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Service Manual L-SERIES(E)_Oct 2007

Contents

1. Reassembling alternator 12 45 ELECTRICAL SYSTEM 2 12 1 Installing rectifier assembly and regulator assembly Install the rectifier assembly and regulator assembly on the Regulator assembly rear bracket Regulator assembly Installing rectifier assembly and regulator assembly 2 12 2 Installing stator Soldering must be finished as quickly as possible Extended heating will damage the diodes Install the stator and solder the leads of the stator to the rectifier Soldering Installing stator 2 12 3 Installing front bearing Drive the front bearing into the front bracket and secure the Front bearing retainer with a screw Screw Front bearing bracket H Bearing retainer Installing front bearing 12 46 ELECTRICAL SYSTEM 2 12 4 Installing rear bearing Press fit the rear bearing to the rotor Rear bearing 2 12 5 Installing pulley 1 Insert the rotor into the front bracket _ Pulley Apply a cloth to the rotor and set it in a vise 2 Install t
2. lt I 1 C_ Stop solenoid Approx 0 3 to 0 7 mm 0 012 to 0 028 in Threaded portion Apply sealant Installing stop solenoid ETR type 3 3 1 Procedure for installing stop solenoid ETR type 1 Apply a sealant to the threaded portion of the stop solenoid Note Apply the sealant up to the position where the stop solenoid is screwed into the cylinder block Sealant or lubricant THREEBOND 1212 or 1211 2 Temporarily reassemble the stop solenoid and the nut to the cylinder block 3 Move the control rack of the fuel injection pump fully in the stop direction 4 Screw in the stop solenoid until the rod contacts the control rack 5 Turn the stop solenoid in the reverse direction by 90 to 180 from the above condition and temporarily tighten the nut 6 Move the control rack side to side and make sure that there is play of approx 0 3 to 0 7 mm 0 012 to 0 028 in 7 Tighten the nut to the specified torque 3 3 2 Verification after reassembling ETR type 1 After starting the engine turn the starter switch key to the OFF position and make sure that the stop solenoid activates and the engine stops 2 After starting the engine make a short circuit between the terminal of the oil pressure switch and the switch body and make sure that the e
3. 13 5 1 4 Inspecting and adjusting low idle speed and high idle speed 13 6 1 4 1 Preparation iieii iieii iiini aani 13 6 1 4 2 Adjusting low idle speed ee 13 6 1 4 3 Adjusting high idle speed ee 13 6 1 5 Bleeding fuel system eee 13 7 1 5 1 Bleeding air from fuel filter 13 7 1 5 2 Bleeding air from fuel injection pump 13 8 1 6 Adjusting V belt tension cee 13 9 2 Break in operation eee 13 10 2 1 Starting Up ceeeccceceeseeeseeeeeeeeeeeeeneees 13 10 2 2 Inspecting engine condition after StArtiNG UP ren nran 13 10 2 3 Break in operation time ee 13 10 2 4 Inspection and adjustment after break in Operaio e n vie ineieevieceed 13 10 3 Performance test JIS standard 13 11 3 1 Engine equipment condition 13 11 3 2 Test items and purposes 13 11 3 2 1 Operation load test ccceeeeeeeees 13 11 3 2 2 Continuous load test eee 13 11 312 3 LOW IGIG TeSt c f fh edeck ice foc deeecndea peated 13 11 3 3 Other inspections ccesceeeerees 13 11 3 4 Engine output adjustment 13 11 3 4 1 Standard atmospheric conditions 13 11 3 4 2 Calculation of corrected power 13 12 13 1 ADJUSTMENT AND OPERATION 1 Inspection and adjustment of engine 1 1 Inspecting and adjusting valve clearance 1 1 1 Preparation for valve clearance inspection a Cylinder head bolt main 1 Inspect and adjust the v
4. Regulated voltage at 20 C 68 F A007TAO171B 14 7 0 3 V 12 40 A 007TA8271A 28 5 0 5 V 24 25 1 2 4 1 2 3 4 5 6 7 Inspecting output Disconnect the battery ground cable Connect B terminal of the alternator to the ammeter then connect the voltmeter between B terminal and ground Connect the battery ground cable Start the engine Immediately apply all loads such as lamps Increase the engine speed and measure the maximum output current at the specified alternator rotation speed with the voltmeter indicated the specified value If the measured value meets the standard the output is normal Alternator o 3 oO E fe gt Ammeter Inspecting regulated voltage Item Standard Terminal voltage current Alternator rotation speed Output characteristics when hot A007TA0171B 13 5 V 21 A or higher 2500 min 13 5 V 37 A or higher 5000 min A007TA8271A 27 0 V 18 A or higher 2500 min 27 0 V 22 A or higher 5000 min 12 5 ELECTRICAL SYSTEM 1 3 Removing alternator Removing alternator Removing sequence 1 Harness 3 Generator brace 5 Washer 2 Flange bolt 4 Bolt 6 Alternator 1 4 Removing stop solenoid ETR type ETS type Removing stop solenoid Removing sequence 1 Nut 2 Stop solenoid 3 Rubber cap ETS type 12 6 ELECTRICAL SYSTEM 1 5 Removin
5. on Tie rod clip O ie Tie rod o Con 4 Disconnecting tie ro eae O LA d from control rack Speed control lever H Governor shaft cover k Governor spring lever J m L Tension lever Grooved pin B z a Sealing cap Governor lever ail l Governor shaft Grooved pin s a Gear case Removing governor shaft and speed control lever FUEL SYSTEM 1 4 Removing fuel injection pump Removing fuel injection pump Check thickness of the fuel injection timing adjusting shim Removing sequence 1 Bolt 2 Fuel injection pump 3 Shim 8 7 FUEL SYSTEM 2 Disassembling inspecting and reassembling fuel system 2 1 Disassembling and inspecting fuel injection nozzles Wear Wear and damage Carbon deposit clogged injection nozzle tip Disassembling and inspecting fuel injection nozzles Disassembling sequence 1 Nozzle retaining nut 4 Pin 7 Nozzle holder 2 Nozzle tip assembly 5 Spring 3 Piece 6 Washer FUEL SYSTEM 2 1 1 Inspecting and adjusting fuel injection valve opening pressure Never touch the injection nozzle tip during nozzle injection test 1 Mount the nozzle on the nozzle tester 2 Push down the handle at a speed of once a second and read the pressure when injection starts Make adjustment if it is outside the standar
6. 12 17 ELECTRICAL SYSTEM 2 4 9 Inspecting overrunning clutch Do not clean the overrunning clutch in wash oil Make sure that when attempting to turn the overrunning clutch it locks in one direction and rotates smoothly in the opposite direction 2 4 10 Inspecting pinion Check the pinion for wear and damage If faulty replace the pinion with a new one 2 4 11 Inspecting front bracket The ball bearing should rotate smoothly without abnormal noise If defective replace the whole front bracket 2 4 12 Inspecting gears of starter Check gears of the starter for wear or damage If faulty replace the starter 2 4 13 Inspecting continuity of magnetic switch between M terminal and case Check that there is continuity between M terminal and case If no continuity is observed replace the magnetic switch with a new one 2 4 14 Inspecting insulation of magnetic switch between M terminal and B terminal Check that there is no continuity between M terminal and B terminal If continuity is observed replace the magnetic switch with a new one 12 18 Inspecting overrunning clutch Terminal B Terminal S Terminal M Inspecting magnetic switch ELECTRICAL SYSTEM 2 5 Reassembling starter MO000T60481 12V 1 2kW M001T68381 12V 1 7kW 4 1 to 7 6N m oa e 0 42 to 0 77 kgf m 7 to 8 Ibf fi 7 to 9 Ibf ft Apply Multemp PS2 Kyodo Yushi made 4 4 to 7 1 Nem or equivalent 0 45 to 0 72
7. 9 7 3 2 Installing oil filter relief valve and Oil POSSUM issessseeessrrreserrrreesrirnnsserneeens 9 8 3 2 1 Installing oil pressure switch eseese 9 8 3 2 2 Installing relief valve oo eee eee 9 8 3 2 3 Installing oil filter ee eeeeeeeeeeeeees 9 9 9 1 LUBRICATION SYSTEM 1 Removing lubrication system 1 1 Removing oil filter relief valve and oil pressure switch Fatigue and crack Replace Oil drain gasket Removing oil filter relief valve and oil pressure switch Removing sequence 1 Oil filter 3 Relief spring 5 Oil pressure switch 2 Plug 4 Relief plunger LUBRICATION SYSTEM 1 1 1 Removing oil filter 1 Place a drip pan under the oil filter 2 Remove the oil filter using a filter wrench 1 1 2 Removing relief valve Remove the plug from the gear case and take out the relief spring and relief plunger 1 1 3 Removing oil pressure switch Using an oil pressure switch socket wrench remove oil presssure switch Removing oil filter Relief plunger Gear case Removing relief valve Oil pressure switch socket wrench P N MD998054 Removing oil pressure switch 9 3 LUBRICATION SYSTEM 1 2 Removing oil pump oil pan and oil screen Flaking and wear Replace Removing oil pump oil pan and oil screen Removing sequence 1 Oil pump housing 3 Oil pump inner gear 5 Oil screen 2 Oil pump outer gear 4 Oil pan 1 2
8. If faulty it is desirable to replace it as an assembly Inspection item Inspection procedure Judgment Low idling Judgment by rotation speed Varies depending on specifica tion Exhaust color Observe exhaust color during sudden acceleration under no load Observe exhaust color under load No remarkable black smooke is emitted Nozzle injection condition Remove the nozzle and reassemble them so that spray holes face outward Rotate the starter to carefully observe the spray pattern 2 4 Disassembling and inspecting fuel injection pump Disassembing sequence 1 2 3 4 5 6 7 Swivel nipple Stop wire bracket Control rack Tappet guide pin Tappet Tappet shim plate Spring lower seat 8 12 Replace O ring The spray pattem must be good Replace Gasket Contact wear damage rust and seizure of plunger Contact and wear Disassembling and inspecting fuel injection pump 8 Plunger 9 Plunger spring 10 Spring upper seat 11 Control sleeve 12 Lock plates 13 Delivery valve holder 14 O rings 15 16 17 18 19 Delivery valve spring Delivery valve gasket Delivery valve Plunger barrel Pump housing FUEL SYSTEM 2 4 1 Removing swivel nipple 1 Grab the plunger of the pump housing with a vise 2 Remove the swivel nipple from the pump housing 2 4 2 Removing tappets 1 Turn
9. 3 2 Installing flywheel housing 1 Clean the mounting surface of the gasket 2 Apply sealant to the gasket to prevent it from falling off 3 Install the gasket 4 Install the flywheel housing aligning its dowel pin holes and dowel pins and tighten the bolts Note When the dowel pins are worn or when the flywheel housing is replaced replace the dowel pins with new ones At as Oil seal case Installing flywheel housing 7 15 REASSEMBLY OF BASIC ENGINE 3 3 Installing flywheel The person who holds the pulley must be very careful to assure safety by communicating with the person who is installing the flywheel 1 One person must firmly hold the pulley with a wrench to prevent the crankshaft from turning 2 Screw the guide bolt into the rear end of the crankshaft 3 Align the bolt hole of flywheel with the guide bolt and install the flywheel to the crankshaft 4 Temporarily tighten bolts 5 Remove the guide bolt and temporarily tighten the last bolt 6 Tighten the flywheel bolts to the specified torque 7 16 Prevent the flywheel from rotating using a wrench Detent of flywheel Guide bolt M10 x 1 25mm Tightening torque 83 4 to 93 2N m 8 5 to 9 5kgf m 61 5 to 68 7Ibf ft Tightening flywheel bolts REASSEMBLY OF BASIC ENGINE 4 Reassembling cylinder head and valve mechanism Reassemble the cylinder head and valve mechanisms in the reverse order
10. 5 Turn the stop solenoid in the reverse direction by 30 to 45 from the above condition at this time the clearance between the control rack and shaft is 0 15 to 0 20 mm 0 00591 to 0 00788 in and tighten the nut to the specified torque 6 Finally reassemble the rubber cap with the arrow facing upward water drain hole facing downward as illustrated 12 51 ELECTRICAL SYSTEM 3 4 2 Verification after reassembly ETS type 1 After starting the engine turn the starter switch key to the OFF position and make sure that the solenoid activates and the engine stops 2 During engine start turn the starter switch key to the ON position and make sure that the solenoid activates and the engine enters a stopped state 3 Turn the starter switch key from the OFF position to ON and then to START position Make sure that the solenoid activates with the key turned to ON and that the solenoid instantly stops to activate with the key turned to START 12 52 ELECTRICAL SYSTEM 3 5 Installing alternator Installing alternator 3 6 Installing starter Installing starter 12 53 ADJUSTMENT AND OPERATION 1 Inspection and adjustment of ONGOING aoras marnitan aaaea 13 2 1 1 Inspecting and adjusting valve clearance13 2 1 1 1 Preparation for valve clearance inspection13 2 1 1 2 Inspecting valve clearance ee 13 3 1 2 Inspecting fuel injection timing 13 4 1 3 Adjusting fuel injection timing
11. During cooling operation check the engine for abnor malities Protection of engine against water entry Do not allow rainwater etc to enter the engine through the air inlet or exhaust openings Do not wash the engine while it is operating Cleaning fluid water can be sucked into the engine Starting the engine with water inside the combustion chambers can cause the water hammer action which may result in internal engine damage and serious acci dents Maintenance of air cleaner or pre cleaner The major cause of abnormal wear on engine parts is dust entering with intake air Worn parts produce many INTRODUCTION problems such as an increase of oil consumption de crease of output and starting difficulties For effective removal of dust from intake air conduct maintenance of the air cleaner according to the following instruc tions e Do not conduct maintenance of the air cleaner pre cleaner while the engine is operating Engine opera tion without the air cleaner precleaner in place allows foreign matters to enter the turbocharger causing it to damage seriously Remove the air cleaner pre cleaner slowly to prevent dust accumulated on the element from falling off After removing the air cleaner or pre cleaner imme diately cover the opening inlet port in case of air cleaner port in body in case of pre cleaner with plastic sheet or similar means to prevent dust from entering the engine Air cleaners equipped with
12. Stay clear of moving parts during engine running Do not approach rotating or sliding parts of the engine when the engine is in operation Keep objects likely to be caught by rotating parts away from such parts If any part of the clothing or outfit ting is caught by a rotating part se rious bodily injuries could result Lockout and Tagout Be sure to lockout and tagout before starting inspection and maintenance Lockout and tagout are effective methods of cutting off machines and equipment from energy sources To accomplish the lockout tagout remove the starter switch key set the battery switch to OFF and attach a Do Not Run or similar caution tag to the starter switch The starter switch key must be kept by the person who performs inspection and maintenance during the work In the case of pneumatic starting type close the main valve of the air tank and post a tag saying Do Not Open the Valve or the like Keep engine stopped during servicing Be sure to stop the engine before proceeding to inspec tion and service procedure Never attempt to make ad justments on the engine parts while the engine is running Rotating parts such as belt can entangle your body and cause serious injuries Always restore engine turning tools after use Do not forget to remove the tools which have been used for turning the engine during inspection or servic ing after the procedure is finished Remember also that the turning ge
13. 14 7 24 5 Nem 1 5 2 5 kgfm 10 9 18 1 Ibf ft Installing torque spring set double spring 8 29 FUEL SYSTEM 3 2 5 Installing rack set screw The rack set screw are properly adjusted at the factory before shipment Do not work on the rack set screw unless absolutely necessary Adjust and reassemble the rack set screw as described in the following 1 Adjust the speed control lever with the high speed set bolt After setting it to the high idle engine speed secure it by nut 2 Screw in the rack set screw at rated engine speed set it to the rated engine power 3 Secure it by torque set nut 4 Put the rack set screw sealing cap and firmly tighten the sealing cap 8 30 Torque set nut Screw in the rack set screw at rated engine speed Set it to the rated engine power and secure it by torque set nut Sealing cap fix it after setting Special nut 14 7 24 5N m 1 5 2 5 kgfm 10 9 18 1 Ibf ft Installing rack set screw FUEL SYSTEM 3 3 Installing fuel filter Installing fuel filter 8 31 FUEL SYSTEM 3 4 Installing fuel pipe and fuel injection nozzles 24 5 to 29 4 N m 2 5 to 3 0 kgf m 20 6 to24 5N m 18 1 to 21 7 Ibf ft 2 1 to 2 5 kgf m 15 2 to 18 1 Ibf ft Installing fuel pipe and fuel injection nozzles 3 4 1 Installing fuel injection nozzle 1 Clean the nozzle holder hole of cylinder head 49 0 to 68 6 N m 2 Install the gask
14. 16 5 10 Brush length 0 650 0 394 20 58 N 17 5 to 23 7 N 6 86 N Brush spring load 2 10 kgf 1 78 to 2 42 kgf 0 70 kgf 4 6 lbf 3 92 to 5 34 lbf 1 54 Ibf Starter 0 03 0 10 Commutator radial runout MO001T68381 0 0012 0 0039 12V 1 7kW 29 4 28 8 Commutator outside diameter 1 158 1 134 0 75 0 5 to 1 0 0 2 Depth of ndereuts between segments 0 030 0 0197 to 0 0394 0 0079 or less Terminal voltage 11 V Nees penis Current 110 A or less characteristics Rotation speed 2400 min or more 2 7 SERVICE DATA Table 2 7 Maintenance service data table Electrical system 2 3 Unit mm in Inspection point Nominal Standard Limit Remark Secs 0 5 Pinion shaft end play 0 0197 Pinion gai 0 5 to 2 0 gap 0 0197 to 0 0787 18 11 Brush length 0 709 0 4331 34N 28 9 to 39 1 N 20N Brush spring load 3 47 kgf 2 95 to 3 99 kgf 2 04 kgf Starter 2 lbf 6 5035 to 8 7963 Ibf 4 4974 lbf Me TORO Commutator radial runout 293 o 24V 3 2kW 0 0012 0 0039 i 32 0 31 4 Commutator outside diameter 1 2598 1 2362 0 5 0 4 to 0 6 0 2 Depth of undercuts between segments 0 020 0 0158 to 0 0236 0 0079 or less Terminal voltage 23 V No load Ia Current 80 A or less characteristics Rotation speed 3400 min or more 4 8 to 6 0 N 2 2 N Brush spring load 0 49 to 0 61 kgf 0
15. Measuring Positions Standard Perea Nominal Value Standard 13 73 to 14 73 140 to 150 1992 to 2134 Nozzle tester Valve Opening Pressure Measured Values Valve Opening Pressure No Service Hours h Before Adjustment Supplement 10 INSPECTION RECORD SHEET No 10 come ee Serial No Measurement of Camshaft Journal Outside Diameter to Point Cylinder Block Camshaft Bore Clearance L2 l Measuring Positions Standard 33 925 to 33 950 1 3356 to 1 336 Camshaft Journal Outside Diameter 32 925 to 32 950 1 2963 to 1 2972 34 000 to 34 025 Cylinder Block f 1 3386 to 1 3396 Camshaft Bore Inside Diameter 33 000 to 33 025 i 1 2992 to1 3002 Camshaft Journal Outside Diameter to Cylinder Block Camshaft Bore Clearance 0 050 to 0 100 0 0020 to 0 0039 Measured Values Camshaft Journal Outside Cylinder Block Camshaft Part Name Clearance Diameter Bore eo Diameter Reet x vy __ R Po Remark SES Po Remark SES erie oe Supplement 1 1 No 11 INSPECTION RECORD SHEET Engne moa ompan aa Serino Inspection Measurement of Camshaft Journal Outside Diameter to tie mijini Point Cylinder Block Camshaft Bore Clearance L3 l Measuring Positions Standard Momina Standard Limit Value No 2 34 33 925 to 33 950 i 1 34 1 3356 to 1 336 Camshaft Journal l l Outside Diameter No 3 33 32 925 to 32 950 No 4 1 30 1 2963 to 1 2972 No 2 34 34 000 to 34 025 Cylinder Block 1
16. ce eeeeeeeeees 7 12 2 11 Installing PTO gear s es 7 13 2 12 Installing timing gear Case cee 7 13 2 13 Installing crankshaft pulley 7 13 2 14 Installing gear pump housing 7 14 2 15 Installing tappet ee eeeeeeeeeeeeees 7 14 3 Reassembling flywheel 7 15 3 1 Installing oil seal Case eee 7 15 3 2 Installing flywheel housing 7 15 3 3 Installing flywheel eects 7 16 4 Reassembling cylinder head and valve mechanism ccceeeeee 7 17 4 1 Cleaning cylinder head bottom surface 7 17 4 2 Installing valve stem Seal eee 7 17 4 3 Installing valve spring 7 17 4 4 Installing valve lOCK eeeeeeeeeeeeeeeeees 7 18 4 5 Installing cylinder head gasket 7 18 4 6 Installing cylinder head assembly 7 18 4 7 Tightening cylinder head bolts 7 19 4 8 Inserting push rod sessen 7 19 4 9 Reassembling rocker shaft assembly 7 20 4 10 Installing rocker shaft assembly 7 20 4 11 Adjusting valve clearance 7 21 4 12 Installing rocker Cover n se 7 21 4 13 Installing torque spring Set 7 21 7 1 REASSEMBLY OF BASIC ENGINE 1 Reassembling cylinder block crankshaft piston and oil pan 1 1 Installing main bearing 1 Install the main bearings upper and lower with aligning lug groove of the crankcase and main bearing cap Note Install the bearing upper with groove to
17. 2 Parts to which Molykote AG 650 Dow Corning Asia made or the equivalent is applied Gear shaft gear and internal gear of armature 12 35 ELECTRICAL SYSTEM 2 9 2 Installing lever and pinion shaft Reassemble the lever to the pinion shaft and insert them into the front bracket 2 9 3 Installing pinion 1 Install the spring pinion and pinion stopper on the pinion shaft 2 Install a stopper ring into the ring groove on the pinion shaft Using a puller pull the pinion stopper until its groove engages with the stopper ring 2 9 4 Installing spring set and reduction gear 1 Install the two lever springs and packing on the lever 2 Install the reduction gear on the pinion shaft 2 9 5 Installing center bracket Install adjusting washers on the pinion shaft and secure the center bracket with a screw 12 36 Front bracket Pinion shaft Installing lever and pinion shaft Pinion stopper Pinion stopper Stopper ring Installing pinion Lever springs Reduction gear Installing spring set and reduction gear Center bracket Installing center bracket ELECTRICAL SYSTEM 2 9 6 Adjusting pinion shaft end play Adjust the end play thrust gap to 0 5 mm 0 0197 in or less by inserting adjusting washers between the center bracket and reduction gear 1 Install the pinion shaft reduction gear washer and snap ring onto the center bracket 2 Measure the pinion shaft end play by mo
18. 2 12 2 Installing Stator crisi ni 12 45 2 12 3 Installing front bearing s es 12 45 2 12 4 Installing rear bearing 12 46 2 12 5 Installing pulley 12 46 2 12 6 Assembling stator and front bracket 12 46 2 13 Inspecting glow plug 12 47 3 Installing electrical system 12 48 3 1 Installing glow plUQ eee eeeeeeees 12 48 3 2 Installing stop solenoid 12 48 3 3 Installing stop solenoid ETR type 12 49 3 3 1 Procedure for installing stop solenoid ETR YP reiteeni 12 49 3 3 2 Verification after reassembling ETR type i paaa a 12 49 12 2 3 4 Installing stop solenoid ETS type 12 50 3 4 1 Procedure for installing stop solenoid ETS typa einet aiehudeia aie 12 50 3 4 2 Verification after reassembly ETS type 12 51 3 5 Installing alternator ees 12 52 3 6 Installing starter ee eeeeeeeeees 12 52 ELECTRICAL SYSTEM 1 Removing electrical system 1 1 Removing starter Removing starter Removing sequence 1 Harness 2 Starter 12 3 ELECTRICAL SYSTEM 1 2 Inspection before removing alternator A007TA0171B 12V 40A A007TA8271A 24V 25A 1 2 1 Inspecting alternator operation Locate the cause of faulty charging from malfunctions described below Do not remove the alternator for inspection and repair unless inspection cannot be performed with the alternator installed on the engine Adjusted value of voltage regulator is high Overcharge Fa
19. Break in operation time Duration A Engine speed min Load min Low 1 rotation 600 to 900 No load 5 speed Medium 2 rotation 1000 to 1200 No load 5 speed High 3 rotation 1400 to rated speed No load 10 speed 4 25 10 5 50 10 Rated speed 6 75 30 7 100 20 Note The table above is provided solely for reference purpose Run the engine at appropriate speed and load for the break in operation of your engine Be sure to perform break in operation after overhaul or installation 2 4 Inspection and adjustment after break in operation 1 Valve clearance adjustment 2 Ignition timing inspection 3 Exterior bolt and nut tightness check ADJUSTMENT AND OPERATION 3 Performance test JIS standard The following describes the procedures specified in Earth moving machinery Engines Part 1 Test code of net power JIS D0006 1 and Earth moving machinery Engines Part 2 Standard format of specifications and testing methods of diesel engines JIS DO006 2 Other test items may be required in some applications All test results should be evaluated comprehensively in order to determine the engine performance 3 1 Engine equipment condition The engine must be equipped with standard auxiliary devices such as cooling fan air cleaner and alternator 3 2 Test items and purposes 3 2 1 Operation load test Conduct this test to evaluate the engine output
20. Engine model L2A L2C L2E Working voltage 12V ETR 8V or less 3 100 MQ or more at DC 500 V megger Sto Insulation resistance j a P normal temperature normal relative humidity solenoid 1 Stroke 13 5 0 5 mm 0 53 0 02 in Ambient temperature for use 40 to 120 C 40 to 248 F Working voltage 12V ETS 10 to 15V i 100 MQ or more at DC 500 V megger Sto Insulation resistance j _ P normal temperature normal relative humidity solenoid 2 Stroke 10 0 5 mm 0 39 0 02 in Electrical Ambient temperature for use 30 to 120 C 22 to 248 F system Working voltage 24V ETR 16V or less f 100 MQ or more at DC 500V megger Sto Insulation resistance o P normal temperature normal relative humidity solenoid 3 Stroke 13 5 0 5 mm 0 53 0 02 in Ambient temperature for use 40 to 120 C 40 to 248 F Working voltage 24V ETS 20V to 30V 100 MQ or more at DC 500V megger Sto Insulation resistance er p normal temperature normal relative humidity solenoid 4 1 10 Stroke 10 0 5 mm 0 39 0 02 in Ambient temperature for use 30 to 120 C 22 to 248 F GENERAL 5 2 Specifications of L3A L3C and L3E Table 1 2 Specifications of L3A L3C and L3E 1 4 Engine model L3A L3C L3E Type Vertical type water cooled 4 cycle diesel No of cylinders 3 Combustion type Swirl chamber type Valve mechanism Overhead valve type Cylinder bore x stroke
21. External View cceceeeeeeeees 1 2 1 1 External view of L2A L2C and L2E 1 2 1 2 External view of L3A L8C and L3E 1 3 2 System flow diagrams 6 1 4 2 1 Fuel system flow diagram 1 4 2 2 Lubrication system flow diagram 1 4 2 3 Cooling system flow diagram 1 5 2 4 Inlet and exhaust system flow diagram 1 5 3 Engine serial number location 1 6 4 Indication of engine model and total displacement eeeee 1 6 5 Specifications ceeeeecceeeeeeeee 1 7 5 1 Specifications of L2A L2C and L2E 1 7 5 2 Specifications of L3A L8C and LSE 1 11 6 Tips on disassembling and rEASSEMDIING ccceeeeeeeeeeeees 1 15 6 1 Disassembling 1 15 6 2 Reassembling eeeeeceeeeeeteeeeeteee 1 15 tA GENERAL 1 External view 1 1 External view of L2A L2C and L2E Oil filler Rear hanger Thermostat Alternator Exhaust manifold Fan Rear V belt Starter Oil pan Left view Flywheel Engine left view Front hanger Fuel injection nozzle Fuel injection pump Inlet manifold Stop solenoid Water pump 7 Fuel filter N T gt bs Rear Front Q fe Q oQ Oil filler Water drain plug J PTO Oil level gaug
22. Perform the inspection as described below If faulty replace Disconnect the connector the magnetic switch with a new one Do not apply current continuously for longer than 10 seconds 1 Disconnect the connector of M terminal Battery 2 Pull in test 12V Connect the starter to the circuit as shown in the illustration The magnetic switch is normal if the pinion springs out when the switch is turned ON Pull in test 3 Holding test Connect the starter to the circuit as shown in the illustration Pull out the pinion fully by hand The Conneetel magnetic switch is normal if the pinion does not return when it is released Battery 12V Starter Holding test 4 Return test Connect the starter to the circuit as shown in the i i Disconnect the connector illustration Pull out the pinion fully by hand The magnetic switch is normal if the pinion returns immediately when it is released Battery 12V Return test 12 9 ELECTRICAL SYSTEM 2 1 3 No load test Use as thick a wire as possible and firmly tighten each terminal When detecting the rotation at the tip of the pinion be careful as the pinion pops out during operation 1 Connect the starter to the circuit as shown in the illustration 2 In normal condition the pinion pops out when the switch is turned ON and the starter rotates at or more the specified rotation speed If the terminal voltage current or r
23. Type Electromagnetic plunger type Discharge rate 1 4 L 0 57 U S gal min or more at 24V 1 5A Type Electromagnetic plunger type compact type i Discharge rate 0 4 L 0 11 U S gal min or more at 12V 1 5A 1 11 GENERAL Table 1 2 Specifications of L3A L3C and L3E 2 4 Engine model L3A L3C L3E Lubrication system Lubrication system Pressure feed full flow filter system Speci fication API service category CF and CF 4 Upper limit 3 1 L 0 82 U S gal Lower limit 1 8 L 0 48 U S gal Upper limit 3 6 L 0 95 U S gal Engine oil Capacity Lower limit 2 3 L 0 61 U S gal engine total Upper limit 4 2 L 1 11 U S gal Lower limit 3 0 L 0 79 U S gal Upper limit 4 7 L 1 24 U S gal Lower limit 3 5 L 0 92 U S gal Type Gear type internal and external teeth engagement Oil pump YP built into gear case Discharge rate 3 L 0 79 U S gal min or more at 1000 min Type Plunger valve type Relief valve 0 29 0 029 MPa 3 0 0 3 kgf cm Valve opening pressure iae 42 68 4 3 psi 1000 min Oil filter Type Paper element cartridge Cooling system Forced feed circulation type Coolant capacity main unit of engine 1 8 L 0 48 U S gal Type Centrifugal volute type Water pump 50 L 13 21 US gal min Discharge rate a at pump rotation of 4500 min Cooling Type Wax pellet system Thermostat ee
24. Working voltage 24V ETS 20V 30V 100 MQ or more at DC 500V megger Sto Insulation resistance E P normal temperature normal relative humidity solenoid 4 1 14 Stroke 10 0 5 mm 0 39 0 02 in Ambient temperature for use 30 to 120 C 22 to 248 F GENERAL 6 Tips on disassembling and reassem bling This service manual specifies the recommended procedures to be followed when servicing Mitsubishi engines The manual also specifies the special tools that are required for the work and the basic safety precautions to follow when working Note that this manual does not exhaustively cover potential hazards that could occur during maintenance inspection and service work of engine When working on an engine follow the relevant directions given in this manual and observe the following instructions 6 1 Disassembling 1 Use correct tools and instruments Serious injury or damage to the engine will result from using the wrong tools and instruments 2 Use an overhaul stand or work bench if necessary and follow the disassembling procedures described in this manual 3 Keep the engine parts in order of removal to prevent losing them 4 Pay attention to assembling marks Put your marks on the parts if necessary to ensure correct reassembling 5 Carefully check each part for defects during disassembling or cleaning Do not miss symptoms which can not be detected after disassemb
25. abnormal wear of ring gear Crack damage abnormal knock hole Disassembling and inspecting flywheel Disassembling sequence 1 Flywheel 3 Oil seal case oil seal 2 Flywheel housing 5 6 DISASSEMBLY OF BASIC ENGINE 2 1 Removing flywheel a Be careful not to cut yourself with the ring gear when pulling out the flywheel Be careful not to drop or hit the flywheel when removing The personnel who holds the pulley must pay due attention to safety Also personnel must stay in close contact with each other during work Prevent the flywheel from rotating using a wrench 1 One personnel must firmly hold the pulley with a Detent of flywheel wrench to prevent the flywheel from turning 2 Remove one bolt from the flywheel 3 Screw a guide bolt into the threaded hole of the bolt that has been removed 4 Remove remaining bolts from the flywheel 5 Hold the flywheel firmly with both hands and by moving it back and forth pull it out straight Note The ring gear is shrink fitted to the flywheel Do not remove the ring gear unless it is defective Guide bolt M10 x 1 25mm Removing flywheel 2 2 Removing flywheel housing Be careful not to damage the oil seal 1 Remove bolts from the flywheel housing 2 Remove the flywheel housing 2 3 Removing oil seal case Be very careful not to damage the oil seal 1 Remove bolts from the oil seal case 2 Pry out the oil seal case
26. expander 2 Install the oil ring with its end gap 180 away from the joint of the coil spring as shown in the illustration 1 9 Installing piston and connecting rod Do not forcefully insert the piston as it may cause damage to the piston rings and crank pin 1 Apply engine oil to the circumference of the piston and piston rings 2 Place the ring end gaps in diagonal positions avoiding the piston pin direction and its right angle direction 3 Fit the connecting rod bearing upper to the connecting rod aligning the lug and lug groove 4 Turn the crankshaft to place the crank pin of the assembling cylinder to the top dead center 5 Face the front mark arrow stamped on the piston top toward the timing gear case side forward of the engine 6 Insert the piston from the top face of cylinder block using a piston guide commercially available Se Top face mark No 1 compression ring No 2 compression ring Reassembling pistons and piston rings Coil spring butted ends Oil ring abutment Oil ring end gap coil spring joint orientation Oil ring Pa No 1 ring end gap Front L PA spring joint No 2 ring end gap Orienting piston ring end gaps Installing pistons and connecting rods REASSEMBLY OF BASIC ENGINE 1 10 Installing connecting rod cap 1 When the big end of the connecting rod comes into close contact with the crank pin turn the crankshaft 180 while press
27. nut 3 Put a torque spring set sealing cap on the torque spring and firmly tighten the sealing cap 3 2 4 Installing torque set spring Double spring two point control Adjust and reassemble the torque spring set as described in the following 1 Adjust the speed control lever with the high speed set bolt After setting it to the high idle engine speed secure it by nut 2 Screw in the torque spring set at maximum torque engine speed Set it to the maximum torque and secure it by special nut 3 Screw in the adjusting screw at the rated engine speed Set it to the rated engine power and secure it by special nut 4 Put a torque spring set sealing cap on the torque spring and firmly tighten the sealing cap For installation and adjustment Pal A iP Do not wrok on this screw unless absolutely necessary Screw in the torque spring set at the rated engine speed Set it to the rated power and secure it by special nut Special nut 14 7 24 5N m 1 5 2 5 kgf m 10 9 18 1 Ibf ft fix it after setting Installing torque spring set single spring For installation and adjustment Screw in the adjusting screw at the rated engine speed Set it to the rated engine power and secure it by special nut Screw in the torque spring set at maximum torque engine speed Set it to the maximum torque and secure it by special nut Sealing cap fix it after setting Special nut
28. 0020 in or less 0 0039 in INSPECTION AND REPAIR OF BASIC ENGINE Measuring points and directions Measuring crankcase top surface distortion 6 19 REASSEMBLY OF BASIC ENGINE 1 Reassembling cylinder block crankshaft piston and oil pan 7 2 1 1 Installing main bearing eee 7 2 1 2 Installing crankshaft 0 00 0 7 2 1 3 Installing main bearing Cap eee 7 3 1 4 Inserting side seal 7 3 1 5 Installing main bearing cap bolt 7 4 1 6 Measuring crankshaft end play 7 4 1 7 Reassembling piston and connecting rod 7 5 1 8 Installing piston ee eeeeeeeeeeeeeeees 7 6 1 9 Installing piston and connecting rod 7 6 1 10 Installing connecting rod cap 7 7 1 11 Installing oil screen seses 7 8 1 12 Installing oil pan sses 7 8 2 Reassembling gear case timing gear and CamsShalt icc etter tc 7 9 2 1 Installing front plate eeeeeeeeeeee 7 9 2 2 Rotating crankshaft 7 9 2 3 Installing fuel injection pump camshaft 7 9 2 4 Installing camshaft eee 7 10 2 5 Installing idler gear 7 10 2 6 Inspecting and adjusting timing gear after installation 7 11 2 6 1 Inspecting backlash 7 11 2 7 Installing governor weights and Sliding shafts ce eeeeeeeeeeeteeeeeeeenaees 7 11 2 8 Installing speed control lever and governor Shaft eeeseeeeeeeeteeeeeeenaees 7 12 2 9 Installing relief valve 7 12 2 10 Installing oil PUMP 0 0
29. 1 Removing oil pump 1 Remove the oil pump housing from the gear case 2 Remove the oil pump outer gear and oil pump inner Oil pump inner gear Oil pump housing gear from the oil pump housing Gear case Oil pump outer gear Removing oil pump 9 4 LUBRICATION SYSTEM 2 Disassembling inspecting and reassembling lubrication system 2 1 Inspecting oil pump 2 1 1 Measuring clearance between oil pump housing inside diameter and oil pump outer gear outside diameter Measure the clearance using thickness gauges Replace the gear or housing if the limit is exceeded Item Standard Limit Clearance between oil pump housing inside diameter and oil pump outer gear outside diameter 0 100 to 0 196 mm 0 3 mm 0 012 in 0 0039 to 0 0077 in 2 1 2 Measuring the end clearance between oil pump outer gear width and oil pump hous ing depth Measure the end clearance using feeler gauges Replace the gear or housing if the limit is exceeded Item Standard Limit End clearance between oil pump outergear width and oil pump housing depth 0 040 to 0 100 mm 0 25 mm 0 0016 to 0 0039 in 0 0099 in Measuring clearance between oil pump housing inside diameter and oil pump outer gear outside diameter Measuring the difference between oil pump outer gear width and oil pump housing 9 5 LUBRICATION SYSTEM 2 2 Inspecting relief valve 1 Check the relief valve and its seat for contact C
30. 11 2 3 Inspecting fuel injection pump on engine8 12 2 4 Disassembling and inspecting fuel injection PUMP ccc eeeeeeeeeenees 8 12 2 4 1 Removing swivel nipple eee 8 13 2 4 2 Removing tappets s 8 13 2 4 3 Removing plunger scce 8 13 2 4 4 Removing delivery valve 0 00 eee 8 14 2 5 Reassembling fuel injection pump 8 15 2 5 1 Installing plunger barrel eee 8 15 2 5 2 Assembling delivery valve ee 8 16 2 5 3 Assembling control sleeve n se 8 16 2 5 4 Assembling plunger 8 16 2 5 5 Installing tappet 8 17 2 5 6 Installing control rack sses 8 17 2 5 7 Tightening delivery valve holder 8 18 2 5 8 Inspecting control rack for smooth operation seseeeeeeeeeeree 8 18 2 5 9 Installing lock plate eee eeeeeee 8 18 2 5 10 Installing swivel nipple eee 8 18 2 6 Disassembling and inspecting governor COVE Meta dacdes aboot coin a a 8 19 2 7 Reassembling governor cover 8 19 2 8 Disassembling and inspecting torque SPIMING SOt veeeis esse peat cere teen AS 8 20 2 9 Reassembling torque spring set 8 20 2 9 1 Torque spring set single spring type 8 21 2 9 2 Reassembling torque spring set double spring type eee eeeeeeeeeeeeee 8 22 2 10 Inspecting fuel PUMP eee eee 8 23 2 11 Disassembling inspecting and reassembling fuel filter cock switch type push botton 8 24 2 12 Disassembling inspecting and reassembling fuel
31. 34 1 3396 to 1 3396 Camshaft Bore Inside Diameter No 3 33 000 to 33 025 No 4 f 1 2992 to 1 3002 Camshaft Journal Outside Diameter to No 2 Cylinder Block No 3 Camshaft Bore No 4 Clearance 0 050 to 0 100 0 150 0 0020 to 0 0039 0 0059 Measured Values Camshaft Journal Outside Cylinder Block Camshaft Part Name Clearance Diameter Bore Inside Diameter Supplement 12 INSPECTION RECORD SHEET No 12 Compan Engine Model si m sane J Inspecti raer Measurement of Crankshaft End Play Measuring Positions Standard O T o imi Crankshaft End Play 0 050 to 0 175 0 500 0 0020 to 0 0069 0 0197 Measured Values Disassembling During Reassembling Supplement 13
32. 36 psi 4 3 DISASSEMBLY OF BASIC ENGINE 1 Disassembling and inspecting cylinder head and valve mechanism 5 2 1 1 Removing rocker shaft assembly 5 3 1 2 Disassembling rocker shaft assembly 5 3 1 3 Removing cylinder head bolt 5 4 1 4 Removing cylinder head assembly 5 4 1 5 Removing valves and valve spring 5 5 1 6 Removing valve stem Seal eee 5 5 2 Disassembling and inspecting flywheel etek ee he a ee 5 6 2 1 Removing flywheel 5 7 2 2 Removing flywheel housing 0 5 7 2 3 Removing oil seal Case eee 5 7 3 Disassembling and inspecting gear case timing gears and camshatt 5 8 3 1 Removing tappet 5 9 3 2 Removing gear pump housing 5 9 3 3 Removing crankshaft pulley 5 9 3 4 Removing timing gear case ee 5 9 3 5 Removing PTO gear 5 10 3 6 Removing oil PUMP eter eres 5 10 3 7 Removing relief valve 5 10 3 8 Removing governor shaft and speed control lever rr 5 10 3 9 Measuring timing gear backlash 5 11 3 10 Removing idler gear 5 11 3 11 Removing camshaft eee 5 12 3 12 Removing fuel injection pump camshaft 5 13 3 13 Removing front plate eee 5 14 4 Disassembling and inspecting cylinder block crankshaft piston and elle 6 9 Benepe cea aa oar en aay 5 15 4 1 Removing oil pan seseeeeeeeeeeeeeen 5 16 4 2 Removing oil screen sss 5 16 4 3
33. O ring of the lever When dust or water is accumulated at the case bottom or in the element replace the filter as an assembly Replace the fuel filter every 400 hours Check the filter every 100 hours If defective replace the filter regardless of the replacement interval Replace the entire assembly if water sediment is accumulated inside Inspect every 100 hours Replace every 400 hours Inspecting fuel filter cartridge type 8 25 FUEL SYSTEM 3 Installing fuel system 3 1 Installing fuel injection pump Installing fuel injection pump 8 26 FUEL SYSTEM 3 2 Installing governor 14 7 to 24 5N m 1 5 to 2 5kgf m Replace 10 8 to 18 1Ibf ft g Fatigue and crack Q p A A g Wear and damage of weight Fatigue and crack Wear and damage of sliding sleeve Replace Wear and damage of sliding shaft contact Installing governor 8 27 FUEL SYSTEM 3 2 1 Installing speed control lever and governor shaft 1 Insert the governor shaft into the gear case while placing the governor lever and the tension lever 2 Drive the grooved pin A into the gear case 3 Drive new sealing cap into the gear case 4 Thoroughly apply Alvania Grease 2 or 3 to the governor shaft cover 5 With governor shaft cover installed on speed control lever install a new O ring on the speed control lever and insert i
34. Valve opening pressure 76 5 1 5 C 169 7 34 7 F Type Suction PP fan A 4 variable pitch blades 290 mm 11 42 in Cooling fan N of blades 5 variable pitch blades 320 mm 12 60 in Outside diameter 6 variable pitch blades 320 mm 12 60 in Inlet Air cleaner Type Paper element system 1 12 GENERAL Table 1 2 Specifications of L3A L3C and L3E 3 4 Engine model L3A L3C L3E Electrical system Voltage polarity 12V negative ground 24V negative ground Type MO000T6048 1 Manufacturer Pinion engagement type Mitsubishi Electric Corporation Pinion shift reduction type Starter 1 Output 12V 1 2 kW Number 1 Pinion ring gear ratio 14 106 Type M001T68381 Manufacturer Mitsubishi Electric Corporation Pinion engagement type Pinion shift reduction type Starter 2 Output 12V 1 7 kW Number 1 Pinion ring gear ratio 14 106 Type M002T66071 Manufacturer Mitsubishi Electric Corporation Pinion engagement type Pinion shift reduction type Starter 3 Output 24V 3 2 kW Number 1 Pinion ring gear ratio 15 106 Type A007TA0171B Three phase current generator Type integral with IC regulator Alternator 1 Manufacturer Mitsubishi Electric Corporation Output 12V 40A Rated voltage generating speed 5000 min at 13 5V 37A when hot Regulator adjusting voltage 14 7 0 3V T
35. Width across flats l Spanner Mee 8 mm x 10 mm 0 32 x 0 39 in Width across flats 2 spanner Moen 12 mm x 14 mm 0 47 x 0 55 in Width across flats Spanner MEK38017012 17 mm x 19 mm 0 69 x 0 75 in 4 Screwdriver MM300110 5 Tool bag MM300783 SERVICE TOOLS 2 Special tools Tool name Part No Shape Use 30L91 00030 L2A L3A Piston pin setting 30L91 00020 ea For pulling out and press fitting tool L2C L3C piston pins 30L91 10010 L2E L3E Compression gauge T332270 For measuring compression adapter Oil pressure switch socket MD998054 For removing and installing oil wrench 26 pressure switch Range applicable for removing Piston ring pliers 31391 12900 and installing piston rings 60 to 95 mm 2 36 to 3 74 in 3 3 DETERMINATION OF OVERHAUL 1 Determining overhaul timing 4 2 2 Testing compression pressure 4 3 4 1 DETERMINATION OF OVERHAUL 1 Determining overhaul timing In most cases the engine should be overhauled when the compression pressure of the engine becomes low An increase in engine oil consumption and blow by gas are also considered to evaluate the engine condition Besides such symptoms as a decrease in output increase in fuel consumption decrease in oil pressure difficulty of engine starting and increase in noise are also considered for judging the overhaul timing although those symptoms are often
36. air from fuel filter switch cock type Left side plug Right side plug Cock lever open Bleeding air from fuel filter 13 7 ADJUSTMENT AND OPERATION 1 5 2 Bleeding air from fuel injection pump Loosen the air vent screw of pump to discharge air in the fuel pipe and fuel injection pump Note Air in the fuel injection pipe and fuel injection nozzle is automatically discharged by cranking of the engine 13 8 Air vent screw Bleeding air from fuel injection pump ADJUSTMENT AND OPERATION 1 6 Adjusting V belt tension 1 Loosen the adjusting bolt and fixing bolt of the alternator Loop the V belt over the water pump pulley alternator pulley and crankshaft pulley 2 With the alternator pushed toward the V belt tension side tighten the adjusting bolt at an appropriate position 3 Inspect the V belt tension to make sure it is within the specified value Belt tension with pushing force of approx 98 N 10 kgf 22 Ibf Approx 10 mm 0 39 in Water pump __ Adjusting bolt pulley Alternator pulley Approx 10 mm 0 39 in oe Deflection approx 10 mm 0 39 in pushing force approx 98 N 10 kgf 22Ibf Crankshaft pulley Adjusting deflection of V belt 13 9 ADJUSTMENT AND OPERATION 2 Break in operation After the engine is overhauled couple the engine to the dynamometer and run the engine for break in operation and inspection 2 1 St
37. and the other gears Fuel injection pump camshaft gear 3 Fix the idler gear shaft with a snap ring 4 Move the idler gear back and forth and make sure there is end play Apply engine oil Camshaft gear Crankshaft gear Idler gear WW ty Installing idler gear 7 10 2 6 Inspecting and adjusting timing gear after installation Be sure to inspect and adjust the timing gear when the timing gear has been reassembled 2 6 1 Inspecting backlash Check backlash between each gear after installing the timing gears 2 7 Installing governor weights and sliding shaft Install the governor weights and sliding shaft on the fuel injection pump camshaft gear REASSEMBLY OF BASIC ENGINE Measuring timing gear backlash Sliding shaft 18 Governor weight Installing governor weight and sliding shaft 7 11 REASSEMBLY OF BASIC ENGINE 2 8 Installing speed control lever and governor shaft 1 Insert the governor shaft into the gear case with the governor lever and the tension lever positioned in place 2 Drive the grooved pin into the gear case 3 Drive new sealing cap into the gear case 4 Thoroughly apply Alvania Grease 2 or 3 to the governor shaft cover 5 Install new O ring on the speed control lever and insert it into the gear case through the governor shaft 6 Drive the grooved pin into the gear case 7 Install the governor spring lever Note Install the governor spring le
38. be careful not to dam age the tip 1 Loosen the retaining nut then remove the nozzle tip and clean the needle valve and body 2 Clean the nozzle tip in clean wash oil After cleaning assemble the needle valve and body in clean diesel fuel Note The needle valve and body are precision parts Handle them carefully and do not change the combination of the valve and body 3 Tighten the nozzle tip retaining nut to the specified torque 4 If the spray pattern is still faulty after cleaning and adjusting replace the nozzle tip Note When using a new nozzle tip remove the anti corrosive agent from the nozzle tip and clean the nozzle tip in wash oil Then clean the tip again in the fuel before assembly 8 10 Defective spray pattern Td Le eo ey ee i fw amp Aik Good Large After Deflected Branched spray dribble spray spray angle Checking fuel spray pattern from fuel injection nozzle Needle valve Body Cleaning nozzle tip assembly FUEL SYSTEM 2 2 Reassembling fuel injection nozzles Tightening torque 34 3 to 39 2 N m 3 5 to 4 0 kgf m 25 3 to 28 9 Ibf ft Tightening torque 49 0 to 58 8 N m 5 0 to 6 0 kgf m 36 2 to 43 4 Ibf ft Reassembling fuel injection nozzles 8 11 FUEL SYSTEM 2 3 Inspecting fuel injection pump on engine Do not disassemble the fuel injection pump unless it is absolutely necessary
39. brush measure the spring load at which the spring lifts from the brush If the measured value is less than the limit replace the spring with a new one Item Standard Limit 17 5 to 23 7 N 6 86 N Brush spring load 1 78 to 2 42 kgf 0 70 kgf 3 92 to 5 34 lbf 1 54 Ibf 2 4 3 Inspecting brush holder for insulation Check that there is no continuity between each brush holder and the brush holder base If continuity is observed replace the whole brush holder assembly Check the brush holders for looseness Measure the length of the brush Replace if the length is equal to or less than the limit Inspecting brushes for wear i Measuring brush spring load Insulated brush holder Checking brush holder for grounding 12 15 ELECTRICAL SYSTEM 2 4 4 Measuring commutator radial runout 1 Inspect the commutator surface If the surface is rough polish it using a 400 to 600 grit sandpaper 2 Measure the commutator radial runout with a dial gauge If the measured value exceeds the limit replace the armature with a new one Item Standard Limit Commutator radial runout ant oe 0 0012 in 0 0039 in 2 4 5 Measuring commutator outside diameter Measure the commutator outside diameter If the measured value is less than the limit replace the armature with a new one Item Standard Limit 29 4 mm 1 158 in 28 8 mm Commutator outside d
40. center journal using a dial gauge If the runout deviates from the standard only slightly grind the crankshaft to repair If the runout exceeds the standard considerably straighten the crankshaft using a press If the limit is exceeded replace the crankshaft If the crankshaft has been repaired by grinding or pressing inspect the crankshaft for cracks and other harmful damage using a magnetic particle method Measuring bend of crankshaft Item Standard Remark 0 06 mm Crankshaft runout 0 0024 in TIR 4 11 Replacing crankshaft gear 4 11 1 Removing crankshaft gear Using a gear puller remove the gear from the crankshaft eet Puller Note Do not strike the gear with a hammer 4 11 2 Installing crankshaft gear 1 Install the key on the crankshaft 2 Press fit the gear fully in alignment with the key Aligning position Installing crankshaft gear 6 18 4 12 Measuring distortion cylinder block top surface Refacing of cylinder head should be kept to an abso lute minimum Excessive grinding of the cylinder head may result in defects such as defective combustion and stamping contact between piston and valve Apply a straight edge to the top surface of the cylinder block and measure its distortion using a feeler gauge If the distortion exceeds the limit grind the cylinder block using a surface grinder Item Standard Limit Distortion of cylinder block 0 05 mm 0 10 mm top surface 0
41. disassembling 12 26 2 7 2 Removing magnetic switch 12 26 2 7 3 Removing rear bracket ee 12 26 2 7 4 Removing brushes brush holder yoke and armature seeren 12 27 2 7 5 Removing ball bearing 12 27 2 7 6 Removing cover S t 12 27 2 7 7 Removing center bracket 12 28 2 7 8 Removing reduction gear and Spring Setecin tt 12 28 2 7 9 Removing pinion s t 12 28 2 7 10 Removing lever and pinion shaft 12 28 2 8 Inspecting and repairing starter MO02T66071 24V 3 2KW noesa 12 29 2 8 1 Inspecting brushes for wear 12 29 2 8 2 Measuring brush spring load 12 29 2 8 3 Inspecting brush holder for insulation 12 29 2 8 4 Measuring commutator radial runout 12 30 2 8 5 Measuring commutator outside diameter12 30 2 8 6 Measuring undercut depth 12 30 2 8 7 Checking armature coil 12 31 2 8 8 Inspecting continuity of yoke assembly 12 32 2 8 9 Inspecting insulation between yoke body ANC DrUShxisssieis seen iced eis 12 32 2 8 10 Inspecting center bracket 06 12 32 2 8 11 Inspecting overrunning clutch 12 33 2 8 12 Inspecting pinion 12 33 2 8 13 Inspecting front bracket ee 12 33 2 8 14 Inspecting gears of starter 12 33 ELECTRICAL SYSTEM 2 8 15 Inspecting continuity of magnetic switch between M terminal and case 12 33 2 8 16 Inspecting insulation of magnetic switch between M terminal and B terminal
42. extremely hot while the engine is operating is provided with various heat shields Do not remove these heat shields If any of these heat shields have been removed owing to un avoidable circumstances during the work be sure to re store them after the work is completed Be careful of exhaust fume poi soning Operate engine in well ventilated area If the engine is installed in an en closed area and the exhaust gas is nm ducted outside ensure that there is no exhaust gas leak from duct Ad joints Take care that the exhaust gas is not discharged toward plants or animals Exhaust gas from the engine contains carbon monox ide and other harmful substances Operating the en gine in an ill ventilated area can produce gas poisoning Protect ears from noises Wear ear plugs Always wear ear plugs when enter ing the machine room engine room Combustion sound and me chanical noise generated by the en gine can cause hearing problems INTRODUCTION Be careful of falling down Lift engine correctly To lift the engine always use a cor rect wire rope capable of withstand a ing the engine weight Attach the wire rope to the lifting hangers provided on the engine us ing a correct sling During lifting process keep the en gine in a well balanced position by taking the center of gravity of the engine into consideration If the wire rope contacts the engine directly place a cloth or other soft padding
43. filter cock switch type changover 8 25 3 Installing fuel system 00 8 26 3 1 Installing fuel injection pump 8 26 3 2 Installing QOVErNOl ee eeeeeeeeeeeeeee 8 27 3 2 1 Installing speed control lever and governor Shafta siki aee k 8 28 3 2 2 Connecting tie rod seeen 8 28 3 2 3 Installing torque spring set Single spring double spring 8 29 3 2 4 Installing torque set spring Double spring two point control 8 29 3 2 5 Installing rack set SCreW ceecee 8 30 3 3 Installing fuel filter 0 eee 8 31 3 4 Installing fuel pipe and fuel injection MOZZIOS e a a EEA 8 32 3 4 1 Installing fuel injection nozzle 8 32 3 4 2 Installing fuel return pipe and fuel injection Ppap i dee idte ce walie ed eis iesabedes 8 32 8 1 FUEL SYSTEM 1 Removing fuel system Cover the openings on the injection pipe nozzle inlet connector and injection pipe to prevent dust from entering the fuel system 1 1 Removing fuel pipe and fuel injection nozzle Replace Holder gasket Removing fuel pipe and fuel injection nozzle Removing sequence 1 No 1 fuel injection pipe 4 Fuel return pipe 2 No 2 fuel injection pipe 5 Fuel injection nozzle 3 No 3 fuel injection pipe 8 2 FUEL SYSTEM 1 1 1 Removing fuel injection pipe Remove the fuel injection pipe and fuel return pipe 1 1 2 Removing fuel injection nozzle Using a wrench loosen the nozz
44. first When reconnecting the cables attach the cable to the posi tive terminal first Charge the battery in a well ventilated area with all filling hole plugs removed Make sure the cable clamps are securely installed on the battery terminals A loose cable clamp can cause sparks that may result in an explosion Before servicing electrical components or conducting electric welding set the battery switch to the Open OFF position or disconnect the cable from the nega tive battery terminal to cut off the electrical cur rent Electrolyte battery fluid contains dilute sulfuric acid Careless handling of the battery can lead to the loss of sight and or skin burns Also keep the battery fluid off the mouth Wear protective goggles and rubber gloves when working with the battery when adding water charg ing etc If electrolyte is spilled onto the skin or clothing immediately wash it away with lots of water Use soap to thoroughly clean The battery fluid can cause blindness if splashing into eyes If it gets into eyes immediately flush it away with plenty of clean fresh water and seek immediate medical attention e If the battery fluid is accidentally swallowed gargle with plenty of water then drink lots of water and seek immediate medical attention When abnormality occurs Stop overheated engine after cooling run Even if the engine comes to overheat do not stop the engine immediately Ab
45. kgf m 7 to 9 Ibf ft Apply Multemp PS2 Kyodo Yushimade or equivalent ave Po 2 4 to 4 4 Nem 0 24 to 0 45 kgf m Apply Molykote RAG650 7 to 9 Ibf ft Dow Corning Asia made or equivalent Reassembling starter MO00T60481 12V 1 2kW M001T68381 12V 1 7kW 2 5 1 Applying grease To avoid mixing of different greases remove old grease before applying new grease Make sure that the starter mounting surface brushes commutator and other electric current conducting compo nents are free from grease When overhauling the starter apply grease to the following sliding surfaces gears and bearings 1 Areas to which Multemp PS2 Kyodo Yushi made or the equivalent is applied Plunger surface a small amount Spline of gear shaft Shaft sliding area of overrunning clutch Sliding area between lever and overrunning clutch Gear shaft Bearing of gear shaft Pinion gear fitting surface Rear bearing 2 Areas to which Molykote AG 650 Dow Corning Asia made or the equivalent is applied Ball Gear shaft gear and internal gear of armature 12 19 ELECTRICAL SYSTEM 2 5 2 Installing pinion Before assembling apply grease to the inner race groove of the front bracket bearing Be sure to use a new stopper ring Do not reuse the stopper ring that has been removed 1 Put
46. of the cylinder block and pistons 2 Screw in two guide bolts in the bolt holes of the cylinder block 3 Place the new cylinder head gasket on the cylinder block aligning to the guide bolts Note The model name is stamped on the front top face of the gasket so that it is not confused with one for other model 4 6 Installing cylinder head assembly Align the cylinder head to the locating guide bolts and install the cylinder head 7 18 Valve lock Installing valve lock Guide bolt eee jee JI ea a th g gasket Installing cylinder head gasket Cylinder head Installing cylinder head assembly REASSEMBLY OF BASIC ENGINE 4 7 Tightening cylinder head bolts In the numerical order as shown in the illustration tighten Cylinder head bolt main 73 5 to 83 4N m cylinder head bolts progressively to the specified torque 5 t 8 5kgf m 54 2 to 61 5lbf ft Cylinder head bolt sub 19 6 to 29 4N m 2 0 to 3 0kgf m 14 7 to 21 7Ibf ft Tightening order of cylinder head bolts L2 Cylinder head bolt main 73 5 to 83 4 N m 7 5 to 8 5 kgf m 54 2 to 61 5 Ibf ft Cylinder head bolt sub 19 6 to 29 4N m 2 0 to 3 0 kgf m 14 7 to 21 7 Ibf ft 4 8 Inserting push rod 1 Insert each push rod into its hole in the cylinder head 2 Make sure that the ball end of each push rod is placed correctly on the tappet cup Inserting push rods 7 19 REA
47. of the disassembly procedures 4 1 Cleaning cylinder head bottom surface Taking care not to damage the cylinder head bottom surface remove residue of old gasket Note First roughly scrape off residue of old gasket using a scraper Then grind off the remaining residue using an engine oil immersed oil stone 4 2 Installing valve stem seal Do not apply oil or liquid gasket to the inner side of stem seal that comes in contact with the valve guide 1 Apply engine oil to the lip of the valve stem seal 2 Push the shoulder of the valve stem seal and fit the valve stem steal into the valve guide 3 Make sure the valve stem steal is fully inserted into the valve guide 4 3 Installing valve spring Install the valve spring with its white or yellow enamel painted side facing upward Scraping gasket Push on in these faces Valve stem seal Installing valve stem seal White or yellow enamel painted side Installing valve spring 7 17 REASSEMBLY OF BASIC ENGINE 4 4 Installing valve lock If valve spring is overcompressed the lower end of the retainer comes into contact with the stem seal and causes damage to the stem seal Install the retainer on the valve spring Compress the valve spring using a valve lifter and install the valve locks 4 5 Installing cylinder head gasket Do not use liquid gasket 1 Make sure that there is no dirt or dents on the top surfaces
48. pinion in the out position with a finger and measure the distance over which the pinion has returned movement amount 5 If the measured value is out of the standard increase or decrease the number of packings between the magnetic switch and the front bracket for adjustment or replace the lever with a new one Note When the number of packings is increased the pinion clearance becomes small Item Standard Pinion gap 0 5 to 2 0 mm 0 0197 to 0 0787 in 12 22 Battery 12V Disconnect the lead with a terminal connected to terminal M Wiring during inspection of pinion clearance Pinion Gently push back the pinion Pinion clearance 0 5 to 2 0 mm 0 0197 to 0 0787 in Inspecting pinion clearance ELECTRICAL SYSTEM 2 6 Inspection before disassembling starter M002T66071 24V 3 2kW 2 6 1 Inspecting pinion clearance Do not apply current continuously for longer than 10 seconds 1 Connect the starter to the circuit as shown in the illustration 2 When the switches SW1 and SW2 are turned ON the pinion springs out to the cranking position and the armature rotates 3 Turn the switch SW2 OFF to stop the rotation of the armature 4 Gently push back the pinion in the out position with a finger and measure the distance over which the pinion has returned movement amount 5 If the measured value is out of the standard increase or decrease the number of packings between the
49. swallowed induce vomit ing immediately and seek medical attention Should LLC enter your eyes flush them immediately with plen ty of water and seek medical attention If LLC splashes onto your skin or clothing wash it away immediately with plenty of water Keep flames away from LLC The LLC can catch flames causing a fire Coolant containing LLC is a hazardous material Do not dispose of it in unauthorized manner Abide by the ap plicable law and regulations when discarding drained coolant Proper disposal of waste oil and coolant LLC Do not discharge waste engine oil or coolant into sew erage river lake or other similar places Such a way of disposal is strictly prohibited by laws and regulations Dispose of waste oil coolant and other environmentally hazardous waste in accordance with the applicable law and regulations or consult a Mitsubishi dealer INTRODUCTION Service battery Handle the battery correctly e Never use flames or allow sparks to generate near the battery The battery releases flammable hydrogen gas and oxygen gas Any flames or sparks in the vicin ity could cause an explosion Do not use the battery the fluid level of which is low ered below the lower limit line Sustained use of the battery could result in an explosion Do not short the battery terminals with a tool or other metal object When disconnecting battery cables always remove the cable from the negative terminal
50. the pump housing upside down and grab the housing with a vise 2 Remove the stop wire bracket and remove the control rack 3 Push in the tappet and pull out the tappet guide pin with tweezers 4 Remove the tappet 2 4 3 Removing plunger Using tweezers remove the tappet shim plate spring lower seat plunger plunger spring spring upper seat and control sleeve from the pump housing Pump housing Swivel nipple Removing tappet guide pin Tappet shim plate gt C_ Spring lower seat B el Plunger spring Spring upper seat 7 li T sleeve IN Removing plunger 8 13 FUEL SYSTEM 2 4 4 Removing delivery valve a The delivery valve plunger and plunger barrel are precision machined parts Do not smear or scratch them b Keep the combination of the plunger barrel and plunger for each cylinder when removing Do not mix the plunger barrel with the plunger of a differ ent cylinder 1 With pump housing faced up grab the housing with a vise 2 Remove outside lock plates first and remove center lock plate at the last 3 Remove the delivery valve holder 4 Remove the delivery valve spring 5 Using tweezers remove the delivery valve gasket delivery valve and plunger barrel from the pump housing 8 14 Pump Lock plate housing Removing lock plate Delivery valve holder Removing delivery valve FUEL SYSTEM 2 5 Reassembling f
51. thrust journal width and the width of the bearing cap assembled with thrust plates Item Standard Limit 0 050 to 0 175 mm 0 500 mm Crankshaft end play 19 992016 0 0069in 0 0197 in 4 8 Removing main bearing cap 1 Remove the main bearing cap bolts 2 Remove the main bearing caps To remove the main bearing caps of front and rear sides use a driver as leverage Place the tip of driver in the oil hole and remove the cap using the crankshaft balance weight as the fulcrum Note a Be careful not to damage the main bearings b Mark the main bearings for their cylinder numbers for reassembly 4 9 Removing crankshaft Be careful not to damage bearings when removing the crankshaft 1 Slowly lift the crankshaft straight up 2 Arrange the bearings in the order of disassembly so that their original positions are restored when reassembling Note a When raising the crankshaft do not allow wire chain to come into contact with the crankshaft To avoid damage to the crankshaft when raising use a cloth belt or pad b Mark the bearings for their cylinder numbers 5 18 Measuring crankshaft end play o Lox Removing crankshaft INSPECTION AND REPAIR OF BASIC ENGINE 1 Inspecting and repairing cylinder head and valve mechanism 0006 6 2 1 1 Measuring clearance between rocker arm and rocker shaft 6 2 1 2 Measuring valve stem out
52. 0059 to 0 0138 in 4 4 Measuring clearance between piston ring groove and piston ring Remove carbon deposits from pistons and check the entire circumference of the piston 1 Remove deposits such as carbon from each ring groove 2 Check each ring groove for wear or damage If it is worn or damaged replace the piston with a new one 3 Insert the piston ring into the piston ring groove Apply a straight edge and insert thickness gauges to measure the clearance between ring and ring groove Measuring piston ring groove If the limit is exceeded replace the piston ring with a new one 5 When the piston ring has been replaced measure the clearance again and if the limit is exceeded then replace the piston with a new one Item Standard Limit No 1 0 3 mm compres 0 0118 sion ring in Clearance between No 2 0 05 to 0 09 mm 0 2 mm ring and ring compres 0 0020 i 0 0035 in 0 0079 groove sion ring i in 0 2 mm Oil ring 0 03 to 0 07 mm 0 0079 0 0019 to 0 0028 in in 6 13 INSPECTION AND REPAIR OF BASIC ENGINE 4 5 Measuring piston pin bore diameter and piston pin outside diameter Measure the piston pin bore diameter and piston pin outside diameter Replace if the limit is exceeded Item Nominal Standard Limit 18 001 to L2A L3A 18 mm 18 007 mm L2C L3C 0 71 in 0 7087 to j Outside 0 7089 in diameter of pi
53. 1 2 1 4 Cooling SyYStem eeeeeeeeereren 2 11 2 1 5 Inlet and exhaust systemMS ee 2 11 2 1 6 Electrical system eee eeeseeeeeeeeneeees 2 11 2 2 Standard bolt and nut tightening torque 2 12 2 3 Standard eyebolt tightening torque 2 13 2 4 Standard union nut tightening torque 2 13 2 5 High pressure fuel injection pipe tightening TOFQUO sis E ATT TE 2 13 2 1 SERVICE DATA 1 Maintenance service data 1 1 Engine general Table 2 1 Maintenance service data table Engine general Unit mm in Inspection point Nominal Standard Limit Remark Maximum rotation speed a rated rotation speed used as reference Varies depending on specification of Adjusted by the governor destination Minimum rotation speed 2 7 MPa Not acceptable at or When oil and water tempera c o e at 280 min 28k Hem below 2 2 MPa tures ompression pressure a min air i 22 kgf cm at 20 to 30 C psi 313 psi 68 to 86 F 0 29 to 0 39 MPa Rotated speed 3 to 4 kgf cm aera 42 7 to 56 9 psi Oil temperature eae oil at 60 to 70 C pressure 0 10 MPa 140 to 158 F Low idling 1 0kgf cm 14 2 psi Inlet open BTDC 18 Values for checking valve Inlet open ABDC 46 timing Valve timing Exhaust open BBDC 46 Different from actual valve opening and closing timing Exhaust open ATDC 18 Inlet 0 25 0 0098 Valve clearance When engine is cold Exhaust 0 25 0 0098 Fuel injecti
54. 12 33 2 9 Reassembling starter MO02T66071 24V 3 2kW ceecee 12 34 2 9 1 Applying grease seee 12 34 2 9 2 Installing lever and pinion shaft 12 35 2 9 3 Installing pinion oo eee eters 12 35 2 9 4 Installing spring set and reduction gear 12 35 2 9 5 Installing center bracket ee 12 35 2 9 6 Adjusting pinion shaft end play 12 36 2 9 7 Installing bearing s e 12 36 2 9 8 Installing armature yoke brush and brush holder eeeeeeeeeeeeeeeeeneeeeneeeees 12 36 2 9 9 Installing rear bracket 12 37 2 9 10 Installing magnetic switch ee 12 37 2 9 11 Inspecting pinion clearance 12 37 2 10 Disassembling and inspecting alternator1 2 38 2 10 1 Separating front bracket from stator 12 39 2 10 2 Removing pulley 12 39 2 10 3 Removing rear bearing 12 39 2 10 4 Removing front bearing eee 12 39 2 10 5 Removing stator s e 12 40 2 10 6 Removing regulator assembly 12 40 2 10 7 Removing rectifier assembly 12 40 2 11 Inspecting and repairing alternator 12 41 2 11 1 Inspecting rectifier ees 12 41 2 11 2 Inspecting rotor oo eee eee eeeeeeeeeeees 12 41 2 11 3 Inspecting stator 12 42 2 11 4 Inspecting brushes for wear 12 42 2 11 5 Replacing brushes 0 eee 12 43 2 12 Reassembling alternator 005 12 44 2 12 1 Installing rectifier assembly and regulator assembly 0 0 eeeeeeeeeeeeeeeees 12 45
55. 2 11 470 to 11 984 Diameter 0 47 0 4516 to 0 4718 Clearance between 0 029 to 0 065 0 200 Rocker Arm and Shaft 0 0011 to 0 0026 0 0079 Measured Values Diameter CS o o a e A S E E E A E 1 ea ooo es o T y see o ooo o T T f Supplement 7 No 7 INSPECTION RECORD SHEET Engine Model omw e eoe O Inspection Measurement of Piston Pin Bore Diameter and Piston Pin Point Outside Diameter Measuring Positions Standard L2A L3A 18 18 013 to 18 019 Piston Pin Bore L2C L3C 0 71 0 7092 to 0 7094 Diameter LOE L3E 21 21 014 to 21 017 0 83 0 8273 to 0 8274 L2A L3A 18 18 001 to 18 007 Piston Pin Outside L2C L3C 0 71 0 7087 to 0 7089 Diameter LOE L3E 21 21 002 to 21 005 0 83 0 8269 to 0 8270 0 006 to 0 018 Clearance between L2C L3C 0 0002 to 0 0007 0 08 Piston Pin Bore and 0 0031 Piston Pin Diameter 0 007 to 0 015 i 0 0003 to 0 0006 Measured Values Part Name Piston Pin Bore Diameter Piston Pin Outside Diameter Clearance Supplement 8 INSPECTION RECORD SHEET No 8 Engine Model Company Serial No pe Measurement of Valve Clearance Measuring Positions Standard Inlet 0 25 Valve Clearance 0 0098 Cold Setting 0 25 Exhaust 0 0098 Measured Values Valve Clearance 2 3 heck M d Supplement 9 Now INSPECTION RECORD SHEET Inspection Measurement of Valve Opening Pressure of Fuel Injection re ee gi em Point Nozzle psi
56. 2 776 in 2 7722 to 2 7729 in STD 76 mm 75 906 to 75 926 mm 2 992 in 2 9884 to 2 9892 in L2E 0 25 OS 76 25 mm 75 156 to 76 176 mm L3E i 3 002 in 2 9983 to 2 9990 in 76 50 mm 76 406 to 76 426 mm 92293 3 012 in 3 0081 to 3 0089 in 4 2 2 Boring finish dimension piston diameter clearance honing allowance 0 02 mm 0 0008 in Item Standard Limit Remark 0 061 to 0 111 mm LAA EDA 0 0024 to 0 0044 in Clearance L2C L3C 0 067 t0 0 117 mii 92 mmn Repair to oversize or replace clearance between piston and cylinder 0 0026 to 0 0046 in 0 0079 in P P 0 074 to 0 124 mm i LSE 0 0029 to 0 0049 in 6 12 INSPECTION AND REPAIR OF BASIC ENGINE 4 3 Measuring piston ring end gap a When replacing rings without boring honing measure the end gap at the bottom of the cylinder where the wear is minimum Cylinder b When replacing the ring use the ring of the same size as the piston Piston Insert the piston ring into the cylinder bore and push it with the piston to achieve squareness Then measure the end gap with feeler gauges Replace the piston ring if the limit is exceeded i Measuring piston ring end gap Item Standard Limit a B 0 15 to 0 30 mm P 0 0059 to 0 0118 in ring No 2 com omm End gap of ring Saran 0 15 to 0 30 mm 0 0591 P 0 0059 to 0 0118 in in ring Oil rin 0 15 to 0 35 mm 8 0
57. 22 kgf 1 1 to 1 3 Ibf 0 5 lbf 18 5 5 0 Brush length 0 7283 0 197 Resistance between slip rings 2 95 Q 2 7 to 3 2 Q ee i 22 7 22 1 Aleator Slip ring outside diameter 0 8937 0 8701 A007TA0171B Terminal ase 12V 40A 2500 min Voltage l Output charac Current 21 A or more teristics when hot Terminal 135V 5000 min voltage Current 37 A or more IC regulator adjusting voltage 14 7 0 3 V at 20 C 68 F j 4 8 to 6 0 N 2 2 N Brush spring load 0 49 to 0 61 kgf 0 22 kgf 1 1 to 1 3 Ibf 0 5 lbf 18 5 5 0 Brush length 0 7283 0 197 Resistance between slip rings 12 4 Q 11 4 to 13 4 Q We wk r 22 7 22 1 ene Slip ring outside diameter 0 8937 0 8701 A007TA8271A Terminal ON 24V 25A 2500 min Voltage l Output Current 18 A or more characteristics when hot Terminal 270V 5000 min voltage Current 22 A or more IC regulator adjusting voltage 28 5 0 5V at 20 C 68 F SERVICE DATA Table 2 7 Maintenance service data table Electrical system 3 3 Unit mm in Inspection point Nominal Standard Limit Remark ETR ETS Clearance of stop solenoid to plunger rack 0 3 t00 7 0 15 to 0 20 0 0118 to 0 0059 to 0 0276 0 0079 12V 0 2 Q Resistance value of glow plug 24 V 4 5 Q 2 9 SERVICE DATA 2 List of tightening torque 2 1 Major bolts and nuts tightening torque 2 1 1 Basic engines Table 2 8 Tightening to
58. 28in Em 0 5 to 0 6 mm Oranbe 0 020 to 0 024 in 8 22 Lock nut Special nut 7 8 to 11 8 N m 0 8 to 1 2 kgf m Torque spring case 5 8 to 8 7 Ibf ft Spring stopper Protrusion amount Torque spring Adjusting screw Setting of torque spring of double spring type Dial gauge spring stopper Torque spring case Spring stopper Measuring protrusion of spring stopper of double spring type FUEL SYSTEM 2 10 Inspecting fuel pump The fuel pump is available in 3 types and the type differs based on engine specifications 1 Electromagnetic plunger type fuel pump For this pump a large sized pump of normal type with a filter element and a small sized pump of compact type without a filter element are available In either type apply the specified voltage and check for operation and fuel leakage Replace filter element For the type with filter element remove the cover and every ee clean or replace the filter element Check for damage on external surfaces and fuel leakage Electromagnetic plunger type fuel pump type compact type 2 Electromagnetic diaphragm type fuel pump Do not disassemble this pump Apply the specified hack farasiamaldanaas voltage and check for operation and fuel leakage fuel leakage Electromagnetic diaphragm type fuel pump 8 23 FUEL SYSTEM 2 11 Disassembling inspecting and reassembling fuel filter cock switch ty
59. 65 x 70 mm 70 x 70 mm 76 x 70 mm y 2 56 x 2 76 in 2 76 x 2 76 in 2 99 x 2 76 in Main specifications Total displacement 0 696 L 0 808 L 0 952 L SP 0 184 U S gal 0 213 U S gal 0 251 U S gal Compression ratio 23 1 Fuel used Diesel oil JIS K2204 Special No 1 Special No 3 Order of ignition 1 3 2 Direction of rotation Dry mass Counterclockwise as viewed from flywheel side 75 kg 165 1b Piston ring Number Compression ring 2 Oil rings with expander 1 Open BTDC 18 Inlet valve Basic engine Valve timing Close ABDC 46 when warm Exhaust Open BBDC 46 valve Close ATDC 18 Starting system Electric starting Type ND PFR type Manufacturer DENSO CORPORATION Fuel Plunger diameter 5 5 mm 0 22 in 6 0 mm 0 24 in injection pump MS retard crank angle 4 8 Cam lift 6 mm 0 24 in Governor Speed governing type Centrifugal weight system Type Throttle type Fuel Manufacturer DENSO CORPORATION injection nozzle Spray angle 15 Fuel system Valve opening pressure 13 73 0 MPa 1400 kgf em 1992 0 psi Paper element cartridge Pane Type or paper element switch cock Type Electromagnetic diaphragm i Discharge rate 0 3 L 0 08 U S gal min or more at 12V 1 3A Type Electromagnetic plunger type Fuel pump i Discharge rate 1 L 0 26 U S gal min or more at 12V 1 5A option
60. 9 9 72 176 17 9 130 M16 x 1 5 24 0 94 145 14 8 107 262 26 7 193 M18 x 1 5 27 1 06 210 21 4 155 378 38 5 279 M20 x 1 5 30 1 18 291 29 7 215 524 53 4 386 M22 x 1 5 32 1 26 385 39 3 284 694 70 8 512 M24 x 1 5 36 1 42 487 49 7 359 878 89 5 648 M27 x 1 5 41 1 61 738 75 3 544 1328 135 5 979 mY AN m OD ard Sard N m kgfm Ibf ft N m kgf m Ibf ft M10 x 1 5 14 0 55 32 3 3 24 58 5 9 43 M12 x 1 75 17 0 67 aT 5 8 42 102 10 4 75 Metric course screw thread M14 x2 22 0 87 93 9 5 69 167 17 0 123 M16 x2 24 0 94 139 14 2 103 251 25 6 185 M18 x 2 5 27 1 06 194 19 8 143 350 35 7 258 M20 x 2 5 30 1 18 272 ATT 201 489 49 9 361 M22 x 2 5 32 1 26 363 37 0 268 653 66 6 482 M24 x 3 36 1 42 468 47 7 345 843 86 0 622 M27 x 3 41 1 61 686 70 0 506 1236 126 0 912 Note a This table lists the tightening torque for standard bolts and nuts b The numerical values in the table are for fasteners with spring washers c The table shows the standard values with a maximum tolerance value of 10 d Use the tightening torque in this table unless otherwise specified e Do not apply oil to threaded portions Dry 2 3 Standard eyebolt tightening torque Table 2 15 Standard eyebolt tightening torque SERVICE DATA 2 4 Standard union nut tightening torque Threads Width Strength classification Dia x Pitch across flats 4
61. 9 to 0 5516 40 38 5 Free length 1 57 1 516 oar aon Aye Squareness L A 1 4 0 055 tr Lf 40 1 57 over entire length Valve spring 35 5 1 3976 55 3 to 61 2 N 5 64 to 6 24 kgf 12 4 to 13 8 lbf Mounting length load 15 28 0 1 1024 138 2 to 152 9 N 14 09 to 15 59 kgf 31 1 to 34 4 lbf Pushrod Runout 0 3 0 012 or less 03 TIR Replace S Se 7 0 012 nop Distortion of cylin 0 10 Cylinder head der head bottom 0 05 0 0020 or less Repair 0 0039 surface Distortion of block top surface 0 05 0 0020 or less oo Repair ps me 0 0039 P ee ree 965 65 00 to 65 03 i 2 56 2 5591 to 2 5602 Cylinder inside L2C L3C 70 70 00 to 70 03 0 7 Repair limit is diameter i 2 76 2 7559 to 2 7571 0 0276 0 2 0 0079 9 76 76 00 to 76 03 pas 2 99 2 9921 to 2 9933 Cylindericity 0 01 0 039 or less 2 3 SERVICE DATA Table 2 2 Maintenance service data table Basic engine 3 4 Unit mm in Inspection point Nominal Standard Limit Remark SID 65 64 919 to 64 939 2 559 2 5559 to 2 5566 L2A 65 25 65 169 to 65 189 alo 2 569 2 5657 to 2 5665 65 50 65 419 to 65 439 9 30 05 2 579 2 5755 to 2 5763 a 070 69 913 to 69 933 2 756 2 7525 to 2 7533 Outside L2C 0 25 05 70 25 70 163 to 70 183 diameter L3C 2 766 2 7623 to 2 7631 70 50 70 413 to 70 433 0 30 03 2 776 2 7722 to 2 7729
62. Bearing Inside Diameter and Crankshaft Pin Outside PPEPTTETETETTTeTiTeTirerrierrieiririrerrieirir iri titi titi te tire eerie eee ee Supplement 6 No 6 Measurement of Rocker Arm Inside Diameter and Rocker Shaft Outside Diameter sessossosssunossosnsossosussssasosnssssosssssnasosnossssssssunssssnossosssssunsssonossssssssunsnnen Supplement 7 No 7 Measurement of Piston Pin Bore Diameter and Piston Pin Outside Diameter Supplement 8 No 8 Measurement of Valve Clearance sesssssssssunossososossssssunosusssosssssssssnossosossssssseanennssnsensonn Supplement 9 No 9 Measurement of Valve Opening Pressure of Fuel Injection Nozzle eeeseeeeeeee e Supplement 10 No 10 Measurement of Camshaft Journal Outside Diameter to Cylinder Block Camshaft Bore Clearance L2 ssssosanssssnossososssansssosossosssssssessonsosnosesssnosssonosnossossnesnnnn Supplement 11 No 11 Measurement of Camshaft Journal Outside Diameter to Cylinder Block Camshaft Bore Clearance L3 ssesssunososnossososssunensosossosssssssosnossosnosesssuosssonosnososssnesnnns Supplement 1 2 No 12 Measurement of Crankshaft End Play sessossosssusonsosnssossssssssssousossssssosussssunosnossssssssnnns Supplement 13 Supplement 1 Now INSPECTION RECORD SHEET c Engine Model m n inspect mp coin Measurement of Cylinder Inside Diameter Measuring Positions Approx 10mm __ below the Direction perpendicular upper edge to the piston pin Middle section Lower section Direction parallel to
63. ELECTRICAL SYSTEM 2 11 3 Inspecting stator 1 Checking continuity between lead wires Check that there is continuity between a pair of lead wires Also check that there is no continuity between a pair of lead wires and other pair of lead wires If defective replace the stator S Checking insulation between lead wire and core Check that there is no continuity between each lead wire and the stator core If continuity is observed replace the stator Note The core cannot be replaced as a single item 2 11 4 Inspecting brushes for wear Measure the length of the brushes If the measured value is less than the limit replace both the brush holder assembly and the brush assembly with new ones Item Standard Limit 18 5 mm 5 0 mm Pr sh length 0 7283 in 0 197 in Ae A oN U Checking for grounding between the leads and the core AA Z eC HO Ho H gt HO D ED a gt ED ED D IVV VV VVVVVY Wear limit line Inspecting brushes 12 43 ELECTRICAL SYSTEM 2 11 5 Replacing brushes 1 To remove the brush and the spring unsolder the brush lead 2 To install a new brush push the brush into the brush holder as shown in the illustration and then solder the lead to the brush 12 44 Soldering Brush holder Installing brushes ELECTRICAL SYSTEM 2 12 Reassembling alternator
64. FF POWER BEFORE CHECKING OR MAINTENANCE DO NOT TOUCH ANY ELECTRIC EQUIPMENT WHEN POWER IS ON DO NOT OPERATE WITH DOOR AND PROTECTIVE COVER OPEN 45A93 51 500 BE CAREFUL OF ROTATING FAN DO NOT PUT FINGERS NEAR ROTATING FAN 45A93 50700 e HOT WATER MAY CAUSE BURNS DO NOT REMOVE RADIATOR CAP UNDER HOT CONDITIONS INTENANC NTENANCE OPERATION AND 4593 51600 4593 50600 HOT SURFACES MAY CAUSE BURN HOT SURFACE MAY CAUSE BURNS DO NOT TOUCH HOT SURFACE 45A93 50900 Warning labels r BE CAREFUL OF ROTATING BELT DO NOT PUT FINGERS NEAR ROTATING BELT 45A93 50800 GENERAL CONTENTS Group Name Contents Group No General External view System flow diagrams Engine serial number location Indication of engine model and total displacement Specifications Tips on disassembling and reassembling Service data Maintenance service data List of tightening torque Service tools Basic tools Special tools Determination of overhaul Determining overhaul timing Testing compression pressure Disassembly of basic engine Disassembling and inspecting cylinder head and valve mechanism Disassembling and inspecting flywheel Disassembling and inspecting gear case timing gear and camshaft Disassembling and inspecting cylinder block crankshaft piston and oil pan Inspection and repair of
65. M002T66071 24V 3 2kW 4 1 to 7 6N m 8 8 to 12 7N m 0 42 to 0 77kgf m 0 90 to 1 90kgf m _ 3 to 6lbf ft 7 to 14lbf ft Apply Multemp PS2 Kyodo Yushi made or the equivalent Apply Multemp PS2 Kyodo Yushi made or the equivalent 2 2 to 4 4N m 0 24 to 0 45kgf m 2 to 3lbf ft 4 4 to 7 1N m 0 45 to 0 72kgf m 3 to 5lbf ft Apply Molykote RAG650 Dow Corning Asia made or the equivalent Reassembling starter MO002T66071 24V 3 2kW 2 9 1 Applying grease a To avoid mixing of different greases remove old grease before applying new grease b Make sure that the starter mounting surface brushes commutator and other electric current conducting compo nents are free from grease When overhauling the starter apply grease to sliding surfaces gears and bearings in the following 1 Parts or areas to which Multemp PS2 Kyodo Yushi made or the equivalent is applied Plunger surface a small amount Sliding area between lever and pinion shaft Lever at the point of contact with plunger and point of support Front bearing of armature shaft Shaft sliding area of pinion shaft Rear bearing of armature shaft Pinion gear fitting surface Center bracket bearing Pnion shaft spline
66. ODUCTION Other cautions Modification of engine prohibited Unauthorized modification of the engine will void the manufacturer s warranty Modification of the engine may not only cause engine damage but also produce personal injuries Never break the seals To ensure proper engine operation the fuel control link is provided with seals that protect the fuel injection vol ume and rotation speed settings against tampering If these seals are broken and the settings are changed proper operation of the engine will no longer be guar anteed and the following problems will be expected to occur e Rapid wear of moving and rotating parts e Engine troubles such as damage and seizure of engine parts e Increased consumption of fuel and lubricating oil e Deterioration of engine performance due to poorly balanced fuel injection volume and governor opera tion Pre operational check and periodic inspec tion maintenance Be sure to perform the pre operational checks and pe riodic inspection maintenance as described in this manual Neglecting the pre operational check or periodic in spection maintenance can arouse various engine trou bles such as damage to parts eventually leading to serious accidents Break in operation A new engine needs to be broken in for the first 50 hours of operation During this period do not subject the engine to heavy loads Operating a new engine under high loads or severe conditions during the br
67. Removing connecting rod cap 5 16 4 4 Pulling out piston 5 17 4 5 Removing piston ring ceses 5 17 4 6 Removing piston pin ce eeeeeeeeees 5 17 4 7 Measuring crankshaft end play 5 18 4 8 Removing main bearing cap 4 5 18 4 9 Removing crankshaft errr 5 18 5 1 DISASSEMBLY OF BASIC ENGINE 1 Disassembling and inspecting cylinder head and valve mechanism Clogged oil hole wear Clogged oil hole wear Damage to threaded portion 3 Wear and damage on both ends bend p 11 Replace Stem seal Valve guide wear damage Crack damage coolant leakage oil leakage scale gasket carbon deposit Contact damage and wear of valve seat surface Local wear Local wear damage and fatigue of stem face Disassembling and inspecting cylinder head and valve mechanism Disassembling sequence 1 Rocker cover 8 Rocker shaft spring 15 Valve lock 2 Rocker shaft assembly including 3 9 9 Rocker shaft 16 Retainer 3 Grooved pin 10 Valve cap 17 Valve spring 4 Snap ring 11 Push rod 18 Valve stem seal 5 Exhaust rocker arm 12 Cylinder head bolt main 19 Intake valve 6 Rocker stay 13 Cylinder head bolt sub 20 Exhaust valve 7 Intake rocker arm 14 Cylinder head 21 Cylinder head gasket DISASSEMBLY OF BASIC ENGINE 1 1 Removing rocker shaft assembly 1 Loo
68. SERVICE MANUAL L00Z 1240330 WONVWISDVRES W MITSUBISHI DIESEL ENGINES L SERIES L2A L2C L2E L3A L3C L3E J3 1 DET VET 371027 vzal SAHAS October 2007 0 MITSUBISHI HEAVY INDUSTRIES LTD Oc L9 L 6966 ON and Printed in Japan Pub No 99619 16120 Pub No 99619 16120 INTRODUCTION This service manual describes the specifications maintenance and service procedures for Mitsubishi diesel engines To maintain the performance of the engine for many years and to ensure safe operation it is important to use the engine correctly and conduct regular inspection and maintenance and also to take necessary measures which involves the disassembly inspection repair and reassembly of the engine and engine parts Read this manual carefully and understand the work procedures fully before disassembling inspecting repairing or reassembling the engine The contents of the manual are based on the engine models that are being produced at the time of publication Due to improvements made thereafter the actual engine that you work on may differ partially from the one described in this manual Pub No 99619 16120 INTRODUCTION How to use this manual This service manual consists of several Groups which are arranged so as to allow you to make reference quickly to specifications maintenance standards adjustment procedures and service procedures including methods for disassembly inspection repair a
69. SSEMBLY OF BASIC ENGINE 4 9 Reassembling rocker shaft assembly Install the rocker shaft assembly in the reverse order of the disassembly sequence observing the followings 1 Apply engine oil to the rocker shaft 2 Install the rocker shaft assembly in the same position as it was Note If the rocker shaft assembly is not installed in the same position the clearance becomes different and it may result in a defect such as wear increase 3 Align oil holes of the rocker shaft with those of the rocker stay and drive a grooved pin into the front rocker stay Note Drive in the grooved pin until it comes into contact with the inside of the rocker shaft 4 After reassembling make sure the rocker arms move freely 4 10 Installing rocker shaft assembly 1 Install the valve caps to the valve heads 2 Tighten the long bolts of the rocker bracket to the specified torque 3 Tighten the short bolts of the rocker bracket 7 20 Rocker arm 9 Rocker stay OF Rocker shaft spring c GF N Rocker shaft SS Grooved pin Tightening torque 14 7 to 21 6 Nem 1 5 to 2 2 kgf m J 10 8 to 15 9 Ibf ft Installing rocker shaft assembly REASSEMBLY OF BASIC ENGINE 4 11 Adjusting valve clearance Adjust the valve clearance For adjusting procedures refer to Adjustment and Operation 4 12 Installing rocker cover 1 Make sure that the gasket is firmly installed into the r
70. Sin 676 75 906 to 75 926 2 992 2 9884 to 2 9892 L2E 76 25 76 156 to 76 176 yt 029S 3 002 2 9983 to 2 9990 Piston 76 50 76 406 to 76 426 9 30 05 3 012 3 0081 to 3 0089 L2A L3A 18 18 001 to 18 007 Piston pin L2C L3C 0 71 0 7087 to 0 7089 outside diameter DRE 21 21 002 to 21 005 0 83 0 8269 to 0 8270 Clearance L2A L3A 0 006 to 0 018 between piston L2C L3C 0 0002 to 0 0007 0 08 pin bore and 007 to 0 015 0 0031 piston pin L2E L3E 0 0003 to 0 0006 0 061 to 0 111 LZA DIA 0 0024 to 0 0044 Clearance between piston 0 067 to 0 117 0 2 F and cylinder LAC LAG 0 0026 to 0 0046 000707 SERA topy rsike orTeplace ee aan 0 074 to 0 124 gt 0 0029 to 0 0049 No 1 0 3 Compression ring 7 0 0118 meaner No 2 0 05 to 0 09 0 2 re naga Compression ring 0 0020 to 0 0035 0 0079 P and ring groove eo 0 03 to 0 07 0 2 g 0 0019 to 0 0028 0 0079 Piston ring No 1 0 15 to 0 30 Compression ring 0 0059 to 0 0118 Closed gap of No 2 0 15 to 0 30 1 5 Repl ring Compression ring 0 0059 to 0 0118 0 0591 P 2ce R 0 15 to 0 35 g 0 0059 to 0 0138 Bend and torsion 0 05 100 n j 0 0020 3 94 or less Connecting rod 3 94 Eda 0 10 to 0 35 0 5 pay 0 0039 to 0 0138 0 0197 2 4 SERVICE DATA Table 2 2 Maintenance service data table Basic engine 4 4 Unit mm in Inspection point Nominal Standard Limit Remark Journ
71. T cm co N m kgf m Ibf ft M8 x 1 25 12 0 47 8 1 0 8 0 1 6 0 7 M10 x 1 25 14 0 55 15 2 1 5 0 2 111 5 M12 x 1 25 17 0 67 253 2 5 40 3 18 4 2 2 M14x 1 5 19 0 75 34 4 3 5 40 4 25 3 0 M16 x 1 5 22 0 87 44 5 4 50 5 3243 7 M18 x 1 5 24 0 94 T4 5 7 5 0 5 55 3 7 M20 x 1 5 27 1 06 98 10 10 0 1 0 T2Z 74 M24 x 1 5 32 1 26 147 15 15 0 1 5 108 11 1 M27 x 1 5 41 1 61 226 20 23 0 2 0 167 14 8 Dry Table 2 16 Standard union nut tightening torque Nominal Cap nut size Adelin eee M mm across flats N m kgf m lbf ft mm in 63 M14 x 1 5 19 0 75 39 4 29 80 M16 x 1 5 22 0 87 49 5 36 100 M20 x 1 5 27 1 06 78 8 58 120 M22 x 1 5 30 1 18 98 10 72 150 M27 x 1 5 32 1 26 157 16 116 180 M30 x 1 5 36 1 42 196 20 145 200 M30 x 1 5 36 1 42 196 20 145 220 M33 x 1 5 41 1 61 245 25 181 254 M36 x 1 5 41 1 61 294 30 217 Maximum tolerance value 10 dry condition 2 5 High pressure fuel injection pipe tightening torque Table 2 17 High pressure fuel injection pipe tightening torque Cap mui size N m kgfm Ibf ft mm MI2x 1 5 3025 4205 29 3 6 M14 x 1 5 49 45 340 5 36 3 6 M18 x 1 5 5941 641 0 4347 2 Dry 2 13 SERVICE TOOLS 1 Basit S ra 3 2 2 Special tools want caadtiarestucekes 3 3 3 1 SERVICE TOOLS 1 Basic tools Table 3 1 Basic tools list No Tool name Part No Use Tool set MM413900 Includes 1 to 5
72. TRICAL SYSTEM 1 Removing electrical system 12 2 1 1 Removing starter 12 2 1 2 Inspection before removing alternator A007TA0171B 12V 40A A007TA8271A 24V 25A neee 12 3 1 2 1 Inspecting alternator operation 12 3 1 2 2 Handling precaution eee 12 3 1 2 3 Inspecting regulated voltage 12 4 1 2 4 Inspecting output ee eeeeeeees 12 4 1 3 Removing alternator eee 12 5 1 4 Removing stop solenoid eee 12 5 1 5 Removing glow plug 12 6 2 Disassembling inspecting and reassembling electrical system 12 7 2 1 Inspection before disassembling starter MO00T60481 12V 1 2kW M001T68381 12V 1 7KW seses 12 7 2 1 1 Inspecting pinion clearance 12 7 2 1 3 NO load toSt viii eeann 12 9 2 2 Disassembling and inspecting starter M000T60481 12V 1 2kW M001T68381 12V 1 7KW coeca 12 10 2 3 Preparation before disassembling 12 11 2 3 1 Removing pinion Set eee 12 11 2 3 2 Removing magnetic switch 12 11 2 3 3 Removing rear bracket eee 12 12 2 3 4 Removing brush holder and brush assembly ceecee 12 12 2 3 5 Removing armature and yoke 12 12 2 3 6 Removing overrunning clutch 12 13 2 3 7 Removing gear shaft eee 12 13 2 4 Inspecting and repairing starter MO0O0T60481 12V 1 2kW M001T68381 12V 1 7KW eee 12 14 2 4 1 Inspecting brushes for wear 00 12 14 2 4 2 Measuring bru
73. a dust indicator will issue an alarm if the element gets clogged Service the cleaner as soon as possible if an alarm is issued Observe safety rules at work site Observe the safety rules established at your workplace when operating and maintaining the engine Do not operate the engine if you are feeling ill Operation of the engine with reduced awareness may cause improper operation that could result in accidents In such a case inform your supervisor of your condi tion When working in a team of two or more people use specified hand signals to communicate among work ers Work clothing and protective gear Wear a hardhat face shield safety shoes dust mask gloves and other protective gear as needed When handling compressed air wear safety goggles hardhat gloves and other necessary protective gear Works without wearing proper protective gear could re sult in serious injuries Use of tools optimum for each work Always keep in mind to select most appropriate tools for the work to be performed and use them correctly If tools are damaged replace with new tools Avoidance of prolonged time of starter oper ation Do not operate the starter for more than 10 seconds at atime even if the engine does not start Wait for at least 30 seconds before next engine cranking Continuous operation of the starter will drain the battery power and cause the starter to seize Do not turn off battery switch during opera tion If the
74. ace Replace a O gt is T Replace 2 Removing inlet cover and exhaust manifold Removing sequence 1 Inlet pipe 2 Inlet cover 3 Exhaust manifold 4 Exhaust elbow INLET AND EXHAUST SYSTEMS 2 Disassembling inspecting and reassembling inlet and exhaust systems 2 1 Inspecting inlet cover and exhaust manifold Crack damage contamination dirt adhesion and corrosion Crack damage contamination dirt adhesion and corrosion Inspecting inlet cover and exhaust manifold 2 2 Measuring distortion of inlet and exhaust manifold Using a straight edge and thickness gauges measure distortion across the cylinder head mounting surfaces of the Straight edge inlet cover and exhaust manifold If the measured distortion exceeds the limit correct by grinding or replace the part Item Limit Distortion on mounting surfaces of intake 0 15 mm cover and exhaust manifold 0 0059 in Measuring distortion on inlet cover INLET AND EXHAUST SYSTEMS 3 Installing inlet and exhaust systems 3 1 Installing inlet cover and exhaust manifold 7 8 to 9 8N m 0 8 to 1 0kgf m 6 to 7 lbf ft Replace Replace 7 8 to 9 8N m Ber ben Replace 6 to 7 Ibf ft Replace 14 7 to 21 6N m 1 5 to 2 2kgf m 14 7 to 21 6N m A 11 to 16 Ibf ft 1 5 to 2 2kgf m 11 to 16 Ibf ft Installing inlet cover and exhaust manifold ELEC
75. ace distortion 0 0020 in 0 0039 in 1 9 Measuring push rod runout Measure the runout of push rod If the standard value is exceeded replace the push rod Item Standard Limit Remark h Less than 0 3 mm 0 3 mm g ai 0 012 in 0 012 in TIR Measuring points Measuring distortion of the bottom surface of the cylinder head Pushrod Measuring runout of push rod INSPECTION AND REPAIR OF BASIC ENGINE 2 Inspecting and repairing flywheel 2 1 Measuring flatness of flywheel Place the flywheel on a surface plate and move a dial gauge on the friction surface of the flywheel to measure the flatness Grind the friction surface of the flywheel if the limit is exceeded Item Standard Limit Flywheel flatness 0 08 mm 0 50 mm i 0 0031 in or less 0 0197 in Measuring flatness of flywheel 2 2 Inspecting ring gear Inspect the ring gear for a missing tooth or worn teeth and if defects are found replace the ring gear 2 3 Replacing ring gear 2 3 1 Removing ring gear 1 Heat the ring gear evenly with an acetylene torch or Ring gear Flywheel other appropriate heat source 2 Remove the ring gear by striking it evenly around the periphery with a hammer through a rod 2 3 2 Installing ring gear 1 Heat the ring gear evenly up to approx 100 C 212 F with an appropriate heater 2 Install the ring gear onto the flywheel with the no gear chamfering side f
76. acing to the flywheel Removing ring gear Note Do not heat the ring gear excessively 6 7 INSPECTION AND REPAIR OF BASIC ENGINE 3 Inspecting and repairing gear case timing gear and camshaft 3 1 Measuring timing gear backlash Measure the backlash of the timing gears by using one of the following two methods measure the gear play with the dial gauge plunger applied to a tooth flank on the pitch circle at a right angle to the tooth axis or measure the clearance between gears by inserting a feeler gauge between the gears at the tooth to tooth contacting area Replace the faulty gear pair if the limit is exceeded Item Standard Limit 0 010 to 0 136 mm Spur Between crank 0 0004 to 0 0054 in gear shaft gear and 3 idler gear 0 040 to 0 118 mm Heli 0 0016 to 0 0047 in Measuring timing gear backlash cal gear E PRA S 0 010 t00 136mm Spur z 2 camshaitpear 0 0004 to 0 0054 in gear 0 300 mm 5 0 0118 So Between idler 0 037 to 0 117 mm Heli in on A s gearand pump 0 0015 to 0 0046in E camshaft gear gear 0 010 to 0 220 mm Spur Between valve 0 0004 to 0 0087 in gear camshaft gear Heli and PTO gear 0 007 to 0 235 mm eal 0 0003 to 0 0091 in gear 3 2 Measuring clearance between idler gear and idler shaft y Measure the inside diameter of the idler gear and outside Q Measuring directions diameter of the idler shaft Replace th
77. adjusted 3 Close the cock of the fuel filter and reassemble the delivery valve spring fuel injection pipe 4 With the delivery valve installed check the fuel injection timing as follows Note If the fuel injection pump and the engine are dirty removing the delivery valve allows dirt and dust to enter the fuel injection pump 5 Remove the tie rod cover and disconnect the tie rod from the control rack 6 Set the control rack to the medium position in the operating range and then remove the No 1 fuel injection pipe on the nozzle side When the crankshaft is gradually rotated forward clockwise fuel begins to swell at the tip of the pipe This timing is the fuel injection timing In this case the timing is delayed by 1 as compared to the normal fuel injection timing Mark on timing gear case Advanced by this angles TDC mark Retard Adjusting shim IT mark One division corresponds to 2 Retarded by this Crankshaft pulley Add shims thicker Advance Reduce shims thinner Adjusting fuel injection timing 13 5 ADJUSTMENT AND OPERATION 1 4 Inspecting and adjusting low idle speed and high idle speed a The minimum no load speed low idle speed and the maximum no load speed high idle speed of each engine have been checked on test bench and then their setting bolts have been sealed by sealing cap at the factory Only the service shops designated b
78. affected by other causes and are not always effective to judge the overhaul timing Decreased compression pressure shows a variety of symptoms and engine conditions thus making it difficult to accurately determine when the engine needs an overhaul The following shows typical problems caused by reduced compression pressure 1 Decreased output power 2 2 Increased fuel consumption 3 Increased engine oil consumption 4 iN Increased blow by gas through the breather due to worn cylinder liners and piston rings Visually check the blow by amount o1 Increased gas leakage due to poor seating of inlet and exhaust valves 7 8 Abnormal exhaust color after warm up operation 5 6 Difficulty in starting 7 Increased noise from engine parts The engine can exhibit these conditions in various combinations Some of these problems are directly caused by worn engine parts while others are not Phenomena described in items 2 and 6 will result from improper fuel injection volume fuel injection timing worn plunger faulty nozzles and also faulty conditions of electrical devices such as battery and starter The most valid reason to overhaul an engine is a decrease in compression pressure due to worn cylinder liners and pistons as described in item 4 In addition to this item it is reasonable to take other problems into consideration for making the total judgement DETERMINATION OF OVERHAUL 2 Testing compression pr
79. al Adjust smoke set J YES Is the engine correctly adjusted on Adjust engine valve clearance excessive fuel injection timing out of order YES Are fuel injection nozzles normal spray state gt ___inspectiuelinjecton nozzes Inspect fuel injection nozzles fuel injection nozzles injection valve opening pressure too high J YES Is the Is the compression pressure normal pressure normal Ts the compression pressure nomal gt Inspect valves cylinder head gasket pistons and piston ngs Inspect valves Inspect valves cylinder head gasket pistons and piston rings head gasket pistons and piston rings Jp yes Inspect fuel injection pump Problem Excessive black smoke 14 6 TROUBLESHOOTING 1 6 Idling malfunction 1 6 1 Check items before troubleshooting 1 Engine control system malfunction 2 Viscosity of engine oil too high 3 Use of poor quality fuel 1 6 2 Problem Unstable idling NO Is the engine correctly adjusted gt Adjust engine engine idle speed valve clearance and fuel injection timing YES NO Are fuel injection nozzles normal spray state gt Inspect fuel injection nozzles injection valve opening pressure too high p J J YES NO Is the compression gt Inspect valves pistons and piston rings pressure normal J YES Inspect fuel injection pump and governor system Problem Unstable idling 14 7 TROUBLESHOOTING 1 7 Low output 1 7 1 Check ite
80. al outside diameter STD 943 42 203 t042 380 1 69 1 6915 to 1 6921 0 70 Repair limit is e a 40 39 965 to 39 980 20 0276 0 15 70 0059 Pin outside diameter STD 1 57 1 5734 to 1 5740 Runout 0 06 0 0024 or less TIR Crankshaft Clearance between main bearing and 0 030 to 0 075 0 10 crankshaft 0 0012 to 0 0030 0 0039 Clearance between connecting rod 0 028 to 0 071 0 150 bearings 0 0011 to 0 0028 0 0059 End pla 0 050 to 0 175 0 500 i 0 0020 to 0 0069 0 0197 0 010 to 0 136 Spur 0 0004 to 0 0054 gear Between crank gear and idler gear 0 040 to 0 118 Helical 0 0016 to 0 0047 gear Between idler gear 0 010 to 0 136 Spur Timing gear and valve camshaft gear 0 0004 to 0 0054 gear 0 300 Replace backlash Between idler gear 0 037 to 0 117 Helical 0 0118 and pump camshaft gear 0 0015 to 0 0046 gear 0 010 to 0 220 Spur Between valve camshaft gear 0 0004 to 0 0087 gear and PTO gear 0 007 to 0 235 Helical 0 0003 to 0 0091 gear z 27 31 27 27 to 27 47 26 37 Cam height of camshaft major axis 1 08 1 0736 to 1 0815 1 0382 ioa ai d 30 29 9 to 30 1 29 Cam height of fuel injection pump camshaft major axis 1 18 1 177 to 1 185 1 1417 Replace Flywheel flatness 0 08 0 0031 or less ay z i vee 0 0197 i 0 007 to 0 049 0 150 Clearance between tappet and cylinder block bore 0 0003 to 0 0019 0 0059 Replace tappet Clearance between camshaft journal and 0 050 to 0 100 0 150 Replace camshaft cylinder
81. alve clearance when the engine 23B tn BIAN is cold 8 5kgf m 54 2 to 61 5Ibf ft 2 Slightly loosen cylinder head bolts and tighten them to the specified torque in the order as shown in the illustration Note Be careful that the tightening torque of cylinder head bolts is different between main bolts and sub bolts Cylinder head bolt sub 19 6 to 29 4N m 2 0 to 3 0kgf m 14 7 to 21 71bf ft Tightening order of cylinder head bolts L2 Cylinder head bolt main 73 5 to 83 4 N m 7 5 to 8 5 kgf m 54 2 to 61 5 Ibf ft Cylinder head bolt sub 19 6 to 29 4N m 2 0 to 3 0 kgf m 14 7 to 21 7 Ibf ft Tightening order of cylinder head bolts L3 13 2 ADJUSTMENT AND OPERATION 1 1 2 Inspecting valve clearance 1 Set No 1 cylinder to the top dead center in compression stroke This position is where the TDC mark on the crankshaft pulley aligns with the mark on the gear case Note The compression top is where the rocker arm does not move when the crankshaft is rotated in the forward and backward direction by both 20 approx If the rocker arm moves it is the top dead center in exhaust stroke Rotate the crankshaft another full turn to set the No 1 cylinder to the top dead center in compression stroke 2 Start adjusting the valve clearance from the No 1 cylinder and adjust the valve clearance of other cylinders according to the ignition order Note To set the next cylinder to the compression top afte
82. alve guide 1 Pull out the valve guide from the bottom to the top face of the cylinder head with a press using a blanking tool Unit mm in 2 Using a stopper press fit the new valve guide from the top surface of cylinder head After press fitting make sure the dimensions of valve position are as shown in the illustration 3 After press fitting the guide insert new valve and make sure that it slides 4 Inspect contact between the valve and valve seat T S 5 S lo 10 oO lt 1440 5 0 55 0 020 624 0 94 Stopper Unit mm in Press fitting valve guide 6 3 INSPECTION AND REPAIR OF BASIC ENGINE 1 4 Inspecting valve face Apply a thin coat of Shinmyoutan or equivalent lead free coloring paste on the valve face and strike the valve face against the valve seat using a valve lapper to check for contact condition If the contact is not even or any defects are found or if the limit is exceeded reface or replace the valve Shinmeitan Note a Inspect the valve face after the valve guide is repaired or replaced b Do not rotate the valve when pressing the valve face coated with Shinmyoutan or equivalent lead free dye against the valve seat c Always lap the valve and valve seat after the valve has been refaced or replaced Bad Contact must be at face center Valve to valve seat contact Item Stand
83. ar must be returned to the operating condition before starting the engine Starting the engine with the turning tools inserted or with the turning gear in engagement can lead to not only engine damage but also personal injuries INTRODUCTION Be careful of burns Do not touch the engine during or immedi ately after operation Do not touch the engine during or immediately after operation to avoid risk of burns To conduct maintenance and in spection work wait until the engine has cooled sufficiently checking the temperature gauge Slowly and carefully open radiator cap Never attempt to open the radiator cap while the engine is running or immediately after the engine stops Give a sufficient cooling time to the engine coolant before opening the cap When opening the radiator cap slowly turn the cap to release internal pressure To prevent scalds with steam gushing out wear thick rubber gloves or cover the cap with a cloth Close the radiator cap tightly without fail The coolant is very hot and under pressure during en gine running or just after the engine stops If the radia tor cap is not closed tightly steam and hot coolant may gush out and can cause scalds Add coolant only after the coolant tempera ture dropped Do not add coolant immediately after the engine stops Wait until the coolant temperature lowers sufficiently to avoid a risk of burns Never remove heat shields The exhaust system which becomes
84. ar shaft 12 11 ELECTRICAL SYSTEM 2 3 Preparation before disassembling Mark the mating marks on magnetic switch front bracket center bracket yoke and rear bracket to each other for reassembly 2 3 1 Removing pinion set The starter generates heat if it is left with current being applied Remove the pinion within 10 seconds 1 Connect the starter to the circuit as shown in the illustration 2 Turn the switches SW1 and SW2 ON to move the pinion out and then turn the SW2 OFF to stop the rotation of the armature and the pinion 3 Place an appropriate tube on the pinion stopper Tap the tube with a hammer to drop the pinion stopper to the clutch side This will expose the stopper ring 4 Remove the stopper ring with pliers and remove the pinion Note Do not reuse the stopper ring for reassembly 2 3 2 Removing magnetic switch Disconnect the leads and remove the magnetic switch 12 12 a i Battery 12V Disconnect the lead with a terminal connected to terminal M Connection to move the pinion forward Stopper ring Pinion stopper Pinion Screw Magnet switch Removing magnetic switch ELECTRICAL SYSTEM 2 3 3 Removing rear bracket Remove the through bolts and screws of the brush holder and then remove the rear bracket Rear bracket 2 3 4 Removing brush holder and brush assem bly Apply a socket of the same diameter as the c
85. ard Limit Valve seat angle 44 Seat width Valve seat 0 4 to 0 6 mm Valve sinkage 0 0158 to 0 0236 in 1 0 mm 0 5 mm Valve margin 0 0394 in E Valve margin Valve seat angle Valve sinkage Valve to valve seat contact position 1 5 Refacing valve face If the valve face is significantly worn out reface the valve Valve refacer face using a valve refacer Note a Grind the valve face using the valve refacer at the specified angle b Secure the valve margin width equal to or greater than the limit If the dimensions after refacing does not meet the specified values replace the d Set the valve face angle at the specified valve with a new one Refacing valve face INSPECTION AND REPAIR OF BASIC ENGINE 1 6 Measuring perpendicularity and free length of valve spring Measure the perpendicularity and free length of the valve spring If the limit is exceeded replace the valve spring with anew one Item Standard Limit 40 mm 38 5 mm Free length 1 57 in 1 516 in 0 2 0 or less A 20 3 A 14 ee Perpendicularity gap te 0 079 in tf 0 055 in or less is Lf 40 mm 1 57 in 0e i length 35 5 1 3976 55 3 to 61 2 N 5 64 to 6 24 kgf Set length set 12 4 to 13 8 Ibf 15 e o force 28 0 1 1024 138 2 to 152 9 N 14 09 to 15 59 kgf 31 1 to 34 4 lbf 1 7 Lapping valve and valve seat Always lap the valve against the valve seat after
86. arting up 1 Before starting the engine check the levels of coolant engine oil and fuel Bleed air from the fuel and cooling systems 2 Stop the fuel supply and crank the engine with the starter for about 10 seconds to lubricate the engine 3 Move the control lever slightly in the fuel increase direction but not to the full injection position and then turn the starter switch key to the START position to start the engine 4 After the engine is started adjust the control lever to let the engine operate at a minimum no load speed low idle speed 5 Turn the starter switch key to the OFF position and make sure that the engine is stopped 2 2 Inspecting engine condition after starting up During the break in operation check the followings If any abnormality is found stop the engine investigate the cause and take appropriate measures 1 The oil pressure must be within the specified value 2 The coolant temperature must be within the specified value 3 The engine must be free from any leakages such as oil coolant and fuel Pay special attention to oil leakage from the fitting face of turbocharger lube oil pipe 4 Check for an abnormal noise Note Knocking noise will disappear as the coolant temperature rises 5 Check for the color of smoke and odors 13 10 2 3 Break in operation time The relationship between the load in break in operation and the operation time is as shown below
87. backlash of the timing gears by using one of the following two methods measure the gear play with the dial gauge plunger applied to a tooth flank on the pitch circle at a right angle to the tooth axis or measure the clearance between gears by inserting a feeler gauge between the gears at the tooth to tooth contacting area Replace the faulty gear pair if the limit is exceeded Item Standard Limit 0 010 to 0 136 mm Spur Between crank 0 0004 to 0 0054 in gear shaft gear and 3 ider gear 0 040 to 0 118 mm ig 0 0016 to 0 0047 in gear E PRA S 0 010 t00 136mm Spur 4 i camshaft gear 0 0004 to 0 0054 in gear 0 300 mm F 0 0118 on Between idler 0 037 to 0 117 mm Heli in sear and pump 0 0015 to 0 0046 in E camshaft gear gear 0 010 to 0 220 mm Spur Between valve 0 0004 to 0 0087 in gear camshaft gear Heli and PTO gear 0 007 to 0 235 mm cal 0 0003 to 0 0091 in gear 3 10 Removing idler gear 1 Remove the snap ring 2 Remove the idler gear Measuring timing gear backlash gt Snap ring N Idler gear Wi ey Removing idler gear 5 11 DISASSEMBLY OF BASIC ENGINE 3 11 Removing camshaft Be careful not to cause damage to the cam lobe of the camshaft and the cam shaft hole of the cylinder block when removing the camshaft 1 Remove the camshaft stopper washer Camshaft stopper washer 2 Pull out the camshaft togethe
88. basic engine Reassembly of basic engine Inspecting and repairing cylinder head and valve mechanism Inspecting and repairing flywheel Inspecting and repairing gear case timing gear and camshaft Inspecting and repairing cylinder block crankshaft piston and oil pan Reassembling cylinder block crankshaft piston and oil pan Reassembling gear case timing gears and camshaft Reassembling flywheel Reassembling cylinder head and valve mechanism Fuel system Lubrication system Removing fuel system Disassembling inspecting and reassembling fuel system Installing fuel system Removing lubrication system Disassembling inspecting and reassembling lubrication system Installing lubrication system Cooling system Removing cooling system Disassembling inspecting and reassembling cooling system Installing cooling system 10 Inlet and exhaust system Removing inlet and exhaust sysytems Disassembling inspecting and reassembling inlet and exhaust systems Installing inlet and exhaust systems 11 Electrical system Removing electrical system Disassembling inspecting and reassembling electrical system Installing electrical system 12 Adjustment and operation Inspection and adjustment of engine Break in operation Performance test JIS standard 13 Troubleshooting Troubleshooting 14 Supplement inspection record sheet Supplement inspection record sheet Supplement GENERAL 1
89. battery switch is turned OFF when the engine is running not only various meters will stop working but also the alternator may have its diode and transistor deteriorated Cautionary instructions for transporting en gine When transporting the engine on a truck consider the engine weight width and height to ensure safety Abide by road traffic law road vehicles act vehicle restriction ordinance and other pertinent laws Avoid continuous engine operation in a low load condition Do not operate the engine continuously for more than 10 minutes at a load of less than 30 Engine opera tion in a low load condition increases the emission of unburned fuel Therefore a prolonged time of engine operation in a low load condition increases the quantity of unburned fuel adhering to engine parts provoking the possibility of engine malfunctioning and shortening the service life of the engine Ventilation of engine room Always keep the engine room well ventilated Insuffi cient amount of intake air causes the operating temper ature to rise resulting in poor output and lowered performance It is highly recommended to calculate the required amount of air supply to the engine and install an ade quate ventilation system before installing the engine Avoid contact with high pressured fuel Should fuel leak from a fuel injection pipe do not touch the spouting fuel directly Fuel in the fuel injection pipes is under high pressure If high press
90. block bore 0 0020 to 0 0039 0 0059 or cylinder block Hane i i 20 0 030 to 0 066 0 200 Clearance between idler gear bushing and idler shaft 0 79 0 0012 to 0 0026 0 0079 1 3 Fuel system Table 2 3 Maintenance service data table Fuel system Unit mm in Inspection point Nominal Standard Limit Remark 13 73 MPa 13 73 to 14 73 MPa Fuel injection nozzle pressure 140 kgf cm 140 to 150 kgf cm Adjust with washers 1992 psi 1992 to 2134 psi SERVICE DATA 1 4 Lubrication system Table 2 4 Maintenance service data table Lubrication system Unit mm in Inspection point Nominal Standard Limit Remark Clearance between oil pump housing inside diameter 75 5 0 100 to 0 196 0 3 Replace and oil pump outer gear outside diameter 2 972 0 0039 to 0 0077 0 012 P Oil pump Clearance between oil pump outer gear width and oil 10 0 040 to 0 100 0 25 Replace pump housing 0 04 0 0016 to 0 0039 0 0099 P Pa 0 29 0 029 MPa Relief valve opening pressure 5 1000 min 3 0 0 3 kgf cm Replace min 43 4 3 psi 0 05 0 01 MPa Oil pressure at which oil pressure switch illuminates 0 5 0 1 kgf cm Replace 7 0 7 psi 1 5 Cooling system Table 2 5 Maintenance service data table Cooling system Unit mm in Inspection point Nominal Standard Limit Remark Temperature at which valve starts openin se LIC p a 167 t
91. case and tighten the bolts 2 13 Installing crankshaft pulley The bar could come off Be very careful 1 Screw two guide bolts into the threaded holes at the rear end of the crankshaft Place a bar across the two guide bolts so that the crankshaft does not turn 2 Install the woodruff key on the crankshaft 3 Install the crankshaft pulley and tighten the nuts to the specified torque PTO gear Ball bearing Installing PTO gear Bolts on front 8 pcs Bolts on rear 4 pcs 98 1 to 117 7 N m 10 to 12 kgf m 72 3 to 86 8 Ibf ft Prevent the crankshaft from rotating Installing crankshaft pulley 7 13 REASSEMBLY OF BASIC ENGINE 2 14 Installing gear pump housing 1 Install the gear pump housing to the stud bolts on the Stud M8 x 1 25 mm 15 mm Gear pump ear Case 8 housing 2 Tighten the gear pump housing bolt 3 Install the last stud bolt to the gear pump housing 2 15 Installing tappet Coat the periphery of tappets with engine oil insert them into the tappet holes and place them gently on the camshafts Apply engine oil Inserting tappet 7 14 REASSEMBLY OF BASIC ENGINE 3 Reassembling flywheel 3 1 Installing oil seal case Be careful not to damage the oil seal 1 Install the new oil seal gasket 2 After applying engine oil to the entire circumference of the oil seal lips install the oil seal case on the cylinder block
92. connector p Battery 24V Return test ELECTRICAL SYSTEM 2 6 3 No load test Use as thick a wire as possible and firmly tighten each terminal When detecting the rotation at the tip of the pinion be careful as the pinion pops out during operation 1 Connect the starter to the circuit as shown in the illustration 2 In normal condition the pinion pops out when the switch is turned ON and the starter rotates at or more the specified rotation speed If the terminal voltage current or rotation speed does not meet the standard disassemble inspect and repair the starter Item Standard Starter model MO002T66071 Nominal output V kW 24 3 2 Terminal voltage V 23 Ng lo dicharac Current A 80 or less teristics Rotation speed min 3400 or more Ammeter Test at no load 12 25 ELECTRICAL SYSTEM 2 7 Disassembling and inspecting starter M002T66071 24V 3 2kW Looseness abnormal noise and rotation condition of bearing Rotation condition Replace Stopper ring 7 Rotation condition Broken coil wire Metal wear Wear and damage of gear Broken wire short circuit and ground of coil roughness and wear of commutator and damage and wear of gear Wear of brushes rust and deterioration of spring and insulation check of hold
93. cover bolt M6 x 1 0 7 8 to 9 8 0 8 to 1 0 5 8 to 7 2 Exhaust manifold bolt M8 x 1 25 14 7 to 21 6 1 5 to 2 2 10 8 to 15 9 2 1 6 Electrical system Table 2 13 Tightening torque list Electrical system Threads Torque Description Dia x Pitch Remark mm N m kgf m lbf ft Starter through bolt 44 to 7 1 0 45 to 0 72 3 3 to 5 2 Starter brush holder tightening screw 2 4 to 4 4 0 24 to 0 45 1 7 to 3 3 Stater magnetic switch screw 4 1 to 7 6 0 42 to 0 77 3 0 to 5 6 Starter terminal M 8 8 to 12 7 0 90 to 1 30 6 5 to 9 4 Starter terminal B M8 x 1 25 7 8 to 11 8 0 8 to 1 2 5 8 to 8 7 Stop solenoid fixing nut M30 x 1 5 39 2 to 49 0 4 0 to 5 0 28 9 to 36 2 Blind plug for stop solenoid M30 x 1 5 39 2 to 49 0 4 0 to 5 0 28 9 to 36 2 Glow plug M10 x 1 25 14 7 to 19 6 1 5 to 2 5 10 8 to 18 1 Glow plug lead wire nut M4 x 0 7 0 98 to 1 47 0 10 to 0 15 0 7 to 1 1 Alternator terminal B MS x 0 8 2 9 to 4 9 0 3 to 0 5 2 2 to 3 6 2 11 SERVI 2 2 Standard bolt and nut tightening torque Table 2 14 Standard bolt and nut tightening torque CE DATA Threads Width Strength classification Description Dia x Pitch across flats mm mm in 7T 10 9 ANY DOD L N m kgfm Ibf ft N m kef m Ibf ft M8 x 1 25 12 0 47 17 1 7 13 30 3 1 22 M10 x 1 25 14 0 55 33 3 4 24 60 6 1 44 Mete Ratamacbile scseueaieeaal M12 x 1 25 17 0 67 60 6 1 44 108 11 0 80 M14 x 1 5 22 0 87 97
94. d 3 To adjust the injection start pressure remove the set screw on the nozzle holder loosen the cap nut and turn the adjusting screw with a driver 4 After adjustment tighten the cap nut and set screw with the specified torque 5 After tightening the set screw check if the injection start pressure is within the standard again Item Standard 13 73 to 14 73 MPa 140 to 150 kgf cm 1992 to 2134 psi Valve opening pressure Note Change in washer thickness by 0 1 mm 0 004 in results in a pressure change of 1 0 MPa 10 kgf cm 142 psi Washers are available in 10 different thicknesses at intervals of 0 05 mm 0 0020 in in the range between 1 25 and 1 70 mm 0 0492 and 0 0669 in Nozzle tester Checking valve opening pressure Nozzle tip end Replacing fuel injection nozzle tips 8 9 FUEL SYSTEM 2 1 2 Inspecting fuel spray pattern of fuel injec tion nozzle 1 When adjusting the nozzle opening pressure using the nozzle tester check for nozzle hole condition and fuel spray pattern 2 Checking points of fuel spray are as follows Fuel is injected from all spray holes simultaneously Fuel is injected conically at the specified spray angle Fuel is injected in a spray of fine droplets Fuel is injected without after dribbling 3 If spray condition is faulty clean or replace the nozzle tip 2 1 3 Cleaning and replacing faulty nozzle When pulling out the nozzle tip
95. depth of undercutting between the commutator segments Undercut If the measured value is less than the limit repair or replace with a new part Item Standard Limit 0 4 to 0 6 mm 0 2 mm Undercutting depth 19 0158 to 0 0236 in 0 0079 in Measuring commutator mica depth 12 31 ELECTRICAL SYSTEM 2 8 7 Checking armature coil 1 Inspect the armature coil using a growler Hold a piece of iron plate against the armature core If the iron plate vibrates replace the armature with a new one 2 Check that there is no continuity between the commutator and the shaft core If any continuity is observed replace the armature with anew one 3 Check that there is continuity between segments in various combinations If poor or no continuity is observed replace the armature with a new one 12 32 Growler tester yy Hy Si N S S SY 6 SAS SEES SSE KSKSED cS lt S S Se KS S Se S gt lt gt y A CXS XS pox VISE bg p Testing breaks of armature coil ELECTRICAL SYSTEM 2 8 8 Inspecting continuity of yoke assembly Check that there is continuity between M terminal of field coil and the lead wire for the brush If no continuity is observed replace the yoke assembly with a new one 2 8 9 Inspecting insulation between yoke body and brush Check that there is no continuity between yoke body and brush If continu
96. ds the limit 7 Measure the clearance between the connecting rod bearing and the crank pin again Use the undersize bearing if the limit is exceeded 8 If an undersize bearing is used grind the crank pin to the specified undersize Item Nominal Standard Limit Crankpin outside 640mm 39 965 to 39 980 mm 0 70 mm diameter STD 1 57 in 1 5734 tol 5740 in 0 0276 in Clearance between crankpin and 0 028 to 0 071 mm 0 150 mm connecting rod 0 0011 to 0 0028 in 0 0059 in bearing Undersize grinding dimensions of crankshaft Item Undersize Finish dimension 0 25 mm 39 75 0035 mm 0 0098 in 1 5650 100014 in Crankpin undersize 0 50 mm 39 50 0035 mm 0 0197 in 1 5551 100014 in Measuring Measuring directions points FH Measuring Measuring directions points Tightening torque 31 4 to 34 3 N m 3 2 to 3 5 kgf m 23 1 to 25 3 Ibf ft Finish dimension of fillet radius INSPECTION AND REPAIR OF BASIC ENGINE 4 9 Measuring clearance between main bear ing and crankshaft journal a When grinding crank journals be sure to grind all the journals to the same size b Finish the fillet radius to the specified dimension 1 2 b 1 Reassemble main bearings 2 3 Measure the inside diameter of the main bearings 4 5 Tighten the main bearing caps to the specified torque 4 Measure the outside diameter of
97. e Inlet 1 Inlet a g Inlet 3 ema ried R po Remark SES po Remark SES PA oe Supplement 4 INSPECTION RECORD SHEET No 4 ea ee Point Surfaces Measuring Positions Standard Ts Distortion of Cylinder Head Bottom Surfaces 0 05 or less 0 10 0 0020 0 0039 Measured Values Part Name Distortion of Cylinder Head Bottom Surfaces ESERIES Remark a n Supplement 5 No 5 INSPECTION RECORD SHEET inspection Measurement of Clearance Between Connecting Rod Point Bearing Inside Diameter and Crankshaft Pin Outside l Measuring Positions Standard Nominal Value Standard f 40 40 008 to 40 036 Connecting Rod Bearing Inside Diameter 1 57 1 5751 to 1 5762 40 39 965 to 39 980 0 70 Crankshaft Pin Outside Diameter 1 57 1 5734 to 1 5740 0 0276 learance Between Connecting Rod 0 028 to 0 071 0 150 Bearing Inside Diameter and Crankshaft 9 Pin Outside Diameter EE 0 0011 to 0 0028 0 0059 Measured Values Connecting Rod Bearing Crankshaft Pin Outside Part Name Clearance Inside Diameter Diameter Eri Ea Supplement 6 INSPECTION RECORD SHEET No 6 C RR Serial No No inspection Measurement of Rocker ee Inside Diameter and Rocker dd a Point Shaft Outside Diameter Measuring Positions Standard Nomina Standard Value Arm Inside o12 12 013 to 12 035 Diameter 0 47 0 4730 to 0 4738 Rocker Shaft Outside o1
98. e Oil filter i j Right view Oil drain plug Engine right view GENERAL 1 2 External view of L3A L3C and L3E Oil filler Thermostat Rear hanger Alternator Exhaust manifold Front h Rear Starter V belt Oil pan Left view Flywheel Engine left view Fuel injection nozzle Front hanger Inlet manifold Stop solenoid Fuel injection pump Water pump Fuel filter Rear Front Oil filler Water drain plug PTO Oil filter Oil level gauge Engine right view Oil drain plug 1 3 GENERAL 2 System flow diagrams 2 1 Fuel system flow diagram Fuel injection nozzle Fuel leak off pipe Fuel injection pipe OG To fuel tank lt o1 LI Fuel injection pump Fuel filter Fuel system flow diagram 2 2 Lubrication system flow diagram Rocker shaft af Camshaft Oil main gallery Oil pump Oil screen Oil drain plug Lubrication system flow diagram 1 4 GENERAL 2 3 Cooling system flow diagram Water pump Water bypass pipe Thermostat Radiator Cooling fan Cooling system flow diagram 2 4 Inlet and exhaust syst
99. e idler gear or idler 7 Measuring shaft if the clearance exceeds the limit LEA j points Item Standard Limit Clearance between idler 0 030 to 0 066 mm 0 200 mm gear and idler shaft 0 0012 to 0 0026 in 0 0079 in Measuring idler gear inside diameter and idler shaft outside diameter 3 3 Replacing idler shaft Press fit the idler shaft into the cylinder block to the 23 3 mm 0 917 in dimension in the illustration Replacing idler shaft INSPECTION AND REPAIR OF BASIC ENGINE 3 4 Measuring clearance between camshaft journal and cylinder block bore Calculate the clearance between the outside diameter of the camshaft journal and inside diameter of the cylinder block bore Replace the camshaft or cylinder block if the Measuring Measuring directions clearance exceeds the limit Note Start measurement from the No 2 camshaft hole because the No 1 camshaft hole is for ball bearings Item Standard Limit Clearance between camshaft 0 050 to 0 100 mm 0 150 mm journal and cylinder block bore 0 0020 to 0 0039 in 0 0059 in holes 3 5 Measuring cam lift Measure the minor and major axes of cam to determine cam t lobe lift If the lift is less than the limit replace the camshaft with a new one 4 Measuring Measuring directions Item Standard Limit Cam height of camshaft 27 27 to 27 47 mm 26 37 mm major axis 1 0736 to 1 0815 in 1 0382 in 3 6 Measu
100. e the center bracket Once the center bracket is removed the adjusting washer that adjusts the pinion shaft end play can be removed 2 7 8 Removing reduction gear and spring set 1 Remove the reduction gear from the pinion shaft 2 Remove the packing and lever spring from the lever 2 7 9 Removing pinion set 1 Place an appropriate tube on the pinion stopper Tap the tube with a hammer to drop the pinion stopper to the clutch side This will expose the stopper ring 2 Ply out the stopper ring and remove the pinion Note Do not reuse the stopper ring for reassembly 2 7 10 Removing lever and pinion shaft Pull out the lever and pinion shaft from the front bracket Center bracket Reduction gear Removing reduction gear and spring set Appropriate tube Front bracket Pinion shaft Removing lever and pinion shaft 12 29 ELECTRICAL SYSTEM 2 8 Inspecting and repairing starter M002T66071 24V 3 2kW 2 8 1 Inspecting brushes for wear Measure the length of the brushes If the measured value is less than the limit replace both the brush holder assembly and the brush assembly with new ones Measure the length of the Item Standard Limit brush Replace if the length is equal to or less than the limit 18 mm 11 mm Brush length 0 709 in 0 4331 in Inspecting brushes for wear 2 8 2 Measuring brush spring load Using a new brush measure the spring load at which the spri
101. e to the armature shaft end and install a ball on it 6 Install the armature Note The adjustment of play in the axial direction of the armature shaft is not necessary 2 5 5 Installing brush holder and brush assembly Attach the socket to the commutator of the armature While sliding the brushes on the socket install the brush holder and brush assembly on the armature Brush holder Brush assembly 2 5 6 Installing rear bracket Install the rear bracket to the yoke and tighten the through Screw 2 4 to 4 4 Nem 0 24 to 0 45 kgf m 2 to 3 lbf ft bolt and the brush holder screws Through bolt 4 4 to 7 1 N m 0 45 to 0 72 kgf m 3 to 5 Ibf ft 2 5 7 Installing magnetic switch 1 Install the magnetic switch and tighten the screws Magnet switch 2 Connect the lead to the terminal M and secure it with 4 1to7 6N m 0 42 to 0 77 kgf m 3 to 6 Ibf ft the fixing nut Terminal M 8 8 to 12 7 N m 0 90 to 1 30 kgf m 7 to 9 Ibf ft Installing magnetic switch 12 21 ELECTRICAL SYSTEM 2 5 8 Inspecting pinion clearance Do not apply current continuously for longer than 10 seconds 1 Connect the starter to the circuit as shown in the illustration 2 When the switches SW1 and SW2 are turned ON the pinion springs out to the cranking position and the armature rotates 3 Turn the switch SW2 OFF to stop the rotation of the armature 4 Gently push back the
102. eak in period can shorten the service life of the engine VIII Warming up operation After starting the engine run the engine at low idling speeds for 5 to 10 minutes for warming up Start the work after this operation is completed Warm up operation circulates the lubricant through the engine Therefore individual engine parts are well lu bricated before they are subjected to heavy loads This is very important for longer service life high perfor mance and economical operation Do not conduct warm up operation for a longer time than necessary Prolonged warm up operation causes carbon build up in the cylinders that leads to incom plete combustion Avoid engine operations in a overload con dition If the engine is considered to be in an overloaded con dition which is identified by too much black smoke etc immediately reduce the load on the engine such that the correct output and load conditions may be achieved Overloading the engine causes not only high fuel con sumption but also excessive carbon deposits inside the engine Excessive carbon deposits can cause various engine problems and shorten the service life of the en gine remarkably Cooling operation before stopping engine Always conduct the cooling operation low speed idling for 5 to 6 minutes before stopping the engine Abruptly stopping the engine immediately after high load operation can cause partial overheating and short en the service life of the engine
103. ear caps using hands 3 When the side seals are installed partway into caps use a tool with flat surface such as flat head screwdriver to install completely taking care not to bend them Installing main bearing cap Side seal Round portion Round portion Inserting side seal 1 3 REASSEMBLY OF BASIC ENGINE 1 5 Installing main bearing cap bolt 1 Tighten the main bearing cap bolts alternately and progressively to the specified torque 2 Make sure that the crankshaft rotates smoothly Tightening torque 49 0 to 53 9N m 5 0 to 5 5 kgf m 36 2 to 39 8 Ibf ft 1 6 Measuring crankshaft end play Attach a dial gauge to the end of the crankshaft to measure the end play If the end play deviates from the standard value loosen the main bearing cap bolts and retighten Make sure that the camshaft turns freely Item Standard Limit Measuring crankshaft 0 050 to 0 175 mm 0 500 mm end play 0 0020 to 0 0069 in 0 0197 in Measuring crankshaft end play REASSEMBLY OF BASIC ENGINE 1 7 Reassembling piston and connecting rod 1 With the identification mark of connecting rod facing Identification mark upward place the rod on the piston pin setting tool Connecting rod Piston pin setting tool P N 30L91 00030 for L2A L3A 30L91 00020 for L2C L3C 30L91 10010 for L2E L3E Reassembling pisto
104. ectifier assembly 4 Rotor 8 Front bracket 12 Rear bracket 12 39 ELECTRICAL SYSTEM 2 10 1 Separating front bracket from stator Rear bracket Do not disassemble the alternator unless the repair is necessary Do not insert the screwdrivers too deep as it can dam age the stator 1 Remove the through bolts 2 With two flat head screwdrivers inserted between the front bracket and stator pry them apart 2 10 2 Removing pulley Pulley When setting the rotor in a vise be sure to hold the Front bracket base of the rotor claw Do not hold the rotor claw as it causes damage to the claw 1 Apply a cloth to the rotor and set it in a vise 2 Remove the pulley nut and then pull out the pulley 2 10 3 Removing rear bearing Remove the rear bearing from the rotor using a bearing puller Rear bearing Py Removing rear bearing 2 10 4 Removing front bearing Remove the screw and then remove the bearing retainer and front bearing from the front bracket Screw Front bearing Front bracket HE Bearing retainer Removing front bearing 12 40 ELECTRICAL SYSTEM 2 10 5 Removing stator Unsoldering must be finished as quickly as possible Extended heating will damage the diodes Cut off the joint of the stator and remove the stator from the rectifier 5 Stator core AI Rectifier Soldering Removing stator 2 10 6 Removing regulator asse
105. em flow diagram lt I Inlet 4 Exhaust Air breather pipe Blow by gas blow by gas reduction From air cleaner Vo To muffler Inlet cover Exhaust manifold Inlet and exhaust system flow diagram 1 5 GENERAL 3 Engine serial number location The engine serial number is stamped on the injection pump mount upper side of tie rod cover of the cylinder block 4 Indication of engine model and total displacement The engine type and displacement are stamped on the side of the injection pump mount of the cylinder block Engine serial Me ZA Engine model and cylinder capacity GENERAL 5 Specifications 5 1 Specifications of L2A L2C and L2E Table 1 1 Specifications of L2A L2C and L2E 1 4 Engine model L2A L2C L2E Main specifications Type Vertical type water cooled 4 cycle diesel No of cylinders 2 Combustion type Swirl chamber type Valve mechanism Overhead valve type Cylinde bore x stroke 65 x 70 mm 70 x 70 mm 76 x 70 mm y 2 56 x 2 76 in 2 76 x 2 76 in 2 97 x 2 76 in Total displacement 0 464 L 0 538 L 0 635 L P 0 126 U S gal 0 142 U S gal 0 168 U S gal Compression ratio 23 1 Fuel used Diesel oil JIS K2204 Special No 1 Special No 3 Order of ignition 1 2 Direction of rotation Count
106. ement Measurements are based on the International System of Units SI and their converted metric values are indicated in parentheses For metric conversion the following rates are used e Pressure 1 MPa 10 197 kgf cm e Torque 1 Nm 0 10197 kgf m e Force 1 N 0 10197 kgf e Horsepower 1 kW 1 341 HP 1 3596 PS e Meter of mercury 1 kPa 0 7 cmHg e Meter of water 1 kPa 10 197 cmH2O cmAq e Rotational speed 1min 1 rpm INTRODUCTION Safety Cautions Fire and explosion Keep flames away Store fuel and engine oil in a well ventilated designated area Make sure that the caps of fuel and engine oil containers are tightly closed Do not use flames do not smoke and do not work near a heater or other fire hazard where fuel or oil is handled or when cleaning solvent is being used for washing parts Wipe off spilled fuel oil and LLC immediately and thor oughly Spilled fuel oil and LLC may ignite and cause a fire Keep surrounding area tidy and clean Do not leave combustible or explosive materials such as fuel engine oil and LLC near the engine Such sub stances can cause fire or explosion Remove dust dirt and other foreign materials accumu lated on the engine and surrounding parts thoroughly Such materials can cause fire or the engine to over heat In particular clean the top surface of the battery thoroughly Dust can cause a short circuit Always operate the engine at a position at
107. en 3 1 1 Installing oil pump Install the oil pump inner gear oil pump outer gear and oil Oil pump inner gear pump housing and tighten the bolts to the specified torque 7 8 to 9 8 N m 0 8 to 1 0 kgf m 5 8 to 7 2 Ibf ft Oil pump housing Gear case Oil pump outer gear Installing oil pump 9 7 LUBRICATION SYSTEM 3 2 Installing oil filter relief valve and oil pressure 7 85 to 11 8 N m 0 8 to 1 2 kgf m 5 8 to 8 7 Ibf ft 39 2 to 49 0 N m 4 0 to 5 0 kgf m 29 to 36 Ibf ft Installing oil filter relief valve and oil pressure 3 2 1 Installing oil pressure switch Oil pressure switch 7 85t011 8 Nm socket wrench Do not allow sealant to squeeze out at the thread end 0 8 to 1 2 kgfm P N MD998054 Do not overtighten 5 8 to 8 7 Ibf ft 1 Using an oil pressure switch socket wrench tighten the Z oil pressure switch to the specified torque A 2 Apply a sealant to the threaded portion when installing p the switch fi pply HERME SEAL H1 or THREEBOND 1344N Installing oil pressure switch 3 2 2 Installing relief valve Insert the relief plunger and relief spring into the gear case zg 39 2 to 49 0 N m and tighten the plug to the specified torque Relief plunger Plug 4 0 to 5 0 kgf m 28 9 to 36 2 Ibf ft Gear case Relief spring Installing relief valve LUBRICATION SYSTEM 3 2 3 Installing oil filter 1 Apply a light coating of engine oil to the fi
108. er Disassembling and inspecting starter MO02T66071 24V 3 2kW Disassembly sequence 1 Magnet switch Rear bracket Brush and brush holder Yoke Armature 1 ao A WwW PD O O N QOQ 12 26 Rear bearing Front bearing Cover set Center bracket Reduction gear 11 12 13 14 15 Spring set Pinion set Lever Pinion shaft Front bracket ELECTRICAL SYSTEM 2 7 1 Preparation before disassembling Mark the mating marks on magnetic switch front bracket center bracket yoke and rear bracket to each other for reassembly 2 7 2 Removing magnetic switch Disconnect the leads and remove the magnetic switch Magnetic switch 2 7 3 Removing rear bracket Remove the through bolts and screws of the brush holder and then remove the rear bracket Through bolt Removing rear bracket 12 27 ELECTRICAL SYSTEM 2 7 4 Removing brushes brush holder yoke and armature While lifting the two brushes remove the yoke and brush holder assembly Then pull out the armature 2 7 5 Removing ball bearing Remove the bearings from both ends of the armature using a puller 2 7 6 Removing cover set Remove the cover and pull out the snap ring and the washer 12 28 Brush holder Armature Removing brushes brush holder yoke and armature Rear bearin Front bearing Removing cover ELECTRICAL SYSTEM 2 7 7 Removing center bracket Remove the screw then remov
109. erclockwise as viewed from flywheel side Dry mass 61 kg 134 1b Compression ring 2 Piston ning Number Oil ring with expander 1 Open BTDC 18 Inlet valve Basic engine Valve timing Close ABDC 46 when warm Exh st Open BBDC 46 valve Close ATDC 18 Starting system Electric starting Type ND PFR type Manufacturer DENSO CORPORATION AN p Plunger diameter 5 5 mm 0 22 in 6 0 mm 0 24 in MS retard crank angle 4 8 Cam lift 6 mm 0 24 in Governor Speed governing type Centrifugal weight system Type Throttle type Fuel Manufacturer DENSO CORPORATION injection nozzle Spray angle 15 Fuel system Fuel filter Valve opening pressure Type 13 73 0 MPa 1400 kgf em 1992 0 psi Paper element cartridge or paper element switch cock Fuel pump option Type Electromagnetic diaphragm Discharge rate 0 3 L 0 08 U S gal min or more at 12V 1 3A Type Electromagnetic plunger type Discharge rate 1 L 0 26 U S gal min or more at 12V 1 5A Type Electromagnetic plunger type i Discharge rate 1 4 L 0 37 U S gal min or more at 24V 1 5A 3 Type Electromagnetic plunger type compact type Discharge rate 0 4 L 0 11 U S gal min or more at 12V 1 5A 1 7 GENERAL Table 1 1 Specifications of L2A L2C and L2E 2 4 Engine model L2A L2C L2E Lubrication system Lubrication s
110. ermostat Replace Disassembling and inspecting thermostat Disassembling sequence 1 Thermostat cover 2 Thermostat 2 2 Inspecting thermostat Be careful of burns or a fire when measuring tempera ture as it involves a high temperature and open flame To test the thermostat operation immerse the thermostat in a container filled with water Heat the water while measuring the water temperature Record the temperature at the conditions shown in the table below If the temperatures are not within the standard range replace the thermostat Note a Stir the water in the container with a stick to ensure uniform temperature distribution b Before installing the thermostat be sure to check the valve opening temperature stamped on the thermostat valve side face Item Standurd 76 5 1 5 C 167 to 172 F Temperature at which valve starts opening Temperature at which valve lift becomes 90 C 6 mm 0 24 in or more 194 F 3 Thermostat case Stir hot water well 66 66 6 6 Inspecting thermostat 10 3 COOLING SYSTEM 2 3 Reassembling thermostat 8 to 10 Nem 0 8 to 1 0 kgf m 5 8 to 7 2 Ibf ft Reassembling thermostat 2 4 Inspecting thermoswitch Both water and the thermoswitch become hot Pay attention to prevent burn and fire Immerse the temperature senser in oil and measure the resistance while raising the oil temperature If the resi
111. essure i Compression a Be sure to measure the compression pressure for r al gauge p adapter P N ST332270 all the cylinders It is not a good practice to mea sure the compression pressure for only one cylin der and presume the compression for the remaining cylinder b Also be sure to check engine speed when measur ing the compression pressure as compression pressure varies with engine speed c Measuring the compression pressure at regular in tervals is important to obtain correct data d When measuring the compression pressure for cylinders one by one do not remove other fuel injection nozzles from their positions except for the one being measured Testing compression pressure 1 Remove the injection nozzle from the cylinder head where the compression pressure is to be measured 2 Remove the glow plugs from all cylinders 3 Attach the compression gauge adapter to the injection nozzle mount and connect compression gauge 4 Stop the fuel supply 5 Crank the engine with the starter then read the compression gauge indication while the engine is running at the specified speed 6 If the compression pressure is lower than the limit overhaul the engine Item Standard Limit Engine speed 280 min Not acceptable at Compression sone or below 2 2 MPa 28 kgf cm pressure 398 psi 22 kgf cm P 313 psi Difference between Within 0 25 MPa each cylinder 2 5 kgf cm y
112. et to the nozzle tip and tighten the fuel 5 0 to 6 0 kgf m injection nozzle 96210 4911 n Installing fuel injection nozzles 3 4 2 Installing fuel return pipe and fuel injection pipe Fuel injection pipe Install the fuel return pipe and fuel injection pipe 24 5 to 29 4 N m Fuel return pipe 2 5 to 3 0 kgf m 20 6 to 24 5 N m 18 1 to 21 7 Ibf ft 2 1 to 2 5 kgf m 18 1 to 21 7 Ibf ft Installing fuel return pipe and Installing fuel injection pipe 8 32 LUBRICATION SYSTEM 1 Removing lubrication system 9 2 1 1 Removing oil filter relief valve and Oil pressure Switch seeren 9 2 1 1 1 Removing oil filter eres 9 3 1 1 2 Removing relief Valve eects 9 3 1 1 3 Removing oil pressure switch 00 9 3 1 2 Removing oil pump oil pan and oil screen9 4 1 2 1 Removing oil PUMP sses 9 4 2 Disassembling inspecting and reassembling lubrication system 9 5 2 1 Inspecting oil PUMP sseeeesssseeessrressrrrrnnns 9 5 2 1 1 Measuring clearance between oil pump housing inside diameter and oil pump outer gear outside diameter 9 5 2 1 2 Measuring the end clearance between oil pump outer gear width and oil pump housing depth eee 9 5 2 2 Inspecting relief Valve eee 9 6 2 3 Inspecting oil pressure switch 0 9 6 3 Installing lubrication system 9 7 3 1 Installing oil pump oil pan and oil screen 9 7 3 1 1 Installing oil PUMP
113. from the cylinder block using a screwdriver Removing oil seal case 5 7 DISASSEMBLY OF BASIC ENGINE 3 Disassembling and inspecting gear case timing gears and camshaft Replace Wear of cam contact 21 20 Gasket surface and circumference contact 1 Fea N surface O ring a Fatigue and crack 27 26 Wear and damage of weight Wear and damage of sliding sleeve 30 Wear and damage of 29 sliding shaft contact Rotation condition gt Replace Gasket Replace Sealing cap 24 25 Damage wear abnormal key groove Z xt 5 8 Flaking wear deformation and key groove wear Fatigue and crack Clogged oil hole Replace Gasket Crack abnormal knock hole clogged oil hole Wear damage aging of lip surface Disassembling and inspecting gear case timing gears and camshaft Disassembling sequence 1 Tappet 13 Relief spring 25 Camshaft 2 Oil pump cover 14 Relief plunger Remove parts 23 to 25 ap aruni 3 Gear pump housing 15 Grooved pin 26 Sliding shaft 4 Crankshaft pulley 16 Governor shaft 27 Governor weight 5 Gear case 17 Tension lever 28 Fuel injection pump camshaft gears 6 Ball bearing 18 Governor lever 29 Ball bearing 7 PTO gear 19 Governor spring lever 30 Snap ring 8 Ball bearing 20 Grooved pin 31 Ball bearing Remove parts oa as a
114. g glow plug Removing glow plug Removing sequence 1 Glow plug plate 2 Glow plug ELECTRICAL SYSTEM 2 Disassembling inspecting and reassembling electrical system 2 1 Inspection before disassembling starter M000T60481 12V 1 2kW M001T68381 12V 1 7kW 2 1 1 Inspecting pinion clearance Do not apply current continuously for longer than 10 seconds 1 Connect the starter to the circuit as shown in the illustration 2 When the switches SW1 and SW2 are turned ON the pinion springs out to the cranking position and the armature rotates 3 Turn the switch SW2 OFF to stop the rotation of the armature 4 Gently push back the pinion in the out position with a finger and measure the distance over which the pinion has returned movement amount 5 If the measured value is out of the standard increase or decrease the number of packings between the magnetic switch and the front bracket for adjustment or replace the lever with a new one Note When the number of packings is increased the pinion clearance becomes small Item Standard 0 5 to 2 0 mm 0 0197 to 0 0787 in Pinion gap 12 8 Battery 12V Disconnect the lead with a terminal connected to terminal M Wiring during inspection of pinion clearance Pinion Gently push back the pinion Pinion clearance 0 5 to 2 0 mm 0 0197 to 0 0787 in Inspecting pinion clearance ELECTRICAL SYSTEM 2 1 2 Inspecting magnetic switch
115. g piston outside diameter 6 12 4 2 2 Boring finish dimension eeeee eee 6 12 4 3 Measuring piston ring end gap 6 13 4 4 Measuring clearance between piston ring groove and piston ring eeen 6 13 4 5 Measuring piston pin bore diameter and piston pin outside diameter 6 14 4 6 Measuring connecting rod end play 6 14 4 7 Inspecting connecting rod bend and twist6 15 4 8 Measuring clearance between connecting rod bearing and crankpin s es 6 16 4 9 Measuring clearance between main bearing and crankshaft journal 6 17 4 10 Measuring crankshaft runout 6 18 4 11 Replacing crankshaft gear 6 18 4 11 1 Removing crankshaft gear ee 6 18 4 11 2 Installing crankshaft gear 6 18 4 12 Measuring distortion cylinder block TOP SUITACE sy deeis ddl al 6 19 6 1 INSPECTION AND REPAIR OF BASIC ENGINE 1 Inspecting and repairing cylinder head and valve mechanism 1 1 Measuring clearance between rocker arm and rocker shaft Measure the inside diameter of the rocker arm and outside diameter of the rocker shaft Replace the rocker arm or rocker shaft if the clearance exceeds the limit Item Nominal Standard Limit 12mm 12 013 to 12 035 mm 0 47 in 0 4730 to 0 4738 in Rocker arm inside diameter Rocker shaft 12mm 11 470 to 11 984 mm outside diameter 0 47 in 0 4516 to 0 4718 in Clearance between rocker arm and shaf
116. g screw lightly using lock nut 2 Set the scale to zero Turn the torque spring case until the scale reading reaches the load value A g in the table below At this position secure the adjusting screw using the speical nut 3 Temporarily loose the adjusting screw until A g load decreases by approx 200 g 7 05 oz and then tighten the adjusting screw again until the load reaches B g in the table below At this position tighten the lock nut to the specified torque to secure the adjusting screw 4 To check that the torque spring set is adjusted to the appropriate load place the torque spring set as shown in the illustration Slowly push the scale to the torque spring set until the spring stopper moves or the pointer of the dial gauge swings Check the load against the torque spring at that moment is equal to C g of the table below A B C Color 10 10 570 0 G 570 0 E 570 30 g Green 20 116 oz 20 112 oz 19 40 0 0z 10 0 20 PA 0 1520 10 g our 30 g a i Red 53 620 53 62 0 35 oz 52 91 To oz 970 0 g 970 10 g 950 g 40 35 v Yellow 34 22 o oz 34 22 0 35 oz 33 51 106 oz 10 0 20 12700 g 1270 10 g 1250 30 g Purple 44 80 S 5 oz 44 80 035 0z 44 09 106 oz Note Load values A B and C vary based on models FUEL SYSTEM Lock nut Adjusting Torque spring case Fixed scale Special nut Lock nut 7 8 to 11 8N m 0 8 to 1 2k
117. gf m 5 8 to 9 7 Ibf ft Special nut Torque spring case Spring stopper Torque spring Adjusting screw Setting of torque spring of single spring type Dial gauge Block gauge Sliding scale Special nut Inspecting torque spring of single spring type 8 21 FUEL SYSTEM 2 9 2 Reassembling torque spring set double spring type Reassemble the torque spring set of the double spring type as described in the following 1 Screw in the adjusting screw so that the end of the spring stopper protrudes from the torque spring case as the protrusion table below 2 Then tighten the locknut to the specified torque to secure the adjusting screw 3 With the spring stopper pushed in as described above 1 make sure the spring stopper moves smoothly and is properly retracted to the end face of the torque spring case 4 To check the protrusion of the spring stopper is correctly adjusted place the torque spring set as shown in the illustration Apply a dial gauge to the end of the spring stopper and set the pointer to zero Then push in the spring stopper and slightly displace the torque spring set to the side Read extension of the dial gauge to the end of the torque spring case Protrusion mm Color 0 2 to 0 3 mm None 0 008 to 0 012 in 0 to 0 4 mm 0 to 0 016 in White 0 3 to 0 4 mm Blue 0 012 to 0 016 in 0 4 to 0 5 mm 0 016 to 0 020 in Bick 0 6 to0 7 mm 0 024 to 0 0
118. gine by its side 2 Mark the cylinder number on the connecting rod and connecting rod cap so that their combination is not changed when reassembling 3 Remove the connecting rod caps Note Mark the cylinder No and upper lower on connecting rod bearings to ensure correct reassembling 5 16 Oil screen Removing connecting rod cap DISASSEMBLY OF BASIC ENGINE 4 4 Pulling out piston 1 Turn the crankshaft to bring the piston to the top dead center 2 Using a piece of wood such a hammer handle push the mating surface of the connecting rod cap and pull the piston and connecting rod upward from the cylinder 4 5 Removing piston ring Remove the piston rings using piston ring pliers 4 6 Removing piston pin Remove the piston pin using a piston pin setting tool Special tool name Part No For L2A L3A 30L91 00030 Piston pini For L2C L3C 30L91 00020 setting tool For L2E L3E 30L91 10010 Part ee Identification descrip Applicable to 3 mark tion D18 Forl8mm 0 70868 in piston pin Push rod D21 For 21mm 0 82677 in piston pin O Identification mark Connecting rod Piston pin setting tool Removing piston pin 5 17 DISASSEMBLY OF BASIC ENGINE 4 7 Measuring crankshaft end play Measure the crankshaft end play difference between the crankshaft
119. he spacer and pulley and secure the pulley with Front bracket a nut 2 12 6 Assembling stator and front bracket 1 When installing the rotor into the rear bracket lift the brushes with a piece of wire inserted through the small hole in the bracket After installation remove the wire 2 Assemble the front bracket stator and rear bracket and secure them with through bolts Through Joining stator and front bracket 12 47 ELECTRICAL SYSTEM 2 13 Inspecting glow plug Check continuity between the terminal and the body as shown in the illustration If no continuity is indicated or the resistance is large replace the glow plug with a new one Item Standard 12V 0 2 Q Resistance value 24 V 4 5 Q 12 48 Inspecting glow plug ELECTRICAL SYSTEM 3 Installing electrical system 3 1 Installing glow plug 0 98 to 1 47 N m 0 10 to 0 15 kgf m 0 72 to 1 08 Ibf ft A 14 7 to 19 6 N m 1 5 to 2 0 kgf m 10 8 to 14 5 lbf ft Installing glow plug 3 2 Installing stop solenoid ETR type N ETS type 4 0 to 5 0kgf m 28 9 to 36 2Ibf ft Installing stop solenoid 12 49 ELECTRICAL SYSTEM 3 3 Installing stop solenoid ETR type These areas must be free from sealants Cylinder block Control rack Nut 39 2 to 49 0 Ne m 4 0 to 5 0 kgf m 28 9 to 36 2 Ibf ft
120. heck Oil pump inner gear Oil pump housing the spring for fatigue and damage If faulty replace the Relief relief valve with new one 2 Measure the relief valve opening pressure If the pressure does not fall within the standard range replace the relief valve with new one Item Standard 0 29 0 029 MPa Relief valve opening pressure 3 0 0 3 kgf cm 43 4 3 psi Note Start oil pressure measurement at the engine front side gear case Engine oil pressure measuring port PT1 8 2 3 Inspecting oil pressure switch 1 Connect a tester ohm range between the terminal and body to check for continuity The switch is normal if there is continuity between them If there is no continuity replace the switch 2 Insert a thin rod from the oil hole and lightly push it The switch is normal if there is no continuity between them If there is continuity when the rod is pushed in replace the switch 3 When air pressure of 0 05 MPa 0 5 kgf cm 7 1 psi is applied from the oil hole and there is no continuity the switch is normal Also check for air leaks If there are air leaks the diaphragm is damaged Replace the switch Inspecting oil pressure switch 2 LUBRICATION SYSTEM 3 Installing lubrication system 3 1 Installing oil pump oil pan and oil screen 7 8 to 9 8N m 0 8 to 1 0kgf m 5 8 to 7 2 Ibf ft Replace Installing oil pump oil pan and oil scre
121. iameter 1 134 in 2 4 6 Measuring undercut depth Measure the depth of undercutting between the commutator segments If the measured value is less than the limit repair or replace with a new part Item Standard Limit 0 5 to 1 0 mm 0 2 mm Undercutting depth 19 9197 to 0 0394 in 0 0079 in 12 16 Commutator Measuring commutator outside diameter Undercut Measuring commutator mica depth ELECTRICAL SYSTEM 2 4 7 Checking armature coil 1 Inspect the armature coil using a growler Hold a piece of iron plate against the armature core If Growler tester the iron plate vibrates replace the armature with a new one Inspecting armature coil for short circuit 2 Check that there is no continuity between the commutator and the shaft core If any continuity is observed replace the armature with yy GY Sh Sy S i S SS Q 5 S ES anew one AS s Ch if I aN 2 E E y n Fel p Checking armature coil for grounding SEES SEE lt 2 RECS lt gt 5 OG SS XZ QS SS SE SESS ES V7 q yo im 3 Check that there is continuity between segments in various combinations If poor or no continuity is observed replace the armature with a new one Checking armature coil for breaks 2 4 8 Inspecting rear bracket Replace the rear bracket if the bearing is worn
122. ing the piston head 2 Fit the connecting rod bearing lower to the rod cap with the lug aligned with the lug groove 3 Install the cap to the connecting rod aligning the mating marks made during disassembly Note For new connecting rod on which there is no mating mark orient the lugs of upper and lower bearings on the same side as shown in the illustration 4 Tighten the connecting rod cap nuts evenly and progressively to the specified torque 5 Inspect end play of the connecting rod If end play is small loosen and retighten the cap nuts Item Standard Limit End play of connecting 0 10 to 0 35 mm 0 5 mm rods 0 0039 to 0 0138 in 0 0197 in La Tightening torque gt 31 4 to 34 3 N m 3 2 to 3 5 kgf m 23 1 to 25 3 Ibf ft Measuring end play of connecting rod 7 7 REASSEMBLY OF BASIC ENGINE 1 11 Installing oil screen 1 Turn the engine upside down so that the oil pan mounting surface is facing up 2 Install the oil screen so that the tip of the screen does not contact the oil pan 1 12 Installing oil pan 1 Install new oil pan gasket 2 Tighten oil pan bolts evenly and diagonally Installing oil pan REASSEMBLY OF BASIC ENGINE 2 Reassembling gear case timing gear and camshaft 2 1 Installing front plate 1 Clean the mounting surface of the gasket 2 Apply sealant to the gasket to prevent it from falling 3 With align
123. ing to the dowel pin install the gasket and the front plate 4 Secure the front plate with mounting bolts 2 2 Rotating crankshaft 1 Install two bolts in the flywheel mounting holes of the crankshaft 2 Rotate the crankshaft with a bar using the bolts to bring the No 1 cylinder at the top dead center 2 3 Installing fuel injection pump camshaft 1 Insert the fuel injection pump camshaft with the bearing and gear installed into the cylinder block hole 2 Install the bearing into the cylinder block hole completely by tapping the gear with a plastic hammer 3 Make sure that the fuel injection pump camshaft rotates lightly 4 Tighten the camshaft stopper bolts Driving in fuel injection pump camshaft Camshaft stopper washer O Fuel ee s Q camshaft gear Installing camshaft stopper washers 7 9 REASSEMBLY OF BASIC ENGINE 2 4 Installing camshaft Be careful not to damage camshaft journals cams and camshaft holes during insertion 1 Apply engine oil to the camshaft journals and cams 2 2 Slowly insert the camshaft assembly 3 Install the camshaft stopper 4 4 Make sure that the camshaft rotates freely Move the camshaft gear back and forth and make sure there is end play Camshaft stopper washer 2 5 Installing idler gear 1 Apply engine oil to the idler gear shaft 2 Install the idler gear while aligning all match marks on it
124. ition of the operating range 8 Feed fuel from the fuel hose and check that the fuel flows out from the delivery holder 9 Rotate the crankshaft forward clockwise The fuel injection timing is the moment when the fuel stops flowing from the delivery valve holder outlet Note When the fuel stops flowing rotate the crankshaft backward counterclockwise to allow the fuel flowing again And then rotate the crankshaft forward clockwise to ensure the accurate timing when the fuel stops flowing 10 It is normal that IT mark of the crankshaft pulley aligns the mark on the gear case at the position that fuel flow stopped 13 4 Delivery valve Tie rod clip Tie rod Fuel injection timing mark on gear case side Fuel injection timing Injection timing mark on pulley side TDC mark Fuel injection timing ADJUSTMENT AND OPERATION 1 3 Adjusting fuel injection timing When using the shim apply sealant to both side of the shim to prevent oil leakage 1 If the fuel injection timing does not meet the specified value increase or decrease the thickness of the fuel injection pump adjusting shim to adjust the timing adjusting value standard value 1 5 Note A change in thickness of the shim by 0 1 mm 0 004 in results in a change in the fuel injection timing by approx 1 2 After adjusting check that the fuel injection timing is properly
125. ity is observed replace the yoke assembly with a new one 2 8 10 Inspecting center bracket Check the bearing If the bearing is worn replace the center bracket Checking field coils for grounding 12 33 ELECTRICAL SYSTEM 2 8 11 Inspecting overrunning clutch Do not clean the overrunning clutch in wash oil Make sure that when attempting to turn the overrunning clutch it locks in one direction and rotates smoothly in the opposite direction 2 8 12 Inspecting pinion Check the pinion for wear and damage If faulty replace the pinion with a new one 2 8 13 Inspecting front bracket The ball bearing should rotate smoothly without abnormal noise If defective replace the whole front bracket 2 8 14 Inspecting gears of starter Check gears of the starter for wear or damage If faulty replace the starter 2 8 15 Inspecting continuity of magnetic switch between M terminal and case Check that there is continuity between M terminal and case If no continuity is observed replace the magnetic switch with a new one 2 8 16 Inspecting insulation of magnetic switch between M terminal and B terminal Check that there is no continuity between M terminal and B terminal If continuity is observed replace the magnetic switch with a new one 12 34 Inspecting overrunning clutch Terminal S Terminal M Checking magnetic switch for continuity ELECTRICAL SYSTEM 2 9 Reassembling starter
126. ive to the threaded portion Groove Tappet shim plate Tappet guide pin hole Control sleeve Protrusion Fork Control rack Installing control rack 8 17 FUEL SYSTEM 2 5 7 Tightening delivery valve holder 1 Place the pump housing upright and grab the housing with a vise 2 Tighten the delivery valve holder to the specified torque 2 5 8 Inspecting control rack for smooth opera tion 1 Remove the pump housing from the vise and check the control rack for smooth movement If the movement is not smooth the following defects are suspected Sliding of the element is poor A foreign substance is present in the teeth of rack or sleeve The valve holder is overtightened 2 Check the injection timing 2 5 9 Installing lock plate 1 Grab the pump housing with a vise 2 Install the center lock plate first and then side lock plates later 3 Tighten the screws to the specified torque 2 5 10 Installing swivel nipple 1 Install the swivel nipple on the pump housing 2 Tighten the hollow screw to the specified torque 8 18 34 3 to 38 2N m l 3 5 to 3 9 kgf m 7 s 25 3 to 28 2 Ibf ft oO Delivery valve Pump housing 0 3 to 0 4 kgf m 2 2 to 2 9 Ibf ft Installing lock plate Tightening torque 9 8 to 14 7 N m 1 0 to 1 5 kgf m 7 2 to 10 8 Ibf ft Installing
127. jection nozzle holder M20 x 1 5 49 0 to 68 6 5 0 to 7 0 36 2 to 50 6 Fuel injection pipe nuts M12 x 1 5 24 5 to 29 4 2 5 to 3 0 18 1 to 21 7 Fuel return pipe nut M12 x 1 5 20 6 to 24 5 2 1 to 2 5 15 2 to 18 1 Nut for setting torque spring M12 x 1 0 14 7 to 24 5 1 5 to 2 5 10 8 to 18 1 Adjusting screw nut for setting torque spring M8 x 1 7 8 to 11 8 0 8 to 1 2 5 8 to 8 7 2 10 2 1 3 Lubrication system Table 2 10 Tightening torque list Lubrication system SERVICE DATA Threads Torque Description Dia x Pitch Remark mm N m kgf m lbf ft Oil relief valve M18 x 1 5 39 2 to 49 0 4 0 to 5 0 28 9 to 36 2 Oil pan drain plug M18 x 1 5 49 0 to 58 8 5 0 to 6 0 36 2 to 43 4 Oil pressure switch PT1 8 7 85 to 11 8 0 8 to 1 2 5 8 to 8 7 Oil pump M6 x 1 0 7 8 to 9 8 0 8 to 1 0 5 8 to 7 2 2 1 4 Cooling system Table 2 11 Tightening torque list Cooling system Threads Torque Description Dia x Pitch Remark mm N m kgf m lbf ft Thermoswitch M16 x 1 5 19 6 to 29 4 2 0 to 3 0 14 5 to 21 7 Thermostat cover bolt M6 x 1 0 8 to 10 0 8 to 1 0 5 8 to 7 2 Hole plug for thermoswitch M16x 1 5 19 6 to 24 5 2 0 to 2 5 14 5 to 18 1 2 1 5 Inlet and exhaust systems Table 2 12 Tightening torque list Inlet and exhaust systems Threads Torque Description Dia x Pitch Remark mm N m kgf m Ibf ft Intake
128. le and remove the fuel injection nozzle and holder gasket Note Using a wire or screwdriver remove the holder gasket Removing fuel injection nozzle 8 3 FUEL SYSTEM 1 2 Removing fuel filter Removing fuel filter Removing sequence 1 Fuel hose 2 Fuel filter 3 Fuel filter support 8 4 FUEL SYSTEM 1 3 Removing governor Replace g Fatigue and crack Wear and damage of sliding sleeve Replace Wear and damage of sliding shaft contact Removing governor Removing sequence 1 Tie rod cover 7 Tension lever 13 Governor lever 2 Governor lever 8 Start spring 14 Grooved pin 3 Governor spring 9 Tie rod spring 15 Speed control lever 4 Sealing cap 10 Tie rod 16 Sliding shaft 5 Grooved pin 11 Tie rod crip 17 Governor weight 6 Governor shaft 12 Governor lever 18 Torque spring set rack set screw 8 5 FUEL SYSTEM 1 3 1 Disconnecting tie rod from control rack 1 Remove the tie rod cover 2 Remove the tie rod clip and disconnect the tie rod from the control rack 1 3 2 Removing governor shaft and speed con trol lever 1 Remove the sealing cap from the side of the gear case 2 Pull out the grooved pin A 3 Remove the governor shaft and remove tension lever and governor lever 4 Remove the governor spring lever 5 Remove the grooved pin B and remove speed control lever 6 Remove the governor cover
129. least 1 m 3 28 ft away from buildings and other equipment to prevent possible fire caused by engine heat Avoid accessing crankcase until engine cools Do not attempt to open the side cover of the crankcase before the engine cools down Wait at least 10 minutes after stopping the engine Opening the cover when the engine is hot allows fresh air to flow into the crankcase which can cause oil mist to ignite and explode Care about fuel oil and exhaust gas leakage If any fuel oil or exhaust gas leakage is found immedi ately take corrective measures to stop it Such leakages if left uncorrected can cause fuel or engine oil to reach hot engine surfaces or hot exhaust gas to contact flammable materials possibly leading to personal injury and or damage to equipment Use explosion proof lighting apparatus When inspecting fuel engine oil coolant battery elec trolyte etc use a flameproof light An ordinary light if accidentally broken may ignite and cause an explo sion Prevent electrical wires from short circuit ing Avoid inspecting or servicing the electrical system with the ground cable connected to the battery Otherwise a fire could result from short circuiting Be sure to dis connect the battery cable from the negative terminal before beginning with the work procedure Short circuits possibly resulting in fire may be caused by a loose terminal or damaged cable wire Inspect the terminals cables and wires a
130. leeding NO screw of the fuel injection pump is gt loosened Inspect fuel filter fuel pipe and fuel tank Does fuel flow in the fuel line Is the engine correctly adjusted fuel NO injection timing and valve clearance gt Adjust engine Are fuel injection nozzles normal NO spray state and injection valve opening Inspect fuel injection nozzles pressure YES Is the compression pressure NO Inspect valves pistons piston rings in cylinders normal gt and cylinder head gasket YES Inspect fuel injection pump Problem Starting trouble 14 3 TROUBLESHOOTING 1 3 Knocking The diesel engine rotates producing unique combustion noise diesel knock due to its combustion system This knock noise is normal unless it is especially loud 1 3 1 Check items before troubleshooting 2 Use of poor quality fuel low cetane number fuel such 1 Clogging of air cleaner element as kerosene 1 3 2 Problem Knocking Is the fuel injection timing normal NO ear eer ee fuel injection timing is early ca Adustuelinection timing Jb ves NO Are fuel injection nozzles normal drop in gt Examine fuel injection nozzles injection valve opening pressure and faulty byes gt NO p A Is the compression pressure gt Inspecting valves pistons piston rings in cylinders normal and cylinder head gasket Jb ves Is the fuel injection pump normal variations in injection amount Jb ves Generati
131. ling or cleaning 6 When lifting or carrying heavy parts exercise utmost caution to ensure safety Pay attention to balance of heavy parts when handling Get help and use jacks chain blocks and guide bolts as necessary 6 2 Reassembling 1 Wash all engine parts except such parts as oil seals O rings and rubber sheets in cleaning oil and dry them with compressed air 2 Use correct tools and instruments 3 Use only high quality lubricating oils and greases of appropriate types Be sure to apply oil grease or adhesive to the part wherever specified 4 Use a torque wrench to tighten parts correctly when their tightening torques are specified Refer to List of Tightening Torque 5 Replace all gaskets and packings with new ones unless specified otherwise Apply adhesive if necessary Use only the proper amount of adhesive SERVICE DATA 1 Maintenance service data 2 2 1 1 Engine general 2 2 1 2 Basic ONQING 0 eee i eieren ianork k iiiu 2 2 1 3 Fuel syste M eneen ieee 2 5 1 4 Lubrication system eeeeeeeeeeeeeen 2 6 1 5 Cooling System sssssseeeseeesseeeeseeerreeene 2 6 1 6 Inlet Exhaust system 2 6 1 7 Electrical system aaeeeeerrnnnrnns 2 7 2 List of tightening torque 2 10 2 1 Major bolts and nuts tightening torque 2 10 2 1 1 Basic engines 2 10 2 1 2 Fuel SYStOMM eee eeeneeeeeeseeeeresnereeeeeeeees 2 10 2 1 3 Lubrication system seser 2 1
132. ll the cylinders and replace the pistons and piston rings with oversize ones Replace the cylinder block if the limit is exceeded Measuring cylinder inside diameter Approx 10 mm 0 39 in from top end Center Front lt gt Bottom Measuring Measuring positions directions Measuring position of cylinder inside diameter Item Nominal Standard Limit Remark LALA sein 2559110 2 5600in Poe ese didmerer PG L3G prea passe i in Maa S ae es LIEL3E ooi 29921 102 9933 in Cylindericity of cylinder sis ane jess gt a 6 11 INSPECTION AND REPAIR OF BASIC ENGINE 4 2 Reboring cylinder Cylinders shall be rebored according to the following procedure 4 2 1 Measuring piston outside diameter Using a micrometer measure the piston outside diameter at Direction at right angles to piston pin the skirt perpendicular to the piston pins as shown in the illustration Item Nominal Standard STD 65 mm 64 919 to 64 939 mm 2 559 in 2 5559 to 2 5566 in L2A 0 25 OS 65 25 mm 65 169 to 65 189 mm L3A 2 569 in 2 5657 to 2 5665 in 65 50 mm 65 419 to 65 439 mm 9 30 05 2 579 in 2 5755 to 2 5763 in Jian 60013 60535 am Measuring piston outside diameter 2 756 in 2 7525 to 2 7533 in L2C 0 25 OS 70 25 mm 70 163 to 70 183 mm L3C 2 766 in 2 7623 to 2 7631 in 70 50 mm 70 413 to 70 433 mm 05003
133. losest to the fuel tank the fuel filter the first and the fuel injection pump the last 1 5 1 Bleeding air from fuel filter 1 Cartrige type paper element Loosen the air vent screw marked by the letter 1 Tighten the air vent screw when fuel does not show air bubbles Loosen the air vent screw marked by the letter 2 Tighten the air vent screw when fuel does not show air bubbles Note Place the starter key in the ON position for the fuel pump type When the fuel supply is gravity type fuel will flow into the filter by itself 2 Cock type paper element 1 Place the fuel filter cock lever in the OPEN position and push the button several times to bleed the filter Note When the fuel supply is gravity type fuel will drop by itself and when the fuel supply is the pump type fuel and air in the filter will flow out with the starter key positioned ON 3 Cock type paper element 2 Loosen the left side air vent screw Tighten the air vent screw when fuel does not show air bubbles Loosen the right side air vent screw Tighten the air vent screw when fuel does not show air bubbles Note When the fuel supply is gravity type fuel will flow into the filter by itself and when the fuel supply is the pump type fuel and air in the filter will flow out with the starter key positioned ON Air vent screw Loosen air vent screws in numerical order to bleed air Press the push button several Cock lever open Bleeding
134. lter gasket 2 Screw the filter in by hand When the filter gasket contacts the mounting surface screw the filter in another turn Tighten the oil filter by hand Apply engine oil Installing oil filter 2 9 9 COOLING SYSTEM 1 Removing cooling system 10 2 1 1 Removing cooling fan fan pulley V belt thermostat thermoswitch and Water PUMP 0 0 tee ee ea eens 10 2 2 Disassembling inspecting and reassembling cooling system 10 3 2 1 Disassembling and inspecting thermostat10 3 2 2 Inspecting thermostat 10 3 2 3 Reassembling thermostat ee 10 4 2 4 Inspecting thermoswitch ceeeee 10 4 2 5 Inspecting water PUMDP eee 10 4 2 5 1 Checking water pump for smooth rotation10 4 3 Installing cooling system 10 5 3 1 Installing cooling fan fan pulley V belt thermostat thermoswitchand water PUMP 00 cee eens 10 5 10 1 COOLING SYSTEM 1 Removing cooling system 1 1 Removing cooling fan fan pulley V belt thermostat thermoswitch and water pump Replace Removing cooling fan fan pulley V belt thermostat thermoswitch and water pump Removing sequence 1 Fan 4 V belt 7 Pipe 2 Fan spacer 5 Thermostat case 8 Water pump 3 Fan pulley 6 Thermoswitch 10 2 COOLING SYSTEM 2 Disassembling inspecting and reassembling cooling system 2 1 Disassembling and inspecting th
135. magnetic switch and the front bracket for adjustment or replace the lever with a new one Note When the number of packings is increased the pinion clearance becomes small Item Standard Pinion gap 0 5 to 2 0 mm 0 0197 to 0 0787 in Disconnect the lead with a terminal connected to Battery terminal M 24V Wiring during inspection of pinion clearance Pinion Gently push back the pinion Pinion clearance 0 5 to 2 0 mm 0 0197 to 0 0787 in Inspecting pinion clearance 12 23 ELECTRICAL SYSTEM 2 6 2 Inspecting magnetic switch Perform the inspection as described below If faulty replace the magnetic switch with a new one Do not apply current continuously for longer than 10 seconds 1 2 Disconnect the connector of M terminal Pull in test Connect the starter to the circuit as shown in the illustration The magnetic switch is normal if the pinion springs out when the switch is turned ON Holding test Connect the starter to the circuit as shown in the illustration Pull out the pinion fully by hand The magnetic switch is normal if the pinion does not return when it is released Return test Connect the starter to the circuit as shown in the illustration Pull out the pinion fully by hand The magnetic switch is normal if the pinion returns immediately when it is released 12 24 Battery 24V Battery 24V Starter Holding test Disconnect the
136. mbly Remove the screws of the regulator assembly and then remove the regulator assembly Regulator assembly 2 10 7 Removing rectifier assembly 1 Remove the screw and nut from the rectifier 2 Remove the rectifier assembly Rear bracket Rectifier assembly Removing rectifier assembly 12 41 ELECTRICAL SYSTEM 2 11 Inspecting and repairing alternator 2 11 1 Inspecting rectifier Check that diodes in a rectifier function properly To check measure both negative and positive resistance alternately twice If both infinite negative and infinite positive resistances are observed the diode is open circuited If measured value is close to 0 Q the diode is short circuited In either case replace the rectifier with a new one Note Use a wide measuring range as much as possible The current flow during test is significantly lower than the current that normally flows in the rectifier by which Checking rectifier the accurate resistance may not be measured using a tester and this tendency is noticeable if the measuring range is small 2 11 2 Inspecting rotor 1 Check that there is continuity between slip rings If no continuity is observed replace the rotor with a new one 2 Check that there is no continuity between the slip ring and the shaft or the core If continuity is observed replace the rotor with a new one Checking field coils for grounding 12 42
137. ms before troublshooting 1 Seizure of engine moving parts 2 3 2 Viscosity of engine oil too high 3 4 Clogging of air cleaner element 5 6 Use of poor quality fuel 5 6 Clogging of muffler Powertrain malfunction 1 7 2 Problem Low output Does fuel including the fuel amount Is fuel in the fuel line sufficient 4 ual ian flow sufficiently in Inspect fuel filter e drop types fuel pipe and fuel tank Does fuel flow with the switch turned ON in the electromagnetic type YES gt Fuel pump Is the engine correctly adjusted NO valve clearance and fuel injection timing gt Adjust engine Are fuel injection nozzles normal NO a spray state and injection valve Inspect fuel injection nozzles opening pressure I YES i NO e gt Inspect valves cylinder head gasket pistons and piston rings I YES Inspect fuel injection pump Problem Low output 14 8 SUPPLEMENT INSPECTION RECORD SHEET L SERIES No 1 Measurement of Cylinder Inside Diameter Gua DduseuLebasaeeeedeeedebend es enue Sudse sabes ER Supplement 2 No 2 Measurement of Valve Guide Inside Diameter and Valve Stem Outside Diameter EEEE AEE T EE AATTEET E AOT E I E A T T T AORE Supplement 3 No 3 Measurement of Valve Seat Angle Valve Sinkage and Valve Margin srr Supplement 4 No 4 Measurement of Distortion of Cylinder Head Bottom Surfaces seereeeeererereeeee Supplement 5 No 5 Measurement of Clearance Between Connecting Rod
138. n and connecting rod 1 2 Set the piston pin push rod and guide to the piston pin Pushrod Piston pin Guide gt S Stamped identification mark Pushrod D18 For 18 mm 0 71 in piston pin D21 For 21 mm 0 83 in piston pin Guide LED21 L2E L3E For 18 mm 0 83 in piston pin LCE D18 L2C L3C For 18 mm 0 71 in piston pin L A L2A L3A For 18 mm 0 71 in piston pin Reassembling piston and connecting rod 2 3 Reassemble the piston to the connecting rod with the front mark A on the piston top and the identification ificati Pushrod mark of the connecting rod facing upward lgentiicatiommark Install the piston pin from the piston pin guide Connecting rod 4 Press in the piston pin with the push rod using hydraulic press pin press in load 9807 4903 N 1000 500 kgf 2205 1102 lbf until the guide contacts the piston setting tool 5 After reassembling make sure that the piston and the connecting rod move lightly on the piston pin Reassembling piston and connecting rod 4 7 5 REASSEMBLY OF BASIC ENGINE 1 8 Installing piston Every piston ring has a top mark such as R near the end gap Install all piston rings with this mark facing upward If the rings are installed upside down it could cause malfunctions such as excessive oil consumption or an engine seizing 1 Install the piston rings to the piston with a ring
139. n pressure It is therefore necessary to conduct a careful study to determine the cause From the reason above troubleshooting described in this section is summarized as the inspecting order from items which are more likely to cause problems or items easy to inspect in sequence The diesel engine has the following characteristics from its structure and combustion system It is necessary to fully understand these characteristics before performing troubleshooting The engine produces unique combustion noise diesel knock in the normal condition The engine discharges slight black smoke at heavy load High compression and high torque cause vibration on a single unit of the engine Slight hunting is caused during acceleration and deceleration 14 2 TROUBLESHOOTING 1 2 Starting trouble 1 2 1 Check items before troubleshooting 1 Clogging of air cleaner element 2 Coagulation of engine oil 3 Use of poor quality fuel 4 Drop in cranking speed 1 2 2 Problem Starting trouble switch is turned ON NO NO Is the preheating Is power applied to the glow plug gt l p i l Inspect key switch device normal wire immediately after the key wiring and glow signal YES gt Inspect glow plug If the preheating device is equipped with a fuel pump does the pump operate when gt Inspect wiring Is the electrical the key switch is turned ON of fuel pump wiring normal Is fuel drained when the air b
140. nd reassembly of the Mitsubishi Diesel Engine standard model for land use A short summary describing the content of each Group is given in the General Contents page and there is also a detailed table of contents at the beginning of each Group Regarding the procedures for operation and periodical maintenance of the engine refer to the Operation and Maintenance Manual For information on the engine components and ordering of service parts refer to the Parts Catalogue Structure and function of the engine are described in the relevant training manuals Methods of presentation 1 Index numbers allotted to parts in exploded views are not only a call out of part names listed in the text but also an indi cation of the sequence of disassembly 2 Inspections to be conducted during disassembly process are indicated in boxes in the relevant exploded views 3 Maintenance standards required for inspection and repair works are indicated in the appropriate positions in the text They are also collectively indicated in Group 2 the General Contents group 4 Fasteners to be tightened in wet condition or with engine oil applied are identified by Wet placed after tightening torque values If no such indication is suffixed the fastener should be tightened in dry condition or without lubricating with engine oil 5 In this manual important safety or other cautionary instructions are emphasized with the following marks headed Indica
141. nd repair or replace the faulty parts before beginning with the service proce dure Keep fire extinguishers and first aid kit handy Keep fire extinguishers handy and become familiar with their usage Keep a first aid kit at the designated place where it is easily accessible by anyone at any time Establish response procedures to follow in the event of fire or accident Provide an emer gency evacuation route contact points and means of communication in case of emergency INTRODUCTION Stay clear of all rotating and moving parts Install protective covers on rotating parts Make sure the protective covers for engine rotating parts are properly installed as intended Repair loose or damaged protective covers as necessary Never remove the covers guarding personnel from rotating parts when the engine is oper ating When combining the engine with the engine driven ma chine or radiator always provide a cover on every ex posed moving part such as driving belt and coupling Never remove protective covers Ensure safety of neighboring people before starting engine Before starting the engine ensure that there is nobody in the neighborhood and that no tools are left on or near the engine Verbally notify people around the engine or in the work area when starting the engine When the starter device is posted with a sign that pro hibits startup operation do not operate the engine
142. ng lifts from the brush If the measured value is less than the limit replace the spring with a new one Item Standard Limit Brush sprin 28 9 to 39 1N 20N ead E 2 95 to 3 99kgf 2 04kgf on 6 5035 to 8 7963 lbf 4 4974 Ibf Measuring brush spring load 2 8 3 Inspecting brush holder for insulation Check that there is no continuity between each brush holder and the brush holder base If continuity is observed replace Insulated brush holder the whole brush holder assembly Check the brush holders for looseness LB S A R NINNE oo Brush holder base Checking brush holder for grounding 12 30 ELECTRICAL SYSTEM 2 8 4 Measuring commutator radial runout 1 Inspect the commutator surface If the surface is rough polish it using a 400 to 600 grit sandpaper Commutator 2 Measure the commutator radial runout with a dial gauge If the measured value exceeds the limit replace the armature with a new one Item Standard Limit 0 03 mm 0 10 mm Commutator radial runout 0 0012 in 0 0039 in 2 8 5 Measuring commutator outside diameter Measure the commutator outside diameter If the measured value is less than the limit replace the armature with a new one Item Standard Limit 32 0 mm 31 4 mm Commutator outside diameter 1 2598 in 1 2362 in Measuring commutator outside diameter 2 8 6 Measuring undercut depth Measure the
143. ngine stops 12 50 ELECTRICAL SYSTEM 3 4 Installing stop solenoid ETS type These areas must be Nut Cylinder block free from a sealant 39 2 to 49 0N m 4 0 to 5 0kgf m Control rack 28 9 to 36 2Ibf ft Do not allow wash fluid to enter the inside of the solenoid from the clearance A gt Rubber cap Stop solenoid 0 15 to 0 20mm 0 00591 to 0 00788 in Ht Threaded portion Apply a sealant Water drain hole Installing stop solenoid ETS type 3 4 1 Procedure for installing stop solenoid ETS type Do not allow wash fluid to enter the terminal and the inside cord and shaft of the solenoid 1 Apply a sealant to the threaded portion of the stop solenoid Note Apply the sealant up to the position where the stop solenoid is screwed into the cylinder block Sealant or lubricant THREEBOND 1212 or 1211 2 Temporarily reassemble the stop solenoid and the nut to the cylinder block 3 Move the control rack of the fuel injection pump fully in the stop direction 4 Screw in the stop solenoid while pushing in the plunger until the shaft contacts the control rack At this time the clearance of A should be 0 mm 0 in position where the plunger is also turned by screwing in the stop solenoid
144. nion has returned movement amount 5 If the measured value is out of the standard increase or decrease the number of packings between the magnetic switch and the front bracket for adjustment or replace the lever with a new one Note When the number of packings is increased the pinion clearance becomes small Item Standard Pinion gap 12 38 0 5 to 2 0 mm 0 0197 to 0 0787 in Through bolt 4 4 to 7 1N m 0 45 to 0 72kgf m 3 to 5ibf ft Screw 2 4 to 4 4N m 0 24 to 0 45kgf m 2 to 3lbf ft Connector Magnet switch Terminal M 8 8 to 12 7N m th screws 4 1 to 7 6N m 0 42 to 0 77kgf m 7 to 9lbf ft Installing magnetic switch Disconnect the lead with a terminal connected to Battery terminal M 24V Wiring during inspection of pinion clearance Gently push back the pinion Pinion clearance 0 5 to 2 0 mm 0 0197 to 0 0787 in Inspecting pinion clearance ELECTRICAL SYSTEM 2 10 Disassembling and inspecting alternator Dirt damage and seizure of Rotation condition slip ring and coil resistance Crack damage Crack damage g Rotation condition Deformation and damage Disassembling and inspecting alternator Disassembling sequence 1 Through bolt 5 Rear bearing 9 Stator 2 Nut 6 Bearing retainer 10 Regulator assembly 3 Pulley spacer 7 Front bearing 11 R
145. o 172 F Thermostat Replace Temperature at which valve lift becomes 6 0 24 or 90 C more 194 F 30 mQ 111 3 5 C meer ee Thermoswitch 225 to 238 F in oil of 120 C 248 F Deflection amount of belt when it is pushed between crankshaft pulley and alternator pulley with Approx 10 a force of approx 0 39 98 N 10 kgf 22 Ibf 1 6 Inlet Exhaust system Table 2 6 Maintenance service data table Inlet Exhaust system Unit mm in Inspection point Nominal Standard Limit Remark Distortion on mounting surfaces of intake cover and 0 15 Rr ende eine exhaust manifold 0 0059 pair by amp 8 P 2 6 SERVICE DATA 1 7 Electrical system Table 2 7 Maintenance service data table Electrical system 1 3 Unit mm in Inspection point Nominal Standard Limit Remark Pinion clearance 0 31020 0 0197 to 0 0787 16 5 10 0 Brush length 0 650 0 394 20 58 N 17 5 to 23 7 N 6 86 N Brush spring load 2 10 kgf 1 78 to 2 42 kgf 0 70 kgf 4 6 Ibf 3 92 to 5 34 lbf 1 54 Ibf Starter 0 03 0 10 Commutator radial runout MO00T60481 0 0012 0 0039 12V 1 2kW 29 4 28 8 Commutator outside diameter 1 158 1 134 0 75 0 5 to 1 0 0 2 Depth of ndercuts between segments 0 030 0 0197 to 0 0394 0 0079 or less Terminal voltage 11 V aa eye Current 90 A or less characteristics Rotation speed 2500 min or more Pinion clearance Dee 0 0197 to 0 0787
146. ocker cover 2 Tighten the rocker cover mounting nuts to the specified torque 4 13 Installing torque spring set For installing procedures of the torque spring set refer to item Installing Fuel System Ignition order Rotation angle t 2 180 1 3 2 240 Mark on gear case side TDC mark on crankshaft pulley side Timing mark Tightening torque 4 9to6 9N m 0 5 to 0 7 kgf m 3 6 to 5 1 Ibf ft Installing rocker cover 7 21 FUEL SYSTEM 1 Removing fuel system 000 8 2 1 1 Removing fuel pipe and fuel injection NOZZE aeara EA TAA AA A 8 2 1 1 1 Removing fuel injection pipe s es 8 3 1 1 2 Removing fuel injection nozzle 8 3 1 2 Removing fuel filter eee 8 4 1 3 Removing QOVEFNON ce eeeeeeeeeeeeeeeeeees 8 5 1 3 1 Disconnecting tie rod from control rack 8 6 1 3 2 Removing governor shaft and speed control lever 8 6 1 4 Removing fuel injection pump 8 7 2 Disassembling inspecting and reassembling fuel system 8 8 2 1 Disassembling and inspecting fuel injection HOLOS aa itete eave henises ets aes 8 8 2 1 1 Inspecting and adjusting fuel injection valve OPENING pressure seeen 8 9 2 1 2 Inspecting fuel spray pattern of fuel injection NOZZ16 vei Assisi nits eceietel ae eee alee diy 8 10 2 1 3 Cleaning and replacing faulty nozzle 8 10 2 2 Reassembling fuel injection nozzles 8
147. olt 2 Remove the cylinder head assembly by lifting it up Note If the cylinder head assembly cannot be removed due to crimping of the cylinder head gasket tap the thick area on the side of the cylinder head using a plastic hammer to give a shock 3 Remove the gasket from the cylinder head Note If there is a cylinder head problem check the bolts for tightness with a torque wrench before removing the cylinder head bolts Cylinder head bolt main Cylinder head bolt sub Loosening order of cylinder head bolt L3 Removing cylinder head assembly DISASSEMBLY OF BASIC ENGINE 1 5 Removing valves and valve spring 1 Use a valve lifter to compress the valve spring and Valve lifter remove the valve lock 2 Remove the retainer valve spring and valve Note Put match marks for easy identification of the installing position if the valve is to be reused When reassembling do not change the combination of the valve and valve seat 1 6 Removing valve stem seal Grab the stem seal with pliers and remove Note Be sure to replace the stem seal with the new one Valve stem seal when reassembling the valve and valve spring Removing valve stem seal 5 5 DISASSEMBLY OF BASIC ENGINE 2 Disassembling and inspecting flywheel Wear damage aging of oil seal ihveasediparten Replace Gasket Streak stepped wear and crack of worn surface and damage and
148. ommutator to the commutator of the armature Remove the brush holder and brush assembly by sliding on the socket Screw Through bolt 2 3 5 Removing armature and yoke 1 Remove the armature and the yoke 2 Remove the packing from the internal gear 3 Remove the packing and plate on the lever support 4 5 Remove the ball from the internal gear Remove the planetary gears Brush holder Packing Planetary gear Removing armature and yoke 12 13 ELECTRICAL SYSTEM 2 3 6 Removing overrunning clutch Pull out the internal gear gear shaft overrunning clutch and lever as an assembly from the front bracket and remove the lever 2 3 7 Removing gear shaft 1 Remove the stopper ring and then the stopper 2 Separate the overrunning clutch internal gear and gear shaft 12 14 Lever Overrunning clutch Internal gear Gear shaft Front bracket Stopper Overrunning clutch Stopper ring Removing gear shaft ELECTRICAL SYSTEM 2 4 Inspecting and repairing starter M000T60481 12V 1 2kW M001T68381 12V 1 7kW 2 4 1 Inspecting brushes for wear Measure the length of the brushes If the measured value is less than the limit replace both the brush holder assembly and the brush assembly with new ones Item Standard Limit 16 5 mm 10 0 mm Brush length 0 650 in 0 394 in 2 4 2 Measuring brush spring load Using a new
149. on of mechanical noise wear of and damage to main working parts Problem Knocking 14 4 TROUBLESHOOTING 1 4 Overheating 1 4 1 Check items before troubleshooting 1 Quantity and leakage of coolant 2 3 4 5 Clogging of muffler 6 7 8 Loosening of fan belt Clogging of radiator fins Concentration of LLC 6 7 8 Quantity and degradation of engine oil Swirling of cooling air Thermostat malfunction 1 4 2 Problem Overheating Overheat often occurs by engine load mismatching when the engine is set up If the engine itself is normal and overheat occurs measure the ambient and coolant temperatures in the loaded condition thermostat full open If the temperature difference is greater than 60 C 140 F the investigation into other components as well as the engine is suggested NO Does the engine run continuously under overload gt Examine the cause of load NO low fy ot vinden head ga blow by of cylinder head gasket clogging of water pump i ich aca water hose and radiator and faulty thermostat NO Is the fuel injection timing gt Adjustfuel hidetion iag normal Problem Overheating 14 5 TROUBLESHOOTING 1 5 Excessive black smoke 1 5 1 Check items before troubleshooting 1 Clogging of air cleaner element 2 Use of poor quality fuel 3 Overload 1 5 2 Problem Excessive black smoke NO Is the smoke set amount of gt the fuel injection pump norm
150. on shift reduction type Starter 1 Output 12V 1 2 kW Number 1 Pinion ring gear ratio 14 106 Type M001T68381 Manufacturer Mitsubishi Electric Corporation Pinion engagement type Pinion shift reduction type Starter 2 Output 12V 1 7 kW Number 1 Pinion ring gear ratio 14 106 Type M002T66071 Manufacturer Mitsubishi Electric Corporation Pinion engagement type Pinion shift reduction type Starter 3 Output 24V 3 2 kW Number 1 Electrical Pinion ring gear ratio 15 106 System Type A007TA0171B Three phase current generator Type integral with IC regulator Manufacturer Mitsubishi Electric Corporation Alternator 1 Output V A 12V 40A Rated voltage generating speed 5000 min at 13 5V 37A when hot Regulator adjusting voltage 14 7 0 3V Type A007TA8271A Three phase current generator Type integral with IC regulator Manufacturer Mitsubishi Electric Corporation Alternator 2 Output 24V 25A Rated voltage generating speed 5000 min at 27 0V 22A when hot Rated voltage current Regulator adjusting voltage 28 5 0 5V Type Sheathed Glow plug 1 Rated voltage current 10 5V 9 7A 1 0A 30 second duration Type Sheathed Glow plug 2 22 5V 4 8A 0 5A 30 second duration 1 9 GENERAL Table 1 1 Specifications of L2A L2C and L2E 4 4
151. on timing before TDC Varies oep end TERS specification 1 2 Basic engine Table 2 2 Maintenance service data table Basic engine 1 4 Unit mm in Inspection point Nominal Standard Limit Remark ST 12 12 013 to 12 035 Rocker arm inside diameter 0 47 0 4730 to 0 4738 o Moe 12 11 470 to 11 984 Rocker arm Rocker shaft outside diameter 0 47 0 4516 to 0 4718 Clearance between 0 029 to 0 065 0 200 Repl k rocker arm and rocker shaft 0 0011 to 0 0026 0 0079 Place rocker arm Te 9 6 6 6 565 to 6 580 6 500 Valve isin 0 260 0 2585 to 0 2591 0 2559 outside diameter riad 66 6 6 530 to 6 550 6 500 0 260 0 2571 to 0 2579 0 2559 Gie Valve guide Inlet g6 6 6 600 to 6 615 inside diameter Exhaust 0 260 0 2598 to 0 2604 Clearance nlet 0 020 to 0 050 0 100 betweeti valve 0 0008 to 0 0020 0 0039 d Replace valve and valve guide stem and valve TEPEN 0 050 to 0 085 0 150 guide 0 0020 to 0 0034 0 0059 SERVICE DATA Table 2 2 Maintenance service data table Basic engine 2 4 Unit mm in Inspection point Nominal Standard Limit Remark Valve seat angle 44 Seat width Valve sinkase 0 5 0 4 to 0 6 2 0 0197 0 0158 to 0 0236 Valve seat and Ja valve ai 1 0 0 5 VOIS a Val alve margin 0 0394 0 0197 o dee margin 14 13 5 to 14 5 Valve guide mounting length 0 5516 0 531
152. otation speed does not meet the standard disassemble inspect and repair the starter Vv Voltmeter Battery 12V Test at no load Item Standard Starter model name M000T60481 M001T68381 Nominal output V kW Terminal voltage V 12 1 2 12 1 7 11 11 No load characteristics Current A Rotation speed min 12 10 2500 or more 90 or less 110 or less 2400 or more ELECTRICAL SYSTEM 2 2 Disassembling and inspecting starter M000T60481 12V 1 2kW M001T68381 12V 1 7kW Looseness abnormal noise and rotation condition of bearing Pinion gear Replace Stopper ring Overrunning clutch function Broken coil wire Wear and damage of gear Brushes wear Broken wire short circuit and ground of coil roughness and wear of commutator and damage and wear of gear Bearing wear Brushes wear spring rust and deterioration and holder insulation status Disassembling and inspecting starter MOO0T60481 12V 1 2kW M001T68381 12V 1 7kW Disassembling sequence 1 Pinion set Magnet switch Rear bracket Brush holder Brush assembly Armature Yoke N DO oO fF W PLP 10 11 12 13 14 Packing Packing Plate Ball Planetary gear Lever Front bracket 15 16 17 18 19 Snap ring Stopper Overrunning clutch Internal gear Ge
153. pe push botton Wash in a gas oil Every 100 hrs Replace Every 400 hrs Replace Check for clogging water and dust Replace Disassembling inspecting and reassembling fuel filter cock switch type push botton Disassembling sequence 1 Ring nut 2 Cup 3 O rings 4 Element 5 O rings 9 Valve 6 Cock lever 10 Filter body 7 O rings 8 Spring Note a Disassemble the fuel filter only when removing the element Do not disassemble the cock lever unless absolutely necessary b When removing the cock lever and reassembling it after cleaning apply silicon oil to the O ring of the lever 8 24 FUEL SYSTEM 2 12 Disassembling inspecting and reassembling fuel filter cock switch type changeover Do not evulse Wash in a gas oil Every 100 hrs Replace Every 400 hrs Check for clogging water and dust Replace 11 O 10 Replace Disassembling inspecting and reassembling fuel filter cock switch type changeover Disassembling sequence 1 Ring nut 2 Cup 3 Element 4 Element spring float 5 O rings 9 Valve 6 Cock lever 10 Air bleed plug 7 O rings 11 Packing 8 Spring 12 Filter body Note a Disassemble the fuel filter only when removing the element Do not disassemble the cock lever unless absolutely necessary b When removing the cock lever and reassembling it after cleaning apply silicon oil to the
154. r adjustment of No 1 cylinder rotate the crankshaft in the forward direction clockwise toward the timing gear case by the angle corresponding to the number of cylinders 3 Insert a thickness gauge between the rocker arm and bridge cap Turn the adjusting screw while measuring the clearance and adjust the clearance so that the thickness gauge can move with slight stiffness 4 After adjustment tighten the lock nut firmly Then check the clearance again Item Standard Inlet 0 25 mm 0 0098 in Valve clearance Exhaust 9 23 im 0 0098 in Ignition order Rotation angle 1 2 180 1 3 2 240 Mark on gear case side TDC mark on crankshaft pulley side Adjusting valve clearance 13 3 ADJUSTMENT AND OPERATION 1 2 Inspecting fuel injection timing To prevent the outflow of fuel stop the fuel supply before removing the delivery valve The fuel injection timing varies with the output speed and other engine specifications Be sure to check the engine s specification sheet 1 Remove the No 1 fuel injection pipe 2 Remove the No 1 delivery valve holder of the fuel injection pump 3 Pull out the spring and delivery valve Then do not remove the delivery valve seat 4 Install the delivery valve holder 5 Remove the tie rod cover 6 7 6 Disconnect the tie rod from the control rack 7 Set the control rack to the medium pos
155. r case uia Bolt on rear Note Bolts have different lengths Pay attention to the positions of bolts to ensure correct reassembling N Bolt on front Removing gear case 5 9 DISASSEMBLY OF BASIC ENGINE 3 5 Removing PTO gear Pull out the PTO gear together with two ball bearings from the gear case 3 6 Removing oil pump Remove the oil pump housing from the gear case and then remove the oil pump outer gear and oil pump inner gear 3 7 Removing relief valve 1 Remove the plug from the gear case 2 Remove the oil relief spring and relief plunger 3 8 Removing governor shaft and speed control lever Remove the sealing cap from the side of the gear case Pull out the grooved pin A Remove the governor shaft Remove the tension lever and governor lever Remove the governor spring lever 5 10 PTO gear Ball bearing Removing PTO gear Oil pump inner gear Oil pump housing Gear case Oil pump outer gear Removing oil pump Relief plunger Gear case spring Removing relief valve Speed control lever l Governor shaft cover JF Tension lever Grooved pin B a A Governor spring lever Sealing cap at Governor lever Governor shaft Grooved pin aL pl lt Gear case Removing governor shaft and speed control lever DISASSEMBLY OF BASIC ENGINE 3 9 Measuring timing gear backlash Measure the
156. r with camshaft gear ball bearings 9 i y S Camsnaft gear Removing camshaft 2 5 12 DISASSEMBLY OF BASIC ENGINE 3 12 Removing fuel injection pump camshaft When pulling out the fuel injection pump camshaft be careful not to cause damage to the cam portion of the fuel injection pump camshaft and the cam hole of the cylinder block 1 Remove the sliding shaft and the governor weight Governor weight Removing sliding shaft and 2 Remove the camshaft stopper washer governor weight Camshaft stopper washer oO m e Fuel 2B Q camshaft gear 3 Remove the fuel injection pump camshaft together with Removing fuel injection pump the fuel injection pump camshaft gear and ball camshaft 1 bearings Removing fuel injection pump camshaft 2 5 13 DISASSEMBLY OF BASIC ENGINE 3 13 Removing front plate 1 Remove the front plate bolts 2 Remove the front plate from the crankcase Note If it is difficult to remove the front plate lightly tap it with a plastic hammer 5 14 Fixing bolts of front plate 7 Removing front plate DISASSEMBLY OF BASIC ENGINE 4 Disassembling and inspecting cylinder block crankshaft piston and oil pan 7 Flaking scratches foe eae Connecting rod bend seizure ge gap twist big end thrust clearance Piston wear sticking streaks ring groove wear Flaking scratches
157. re troubleshooting 14 4 1 3 2 Problem Knocking eeen 14 4 1 4 Overheating ceeeeeeeeeeesteeeeeneees 14 5 1 4 1 Check items before troubleshooting 14 5 1 4 2 Problem Overheating ee 14 5 1 5 Excessive black smoke 14 6 1 5 1 Check items before troubleshooting 14 6 1 5 2 Problem Excessive black smoke 14 6 1 6 Idling malfunction eee 14 7 1 6 1 Check items before troubleshooting 14 7 1 6 2 Problem Unstable idling 0 ee 14 7 T7 LOW OULDUb nean eo faecatexsaieones 14 8 1 7 1 Check items before troublshooting 14 8 1 7 2 Problem Low output ossee 14 8 14 1 TROUBLESHOOTING 1 Troubleshooting 1 1 Before troubleshooting a For the fuel injection pump the injection quantity of each cylinder can be measured only with a pump tester Do not adjust or disassemble the fuel injection pump even during troubleshooting unless absolutely necessary To inspect the combustion state of each cylinder loosen the fuel injection pipe of any cylinder to stop injection and compare the extent of a drop in the engine speed with that of other cylinders Troubles of the diesel engine often occur in combination of various problem causes and therefore it is often very difficult to determine the defect from a problem phenomenon Especially a similar phenomenon occurs in troubles of the fuel injection pump fuel injection nozzles and compressio
158. refacing the valve seat or after replacing the valve 1 Apply a thin coat of lapping compound evenly to the valve face Note a Do not allow the compound to adhere on the valve stem b Compound spreads more evenly if it is mixed with a small amount of engine oil c Use medium grain compound 120 to 150 mesh for initial lapping then use fine grain compound 200 mesh or finer for finishing 2 Use a valve lapper for lapping Strike the valve against the valve seat while rotating the valve little by little 3 Wash off the compound using diesel fuel 4 Coat the contact surface of the valve with engine oil then lap the valve again 5 Check valve to seat contact aC Spring perpendicularity gap Vo Ca Free length a Squareness and free length of spring Lapping valve and valve seat 6 5 INSPECTION AND REPAIR OF BASIC ENGINE 1 8 Measuring distortion of the bottom surface of the cylinder head Refacing of cylinder head should be kept to an abso lute minimum Excessive grinding of the cylinder head may result in defects such as defective combustion and stamping contact between piston and valve With a straight edge placed on the bottom face of the cylinder head measure the bottom face distortion using a feeler gauge If the measurement exceeds the limit grind the bottom face using a surface grinder Item Standard Limit x 0 05 mm 0 10 mm Bottom surf
159. ring cam height of fuel injection pump camshaft Measure the cam height Replace the camshaft if the height is less than the limit 7 4 Measuring Measuring directions points Item Standard Limit 29 mm 1 1417 in Cam height of fuel injection pump 29 9 to 30 1 mm camshaft longer diameter 1 177 to 1 185 in Measuring cam height of fuel injection pump camshaft 6 9 INSPECTION AND REPAIR OF BASIC ENGINE 3 7 Inspecting tappet Inspect the cam contact surface of the tappets Fit new tappets if the surface is excessively worn or damaged QO Good Bad Bad Inspecting tappets 3 8 Measuring clearance between tappet and tappet guide hole Measuring directions Measuring directions Measure clearance between the tappet and tappet hole Replace the tappet with a new one if the limit is exceeded Item Standard Limit Clearance between camshaft 0 007 to 0 049 mm 0 150 mm journal and cylinder block bore 0 0003 to 0 0019 in 0 0059 in Measuring clearance between tappet and tappet guide hole 6 10 INSPECTION AND REPAIR OF BASIC ENGINE 4 Inspecting and repairing cylinder block crankshaft piston and oil pan 4 1 Measuring cylinder inside diameter Use a cylinder gauge to measure the inside diameter and cylindericity of the cylinder at three locations in the A and B directions as shown in the illustration If any one of the cylinders exceeds the repair limit bore a
160. rol rack side opposite side to the knock pin The protrusion can be seen through the housing hole 2 5 4 Assembling plunger 1 Assemble the spring upper seat and plunger spring 2 Place the stamped side of the collar of the plunger to the opposite side to the protrusion of the control sleeve opposite side to the control rack side Assemble the spring lower seat to the plunger and insert the plunger into the control sleeve 8 16 Delivery valve holder Be Delivery valve lt Spring S SONS me J Delivery valve i gasket Delivery valve Pump housing N Control sleeve E a boe gt Control rack side Knock pin Plunger spring Spring upper S e if ok Sleeve x Control rack side I Pe Protrusion Plunger Control sleeve Assembling direction of plunger FUEL SYSTEM 2 5 5 Installing tappet 1 Install the tappet shim plate 2 Install the tappet so that its groove is positioned to face the tappet guide pin hole 3 Push down the tappet and install the tappet guide pin 2 5 6 Installing control rack 1 Align the control sleeve position so that the protrusion of the control sleeve fits into the fork of the control rack 2 Install the control rack 3 Install the stop wire bracket 4 Tighten the countersunk head screws to the specified torque Note When reusing the countersunk head screws apply adhes
161. rque list Basic engines Threads Torque Description Dia x Pitch Remark mm N m kgf m lbf ft Main M10 x 1 25 73 5 to 83 4 7 5 to 8 5 54 2 to 61 5 Cylinder head bolt Sub M8 x 1 25 19 6 to 29 4 2 0 to 3 0 14 5 to 21 7 Rocker cover nut M6 x 1 0 4 9 to 6 9 0 5 to 0 7 3 6 to 5 1 Rocker stay bolt M8 x 1 25 14 7 to 21 6 1 5 to 2 2 10 8 to 15 9 Main bearing cap bolt M10 x 1 25 49 0 to 53 9 5 0 to 5 5 36 2 to 39 8 Connecting rod cap nut M8 x 1 0 31 4 to 34 3 3 2 to 3 5 23 1 to 25 3 Flywheel bolt M10 x 1 25 83 4 to 93 2 8 5 to 9 5 61 5 to 68 7 Crankshaft pulley nut M16 x 1 5 98 1 to 117 7 10 to 12 72 3 to 86 8 4T 3 6 mm 0 1417 in thick M6 x 1 0 8 8 to 10 8 0 9 to 1 1 6 5 to 8 0 Rocker nut 6T 5 0 mm 0 1969 in thick M6 x 1 0 11 8 to 13 7 1 2 to 1 4 8 7 to 10 1 2 1 2 Fuel system i Table 2 9 Tightening torque list Fuel system Threads Torque Description Dia x Pitch Remark mm N m kgf m lbf ft Hollow screw fuel injection pump M10 x 1 0 9 8 to 14 7 1 0 to 1 5 7 2 to 10 8 Delivery valve holder fuel injection pump 34 3 to 38 2 3 5 to 3 9 25 3 to 28 2 Air bleeding plug fuel injection pump 4 9 to 6 9 0 5 to 0 7 3 6 to 5 1 Lock plate fuel injection pump 3 2 to 4 0 0 3 to 0 4 2 2 to 2 9 Stop wire bracket fuel injection pump 3 2 to 4 0 0 3 to 0 4 2 2 to 2 9 Fuel injection nozzle retaining nut M16 x 0 75 34 3 to 39 2 3 5 to 4 0 25 3 to 28 9 Fuel in
162. rupt stopping of an overheated engine can cause the coolant temperature to rise re sulting in seized engine parts If the engine comes to overheat run the engine at low idling speed cooling operation and stop the engine after the coolant tem perature lowers sufficiently Do not add coolant immediately after stopping the en gine Adding coolant to a hot engine can cause the cyl inder heads to crack due to sudden change in temperature Add coolant little by little after the engine cools down to room temperature Avoid immediate restart after abnormal stop If the engine stops abnormally do not restart the en gine immediately If the engine stops with an alarm check and remedy the cause of the problem before re starting Sustained use of the engine without any rem edy could result in serious engine problems Avoid continuous engine operation with too low oil pressure If an abnormal engine oil pressure drop is indicated stop the engine immediately and inspect the lubrica tion system to locate the cause Continuous engine op eration with low oil pressure may cause bearings and other parts to seize Stop the engine immediately if the fan belt breaks If the fan belt breaks stop the engine immediately Continuous engine operation with the broken fan belt could cause the engine to overheat and thereby the coolant to boil into steam which may gush out from the reserve tank or radiator and cause personal injuries VII INTR
163. seizure Cylinder flaws stepped wear Top face distortion Replace Oil pan gasket Plug dowel pins damage clogging or contamination of oil water holes Flaking scratches seizure Crankshaft gear teeth damage sticking to bearing Journal pin damage local wear cracks bend clogged oil hole Disassembling and inspecting cylinder block crankshaft piston and oil pan Disassembling sequence 1 Oil pan 7 No 1 compression 12 Main bearing cap 2 Oil screen 8 No 2 compression 13 Lower main bearing 3 Connecting rod cap 9 Oilring 14 Crankshaft 4 Lower connecting rod 10 Piston 15 Upper main bearing bearing Remove parts 5 to 10 as a unit 16 Cylinder block 5 Connecting rod 11 Upper connecting rod 6 Piston pin bearing Note When replacing the crankcase carefully remove parts relief valve etc mounted on the non reusable crankcase so that they can be reused 5 15 DISASSEMBLY OF BASIC ENGINE 4 1 Removing oil pan Do not insert a chisel or screwdriver between the oil pan and crankcase to remove the oil pan as it could deform the oil pan flange 1 Turn the engine around 2 Remove bolts from the oil pan 3 To remove oil pan tap bottom corners of the oil pan with a plastic hammer 4 2 Removing oil screen Loosen the nut and remove the oil screen and gasket 4 3 Removing connecting rod cap 1 Lay the en
164. sen the rocker arm adjusting screw by about one turn 2 Loosen the rocker stay bolts and remove the rocker shaft assembly Note When removing the rocker shaft assembly remove it together with the rocker stay bolts and keep them together for reassembling 1 2 Disassembling rocker shaft assembly 1 Pull out the grooved pin with a pair of pliers 2 Remove snap rings from both ends of the rocker shaft Disassemble the rocker shaft assembly into the rocker arms rocker stays rocker shaft springs and rocker shaft Note Be sure to arrange the parts of rocker shaft assembly in the order of disassembling Reassemble the rocker shaft assembly in the reverse order of disassembly by making sure of the original combination of rocker arm and shaft assembly so that the same clearance between the rocker shaft and arms is restored when reassembling Rocker stay bolt Rocker shaft assembly Je S O o j VA FEZ Se Removing rocker shaft assembly Grooved pin Rocker arm Rocker stay 9 Rocker shaft spring Rocker shaft Disassembling rocker shaft assembly 5 3 DISASSEMBLY OF BASIC ENGINE 1 3 Removing cylinder head bolt Loosen cylinder head bolts in the numerical order as shown in the illustration 1 4 Removing cylinder head assembly When removing the cylinder head gasket be careful not to damage the cylinder head or crankcase surface by tools such as a screwdriver 1 Remove the cylinder head b
165. sh spring load 12 14 2 4 3 Inspecting brush holder for insulation 12 14 2 4 4 Measuring commutator radial runout 12 15 2 4 5 Measuring commutator outside diameter12 15 2 4 6 Measuring undercut depth ee 12 15 2 4 7 Checking armature Coil ee 12 16 2 4 8 Inspecting rear bracket eee 12 16 2 4 9 Inspecting overrunning clutch 12 17 2 4 10 Inspecting PINION sessen 12 17 2 4 11 Inspecting front bracket ee 12 17 2 4 12 Inspecting gears of starter 12 17 2 4 13 Inspecting continuity of magnetic switch between M terminal and case 12 17 2 4 14 Inspecting insulation of magnetic switch between M terminal and B terminal 12 17 2 5 Reassembling starter MO00T60481 12V 1 2kW M001T68381 12V 1 7KW ae 12 18 2 5 1 Applying grease 12 18 2 5 2 Installing pinion 12 19 2 5 3 Installing gear shaft ee 12 19 2 5 4 Installing yoke and armature 12 20 2 5 5 Installing brush holder and brush assembly ssec 12 20 2 5 6 Installing rear bracket eee 12 20 2 5 7 Installing magnetic switch 0 12 20 2 5 8 Inspecting pinion clearance 12 21 2 6 Inspection before disassembling starter MO02T66071 24V 3 2kW aossen 12 22 2 6 1 Inspecting pinion clearance 12 22 2 6 3 No load test oeenn 12 24 2 7 Disassembling and inspecting starter MO02T66071 24V 3 2kW neeese 12 25 2 7 1 Preparation before
166. side diameter and valve guide inside diameter 2 6 2 1 3 Replacing valve guide 6 3 1 4 Inspecting valve face n 6 4 1 5 Refacing valve face 6 4 1 6 Measuring perpendicularity and free length Of vale Spring crensian 6 5 1 7 Lapping valve and valve seat 4 6 5 1 8 Measuring distortion of the bottom surface of the cylinder head 6 6 1 9 Measuring push rod runout cee 6 6 2 Inspecting and repairing flywheel 6 7 2 1 Measuring flatness of flywheel 6 7 2 2 Inspecting ring Gear nesses 6 7 2 3 Replacing ring gear 6 7 2 3 1 Removing ring gear 6 7 2 3 2 Installing ring gear eeren 6 7 3 Inspecting and repairing gear case timing gear and camshaltt 6 8 3 1 Measuring timing gear backlash 6 8 3 2 Measuring clearance between idler gear and idler shaft cccceeeeeeeeeeeeeeeeeees 6 8 3 3 Replacing idler shaft eee 6 8 3 4 Measuring clearance between camshaft journal and cylinder block bore 6 9 3 5 Measuring Cam lift 6 9 3 6 Measuring cam height of fuel injection pump camshaft Grrencusn i aneian 6 9 3 7 Inspecting tappet ee eeeeeeeeeees 6 10 3 8 Measuring clearance between tappet and tappet guide hole eee 6 10 4 Inspecting and repairing cylinder block crankshaft piston and oil pan 6 11 4 1 Measuring cylinder inside diameter 6 11 4 2 Reboring cylinder 6 12 4 2 1 Measurin
167. st Note Before checking bend tighten the connecting rod cap to the specified torque 3 To inspect the connecting rod with the piston installed turn the piston upside down and place it on a surface plate Insert a round bar having the same diameter as the crankpin into the big end bore and measure the height of the bar using a dial gauge Item Standard Limit Bend and twist of ieee 0 15 100 mm connecting rod i p ieee 0 0059 3 94 in 0 05 0 0020 100 0 05 0 0020 Connecting rod bend Unit mm in Tightening torque of connecting rod cap 31 4 to 34 3 N m 3 2 to 3 5 kgf m 23 1 to 25 3 Ibf ft 0 05 100 0 0020 Measuring bend of connecting rod 6 15 INSPECTION AND REPAIR OF BASIC ENGINE 4 8 Measuring clearance between connecting rod bearing and crankpin When grinding crank pins be sure to grind all the pins to the same size Finish the fillet radius to the specified dimension 1 Reassemble the bearing into the big end of the connecting rod 2 Tighten the connecting rod cap bolts to the specified torque 3 Measure the inside diameter of the connecting rod bearing s Measure the outside diameter of the crank pin o1 a Calculate the clearance from the difference between the inside diameter of the connecting rod bearing and outside diameter of the crank pin 6 Replace the connecting rod bearing if the clearance excee
168. stance extremely deviates from the standard replace the thermoswitch Temperature Standard 120 C 248 F 30 m Q 2 5 Inspecting water pump 2 5 1 Checking water pump for smooth rotation Check to make sure that the impeller and shaft of water pump rotate smoothly without noise and irregularities If faulty replace the water pump assembly 10 4 Checking impeller and shaft for smooth rotation COOLING SYSTEM 3 Installing cooling system 3 1 Installing cooling fan fan pulley V belt thermostat thermoswitch and water pump Replace Replace ZX 19 6t029 4N m 2 0 to 3 0 kgf m 14 to 22 Ibf m Installing cooling fan fan pulley V belt thermostat thermoswitch and water pump 10 5 INLET AND EXHAUST SYSTEMS 1 Removing inlet and exhaust Systems ceeeeeeeeee 11 2 1 1 Removing inlet cover and exhaust manifold 11 2 2 Disassembling inspecting and reassembling inlet and exhaust systems 2222 c cece 11 3 2 1 Inspecting inlet cover and exhaust manifold cececeeeeeteeee 11 3 2 2 Measuring distortion of inlet and exhaust manifold ceceeeeeeeeeee 11 3 3 Installing inlet and exhaust systems 0eeeeeee 11 4 3 1 Installing inlet cover and exhaust manifold erimesine 11 4 INLET AND EXHAUST SYSTEMS 1 Removing inlet and exhaust systems 1 1 Removing inlet cover and exhaust manifold Repl
169. ston pin ji E ey to 21 mm 1 005 mm PEE 0 83 in 0 8269 to J 0 8270 in Clearance 0 006 to L2A L3A 0 018 mm between L2C L3C J 0 0002 to piston pn 0 0007 in 0 08 mm bore and 0 0031 in piston pin 0 007 to outside L2E L3E 0 015 mm diameter 0 0003 to 0 0006 in 4 6 Measuring connecting rod end play 1 Install the connecting rods onto the respective crankpins and tighten the connecting rod cap bolts to the specified torque 2 Measure the clearance to the crank arm end play at two positions above and below the crankpin 3 If the limit is exceeded replace the connecting rod with anew one Item Standard Limit Pia caus od enanle 0 10 to 0 35 mm 0 50 mm z Pay 0 0039 to 0 0138 in 0 0197 in 6 14 f Measuring points Measuring directions Measuring piston pin bore and piston pin outside diameter Tightening torque 31 4 to 34 3 N m 3 2 to 3 5 kgf m 23 15 to 25 32 Ibf ft Measuring end play of connecting rod INSPECTION AND REPAIR OF BASIC ENGINE 4 7 Inspecting connecting rod bend and twist 1 Measure the dimensions of C and L in the illustration to check bend and twist of the connecting rod Straighten the connecting rod with a press to meet the standard If the standard is exceeded after correction replace the connecting rod with a new one 2 In general a connecting rod aligner is used to check bend and twi
170. swivel nipple FUEL SYSTEM 2 6 Disassembling and inspecting governor cover 5 3 p S 4 2 P i i S Fatigue and crack 6 8 2 xO wy Replace O ring oO 7 Disassembling and inspecting governor cover Disassembling sequence 1 Set bolt 4 Stop lever 7 Lever 2 Set bolt 5 Return spring 8 Governor lever 3 Jam nut 6 Grooved pin 2 7 Reassembling governor cover Reassembling governor cover 8 19 FUEL SYSTEM 2 8 Disassembling and inspecting torque spring set Single spring type OG Q 2 i 7 2 Y No Fatigue and crack 3 4 5 6 Double spring type Fatigue and crack Disassembling and inspecting torque spring set Disassembling sequence 1 Locknut 4 Spring stopper 2 Adjusting screw 5 Torque spring 2 spring type 3 Torque spring 6 Torque spring case 2 9 Reassembling torque spring set Approx 2mm 0 08in Single spring type 7 8 to 11 8N m 0 8 to1 2kgf m 5 8 to 8 7lbf ft Double spring type Approx 2mm 0 08in Reassembling torque spring set 8 20 2 9 1 Torque spring set single spring type Reassemble the torque spring set of the single spring type as described in the following 1 To lightly tighten adjusting screw turn the adjusting screw with a screwdriver until you feel resistance At the position where you feel resistance secure the adjustin
171. t 0 029 to 0 065 mm 0 200 mm 0 0011 to 0 0026 in 0 0079 in 1 2 Measuring valve stem outside diameter and valve guide inside diameter Measure the diameter at the top and bottom ends at right angles to the outer and inner surfaces since valve stems and valve guides are more likely to wear at both ends If the outside diameter is less than the limit or the clearance exceeds the limit replace either the valve or the valve guide with a new one Item Nominal Standard Limit 6 6mm 6 565 to 6 580 mm 6 500 mm Valve Inlet 0 260 in 0 2585 to 0 2591 in 0 2559 in stem outside 6 6mm 6 530 to 6 550 mm 6 500 mm diameter Exhaust 0 260 in 0 2571 to 0 2579 in 0 2559 in Clear Inlet f 0 020 to 0 050 mm 0 100 mm ance 0 0008 to 0 0020 in 0 0039 in between valve SAD hait 0 050 to 0 085mm 0 150 mm and ai 7 0 0020 to 0 0034 in 0 0059 in valve guide Valve Inlet a66 ae guide 0 260 in 6 600 to 6 615 mm inside 6 6mm 0 2598 to 0 2604 in diameter Exhaust 0 260 in 6 2 Measuring ra directions t Measuring Measuring rocker arm inside diameter and rocker shaft outside diameter Measuring directions a Measuring points Inside Measuring micrometer directions Measuring points Measuring valve guide inside diameter INSPECTION AND REPAIR OF BASIC ENGINE 1 3 Replacing v
172. t into the gear case 6 Drive the grooved pin B into the gear case 7 Install the governor spring lever Note Assemble the speed control lever and the governor spring lever with the minimum assembling angle 3 2 2 Connecting tie rod Connect the tie rod to the control rack of fuel injection pump and fix them with the tie rod clip 8 28 Speed control lever J Governor shaft cover cu L Tension lever Grooved pin ay A Governor spring lever Sealing cap __ Governor shaft ee Grooved pi gee roove pin SS Governor lever Gear case Installing speed control lever and governor shaft Protrusion approx 2mm Grooved pin 0 08 in A Saa Section AA Tension Governor lever Sealing cap Gear case Reassembling speed control lever Tie rod Connecting tie rod FUEL SYSTEM 3 2 3 Installing torque spring set Single spring double spring The torque spring set is properly adjusted at the fac tory before shipment Do not work on the torque spring set unless absolutely necessary Adjust and reassemble the torque spring set as described in the following 1 Adjust the speed control lever with the high speed set bolt After setting it at the high idle engine speed secure it by nut 2 Screw in the torque spring set at the rated engine speed Set it to the rated engine power and secure it by special
173. tes an immediately hazardous situation which if not avoided will result in death or serious injury Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates an immediately hazardous situation which if not avoided may result in minor or moderate injury Indicates a potentially hazardous situation which if not avoided can result in property damage Note Emphasizes important matter or indicates information useful for operation or maintenance of the engine INTRODUCTION Terms used in this manual Nominal means the rated design size or magnitude of a part to be measured Standard means the quantitative requirement for dimension of a part clearance between parts and performance This is given in a form of tolerance Therefore the values shown are not in agreement with the design values Limit means that if this value is reached the part must be repaired or replaced with a new part Abbreviations e BTDC Before Top Dead Center e ATDC After Top Dead Center e BBDC Before Bottom Dead Center e ABDC After Bottom Dead Center e TIR Total Indicated Runout e API American Petroleum Institute e ASTM American Society for Testing and Materials e JIS Japanese Industrial Standards e LLC Long Life Coolant e MIL Military Specifications and Standards U S A e MSDS Material Safety Data Sheet e SAE Society of Automotive Engineers U S A Units of measur
174. the crankcase and install the bearing lower without groove to the main bearing cap 2 Install the flange main bearing to the rearmost crankcase mating surface 3 Apply a small amount of engine oil to each bearing 1 2 Installing crankshaft 1 Wash the crankshaft thoroughly with cleaning oil and dry it completely by compressed air Note When washing the crankshaft clean the inside of the oil holes completely and make sure that no foreign substances or dirt is present 2 Hold the crankshaft horizontally and slowly install it to the cylinder block 3 Apply a small quantity of engine oil to the crankshaft journals Tie Installing crankshaft REASSEMBLY OF BASIC ENGINE 1 3 Installing main bearing cap The foremost and rearmost caps should be installed so that they are flush with the cylinder block surface 1 Apply sealant to the mating surface of the foremost and rearmost caps and the cylinder block mating faces before installing the main bearing caps Sealant or lubricant THREEBOND 1212 or 1211 2 Install the main bearing caps so that their front marks arrow and cap numbers are in numerical order from the front of the engine 3 Temporarily tighten bolts 1 4 Inserting side seal 1 Apply a sealant to the outer periphery of new side seals Sealant THREEBOND 1212 or 1211 2 With the round section of the side seals facing outward press them partway into the front and r
175. the crank journal 5 Calculate the clearance between the inside diameter of the main bearing and outside diameter of the crank journal 6 Replace the main bearing if the clearance exceeds the limit 7 Measure the clearance between the main bearing cap and the crank journal again Use the undersize bearing if the limit is exceeded 8 If an undersize bearing is used grind the crank journal to the specified undersize Item Nominal Standard Limit a 943 mm 42 965 to 42 980 mm E STD 1 69 in 1 6915 to 1 6921 in Clearance between main bearing and crankshaft journal 0 030 to 0 075 mm 0 10 mm 0 0012 to 0 0030 in 0 0039 in Undersize grinding dimensions of crankshaft Item Undersize Finish dimension 0 25 mm 42 75 0035 mm 0 0098 in 0 0008 Granik jornal 1 6831 00014 in undersize 0 020 0 50 mm 42 50 0 035 mm 0 0197 in 1 6732 100014 in Tightening torque 49 0 to 53 9 N m 5 0 to 5 5 kgf m 36 2 to 39 8 Ibf ft Measuring Measuring directions points Measuring Measuring directions points Measuring crank journal outside diameter R25 mm 0 082 og in R252 mm 0 08 2coe in Finish dimension of fillet radius 6 17 INSPECTION AND REPAIR OF BASIC ENGINE 4 10 Measuring crankshaft runout Support the crankshaft at the front and rear journals with V blocks and measure the crankshaft runout at the
176. the overrunning clutch through the front bracket 2 Fit the internal gear into the gear shaft 3 Put the gear shaft through the overrunning clutch and install the stopper on it 4 Install the stopper ring firmly to the shaft groove of overrunning clutch 5 Using a gear puller firmly pull the pinion stopper closer to the stopper ring to fix 2 5 3 Installing gear shaft Be sure to use a new stopper ring Do not reuse a removed one 1 Reassemble the lever to the overrunning clutch 2 Fit the internal gear into the gear shaft 3 Put the gear shaft through the overrunning clutch and install the stopper on it 4 Fit the stopper ring into the groove of the stopper ring and firmly pinch it 5 Using a gear puller firmly pull the pinion and fit the stopper into the stopper ring Note The adjustment of play in the axial direction of the gear shaft is not necessary because its required amount is automatically secured 12 20 Stopper Stopper ring Shaft of n overrunning clutch j i spring Installing pinion Stopper Stopper ring Shaft of overrunning clutch Pinion Gear shaft Installing gear shaft ELECTRICAL SYSTEM 2 5 4 Installing yoke and armature 1 Install the planetary gears on the gear shaft 2 Packing 3 Install the packing on the internal gear Install the plate and packing 4 5 Install the yoke on the front bracket wewrwmawT ow Apply greas
177. the piston pin Standard ae es 965 65 00 to 65 03 L2A L3A 2 56 2 5591 to 2 5602 0 7 0 0276 Repair limit 0 20 0 0079 Cylinder Inside L2C L3C 70 70 00 to 70 03 Diameter 2 76 2 7559 to 2 7571 076 76 00 to 76 03 aa en 2 99 2 9921 to 2 9933 Measured Values Cylinder Inside Diameter X 2 Y Supplemnt 2 INSPECTION RECORD SHEET No 2 cme O ee e _ Serial No inspection Measurement of Valve Guide Inside Diameter and Valve Point Stem Outside Diameter Measuring Positions Standard Nominal Standard Limit Value 6 6 6 600 to 6 615 Vave G id 0 260 0 2598 to 0 2604 Inside Diameter 6 6 6 600 to 6 615 0 260 0 2598 to 0 2604 6 6 6 565 to 6 580 6 500 Valve Stem 0 260 0 2585 to 0 2591 0 2559 6 6 Outside Diameter 6 530 to 6 550 6 500 0 260 0 2571 to 0 2579 0 2559 0 020 to 0 050 0 100 Clearance 0 0008 to 0 0020 0 0039 between Valve Stem and Valve 0 050 to 0 085 0 150 Guide 0 0020 to 0 0034 0 0059 Measured Values Part Name Valve Guide Inside Diameter Valve Stem Outside Diameter Clearance B A A B ee 1 2 3 Supplement 3 Now INSPECTION RECORD SHEET Point Valve Margin Measuring Positions Standard NETE Valve Seat Angle Valve margin i eae Valve Sinkage 0 0158 to 0 0236 sinkage 1 0 0 5 Valve Margin 0 0394 0 0197 Measured Values Valve Seat Angle Valve Sinkage Valve Margin Valv
178. to avoid damage to the en gine and wire rope Do not climb onto the engine Do not climb onto the engine nor step on any engine parts located on the lateral sides To work on parts located on the upper section of en gine use a ladder stool etc that is firmly secured Climbing on the engine may not only damage engine parts but also cause parts to fall off and result in per sonal injuries Establish firm scaffold during work When working on the upper part of the engine and other hard to reach places use a stable work platform Standing on a decrepit stool or parts box may result in personal injury Do not place any unnecessary objects on a work platform VI Be careful of handling fuel engine oil and LLC Use only specified fuel engine oil and long life coolant LLC Use only the fuel oil and LLC specified in this manual and handle them carefully Use of any other fuel oil or LLC or improper handling may cause various engine problems and malfunctions Obtain the Material Safety Data Sheets MSDS issued by the fuel oil and LLC suppliers and follow the direc tions in the MSDSs for proper handling Handle LLC long life coolant carefully When handling LLC always wear rubber gloves and protective face mask If LLC or cooling water containing LLC comes into contact with your skin or eyes or if it is swallowed you would suffer from inflammation irrita tion or poisoning Should LLC be accidentally
179. torque fuel consumption rate and governor performance under various load conditions 3 2 2 Continuous load test Operate the engine continuously for 10 hours at 90 load continuous load application of nominal net brake power while the engine speed is maintained at revolutions corresponding to the nominal brake power In this test evaluate the fuel consumption rate and operating condition and confirm that the engine is capable of continuous operation 3 2 3 Low idle test Conduct this test to confirm that the engine can operate stably at the specified low idle speed 3 3 Other inspections Check for gas coolant and oil leaks abnormal odors and hunting Make adjustment as needed 3 4 Engine output adjustment Diesel engine output is affected by atmospheric pressure temperature and humidity Therefore correction calculations must be performed to obtain the value of engine output under the standard atmospheric conditions 3 4 1 Standard atmospheric conditions Base temperature 298 K 25 C 77 F Total pressure 100 kPa 750 mmHg Dry pressure 99 kPa 743 mmHg 13 11 ADJUSTMENT AND OPERATION 3 4 2 Calculation of corrected power Multiply the measured brake power or torque by the calculated diesel engine correction factor to obtain a corrected value If the applicable range of the correction formula is exceeded indicate the corrected values and record the test conditions on the test record Colculation ou
180. tput Correction factor c x Measured brake power Atmospheric conditions during test Temperature 7 283K 10 C 50 F lt 7 313K 40 C 104 F Dry atmospheric pressure Pa 80kPa 600mmHg lt Pa S110kPa 825mmHg i ac fay fa Atmospheric factor Jm Engine factor Range of correction equation use The range of correction factor ec is as follows 0 95 amp c lt 1 1 Calculation of engine factor Jm Calculation of correction factor fa fm 0 036g 1 14 Natural aspiration engine and engine with qc Corrected fuel supply volume mechanically driven air charger q 4 c r A 7 z X Fuel flow rate g s 4 Stroke volume J X Engine speed min Turbocharged engine without air cooler z 120000 4 cycle engine or with air to air cooler r Ratio between pressure at turbocharger or fis ae 1 2 air cooler outlet and atmospheric pressure P 298 r 1 for natural aspiration engine Applicable range of engine factor fm 37 2 Sq S65mg cycle 99 07 T 07 de37 2mg I cycle fm 0 2 constant faz py gt Cog 65mg lcycle lt q fm 1 2 constant Turbocharged engine with air to liquid cooler 13 12 TROUBLESHOOTING 1 Troubleshooting cceeeeees 14 2 1 1 Before troubleshooting eee 14 2 1 2 Starting trouble 14 3 1 2 1 Check items before troubleshooting 14 3 1 2 2 Problem Starting trouble 0 0 14 3 PS AKMOCKING ra e E 14 4 1 3 1 Check items befo
181. uel injection pump 4 9 to 6 9 Ne m 0 5 to 0 7 kgf m 3 6 to 5 1 Ibf ft 9 8 to 14 7 Nem 1 0 to 1 5 kgf m 7 2 to 10 8 Ibf ft 3 2 to 4 0 Nem 0 3 to 0 4 kgf m 2 2 to 2 9 Ibf ft 3 2 to 4 0 Nem 0 3 to 0 4 kgf m 2 2 to 2 9 Ibf ft 34 3 to 38 2 N m 3 5 to 3 9 kgf m 25 3 to 28 2 Ibf ft CD f C t TENN N rR AEN Reassembling fuel injection pump 2 5 1 Installing plunger barrel Align the plunger barrel groove with the knock pin of the pump housing and insert the pluger barrel into the pump housing Note If the knock pin is not aligned with the plunger barrel groove the plunger barrel will not be installed correctly Make sure that O ring is not protruded from the pump housing when the delivery valve holder is snugly tightened Plunger barrel T Pump housing we L Control rack a side Knock pin Viewed from above Inserting plunger barrel 8 15 FUEL SYSTEM 2 5 2 Assembling delivery valve a Do not reuse the O ring b Install a new O ring so that it is not cut with threads of the valve holder Assemble the delivery valve delivery valve gasket and delivery valve spring Then with the O ring installed temporarily tighten the delivery valve holder 2 5 3 Assembling control sleeve 1 Reverse the pump housing and grab the housing with a vise 2 Install the sleeve with the protrusion of the control sleeve the cont
182. ulty battery Low adjusted value of voltage relay Faulty alternator output Over dis Electric power consumption is extremely high charge P p y mg Special load is used Faulty wiring 1 2 2 Handling precaution Improper handling could cause damage or failure to the alternator 1 Connect battery cables correctly B terminal is positive and E terminal is negative 2 Do not use any high voltage tester such as megger 3 Do not disconnect lead wire from B terminal of the alternator while the engine is running 4 Battery voltage is constantly applied to B terminal of the alternator Do not ground at this terminal 5 Do not short circuit or ground at L terminal For a built in IC regulator type 6 When a steam cleaner is used do not allow the steam directly contact the alternator 12 4 ELECTRICAL SYSTEM 1 2 3 1 2 3 4 5 Inspecting regulated voltage Disconnect the battery terminal and connect an ammeter Connect a volt meter to terminal L ground line Make sure that the volt meter indicates 0 when the starter switch is OFF position Make sure that the volt meter indicates much lower voltage than battery voltage when the starter switch is ON position Disconnect the terminal of ammeter and start the engine Measure the adjusting voltage with volt meter Alternator Ammeter Checking regulated voltage Item Standard V A
183. unit 21 Speed control lever 32 Fuel injection pump camshaft 9 Oil pump housing 22 Idler gear Remove parts 28 to 32 as a unit 10 Oil pump outer gear 23 Camshaft gear 33 Torque spring set 11 Oil pump inner gear 24 Ball bearing 34 Front plate 12 Plug DISASSEMBLY OF BASIC ENGINE 3 1 Removing tappet Remove the tappet from the cylinder block using the push rods Note If the camshaft is removed before the tappet the tappet will fall in the oil pan 3 2 Removing gear pump housing 1 Remove the bolts and one stud M8x1 25mm 15mm shown in the illustration from the gear pump housing 2 Screw a jack bolt into the stud threaded hole and remove the gear pump housing Gear pump housing 3 3 Removing crankshaft pulley The bar that stops the the crankshaft from turning may come off Pay due attention to safety 1 Screw two guide bolts into the threaded holes at the rear end of the crankshaft Stick a bar across the guide bolts to prevent the crankshaft from turning 2 Remove the crankshaft pulley 3 Take out the woodruff key of the crankshaft Prevent the crankshaft from rotating 3 4 Removing timing gear case Bolts on front 8 pcs Bolts on rear 4 pcs The front plate is bolted to the crankcase from inside the gear case Do not attempt to remove the front plate together with the gear case by tapping 1 Remove bolts from the timing gear case 2 Remove the timing gea
184. ured fuel contacts you skin it penetrates through the skin and may result in gangrene INTRODUCTION About warning labels Maintenance of warning labels Make sure all warning caution labels are legible Clean or replace the warning caution labels when the description and or illustration are not clear to read For cleaning the warning caution labels use a cloth water and soap Do not use cleaning solvents gasoline or other chemicals to prevent the letters from getting blurred or the adhesion from being weakened Replace damaged or fractured labels with new ones If any engine part on which a warning label is attached is replaced with a new one attach a new identical warning label to the new part ROTATING PARTS Re CAN CAUSE SEVERE Q JS PERSONAL INJURY e KEEP AWAY FROM ROTATING FLYWHEEL e DO NOT OPERATE WITHOUT FLYWHEEL COVER 45498 51100 TURNING CAN k CAUSE SEVERE F PERSONAL INJURY OIL WIST IS W FLAMMABLE AND z EXPLOSIVE BE SURE NO DANGER AROUND MOVING PARTS BEFORE TURNING KEEP TURNING DEVICE OR BAR IN OFF POSI TION WHEN NOT IN USE 45A93 51200 DO NOT OPEN INSPECTION COVER WITHIN 10 MINUTES AFTER ENGINE STOP 45A93 51300 HIGH PLACE MAY CAUSE FALLING e BE CAREFUL WHERE YOU STEP ON SCAFFOLD e DO NOT PUT ANY IMPROPER MATERIALS ON ENGINE AND SCAFFOLD 45A93 51400 amp VOLTAGE MAY CAUSE ELECTRIC SHOCK TURN O
185. ver to the speed control lever with the minimum assembling angle 2 9 Installing relief valve Insert the relief plunger and relief spring into the gear case and tighten the plug to the specified torque 2 10 Installing oil pump Install the oil pump inner gear oil pump outer gear and oil pump housing to the gear case and tighten the bolts to the specified torque 7 12 Speed control lever i Governor shaft cover ES L Tension lever pet Grooved pin B Za Governor spring lever H Sealing cap Governor lever J _ Governor shaft i Grooved pinA SKS p Gear case Installing speed control lever and governor shaft Governor lever Protrusion _ approx 2mm Grooved pin 0 08 in Tension Section AA Sealing cap Gear case Reassembling speed control lever 39 2 to 49 0 N m Relief plunger 4 0 to 5 0 kgf m 28 9 to 36 2 Ibf ft Gear case Relief spring Oil pump inner gear 7 8 to 9 8 Nem 0 8 to 1 0 kgf m 5 8 to 7 2 Ibf ft Gear case Oil pump outer gear Installing oil pump REASSEMBLY OF BASIC ENGINE 2 11 Installing PTO gear Install ball bearings on both sides of PTO gear and install the PTO gear into the gear case 2 12 Installing timing gear case 1 Apply sealant to the gasket to prevent it from displacing and install the gasket on the front plate 2 Apply engine oil to the oil seal lip 3 Install the timing gear
186. ving the shaft in the axial direction If the measured value exceeds 0 5 mm 0 0197 in make an adjustment by adding adjusting washer s 2 9 7 Installing bearing Install the bearings on both ends of the armature 2 9 8 Installing armature yoke brush and brush holder 1 Align the knock pin with the center bracket and reassemble the armature to the yoke 2 Reassemble the brush holder and brushes Adjusting washer Reduction gear Snap ring End play I Maximum of 0 5 mm 0 0197 in Adjusting pinion shaft end play Rear bearin Front bearing Brush holder Armature Installing brush holder 12 37 ELECTRICAL SYSTEM 2 9 9 Installing rear bracket Install the rear bracket to the yoke and tighten the through bolt and the brush holder screws 2 9 10 Installing magnetic switch 1 Install the magnetic switch and tighten the screws 2 Connect the lead to the terminal M and secure it with the fixing nut 2 9 11 Inspecting pinion clearance Do not apply current continuously for longer than 10 seconds 1 Connect the starter to the circuit as shown in the illustration 2 When the switches SW1 and SW2 are turned ON the pinion springs out to the cranking position and the armature rotates 3 Turn the switch SW2 OFF to stop the rotation of the armature 4 Gently push back the pinion in the out position with a finger and measure the distance over which the pi
187. y Mitsubishi are authorized to perform checking and adjustment of these settings Be sure to seal all the external stoppers in the same manner as they were sealed at the factory if adjustments have been made on the governor Whether the seals are intact or not has important bearing on the validity of claims under warranty Be sure to seal all of the specified locations When inspecting and adjusting the governor be prepared to operate the engine stop lever manually in anticipa tion of engine overrewving running at an extremely high speed g g 1 4 1 Preparation 1 Operate the engine to warm up until coolant temperature reaches 60 C or higher 2 Make sure that valve clearance fuel injection timing i iti i Low idle set bolt nozzle opening pressure spray condition and oil Hh ee sealing are normal 1 4 2 Adjusting low idle speed High speed 1 Loosen the lock nut of idling set bolt set bolt 2 By turning the bolt adjust the low idling speed 3 Secure the set bolt with the lock nut Adjusting engine speed 1 4 3 Adjusting high idle speed 1 Loosen the lock nut of high speed set bolt 2 By turning the bolt adjust the high idling speed 3 Secure the set bolt with the lock nut 13 6 ADJUSTMENT AND OPERATION 1 5 Bleeding fuel system Completely wipe off any spilled fuel from air vent plug with a cloth as spilled fuel can cause a fire Bleeding of the fuel system must be started from the place c
188. ype A007TA8271A Three phase current generator Type integral with IC regulator Alternator 2 Manufacturer Mitsubishi Electric Corporation Output 24V 25A Rated voltage generating speed 5000 min at 27 0V 22A when hot Regulator adjusting voltage 28 5 0 5V Glow plug 1 Type Sheathed Rated voltage current 10 5V 9 7A 1 0A 30 second duration Glow plug 2 Type Rated voltage current Sheathed 22 5V 4 8A 0 5A 30 second duration GENERAL Table 1 2 Specifications of L3A L3C and L3E 4 4 Engine model L3A L3C L3E Working voltage 12V ETR 8V or less 100 MQ or more at DC 500V megger Sto Insulation resistance pace a P normal temperature normal relative humidity solenoid 1 Stroke 13 5 0 5 mm 0 53 0 02 in Ambient temperature for use 40 to 120 C 40 to 248 F Working voltage 12V ETS 10V to 15V 100 MQ or more at DC 500V megger Sto Insulation resistance fr cha p normal temperature normal relative humidity solenoid 2 Stroke 10 0 5 mm 0 39 0 02 in Electrical Ambient temperature for use 30 to 120 C 22 to 248 F system Working voltage 24V ETR 16V or less 100 MQ or more at DC 500V megger Sto Insulation resistance S a P normal temperature normal relative humidity solenoid 3 Stroke 13 5 0 5 mm 0 53 0 02 in Ambient temperature for use 40 to 120 C 40 to 248 F
189. ystem Pressure feed full flow filter system Speci fication API service category CF and CF 4 Upper limit 2 0 L 0 53 U S gal Engine oil Capacity Lower limit 1 2 L 0 32 U S gal engine total Upper limit 2 5 L 0 66 U S gal Lower limit 1 7 L 0 45 U S gal Gear type internal and external teeth engagement Type ae Oil pump built into gear case Relief valve Discharge rate Type 3 L 0 79 U S gal min or more at 1000 min Plunger valve type Valve opening pressure 0 29 0 029 MPa 3 0 0 3 kgf cm 42 68 4 3 psi 1000 min Oil filter Cooling system Type Paper element cartridge Forced feed circulation type Coolant capacity ma in unit of engine 1 2 L 0 32 US gal Type Centrifugal volute type Water pump 50 L 13 21 U S gal min Discharge rate f e Cooling at pump rotation of 4500 min system Type Wax pellet Thermostat Valve opening pressure 76 5 1 5 C 169 7 2 7 F Type Suction PP fan Cooling fan NO Ot alate 4 variable pitch blades 260 mm 10 24 in Outside diameter Inlet Air cleaner Type Paper element system GENERAL Table 1 1 Specifications of L2A L2C and L2E 3 4 Engine model L2A L2C L2E Voltage polarity 12V negative ground 24V negative ground Type MO000T6048 1 Manufacturer Pinion engagement type Mitsubishi Electric Corporation Pini

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