exhaust gas is found, take measures to prevent leakage immediately. Fuel, Mitsubishi R16 diesel engine lubricating oil splashing on high-temperature parts of Mitsubishi R16 diesel engine, or waste gas contacting combustible materials may cause fire, causing personal accident or machine damage accident.
Use of explosion-proof lighting
When testing fuel, Mitsubishi R16 diesel engine lubricants, cooling water, or battery electrolyte, use explosion-proof lighting. If you use lighting equipment without explosion-proof performance, there is a danger of ignition and explosion. Prevent short circuit of the electrical wiring. Repair the electrical system of the Mitsubishi R16 diesel engine with the battery connected. In case of a short-circuited wire, a fire may occur. The battery (-) terminal must be removed before work. Loose or damaged cables and wires at the terminals can cause a fire. Check and repair or replace before operation.
Standing fire extinguishers and first-aid kits should be equipped with fire extinguishers. Know how to use fire extinguishers. The first aid kit should be placed in the prescribed place, and in case of need, it should be able to be used immediately. To
Prescribe measures for fire and accident management, as well as contact locations and methods for first aid.
The rotating part should be reinstalled with a protective cover. The rotating part of the Mitsubishi R16 diesel engine is equipped with a protective cover.
Check that these protective covers are installed correctly. Loose or damaged protective covers are found and repaired. The cover of the rotating part must not be removed during operation. When equipped with driven equipment or heat sinks, protective covers must be installed on the exposed connecting belts, couplings, etc.
Check surrounding safety when starting
When starting the Mitsubishi R16 diesel engine, make sure that there are no people or tools around the Mitsubishi R16 diesel engine. Call each other when starting. Never start a Mitsubishi R16 diesel engine with a warning sign prohibiting starting, such as a start switch.
During operation, never approach the rotating parts. During operation, never approach the rotating parts. In addition, do not place objects around the rotating parts that are easily caught. A serious personal accident may occur if a body or tool is involved in a rotating part.
About Lock Machine
Before starting maintenance, lock the Mitsubishi R16 diesel engine. The so-called machine lock refers to a safe shutdown mode that cuts off the power source of mechanical equipment. To lock the generator, remove the key of the start switch and cut off the battery switch. At the same time, put a "No Operation" or similar sign on the start switch. The key of the start switch shall be kept by the maintenance operator himself.
Always stop before maintenance
When performing maintenance, be sure to stop the Mitsubishi R16 diesel engine. In particular, it is absolutely impossible to adjust each part while the Mitsubishi R16 diesel engine is running. Embedding in rotating parts can cause serious accidents.
The turning tool must be put back in place after use
The turning tool used for maintenance must be removed after use. In addition, the crank gear must be restored to the operating state when the Mitsubishi R16 diesel engine is started. If the turning tool is inserted into the Mitsubishi R16 diesel engine or the gear of the turning gear is turned on and the Mitsubishi R16 diesel engine is started, it will not only damage the Mitsubishi R16 diesel engine, but also cause a personal accident.
Beware of exhaust gas poisoning
Pay attention to ventilation during operation
When the Mitsubishi R16 diesel engine is installed indoors, when exhaust is exhausted to the outside, check that there is no leakage of waste exhaust at the connecting parts of the exhaust pipe. The exhaust gas of the Mitsubishi R16 diesel engine contains harmful components such as carbon monoxide. When running in a poorly ventilated area, there is a danger of poisoning the exhaust gas.
Risk of hearing impairment
Wear earplugs when entering the engine room (Mitsubishi R16 diesel engine room). Explosive sounds and mechanical noise from Mitsubishi R16 diesel engines can cause hearing impairment.
Watch out for heavy objects falling
Use caution when lifting Mitsubishi R16 diesel engines
According to the quality of the Mitsubishi R16 diesel engine, use a steel cable with sufficient load capacity. When lifting, the spreader must be installed on the lifting plate of the Mitsubishi R16 diesel engine. When lifting, consider the position of the center of gravity of the Mitsubishi R16 diesel engine for a smooth lifting operation.
The hoisting plate installed on the body of the Mitsubishi R16 diesel engine is designed only for lifting the Mitsubishi R16 diesel engine. When a Mitsubishi R16 diesel engine is equipped with a generator, a marine clutch, etc., it should be noted that the suspension plate on the side of the Mitsubishi R16 diesel engine is not affected by the additional quality.
The lifting angle of the lifting wire relative to the lifting hole plate of the Mitsubishi R16 diesel engine is maintained within 60 °. If the lifting angle is too large, the weight on the hanging plate will be too large, which may cause the danger of the hanging plate being damaged. When the cable directly touches the Mitsubishi R16 diesel engine, a soft material such as cloth must be used to fill the space between the cable and the Mitsubishi R16 diesel engine to prevent damage to the cable or Mitsubishi R16 diesel engine.
Don't stand on Mitsubishi R16 diesel engine
Do not stand on the Mitsubishi R16 diesel engine, or use your feet to support the components on the side of the Mitsubishi R16 diesel engine. When working on the upper part of the Mitsubishi R16 diesel engine, prepare work platforms such as feet, and be careful not to drop or fall. Inadvertent operation methods will not only damage the components of the Mitsubishi R16 diesel engine, but also cause accidents caused by falling from the Mitsubishi R16 diesel engine.
Pay attention to the safety of your feet during maintenance operations
When inspecting the upper part of the Mitsubishi R16 diesel engine or parts that cannot be reached by hands, stand on a stable and reliable workbench. Using an old workbench or replacing it with a parts box may cause personal accidents. Also, do not place objects on the workbench.
Use of Fuel, Lubricant and LLC
Use prescribed fuel, lubricating oil and coolant (LLC)
To use the fuel, Mitsubishi R16 diesel engine oil and coolant (LLC) specified in this manual, pay full attention when using it. Using materials other than those specified, or
If the storage method is wrong, it will cause a lot of abnormal phenomena and cause engine failure. Use and Storage of Mitsubishi R16 Diesel Engine Lubricants and Coolants (LLC)
Law, you can directly obtain the MSDS issued by the manufacturer from
The contents described are implemented.
Cautions for using LLC
Wear rubber gloves and a mask when using the LLC. LLC or LLC mixed cooling water comes into contact with the skin, and if it gets into the eyes or mouth by mistake, it can damage the skin or eyes and even poison. If you drink the LLC by mistake, try to spit it out immediately and ask your doctor for treatment immediately. If LLC gets into your eyes by mistake, wash them with water and get medical attention. When LLC adheres to skin or clothing, rinse immediately with plenty of water. LLC Do not store near fire. LLC near fire sources can cause a fire. The waste drainage (mixed LLC) discharged when the cooling water is replaced is harmful and cannot be discarded. The treatment of waste water and drainage shall be implemented in accordance with relevant laws and regulations.
Waste oil, LLC and cooling water treatment Waste oil, LLC and cooling water cannot be discarded. Various laws and regulations have strict regulations on this. When disposing of environmentally hazardous waste such as used oil, LLC, and cooling water, it must be implemented in accordance with relevant laws and regulations.
Risk of burns
Do not touch the Mitsubishi R16 diesel engine during operation or just stopped
Do not touch any part of the Mitsubishi R16 diesel engine while it is running or just stopped. Danger of burns. When performing maintenance, you can confirm that the Mitsubishi R16 diesel engine has cooled down to normal temperature through the water temperature gauge before starting work.
Pay attention when opening and closing the end cap of the radiator
Never hit the end cap of the radiator water tank while the Mitsubishi R16 diesel engine is running or just stopped. After the Mitsubishi R16 diesel engine is stopped, the temperature of the cooling water will drop sufficiently before the end cover can be opened. When you open the end cap of the radiator, the internal pressure is released, so open it slowly. In addition, in order to prevent burns during steam discharge, wear thick rubber gloves or wrap the end caps with a cloth. When closing the end cap of the radiator water tank, be sure to tighten it tightly. The temperature of the cooling water is high during operation or immediately after shutdown. If the end cover is opened, steam or hot water will be sprayed, which may cause burns.
Replenish the cooling water after the water temperature drops
Replenish the cooling water, and wait until the temperature of the cooling water sufficiently drops to near normal temperature. There is a danger of burns immediately after the Mitsubishi R16 diesel engine is stopped.
Do not remove the heat shield
A heat shield is installed in the high-temperature exhaust system. Do not remove the heat shield. When the heat shield must be removed during maintenance, it must be reinstalled after maintenance.
When changing the lubricating oil, pay attention to burns. When draining the lubricating oil or changing the lubricating oil filter, do not directly operate it by hand. Hot oils or components can burn the skin on your hands.
Attention to the use of batteries
Never use open flames near the battery, or splashes such as welding sparks. Flammable hydrogen and oxygen are produced in the battery. Use of an open flame near the battery may cause ignition
The danger of an outbreak.
When the electrolyte is below the minimum liquid level, stop using the battery. Danger of explosion.
Do not use metal objects such as tools to contact the two terminals of the battery.
When removing a terminal, be sure to start from the (-) terminal side first. When installing, start from the (+) terminal side. When charging, remove all end plugs of the battery in a well-ventilated place. Connect the terminals securely. When the terminals are loose, there is a danger of explosion if a fire occurs due to poor contact.
When repairing the Mitsubishi R16 diesel engine electrical system or welding, the battery switch should be turned OFF, or the cable at the (-) end of the battery should be removed to disconnect the electrical circuit.
The electrolyte used was dilute sulfuric acid. Improper handling can cause blindness or burns. In addition, you must not drink electrolyte by mistake.
Wear protective glasses and rubber gloves during battery maintenance and repair (water replenishment, charging, etc.). When the electrolyte adheres to the skin or clothes, immediately rinse it with plenty of water and wash it with laundry soap. If the electrolyte gets in your eyes, there is a danger of blindness. Rinse with a large amount of water and immediately ask the doctor to treat the electrolyte by mistake. After rinsing with a large amount of water repeatedly, drink a lot of water and immediately ask the doctor for treatment.
When an exception occurs
Mitsubishi R16 diesel engine cannot be immediately filled with cooling water after overheating shutdown
When the Mitsubishi R16 diesel engine overheats for some reason and has to stop immediately, the cooling water cannot be injected immediately after the shutdown. If the cooling water is injected immediately, components such as the cylinder head of the Mitsubishi R16 diesel engine will be damaged due to extreme temperature differences. Only after the Mitsubishi R16 diesel engine has cooled to normal temperature can the cooling water be slowly injected.
Precautions when restarting after abnormal shutdown
After an abnormal stop, it cannot be restarted immediately. When an abnormal alarm is issued and the machine is stopped at the same time, the cause of the failure must be identified, and the faulty part must be repaired before it can be started again. If you continue to operate without troubleshooting, it may cause more serious accidents.
When the lubricant pressure of Mitsubishi R16 diesel engine drops, immediately stop the machine. For some reason, when the lubricant pressure of Mitsubishi R16 diesel engine drops abnormally, immediately stop the machine. Check all parts of the lubricant system of Mitsubishi R16 diesel engine to confirm the cause of the failure.
If it continues to run under low oil pressure, it will cause accidents such as burnout of Mitsubishi R16 diesel engine bearings.
Stop immediately when V-belt is cut
When the belt is cut, stop it immediately. If the V-belt continues to run, the Mitsubishi R16 diesel engine will overheat, and the cooling water in the supplemental water tank or radiator will form steam, which may cause burns.
Prohibition of alteration
After the Mitsubishi R16 diesel engine is modified without authorization, the manufacturer will not bear any warranty even during the warranty period. After the Mitsubishi R16 diesel engine is transformed, not only will various damage occur, but also the danger of personal accidents.
Implement daily operation inspections and regular maintenance
The daily operation inspection and regular maintenance must be implemented in accordance with the requirements of this manual. The negligence of daily operation inspection and regular maintenance will produce many failures, causing damage to major parts of Mitsubishi R16 diesel engines or major accidents.
Wear protective gear properly
Wear protective equipment such as hard hats, protective masks, safety work shoes, dust masks and gloves according to the requirements of the job. When using compressed air, wear protective gear such as protective glasses, hard hat and gloves. If you do not use these protective equipment, you may cause serious personal accidents.
Do not arbitrarily cut the seal
In order to maintain the normal performance of the Mitsubishi R16 diesel engine, a fuel injection seal and a speed control seal are provided on the connecting rod part of the fuel control Mitsubishi R16 diesel engine. No warranty is given when using Mitsubishi R16 diesel engines after cutting off these seals. When the seal is cut off, the following problems occur.
Increased wear of sliding and rotating parts. Burnout, damage, and other failures occur in each part. Fuel consumption and lubricant consumption dramatically increase fuel injection and governor imbalance, performance degradation, and major accidents such as overspeed. .
Check also after operation
After running, check again for abnormalities in each part. If any abnormality is found, repair it immediately.
The new Mitsubishi R16 diesel engine or the overhauled unit must not be operated excessively within the first 50 hours of operation, and run-in operation is required. The parts of the new Mitsubishi R16 diesel engine or after overhaul have not completely run in. Excessive use will shorten the life of the Mitsubishi R16 diesel engine.
Implement warm-up operation
After starting the Mitsubishi R16 diesel engine, it is necessary to perform a warm-up operation with an idle speed of 5 to 10 minutes, and then enter the actual operation. Warm-up operation lubricates the action of various parts of the Mitsubishi R16 diesel engine, which can prolong the life of the Mitsubishi R16 diesel engine, and at the same time, it is beneficial to improve the performance and economy of the Mitsubishi R16 diesel engine. Also, do not perform unnecessary long warm-up operations. Carbon deposits in the cylinder easily cause poor combustion.
Prohibition of overload operation In the case of smoky overload operation, immediately reduce the load and restore the proper output power and load operation. Overload operation not only increases the fuel consumption, but also causes the Mitsubishi R16 diesel engine to malfunction due to carbon deposits and shortens the life of the Mitsubishi R16 diesel engine.
Implement cooling operation
Before the Mitsubishi R16 diesel engine is stopped, perform a cooling operation (idling operation) for 5 to 6 minutes. During severe stoppages during high load operation, parts of the Mitsubishi R16 diesel engine are in an abnormally high temperature state, which is not conducive to the long-term use of the Mitsubishi R16 diesel engine. During cooling operation, check the Mitsubishi R16 diesel engine for abnormalities.
Prohibit continuous low load operation
During continuous operation at low load (less than 30%), it cannot exceed 1 hour. Carbon deposits in the cylinder easily cause poor combustion. In addition, after a low-load operation of about 1 hour, a load of 30% or more is applied for 5 minutes or more to prevent carbon deposition.
Be careful not to immerse the Mitsubishi R16 diesel engine in water
Be careful not to let rainwater, etc. come in through the exhaust pipe opening or the intake pipe opening. Do not clean the Mitsubishi R16 diesel engine during operation. The cleaning agent (water) may be sucked into the interior of the Mitsubishi R16 diesel engine. If water is immersed in the combustion chamber of a Mitsubishi R16 diesel engine, the water pressure of the Mitsubishi R16 diesel engine when the Mitsubishi R16 diesel engine starts may cause internal damage and cause a serious accident.
Care for the air filter or air filter
The inhaled air contains dust, which will cause premature wear of various parts of the Mitsubishi R16 diesel engine. After various parts of the Mitsubishi R16 diesel engine are worn out, failures such as increased consumption of lubricating oil, decreased output power, and difficulty in starting occur. In order to effectively remove dust from the air, the following requirements must be observed when maintaining the air filter or air filter.
Never perform maintenance on the air cleaner or air filter while the Mitsubishi R16 diesel engine is running. Mitsubishi S16 diesel engine inhalation of foreign matter can cause serious accidents. When disassembling the air filter or air filter, be careful not to let the dust adhered to the inside of the Mitsubishi R16 diesel engine. After removing the air filter or air filter, in order to prevent dust from entering the interior of the Mitsubishi R16 diesel engine, immediately use an air filter to cover the air inlet with a plastic cloth, etc., and use an air filter to seal the air inlet Live on the body. When a dust accumulation indicator is installed on the air filter, an alarm will be issued when the mesh is blocked, and maintenance shall be performed when the alarm occurs.
Observe workplace safety rules
In the work place where operation or maintenance is performed, the safety rules stipulated by the work place must be observed. Do not operate the Mitsubishi R16 diesel engine when you are unwell, and explain it to the person in charge of the site management. When you are unwell, your concentration will decrease. If you operate the Mitsubishi R16 diesel engine, it will be easy to cause accidents due to misoperation. When working together, use prescribed gestures to communicate with each other.
Use the right tools for maintenance work
In the maintenance work, not only must use the correct tools, but also pay attention to the correct use. If the tool is found to be damaged, replace it with a new one.
Do not use the starter motor continuously
The use of the starter motor should be controlled within 10 seconds. If the starter is unsuccessful, it should be restarted after an interval of more than 1 minute. If the starter motor is continuously operated because the Mitsubishi R16 diesel engine cannot be started, the battery power will be quickly consumed and the starter motor may burn out.
Do not disconnect the battery switch during operation
Do not turn off the battery switch during operation. If the battery switch is turned off during operation, not only the meters cannot operate, but also the performance of the diode or transistor of the Mitsubishi S16 diesel charger.
Precautions during transportation
When the Mitsubishi R16 diesel engine is transported on the road, it is necessary to confirm the quality, width and height of the Mitsubishi R16 diesel engine, and to comply with relevant laws and regulations such as the Road Traffic Law, Road Transport Vehicle Law and Vehicle Restriction Regulations.
Pay attention to the ventilation of the equipment room
Always maintain good ventilation in the equipment room. Insufficient intake of air from a Mitsubishi R16 diesel engine will cause the temperature of the Mitsubishi R16 diesel engine to rise, the output power to be insufficient, and the performance to be reduced. When setting up a Mitsubishi R16 diesel engine, it is recommended to install ventilation equipment in the engine room based on the necessary air volume of the Mitsubishi R16 diesel engine.
No contact with high-pressure injection fuel
When the fuel injection pipe of the Mitsubishi R16 diesel engine leaks, it cannot directly contact the injected fuel. The fuel in the Mitsubishi R16 diesel engine's fuel injection pipe is high pressure. After contact with the human body, the fuel will invade the skin and cause skin "necrosis".
Maintenance inspection of warning labels
Make sure all warning labels are legible.
When the description and illustration of the warning label cannot be recognized, clean or replace it.
When cleaning warning labels, use cloth, water, and laundry soap. Avoid using solvents, benzine, or chemicals to avoid light printing of warning labels and peeling off of adhesives.
Damaged or defective warning labels must be replaced.
When replacing Mitsubishi R16 diesel engine parts with warning labels, the same new warning labels must also be attached to the newly replaced parts. If you need to purchase a new warning label, please contact our designated dealer.
Precautions during assembly
This maintenance manual describes the main points of the maintenance work recommended by our company. In addition, special tools and safety precautions used in the work are also included. However, when there are various dangers, this manual cannot list all safety matters.
During maintenance work, follow the instructions in this service manual and pay full attention to the following items.
Precautions when disassembling
Use correct and appropriate tools and utensils. Failure to do so could cause serious damage or accidents.
Do not use sharp-edged removal bolts to avoid damage to the mounting surface. If necessary, prepare scaffolds, work tables for understanding the body parts, etc., and disassemble in the order of disassembly. Disassembled parts should not be placed directly on the ground, but on a workbench.
Organize disassembled parts and store them in order to avoid loss. Disassembled components should be arranged in the order of the installation position. When used again, if there is no special reason, it should be installed in the original place. Pay attention to the assembly marks when disassembling, and mark the parts without assembly marks when necessary.
When disassembling and cleaning, always pay attention to any abnormalities. After disassembly or cleaning, some faults will no longer be found. Be careful not to leave these faults out.
Pay attention to safety, and pay special attention to the balance of disassembled parts and the movement of heavy objects. (If necessary, use jacks, chain hoists, and guide bolts with the help of manpower.) Use protective gloves when touching preheated parts. Direct touching with your hands can cause burns.
Precautions during assembly
Parts other than Mitsubishi diesel oil seals, O-rings, and rubber seals should be thoroughly cleaned with cleaning oil, and then completely dried with compressed air. Use correct and appropriate tools and utensils. Use the right quality lubricants and greases. In addition, the area where the application of lubricant, grease, or adhesive is indicated must be applied. Be sure to use a torque wrench at the location where the torque is indicated, and tighten it according to the specified torque. Refer to "Tightening Torque List". Gaskets, gaskets, and O-rings should be replaced with new ones in principle. In addition, apply adhesive if necessary. However, be careful not to apply too much adhesive. Use protective gloves when touching preheated parts. Direct touching with your hands can cause burns.
Chapter 1 Overview
1. Outline drawing ...... 1-3
2. Overview of each system ....... 1-11
2.1 Overview of Mitsubishi R16 Diesel Engine Fuel System ... 1-11
2.2 Overview of Mitsubishi R16 Diesel Engine Lubricant System .............. 1-12
2.3 Outline of Mitsubishi R16 Diesel Engine Cooling System ... 1-13
2.4 Mitsubishi R16 Diesel Engine Intake and Exhaust System Overview .............. 1-16
3. Contents of Nameplate Labels ... 1-17
3.1 Nameplate. 1-17
3.2 Instruction Board ........ 1-17
3.3 Certification Marks for Exhaust Gas Emission Standards ... 1-17
4. Technical Specifications ............ 1-18
1. Outline drawing S16R-Y1PTA
Front side view
Rear side view
Left side view
Right side view
Outline Drawing S16R-Y2PTAW
Front side view
Rear side view
Left side view
Right side view