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-

Engine model 4DQ5
Working voltage volt
12
Polarity Negative
(- ) ground
Type Sheathed
Rated voltage -volt -10.5 -8.3
Glow plugs current ampere
Resistance at normal ohm 1.26
temperature
Model M002T54172
Type Totally enclosed, drip-proof, pinion-shift type
....
with overrunning clutch
=
cv
S Manufacturer
Mi tsub ishi- Electric
.9-
Starter
i volt -
Voltage-output kilowatt
12 - 2
co
.l:t
No. of pinion teeth/
...
11/121
....
<:J
No. of ring gear teeth
~
Model A001T25070
Type 3-phase AC type
Voltage-ou tpu t volt -
ampere
12 -35
Alternator Manufacturer Mitsubishi-Electric
Rated speed 5000
Working speed rpm 1000 ~ 13500
Speed ratio to crankshaft 1.68
Regulator Type
IC type built in alternator
Regulated voltage volt 14.4 ± 0.3
-7-

DISASSEMBLY
(1) Drain the oil.
(2) Remove the fan belt and alternator as follows:
(a) Loosen bolt (1) securing fan belt adjusting plate
and alternator, and remove fan belt (2).
(b) Remove bolts (1) and (3) and remove alternator.
(3) Remove the starter as follows:
(a) Loosen attaching nuts (1).
(b) Remove starter from rear plate.
(4) Remove the fuel filter as follows:
(a) Disconnect fuel feed pipes (1) (2).
(b) Loosen attaching bolts (3) and remove fuel filter
(4).
-8-

(5) Remove the injection pipes and injection nozzles as
follows:
(a) Loosen connectors (1) and disconnect injection
pipes (2).
(b) Remove fuel return pipe (3) by loosening union
nut.
(c) Loosen nuts (4) and remove fuel leak-off pipe (5).
(d) Remove nozzle assemblies.
(6) Remove the lube oil pipe from injection pump.
(7) Remove the water pump pulley and crankshaft pulley
as follows:
(a) Loosen water pump shaft nut (1) and remove
water pump pulley (2).
(b) Loosen crankshaft nut (3) and remove crankshaft
pulley (4).
(8) Remove the timing gear case.
(9) Remove the rocker cover.
-9-

(10) Disconnect the water pump bypass hose and oil
pipe. To disconnect bypass hose, displace thermo-
stat elbow and water pump clamp.
(I 1) Remove the water pump as follows:
(a) Loosen attaching bolts (1).
(b) Remove water pump assembly (2).
(12) Remove the rocker shaft assembly
as follows:
(a) Loosen union nut (1).
(b) Loosen short bolts (2) and long bolts (3).
(c) Remove rocker shaft assembly (4).
(d) Remove oil pipe (5) and
"0" rings (2 pcs -to
be replaced with new ones).
(e) Remove
valve push rods and valve caps.
(f) Remove intake manifold.
(13) Remove the cylinder head assembly
as follows:
(a) Loosen cylinder head bolts (1).
(b) Remove cylinder head and gasket.
-10-

(14) Remove the oil pan and oil pump assembly as
follows:
(a) Loosen attaching bolts and remove oil pan (1) and
gasket.
(b) Loosen attaching bolts and remove oil pump (2)
assembly.
(15) Remove the timing gear train
as follows:
(a) Loosen idler gear bolt (1).
(b) Remove thrust plate (2) and idler gear (3).
(Draw idler gear while twisting it in the direction
of its helix.)
(c) Loosen injection pump drive gear nut (4).
(d) Remove injection pump drive gear (5).
(16) Remove the camshaft assembly
as follows:
Take out camshaft assembly (1) from crankcase.
[NOTE]
There are tappets in crankcase; this makes it
!}ecessary to turn crankcase upside down when
removing camshaft assembly.
(17) Remove the front plate and injection pump
assembly
as follows:
(a) Loosen attaching bolts (1).
(b) Remove front plate and injection pump
assembly.
-11-
• .
.. ~ ...... .
@l .,
..

(18) Remove the flywheel and rear plate.
(19) Remove the connecting rod bearing caps and
bearings (lower shells) by loosening attaching bolts.
(20) Remove the connecting rods and pistons.
(21) Remove the main bearing caps by loosening
attaching bolts.
-12 -

(22) Remove the crankshaft.
(23) Remove the main bearing shells.
(24) Disassemble piston and connecting rod
as follows:
(a) Remove compression rings (1) and oil ring (2)
by using piston ring tool (A).
(b) Remove oil ring spring.
(c) Remove snap
rings (3) by using snap ring tool
(B).
-13-

(d) Remove piston pin (4) by using drift (C).
(e) Remove piston pin bushing and connecting rod
bearing (upper).
(25) Disassemble the rocker shaft assembly
as follQws:
(a) Remove snap rings on both ends (1).
(b) Remove rocker assembly (2).
(c) Remove rocker bracket (3).
(d) Remove rocker assembly (4).
(e) Remove spring (5).
(26) Disassembly the cylinder head
as follows:
(a) Remove nozzle holders.
(b) Remove glow plugs (l).
(c) Loosen bolts (2) securing exhaust and intake
manifolds.
(d) Remove exhaust manifold (3).
(e) Loosen thermostat cover bolts and remove
thermostat cover (4).
(f) Remove thermostat (5).
-14-

(g) Remove valve cotters (6).
(Depress valve spring
by valve lifter.)
(h) Remove retainer (7).
(i) Remove valve spring (8).
G) Take out valve (9).
(k) Remove valve guide by using valve guide
remover (A).
-15 -
lO-Valve guide
ll-Cy Iinder head A-Valve guide remover

INSPECTION AND REPAIR
Cylinder head
(1) Inspection
Check the gasketed surface of the cylinder head for
flatness by using a straightedge and thickness gauge as
in the case of checking the crankcase surfaces. This
check is to be made with the precombustion chamber
jets removed.
Use a surface grinder to reface the cylinder head, as
necessary, to the specified flatness.
Specifications Unit: mm (in.)
Item Standard Repair limit
Warpage of gasketed O.OS,max 0.20
surface of cylinder (0.0020) (0.0079)
head
(2) Precombustion chamber jet replacement
Do not remove the jets unless they have to be re-
placed. To remove the jet as when cracks are noted
in it, drive it out with a drift pin of about 6 mm
0/4 in.) diameter inserted through glow plug hole,
as shown.
A·lntake port C·Jet
B-Exhaust port
-16 -
B-
L...::t=--- ..... --_ .... ~ ... ·F
I
o
Checking cylinder head gasketed surface for flatness
Removing precombustion chamber jet
©
Direction of precombustion chamber jet
orifice in installed state