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Operation Manual Mitsubishi SL-Series diesel engines
Version 08/2004

TROUBLESHOOTING

ENGLISH

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

Cause

Correction

Engine will not start

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

Not enough power

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*

Table 12

Troubleshooting

Содержание L2A

Страница 1: ... 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...

Страница 2: ...g trouble Items to be recorded The following items are recommended to be recorded 1 Operating hours service hour meter reading 2 The amount of oil fuel and coolant soft water required for refilling 3 Oil and coolant change intervals 4 Engine oil pressure exhaust temperature coolant temperature and inlet air temperature 5 Parts serviced kinds of service adjustment repairs or replacement and the res...

Страница 3: ...gine S4L S4L2 19 4 4 Engine S4L T S4L2 T 20 5 OPERATION 21 5 1 Pre start inspection 21 5 2 Starting the engine 22 5 3 Warming up the engine 23 5 4 Starting the load 23 5 5 Stopping the engine 23 6 MAINTENANCE 25 6 1 Every 50 service hours 26 6 2 Every 100 service hours 27 6 3 Every 250 service hours or once a year 27 6 4 Every 500 service hours 28 6 5 Every 1000 service hours 29 6 6 Every 2 years ...

Страница 4: ...37 9 4 Why LLC 37 9 5 How LLC works 37 9 6 Practical reported cases of circuit trouble for which additive is blamed 38 10 STORAGE 39 10 1 Storage of the engine in a non operational condition 39 10 2 Storage of the engine in an operational condition 39 11 TROUBLESHOOTING 40 11 1 General 40 11 2 Problems 41 12 ADDITIONAL INFORMATION 44 ...

Страница 5: ...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 Connect the battery earth cable carefully 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 oc...

Страница 6: ...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 Do not touch any hot components 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...

Страница 7: ... precautions Lift the engine carefully 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 1 4 Exhaust fumes Exhaust fumes 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...

Страница 8: ...e 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 lnstall the protective covers To prevent personal injury make sure all protective covers and guards are placed on the rotating parts Keep the turning tool disengaged when it is not in use When n...

Страница 9: ...ly 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 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...

Страница 10: ...eposit carbon in cylinders and cause incomplete fuel combustion Stop the engine only after it has cooled down 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 ...

Страница 11: ...mance Violation to emission regulations Do not turn OFF the battery switch during operation 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 AIways keep the engine compartment well ventilated Unless the engine compartment is properly ventilated the air suppl...

Страница 12: ...ver 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 Keep grit laden air out of the engine Dust and dirt entering the engine will cause early wear of the moving parts This could res...

Страница 13: ... lubrication system Operating the engine with low oil pressure can cause bearings and other parts to seize lf the engine overheats 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 gr...

Страница 14: ...sted 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 brok...

Страница 15: ...ore 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 cau...

Страница 16: ... filter Paper element type Oil capacity FULL level EMPTY level l Exclusive of oil filter capacity 0 5 l Shallow type oil pan 3 7 2 3 Deep type oil pan 5 7 3 1 Shallow type oil pan 5 5 3 7 Deep type oil pan 7 6 4 2 FUEL SYSTEM Fuel injection pump Bosch M Nozzle Throttle type Fuel injection pressure 140 kgf cm2 Fuel to be used Diesel fuel see chapter 7 Governor Centrifugal weight type INTAKE SYSTEM ...

Страница 17: ... SIDE VIEW Fuel injection nozzle Air inlet cover Coolant drain plug Dipstick REAR LEFT SIDE VIEW REAR FRONT Thermostat Hanger Alternator Fan V belt Oil pan Exhaust manifold Flywheel Fuel injection pump Crankshaft pulley FRONT Oil filter Oil filler Oil filler Hanger Stop solenoid Fuel filter Oil pressure switch Oil drain plug Thermoswitch Starter Flywheel housing ...

Страница 18: ...lter Crankshaft pulley FRONT Hanger Fuel injection nozzle Air inlet cover Oil drain plug REAR Stop solenoid RIGHT SIDE VIEW LEFT SIDE VIEW REAR FRONT Fan Alternator Thermoswitch Hanger Thermostat Flywheel Turbocharger Exhaust manifold Flywheel housing Starter Dipstick Coolant drain plug Fuel filter Oil pressure switch Fuel injection pump Oil filler V belt Oil pan ...

Страница 19: ...DE VIEW Fuel injection nozzle Air inlet cover Coolant drain plug Oil pressure switch Oil filter REAR LEFT SIDE VIEW REAR FRONT Thermostat Thermoswitch Alternator Fan V belt Oil pan Flywheel Crankshaft pulley Oil filler Dipstick FRONT Exhaust manifold Starter Air vent screw Oil filler Hanger Stop solenoid Fuel filter Oil drain plug Flywheel housing Hanger ...

Страница 20: ...p Dipstick Crankshaft pulley FRONT Hanger Fuel injection nozzle Air inlet cover Fuel filter REAR Stop solenoid RIGHT SIDE VIEW LEFT SIDE VIEW REAR FRONT Fan Alternator Thermoswitch Hanger Thermostat Turbocharger Exhaust manifold Starter Flywheel housing Oil filler Air vent screw Oil pressure switch Oil filter Oil drain plug Flywheel Oil pan V belt ...

Страница 21: ...ULL 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 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 di...

Страница 22: ...ximately 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 Glow plug type Coolant temperature Heating time Quick heating type Below 5 C 41 F About 3 seconds Above 5 C 41 F About 1 second Stand...

Страница 23: ...in carbon deposits in the combustion chambers and incomplete fuel combustion 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 Warm up CAUTION Always keep the engine room well ventilated Unless it is properly ventilated the air supply will be inadequate resulting in lack of a...

Страница 24: ...utomatically 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 walk around 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 ch...

Страница 25: ...21 Check fuel level 21 Check coolant level 21 Every 50 Service Hours Drain water and sediment from the fuel tank and water separator 26 Check the battery electrolyte level and specific gravity 26 First 50 Service Hours of New or Reconditioned Engine Change engine oil See SPECIFICATIONS page 16 27 Change oil filter 27 Retighten nuts and bolts Every 100 Service Hours Clean fuel filter element After ...

Страница 26: ... necessary 2 Test the specific gravity of the battery electrolyte with a battery hydrometer The following chart of specific gravity reading gives a general idea of the battery condition When Required Prime fuel system 31 Clean air cleaner element 31 Change air cleaner element 31 Interval Item Remarks specifications Page Table 3 Lubrication and maintenance charts DANGER Do not smoke while draining ...

Страница 27: ...aining 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 6 3 2 Changing the oil filter 1 Remove the used oil filter with a filter wrench 2 Make sure that the formerly used packaging is removed from the filter base and clean the base with a clean cloth 3 Check the new oil filter and mak...

Страница 28: ... 3 Remove and discard the filter element 4 Put the new filter 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 31 for priming Cartridge type fuel filter 1 Change the filter if water and sediment have been collected in the filter 2 After changing the filter prime th...

Страница 29: ...or smooth rotation If the alternator fails to rotate smoothly consult your Mitsubishi dealer 6 6 Every 2 years 6 6 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 6 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 2 Remove the filIer...

Страница 30: ...lean 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 6 4 Refilling 1 Tighten the radiator drain valve and the engine drain plug 2 Remove the by pass hose A at the thermostat housing 3 Remove the cabin heater hose B at the thermostat housing if installed 4 Pour pure undiluted LLC into the radiator see COOLANT AND ANTIFRE...

Страница 31: ...ed 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 6 7 2 Procedure Fuel filter with air valve 1 Turn the valve lever to the AIR position and feed the fuel 2 If the fuel flows free of bubbles through the fuel return pipe turn the valve lever to the ON position Fuel filter with air vent ...

Страница 32: ...e 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 ...

Страница 33: ... 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...

Страница 34: ...re 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 surface...

Страница 35: ...ar to moving parts It is best to stick with the same brand and one type of oil at successive service intervals A oil B oil 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 Property Unit Test Method Limit Viscosity cSt 100 C 212 F JIS K 2283 30 15...

Страница 36: ...tc 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 NOTE Harmful chemical properties and substances contained in water as coo...

Страница 37: ... 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...

Страница 38: ... 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...

Страница 39: ...battery to the engine 3 Remove the covers from the starter and the alternator 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 ...

Страница 40: ...e original parts Use only original parts to replace those that have failed or reached their service limits When ordering specify the needed replacement parts by referring to the Parts Catalogue 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 car...

Страница 41: ... 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 Not enough power Wrong viscosity grade of oil Change oil Clogged air cleaner Clean or replace Clogged fuel filter Clean or replace Defe...

Страница 42: ...epair or replace Wrong injection timing Adjust Wrong fuel cetane number Change fuel Poor compression cylinders piston rings etc worn Repair or replace Too much black or gray smoke 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 Adj...

Страница 43: ...lication the rating and service hour meter reading of your engine Oil consumption too high 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 Oil pressure too low Not enough oil in engine Add oil Oil viscosity too low Change oil Clogged oil filte...

Страница 44: ...nex 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 SL 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 Engin...

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