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. Illustrations guide the operator through correct procedures
of checking, starting, operating, and stopping the engine. Operating techniques outlined in this manual
are basic. Skills and techniques develop as the operator gains knowledge of the engine.
The MAINTENANCE section is a guide to engine care. The illustrated, step-by-step instructions are
grouped by service intervals. Items without specific intervals are listed under "When Required." Items in
the Lubrication and Maintenance Chart are referred to in the detailed instructions which follow.
Notice that the technical information in this manual depends on the specification of the engine and the
accessories. All specifications are subject to change without any prior notice.
For items other than those in this publication, please refer to the operation manual of the equipment
in which this engine is installed.
Operation Manual
Mitsubishi SS-Series diesel engines
Version 08/2004
Copyright © 2003 MHI Equipment Europe B.V.
Operation Manual Mitsubishi SS-Series diesel engines
Version 08/2004
ENGLISH
1 / 46
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. Some of the CAUTION
signs also indicate a specific potential hazard which could result in serious
personal injury or death.
NOTE
Indicates procedures, conditions, etc. which are important to highlight.
Symbols
3
;
Indicates a proper action or "DO".
Indicates a prohibited action or "DON’T".
Recommendation of daily operation records
It is obvious to every engine user and operator that an
engine should not be run to destruction. Daily recording
is a preventive maintenance program and will serve as a
guide for:
•
•
•
Effective troubleshooting (to help a serviceman
from your Mitsubishi dealer to pin-point a problem).
Quick service and less downtime (to help a
serviceman from your Mitsubishi dealer save time
(and costs for service))
Grasp of operating conditions (to help you
recognize conditions, signs or indications of
approaching trouble)
Items to be recorded
The following items are recommended to be recorded:
1.
2.
3.
4.
5.
6.
Operating hours (service hour meter reading)
The amount of oil, fuel, and coolant (soft water)
required for refilling
Oil and coolant change intervals
Engine oil pressure, exhaust temperature, coolant
temperature, and inlet air temperature
Parts serviced, kinds of service (adjustment, repairs
or replacement), and the results of each service
Changes in operating conditions (for example,
"Exhaust smoke turned black,” etc.)
2 / 46
ENGLISH
Operation Manual Mitsubishi SS-Series diesel engines
Version 08/2004
TABLE OF CONTENTS
TABLE OF CONTENTS
1
SAFETY.......................................................................................................................................... 5
2
IMPORTANT INFORMATION ................................................................................................ 14
3
SPECIFICATIONS ..................................................................................................................... 16
4
NOMENCLATURE .................................................................................................................... 18
5
OPERATION ............................................................................................................................... 22
6
MAINTENANCE ......................................................................................................................... 26
7
FUEL SPECIFICATIONS ........................................................................................................ 35
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
2.1
2.2
2.3
4.1
4.2
4.3
4.4
5.1
5.2
5.3
5.4
5.5
6.1
6.2
6.3
6.4
6.5
6.6
7.1
7.2
7.3
Preventing fire and explosions................................................................................................. 5
Prevent burns........................................................................................................................... 6
Lifting precautions.................................................................................................................... 7
Exhaust fumes ......................................................................................................................... 7
Prevention of cuts and other injuries........................................................................................ 7
Maintenance precautions......................................................................................................... 9
Operating precaution ............................................................................................................. 10
Maintenance precautions....................................................................................................... 12
If any trouble should occur..................................................................................................... 13
Operating the engine properly ............................................................................................... 14
Service the engine properly ................................................................................................... 14
If any trouble should occur..................................................................................................... 15
Engine S4S ............................................................................................................................ 18
Engine S4S-DT ...................................................................................................................... 19
Engine S6S ............................................................................................................................ 20
Engine S6S-DT ...................................................................................................................... 21
Pre-start inspection ................................................................................................................ 22
Starting the engine................................................................................................................. 23
Warming up the engine.......................................................................................................... 24
Starting the load..................................................................................................................... 24
Stopping the engine ............................................................................................................... 24
Every 50 service hours .......................................................................................................... 27
Every 250 service hours or once a year ................................................................................ 28
Every 500 service hours ........................................................................................................ 29
Every 1000 service hours ...................................................................................................... 31
Every 2 years ......................................................................................................................... 31
When required ....................................................................................................................... 33
Recommended types of fuels ................................................................................................ 35
Caring for the diesel fuel tank ................................................................................................ 35
Caring for the fuel supply ....................................................................................................... 35
8
LUBRICANT SPECIFICATIONS ........................................................................................... 36
9
COOLANT AND ANTIFREEZE SPECIFICATIONS ........................................................ 38
8.1
8.2
8.3
9.1
9.2
9.3
Recommended types of engine oils....................................................................................... 36
Recommended oil viscosities................................................................................................. 36
Limiting requirements for engine oils ..................................................................................... 37
Coolant specifications ............................................................................................................ 38
Recommended types of LLC's (Long Life Coolant) ............................................................... 38
How to use non-amine type LLC............................................................................................ 39
Operation Manual Mitsubishi SS-Series diesel engines
Version 08/2004
ENGLISH
3 / 46
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 ................................................................................................................................... 41
10.1 Storage of the engine in a non-operational condition ............................................................ 41
10.2 Storage of the engine in an operational condition.................................................................. 41
11
TROUBLESHOOTING ............................................................................................................. 42
12
ADDITIONAL INFORMATION ............................................................................................... 46
4 / 46
11.1 General .................................................................................................................................. 42
11.2 Problems................................................................................................................................ 43
ENGLISH
Operation Manual Mitsubishi SS-Series diesel engines
Version 08/2004
SAFETY
1
SAFETY
1.1
Preventing fire and explosions
Fire hazards!
2
2
Connect the battery earth cable
carefully!
Booster
cable
connection
order
Service
battery
Engine
block
Flat 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.
Finally, connect the earth cable (negative terminal)
to the engine block, when starting the engine
using another battery. If it is accidentally
connected to the negative terminal of the mounted
battery, a spark may occur, igniting the explosive
gas produced by the battery. After starting the
engine, first disconnect the earth cable.
Do not fill fuel tank while the engine
is running!
Shut off the engine when fueling and use extra
caution if the engine is hot.
AIways be alert to any fuel or oil
leaks!
:
Do not bring close to flammable
materials!
:
If you discover any leaks, take counter-measures
immediately. If there are fuel or oil spills on the hot
engine, fire may occur, resulting in personal injury
or damage to the equipment.
Do not put flammable materials on hot parts of the
exhaust pipe. Keep them away from the pipe. In
addition, do not operate the engine in areas where
flammable materials are present.
Operation Manual Mitsubishi SS-Series diesel engines
Version 08/2004
ENGLISH
5 / 46
SAFETY
Keep the engine and its
compartment clean!
:
2
Remove all flammable materials such as fuel, oil,
and other debris, before they accumulate on the
engine.
1.2
Prevent burns
Remove the radiator filler cap
carefully!
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.
Avoid burns!
:
:
Under operating temperatures, the engine coolant
is hot and under pressure. The steam can cause
personal injury. Check the coolant level only after
the engine has been turned off and the filler cap is
cool enough to touch with your bare hands. If
necessary grip the cap with a cloth and remove it
slowly in order to gradually relieve the pressure.
6 / 46
Do not touch any hot components!
Immediately after completing operations do not
change the oil or the coolant. Hot oil or coolant
may burn the skin. Allow the engine to cool down
to room temperature before replacement.
ENGLISH
Operation Manual Mitsubishi SS-Series diesel engines
Version 08/2004
SAFETY
Turn off the battery switch before
servicing!
:
1.4
Exhaust fumes
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
Lifting precautions
Lift the engine carefully!
1.5
Prevention of cuts and other
injuries
Stay clear of all rotating and moving
parts!
:
:
Never allow anyone to walk or stand underneath a
suspended engine. Operate the hoist carefully
without jerking it. Remember, sudden impact of
loads can cause serious accidents.
Operation Manual Mitsubishi SS-Series diesel engines
Version 08/2004
Operate the engine in safe areas only! Operate
the engine in a well ventilated area. Never operate
it in an enclosed area. In particular, do not operate
it near an air inlet port on the downwind side.
The rotating parts of the engine are dangerous.
Always stay clear of them during operation.
ENGLISH
7 / 46
SAFETY
Use care during checking and
servicing!
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.
lnstall the protective covers!
To prevent personal injury, make sure all
protective covers and guards are placed on the
rotating parts.
Ensure that everything is in order
before restarting the engine!
Keep the turning tool disengaged
when it is not in use!
2
Before starting the engine, make sure that no one
is working on or close to the engine. Remove all
foreign material from the engine, such as debris,
oil, tools, and other items which are not part of the
engine.
8 / 46
When not in use, properly lock the turning gear in
the disengaged position. Failure to follow this
recommendation can cause personal injury and
engine damage.
ENGLISH
Operation Manual Mitsubishi SS-Series diesel engines
Version 08/2004
SAFETY
1.6
Maintenance precautions
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.
Handle battery electrolyte carefully!
2
If battery electrolyte comes into contact with the
eyes or skin, wash them clean immediately by
using plenty of water. If it comes into contact with
the eyes, wash out your eyes immediately and
then see a doctor.
Operation Manual Mitsubishi SS-Series diesel engines
Version 08/2004
Handle antifreeze carefully!
:
If you accidentally drink antifreeze, make yourself
vomit and see a doctor immediately. If antifreeze
comes into contact with the eyes, immediately
wash them clean by using plenty of water and
then go and see a doctor.
Dress properly for the job!
:
For your own protection, you may need any
number of special items - hard hat, face shield,
safety shoes, goggles, heavy gloves, ear
protectors, etc. Please do use these when
required.
ENGLISH
9 / 46
SAFETY
1.7
Operating precaution
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.
2
Stop the engine only after it has
cooled down!
Warm up the engine before
operation!
Stopping the engine immediately after it has been
working under a load, can result in overheating
and accelerated wear of the engine components.
Before stopping the engine, leave it idling for 5 to
10 minutes. This allows the hot areas in the
engine to cool down gradually, which extends
engine life. While the engine is running, make a
walk-around inspection to make sure everything is
functioning properly.
Warm-up
Use the starting motor correctly!
:
F
OF
After starting the engine, leave it idling for 5 to 10
minutes before operating under full load, for
maximum engine life.
NOTE: Long periods of warming up the engine are
not recommended. They can deposit carbon in
cylinders and cause incomplete fuel combustion.
10 / 46
T
AR
ST
When starting the engine, do not crank it for more
than 10 seconds at a time. After every 10 seconds
of engine cranking, allow 30 seconds for the
starting motor to cool before cranking it again.
ENGLISH
Operation Manual Mitsubishi SS-Series diesel engines
Version 08/2004
SAFETY
Do not break any seals for settings!
:
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.
Accelerated wear of the engine components
Seizure of or damage to the engine
components
Increase in fuel and oil consumption
Maladjusted injection quantity and poor
engine performance
Violation to emission regulations
•
•
•
:
AIways keep the engine
compartment well ventilated!
:
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:
•
•
Avoid overloading!
:
Do not turn OFF the battery switch
during operation!
ON
OFF
Overloading can cause incomplete combustion,
often indicated by black smoke, high fuel
consumption, and carbon deposits in the
combustion chambers, adversely affecting the
engine lifespan.
To avoid damage to the alternator diodes and the
transistors, do not turn OFF the battery switch
when the engine is running. This could also result
in a failure of instruments to work properly.
Operation Manual Mitsubishi SS-Series diesel engines
Version 08/2004
ENGLISH
11 / 46
SAFETY
1.8
Maintenance precautions
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.
Use of any other fuel, oil, or coolant can cause
engine damage and reduce the engine service
life.
Keep water out of the engine!
Perform all recommended
inspections!
2
Keep grit-laden air out of the
engine!
:
Perform pre-start inspection and periodic
inspection on items listed in this manual. Failure to
follow this recommendation can cause engine
damage, injury, or death.
Dust and dirt entering the engine will cause early
wear of the moving parts. This could result in a
loss of power, high oil consumption, starting
problems, or other failures. Service the air filter as
instructed.
1. Do not service the air filter while the engine is
running.
2. When removing the air filter element for
service, prevent any dust from entering the air
intake to the cylinders.
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ENGLISH
Operation Manual Mitsubishi SS-Series diesel engines
Version 08/2004
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. Suddenly stopping an overheated
engine can result in a steep rise in the coolant
temperatures and the seizure of running parts.
First leave the engine idling to allow the hot areas
in the engine to cool down, then gradually add the
coolant. Remember, adding coolant to an
overheated engine can cause damage to the
cylinder head.
2
Y
NC
GE
E R OW N
M
E
D
UT
SH
Do not restart the engine immediately after it has
suddenly stopped. Check for the cause and make
the necessary repairs before restarting the engine.
A failure to follow this precaution can cause
serious engine problems.
2
If the fan belt is broken:
OFF
If the engine oil pressure is low:
:
Operation Manual Mitsubishi SS-Series diesel engines
Version 08/2004
Stop the engine immediately. Operating the
engine with a broken fan belt can cause engine
overheating, which, in its turn, can cause the
coolant to burst out of the reservoir tank and the
radiator cap.
ENGLISH
13 / 46
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.
If it is not properly ventilated, the air supply will
be inadequate, resulting in lack of air for fuel
combustion and loss of power.
3. Start the engine properly. After every 10
seconds of engine cranking, allow 30 seconds
for the starting motor to cool before cranking it
again.
4. After starting the engine, leave it idling for 5 to
10 minutes before operating it at full load, for
maximum engine life.
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. To avoid damage to the alternator, do not turn
OFF the battery switch when the engine is
running.
6. Avoid overloading. Overloading can cause
incomplete combustion, often indicated by
black exhaust, high fuel consumption, and
carbon deposits in the combustion chambers,
affecting engine lifespan.
7. It is advised to break in the engine within the
first 50 hours of operation. The way to do this
is by operating the engine under a lighter load
and lower speeds than normal. When an
engine is properly broken in, it contributes to
the maximum service life of the engine.
8. Stopping the engine immediately after it has
been working under load can result in
accelerated wear of engine components.
Before stopping, leave the engine idling for
about 5 minutes. This allows hot areas of the
engine to cool down gradually, extending the
engine life. Whilst the engine is running, make
a walk-around inspection and check for oil,
fuel, or coolant leaks.
14 / 46
2.2
Service the engine properly
1. Use the recommended fuel, oil, and coolant
listed in this manual. The use of any other
fuel, oil, or coolant can result in higher
maintenance costs and can reduce the engine
service life.
2. Be sure to perform pre-start inspection and
periodic service on items specified in this
manual. Improper inspection or service is
dangerous and could result in damage to the
engine, injury, or death.
3. At the end of each day of operation, check the
engine for broken, defective, or missing parts.
If you discover any items that need attention,
repair, replacement, or adjustment after your
daily check, report it as soon as possible.
Keep in mind that even minor defects could
result in very serious trouble.
4. When washing the engine, cover the air inlet
and the exhaust openings with tape to prevent
water or cleaning agent from getting inside the
engine. Do not attempt to wash the engine
when it is running. If water or cleaning agent
gets inside the combustion chambers, the
hammering action of water could cause
damage to the engine.
5. Clean air is essential to a satisfactory engine
operation and to a long engine life. This is also
the reason why it is very important to service
the air cleaner properly. The air cleaner
prevents dust and grit-laden air from getting
into the engine. Dust and dirt entering the
engine will cause rapid wear of piston rings,
cylinders, and pistons, resulting in loss of
power and high oil consumption. Also, if dust
and dirt are allowed to build up in the air
cleaner passages, then this will eventually
restrict the air supply to the engine and result
in heavy carbon deposits on the pistons and
valves due to an incomplete combustion.
Therefore:
• Do not service the air cleaner when the
engine is running.
• When removing the air cleaner from the
engine for servicing, prevent dust from
entering the air passage to the cylinders.
• Service the air cleaner element at
reasonable intervals, or whenever the
signal of the indicator is visible. That is, if
your engine is equipped with an indicator
signal.
• Do not use the element if any tears, rips,
or damage are evident.
ENGLISH
Operation Manual Mitsubishi SS-Series diesel engines
Version 08/2004
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. If the engine oil pressure becomes low, stop
the engine and check for the cause. Operating
the engine while the oil pressure is low can
cause seizure of the bearings and other parts.
Operation Manual Mitsubishi SS-Series diesel engines
Version 08/2004
ENGLISH
15 / 46
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/
9.0
Deep type oil pan: 14/11
Bosch A or VE type
Nozzle
Throttle type
Hole type
Throttle type
Hole type
Fuel injection pressure
120 kgf/cm2
180 kgf/cm2
120 kgf/cm2
180 kgf/cm2
Fuel to be used
Diesel fuel; see chapter 7
Governor
Centrifugal weight type
Air cleaner
Paper-element type
Turbocharger model
Without
Cooling method
Table 1
22
1-3-4-2
Dry weight (kg)
COOLING
SYSTEM
4.996
22
Firing order
INTAKE SYSTEM
Direct
injection
type
6
Bore x Stroke (mm)
Compression ratio
FUEL SYSTEM
Swirl
chamber
type
4
Total displacement (l)
LUBRICATING
SYSTEM
S6S-DT
4-cycle, water-cooled, vertical, overhead valve, diesel engine
Combustion chamber
ENGINE
PROPER
S6S
TD04H
Without
TD06H
Forced circulation of water
Water pump
Centrifugal type
Coolant capacity (l)
(Engine proper only)
5.5
5.0
9.0
8.5
Specifications
1 All specifications are subject to change without any prior notice.
16 / 46
ENGLISH
Operation Manual Mitsubishi SS-Series diesel engines
Version 08/2004
SPECIFICATIONS
Model
System
Item
S4S
Starter (V - kW)
ELECTRICAL
SYSTEM
S6S
12 - 2.2
Alternator (V - A)
S6S-DT
12 - 3.0
AC generator (12 - 50)
Glow plug
Sheathed type
Battery
(capacity depends on application)
Table 1
S4S-DT
12V, 140 Ah or more
12V, 200 Ah or more
Specifications
Operation Manual Mitsubishi SS-Series diesel engines
Version 08/2004
ENGLISH
17 / 46
NOMENCLATURE
4
NOMENCLATURE
4.1
Engine S4S
Oil filler
Hanger
Hanger
Thermostat
Exhaust manifold
Thermoswitch
Engine serial number
Alternator
Starter
V-belt
Oil pressure switch
Oil pan
REAR
FRONT
RIGHT SIDE VIEW
Fuel injection nozzle
Fuel filter
Inlet manifold
Fan
Stop solenoid
Air vent screw
Governor
Water pump
Speed control lever
Coolant drain plug
Fuel injection pump
Dipstick
Fuel feed pump
Flywheel
Oil filter
Oil drain plug
Flywheel housing
REAR
FRONT
LEFT SIDE VIEW
18 / 46
ENGLISH
Operation Manual Mitsubishi SS-Series diesel engines
Version 08/2004
NOMENCLATURE
4.2
Engine S4S-DT
Turbocharger
Oil filler
Hanger
Hanger
Thermostat
Exhaust manifold
Thermoswitch
Engine serial number
Alternator
Starter
V-belt
Oil pressure switch
Oil pan
REAR
FRONT
RIGHT SIDE VIEW
Fuel injection nozzle
Fuel filter
Inlet manifold
Fan
Stop solenoid
Air vent screw
Oil cooler
Water pump
Speed control lever
Governor
Fuel injection pump
Coolant drain plug
V-belt
Dipstick
Fuel feed pump
Oil filter
Oil drain plug
Flywheel
FRONT
Flywheel housing
REAR
LEFT SIDE VIEW
Operation Manual Mitsubishi SS-Series diesel engines
Version 08/2004
ENGLISH
19 / 46
NOMENCLATURE
4.3
Engine S6S
Oil filler
Hanger
Hanger
Thermostat
Thermoswitch
Exhaust manifold
Alternator
Engine serial number
Oil pressure switch
Starter
V-belt
Oil pan
REAR
FRONT
RIGHT SIDE VIEW
Inlet manifold
Fuel filter
Fuel injection nozzle
Fan
Stop solenoid
Air vent screw
Governor
Water pump
Speed control lever
Fuel injection pump
Coolant drain plug
Fuel feed pump
Dipstick
Oil drain plug
Flywheel
Flywheel housing
Oil filter
REAR
FRONT
LEFT SIDE VIEW
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ENGLISH
Operation Manual Mitsubishi SS-Series diesel engines
Version 08/2004
4.4
Engine S6S-DT
Turbo charger
Oil filler
Oil filler
Thermostat
Hanger
Hanger
Thermoswitch
Engine serial number
Exhaust manifold
Alternator
Oil pressure switch
Starter
V-belt
Oil pan
REAR
FRONT
RIGHT SIDE VIEW
Inlet manifold
Fuel filter
Governor
Fan
Stop solenoid
Air vent screw
Fuel injection nozzle
Fuel injection pump
Speed control lever
Oil cooler
Water pump
Coolant drain plug
Fuel feed pump
Dipstick
Oil filter
Oil drain plug
Flywheel
Flywheel housing
REAR
FRONT
LEFT SIDE VIEW
Operation Manual Mitsubishi SS-Series diesel engines
Version 08/2004
ENGLISH
21 / 46
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.
5.1.2 Check engine oil level
Maintain the engine oil level between the MAX
and MIN marks on the dipstick. Add oil if
necessary (see page 36).
NOTE
NOTE
The engine should be put in the horizontal
position to check the oil level. The dipstick
should be withdrawn, wiped clean, re-inserted in
the oil level guide for 2 seconds, and again
withdrawn so that the oil level on the dipstick can
be seen.
When adding coolant, maintain the
recommended concentration of Long Life
Coolant (see page 38). Do not add water. This
dilutes Long Life Coolant and adversely affects
the freeze protection.
CAUTION
Check the coolant level only when the engine is
cold.
22 / 46
ENGLISH
Operation Manual Mitsubishi SS-Series diesel engines
Version 08/2004
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. Move the speed control lever to the HIGH
SPEED position.
2. Turn the starter switch key to the ON position
and make sure that the oil pressure, coolant
temperature, and glow plug indicators are lit.
See Table 2 Starting Aid Chart for heating
time.
Heating time
Glow plug
type
Coolant
temperature
Quickheating
type
Below 5°C (41°F)
About 3 seconds
Above 5°C (41°F)
About 1 second
Standard type
Normally
About 6 seconds
Table 2
Starting Aid Chart
3. When the glow plug indicator goes off, turn
the key to the START position.
HIGH SPEED
1. Move the speed control lever to the FULL
THROTTLE position.
2. Turn the starter switch key to the HEAT
position and continue to hold it there for
approximately 6 seconds. Do not use the glow
plugs for more than 15 seconds at a time.
3. Turn the key to the START position and
release the key when the engine starts. The
key will return to the ON position when
released.
4. Move the speed control lever to the idling
position.
WARNING
Before starting the engine, make sure that no
one is working on or close to the engine. Keep
the engine free of foreign material such as
debris, oil, tools, and other items which are not
part of the engine.
CAUTION
IDLING
•
START
•
•
Operation Manual Mitsubishi SS-Series diesel engines
Version 08/2004
ENGLISH
After every 10 seconds of engine cranking,
allow 30 seconds for the starter to cool down
before cranking again.
To avoid damage to the starter, do not turn
the starter switch key to the START position
while the engine is running.
When cranking the engine for starting, do
not apply any load to the engine (disengage
the clutch if the engine is equipped with a
clutch).
23 / 46
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. Unless it is properly ventilated,
the air supply will be inadequate, resulting in
lack of air for fuel combustion and a loss of
power.
During the first 50 hours of operation,
operate the engine under a lighter load and
lower speed than normal. A proper break in
contributes to the maximum service life of
the engine.
Avoid overloading. This can cause
incomplete combustion, often indicated by
black exhaust smoke, high fuel
consumption, and carbon deposits in the
combustion chambers, affecting the engine’s
lifespan.
To avoid damage to the alternator, do not
turn OFF the battery switch when the engine
is still running.
To avoid damage to the starter, do not turn
the starter switch key to the START position
when the engine is still running.
Stopping the engine
5.5.1 Engine with a keystop device
5.4
Starting the load
OFF
When the engine has been running long enough
to warm up, apply the load. During the operation,
check that:
1. All alarm indicators are OFF.
2. The engine is free from any abrupt noises and
vibrations.
3. Exhaust smoke is normal.
WARNING
•
•
Stay clear of all rotating and moving objects
during the operation.
At operating temperature, the engine is very
hot. Any contact with the engine can cause
severe burns.
24 / 46
Turn the starter switch key to the OFF position.
The engine will take approximately 5 seconds to
stop after the key has been turned to the OFF
position.
ENGLISH
Operation Manual Mitsubishi SS-Series diesel engines
Version 08/2004
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. While
the engine is still running, make a walkaround inspection, and check for oil, fuel, or
coolant leaks.
If the engine stops abruptly, try to find the
problem and its source and make the
necessary repairs before starting it again.
After starting the engine, check to be sure
that the engine has no problems.
Remove the key from the starter switch,
because leaving it in the ON position after
the engine has stopped, can cause the
battery to discharge.
Operation Manual Mitsubishi SS-Series diesel engines
Version 08/2004
ENGLISH
25 / 46
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. For example, at Every
500 Service Hours, also service those items
listed under Every 250 Service Hours, Every
Interval
Every 10 Service Hours
[Pre-Start Inspection]
Every 50 Service Hours
First 50 Service Hours
of New or
Reconditioned Engine
50 Service Hours and Every 10 Service Hours
[pre-start inspection].
3. For special items marked with an asterisk (*),
rely on the expert knowledge of the service
men and the service facilities offered to you at
your Mitsubishi dealer.
Item
Remarks (specifications)
Walk-around inspection
22
Check engine oil level
22
Check fuel level
22
Check coolant level
22
Drain water and sediment from the fuel
tank and water separator
27
Check the battery electrolyte level and
specific gravity
27
Change engine oil
See SPECIFICATIONS (page 16)
28
Retighten nuts and bolts
*
See SPECIFICATIONS (page 16)
Change oil filter
Every 1000 Service
Hours
Every 2 Years
Table 3
26 / 46
28
28
Clean fuel filter element
After cleaning, prime (page 33)
Clean radiator fins
Every 500 Service
Hours
28
Change oil filter
Change engine oil
Every 250 Service
Hours or once a year
Page
29
29
Check and adjust valve clearance
0.25 mm (0.0098 in.) for both inlet and
exhaust valves
*
Change fuel filter element
After changing, prime (page 33)
29
Check and adjust injection pressure
See SPECIFICATIONS (page 16)
*
Check and adjust fan belt
Deflection: 13 mm (0.5 in.)
30
Check glow plugs
*
Retighten nuts and bolts
*
Check starter
31
Check alternator
31
Check turbocharger
*
Change coolant
See SPECIFICATIONS (page 16)
31
Lubrication and maintenance charts
ENGLISH
Operation Manual Mitsubishi SS-Series diesel engines
Version 08/2004
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. gal) of fuel to remove the water and
sediment.
It is evident that invisible particles of dirt in
sediment which might pass through the filter will
damage the finely finished parts of the fuel
injection system.
Specific gravity at 20°C
(68°F)
1.26 to 1.28
Fully charged
1.22 to 1.26
Three-fourths charged (To
be recharged)
Below 1.22
One-fourth charged (To be
recharged)
Table 4
DANGER
Specific gravity reading
WARNING
Do not smoke while draining out the water and
sediment. Keep flames and sparking devices
away from this area. Clean up any spillage
before starting the engine.
•
•
•
6.1.2 Check the battery electrolyte level
and specific gravity
1. Maintain the electrolyte level between UPPER
and LOWER marks on the case. If the battery
has not got any level marks, maintain the level
10 to 15 mm (0.4 to 0.6 in.) above the cells.
Remove the filler caps and add distilled water
when necessary.
2. Test the specific gravity of the battery
electrolyte with a battery hydrometer. The
Operation Manual Mitsubishi SS-Series diesel engines
Version 08/2004
Battery condition
•
ENGLISH
Battery gives off flammable fumes that are
explosive.
Do not smoke when observing the battery
electrolyte level.
Electrolyte is an acid and can cause
personal injury if it comes into contact with
the skin or eyes.
Always wear goggles when working with the
battery.
27 / 46
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. Tighten it by 3/4 to 1 turn.
Packing
DANGER
Hot oil and components can cause personal
injury. Do not allow hot oil or components to
come into contact with the skin.
6.2.2 Changing the oil filter
6.2.3 Filling with oil
1.
1. Install the drain plug and tighten it to the
specified torque.
Remove the used oil filter with a filter
wrench.
NOTE
Torque
Check particles collected in the used oil filter. If
they are metallic particles, you should consult
your Mitsubishi dealer.
4.5 ± 0.5 kgf/m
(33 ± 4 lbf/ft)
[44 ± 5 N/m]
Table 5
2. Make sure that the formerly used packaging is
removed from the filter base and clean the
base with a clean cloth.
2. Fill the crankcase with oil.
Refill capacity
See SPECIFICATIONS
API Service Classification
CF or CF-4
Table 6
28 / 46
Specified torque
ENGLISH
Fill crankcase
Operation Manual Mitsubishi SS-Series diesel engines
Version 08/2004
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.
Put the cleaned element in the cup and install
the cup, making sure the O-ring is properly
fitted into place. Tighten the ring nut.
5. Turn the valve to the ON position and prime
the fuel system (see page 33).
OFF
6.3
6.3.1 Change fuel filter element
Water separator element
1. Turn the lever to CLOSE (C) position to shutt
off fuel supply.
2. Loosen the ring nut and remove the cup.
3. Remove and discard the element.
4. Put the new element in the cup and install the
cup, making sure the O-ring is properly fitted
in place. Tighten the ring nut.
5. Turn the lever to OPEN (O) position.
Element
Ring nut
Valve
Element
ON
Every 500 service hours
Lever
Cup
O-ring
Ring nut
6.2.5 Clean the radiator
Direct the pressurized air to the fins in the
opposite direction of the fan’s air flow.
Fuel filter element (A-type)
1. Loosen the drain plug and allow the fuel to
drain.
2. Loosen the plug that holds the bowl and
element. Remove the bowl and element.
Discard the element.
3. Install the new element and bowl with the
plug. Make sure the seal rings are properly
fitted in place.
4. Tighten te drain plug.
Bowl
Element
Drain
plug
Fuel filter element (B-type)
1. Loosen the drain plug and allow the fuel to
drain.
2. Loosen the connector from the level sensor.
3. Remove the element from the body.
Operation Manual Mitsubishi SS-Series diesel engines
Version 08/2004
ENGLISH
29 / 46
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.
Adjusting bolt
After replacing the elements, be sure to prime
the fuel system. See page 33 for priming.
Water pump
pulley
Adjusting plate
Body
Alternator pulley
13 mm
(0.5 in.)
Mounting bolt
Level sensor
Crankshaft
pulley
Adjusting
Drain plug
Fuel filter (cartridge type)
1. Remove the cartrigde with a filter wrench.
2. Apply a small amount of fuel to the O-ring of
the new cartrigde.
3. Install new cartrigde by hand.
4. After replacing the cartridge, be sure to prime
the fuel system. See page 33 for priming.
1. Loosen the adjusting plate bolt and the
mounting bolt.
2. Insert a bar between the alternator and the
cylinder block to move the alternator to obtain
the required belt deflection.
3. Tighten the mounting bolt and the adjusting
bolt.
NOTE
Do not add fuel to the new cartridge. Invisible
particles of dirt which might get inside the
injection pump can damage its finely finished
parts.
CAUTION
•
•
30 / 46
ENGLISH
If the fan belt is too tight, excessive stress is
put on to the fan bearings and belt, which
might shorten the life of both. If it is too
loose, it will slap against the pulleys, causing
unnecessary wear and tear to the belt, which
could cause possible slipping, to the extent
that the engine will overheat.
Keep the belt free from oil or grease.
Operation Manual Mitsubishi SS-Series diesel engines
Version 08/2004
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. Then allow the coolant to drain into the
containers.
6.4.2 Check the alternator
1. Check for visual defects.
2. Remove the belt from the alternator. Turn the
pulley by hand to check the alternator for
smooth rotation. If the alternator fails to rotate
smoothly, consult your Mitsubishi dealer.
6.5.3 Flushing
6.5
Every 2 years
6.5.1 Change coolant
Long Life Coolant (LLC) used in your engine
retains its efficiency for 2 years. Be sure to change
the coolant every 2 years.
6.5.2 Draining
1. Start and operate the engine until the coolant
temperature is 70°C to 80°C (158°F to 176°F).
Then stop the engine.
Operation Manual Mitsubishi SS-Series diesel engines
Version 08/2004
1. Close the radiator drain valve and install the
engine drain plug.
2. Fill the cooling system with a cleaning solution
which does not chemically attack rubber or
metal surfaces. Start and operate the engine
at 800 to 900 rpm and let the engine run for 15
minutes. Stop the engine and drain the
cleaning solution.
3. Fill the system with clean water and operate
the engine at 800 to 900 rpm for 10 minutes.
Continue to flush the system until the draining
water is clear.
6.5.4 Refilling
1. Tighten the radiator drain valve and the
engine drain plug.
2. Remove the by-pass hose (A) at the
thermostat housing.
ENGLISH
31 / 46
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. Fill the cooling system slowly with coolant
through the radiator cap opening to avoid air
being trapped in the system.
32 / 46
6. Re-install the by-pass and cabin heater hoses,
if coolant reaches the top level and tighten the
clamps.
7. Bleed the air at the cabin heater system.
8. Run the engine for a few minutes at low idle
with the radiator cap open.
9. Stop the engine and check the coolant level;
fill-up if necessary, re-install the radiator cap.
10. Start and operate the engine until the coolant
temperature is between 70°C and 80°C
(158°F to 176°F). Check for any leaks. Then
stop the engine. Repair any leakage if
necessary.
11. Check the coolant level in the reservoir tank
and add water if the coolant level is low.
Maintain the coolant level to FULL line on the
tank when the engine is cold.
ENGLISH
Operation Manual Mitsubishi SS-Series diesel engines
Version 08/2004
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. If the vent plug is tightened before the
priming pump plunger is locked, fuel
pressure acts on the feed pump, making it
difficult to restore the plunger.
2. Clean up fuel spillage.
6.6.2 Procedure
Fuel filter
1. Loosen the air vent plug on the fuel filter (by
turning it 1.5 turns).
2. Unlock the priming pump plunger by turning it
to the left, and operate the pump.
3. Tighten the air vent plug when the fuel flows
free of bubbles.
6.6.3 Clean/change air cleaner element
Service the air cleaner only when it is necessary,
or when the dust indicator indicates RED.
6.6.4 Cleaning
Priming button
1. Direct air — 7 kgf/cm2 (100 psi) [686 kPa]
maximum — inside the element along the
length of pleats.
2. Insert a light inside the clean element and
check. Replace the element if rips or tears are
found.
Air vent plug
.
Fuel injection pump
1. Loosen the air vent plug on the injection pump
(by turning it 1.5 turns).
2. Unlock the priming pump plunger by turning it
to the left, and operate the pump.
3. Tighten the air vent plug when the fuel flows
free of bubbles.
.
NOTE
Replace the element if it is excessively dirty.
Operation Manual Mitsubishi SS-Series diesel engines
Version 08/2004
ENGLISH
33 / 46
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.
34 / 46
ENGLISH
Operation Manual Mitsubishi SS-Series diesel engines
Version 08/2004
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.
Before starting the engine after 50 service hours,
remove the drain plug and drain off any sediment
or water which may have accumulated.
7.3
Caring for the fuel supply
It is important to buy clean fuel and keep it clean.
Natural settling is an effective method of cleaning
fuel. Allow the fuel to stand for at least 10 days in
the fuel storage tank after the tank has been filled
and before the fuel is transferred to the diesel fuel
tank. Be sure to drain all the water and sediment
that has settled in the bottom of the tank before
the tank is refilled. Occasionally, drain all of the
fuel and clean the tank thoroughly.
Operation Manual Mitsubishi SS-Series diesel engines
Version 08/2004
ENGLISH
35 / 46
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. Improper oil
selection may result in congealed oil film on the
cylinder walls and the bearing surfaces. This can
result in high friction loads and more cranking
effort, thus standing in the way of achieving
sufficient cranking speeds for reliable starting and
affecting engine life.
8.2
Recommended oil viscosities
There are two important considerations related to
satisfactory engine operation under ambient
temperature conditions — (1) the ability to crank
the engine fast enough to assure starting, and (2)
adequate lubrication of internal wearing surfaces
during starting and warm-up. These
considerations can be adequately met through
proper grade selection. Recommended oil
viscosities are shown in the chart below:
CF or CF-4
Starting
temperature, °C (°F)
-30
(-22)
-25
(-13)
-20
(-4)
-15
(5)
-10
(14)
-5
(23)
0
(32)
10
(50)
20
(68)
30
(86)
40
(104)
SAE30
S A E 40
S A E 15 W - 4 0
Oil viscosities
SAE10W-30
SAE5W-20
Table 8
Recommended oil viscosities
Mitsubishi recommends the all-season type
engine oil of SAE 10W-30.
36 / 46
ENGLISH
Operation Manual Mitsubishi SS-Series diesel engines
Version 08/2004
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. Change the oil if any of these
requirements are not met.
NOTE
•
Oil change intervals depends on the fuel
properties. Be sure to use the recommended
fuels only.
The limit of total base number is 1/2 of that
of a new oil in case of a perchloric-acid
analysis method.
•
A oil
B oil
Property
Viscosity
Unit
Test Method
cSt @ 100°C (212°F)
JIS
K 2283
+30% / -15% , max. of new oil
JIS
K 2501
2.0, min.
Total base number (HCl)
mgKOH/g
Total acid number
mgKOH/g
+3.0, max. of new oil
JIS
K 2275
0.2, max.
°C (°F)
JIS
K 2265
180 (356), min.
ASTM
D 893
0.5, max.
Pentane insolubles
Wt%
Pentane insolubles coagulated
Wt%
Table 9
Limit
Vol%
Water content
Flash point
Limiting requirements for
engine oils
3.0, max.
Limiting requirements for engine oils
Operation Manual Mitsubishi SS-Series diesel engines
Version 08/2004
ENGLISH
37 / 46
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.
Main malign effect
Chemical
symbol
Unit
Recommended
limit
pH, 25°C (77°F)
-
-
Electrical conductivity,
25°C (77°F)
-
Total hardness
Item
Corrosion
and rust
Scale
formation
6.5 to 8.5
(6.5 to 8.0)
O
O
µ Ω /cm
< 400
(< 250)
O
O
CaCO3
PPM
< 100
(< 95)
-
O
M alkalinity
CaCO3
PPM
< 150
(< 70)
-
O
Chlorine ion
Cl-
PPM
< 100
(< 100)
PPM
< 100
(< 50)
O
-
Fe
PPM
< 1.0
(< 1.0)
-
O
SiO2
PPM
< 50
(-)
-
O
-
PPM
< 400
(< 250)
-
O
Sulfuric acid ion
Total iron
Silica
Residue from
evaporation
Table 10
SO
2–
4
Coolant specifications
The values indicated in ( ) are the limits set forth
by Mitsubishi. In addition to the items specified
above, turbidity is specified to be <15 mg/l.
9.2
Recommended types of LLC's
(Long Life Coolant)
For Mitsubishi diesel engines, all-season, nonamine type LLC's or equivalents are
recommended.
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9.2.1 Features of recommended brands
•
•
•
•
•
ENGLISH
No amines (methyl amines, ethyl amines, npropyl amines, etc., all being derivatives of
ammonia, NH3) are contained.
Silicate and borate are not contained.
Close to neutral on the pH scale, and hence,
slightly basic (alkaline).
Balanced additive ingredients; some being
substitutes for amines.
Long life (the coolant with 30% concentration,
for example, retains its effectiveness for more
than 2 years).
Operation Manual Mitsubishi SS-Series diesel engines
Version 08/2004
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. The engine coolant with any of the
recommended additives should be changed
every 2 years.
NOTE
When using any other LLC, refer to the coolant
mixture chart shown on the container.
WARNING
Consult your Mitsubishi dealer for disposal of a
used coolant containing LLC.
2. The proper concentration of LLC is from 30%
to 60% all year round. Aim at a temperature
level which is 5°C (9°F) lower than the
expected lowest temperature. LLC of less
than 30% concentration does not provide
sufficient corrosion protection. Concentrations
over 60% adversely affect freeze protection
and heat transfer rates. When adding coolant,
use LLC of the same concentration.
Why LLC?
Today's full-blown trend is toward smaller and
more lightweight engines, higher output, lower fuel
consumption, and lower exhaust emission levels.
Engine application has also expanded. In most
applications, the engine coolant is compelled to
withstand severe conditions such as continuous
high-power operation with a higher coolant
temperature and a higher speed of coolant
recirculation in the cooling circuit. Many materials
involved in the circuit (such as steel, aluminum,
copper, solder, and rubber) are also subject to
severe servicing. These materials differ in ionizing
tendency and this difference promotes cavitation
and deterioration through the medium of engine
coolant. The ideal of breaking the link between
cause and effect to preserve the circuit can be
realized by using LLC.
9.5
How LLC works
LLC contains several chemicals in such
proportions as to produce a chemical reaction that
suppresses corrosion of the engine parts in
contact with coolant. "Corrosion" is the result of a
phenomenon called "ionization."
The power of LLC to defeat the ionic reaction is
generally subject to wear and the engine coolant
becomes increasingly weak at that time.
Moreover, if its chemicals are not properly
proportioned to match the circuit metals which
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ENGLISH
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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. The
cause of coolant leakage from and clogging of the
coolant circuit in the radiator is usually traceable to
such a malcondition of the coolant.
The worse case scenario is that the process of the
ionic reaction or corrosion will go on faster than
when the coolant is straight water without
additives, if there is not a good match between the
chemical proportions and the circuit metals.
9.6
Practical reported cases of
circuit trouble for which
additive is blamed
Case 1:
Amines are generally effective in suppressing the
rusting of ferrous metals but are said to be
problematic for copper and cupric metals because
of copper involvement in pittings reported on Fe
metals. The mechanism of Fe-surface pitting may
be explained as that of galvanic or local-cell
action. Suppose a cluster of copper molecules
precipitates and deposits itself on a surface of Fe,
a base metal relative to copper. The copper
deposit introduces a localized galvanic cell which,
by its ionic action, rapidly eats into the Fe surface
to result in a pit.
Case 2:
A silicate (there are several types of silicate) is
highly effective in protecting aluminium against
rusting. This compound of silicon is unstable in a
solution whose pH is 9 or less: it is prone to turn to
gel and settle down in the solution. For this
reason, the pH is usually specified to be 10 or so.
This means that the silicate has to be used in a
high-alkalinity coolant. When the silicate is used
up, the high alkalinity starts chemically attacking
the aluminium.
Example
The mechanical seal of the water pump may
rapidly wear down as the secondary effect of
silicate gel in the above context.
Case 3:
As the additive as a whole deteriorates or when its
concentration in the coolant is too low, its anticorrosion performance falls and consequently the
circuit metals begin to corrode. Of those metals
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ENGLISH
Operation Manual Mitsubishi SS-Series diesel engines
Version 08/2004
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. Apply a coat of preservative to the exposed
machined surfaces of the engine.
7. Cover the air inlet, the exhaust openings, and
the breather by taping them.
8. Loosen the fan belt.
9. Tape the starter and the alternator terminals.
Cover the starter and alternator with a
polyethylene sheet and put a desiccant inside.
10. Disconnect the cables from the battery and
charge the battery. Flush the top of the battery
with clean water and coat the poles with acidfree vaseline to prevent further corrosion.
Keep the battery in a cool, dry place.
11. Cover the engine to protect it against the
weather.
NOTE
•
•
•
•
Store the engine in a well-ventilated room.
It is not necessary to drain the coolant if it
contains LLC.
Attach a "DO NOT OPERATE" sign or
similar warning tag to the starter switch or
any of the controls.
New engine oil may be used instead of
preservative.
4. Adjust the fan belt.
5. Remove the covering and the taping from the
various ports.
6. Drain the preservative and fill the engine with
the recommended engine oil.
7. Fill the fuel tank and prime the fuel system.
8. Check under and around the engine for items
such as loose or missing bolts, oil, fuel, or
coolant leaks.
9. Remove the rocker cover and lubricate the
valve mechanism.
10. Crank the engine 3 times, 10 seconds each
time, at intervals of 1 minute, with the fuel
supply shut off.
11. Make sure the engine oil pressure rises
properly.
12. Open the fuel supply valve and start the
engine.
13. Allow the engine to leave it idling.
14. When the engine has run long enough to
warm up, apply the load and bring it to an
operating speed.
10.2 Storage of the engine in an
operational condition
10.2.1 Follow steps 1 through 3 mentioned
below once a month:
1. Crank the engine 2 times, for 10 seconds
each time, with the starter at intervals of 30
seconds, with the fuel supply shut off. Open
the fuel supply valve afterwards.
2. Start and operate the engine at 800 rpm under
no-load condition for 5 minutes.
3. Increase the engine speed from 1000 to
1200 rpm and operate the engine under noload condition for 10 minutes.
10.1.2 Service during storage
Charge the battery at least once a month.
10.1.3 Remove the engine from storage
1. Remove the covers from the engine.
2. Connect a fully charged battery to the engine.
3. Remove the covers from the starter and the
alternator.
Operation Manual Mitsubishi SS-Series diesel engines
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ENGLISH
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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.
11.1.4 Perform servicing work safely
Use the right kind of hand tools to carry out each
working step in repair work. Avoid injury to
yourself and damage to the parts by using proper
tools. When lifting or carrying a part that is too
heavy for one person to handle, get another
person’s help and, if necessary, use a jack or a
hoisting device.
11.1.2 Dust and dirt are often the main
causes
“Wear” is usually the result of abrasive particles.
When disconnecting or disassembling a part or
component, be sure to keep out dust and dirt.
CAUTION
•
•
11.1.3 Use original parts
Use only original parts to replace those that have
failed or reached their service limits. When
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ENGLISH
Never attempt to break the seals of the
governor for maximum speed setting or
maximum injection quantity setting.
The maximum injection quantity of the
injection pump has been set on the basis of
the output power of each engine verified at
the bench test. Never attempt to vary this
injection quantity in the field.
Operation Manual Mitsubishi SS-Series diesel engines
Version 08/2004
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.
Problem
Engine will not start
Not enough power
Table 12
Cause
Correction
Fuse off
Replace
Defective starter switch
Repair or replace*
Slow cranking speed
Recharge battery
Wrong viscosity grade of oil
Change correct oil
Seized running parts
Repair*
Air in fuel system
Prime
No fuel in tank
Refuel
Bad quality fuel
Change fuel
Clogged fuel filter
Clean or replace
Defective fuel injection pump
Repair or replace*
Defective control timer unit
Replace*
Clogged air cleaner
Clean or replace
Defective starter or relay
Repair or replace*
Open electrical circuit
Repair
Wrong viscosity grade of oil
Change oil
Clogged air cleaner
Clean or replace
Clogged fuel filter
Clean or replace
Defective fuel injection pump
Repair or replace*
Defective fuel injection nozzles
Repair or replace*
Wrong injection timing
Adjust*
Bad quality fuel
Change correct fuel
Overheating
Flush cooling system and replace parts
Wrong valve clearance
Adjust
Poor compression (cylinders, piston, rings, etc.
worn)
Repair or replace*
Troubleshooting
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ENGLISH
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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 correct level
Oil viscosity too low
Change oil
Defective thermostat (coolant temperature too
low)
Replace
Defective fuel injection nozzles
Repair or replace*
Wrong injection timing
Adjust*
Wrong fuel cetane number
Change fuel
Poor compression (cylinders, piston rings, etc.
worn)
Repair or replace*
Bad quality fuel
Change fuel
Defective fuel injection pump
Repair or replace*
Defective fuel injection nozzles
Repair or replace*
Wrong injection timing
Adjust*
Clogged air cleaner
Clean or replace
Wrong valve clearance
Adjust
Poor compression (cylinders, piston rings, etc.
worn)
Repair or replace*
Bad quality fuel
Change fuel
Defective fuel injection pump
Repair or replace*
Defective fuel injection nozzles
Repair or replace*
Wrong injection timing
Adjust*
Clogged air cleaner
Clean or replace
Poor compression (cylinders, piston rings, etc.
worn)
Repair or replace*
Troubleshooting
ENGLISH
Operation Manual Mitsubishi SS-Series diesel engines
Version 08/2004
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 pressure switch
Replace*
Troubleshooting
Remarks:
1. Consult your Mitsubishi dealer for items
marked with an asterisk (*).
2. Consult your Mitsubishi dealer for any items
other than those listed in the table.
3. When communicating with your Mitsubishi
dealer, specify the engine model name, the
engine serial number, the application, the
rating, and service hour meter reading of your
engine.
Operation Manual Mitsubishi SS-Series diesel engines
Version 08/2004
ENGLISH
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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.G.L. Manders
General Manager
Engine Division
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ENGLISH
Operation Manual Mitsubishi SS-Series diesel engines
Version 08/2004