Mitsubishi S4S-DT Operation & Maintenance Manual
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Mitsubishi S4S-DT Operation & Maintenance Manual

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OPERATION &
MAINTENANCE MANUAL
199610-29120
The operator and supervisor are requested to read this Oper-
ation and Maintenance Manual carefully before operating the
engine or conducting inspection and maintenance.
Never operate the engine or conduct maintenance work with-
out completely understanding this manual.
July 2009
Pub. No. 99610-29120

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  • Page 1 OPERATION & MAINTENANCE MANUAL 199610-29120 The operator and supervisor are requested to read this Oper- ation and Maintenance Manual carefully before operating the engine or conducting inspection and maintenance. Never operate the engine or conduct maintenance work with- out completely understanding this manual. July 2009 Pub.
  • Page 2 INTRODUCTION This operation and maintenance manual contains detailed operation, inspection and maintenance information for engines from Mitsubishi Heavy Industries, Ltd. Please read this manual thoroughly before proceeding with operation, inspection, and maintenance work for correct use and servicing. Failure to follow directions in this manual may result in serious accidents.

  • Page 3: Limited Warranty

    FOREWORD Limited warranty Mitsubishi Heavy Industries, Ltd. will repair or replace parts returned to us when we judges that the parts are defec- tive in material and/or workmanship after conducting inspection. Mitsubishi Heavy Industries, Ltd.'s warranty is limited to the compensation work of repair or replacement of parts.

  • Page 4: Warranty Coverage

    Protection Agency. Warranty coverage Mitsubishi Heavy Industries, Ltd. warrants to the first owner and each subsequent purchaser of a new non-road die- sel engine that the emission control system of your engine: is designed, built and equipped so as to conform at the time of sales with all applicable regulation of the U.S. Envi- ronmental Protection Agency.If the vehicle in which the engine is installed is registered in the state of California, a...
  • Page 5 MANUFACTURER'S WARRANTY COVERAGE: The 2008 and later heavy-duty off-road engines are warranted for the Warranty Period. If any emission-related part on your engine is defective, the part will be repaired or replaced by Mitsubishi Heavy Industries, Ltd. OWNER'S WARRANTY RESPONSIBILITIES: As the heavy-duty off-road engine owner, you are responsible for the performance of the required maintenance...
  • Page 6 Subsection (e) shall be warranted for the warranty period defined in Subsection (b) (2). If any such part fails during the period of warranty cove rage, it shall be repaired or replaced by Mitsubishi Heavy Industries, Ltd. according to Subsection (4) bel o w. Any such part repaired or replaced under the war- ranty shall be warranted for the remaining warranty period.
  • Page 7 Heavy Industries, Ltd. shall not be liable to warrant failures of warranted parts caused by the use of a non- exempted add-on or modified part. (11) The Air Resources Board may request and, in such case, Mitsubishi Heavy Industries, Ltd. shall provide, any documents which describe that Mitsubishi Heavy Industries, Ltd.'s warranty procedures or policies.
  • Page 8 (F) Any other part with the primary purpose of reducing emissions or that can increase emission during fail- ure without significantly degrading engine performance. (e) Mitsubishi Heavy Industries, Ltd. shall furnish with each new engine written instructions for the maintenance and use of the engine by the owner.

  • Page 9: Important Information

    If you lost or damaged this manual, obtain a new tors.Also add safety, caution and operating signs that describe the original warning label statements in the copy at a dealer of Mitsubishi Heavy Industries, Ltd. native language of the operators. as soon as possible.
  • Page 10 FOREWORD Warning indication The following means are used to call the attention of the operators and maintenance personnel to potential dangers of the engine. Warning statements in the manual Warning labels affixed on the engine Warning statements The warning statements in this manual describe potential danger in operating, inspecting or maintaining the engine, using the following 5 classifications to indicate the degree of potential hazard.
  • Page 11 FOREWORD Units of measurement Measurements are based on the International System of Units (SI), and they are converted to the metric system units in this manual using the following conversion rates. Pressure :1 MPa = 10.197 kgf/cm 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 = 0.75 cmHg...

  • Page 12: Table Of Contents

    CONTENTS Do not add coolant immediately after a sudden Chapter 1 stop due to overheating........1-5 BASIC SAFETY PRECAUTIONS Avoid immediate restart after abnormal stop..1-5 Fire and explosions ......1-1 Avoid continuous engine operation at low oil Keep flames away..........1-1 pressure ............
  • Page 13 CONTENTS Chapter 3 Chapter 6 OPERATION COOLANT Preparations for operation ....3-1 Recommended water for coolant ..6-1 Long life coolant (LLC)......6-1 Engine external - Inspect ......... 3-1 Battery electrolyte level - Inspect ..... 3-1 Genuine LLC........6-1 Fuel tank oil level - Check ........ 3-2 Other brand LLCs .......
  • Page 14 TROUBLESHOOTING Fuel tank - Drain water........8-2 General precautions......11-1 Fuel filter - Drain water........8-3 Contact a dealer of Mitsubishi Heavy Fuel system (in-line type fuel injection pump) Industries, Ltd. for repair service ....11-1 - Bleed air............8-4 Considerations before work ......
  • Page 15 CONTENTS Fig. 8-6 Fuel filter - Bleed air ......8-4 List of illustrations Fig. 8-7 Fuel injection pump - Bleed air....8-4 Fig. 2-1 Engine left view ........2-1 Fig. 8-8 Fuel filter - Bleed air (1)......8-5 Fig. 2-2 Engine right view ........2-1 Fig.
  • Page 16 CONTENTS List of tables Table 3-1 Standard values at rated speed....3-5 Table 4-1 Recommended limit and use limit of fuel property..........4-2 Table 5-1 Engine oil properties ....... 5-4 Table 6-1 Water quality standards ......6-1 Table 6-2 LLC specification ........6-3 Table 6-3 Recommended LLC concentration ..

  • Page 18: Basic Safety Precautions Fire And Explosions

    Chapter 1 BASIC SAFETY PRECAUTIONS Fire and explosions Keep flames away Use explosion-proof lighting Do not use flames near the engine (in apparatus the engine room). Fuel vapor or other When inspecting fuel, engine oil, coolant, battery elec- gas can catch fire and produce dan- trolyte, etc., use a flameproof light.

  • Page 19: Stay Clear Of All Rotating And Moving Parts

    Chapter 1 BASIC SAFETY PRECAUTIONS Stay clear of all rotating and moving parts Install protective covers around Lockout and tagout rotating parts Be sure to lockout and tagout before starting inspec- Make sure the protective covers of tion and maintenance. the engine are correctly installed.

  • Page 20: Be Careful Of Exhaust Fume Poisoning

    Chapter 1 BASIC SAFETY PRECAUTIONS Be careful of exhaust Be careful of falling down fume poisoning Lift engine carefully To lift the engine, use slings capable Operate engine in a well-venti- of supporting the weight of the lated area engine. If the engine is installed in an Attach the wire rope to the hangers enclosed area, and the exhaust gas...

  • Page 21: Protect Ears From Noise

    Chapter 1 BASIC SAFETY PRECAUTIONS Protect ears from noise Be careful of burns Wear ear plugs Do not touch the engine during Always wear ear plugs when entering or immediately after operation the machine room (engine room). To avoid burns, do not touch the Combustion sound and mechanical engine during or immediately after noise generated by the engine can...

  • Page 22: Be Careful When Handling Fuel, Engine Oil Or Llc

    Chapter 1 BASIC SAFETY PRECAUTIONS Be careful when handling When abnormality occurs fuel, engine oil or LLC Do not add coolant immediately after a sudden stop due to over- Use only specified fuel, engine heating oil and LLC If the engine stops suddenly or if you have no choice Use fuel, oil and LLC specified in this manual, and but stop the engine suddenly due to overheating, do handle them carefully.

  • Page 23: Service Battery

    Chapter 1 BASIC SAFETY PRECAUTIONS Service battery Handle the battery correctly Never use flames or allow sparks to generate near the battery. The bat- tery releases flammable hydrogen gas and oxygen gas. Any flames or sparks in the vicinity could cause an explosion.

  • Page 24: Other Cautions

    If there is a need to modify the engine, contact a Failure to conduct the specified inspections may dealer of Mitsubishi Heavy Industries, Ltd. cause various engine problems, damage to parts, and Observe safety rules at work serious accidents.

  • Page 25: Conduct Cooling Operation Before Stopping The Engine

    Chapter 1 BASIC SAFETY PRECAUTIONS Conduct cooling operation Use of tools optimum for each before stopping the engine work Before stopping the engine, let it idle in low gear for 5 Always keep in mind to select most appropriate tools to 6 minutes to cool down.

  • Page 26: Name Of Parts

    Chapter 2 NAME OF PARTS Engine external diagrams The external diagram is for the standard type of the engine. The installed equipment and shapes differ according to the engine type. S4S in-line type fuel injection pump left view Governor Fuel filter Fuel injection nozzle Stop solenoid Air inlet...
  • Page 27 Chapter 2 NAME OF PARTS S4S-DT in-line type fuel injection pump left view Governor Stop solenoid Fuel filter Fuel injection nozzle Glow plug Water pump (coolant inlet) Oil cooler Rear Front Fuel return port Coolant drain plug Fuel injection pump...
  • Page 28 Chapter 2 NAME OF PARTS S4S distoributor type fuel injection pump left view Fuel inlet Fuel injection nozzle Fuel filter Air inlet Fuel return port Water pump (coolant inlet) Magnetic valve (stop solenoid) Front Rear Coolant drain plug Crankshaft pulley Oil level gauge Flywheel Fuel injection pump...
  • Page 29 Chapter 2 NAME OF PARTS S4S-DT distoributor type fuel injection pump left view Fuel inlet Fuel injection nozzle Fuel filter Glow plug Oil cooler Fuel return port Water pump (coolant inlet) Magnetic valve (stop solenoid) Rear Front Coolant drain plug...
  • Page 30 Chapter 2 NAME OF PARTS S6S in-line type fuel injection pump left view Governor Fuel filter Stop solenoid Air inlet Fuel injection nozzle Water pump (coolant inlet) Rear Front Coolant drain plug Fuel injection pump Fuel feed pump Oil filter Fuel inlet Flywheel Fuel return pipe...
  • Page 31 Chapter 2 NAME OF PARTS S6S distoributor type fuel injection pump left view Fuel inlet Magnetic valve Air inlet Fuel filter (stop solenoid) Fuel injection nozzle Fuel return port Water pump (coolant inlet) Coolant drain plug Rear Front Oil filter Fuel injection pump Flywheel Oil level gauge...
  • Page 32 Chapter 2 NAME OF PARTS S6S-T distributor type fuel injection pump left view Fuel injection nozzle Magnetic valve (Stop solenoid) Oil cooler Fuel filter Water pump Coolant (Coolant inlet) drain plug Front Rear Fuel injection pump Oil filter Relief valve Flywheel Oil level gauge Oil drain plug...

  • Page 33: Equipment And Instrument

    Chapter 2 NAME OF PARTS Equipment and instrument The installed equipment and shapes differ on the engine type. Starter switch The starter switch is used to start the engine. HEAT HEAT When the key is turned to this position, the glow plugs START become hot and allow easy startup of a cold engine.

  • Page 34: Water Temperature Meter And Thermo Unit

    Chapter 2 NAME OF PARTS Water temperature meter and thermo unit The engine coolant temperature detected by the thermo unit is displayed by the water temperature meter. When the water temperature meter shows 95°C [203°F], idle the engine in low gear until the tempera- 80 120 ture becomes normal.

  • Page 35: Stop Solenoid

    Chapter 2 NAME OF PARTS Stop solenoid The stop solenoid operates for normal shutdown of engine operation. The stop solenoid moves the rack of fuel injection Stop solenoid (ETR) pump to cut the fuel, and consequently stops the engine. Two types of stop solenoids are available. RUN OFF (ETS: Energized To Stop) type Not energized while the engine is running.

  • Page 36: Engine Protection Devices

    Stop the engine if the protection device is activated, investigate the cause of abnormality and restore it. When the cause of abnormality is unknown, contact a dealer of Mitsubishi Heavy Industries, Ltd. The installed protection devices, type (set value) or shapes varies according to the specifications.

  • Page 38: Preparations For Operation

    Preparations for operation Should an engine abnormality be observed during operation, stop the engine and correct the problem, or contact a dealer of Mitsubishi Heavy Industries, Ltd. Always conduct the following inspection before starting the engine. Engine external - Inspect Be sure to keep combustible materials away from the engine, especially from the hot engine parts such as exhaust manifolds, or the battery.

  • Page 39: Fuel Tank Oil Level - Check

    Chapter 3 OPERATION Fuel tank oil level - Check When working around fuel, make sure there are no open flames, heaters or other fire hazards. Wipe off any spilled fuel completely.Spilled fuel can ignite and cause a fire. Do not remove the strainer when filling the fuel tank. For fuel to be used, refer to "FUEL"...

  • Page 40: Coolant Level - Check

    Chapter 3 OPERATION Coolant level - Check Stand the lever to Turn the cap about Remove the radiator filler cap only after the engine the upright position half a turn has cooled to room temperature. Place a waste cloth over the cap, and loosen the cap about a half-turn or stand the lever to the upright position to release inter- nal pressure.

  • Page 41: Starting

    Chapter 3 OPERATION Starting The starting method changes based on the application and specifications.Start the engine according to the specified procedure. Before starting the engine, check to make sure no one is near the engine and that tools are not left on or near the engine.In a loud voice, notify people in the area when starting the engine.

  • Page 42: Operation

    Chapter 3 OPERATION Operation Cautions when operating Inspection during operation Carefully check the exterior of engine such as piping joints for leaks. Do not approach rotating parts during operation. Check for abnormal engine noises or vibrations such Entanglement by rotating parts can cause serious as knocking.

  • Page 43: Stopping

    Engine stopping method may differ depending on the specifications. Follow the instructions according to the specifications of the equipment. Inspection after stopping Inspect the engine for fuel, oil or coolant leakage. If any leakage is found, repair the leakage or contact a dealer of Mitsubishi Heavy Industries, Ltd.

  • Page 44: Fuel

    Chapter 4 FUEL Recommended fuel Use a fuel specified in this manual only. Do not refill the fuel tank more than the specified level, as it may Diesel fuel result in a fire. equivalent Use a diesel fuel equivalent for "JIS K 2204 diasel fuel".

  • Page 45: Table 4-1 Recommended Limit And Use Limit Of

    Chapter 4 FUEL Table 4-1 Recommended limit and use limit of fuel property Properties Recommended limits Use limits Test method JIS K 2265 :2007 Flash point 50°C [122°F] or higher 45°C [113°F] ISO 3769 ISO 2719 Initial boiling point 170°C [338°F] or higher JIS K 2254 :1998 Distillation...
  • Page 46 Chapter 4 FUEL Table 4-1 Recommended limit and use limit of fuel property Properties Recommended limits Use limits Test method Foreign materials JIS B 9931 :2000 (foreign materials at engine fuel 5.0 mg/liter or less ISO 4405 inlet) Lubricity: MWSD (Measured mean 460 μm [0.02 in.] or less Wear Scar Diameter) by HFRR (calculated wear scar diameter at...

  • Page 48: Engine Oil

    Chapter 5 ENGINE OIL Recommended engine oil Use only the engine oils recommended in this manual. Never use other oils. The use of inappropriate or inferior oils will result in sticking of piston rings, seizure between piston and cylinder, or premature wear of bearings and moving parts, and significantly shortens the service life of the engine.

  • Page 49: Engine Oil Performance Requirements

    Chapter 5 ENGINE OIL Abrasion powder in the engine oil also accelerates Engine oil performance deterioration as it can catalyze oxidation reaction. requirements Dust and dirt entered from outside deteriorate the en- Engine oil requires the following performances. gine oil as well. Contamination and deterioration pro- Excellent dispersion performance (the ability of oil to cess accelerates with operation time.

  • Page 50: Definition Of Properties Of Engine Oil

    Chapter 5 ENGINE OIL Definition of properties of engine oil Viscosity Water content Viscosity is a basic physical property of engine oil and Water in oil promotes corrosion/wear, and decreases is considered as the most important aspect when eval- lubricity in sliding parts. uating oil.

  • Page 51: Service Limits Of Engine Oil

    Chapter 5 ENGINE OIL Service Limits of engine oil Engine oil degrades through the use and by lapse of time. To determine the timing of engine oil replacement, analyze the used oil, and understand the condition of oil deterio- ration and oil defacement. It is also required to compare the oil analysis results and the engine analysis results including inside contamination and wear condition of engine, and to consider the engine operating condition.

  • Page 52: Recommended Water For Coolant

    Be sure to use Mitsubishi Heavy Industries, Ltd. genuine long life coolant (LLC) "GLASSY long life coolant (Ethyl- ene glycol type)" or "PG GLASSY long life coolant (Non-amine type)" as coolant. When using other brand LLCs by necessity, be sure to use the LLC that meets the specification in Mitsubishi Heavy Industries, Ltd.

  • Page 53: Other Brand Llcs

     LLC shall be a homogeneous liquid. GLASSY long life coolant (Non-amine type)", be sure  Engine cooling system shall not receive troubles to use the LLC which meets specification in Mitsubishi such as corrosions and precipitation products etc. by Heavy Industries, Ltd.

  • Page 54: Llc Specification

    Chapter 6 COOLANT LLC specification LLC shall examine according to JIS K2234 section 7 (examination methods), and satisfy this specification. General matters and the sample to the examination is shown in JIS K2234. Table 6-2 LLC specification Property Standard External Not precipitation Minimum 1.112 g/cm [69.4199 lb/ft...
  • Page 55 Chapter 6 COOLANT Table 6-2 LLC specification Property Standard Aluminum ±0.60 mg/cm Cast iron ±0.30 mg/cm Steel ±0.30 mg/cm Mass change Brass ±0.30 mg/cm Test piece Solder ±0.60 mg/cm Circulation Copper ±0.30 mg/cm metallic causticity (88±3°C External of test piece after the Not corrosion on surface excluding between [190±37°F], examination...

  • Page 56: Maintenance Of Llc

    Failure to renew LLC may cause malfunctions due to performance degradation of preventing rust and cavitation. The coolant mixed with LLC which Mitsubishi Heavy Industries, Ltd. recommended expires in 2 years. Be sure to change coolant at least once every 2 years.

  • Page 57: Importance Of Llc

    Chapter 6 COOLANT Importance of LLC Examples of abnormali- Today's trend is toward smaller and lighter engines ties caused by LLC (amine offering greater output, lower fuel consumption and type) lower exhaust emission levels. Conditions to which engine coolant is subjected, Pitting of iron parts therefore, are becoming severer due to longer operat- Amines are generally effective in suppressing the rust-...

  • Page 58: Maintenance Schedule

    Check the operating record of the engine to determine the most appropriate service intervals. (Feel free to consult a dealer of Mitsubishi Heavy Industries, Ltd. regarding service intervals.) Service the items at multiples of the original requirement. For example, at 1000 service hours, also service those items listed under every 250 service hours and every 50 service hours.

  • Page 59: Maintenance Schedule

    Chapter 7 MAINTENANCE SCHEDULE Maintenance schedule Table 7-1 Maintenance schedule Interval and Service item Page Fuel tank - Drain water Every 50 service hours Air cleaner - Check 8-14 First 50 service hours for Engine oil and Oil filter - Replace a new or overhauled Bolts and nuts on the engine - Retighten engine...

  • Page 60: Periodic Inspection And Maintenance Procedures

    Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Basic engine Belt and belt tension - Inspect and Adjust If defects such as cuts or surface separations are found during inspection, replace the belt. Keep oil and grease away from the belt. They may cause the belt to slip and shorten the service life. Excessive belt tension can cause rapid wear of the alternator bearing and shorten the service life of the belt.

  • Page 61: Fuel System

    Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Fuel system Fuel tank - Drain water When working around fuel, make sure there are no open flames, heaters or other fire hazards. Wipe off any spilled fuel completely. Spilled fuel can ignite and cause a fire. Do not remove the strainer when filling the fuel.

  • Page 62: Fuel Filter - Drain Water

    Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Fuel filter - Drain water When handling fuel, make sure there are no open flames or other fire hazards near the engine. Wipe off any spilled fuel completely.Spilled fuel can ignite and cause a fire. Drain water for the fuel filter if the warning of water draining for fuel filter is occurred.

  • Page 63: Fuel System (In-Line Type Fuel Injection Pump) - Bleed Air

    Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Fuel system (in-line type fuel injection pump) - Bleed air While depressing, When fuel overflow from the air vent plug, wipe thor- turn coockwise Turn counter- Move cap up oughly with a cloth. Spilled fuel causes fire hazard and down clockwise After bleeding, lock the priming pump securely.If the...

  • Page 64: Fuel System (Distributor Type Fuel Injection Pump) - Bleed Air

    Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Fuel system (distributor type fuel injection pump) - Bleed air When handling fuel, make sure there are no open flames or other fire hazards near the engine. When fuel overflows from the air vent plug, wipe thoroughly with a cloth.Spilled fuel can ignite and cause a fire. After replacing fuel filter or draining water from fuel fil- ter, or when running out of fuel, bleed the fuel system as follows:...

  • Page 65: Fuel Filter (In-Line Type Fuel Injection Pump) - Replace

    Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Fuel filter (in-line type fuel injection pump) - Replace Air vent plug When handling fuel, make sure there are no open Filter bracket flames or other fire hazards near the engine. Wipe off any spilled fuel completely.

  • Page 66: Fuel Filter (Distributor Type Fuel Injection Pump) - Replace

    Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Fuel filter (distributor type fuel injection pump) - Replace fuel filter. When handling fuel, make sure there are no open Body flames or other fire hazards near the engine.Wipe off any spilled fuel completely.Spilled fuel can ignite and Level sensor cause a fire.

  • Page 67: Lubricating System

    When draining oil or changing the oil filter, wear gloves. Hot engine oil and parts may cause burns. Do not dump waste oil. It is forbidden by law. For disposal of waste oil, consult a dealer of Mitsubishi Heavy Indus- tries, Ltd.

  • Page 68: Engine Oil - Refill

    Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Engine oil - Refill 1. Make sure that the oil drain plug is tightened. Oil filler 2. Remove the oil filler cap. Oil level gauge 3. Fill the engine oil pan with specified engine oil to the specified level.

  • Page 69: Oil Filter - Change

    Note: Check the element of the oil filter that has been Apply engine oil removed. If metal particles are found, consult a dealer of Mitsubishi Heavy Industries, Ltd. 4. Thoroughly wipe off oil on the mounting surface of oil filter with a waste cloth.

  • Page 70: Cooling System

    Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Cooling system Coolant - Change Stand the lever to Turn the cap about Remove the radiator filler cap only after the engine the upright position half a turn has cooled to room temperature. Place a waste cloth over the cap, and loosen the cap about a half-turn or stand the lever to the upright position to release inter- nal pressure.

  • Page 71: Radiator Coolant Level

    Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Cooling system - Clean Clean the cooling system when operating the engine Water drain plug first time, or restarting the engine after storage with coolant drained. 1. Close coolant drain cocks and plugs. 2.

  • Page 72: Radiator Fins - Check And Clean

    Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Radiator fins - Check and Clean When handling compressed air, wear safety goggles, a hardhat, gloves and other necessary protective gear. Works without wearing proper protective gear could result in serious injuries. Check the radiator fins for holes and cracks. To clean the radiator fins, blow compressed air from the opposite direction of the normal air flow.

  • Page 73: Inlet And Exhaust Systems

    Fig. 8-24 Turbocharger - Inspect check for looseness or abnormal noise. Replace the turbocharger if looseness or abnormal noise is found. Note: When removing and inspecting turbocharger, contact a dealer of Mitsubishi Heavy Industries, Ltd. 8-14...

  • Page 74: Pre-Cleaner - Clean, Inspect And Replace

    Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Pre-cleaner - Clean, Inspect and Replace Mild Never service the pre-cleaner while the engine is detergent running. Servicing the air cleaner while the engine is running can cause particles of foreign matter to enter Water the engine and result in rapid wear of parts, leading (Wash)

  • Page 75: Air Cleaner Element - Clean, Check And Replace

    Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Air cleaner element - Clean, Check and Replace When handling compressed air, wear safety goggles, a dust mask, a hardhat, gloves and other necessary protec- tive gear. Works without wearing proper protective gear could result in serious injuries. Never service the air cleaner while the engine is running.

  • Page 76: Electrical System

    Chapter 8 PERIODIC INSPECTION AND MAINTENANCE PROCEDURES Electrical system Battery - Inspect If battery electrolyte is spilled on your skin, flush immediately with plenty of water. If battery electrolyte enters the eyes, flush them immediately with lots of fresh water and seek medical attention at once. Do not use open flames or other fire hazards near the battery.

  • Page 77: Starter - Inspect

    If the alternator is dusty, blow foreign material using Alternator compressed air. Remove the belt and check that the movement is smooth when rotating the pulley by hand. Note: If the alternator is defective, consult a dealer of Mitsubishi Heavy Industries, Ltd. Fig. 8-32 Alternator - Inspect 8-18...

  • Page 78: Long-Term Storage

    Chapter 9 LONG-TERM STORAGE Long-term storage The following describes how to store the engine in a non-operable condition for 3 months or more and in an opera- ble condition for 3 months or more. If the engine has been left unattended for 3 months or more, the internal engine parts can rust, and that may cause damage to the engine.

  • Page 79: Using The Engine After Storage

    Chapter 9 LONG-TERM STORAGE Using the engine after storage 1. Remove the cover from the engine. 2. Connect a fully charged battery. 3. Remove the covers from the starters and alternator. 4. Adjust the tension of belt. Note: Inspect and adjust V-belt tension. Refer to "Belt and belt tension - Inspect and Adjust" (8-XX). 5.

  • Page 80: Lifting The Engine

    Chapter 10 TRANSPORTATION Lifting the engine To lift the engine, use wire ropes, shackles and slings Rear hanger Front hanger capable of supporting the weight of the engine. Attach the wire rope to the hangers provided on the engine using a correct sling. Keep the engine balanced during lifting by consider- ing the engine's center of gravity.

  • Page 82: Troubleshooting

    Chapter 11 TROUBLESHOOTING General precautions Contact a dealer of Mitsubishi Cautions against contamination Heavy Industries, Ltd. for repair Dust and foreign materials are the most common service cause of rapid wear of parts. Repairing a malfunctioning engine may require special...

  • Page 83: Troubleshooting

    (Refer to P8-17) Faulty battery Charge battery. Change battery. Faulty starter or starter relay Consult a dealer of Mitsubishi Heavy Industries, Ltd. Oil viscosity too high Use appropriate engine oil. (Refer to P5-1) Lubricating Check amount of engine oil and lubrication system.

  • Page 84: Output Decrease

    Clogged fuel filter (Refer to P8-7) Gauze filter - Clean Faulty fuel feed pump Consult a dealer of Mitsubishi Heavy Industries, Ltd. Fuel system Faulty fuel injection pump Consult a dealer of Mitsubishi Heavy Industries, Ltd. Faulty fuel injection nozzle Consult a dealer of Mitsubishi Heavy Industries, Ltd.

  • Page 85: Exhaust Smoke Is White Or Blue

    Improper fuel property Check cetane index, and use appropriate fuel. (Refer to P4-1) Faulty fuel injection timing Consult a dealer of Mitsubishi Heavy Industries, Ltd. Faulty fuel injection nozzle Consult a dealer of Mitsubishi Heavy Industries, Ltd. Fuel system Check ignition noise, exhaust smoke temperature.

  • Page 86: Exhaust Smoke Is Black Or Charcoal

    Remedies Improper fuel property Use appropriate fuel. (Refer to P4-1) Faulty fuel feed pump Consult a dealer of Mitsubishi Heavy Industries, Ltd. Faulty fuel injection pump Consult a dealer of Mitsubishi Heavy Industries, Ltd. Fuel system Faulty fuel injection nozzle Consult a dealer of Mitsubishi Heavy Industries, Ltd.

  • Page 87: Fuel Consumption Is High

    Fuel consumption is high Table 11-6 Fuel consumption is high Cause Remedies Faulty fuel injection nozzle Consult a dealer of Mitsubishi Heavy Industries, Ltd. Faulty fuel injection timing Consult a dealer of Mitsubishi Heavy Industries, Ltd. Fuel system Improper fuel property Use appropriate fuel.

  • Page 88: Engine Oil Consumption Is High

    Table 11-7 Engine oil consumption is high Cause Remedies Fuel system Faulty fuel injection timing Consult a dealer of Mitsubishi Heavy Industries, Ltd. Check oil leakage. Oil leakage to the outside of engine Consult a dealer of Mitsubishi Heavy Industries, Ltd. Engine oil viscosity too low Use appropriate oil viscosity.

  • Page 89: Overheating

    Low coolant level Check coolant level. (Refer to P3-3) Faulty water pump operation Consult a dealer of Mitsubishi Heavy Industries, Ltd. Cooling sys- Faulty thermostat operation Consult a dealer of Mitsubishi Heavy Industries, Ltd. Check and clean radiator and radiator filler cap.

  • Page 90: When Fuel Has Run Out

    Chapter 11 TROUBLESHOOTING When fuel has run out When fuel runs out while engine is running and the engine has stopped, restart the engine as described below. 1. Return the starter switch to the "OFF" position. 2. Add fuel to the fuel tank. For filling fuel tank, refer to "Fuel tank oil level - Check"...

  • Page 92: Main Specifications

    Chapter 12 MAIN SPECIFICATIONS Main specifications Table 12-1 Main specifications Item Specifications Engine model S4S-DT Water cooled, 4 stroke cycle 4-cycle water-cooled turbocharged Type diesel engine diesel engine No. of cylinders - arrangement 4 cylinder in-line Cylinder bore × stroke φ94 ×...

  • Page 93: Table 12-2 Main Specifications

    DC 12 V - 50 A or DC 24 V - 25 A Turbocharger Mitsubishi TD06H Note: (a) The specifications above are subject to change without prior notice. (b) The specifications above are described for the standard model. The special model specification may differ from those of standard model.

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