Mitsubishi S4E User manual

III
-
Z
u.
-ci
Z~
-I')
-0
fn
(1)=
:Z:Z
II
--
.~
!!III
•
:»~
ID ...
u.
U)~
W "
:)111
...;
a
-!
UIUI
•
II
I:.:
"w
...
+C
-.
en
0
Ie
~
-

FOREWORD
This service manua l has Instructions ,nd procedures for lhe s ubject on the
front cover. The infomlation, specifications, and illustrations used in this
manual are based on i
nformation tha l waS current at the time this issue was
written.
Correct servicing will give this engiM a long productive lif e. Before
attempting to st arl a test, repair or rebuild job, be sure thai yo u have studied
the respective sections of this manua l, and know all the components you will
work on.
Safety is n Ot on ly yo ur concern bu t everybody's con cern. Safe w ork ing habits
cannot be bought Or m anuf,ctured; they must be learned through the job yo u
o. By learning wh at CAUTION 0 1' WARNING symbol emphas izes, know
what is safe - what is not safe. Consult your foreman, jf necessary, for
specific i
nstructions on a job , and the safety equipment required.
NOTES, CAUTIONS and WARNINGS
NOTES, CAUTIONS and WARNINGS are used in this manua l to empha -
size important and criti cal jllstructi ons. They are u s.ed for the following
conditions:
i NOTE]
.Lt. ( CAUTION] ..
.&.IW£':I~ II Nii
An operating procedure, c ondition, etc .,
which it
is essential to hfgJ1llgIH.
Operat ing procedures, practices, etc.,
which
if no t strictly observed, will result
in damage
to or destruction of engine.
Operating procedures, practices, etc .,
which if nOt correctly followed, will
result in personal injury or loss of life.
January 1973

TABLE OF CONTENTS
SERVICE GUIDE
Recommended periodical servici ng schedul
CONSTRUCTION AND FUNCTrON
D escription .
C rank c ase
Cylinder head
Main moving pa ns
Timing gear train . .
Lubrication sy stem
Fue l sy s te m . . ...
Cooling system .. . . . . .
Electrical equipm en1
MAINTENA NCE AND ADJUSTMENT
Inspection and adjustment of engine proper
Crankcase
Cylind er hea
Timing mechanism
Lubrication system
Fuel system .
Cooling system
Electrical equipment
Bench tests . '
DISASSEMBLY AND REASSEMBLY
Hints for facilirating disassembly-reassembly work
Engine dismounting and mounting . .. . .
Rocker arms and rocke r shaft . . . . . . . . . . . . ... . .
Cylinder head ...... . . . . . .. . . . . . .. . .. ... .. .
Timing gears
Lubrication system
Cooling system (water pump complete with thermost3t)
Flywheel and ring gear
Fuel filler . . .. . . . .
Injection nozz les
I njectio n pump and governor
Engine proper . . .
St arter . .
Alternator and re gu lator unit
Page
3
7
16
17
18
20
22
23
36
38
47
47
51
61
63
65
78
79
84
89
89
89
91
95
97
100
102
104
104
106
120
128
132

MA1NTENANCESTANDARDS
Maintenance standards
T,ghtening torque
Applic ation of sealers
TROUBLESHOOTING
Troubleshooting chart ( I)
Trou bl eshooting c har t (2)
SPECIAL SERVICE TOOLS
137
147
148
150
154
157

..
.'
.'
•

What to service What to do
Check oil le vel and repleni sh .
~
Oil p an
."
Change oi l.
.~ E
" "
~-
Oil mler Rtp
ilice fi lter elemen t.
~~
...Ji:;
Oil drcuit Clean by flushing .
Fuel fllter D
rai n out sl udge and con den.sate: .
Rep la c. e filter element.
Feed pump Cl ean inlet connection.
E
Chel;k inj ec tion pres sur e.
J'!
Inj ection
~
;:;
;;
nOlzles
De- ca rbon and clean non)e. 'i
~
and scat s.
"-
Drain out con densa te and
F ue l tank
sl u dge .
, C
lean by flushIng.
Check w ater level and repleni sh.
E Radiator Change coolan
l.
J'!
~
Cl ean r4 d iator fin s.
>-
~
'"
.5
Fan belt C
hec k and adjust tension,
'0
8 Thelmost31
Check for performance.
Coolant circuit Cl ean by flushing.
E
CJe an elemenl.
Air cl eane r
Q Replace element.
:;;
i:;
Bo lts nnd nuts
~
Che ek for tightness an d
Il
on muffler an d
.£
air cleane r retighten.
Inspec t b rush es and commutator
_ c S
tar t er ror we ar; iccondition as necessary .
11 ~
-- E
Check acid lev el and replenish.
~c.
Battery
0' -
Q ~
Check elect roly te S_G.
- .,-
w"
Glow plugs rnspect fo r co ndition.
:.
Valve clearance Check and ad j ust .
c.
0
5.
~
Major bolts Retighten.
~
' s.
~ Packlngs and
w
l.n spe ct for l eaka ge and repair .
se als
- - -- --
C ri teria
7.0 liters
(1.8 gaUon s)
120 ±S kg/em'
(1706 ±71 ps i)
60 lilers
(16 gallon,)
1 61ile"
(4.2 gillon')
1 2mm(l12in.)
of deneCl ion
0.25 mm(0.0098
in.) fOf bothint ake
and e >:.haust ,,.a!VtS
o refers to engines in regub..r service.
@refers;to new eng,ines being broken in.
Servicing intervals (hr5)
Da ily
15 150
300 600
12DD
Remar ks
1 101
0
@ 0
0 0
0 0
0 0
0
0
---
0
,0
0
0
0
0 0
0 Standard d
,"y i
0 conditions
@ 0
I
0
0 I
0 ,
0
0 I
0 -l
JO
-- -
'---
3

·-
-_. ----
<
'.
.
---- ---- - - ---- --- ---- .

'.

CONSTRUCTION AND FUNCTION
LeCl·side view
B
, ·Water pump
2-F an
3·Fan bolt
4·Fu el inj ec t ion pump
5-Fu el teed pump
SoOi l pipe
7·FuBI feed pipe
S-Fuel filtE!'r
9 -R ock or cover
10·Go'.'emor
11 ·Fue l inlet
12 - Adj usting fever
13·Starter

CONSTRUCTION AND FUNCTION
RJght-s: i de ,"' i ew
ill
G) ~
1==-1
,-
(fJ--
~ I 11Il
Q)_ I© 1- I I
@ p
/
j·Cylinder head
2-Cr'ankcase
3·S erv i ce meter
4·Flywh •• 1housing
5·Exl'lust manifold
6·Rocker
covet'
I
/
@
7· 01 f lll. r
6·Thermo"01
9·0il pip.
lO·Fan
1 1·Alte~nator
I = /
®
13·Tim ing gear c&se
14·Mounting bracket
15 · 0H leva l gauge
16·D rB in pl ug
17·0 11 pan
12·A IU Hnator bracket
9

CONSTRUCTION AND FUNCTION
Longitudinal cr oss section
' ·Thermostat
8·C .-snkshah g~ar
15-l m, k, valve 22-Flywheel housing
2·Water pump 9·Tirning
gear c ase- 1S -R ocker ,h.ft
23-Flywheel ,i ng ge. ,
3-Piston
10 -Oi l pao 17 · Rocker bracket
24 -Flywh •• 1
4-Camshaft gear 11·0 11 strainer 1S-Valve push fed 25-C
.m,h.ft
5·Fan 12-Elbow 1S-Cylin
de, he.d
26-CnlO ksh.ft
6-Connecting rod 13·Rocker cover
20·Crankcase
7· Crank'Shaft p u~ley
1 4·Ex h au5 i va lve 21-T'PPQt
10

Tran5\'erse crOss section
~- - ~ ,7=1 1 111
1- Exhauu manifold
-P i st on
3·Valve p ush r od
4. rapp et
5-Camshafr
6.Connecting rod
7·0il pump
S-Oil strainer
9-Rocke .. ~rm
10-0il fill.,
I1·G low plug
12·0il injection nozzle
CONS TRUCTION AND FU NCTION
13-FueJ fi lter
14·Fuel injection pi pe
1S·Fuel injection pump
16·Fuol f •• d pump
11

CONSTRUCTlON AND FUNCTION
Specifications
Model designAtion
S4E
Type
Water-coojed) 4·stroke cycle, in-line, rurbulence-thamber
ty pe diesel
Number of cy li"ld ers
4
Bore X stroke. mm (in.) 94 x 94 (3.
701 x 3 .701 )
Piston displacement. cc (cu in.) 2609 (159)
Co mpression ratio
19 : 1
Firing order
I · 3·4 ·2
Direction of rotation
Clockwise as viewed from liming g ear case si de
Fuel
ASTM No. 2 -D diesel f uel
Crankcase lub ri c ating oil
API service classification CC -class
Overall length, mm
813 (32)
(in.)
Dimensions
Overall widrh. mm
512 (20.1/8) . .
(in.)
Overall h"ght. mm
741 (29-1/8)
(in.)
WeIght (dry). kg (lb) 290 (639)
~
DD model DPS model
Ii>
..,
Maximum output. PS/rpm 35/2400 37/2400
.,.
~
Maximum torque. kg-m (f l-Ib)/rpm
14 .5 (104.9)/1200 15.5 (112.1)/1200
e
~
Compression prcssur•• kg/em' (psi) (rpm) 20 (284.4) (150 -200). mmimum
C)
Mmimum speed, rpm
650 -700
Maximum speed. rpm 2640
Cylinder sleeve
Dry lype, special cast iron
Number of piston rings
Compression rings
2
Oil
I (wirh spring expander)
Valve arrangement
Overhead type
Intake
va l ves
Open 30' before TOC
V.lve timing
Close 50' afte, BDC
Exh3USt va lves
Open 74' befo re BOC
Close
30' afler!DC
Valve clearance
Intake. mm (In.) 0
.25 (0.0098) (cold)
Exhaust.
DUn (in.) 0.25 (0.0098) (cold) ,
Starting system Staning motor
Mod el
NO -EP/KS22A
Fuel feed pump Manufacturer
Nippon Denso
E
Cam lift . DUn (in_)
6 (0 .2 36)
E Model PES4A65B
~
>-
Manufacturer
Nippon Denso
~
0;
PJ u nger diameter )
~
Fue) injeclion pump 6.5 (0.256)
IL
mm (in_)
IPlunger lead Right hand
Cam lift, mm (in.) 8 (0.315)
12

CONSTRUCTION AND FUNCTION
I Inj ection tunins, 25 t 1°
be fore TOC
Ty pe Ce ntr ifugal, n)'Weight, all·speed type
Governor Model
RSY
Manufacture r Nip po n Denso
E ; M
anufac tur er
Ni pp on Denso
0 Nozzle hol
de, Bo sc h type, KC AI7SD
u
I N
oz zle ti p Bosch type,
ND - D NO SD
E
,!! Type Throltle type
;'.
In j ection nO lll es
Spr ay hole dia m et er,
" I (0.039)
0;
mm (in.)
,
u. Splay co
ne ang le 0°
injec ti on p re ssu re , 120 (1706) ± 5 (71)
KgJ ,m ' (p s I)
I F
ilt er el eme nt
Pa per - el ement ty pe
Fuel filter
..
Manuf actu re r Nippon Rokaki
!
~~""
Oil pan,liler (gai) 7,0 (1.8)
Oil mter, lite, (
ga l) 0.67 (
0.1 8)
When operating ] 3 - 4 (42.7 - 56.
9)
kg/em' (psi)
Oil press ure
When idlin g, kg/em' (ps i) 1.0 (14.2), miIlimum
E
~
Type Trochoid type
,..
"
<:
Speed ratio to crankshaft 1/2
0
;;
Oil pump Displacement ,liter
19 .2 (1172)12400 ( engi ne 'peed ), minimum
.~
(cu m.J/min/rpm O
il lempcrature : SO°C (122°F)
.0
,
Di ;charge pressure: 3 kg/em' (42.7 psi)
...J
O il filter Type Paper element type
Type Piston-
valve type
ReHef va l ve
Relief pressure ks/ c m'
3 ± 0.3 (42.7 ± 4.3)
(P,;)
Capacity (excl.
rad iator), liter (gal) 4.6 (1.2)
Ty
pe Cent ri f ugal type
Warer pump
Speed ratio to cr ankshaft
L2 : I
Di splacement ,liler 100 (6103)/2520 (pump ,peed)
( cu m.)/min/rpm
E
Be lt Type Low-edge cog
B· ty pe "V" belt
~
Manu f 2cturer Mi tsubo,lu Be U
~
1;
" IType W
ax type
.~
"0
Ther mostat _
Man u facrure r F uj i Seiko
0 Valve opening 76.5 ±
2' (1 69.7 ± 3. 6°F ) I
u <emperatur
e, 'c (' F) (Fully opens at 90' C (I 94 ' F ))
I
Type Steel
bl ade, pusher t yp e
Number of blad
e>
6
I
F an
I; O ut side diameter.mm 380 (14.
96) x 30°
I (Ill.), pitch I
j Speed ratio to craJlkshaft 1.2 : 1
-. _ - I
13

CONSTRUCTION AND FUNCTION
Voltage 24 V
Polarity Negative
Ty
pe Sheathed type
Glow plugs
Rated voltage. cu rrel'lt 22.5 volts - 4.8 ampere,
Resi st ance val ue ( at
normal temperature) 4.5
~ 0.5 ohms
Model M005T2767I
Manufac t ur er MilSub i,hi E le ctric
, Type Pillion-sluft type
St ar ter Voltage -output
24 ,ai lS ' 3 kilowatts
Pinion/ring gear
11/132
(No. of teeth)
~
Model AP4012B,
c
~
Manufacturer Mit,ubi,hi Electric
E
Q.
Type 3-phase, enclosed type
'3
g
Voltage: - ~lJrrent 24 volts -12.5 ampere,
~
I
Rated voltage: gener·
11 00
~
at ing sp eed, rpm
u
Ra[ed output gener -
~
W atiIlg speed, rpm 1900
Alternator Maximum permissible, 7000
rpm
I
Speed ratio [0 c rank ·
1. 68
shaft
Model RMS4227C.
Manufacturer Mitsublilii Electric
Type Voltage regulator
Regu l ator unit Voltage regullitor
27.5 -30,5 volts .t 3000 rpm
ellt -m voltage (alternator speed)
Safely re Jay cut·in 5
volts , rna>:..
voltage
14