Mitsubishi Heavy Industries BD2G User manual

SERVICE MANUAL
·.MITSUBISHI
. DIESEL ENGINE
for BD2G/BS3G
CONTENTS
• CONSTRUCTION AND FUNCTION
• SPECIALTOOLS
• MAINTENANCE STANDARDS
• DISASSEMBLY AND REASSEMBLY

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DEFINITION OF TERMS
In this manual,
the following terms are used in the dimensional and other
specifications:
NOMINAL VALUE Indicates
part.
the standard dimension
of
a
ASSEMBLY STANDARD ...... Indicates the dimension of a part, the
dimension to be attained at the time of
reassembly or the standard performance. Its
value is rounded to the nearest whole
number needed for inspection and is different
from the design value.
STANDARD CLEARANCE .... Indicates the clearance to be
between mating parts at the
reassem bly.
obtained
time of
REPAIR LIMIT ............. A part which has reached this limit must
be
repaired.
SERVICE LIMIT ............. A part which has reached this limit must
be replaced .
. -,.-

TABLE OF CONTENTS
Group Contents Group No.
External views, Sectional views, Engine serial number location,
General Engine model and application codes, Specifications, Tips on I
disassembly and reassembly
Maintenance standards Maintenance standards, Tightening torque, Sealants 2 •
Special tools Special tool list 3 •
Overhaul instructions Determining when to overhaul the engine, Testing the 4
compression pressure
•
Adjustments, bench test, 5
performance tests
Engine accessory removal and Removal and installation of fuel injection pump, alternator)
6
installation starter, etc. •
Disassembly, inspection and reassembly of engine proper:
Engine proper Cylinder head,
valve mechanism, flywheel, timing gears, 7
camshaft, pistons, connecting rods, crankshaft, crankcase
I
Intake and exhaust systems Inspection
of exhaust manifold 8 •
Disassembly, inspection and reassembly of lubrication
Lubrication system system: 9
Oil pump, oil mter, reliefvalve •
Cooling system Disassembly, inspection
and reassembly of cooling system:
10
Water pump, thermostat. fan, fan belt •
Workshop theory Precautions for disassembly and reassembly
of general parts.
II
Oil seals. O-rings, bearings, lock plates, pins I

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GENERAL
I. GENERAL ............................................................ .
1.1 S4E2 diesel engine -External views ...................................... .
2
..
2
1.2 S4E2 diesel engine -Sectional views
...................................... . 4
1.3 Engine serial number location
........................................... . 6
1.4 Engine model and application codes ...................................... . 6
2. SPECIFICATIONS ........................................................ . 7
3. TIPS ON DISASSEMBLY AND REASSEMBLY ................................ . 10
3.1 Disassembly ......................................................... . 10
3.2 Reassembly ......................................................... . 10

GENERAL
1. GENERAL
1.1 S4E2 diesel engine - External views
CD Fuel filter
<V Fan
® Water pump
® Fuel injection pump
® Fuel feed pump
® Fan belt
(j) Intake manifold
® Stop solenoid
® Governor
(j]) Flyw heel
(j]) Starter
Left-hand side view
2
402884

2
o
o~
CD Exhaust manifold
® Oil filter
® Alternator
® P.T.O. Gear
Right-hand side view
GENERAL
®
4
402885
3

GENERAL
1.2 S4E2 diesel engine - Sectional views
4
CD Rocker arm
® Piston
® Compression ring
@Oil ring
® Connecting rod
® Camshaft
(j) Oil pump
@G!ow plug
® Fuel injection nozzle
Transverse view
I
402886

CD Thermostat
® Water pump
@Piston
® Compression ring
® Oil ring
®Fan
(j) Camshaft gear
® Camshaft
® Connecting rod
(j]) Crankshaft gear
@ Crankshaft
@ Intake valve
® Exhaust valve
® Rocker shaft
Longitudinal view
GENERAL
402887
@ Rocker shaft bracket
@ Cylinder head
@ Valve pushrod
® Crankcase
@) Valve pushrod
@ Flywheel
® Oil strainer
5

GENERAL
1.3 Engine serial number location
The engine serial number is stamped on
the side face of crankcase.
number Iu
II Engine s~erial 'n I
.9/J1 O ........... """"'+t_
1.4 Engine model and application codes
SO 0
l~_
6
Series codes E2: Swirl combustion chamber type
Piston displacement per cylinder:
739 cc (45.1 cu
in.)
Bore x stroke:
98 mm x 98 mm (3.86 in. x3.86 in.)
No.-of-cylinders code (2, 3, 4 or 6)
Sagamihara Machinery Works

GENERAL
2. SPECIFICATIONS
Model designation S4E2
Type Water-cooled, 4-stroke cycle, diesel
No.
of cylinders - arrangement
.4-in line
Type
of combustion chamber Swirl chamber
Valve mechanism
Overhead
Bore x stroke mm (in.) 98 x
98 (3.86 x 3.86)
Piston displacement liter (cu in.) 2.956
(180.3)
Compression ratio
20: I
Ol
Fuel (ASTM specification) Grade No. 2D diesel fuel
~
"
Firing order
"
1-34-2
"
" Direction
of rotation Counterclockwise
as viewed from
flywheel side
Overall length mm (in.)
809 (31.85)
Dimensions Overall wid th
rom (in.) 528 (20.79)
Overall height mm (in.) 750 (29.53)
Weight (dry)
kg (Ib)
270 (595)
Rated output
PS/rpm 40/2400
Maximum torque kgf·m
(lbHt) [N·m1/rpm 15.5 (112.1) [152.01/1200
Compression pressure kgf/ em' (psi) [MPa 1/ rpm 27 (384) [2.61/150 - 200
Maximum speed rpm 2620 ±
20
Minimum speed rpm
870 ± 10
Type of cylinder sleeves Dry) special
cast iron
No. of piston
Compression ring
2
rings
~
Oil ring 1 (w/spring expander)
" B.T.D.C.300
'"
Open
0
~
Intake valves
" Close A.B.D.C. 50°
.~
Valve timing Open B.B.D.C.74°
"
Exhaust valves
u.l A.T.D.C.
30°
Close
Starting system Electric starter
Starting aid Glow plugs
~t;;E
Air cleaner
""~~
Type Paper element
.aJ!1t;
~X>.
_ O~
" Type. Pressure feed by gear
pump
0
API service
".06
CC
'" "
classification
.8 t;
~»
Engine oil
.g~
Refill capacity 7 (1.8)
,...,
(incl. filter) liter (U.S. gal)
7

GENERAL
Model designation S4E2
Type Trochoid
Oil pump Speed ratio
to crankshaft 0.5
Delivery capacity
liter (U.S. ga1)/min (at 1800 engine rpm) 14 (3.7)
E Type . Piston valve
"
~
Relief valve
~
Opening pressure kgf/cm2 (psi)
~
[MPa]
3 ±0.3 (43 ±4.3) [0.3 ±0.03]
c
·3
Oil filter
'"
Type Paper element
.~
Oil filter Opening pressure kgf/cm2 (psi) [MPa] 1.0 ±0.2
(14.2± 2.8) [0.10 ±0.02]
.0
relief valve
.:l
Oil jet check
valve
Opening pressure kgf/cm2 (psi) [MPa] -
Refill capacity (engine water jacket) liter (U.S. gal) 4.6 (1.2)
Type Centrifugal
Water pump Speed ratio to crankshaft 1.3
Delivery capacity 115
liter (U.S. gal)/min (at 2000 engine rpm) (30.4)
E Fan belt Type Low·edge, cog, B type V·belt
"
1;;
Manufacturer
MITSUBOSHI
~
(
""
Type Wax pellet
.5
Thermostat
'0
Valve opening temperature °c (F)
0 76.5 ±2 (169.7 ± 3.6)
u Radiator Type Corrugated fin
Type Polypropylene·blade, circular-arc type
No. of blades 6
Fan 440
Diameter
mm (in.) (17.32)
Speed ratio to crankshaft 1.3
.Type Bosch A
Injection
pump
Manufacturer
NIPPONDENSO
E Diameter
of plunger mm (in.) 6.5 (0.256)
" Type Bosch, piston
1;;
»
~
Feed pump
<l
Manufacturer
NIPPONDENSO
~
Cam lift mm (in.) 6 (0.24)
Governor
Type
Bosch RSV, centrifugal
Manufacturer
NIPPONDENSO
8

GENERAL
Model designation S4E2
Type of nozzle holder Bosch, throttle
Type
of nozzle tip Bosch
ND-DNOSD
Manufacturer NIPPONDENSO
Injection
No_ of spray holes . . 1
S nozzles Diameter
of spray hole mm (in.) 1.0 (0.D4)
'"
~
~
-.; Sprayangle 0°
" Valve 0fening pressure 120
+~o (1706 +~42) [11.8 +~.o]
D..
kgf/cm (psi) [MPa]
Type Cartridge, paper element
Fuel
mter
Manufacturer NIPPON ROKAKI
Voltage -polarity 24V -negative
ground
Model M002T65271 (dry)
Starter
Manufacturer MITSUBISHI ELECTRIC
Type Pinion shift
Output
V-kW
24 -3.2
No.
of pinion teeth/No. of ring gear teeth 11/110
Type 3-phase, with rectifier
S
Manufacturer MITSUBISHI ELECTRIC
'"
~
00
>-
Output
V-A
24-20
00
';;l Alternator Rated voltage generating speed
u rpm
1100
'5
u Rated
output generating speed rpm 5000
iii
Maximum speed
rpm 13500
Speed ratio to crankshaft 1.7
Type Sheathed
Glow plugs Rated voltage -current
V-A
22.5 -4.8
Resistance at nonnal temperature n 4.5 ±0.5
Type -
Air heater Capacity
kW
-
Heater relay Fuse capacity A -
9

GENERAL
3. TIPS ON DISASSEMBLY AND
REASSEMBLY
This Service manual deals with
Mitsubishi'srecommended procedures to
be followed in servicing the Mitsubishi
diesel engines and contains information
on the special tools and basic safety
precautions.
The safety precautions contained
herein, however, are not the whole of
work. .It is the responsibility of the
service personnel to know that specific
requirements, precautions and work
hazards exist and to discuss these with
his foreman
or supervisor.
study this manual carefully and observe
the following general precautions to
help prevent serious injury to the
personnel and' damage to the engine.
3.1 Disassembly
(1) Use only right tools and instruments.
Serious injury to the personnel and
damage
to the engine result from the
wrong use of tools and instruments.
(2) Use an overhaul stand or work bench
if necessary. Also, use assembly bins
to keep the engine parts in order of
removal.
(3) Lay down
the disassembled and
'cleaned parts in the order in which
they
were removed to save time for
reassembling work.
(4) Pay attention to marks on assemblies,
components and
parts for their
positions or
directions. Put on
marks, if necessary, to aid
reassembly.
(5)
Carefully check each part for any
sign
of faulty condition' during
removal or
cleaning. The part will
tell you how it acted or what was
abnormal
about it more accurately
during removal or cleaning.
10
(
(6) When lifting or carrying a pa'rt too
heavy or too awkward for one person
to handle, get another person's help
and, if necessary, use a jack or chain
block.
3.2 Reassembly
(1) Wash all engine parts, except for oil
seals, O-rings, rubber sheets, etc.,
with cleaning solvent and dry them
with pressure air.
(2) Use only right tools and instruments.
(3) Use only good-quaJi ty lubricating oils
and
greases. Be sure to apply a
coat of oil, grease or sealant to
parts as specified.
(4) Be sure to use a torque wrench to
tighten parts for which tightening
torque is specified. (Refer to 2,
Group
No.2.)
(5) Replace gaskets and packings with
new ones. Apply a proper amount of
quick-drying cement to gaskets or
packings, if necessary.

MAINTENANCE STANDARDS
1. MAINTENANCE STANDARDS ............................................. 12
2. TIGHTENING TORQUE .................................................. 19
2.1 Important bolts and nuts ................................. .... . . . . . . . . . . .. 19
2.2 General bolts and nuts
.................................................. 20
3. SEALANTS .............................................................. 21

MAINTENANCE STANDARDS
1. MAINTENANCE STANDARDS Unit· mm (in )
Nominal Assembly standard Repair
Service
Group Inspection
point
value [standard clarance} limit limit Remarks
[clearance} [clearance}
Maximum rpm (no·load) 2620 ± 20 Adjust governor
Minimum rpm (no·load) .
870± 10 setting.
Nominal value: 24 kgf/cm2
Oil and water temp.
Compression pressure
27 kgf/cm' (384 psi) (341 psi) 20- 30°C
[2.6 MPa} at ISO -200 rpm [2.4 MPa}
(68 -86°F)
Nominal value:
2 kgf/cm2
3 - 4 kgf/cm2 (43 -57 psi) (28 psi)
Oil temRerature
[0.3 - 0.4 MPa} at 1500 rpm [0.2
MPa}
Lube oil pressure
Nominal value:
O.5kgf/cm' 60
_70°C
I kgf/cm2 (14 psi) (7 psi) (140 -158°F)
[0.1 MPa}, minimum at idling [0.05
MPa}
-;;;
~
Values are only
" I
" 14° A.T.D.C.
"
Valve timing
In. valves open for checking
" [with 3'mm
In. valves close 3° A.B.D.C.
valve timing and
(0.I2·in.)
Ex. valves open 24° B.B.D.C.
are different
clearance on
Ex. valves close 29° B.T.D.C.
from actual
valve side}
±3 ° (crank angle) ones.
Valve clearance (cold) [ 0.25 } Both intake and
(0.0098)
exhaust valves
Fuel injection timing 22°
B.T.D.C.
Fan drive belt tension 10
-IS
Measure sag at point
indicated by arrows.
(3/8 -5/8)
~
In.: Intake Ex.: Exhaust
12

MAINTENANCE STANDARDS
Unit: mm (in.)
Nominal Assembly standard Repair
Service
Group Inspection point
value
[standard clarance] limit limit Remarks
[clearance] [clearance]
.,:,
Warpage of gasketed 0.05 (0.0020), 0.20 Regrind if warpage
" ~
oa
surface
maximum (0.0079)
is minor.
~
Inside 98 98.000 -98.035 98.200 99.200 Refinish sleeves
to
" +0.25 (+0.0098) or>
diameter
(3.86) (3.85826 -3.85964) (3.86613) (3.90550)
"
" +0.50 (+0.0197)
.,.
~
oversize of nominal
" value by honing and
"0
0.Ql5 (0.00059),
~
Out·of·roundness
maxlmum
use the same oversize
U pistons
and piston
Taper 0.05 (0.0020),
rings
maximum
If repair limit is
reached, replace
bearings.
If service
~
-0.9
limit is reached,
"
on
Clearance on
75
0.050- 0.115 0.200
(-0.035)
regrind journals and
~
"
[(O.OO 197- 0.00453)] [(0.00787)J
use undersize bear-
'"
.;::
journals (2.95) as journal
<.>
'"
rings:
.!< "
"
.D diameter.
'"
Undersize bearings:
~
"
U
."
-0.25 (-0.0098),
::E
-0.50 (-0.0197) and
-0.75 (-0.0295)
Thrust journal length 2.45 0.100-0.264
0.300 Replace thrust
(end play) (0.0965) [(0.00394-0.01039)] [(0.01l8!)J plate.
~
Inside diameter 22.000 -22.021 22.100
" (0.86614 -0.86697) (0.87008)
:g
"
on
+0.10
~
If repair limit is
"
Clearance on 22 0.035
-0.086
0.120 (+0.0039) p.
[(0.00138-0.00339)] [(0.00472)J
reached, replace
p.
tappets (0.87)
as inside
~
diameter
tappets.
.... ~
If repair limit is
"'''''
.a"
Clearance on
[ 0.04 -0.09 J [ 0.15 ] exceeded, replace
e~ journals· (0.0016-0.0035) (0.0059) bushings. Ream if
'" "
U.D
necessary.
~
Warpage of gasketed 0.05 (0.0020), 0.20 Regrind if warpage
"
surface
maximum (0.0079) is minor.
"0
~~
;.,,,
As·installed thickness 1.6 ±0.15
u.a
of gasket (0.063) (±O.0059)
Intake 7.955 -7.940 7.900
"0
~
Diameter of
valves (0.31319 -0.31260) (0.31102)
'"
"
"
"0
valve stems
.a
.~
Exhaust 7.940 -7.920 7.850
~
"
valves (0.31260- 0.31181) (0.30905)
"0
"
.5
i 0.055
-0.085
>,
Intake 0.150
U
"0
Stem
valves
8 [(0.00217
-0.00335)]
[(0.00591)J
" clearance
'"
(0.31)
~
in guide
Exhaust 0.070-0.105
0.200
"
valves
[(0.00276-0.00413)] [(0.00787)1
>
-;;;
> As·installed length
of
17
guides (0.67) ±0.3
(±O.OI2)
13

MAIN"I:ENANCE STANDARDS
(
Unit: mm (in.)
Nominal Assembly standard Repair Service
Group Inspection point value [standard clarance] limit limit Remarks
. [clearance] [clearance]
Angle 30°
Valve sinkage 0.7 ±0.2 (±0.008)
1.3
~~~~
~
(0.028) (0.051)
~;
"
~
V
~alve
"
~
margin
Valve seat Valve
Width 1.2 ±0.14 (±0.0055) 1.6 angle
(0.047) (0.063) sinkage
Refacing is
Valve margin 2.13 (0.0839)
permissible
"'"
up to 1.2
'"
" (0.047).
"'"
~
" 48.85 47.60
"'"
Free length
.S
(1.9232) (1.8740)
;;,
g),
u
c:
.;::
Squareness 1.27 (0.0500),
""
~
maximum
"
~
Test force/length 19±1(42±2)
15 (33)
under test force
[186± 10]/
[147]
kgf (lbl) [N] 43 (1.69) 43 (1.69)
Inside diameter of
20.000 -20.021
~
rocker bushings (0.78740 -0.78823)
E
~
'"
Diameter of rocker
19.984 -19.966 ~
" shafts (0.78677 -0.78606)
~
~ Clearance of . 20
0.016-0.055
0.070
bushings on shaft (0.79) [(0.00063-0.00217)] 1(0.00276)1
14