Mitsubishi S4E BD2F and BS3F service 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

( ( 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 ( )

· :; SERVICE GUIDE (

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 air cleaner 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

CONSTRUCTION AND FUNCTION

Mitsubishi S4E BD2F and BS3F service manual

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