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Chapter 9

TROUBLESHOOTING

9-2

How to Troubleshoot

Starters Do Not Crank or Crank Slowly, Resulting in Start Failure

Starters Crank, But Engine Does Not Start

Table 9-1 Starters Do Not Crank or Crank Slowly, Resulting in Start Failure

Problem

Cause

Remedy

Start
failure

Electrical
system

Blown fuse

Change fuse.

Faulty wire connection between bat-
tery and starter switch

Connect wire correctly.

Faulty wire connection between bat-
tery, starters and starter switch

Connect wire correctly.

Insufficiently charged battery

Inspect and adjust V-belt tension.
Refer to

"Inspection of V-belt and

Adjustment of Belt Tension" (6-2)

Specific gravity of battery fluid too low

Charge battery.

Faulty battery

Install new battery.

Faulty starter or starter relay

Consult a Mitsubishi dealer.

Lubricating
system

Oil viscosity too high

Use appropriate engine oil. Refer to

"Engine Oil" (4-4)

Fuel
system

Air in fuel system

Bleed fuel system.Refer to

"Fuel Sys-

tem" (3-1)

Low fuel level

Add fuel.

Clogged fuel filters

Change fuel filters.
Refer to

"Changing Fuel Filters" (6-5)

Faulty fuel feed pump

Consult a Mitsubishi dealer.

Faulty fuel injection pump

Consult a Mitsubishi dealer.

Engine
mechanical

Faulty moving parts(Interference
between valves and pistons, or for-
eign items in cylinders)

Consult a Mitsubishi dealer.

Table 9-2 Starters Crank, But Engine Does Not Start

Problem

Cause

Remedy

Engine
does not
start

Fuel
system

Empty fuel tank

Add fuel, and bleed fuel system. Refer to

"Fuel System" (3-1)

Damaged fuel pipe

Consult a Mitsubishi dealer.

Loose fuel pipe connection

Tighten connection. Consult a Mitsubishi
dealer

Improper fuel

Use proper fuel. Refer to

"Fuel" (4-2)

Dust or water mixed in fuel

Remove dust or water from fuel tank.
Refer to

"Cleaning Fuel Tank" (6-4)

Clogged fuel filters

Replace fuel filters. Refer to

"Changing

Fuel Filters" (6-5)

Faulty fuel feed pump

Consult a Mitsubishi dealer.

Faulty fuel injection pump

Consult a Mitsubishi dealer.

Air intake
system

Clogged air cleaner

Clean pre-cleaner. Refer to

"Cleaning

and Inspecting Air Cleaner Element" (6-
12)

Engine
mechanical

Compression pressure low
(damaged cylinder liner, piston
or piston ring, or faulty valve seat
or nozzle packing seal)

Consult a Mitsubishi dealer.

Содержание S 12 R

Страница 1: ...Mitsubishi Diesel engine S 12 R Users guide and maintenance manual ...

Страница 2: ...pt as provided in this manual includ ing without limitation thereof warranties as to marketability merchantability fitness for a particular purpose or use or against infringement of any patent The manufacturer will not be liable for any damages or consequential damages including without limitation thereof damages or other costs resulting from any abuse misuse misapplication of the engine and devic...

Страница 3: ...horough safety guidance to the operators Also add safety caution and operating signs that describe the original warning label statements in the native language of the operators The engine must be operated maintained and inspected only by qualified persons who have thorough knowledge of engines and their danger and also received danger avoidance training To prevent occurrence of an accident do not ...

Страница 4: ... potential hazard Failure to follow these directions can lead to serious accidents which can result in personal injury or death in the worst case Indicates a highly hazardous situation which if not avoided can result in death or serious injury Indicates a potentially hazardous situation which if not avoided can result in death or serious injury Indicates a potentially hazardous situation which if ...

Страница 5: ...SAE Society of Automotive Engineers U S LLC Long Life Coolant Units of Measurement Measurements are based on the International System of Units SI and they are converted to the metric sys tem units in this manual based on the following conversion rates Pressure 1 MPa 10 197 kgf cm2 Torque 1 N m 0 10197 kgf m Force 1 N 0 10197 kgf Horsepower 1 kW 1 341 HP 1 3596 PS Meter of mercury 1 kPa 0 7 cmHg Me...

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Страница 7: ... climb onto engine 1 4 Always watch your footing 1 4 Caution Be Careful of Handling Engine Oil and LLC 1 4 Use only specified fuel engine oil and coolant LLC 1 4 Handle LLC carefully 1 4 Properly dispose of drained oil and LLC 1 4 Caution Service Battery 1 5 Handle battery carefully 1 5 Caution When Abnormality Occurs 1 5 If engine overheats conduct cooling operation be fore stopping engine 1 5 If...

Страница 8: ...vel 3 10 Inspection of the air cleaner indicator 3 10 Inspection of Air Tank Air Pressure 3 11 Starting 3 12 Warming up Operation 3 12 During warming up operation 3 12 External inspection during warming up 3 12 Operation 3 13 Inspection during operation 3 13 Stopping 3 14 Emergency Stop 3 14 Inspection After Stopping 3 14 Chapter 4 MAINTENANCE Cautions Concerning Maintenance 4 1 Stop the engine be...

Страница 9: ...justing the V belt tension Alternator side 6 2 Adjusting the V belt tension Water pump side 6 2 Inspection of Damper 6 3 External inspection of damper 6 3 Damper temperature management 6 3 Fuel System 6 4 Inspection of Fuel Control Linkage Ball Joints 6 4 Cleaning Fuel Tank 6 4 Changing Fuel Filters 6 5 Lubricating System 6 6 Changing Engine Oil Oil Filters and Bypass Oil Fil ter 6 6 Draining engi...

Страница 10: ...ever 2 2 fig 2 5 Stop Solenoid 2 2 fig 2 6 Oil pressure unit 2 3 fig 2 7 Thermo unit 2 3 fig 2 8 Revolution Detection Pickup 2 3 fig 2 9 Oil pressure switch 2 4 fig 2 10 Oil filter alarm switch 2 4 fig 2 11 Thermo switch 2 4 fig 2 12 Air cleaner indicator 2 5 fig 2 13 Turning gear position Engine in operation 2 6 fig 2 14 Turning gear position Shaft pushed in 2 6 fig 2 15 Turning gear position Tur...

Страница 11: ...rolyte level 6 14 fig 6 30 Inspecting specific gravity of electrolyte 6 14 fig 6 31 Air starter strainer 6 15 fig 6 32 Draining water from air tank 6 15 fig 6 33 Inspection safety valve of air tank 6 15 fig 6 34 Air starter compressor 6 16 fig 8 1 Hangers for lifting 8 1 fig 8 2 The center of gravity for the engine 8 1 List of Tables Table 3 1 Specific gravity of electrolyte 3 6 Table 4 2 Fuel Use...

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Страница 13: ... it may lead to the explosion of the engine Never open the engine crankcase cover before the engine becomes cool wait at least 10 minutes after the engine stops Check for fuel oil and exhaust gas leaks Inspect fuel oil and exhaust pipes regularly for damage and looseness If a fuel oil and exhaust gas leak is found repair the leakage immediately Fuel or oil spilled on a hot surface of the engine an...

Страница 14: ...jury Keep items that can be easily entangled by rotating parts away from the engine If your body or tool contacts rotating and moving parts serious injury may occur as a result Lock out and Tag out Be sure to lock out and tag out before starting inspection and maintenance Lockout and tagout are effective methods of cutting off machines and equipment from energy sources To lock out and tag out pull...

Страница 15: ... engine stops Wait until the coolant temperature lowers sufficiently to prevent burns Do not dismount heat protection covers The high temperature exhaust components are installed with heat protection covers Do not dis mount these heat protection covers If they must be removed during inspection and maintenance be sure to reinstall them after completing the inspec tion and maintenance Warning Be Car...

Страница 16: ... Oil and LLC Use only specified fuel engine oil and coolant LLC Use fuel oil and LLC specified in this manual and handle them carefully Use of any other fuel oil or LLC and improper han dling may cause various engine problems and mal functions Obtain the MSDSs issued by the fuel oil and LLC suppliers and follow the directions on the MSDSs for proper handling Handle LLC carefully Wear safety mask a...

Страница 17: ... accidentally swallow electrolyte gar gle with plenty of water then drink lots of water Consult a physician immediately Caution When Abnor mality Occurs If engine overheats conduct cool ing operation before stopping engine If the engine overheats do not stop the engine immediately Abrupt stopping of an overheated engine may cause the coolant temperature to rise resulting in seizing of the engine I...

Страница 18: ...en the service life of the engine Warm up engine before use If the auxiliary devices for the starter water heater engine oil priming pump etc are not installed let the engine idle for 5 to 10 minutes before using the engine for work Warm up operation circulates lubricants in the engine and contributes to a longer service life and economical operation Do not conduct warm up operation for an extende...

Страница 19: ...ur supervisor of your condition When working in a team of two or more persons use specified hand signals to communicate among the workers Wear proper work clothes and protective gear Wear the work clothes specified by your workplace Wear a hardhat face shield safety shoes dust pro tective mask gloves and other protective gear as needed When handling compressed air wear safety gog gles hardhat glov...

Страница 20: ...bel To clean warning labels use a cloth water and soap Do not use solvents gasoline or other chemicals to clean warning labels Cleaning with chemicals may cause the labels to peel off If warning labels are damaged or missing replace with new labels If a part of the engine with warning label is replaced with new part also attach new warning label to the new part To obtain replacement warning labels...

Страница 21: ...urbochargers Water drain cock Fuel feed pump Starters Oil filters Fuel return pipe joint Fuel inlet pipe joint Bypass oil filter Damper Fan Breather Rear Front Fuel injection pump Air inlet Governor Thermostat case Alternator Water pump Oil pump Oil pan Oil cooler Fuel filters Exhaust gas outlet Turbochargers Fuel injection pump Water drain cock Fuel feed pump Oil filler Oil level gage Water inlet...

Страница 22: ...he event of an emergency If the starter switch fails to stop engine operation use the manual stop lever When the lever is moved in the STOP direction the engine stops operation Note Should the engine continue operating even after the manual stop lever is operated cut off the fuel supply to stop the engine Stop Solenoid The stop solenoid operates for normal shutdown of engine operation The stop sol...

Страница 23: ...the oil filter for the detection of engine oil pressure Thermo Unit The thermo unit is installed under the thermostat cover for the detection of the temperature of engine coolant Operating temperature range 50 to 120 C 122 to 248 F Revolution Detection Pickup The revolution detection pickup is installed on the fly wheel housing for the detection of engine speed Oil pressure unit fig 2 6 Oil pressu...

Страница 24: ...ch The oil pressure switch turns on and generates an alarm when the pressure of engine lubricating oil drops below the preset level The switch is activated when the oil pressure becomes the entire engine speed range Oil Filter Alarm Switch The oil filter alarm switch turns on and generates an alarm when oil filters become clogged The switch is activated when the pressure difference before and afte...

Страница 25: ...ms with its red signal Be sure to clean the element immediately when alarm signal is shown After cleaning press the bottom on top of the indicator to re set the alarm signal While serving the air cleaner do not enter dust into the air cleaner or damage the element fig 2 12 Air cleaner indicator Button Signal ...

Страница 26: ...ve the plate from the shaft groove 2 Push in the shaft fully to engage it with the ring gear 3 Turn the shaft using a socket wrench and a ratchet handle 4 After turning pull out the shaft insert the plate in the shaft groove and tighten the bolts Make sure the plate is securely inserted in the shaft groove fig 2 13 Turning gear position Engine in operation Bolt Bolt Shaft Plate fig 2 14 Turning ge...

Страница 27: ...re are no flames near the engine Wipe any spilled fuel completely Spilled fuel can ignite and cause fire Do not remove the strainer when filling the fuel tank Use fuel specified in Fuel 4 2 Pouring fuel 1 Make sure the insides of the fuel tank and fuel pipes are clean 2 Pour fuel into the fuel tank 3 Remove the fuel feed pipe and drain plug from the fuel inlet of the engine and check the discharge...

Страница 28: ...ut 1 5 turns 2 Loosen the priming pump cap by turning coun terclockwise and move it up and down 3 When there are no air bubbles in the fuel flowing from the air vent plug tighten the air vent plug to the specified torque 4 Repeat the same procedure with the right fuel filter 5 Repeat the same procedure with the fuel filters located on the other side of the engine Fuel injection pump 1 Loosen the a...

Страница 29: ...sure it is not damaged then retighten the priming pump cap If the head packing is damaged the priming pump or feed pump must be replaced Con tact a Mitsubishi dealer If the priming pump cap is not tightened firmly internal threads can wear quickly due to friction caused by engine vibrations resulting in sudden ejection of the priming pump cap to cause a fuel spill On the other hand if the priming ...

Страница 30: ...w add engine oil of the speci fied type 9 Check the oil pan and other parts for oil leaks Repair any oil leakage found 10 Crank the engine for about 10 seconds or less using the starters and wait for about 1 minute Repeat the above cranking operation several times to circulate oil throughout the engine To crank the engine shut off the fuel supply to the engine keep the control rack of the fuel inj...

Страница 31: ...adiator cap securely 6 Crank the engine for about 10 seconds or less using the starters 7 Wait for about 1 minute then repeat the above cranking operation several times to remove air from the water pump To crank the engine shut off the fuel supply to the engine keep the control rack of the fuel injection pump in the OFF position and operate the starters When conducting the above cranking operation...

Страница 32: ... and UPPER LEVEL lines If there are no level lines on the battery make sure that the fluid surface is about 10 to 15 mm 0 394 to 0 591 in above the top edges of the plate If the fluid level is lower remove the caps and add distilled water to the proper level Note When pouring fresh electrolyte pour the fluid carefully Checking specific gravity of electrolyte Check the specific gravity of the elect...

Страница 33: ...ne remains non operative for 30 minutes check the oil level with the oil level gage 4 If the oil level is low add engine oil of the same brand and type through the oil filler 5 Open the expansion tank cap and check the coolant level Remove the expansion tank cap only after the engine cools to room temperature Place a cloth over the cap and turn the cap about a half turn to release internal pressur...

Страница 34: ...s found be sure to repair or contact a Mitsubishi dealer Before starting the engine clean the top surface of the battery with wet cloth Inspect the engine exterior as described below 1 Make sure there is no combustible material near the engine or battery Also check to make sure the engine and battery are clean If combustible materials or waste are found near the engine or battery remove them 2 Che...

Страница 35: ... on the fuel tank 2 Open the drain cock on the fuel tank and drain at least 1 to 2 L 0 26 to 0 53 U S gal of fuel 3 Make sure water and dust particles were drained together with fuel then close the drain cock Checking Engine Oil Level 1 Check the oil level in the oil pan 2 Pull out the oil level gage and wipe it with a cloth 3 Insert the oil level gage fully into the oil level gage guide then pull...

Страница 36: ...same LLC concen tration Note a Determine the amounts of LLC and water to be poured by using the LLC concentra tion chart b Regarding coolant refer to Coolant 4 5 3 If the reserve tank is installed pour coolant to the reserve tank up to the FULL line Inspection of the air cleaner indicator 1 Check the air cleaner indicator for the element clog 2 If the element clogs the red signal mark is visi ble ...

Страница 37: ... Tank Air Pressure Check the air pressure gage to see if the air pres sure in the air tank conforms to the standard Air tank internal pressure standard 2 94 MPa 30 kgf cm2 426 psi fig 3 21 Inspection of air tank air pressure Air pressure gages ...

Страница 38: ...and deteriorates the diodes and transistors in the alternator Never turn the key to START position If so starter may be damaged During warming up operation do not load the engine if exhaust smoke is black Overloading the engine indicated by black smoke not only causes high fuel consumption but also excessive carbon deposits inside the engine thus it can reduce the service life of the engine After ...

Страница 39: ... operation Check for leakages Inspect the exterior of the engine to make sure there is no leakage from joints Check to make sure the engine does not produce abnormal noise or vibrations Inspect the engine for abnormal operating sound and vibrations such as knocking Check to make sure the exhaust gas is normal color Check the color of the exhaust gas discharged from the exhaust pipe Note Regarding ...

Страница 40: ...e engine stops locate the cause of the problem and correct the problem before restarting the engine Continuing engine operation without correcting the problem can result in a serious accident For stopping the engine follow the instructions since stopping procedure varies depending upon the models and its installed equipment Emergency Stop When stopping the engine by pulling the speed con trol leve...

Страница 41: ...enty of water and seek medical attention LLC is a potent alkaline solution Do not drink or allow it to enter your eyes Always wear protective gear Wear protective gear such as a hardhat face shield work clothes safety shoes dust protective mask etc Be sure to wear protective goggles and other pro tective devices when handling compressed air Compressed air can cause personal injury if han dled care...

Страница 42: ...ch work day This prevents water from mixing with fuel in the tank and gives time for dust and water to separate and settle at the bottom of the tank Before removing the caps from the drum and tank clean the areas around the caps thoroughly Also clean your hands and the hose used for refueling When a hand operated pump is used be careful not to pump water or sediment accumulated at the bottom of th...

Страница 43: ...63 in 2 or lower 40 C 104 F 16 0 mm2 s 0 0248 in 2 or lower 30 C 86 F Sulfur content 0 2 weight or lower 1 0 weight or lower JISK25410 05 weight same as diesel fuel is rec ommended Water and sediment 0 1 volume or lower JIS K2275 Ash 0 03 weight or lower JIS K2272 Copper plate corrosion 100 C 212 F 3 hrs No 3 or lower No 3 or lower ASTM No 3 JIS K2513 Discoloration No 3 Specific gravity 15 C 59 F ...

Страница 44: ...ause increased wear and reduced output Recommended oil viscosity is SAE 15W 40 for all seasons Handling Engine Oil Before pouring engine oil into the engine stop the engine and make sure there are no flames near the engine Oil leaked or spilled onto hot surfaces or electrical components can cause a fire Wipe any spilled oil immedi ately and thoroughly After pouring engine oil close filler cap sure...

Страница 45: ...f LLC should enter eyes flush immediately with plenty of water and seek medical attention Be sure to use long life coolant LLC as coolant because it prevents not only freezing of coolant but also rusting of the cooling system Use an all season non amine type LLC Table 4 3 Water quality standards Item Chemical symbol Unit Recommended Limit Main adverse effect Corrosion and rust Scale formation pH 2...

Страница 46: ...urpose engine In an emer gency engine replace coolant every 2 years LLC concentration When determining the LLC concentration provide a margin of 5 C 41 F below the expected lowest temperature in your region Maintain the LLC con centration between 30 and 60 throughout the year LLC of less than 30 concentration does not pro vide sufficient corrosion protection If the LLC con centration is as low as ...

Страница 47: ...in more corro sion than when plain soft water is used This prob lem is often caused by the use of inappropriate LLC Examples of Abnormalities Caused by LLC Pitting on iron parts Amines are generally effective in suppressing the rusting of ferrous metals but they are said to cause problems for copper parts Dissolved copper copper corrosion in the cooling system deposits on iron parts and copper dep...

Страница 48: ... well as quality of fuel and oil in use When replacing filters use genuine Mitsubishi parts Do not wash and reuse cartridge type filters Always use new filters When filters are changed inspect the removed fil ters for metal particles If metal particles are found consult a Mitsubishi dealer Electrical Parts Do not splash water on electrical parts Water can cause electrical leakage and short circuit...

Страница 49: ...zing of cooling water and rusting of the engine cooling system Note Regarding coolant refer to Coolant 4 5 Battery Never use flames near the battery and be care ful to handle battery since flames can cause an explosion If electrolyte is spilled on skin or clothes wash immediately with lots of water If electrolyte gets into your eyes flush immediately with lots of fresh water and consult a physicia...

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Страница 51: ...erform all daily inspection and maintenance items in an accordance with the following 3 categories Periodic maintenance chart for regular use engine When the engine is used as a regular use engine perform the periodic inspection and maintenance in accordance with the Periodic Maintenance Chart for Engine in Regular Use Periodic maintenance chart for emer gency engine When the engine is used as an ...

Страница 52: ...r supply An engine operated under a fluctuating load throughout a day for supplying rated electric power in lieu of commercial power General definition of emergency engine An engine used for emergency power generation such as main power supply and commercial power supply General definition of general purpose engine An engine used for a purpose other than power generation for example to drive a pum...

Страница 53: ...s Inspection of V belt and Adjustment of Belt Tension 6 2 Changing Fuel Filters 6 5 Every 2000 ser vice hours Changing V belt 6 2 Inspection of Fuel Control Linkage Ball Joints 6 4 Inspection and Adjustment of Valve Clearances Also check the valve mechanisms at the same time Inspection and Adjustment of Fuel Injection Timing Changing Fuel Injection Nozzle Tips Check the spray condition and adjust ...

Страница 54: ...ection and Testing of Fuel Injection Pump Replace parts if necessary Inspection and Testing of Governor Replace parts if necessary Correction or Replacement of Protective Devices High coolant temperature low oil pressure overspeeding starting failure water supply failure undervoltage overvoltage overcurrent low coolant level in tank low fuel level in tank low air pressure in tank etc Checking the ...

Страница 55: ...ng Engine Maintenance Operation Operate the engine with more than 1 2 load for 15 to 30 minutes Check for ease of starting color of exhaust smoke abnormal vibration abnormal noise abnormal smell and gauge indication oil pressure gauge coolant temperature gauge oil temperature gauge exhaust temperature gauge tachometer etc Check fuel injection pump and hydraulic and electronic governor rack movemen...

Страница 56: ...lve Check air compressor drive belt Checking Protection Devices for Proper Operation High coolant temperature low oil pressure overspeeding starting failure water sup ply failure undervoltage overvoltage overcurrent low coolant level in tank low fuel level in tank low air pressure in tank etc Checking Auxiliary Devices for Proper Operation Engine control fuel transfer pump governor motor room vent...

Страница 57: ...ylinderliners and crankshaft If the parts for No 1 and No 2 cylinders are found defective change the parts for all cylinders Replacement of Damper Repair or Replacement of Oil Pump Replacement of Fuel Injection Nozzle Tips Adjust the spray condition and spray pressure after replacement Replacement of Rubber Parts and O rings Replacement of Unit Seal Oil Seal of the Water Pump Disassembly and Inspe...

Страница 58: ...of Air Tank 6 15 First 250 ser vice hours for new engine Inspection and Adjustment of Valve Clearances Check the valve mechanism and parts at the same time Every 1000 ser vice hours or every 2 years Changing Fuel Filters 6 5 Cleaning Air Starter Strainer 6 15 Change zinc rods Every 2000 ser vice hours or every 3 years Retightening External Bolts and Nuts Inspection and Adjustment of Valve Clearanc...

Страница 59: ...ailure undervoltage overvoltage overcurrent low coolant level in tank low fuel level in tank low air pressure in tank etc Checking the Auxiliary Devices for Proper Operation Water heater oil heater oil priming pump fuel transfer pump governor motor etc Every 2 years Changing Coolant 6 9 When required Bleed the fuel system 3 2 Cleaning Pre Cleaner 6 11 Cleaning and Inspecting Air Cleaner Element 6 ...

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Страница 61: ...ct a Mitsubishi dealer Before starting the engine clean the top surface of the battery with wet cloth Inspect the engine exterior as described below 1 Make sure there is no combustible material near the engine or battery Also check to make sure the engine and battery are clean If combustible materials or waste are found near the engine or battery remove them 2 Check the entire engine for leakage o...

Страница 62: ...is appropriate 3 To adjust the belt tension turn the adjusting rod Adjusting the V belt tension Alternator side 1 Remove the alternator front cover and belt cover 2 Loosen all retaining bolts on the alternator and adjusting rod 3 Loosen the upper and lower lock nuts on the adjusting rod Note Note that the lower nut on the adjusting rod has left hand threads 4 Turn the adjusting rod to adjust the V...

Страница 63: ...bserve the following suggestions and provide sufficient ventilation for the vibration damper and equipment In the case of viscous damper of regular use engine make sure the temperature of the outside damper sur face does not exceed 90 C 194 F after the engine is operated at the rated output for 1 hour and emer gency engine for 100 C 212 F In the case of viscous rubber damper of regular use engine ...

Страница 64: ...are no flames near the engine Wipe any spilled fuel completely Spilled fuel can ignite and cause fire Do not remove the strainer when filling the fuel tank Use fuel specified in Fuel 4 2 1 Close the valve on the fuel supply line from the fuel tank 2 Arrange a fuel receiving can 3 Drain all fuel from the fuel tank through the drain cock located on the bottom of the fuel tank into the fuel receiving...

Страница 65: ...fuel to the gaskets on the new fuel filter 7 Install the fuel filter When the gasket contacts the mounting surface on the filter bracket fur ther rotate 3 4 to a full turn Do not use the filter wrench for the installation of fuel filters Do not dent or scratch the fuel filter surfaces 8 After installing the new fuel filter bleed the fuel system Note Regarding bleeding of the fuel system refer to B...

Страница 66: ... Place an oil receiving tray under the oil filters 3 Using the provided filter wrench remove each oil filter Note Check the filter elements in the removed oil filter for metal particles If metal particles are found consult a Mitsubishi dealer Also change the oil filters whenever the filter alarm turns on 4 Wipe oil from the oil filter mounting surface on the filter alarm bracket with a cloth 5 Che...

Страница 67: ...n the OFF position and operate the starters 9 Check the oil level with the oil level gage again and add oil if necessary Inspection of Engine Oil for Mixing of Fuel and Water Sample 1 to 2 L 0 26 to 0 53 U S gal of engine oil and check for abnormal odor and discoloration to deter mine the mixing of fuel and water If fuel is mixed with the engine oil the oil will smell like fuel If water is mixed w...

Страница 68: ... center bolt 4 Remove the center bolt and removet the case from the bracket Remove the used element from the case 5 Put a new element in the case using the center bolt 6 Install the case to the filter bracket Tighten the center bolt 7 Install the oil pipe to the center bolt 8 Install the drain plug 9 Remove the air vent plug and fill up the filter with engine oil Install the air vent plug 10 After...

Страница 69: ...aining coolant immediately after engine operation let the engine idle at low speed for 5 to 6 minutes and lower the coolant temperature to 70 to 80 C 158 to 176 F 2 Open the radiator cap 3 Place coolant receiving cans under the drain cocks on the engine and water pump and open the drain cocks to drain coolant Cleaning the cooling system 1 Close the drain cocks or plug 2 Pour a cleaning solution no...

Страница 70: ...sion tank cap securely 6 Crank the engine for about 10 seconds or less using the starters Wait for about 1 minute then repeat the above cranking operation several times to remove air from the water pump To crank the engine shut off the fuel supply to the engine keep the control rack of the fuel injection pump in the OFF position and operate the starters 7 Check the coolant level in the expansion t...

Страница 71: ...remely hot for a while Conduct work after the exhaust muffler cools Remove the drain plug and allow water to drain from the exhaust muffler Cleaning Pre Cleaner Do not service the air cleaner while the engine is running Maintenance of the air cleaner while the engine is in operation can cause dust to enter the engine and result in rapid wear of parts leading to a shorter service life Remove dust f...

Страница 72: ... other contaminants 4 To remove dust stuck on the element blow dry compressed air onto the outside surface from a distance Blow compressed air on the inside sur face toward outside along the net pattern Then blow compressed air on the outside and inside surface again 5 After cleaning place a light bulb in the element to check for damage pinholes and worn sec tions If damage is found in the element...

Страница 73: ...arters are dusty blow dirt using com pressed air Note If the starters are defective consult a Mitsub ishi dealer Inspection of Alternator 1 Check the exterior of the alternator for damage 2 If the alternator is dusty blow dirt using com pressed air 3 Remove the V belt and turn the pulley to make sure it rotates smoothly Note If the alternator is defective consult a Mitsub ishi dealer fig 6 27 Insp...

Страница 74: ...een the LOWER LEVEL and UPPER LEVEL lines If there are no level lines on the battery make sure that the fluid surface is about 10 to 15 mm 0 394 to 0 591 in above the top edges of the plate If the fluid level is lower remove the caps and add distilled water to the proper level Note When pouring fresh electrolyte pour the fluid carefully Checking specific gravity of electrolyte Check the specific g...

Страница 75: ... start abruptly and cause an unexpected accident 1 Close the starting air handle of the air tank 2 Open the drain valve handle located under the drain valve on the front side of the tank to drain accumulated water from the tank Note The amount of drained water can vary depending on the relative humidity and air consumption 3 Close the drain valve handle after draining water 4 Open the starting air...

Страница 76: ...e handle of the air strainer tank 2 Remove the drain plug and drain water from the air strainer compressor 3 Install the drain plug after draining water 4 Open the starter valve handle of the air starter tank slowly Note The air compressor model and shape differ on the type of the engine fig 6 34 Air starter compressor Drain plug ...

Страница 77: ...e on the terminals of the starters and alternator and seal the openings Cover these sections with polyethylene sheet or processed polyethylene paper and place desic cants in the polyethylene covers 10 Disconnect cables from the battery terminals and charge the battery Clean the terminals apply a thin coat of grease and store them in a cool and dry room 11 Cover the entire engine Note a Store the e...

Страница 78: ...te the starters 11 Make sure the engine oil pressure rises Starting the engine 1 Start the engine With regards to starting the engine refer to Prepa ration for Operation Pre Start Inspection 3 8 2 Conduct a warm up operation to circulate oil throughout the engine 3 Apply load and increase the engine speed to the rated speed Storing Engine in Operable Con dition for More Than 3 Months When the engi...

Страница 79: ...the angle formed by slings attached to hangers within 60 If the angle exceeds this limit excessive load is applied on the hang ers and may damage the hangers Attach wire ropes to the hanger after remov ing the pipe cover and the insulator near the hanger for lifting To prevent wire ropes from contacting the engine place a cloth or other soft padding to prevent damage to the engine and wire ropes f...

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Страница 81: ...lose attention to the disassembly sequence so that you can reassemble the component efficiently Notes Regarding Contamination Dust and foreign particles are the most common cause of rapid wear of parts When disassembling a component take measures to prevent dust and foreign particles from entering the component being disassembled Notes Regarding Parts Handling Handle parts carefully When replacing...

Страница 82: ...el filters Refer to Changing Fuel Filters 6 5 Faulty fuel feed pump Consult a Mitsubishi dealer Faulty fuel injection pump Consult a Mitsubishi dealer Engine mechanical Faulty moving parts Interference between valves and pistons or for eign items in cylinders Consult a Mitsubishi dealer Table 9 2 Starters Crank But Engine Does Not Start Problem Cause Remedy Engine does not start Fuel system Empty ...

Страница 83: ...ler Faulty fuel injection pump Consult a Mitsubishi dealer Faulty fuel injection nozzles Consult a Mitsubishi dealer Incorrect fuel injection timing Consult a Mitsubishi dealer Low compression pressure worn cylinder liners worn piston rings etc Consult a Mitsubishi dealer Table 9 4 Exhaust Smoke is White or Blue Cause Remedy Excessive amount of engine oil Maintain correct oil level Refer to Lubric...

Страница 84: ...ealer Table 9 6 Fuel Consumption is High Cause Remedy Faulty fuel feed pump Consult a Mitsubishi dealer Faulty fuel injection pump Consult a Mitsubishi dealer Incorrect fuel injection timing Consult a Mitsubishi dealer Improper fuel Use proper fuel Refer to Fuel 4 2 Low compression pressure worn piston liners worn piston rings etc Consult a Mitsubishi dealer Insufficient intake air improper ventil...

Страница 85: ...the fuel system refer to Bleed the fuel system 3 2 4 Restart the engine Note Regarding starting of the engine refer to Preparations for Operation Pre Start Inspection 3 8 Table 9 8 Engine Overheats Cause Remedy Radiator heat exchanger leakage Consult a Mitsubishi dealer Low coolant level Add coolant Faulty water pump Consult a Mitsubishi dealer Faulty thermostat Consult a Mitsubishi dealer Table 9...

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Страница 87: ...tsubishi PS6 type 2 Fuel filter Cartridge type paper element spin off type Fuel injection nozzle Hole type Initial fuel injection pressure MPa kgf cm2 psi 34 3 350 4979 Lubricating system Forced circulation type pressure feed by oil pump Lubrication oil Class CD or CF oil API service classification Engine oil capacity liter U S gallon Oil pan Approx 150 39 63 Whole engine Approx 200 52 84 Oil filt...

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