Users guide and and maintenance manual Mitsubishi SS series Version 08/2004 33522051001_2_1
INTRODUCTION INTRODUCTION This publication covers the standard specification model for the Mitsubishi SS-Series diesel engines. The information, specifications, and illustrations in this publication are based on the information that was current at the time this issue was written. This manual contains operation instructions, lubrication and maintenance information. The OPERATION section is a reference for the new operator and a refresher for the experienced operator. Read — study — and keep it handy.
WARNING SIGNS WARNING SIGNS The following safety related signs are used in this manual to emphasize important and critical instructions: DANGER Indicates the most serious specific potential hazard which could result in serious personal injury or death. WARNING Indicates a specific potential hazard which could result in personal injury. CAUTION Indicates operating procedures, practices, etc. which could result in personal injury or damage causing destruction to the engine.
TABLE OF CONTENTS TABLE OF CONTENTS 1 SAFETY.......................................................................................................................................... 5 2 IMPORTANT INFORMATION ................................................................................................ 14 3 SPECIFICATIONS ..................................................................................................................... 16 4 NOMENCLATURE ..........................................
TABLE OF CONTENTS 9.4 9.5 9.6 10 Why LLC? .............................................................................................................................. 39 How LLC works...................................................................................................................... 39 Practical reported cases of circuit trouble for which additive is blamed................................. 40 STORAGE .....................................................................................
SAFETY 1 SAFETY 1.1 Preventing fire and explosions Connect the battery earth cable carefully! Fire hazards! 2 2 Booster cable connection order Service battery Do not smoke while refueling, or when handling fuel containers. Do not use gasoline or diesel fuel for cleaning parts. Good quality commercial, nonflammable, and non-toxic solvents are recommended. Do not spill any fuel on hot surfaces. Clean up any spillage immediately.
SAFETY Keep the engine and its compartment clean! Do not touch any hot components! : 2 Remove all flammable materials such as fuel, oil, and other debris, before they accumulate on the engine. 1.2 At operating temperature, the engine components become very hot. Avoid any contact during operation. Service the engine only after it has been stopped and the components are cool enough to touch with your bare hands.
SAFETY 1.4 Turn off the battery switch before servicing! Exhaust fumes : : Be sure to turn OFF the battery switch before servicing. If electrical equipment, including the starter or alternator, is serviced with the battery switch turned ON, it may be shortcircuited by the current from the battery’s positive terminal, resulting in burns or in fire. 1.3 Exhaust fumes Operate the engine in safe areas only! Operate the engine in a well ventilated area. Never operate it in an enclosed area.
SAFETY Use care during checking and servicing! lnstall the protective covers! 2 : Before performing maintenance, remove the starter switch key and turn OFF the battery switch. Attach a "DO NOT OPERATE" or similar warning tag to the starter switch. To prevent personal injury, make sure all protective covers and guards are placed on the rotating parts.
SAFETY 1.6 Maintenance precautions Handle antifreeze carefully! Stop the engine before servicing it! 2 Always stop the engine before adding or changing oil, coolant, or fuel. Check the coolant level only after the engine has been stopped and the radiator filler cap is cool enough to remove it with bare hands. Never attempt to adjust the fan belt while the engine is running.
SAFETY 1.7 Operating precaution Stop the engine only after it has cooled down! Be sure to break in the engine! 2 2 During the first 50 hours of operation, break in the engine by using lighter loads and lower speeds than normal. A proper break in contributes to the maximum service life of the engine. Warm up the engine before operation! 2 Stopping the engine immediately after it has been working under a load, can result in overheating and accelerated wear of the engine components.
SAFETY Do not break any seals for settings! : : Never attempt to break the seals of the fuel injection pump (governor) controlling injection quantity and minimum and maximum speed settings. Breaking these seals and varying settings could result in: • • • • • AIways keep the engine compartment well ventilated! Unless the engine compartment is properly ventilated, the air supply will be inadequate, resulting in a shortage of air for fuel combustion and the loss of power.
SAFETY 1.8 Maintenance precautions Keep water out of the engine! : Use the recommended fuel, oil, and coolant! 2 Brand A Brand B When washing the engine, cover the air inlet and exhaust opening with tape to prevent water or cleaning agent from getting inside the engine. Do not wash the engine while it is running. If water or cleaning agents get inside the combustion chambers, the hammering action of water can damage the engine.
SAFETY Stop the engine immediately and check the lubrication system. Operating the engine with low oil pressure can cause bearings and other parts to seize. lf the engine overheats: : 3. Service the air filter equipped with a dust indicator when red is shown. Under-frequent service can cause damage. 1.9 If any trouble should occur If the engine suddenly stops: If the engine overheats, do not turn it off immediately.
IMPORTANT INFORMATION 2 IMPORTANT INFORMATION 2.1 Operating the engine properly 1. Never attempt to break the seals of the injection pump governor for maximum speed and maximum injection quantity settings. Breaking these seals and varying the settings could result in: • Accelerated wear of engine components • Increase in fuel and oil consumption • Maladjusted injection quantity and poor engine performance • A violation to emission regulations 2. Always keep the engine room well ventilated.
IMPORTANT INFORMATION 2.3 If any trouble should occur 1. If the engine stops abruptly, try to find the problem and its source and make the necessary repairs before starting the engine again. 2. If the engine overheats, a warning light will come on and, at the same time, the engine will stop. When this happens, do not ever add coolant to the overheated engine. First allow the engine to cool down, then add the coolant gradually. 3.
SPECIFICATIONS SPECIFICATIONS1 3 Model System Item S4S Type S4S-DT Swirl chamber type Direct injection type No. of cylinders 94x120 3.331 17 245 Lubricating method 17 1-5-3-6-2-4 250 345 355 Forced lubrication Oil pump Trochoid pump Oil filter Paper element type Oil capacity: FULL level/EMPTY level (l) (Exclusive of oil filter capacity 0.5 l) Shallow type oil pan: 9.0/6.0 Deep type oil pan: 9.0/6.0 Fuel injection pump Shallow type oil pan: 11.5/ 9.
SPECIFICATIONS Model System Item S4S Starter (V - kW) ELECTRICAL SYSTEM S6S 12 - 2.2 Alternator (V - A) S6S-DT 12 - 3.
NOMENCLATURE 4 NOMENCLATURE 4.
NOMENCLATURE 4.
NOMENCLATURE 4.
4.
OPERATION 5 OPERATION 5.1 Pre-start inspection 5.1.3 Check fuel level 5.1.1 Walk-around Inspection Look around for items such as loose bolts, debris build-up, oil, fuel, or coolant leaks, broken or worn parts. Make sure that the fuel level is at the FULL mark in the sight gauge. 5.1.4 Check the coolant level Maintain the coolant level to the FULL mark on the reservoir tank (when the engine is cold). Add coolant when necessary. 5.1.
OPERATION 5.2 Starting the engine The engine can be equipped with or without a glow timer. For starting instructions, please consult the chapter which specially applies to your engine. Engine with glow timer OFF 4. Release the key when the engine starts. The key will return to the ON position when released. ON Engine without glow timer ON HEAT START OFF ON START 5. Move the speed control lever to the idling position. 5.2.2 Engine without glow timer 5.2.1 Engine with glow timer 1.
OPERATION 5.3 Warming up the engine Allow the engine to leave it idling for 5 to 10 minutes. A proper warm-up is absolutely essential to a maximum service life and performance and it minimalizes the operation costs of the engine. CAUTION • • Warm-up • • . NOTE • Long periods of warming up the engine are not recommended. They can result in carbon deposits in the combustion chambers and incomplete fuel combustion. 5.5 Always keep the engine room well ventilated.
OPERATION NOTE If the electrical system includes a control timer for engine shutdown, the starter switch should be kept in the "OFF" position for at least 10 seconds before making another start attempt (to restart the engine once the engine stopped or has been stopped) in order to reset the control timer automatically. CAUTION • • • Leave the engine idling for 5 minutes. This allows hot areas in the engine to cool down gradually, which extends engine life.
MAINTENANCE 6 MAINTENANCE 1. Service the engine in accordance with the "Lubrication and Maintenance Chart." Under extreme, severe, or dusty operating conditions, service the engine more frequently than is specified in the "Lubrication and Maintenance Chart." 2. Perform service on items at multiples of the original requirement.
MAINTENANCE Interval When Required Table 3 6.1 Item Remarks (specifications) Page Prime fuel system 33 Clean air cleaner element 33 Change air cleaner element 33 Lubrication and maintenance charts Every 50 service hours following chart of specific gravity reading gives a general idea of the battery condition. 6.1.1 Drain water and sediment from the fuel tank and water separator . Remove the drain plug and allow any water and sediment to drain. Drain at least 1 or 2 liters (0.3 to 0.5 U.S.
MAINTENANCE 6.2 Every 250 service hours or once a year 6.2.1 Change engine oil and oil filter; draining oil To avoid burns, drain the oil after the engine has cooled down to the extend that it can be touched with your bare hands. Allow the oil to drain into a container. 3. Check the new oil filter and make sure that the packing is fitted in the groove. 4. Apply a thin coat of engine oil to the packing of the new filter. 5. Install the new filter by hand until its packing touches the base.
MAINTENANCE 3. Start the engine, leave it idling for a few minutes, and check for leaks. Re-tighten the filter in case of leakage. 4. Stop the engine and leave it inert for about 30 minutes; then re-check the oil level. Maintain the oil level between the MAX and MIN marks on the dipstick. Add oil only if necessary. 6.2.4 Cleaning the fuel filter with cut off valve 1. 2. 3. 4. Turn the valve to the OFF position. Loosen the ring nut and remove the cup. Wash the element in kerosene or diesel fuel.
MAINTENANCE 4. Remove the level sensor from the element. Discard the element. 5. Install the level sensor to the new element. 6. Install the new element to the body. 7. Install the connector to the level sensor. 8. Tighten te drain plug. NOTE 6.3.2 Check and adjust the fan belt Checking Correct adjustment exists when the belt can be pushed inward about 13 mm with 100 N thumb pressure exerted midway between the alternator and crankshaft pulley as shown.
MAINTENANCE 6.4 Every 1000 service hours 6.4.1 Check the starter 1. Check for visual defects. 2. Check to see if the pinion is shifted into mesh with the flywheel ring gear when the starter is energized. If the pinion does not shift properly, consult your Mitsubishi dealer. 2. Remove the filIer cap only after the engine has been stopped and the cap is cool enough to remove with your bare hands. 3. Open the radiator drain valve and remove the engine drain plug. Water drain cock 4.
MAINTENANCE 3. Remove the cabin heater hose (B) at the thermostat housing (if installed). 4. Pour pure, undiluted LLC into the radiator; see COOLANT AND ANTIFREEZE SPECIFICATIONS on page 38. The recommended concentration of LLC is illustrated in the chart below: Ambient Temperature, °C (°F) LLC concentration, % Table 7 -10 (14) -20 (-4) -30 (-22) -45 (-49) 30 40 50 60 Recommended LLC Concentrations (reference) 5.
MAINTENANCE 6.6 When required 6.6.1 Prime fuel system Air vent plug Air in the lines may cause the fuel system to become air bound, resulting in an inability to start the engine or the misfiring of one or more cylinders. Prime the fuel system: 1. After the engine has been fueled for the first time after installation. 2. After the engine has been refueled after running out of fuel. 3. After the fuel filter element has been cleaned or replaced. Priming button NOTE 1.
MAINTENANCE CAUTION • • Never service the air cleaner when the engine is running. Without the air cleaner, dust and dirt can enter the engine and can cause rapid wear of the engine parts resulting in loss of power and high oil consumption. Do not clean the element by bumping or tapping it. WARNING When using compressed air for cleaning, wear a protective face shield, protective clothing, and protective shoes.
FUEL SPECIFICATIONS 7 FUEL SPECIFICATIONS 7.1 Recommended types of fuels The quality of fuel is a very important factor in obtaining satisfactory engine performance, long engine life, and acceptable exhaust emission levels. This engine is designed to burn fuels marketed to meet ASTM Designation D 975 (grade No. 2-D). 7.2 Caring for the diesel fuel tank Fill the diesel fuel tank at the end of the day, because the incoming fuel will drive out the moisture-laden air and prevent condensation.
LUBRICANT SPECIFICATIONS 8 LUBRICANT SPECIFICATIONS 8.1 Recommended types of engine oils Use oils that meet the API engine oil classification CF or CF-4 class. Proper oil selection assures cranking ability by maintaining an oil film on the cylinder walls and bearing surfaces in conditions which provide low friction and therefore less cranking effort to achieve cranking speeds necessary for reliable starting.
LUBRICANT SPECIFICATIONS 8.3 CAUTION Avoid mixing oils with different brands. In most cases, oils with different brands are not compatible and, when mixed, they can seize parts such as piston rings, cylinders, etc. and cause wear to moving parts. It is best to stick with the same brand and one type of oil at successive service intervals. If a used oil analysis program is conducted in order to determine the condition of the oil, consult the chart below.
COOLANT AND ANTIFREEZE SPECIFICATIONS 9 COOLANT AND ANTIFREEZE SPECIFICATIONS 9.1 Coolant specifications NOTE Water used in the engine cooling system must be soft, or as free from scale forming minerals as possible and it has to meet the requirements shown in the "Coolant Specifications" chart. Harmful chemical properties and substances contained in water (as coolant) must not exceed the Mitsubishi limits. They are tolerable up to the limits shown in the chart below.
COOLANT AND ANTIFREEZE SPECIFICATIONS Ambient temperature, °C (°F) Non-amine type LLC concentration, % Table 11 -10 (14) -20 (-4) -30 (-22) -45 (-49) 30 40 50 60 Recommended LLC concentrations (reference) ) WARNING LLC is toxic and can cause personal injury if it comes into contact with the skin or the eyes. If LLC gets in your eyes, wash them with water immediately and see a doctor at once. 9.3 How to use non-amine type LLC 9.4 1.
COOLANT AND ANTIFREEZE SPECIFICATIONS they are meant to protect, they are used up due to aging and this allows some metals to precipitate into the coolant or to form new compounds which can result in rusty surface deposits. Some chemicals, calculated to inhibit this ionic reaction, might accelerate the reaction of those metals that have already begun to react. badly affected in such a condition, brass and solder — the materials used in the cores of the radiator — become particularly victimized.
STORAGE 10 STORAGE 10.1 Storage of the engine in a nonoperational condition 10.1.1 Preparation 1. Drain the engine oil and put a preservative into the engine (up to the high level on the dipstick). 2. Make a mixture of preservative and fuel oil in a 50-to-50 ratio and put the mixture into the fuel tank. 3. Start and leave the engine idling for 5 to 10 minutes. 4. Stop the engine and spray volatile preservative (VCI) into the opening of the air inlet. 5. Drain the preservative-fuel mixture. 6.
TROUBLESHOOTING 11 TROUBLESHOOTING 11.1 General ordering, specify the needed replacement parts by referring to the Parts Catalogue. 11.1.1 Think before you act Upon noting a defective indication, recall what you did the last time when you came across the same indication. If what you did was correct and successful, do the same again. If the symptom noted is new to you, think of a possible cause in accordance with the troubleshooting procedure which follows. 11.1.
TROUBLESHOOTING 11.2 Problems For special servicing jobs on your engine, rely on the expert knowledge of the servicemen and the service facilities provided by your Mitsubishi dealer.
TROUBLESHOOTING Problem Overheating Too much white or blue smoke Too much black or gray smoke Fuel consumption too high Table 12 44 / 46 Cause Correction Not enough coolant in system Add coolant Leaks in cooling system Retighten or repair Loose fan belt Adjust Restriction to air flow through radiator Remove restrictions Defective water pump Replace Defective thermostat Replace Defective fan Replace High LLC concentration Adjust LLC concentration Too much oil in engine Drain to corre
TROUBLESHOOTING Problem Oil consumption too high Oil pressure too low Table 12 Cause Correction Too much oil in engine Drain to correct level Oil viscosity too low Change oil Leaks in lubrication system Repair or replace Worn cylinders and piston rings Repair or replace* Worn valve stem seals Replace* Not enough oil in engine Add oil Oil viscosity too low Change oil Clogged oil filter Replace Defective oil pump Repair or replace* Defective relief valve Adjust or replace* Defective p
ADDITIONAL INFORMATION 12 ADDITIONAL INFORMATION To whom it may concern EC-declaration of incorporation (Directive 98/37/EC, Annex II, sub B) Ban on putting into service MHI Equipment Europe B.V. Damsluisweg 2 1332 EC Almere The Netherlands herewith declares that: the Mitsubishi diesel engine, SS-series type is destined to be incorporated in other machines or to be combined with other machines, and is not (entirely) in compliance with the Machinery Directive (98/37/EC). Almere, December 17th 2002 R.A.
