Mitsubishi Heavy Industries ES User manual

SERVICE MANUAL
MITSUBISHI
DIESEL ENGINE
S4E
( for BD2F . BS3F )
• MITSUBISHI
~ HEAVY INDUSTRIES, LTD.

FOREWORD
This service manual has instructions and procedures for the subject on the
front cover. The information, specifications, and illustrations used
in this
manual"are based on information that was current at the time this issue was
written.
Correct servlcmg will give this engine a long productive life. Befote
attempting
to start a test, repair or rebuild job, be sure that you have studied
the respective sections
of this manual, and know all the components you will
work on.
Safety is not only your concern but everybody's concern. Safe working habits
cannot be bought
or manufactured; they must be learned through the job you
do. By learning what CAUTION
Or WARNING symbol emphasizes, know
what
is safe -what is not safe. Consult your foreman, if necessary, for
specific instructions on a job, and the safety equipment reqUired.
NOTES, CAUTIONS and WARNINGS
NOTES, CAUTIONS and WARNINGS are used in this manual to empha-
size
important and critical instructions. They are used for the following
conditions:
[ NOTE 1 .............. An operating procedure, condition, etc.,
which
it is essential to highlight.
.&J CAUTION 1· ....... Operating procedures, practices, etc.,
which if
not strictly observed, will result
in damage to or destruction
of engine.
WARNING
Operating. procedures, practices, etc.,
which
if not correctly followed, will
result in personal injury or loss of life.
January 1978

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TABLE OF CONTENTS Page
SERVICE GUIDE
Recommended periodical servicing schedule 3
CONSTRUCTION AND FUNCTION
Description ........... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Crankcase 16
Cylinder head
........................................... 17
Main moving parts ..................................... '. . 18
Timing gear train'
...... , ...................... , . . . . . . . . . . • 20
Lubrication system ....................................... 22
Fuel system
....... , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Cooling system
36
Electrical equipment ..................................... 38
MAINTENANCE AND ADJUSTMENT
Inspection and adjustment
of engine proper
Crankcase
47
47
Cylinder head ........................................... 51
Timing mechanism ....................................... 61
Lubrication system ....................................... 63
Fuel
system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Cooling system 78
Electrical equipment
..................................... 79
Bench tests
............................................. 84
DISASSEMBLY AND REASSEMBLY
Hints for facilitating disassembly-reassemblY work 89
Engine dismounting and mounting
........................... 89
Rocker
arnlS and rocker shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Cylinder head
........................................... 91
Timing gears 95
Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Cooling system (water pump complete with thermostat)
....... .. 100
Flywheel and ring gear ................................... 102
Fuel filter
............................................. 104
Injection nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 104
Injection pump and governor
............................... 106
Engine proper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 120
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 128
Alternator and regulator unit
............................... 132

MAINTENANCE STANDARDS
Maintenance standards . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 137
Tightening torque
..................... ".................. 147
Application
of sealers ...... ; .............................. " 148
TROUBLESHOOTING
Troubleshooting chart (I)
Troubleshooting chart (2)
SPECIAL SERVICE TOOLS
•••••• • ',0 •••••••••.•••••••••••••••
150
154
157
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· :;
SERVICE GUIDE
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SERVICE GUIDE
RECOMMENDED PERIODICAL SERVICING SCHEDULE
o refers to engines in regular service.
©refers to new engines being broken in.
Servicing intervals (hrs)
What to service What to do
Criteria Daily 75 150 300 600 1200 Remarks
110)
Check oil level and replenish. 0
c:
Oil pan
0
7.0 liters
.;::;
Change oil. © 0
.\1 E (1.8 gallons)
~ ..
.o~
Oil nIler Replace nIter element. 0
" ~
.
-l'~
Oil circuit Clean
by flushing. 0
Fuel filter Drain
out sludge and condensate. 0
Replace nIter element. 0
Feed pump
Clean inlet connection. 0
E Check injection pressure. 0
~
.
~
Injection 120 ± 5
kg/em'
~
>-
De·carbon and clean nozzles
~
nozzles (1706 ±
71 psi)
-;; 0
:> and seats.
u. .
Drain out condensate and
60 liters 0
Fuel tank sludge. (16 gallons)
Clean by flushing. 0
Check water level and replenish. 0
( Change coolant. 16 liters 0
E Radiator (4.2 gallons) I
I
~
,
~
~
Clean radiator fins. 0
>-
~
'"
.S
Fan belt Check and adjust tension. 12 mm
(1/2 in.)
'0
of defiection 0
0
U Thermostat Check for performance. 0
Coolant circuit Clean by fluslting. 0
E Clean element. 0 Standard
duty
~
Air cleaner conditions -
~
Replace element. 0
~
>-
~
Bolts and nuts
~
Check for tightness and
'"
on muffler and·
© 0
'"
.~
retighten.
E aircleaner
Inspect brushes and commutator
0 ~
Starter
for- wear; recondition as necessary.
- c:
ro ~
.~ E Check acid level and replenish. 0
:>0.
Battery
0'-
" :> Check electrolyte S.C.
-0-
0
w"
Glow plugs Inspect for condition. 0
~
0.25 mm(0.0098
"
Valve clearance
Check and adjust.
in.)forbothintake
0
0.
e
and exhaust valves
0.
" Major bolts Retighten. 0
c:
'0,
c:
Packings and
w Inspect for leakage and repair. 0
seals
3

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CONSTRUCTION
AND
FUNCTION

Description
Exterior views
CONSTRUCTION AND FUNCTION
7

CONSTRUCTION AND FUNCTION
Left-side view
8
l-Water pump
2-Fan
3-Fan belt
4-Fuel injection pump
5-Fuel feed pump
6·0il pipe
7-Fuel feed pipe
8-Fuel filter
9-Rocker cover
10-Governor
11·Fuel inlet
l2·Adjusting lever
l3·Starter
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CONSTRUCTION AND FUNCTION
Right-side view
®
,.---------/~-,----!~-/~
CD~...... .. '---==/ H
..... . ~r-- -JI l--~~
~~==~==y=====~=~~~
@. -I©
o
1-Cylinder head
2·Crankcase
3-Service meter
4-Flywheel housing
5-Exhaust manifold
6-Rocker cover
7-0il filler
8-Thermostat
9-0il pipe
10-Fan
""T'IT. 'l1ruii-----@
LL~J--=-F"-'----""-
~\
@ @
13·Timing gear case
14-Mounting bracket
15-0illevel gauge
16-Drain plug
ll-Alter'nator
12-Alternator bracket 11-0il pan
9

CONSTRUCTION AND FUNCTION
Longitudinal cross section
I-Thermostat 8-Crankshaft gear 15-lntake valve 22-Flywheel housing
2-Water
pump
g·Timing gear case
16-Rocker shaft 23-Flywheel ring gear
3·Piston 10-0il pan 17-Rocker
bracket
24-Flywheel
4-Camshaft gear 11-0il strainer 18-Valve push rod 25-Camshaft
5-Fan 12-Elbow 19-Cylinder head 26-Crankshaft
6-Connecting rod 13·Rocker cover 20·Crankcase
7-Crankshaft pulley 14-Exhaust valve 21-Tappet
10

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Transverse cross section
CD
6
1-Exhaust manifold
2-Piston
3-Valve push rod
4-Tappet
®
®
5-Camshaft
6·Connecting rod
7-0il pump
8-0il strainer
®
9-Rocker arm
10-0il filler
11-Glow plug
12·0il injection nozzle
CONSTRUCTION AND FUNCTION
tM~----(j})
@
13-Fuel filter
14-Fuel injection pipe
15-Fuel injection pump
16-Fuel feed pump
11

CONSTRUCTION AND FUNCTION
Specifications
Model designation
Type
Number
of cylinders
Bore x stroke, mm (in.)
Piston displacement, cc (cu in.)
Compression ratio
Firing order
Direction
of rotation
Fuel
Crankcase lubricating oil
Overall length, mm
(in.)
Dimensions Overall width, mm
(in.)
Overall height, mm
(in.)
Weight (dry), kg (lb)
'"
~
'"
Maximum output, PS/rprn
"0
<0
Maximum torque, kg·m (ft.lb)/rpm
~
"
c
" Compression pressure, kg/cm2 (psi) (rpm)
(!)
Minimum speed, rpm
Maximum speed, rpm
Cylinder sleeve
Number
of piston rings Compression rings
Oil
Valve arrangement
Intake valves
Open
Valve timing Close
Exhaust valves
Open
Close
Valve clearance Intake, mm (in.)
Exhaust, mm (in.)
Starting system
Model
Fuel feed pump Manufacturer
E Cam lift, mm (in.)
" Model
~
~
>-
Manufacturer
~
0;
::>
Plunger diameter,
u. Fuel injection pump mm (in.)
Plunger lead
Cam lift, mm (in.)
12
S4E
Water·cooled,4·stroke cycle, in·line, turbulence·chamber
type diesel
4
94 x 94 (3.701 x 3.701)
2609 (159)
19 : 1
1·3·4-2
Clockwise as viewed from timing gear case side
ASTM No. 2·D diesel fuel
API service classification
CC . class
813 (32)
512 (20.1/8)
741 (29·1/8)
290 (639)
DD model DPS model
35/2400 37/2400
14.5 (104.9)/1200 15.5 (112.1)/1200
.20 (284.4) (150 ~ 200), minimum
650 ~ 700
2640
Dry type, special cast iron
2
1 (with spring expander)
Overhead type
30° before TDC
50° after BDC
74° before BDC
30° after TDC
0.25 (0.0098) (cold)
0.25 (0.0098) (cold)
Starting motor
ND . EP/KS22A
Nippon Denso
6 (0.236)
PES4A65B
Nippon Denso
6.5 (0.256)
Right hand
8 (0.315)
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CONSTRUCTION AND FUNCTION
Injection timing 25 ± I° before TDC
Type Centrifugal, flyweight, all-speed type
Governor Model RSV
Manufacturer Nippon Denso
.;
Manufacturer
Nippon Denso
c:
0 Nozzle holder Bosch type, KCAI7SD
"
I Nozzle tip Bosch type,
ND -DNOSD
E
..
Type Throttle type
~
~
Injection nozzles Spray hole diameter,
>-
~
I (0_039)
0;
mm (in_)
" 0°
lL
Spray cone angle
Injection pressure,
120(1706) ±5(71)
kg/em' (psi)
Fuel filter Filter element Paper-element type
Manufacturer Nippon Rokaki
-
Capacity
Oil pan, liter (gal)
7_0 (1.8)
Oil flIter, liter (gal)
0_67 (0.18)
When operating, 3 ~ 4 (42.7 ~ 56.9)
kg/em' (psi)
Oil pressure When idling,
kg/em' (psi) 1.0 (14.2), minimum.
E
..
~
~
Type Trochoid type
>-
~
c:
Speed ratio to crankshaft 1/2
0
."
Oil pump Displacement, liter 19.2 (1172)/2400 (engine speed), minimum
'"
" (cu in.)/min/rpm Oil temperature: 50°C (122°F)
'c
.0
Discharge pressure: 3 kg/em' (42.7 psi)
"
oJ
Oil flIter Type Paper element type
Type Piston-valve type
Relief
valve
Reliefpressure kg/em' 3 ± 0.3 (42.7 ± 4.3)
(psi)
Capacity (exci. radiator), liter (gal) 4.6 (1.2)
Type Centrifugal type
Water pump Speed
rathto crankshaft 1.2 : I
Displacement, liter 100 (6103)/2520 (pump speed)
- '---
(cu in.)/min/rpm
E Belt Type Low-edge cog B-type
"V" belt
..
Manufacturer
Mitsuboshi Belt
~
~
>-
'"
'"
Type
Wax type
.!:
'0
Thermostat
Manufacturer
Fuji Seiko
0 Valve opening 76.5 ± 2° (169.7 ± 3.6°F)
()
.. _-.- ..
temperature, °c CF)
(Fully opens at 90°C (194°F))
Type Steel blade, pusher type
Number
of blades 6
Fan Outside diameter,mrn 380 (14.96) x 30°
(in.) x pitch
Speed ratio to crankshaft 1.2 : I
13

CONSTRUCTION AND FUNCTION
Voltage
24V
i
Polarity Negative
Type Sheathed type
Glow plugs Rated voltage-current 22.5 volts -4.8 amperes
Resistance value (at
normal temperature) 4.5 ± 0.5 ohms
Model M005T27671
Manufacturer Mitsubishi Electric
Starter Type Pinion-shift type
Voltage -
output
24 volts - 3 kilowatts
Pinion/ring gear 11/132
(No.
of teeth)
~
Model AP401:2B,
c
" Manufacturer Mitsubishi Electric
E
c.
Type 3-phase, enclosed type
'5
0'
Voltage -current
24 volts -12.5 amperes
"
[3
Rated voltage gener- 1100
.;::
ating speed, rpm
~
" .Rated
output gener-
"
ill
ating speed, rpm 1900
Alternator
Maximum permissible,
7000
rpm
Speed ratio to crank- 1.68
shaft
Model RMS4227C.
Manufacturer Mitsubishi Electric
Type Voltage regulator
Regulator unit Voltage regulator 27.5
~ 30.5 volts at 3000 rpm
cut-in voltage (alternator speed)
Safety relay cut-in 5 volts, max.
voltage
14

CONSTRUCtiON AND FUNCTION.
Performance curves
15.5
40
"".".-
.
0 /
V
/
0 -
Fully equipped (with fan, alternator and air cleaner)
Corrected to standard conditions [760 mmHg (29.9 in. Hg) pressure,
20°C (68°F) temperature and 65% humidity1
DPS model
I
~
I
"-
I
I
.--
f-....
/
37
/
40
30
In
Q.
~
~
e
~
o
20
0
DD model
14.5
I
I
i
i V
/'
V
/
/
/
-
i----.
.........
.-----
~35
0
1000 1300 lroo 1900 2200 2500 0 1000
1300 16CX> 1900
2200 2500
Speed rpm
2400
Location of engine serial number
The engine serial number
is embossed on the upper left
hand side, directly above the starting motor,
as shown
below.
Engine serial number
Speed rpm
240:>
I
I
I
I
I
15