Mitsubishi Heavy Industries 4DQ5 User manual

SERVICE MANUAL
MITSUBISHI
DIESEL ENGINE
4 5

INDEX
GENERAL
MAJOR DATA AND SPECIFICATIONS
DISASSEMBLY
5
8
INSPECTION AND REPAIR .......................................... 16
REASSEMBLY
LUBRICATING SYSTEM
COOLING SYSTEM
FUEL SYSTEM
37
49
52
56
ELECTRICAL SYSTEM
.............................................. 71
BENCH TEST
MAINTENANCE STANDARDS
SEALANT APPLICATION DATA
87
89
102
TIGHTENING TORQUE ............................................. 103
SPECIAL SERVICE TOOLS 105
TROUBLESHOOTING CHART 110

1. Major component parts
1-1 Left-hand side view
1-Water pump
2-Fan
3-Fan
belt
4-Fuel injection pump
5-Fuel feed pump
6-0il pipe
7-Fuel inlet connector
8-Fuel feed pipe
9-Fuel filter
GENERAL
10-Fuel injection nozzle
11-0il filler cap
12-Fuel
injection pipe
13.Rocker cover
14-lntake manifold
15-Fuel leak-off pipe
16-Cylinder head
17-Adjusting lever
18-Hanger
-1-
19-Crankcase
20-Flywheel housing
21-0il pan
22-Drain plug
23-Control rack stopper
24-Governor
25-Starter
402500

1-2 Right-hand side view
402501
l-Cylinder head
9-0il filler cap
l7-Alternator bracket
2-Crankcase 10-Exhaust
manifold
18-Timing gear case
3-1 ndicator switch
ll-Elbow 19-0il level gauge
4-Flywheel housing
l2-Screw plug
20-0il pipe
5-Rocker cover 13-Water
pump
21-0il bypass alarm switch
6-0il filter
14-Fan
22-0il pan
7-Breather
l5-Fan belt
23-0il pipe
8-0il filler
16-Alternator
-2-

1-3 Longitudinal sectional view
402502
1-Rocker cover 10-Connecting rod
19-Tappet
2- Thermostat case
11-Cran kshaft pu lIey 20-Camshaft
3-Thermostat
12-Crankshaft gear
21-Crankshaft
4-Exhaust valve
13-Timing gear case
22-Flywheel
5-lntake valve
14-Rocker shaft bracket
23-Flywheel housing
6-Water
pump
15-Rocker shaft
24-0il strainer
7-Piston 16-Valve push rod
25-0il pan
8-Camshaft gear
17-Cylinder head 26-Drain plug
9-Fan 18-Cran
kcase
-3-

1-4 Transverse sectional view
1-Exhaust manifold
2-Piston
3-Valve push rod
4-Connecting
rod
5-Tappet
6-Camshaft
7-0il level gauge
8-0il pump
9-0il strainer
10-Rocker arm
11-Rocker cover
12-Glow plug
13-Fuel
injection nozzle
14-lntake manifold
15-Fuel injection pipe
16-Cylinder head
-4-
17-Crankcase
18-Fuel injection pump
19-Fuel feed pump
20-Starter
21-Crankshaft
22-0il pan
-------~------
402503

MAJOR DATA AND SPECIFICATIONS
Engine model 40Q5
Type Water-cooled, 4-stroke, swirl-combustion
chamber type diesel
No.
of cylinders-arrangement 4-in line
Bore x stroke mm (in.) 84 x
94 (3.307 x 3.701)
Piston displacement
cc(cuin.) 2084 (127.l)
Compression ratio 21 : 1
Compression pressure kg/
cm 2 (psi) 26 (369.7), min (at 150
~ 200 rpm)
Firing order
1-3-4-2
Direction of rotation Counterclockwise as viewed from flywheel side
Burns (fuel) Grade No. 2D diesel fuel (ASTM specification)
Engine oil
Class-CC or better (API service classification)
Overall length 717.5 (28-1/4)
ca
Dimensions Overall width mm (in.) 562 (22-1/8)
..
a.I
= Overall height 629.5 (24-3/4)
a.I
(.!)
Weight, dry
kg (lb) 200 (441)
Cylinder sleeves Dry type made
of special cast iron
or integral water-jacket type
No.
of piston Compression rings 2
rings Oil ring 1 (w/spring expander)
Valve arrangement Overhead
Open at: 30°
BTDC
Intake valves 50°
ABDC
Valve Close at:
timing Open at: 74°
BBDC
Exhaust valves 30° ATDC
Close at:
Valve clearance (both intake and mm (in.) 0.25 (0.0098)
exhaust valves) (cold)
Starter Electric
Model ND-EP/KS22A
Fuel feed pump
Cam lift mm (in.) 6 (0.24)
Model PES4A65B
5 Fuel injection Plunger diam mm (in.) 6.5 (0.256)
"til
~
pump Plunger lead Right
a:i
Cam lift mm (in.) 8 (0.31)
::I
r- Model RUV (for prime power)
Governor Type Centrifugal flyweight, all-speed
Fuel injection Type Throttle
nozzles Type
of nozzle holders Bosch
CA 17SD
-5-

Engine model 4DQ5
Type of nozzle tips Bosch
ND-DNOSD21
~
Fuel injection Spray hole diam mm (in.) 1 (0.04)
~
Spray angle 0°
~
nozzles
'1:l
kg/cm2 (psi) 120 +18 (1706 +
14
6)
= Injection pressure
""-
Fuel filter Paper-element type
Type Trochoid
Speed ratio to crankshaft 1/2
Oil pump Capacity at oil temp.
50 ± 5°C (122 ± 9°F); liter (cu in.)/ 8.37 (510.8), min/lOOO (pump rpm)
pressure 3 kg/cm2 min/rpm
(42.7 psi)
e At duty run 3 - 4 (42.7 -56.9)
III
Oil pressure kg/cm2 (psi)
~
'"
At idling 1 - 2 (14.2 -28.4)
>.
'"
=
Oil filter Paper-element type
.sa
~
'"
Type Piston-valve
.~
..
3 Relief valve Valve opening kg/cm2 (psi)
pressure 3 ± 0.2 (42.7 ± 2.8)
Refill capacity Oil pan liter 6.5 (1.7)
Oil filter (U.s. gal) 0.7 (0.18)
Type Piston-valve
Oil bypass Valve opening
valve
kg/cm2 (psi) 0.8 -1.2 (11.4 -17.1)
pressure
Type Centrifugal type
Water pump Speed ratio
to crankshaft 1.3
Capacity liter (cu in.)/ 105 (6408)/3900 (pump rpm)
min/rpm
Type
Wax
e Thermostat Valve opening temperature 76.5 ± 2°C (169.7 ± 3.6°F)
III 90 ± 2°C (194 ±
3.6°p)
~
Valve lift temperature
'"
>.
'"
.Sf
Type Circular-arc pusher type
'0 No.
of blades 6
0 Fan
U Outside diameter mm (in.) 380 (15)
Ratio to crankshaft speed 1.3
Drive belt Type Low-edge cog B
No. of belts 1
Refill capacity (engine water jacket) liter 4.5 (1.2)
(U.S. gal)
-6-