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Service Manual Mitsubishi L-Series diesel engines
Version 08/2004

SPECIFICATIONS AND MAINTENANCE

STANDARDS

ENGLISH

SERVICE SPECIFICATIONS AND
STANDARDS

Unit: mm (in.)

Description

Specification and Standard

Repair Limit

Service Limit

Connecting rod bearing

Type

Aluminum metal with back metal

Oil clearance

0.15 [0.0059]

Under size

0.25 [0.0098], 0.50 [0.0197]

Crankshaft

Type

Fully counterbalanced

Deflection

Within 0.03 [0.0012]

0.05 [0.0020]

End play

0.05 to 0.175 [0.0020 to 0.0069]

0.08 [0.0031]

Journal outside diameter

43 [1.6929]

–0.15 [–0.0059]

–0.70 [–0.0276]

Pin outside diameter

40 [1.5748]

–0.15 [–0.0059]

–0.70 [–0.0276]

Undersize finishing

Journal U.S.

0.25 [0.0098]

42.715 to 42.730 [1.6817 to 1.6823]

0.50 [0.0197]

42.465 to 42.480 [1.6718 to 1.6724]

Pin U.S.

0.25 [0.0098]

39.715 to 39.730 [1.5636 to 1.5642]

0.50 [0.0197]

39.465 to 39.480 [1.5537 to 1.5543]

Main bearing

Type

Aluminum metal with back metal

(No.2: Flanged metal)

Oil clearance

0.10 [0.0039]

Undersize

0.25 [0.0098], 0.50 [0.0197]

Camshaft

Driving method

Gear drive

Front journal

Ball bearing

Journal to cylinder block hole clearance

0.15 [0.0059]

Major diameter of cam (IN and EX)

27.37 [1.0776]

–1.0 [–0.0394]

Oil clearance

0.15 [0.0059]

⋅

Piston pin

Type

Semi-floating type

Outside diameter

Piston pin to piston clearance

0.08 [0.0031]

Piston pin to connecting rod clearance

Press-fit load: 1000±500 kg [2204.6±1102.3 lb]

(Within standard

range)

Injection pump camshaft

Driving method

Gear drive

Bearing

Ball bearing (Front and rear)

Major diameter of cam

30 [1.1811]

–0.7 [–0.0276]

Tappet

Outside diameter

19 [0.7480]

Clearance between tappet and crankcase

0.15 [0.0059]

Pushrod

Deflection

Within 0.3 [0.0118]

Summary of Contents for L2

Page 1: ...MITSUBISHI DIESEL ENGINE SERVICE MANUAL L2 L3 MODELS MITSUBISHI HEAVY INDUSTRIES LTD 08 2004 ...

Page 2: ...of the manual Operation and periodic maintenance are described in the Operation Maintenance Manual component parts and ordering of service parts are described in the Parts Catalogue Structure and function of the engine are described in the various training manuals How to use this manual 1 Parts in illustrations are numbered to correspond with references to those numbers in the disassembly sequence...

Page 3: ...ch could result in serious personal injury or death WARNING Indicates a specific potential hazard which could result in personal injury CAUTION Indicates operating procedures practices etc which could result in personal injury or damage causing destruction to the engine Some of the CAUTION signs also indicate a specific potential hazard which could result in serious personal injury or death NOTE I...

Page 4: ...and other specifications Assembly standard Indicates the dimension of a part the dimension to be attained at the time of reassembly or the standard performance The value is rounded to the nearest number needed for inspection and is different from the design value Repair limit A part which has reached this limit must be repaired Service limit A part which has reached this limit must be replaced ...

Page 5: ...camshaft piston and connecting rod crankshaft cylinder block 3 Lubrication system General oil filter and oil pressure switch 4 Fuel system General fuel injection pump injection nozzle 5 Governor system General torque spring 6 Cooling system General fan and fan belt water pump thermostat water temperature gauge unit and thermoswitch 7 Air cleaner Air cleaner 8 Electrical system General starter alte...

Page 6: ... 22 5 4 Adjusting the fan belt tension 23 5 5 Bleeding air from the fuel system 23 5 6 Replacing the fuel filter 24 5 7 Checking and adjusting injection timing 26 5 8 Adjusting the engine speeds 27 5 9 Checking and adjustment of nozzles 28 6 TROUBLESHOOTING 31 6 1 Hints on using the trouble diagnosis chart 31 6 2 Hard starting 32 6 3 Knocking 33 6 4 Overheating 34 6 5 Black smoky exhaust 35 6 6 Un...

Page 7: ...tion of governor system 57 12 7 Disassembly and reassembly of governor levers 57 12 8 Installation of gear case assembly 58 13 TIMING GEARS 59 13 1 Disassembly 59 13 2 Removal 60 13 3 Inspection 60 13 4 Installation of timing gears 61 14 CAMSHAFTS VALVE AND INJECTION PUMP 62 14 1 Disassembly 62 14 2 Removal of Valve Camshaft 63 14 3 Inspection 64 14 4 Installation 65 15 PISTON AND CONNECTION ROD 6...

Page 8: ...mbly 90 21 5 Inspection 91 21 6 Reassembly of plunger 91 21 7 Reassembly of delivery valve 91 22 INJECTION NOZZLE 92 22 1 Disassembly 92 22 2 Removal 92 22 3 Disassembly 93 22 4 Inspection 94 22 5 Assembly 94 22 6 Adjustment 94 22 7 Installation 95 GOVERNOR SYSTEM 23 GENERAL 98 23 1 Specification 98 23 2 Disassembly 99 24 TORQUE SPRING 100 24 1 Installation of torque spring set 100 24 2 Assembling...

Page 9: ...ing diagrams 120 32 STARTER 122 32 1 Structure 122 32 2 Inspection assembly 123 32 3 Disassembly 125 32 4 Inspection 126 32 5 Assembly and adjustment 128 33 ALTERNATOR AND DYNAMO 129 33 1 Structure 129 33 2 Dynamo 130 33 3 Inspection of the alternator installed on the engine 130 33 4 Output inspection 131 33 5 Removal 131 33 6 Disassembly of alternator 131 33 7 Inspection 132 33 8 Installation 135...

Page 10: ...S AND MAINTENANCE STANDARDS 145 38 1 Engine Main Parts 145 38 2 Lubrication System 148 38 3 Fuel System 148 38 4 Governor System 149 38 5 Cooling System 149 38 6 Electrical System 150 39 TIGHTENING TORQUE CHART AND SEALANT CHART 152 39 1 Tightening Torque for Main Bolts 152 39 2 Tightening Torque for Common Bolts and Nuts 152 39 3 Tightening Torque for Common Plugs 153 39 4 Sealant Chart 153 40 SP...

Page 11: ...10 155 Service Manual Mitsubishi L Series diesel engines Version 08 2004 ENGLISH ...

Page 12: ...11 155 Service Manual Mitsubishi L Series diesel engines Version 08 2004 ENGLISH GENERAL ...

Page 13: ... C Cylinder bore A ø65 C ø70 E ø76 11 Application 11 Agricultural 31 Industrial 61 For export only A Subdivision of specification t 1 2 Engine model embossment and engine number stamp 1 2 1 Embossment of engine model and cylinder volume The engine model and cylinder volume are embossed on the side of injection pump mounting portion of the cylinder block Model Application Use L2A 11 12 For Agricult...

Page 14: ...ISH GENERAL 1 2 2 Engine number stamp The engine number is stamped on the injection pump mounting portion of the cylinder block on the upper side of the tie rod cover It is a serial number beginning with 1001 shown as below Figure 2 Engine number Number Engine model 1001 ALL models Table 2 Engine number stamp ...

Page 15: ...ent screw Fuel injection pump Side oil filler Oil pressure switch RIGHT SIDE VIEW FRONT Dipstick Coolant drain plug Oil drain plug Fuel injector Air inlet cover Stop solenoid Fuel filter Oil filter REAR LEFT SIDE VIEW REAR FRONT Oil pan Crankshaft pulley Thermostat housing Thermoswitch Alternator Fan V belt Top oil filler Exhaust manifold Flywheel housing Flywheel Starter ...

Page 16: ...el injection pump Side oil filler Oil pressure switch FRONT Dipstick Oil drain plug Fuel injector Air inlet cover Stop solenoid Fuel filter Coolant drain plug REAR Oil filter RIGHT SIDE VIEW LEFT SIDE VIEW REAR FRONT Oil pan Crankshaft pulley V belt Alternator Fan Thermoswitch Thermostat housing Top oil filler Exhaust manifold Flywheel housing Flywheel Starter ...

Page 17: ...smaller in contour volume than the same class of competitor s engines 3 2 2 Low noise and economical fuel consumption Low noise and economical fuel consumption are attained by the well designed cylinder block construction having curved side faces the rearranged combustion chambers and the compacted fuel injection system 3 2 3 Easy starting The engine can be started instantly only by keeping the st...

Page 18: ...s Version 08 2004 FEATURES ENGLISH GENERAL 3 2 4 Multipurpose engine The L series engine can be equipped with various kinds of optional devices Ex Key OFF stop system Fuel cutoff valve Torque spring Manual stop lever Figure 4 Nozzle holders and return pipe ...

Page 19: ...rication Oil pump Gear type Oil filter Paper element type Oil capacity FULL level EMPTY level l Exclusive of oil filter capacity 0 5 l 2 4 1 4 3 0 1 5 or 3 6 1 8 or 4 8 3 0 FUEL SYSTEM Fuel injection pump Bosch type NC Nozzle Throttle type Fuel injection pressure 140 kgf cm2 1 991 psi 13 729 kPa Fuel to be used Diesel fuel see chapter 7 Governor Centrifugal weight type INTAKE SYSTEM Air cleaner Pa...

Page 20: ...hour of a new engine and thereafter every 100 hours of operation or once a year whatever comes first Except generator application 250 hours or once a year whatever comes first can be applied for industrial and marine application 5 1 3 Engine oil to be used Engine oil must conform to the API classification and viscosity number specified in the table below Figure 5 Checking oil level Figure 6 Oil le...

Page 21: ...re 1 Remove the oil filter with a filter wrench or the like API classification Atm temperature Viscosity Class CF or CF 4 Above 20 C 68 F SAE30 5 to 20 C 41 to 68 F SAE20 Below 5 C 41 F SAE10W 30 All seasons SAE10W 30 Table 4 API classification Figure 7 Oil filter Tightening torque N m kgf m lbf ft Description Standard Oil pan drain plug tightening torque 49 0 to 58 8 5 0 to 6 0 36 17 to 43 40 Tab...

Page 22: ... when the cylinder head bolts are retightened Unit N m kgf m lbf ft Tightening torque 10 8 to 12 7 1 1 to 1 3 7 96 to 9 40 Table 7 Tightening torque CAUTION Be careful not to twist the O ring Figure 8 Cylinder head bolt tightening sequence L2 M10 bolt 73 5 to 83 4 N m 7 5 to 8 5 kgf m 54 25 to 61 48 lbf ft M8 bolt 19 6 to 29 4 N m 2 0 to 3 0 kgf m 14 47 to 21 70 lbf ft Tightening torque Unit N m k...

Page 23: ... center for the No 2 cylinder and that for the No 3 cylinder perform as follows a L2 Two cylinder engine Turn the crankshaft 180 clockwise from TDC Top Dead Center of the No 1 cylinder to set the No 2 cylinder TDC b L3 Three cylinder engine Turn the crankshaft 240 clockwise from TDC of the No 2 cylinder to set the No 3 cylinder TDC Further turn the crankshaft 240 clockwise from No 3 cylinder TDC a...

Page 24: ...down and enters the fuel filter wait for fuel to overflow from the air vent screw Then tighten the air vent screw 3 For engine with the electromagnetic fuel pump turn the starting switch key to the ON position to feed fuel to the fuel filter Loosen the air vent screw on the filter and after bleeding air tighten the air vent screw 4 Loosen the air vent screw on the fuel injection pump to let air bl...

Page 25: ...ter Clean or replace the element 5 6 3 Fuel pump The following three types of fuel pumps are available Which type of pump is to be used for an engine depends upon engine specification 1 Plunger type electromagnetic pump The plunger type pumps are classified as the com mon large sized pump having a filter element or as the compact lightweight low priced pump with out filter element Regardless of cl...

Page 26: ...or normal function and make sure that it does not leak fuel or make unusual noise 5 6 4 Draining water from the water sedimentator For engine provided with a water sedimentator remove the filter ring nut involved and take out the cup Wipe off water and dust accumulated in the cup Figure 18 Diaphragm type fuel pump Figure 19 Mechanical type fuel pump Camshaft fuel injection pump Adapter Fuel pump P...

Page 27: ...on clockwise and find an instant that fuel stops flowing from the delivery valve holder This instant is the real injection timing 7 If they do not coincide with each other adjust thickness of the injection pump mounting shim Increasing or decreasing shim thickness by 0 1 mm 0 0039 in causes the real injection timing to vary about 1 Figure 20 Removing delivery valve CAUTION Be sure to shut off the ...

Page 28: ...l injection timing which will come approx 1 later than standard injection timing 5 8 Adjusting the engine speeds To adjust engine speed remove the cooling fan and install the safety cover over the fan to reduce the risk of injury 1 The upper limit of engine speed can be adjusted with the HIGH SPEED stopper bolt This stopper bolt has been set properly and sealed in the factory before shipping of th...

Page 29: ...f gage pressure exceeds the specified range disassemble the nozzle and adjust by using the adjusting shim Increasing or decreasing shim thickness by 0 1 mm 0 0039 in will cause injection pressure to vary about 0 98 MPa 10 kgf cm2 142 psi 4 When reassembling the nozzle use the following values of tightening torque Figure 25 Testing injection start pressure Injection start pressure 13 7 MPa 140 kgf ...

Page 30: ... normal 5 9 3 Injection Test 1 Operate the tester handle at a speed of 4 to 6 strokes per second 2 A nozzle should inject fuel spray uniformly in the shape of a cone 5 9 4 Checking the compression pressure Make sure of the following 1 The engine oil level air cleaner starting motor and battery are well conditioned 2 Warm up the engine to the coolant temperature of 50 C 122 F or more Measure the co...

Page 31: ...engine with the starting motor until a stable reading of the compression gage is obtained 5 After reading the gage remove the compression gage and adapter Put back the glow plug 6 Check all cylinders using the same procedure described above Special tool name Part No Compression gage adapter ST332270 Table 16 Tools ...

Page 32: ...hen proceeding stepwise to less possible or more complicated items 4 Before troubleshooting you should have a right understanding of the following features about the structure and fuel combustion in the diesel engines a Normal engine operation is accompanied by combustion noise diesel knocking sound b A heavy loaded engine exhausts some black smoke c When operated an engine may cause vibration bec...

Page 33: ...Yes Yes Z Inspect glow plug Is electric wiring normal Does fuel feed pump if provided operate when key switch is turned ON No Z Inspect fuel pump and or wiring V Yes Does fuel flow in fuel line No Z Does fuel flow out when fuel injection pump air vent screw is loosened No Z Inspect fuel filter fuel pipe and fuel tank V Yes Is engine in good order Injection timing and valve timing No Z Adjust engin...

Page 34: ...gging of the air cleaner 2 Use of poor quality fuel Low cetane number fuel such as used for burner 6 3 2 Diagnosis Is injection timing correct No Z Adjust injection timing V Yes Do injection nozzles operate properly Check for lowering of injection start pressure and improper shape of fuel spray No Z Inspect injection nozzles V Yes Is cylinder compression proper No Z Inspect valves pistons piston r...

Page 35: ...ng No Z Find the cause over overload V Yes Is cooling system in good order Check cylinder head gasket for leaking water pump water hose and radiator fins for clogging and thermostat for malfunctioning No Z Repair cooling system V Yes Is injection timing correct No Z Adjust injection timing CAUTION Overheating is mostly caused by mis matching load to the engine If overheating arises only when the e...

Page 36: ...e set of injection pump correct No Z Adjust smoke set V Yes Is engine adjusted properly Check for excessive valve clearance and improper injection timing No Z Adjust engine V Yes Do injection nozzles operate properly Check for improper shape of fuel spray and for excessively high injection starting pressure No Z Inspect injection nozzles V Yes Is cylinder compression proper No Z Inspect valves cyl...

Page 37: ...or quality fuel 6 6 2 Diagnosis Is engine adjusted properly Check for idling speed valve clearance and injection timing No Z Adjust engine V Yes Do injection nozzles operate properly Check for shape of fuel spray and injection starting pressure No Z Inspect injection nozzles V Yes Is cylinder compression pressure proper Check equality between cylinders No Z Inspect valves pistons and piston rings ...

Page 38: ...without fuel feed pump Is gravitational flow of fuel normal Engine with electromagnetic fuel feed pump Does fuel pump feed fuel with key switch placed in ON No Z Inspect fuel filter fuel pipe and fuel tank V V Yes Yes Z Inspect fuel pump Is engine adjusted properly Check for valve clearance and injection timing No Z Adjust engine V Yes Do injection nozzles operate properly Check for condition of f...

Page 39: ...38 155 Service Manual Mitsubishi L Series diesel engines Version 08 2004 ENGLISH TROUBLESHOOTING GENERAL ...

Page 40: ...39 155 Service Manual Mitsubishi L Series diesel engines Version 08 2004 ENGLISH ENGINE MAIN PARTS ...

Page 41: ...NGS Type Uniformly pitched single Identification mark White paint atop common to inlet and exhaust valves CYLINDER HEAD GASKET Material Carbon sheet Graphoil CYLINDER HEAD BOLTS Material Special steel Size x number bolts M10 x 6 M10 x 8 M8 x 2 M8 x 3 CAMSHAFT Material valve cam Carbon steel Material pump cam Arrangement drive Side gear driven CYLINDER BLOCK Cylinder bore mm in L2A L2C L2E L3A L3C ...

Page 42: ... of teeth 26 Idle gear Number of teeth 40 Injection pump camshaft gear Number of teeth 52 Valve camshaft gear Number of teeth 52 Tool name Part No Shape Use Piston pin setting tool For L2A L3A 30L91 00030 For L2C L3C 30L91 00020 For L2E L3E 30L91 10010 Removal and installation of piston pin Compression gage adapter ST332270 Measurement of cylinder compression Piston ring pliers 31391 12900 Removin...

Page 43: ...NGINE MAIN PARTS ENGINE MAIN PARTS 8 ROCKER ARMS AND ROCKER SHAFT 8 1 Disassembly Disassembly sequence 1 Oil filter cap 2 Breather hose 3 Rocker cover 4 Rocker cover gasket 5 Rocker shaft 6 Rocker spring 7 Adjust screw 8 Rocker arm 2 2 3 4 5 6 3 7 8 9 4 5 6 8 7 L2 L3 9 1 Figure 30 Rocker system components parts ...

Page 44: ...ling rocker shaft and rocker cover Front identification mark on the valve side ø3 0 12 in hole 1 mm 0 04 in deep Rocker cover nut tightening torque 4 9 to 6 9 N m 0 5 to 0 7 kgf m 3 62 to 5 06 lbf ft Stay tightening torque 14 7 to 21 6N m 1 5 to 2 2 kgf m 10 85 to 15 91 lbf ft CAUTION a Be careful not to confuse proper direction of installation of the rocker shaft b After installing the rocker sha...

Page 45: ...R HEAD 9 1 Disassembly Disassembly sequence 1 Cylinder head 2 Valve guide 3 Cylinder head bolt main bolt 4 Cylinder head bolt sub bolt 5 Seat ring 3600 min 1 specification engine 6 Water outlet fitting 7 Cylinder head gasket 8 Mouth piece 9 Thermostat 10 Thermostat fitting Cylinder head cross section Figure 33 Cylinder head component parts ...

Page 46: ...le holder assemblies and glow plugs from the cylinder head 11 Remove the inlet manifold and exhaust manifold from the cylinder head 12 Remove the valve stem seals Figure 34 Sequence for loosening cylinder head bolts L2 Figure 35 Sequence for loosening cylinder head bolts L3 CAUTION a When disconnecting each injection pipe from the delivery valve holder of the injection pump hold the holder with a ...

Page 47: ...n press fitting Press fit the guide from the upper side of the cylinder head to a height of 14 0 5 mm 0 5512 0 0197 in from the valve spring seat face Check cylinder head surface for a warpage between bolt holes within 0 05 mm 0 0020 in Check guide for wear and damage Check for cracks damage water leak and remove oil sludge sealant deposit carbon deposit Check for valve contact wear damage and sin...

Page 48: ...kage Figure 40 Refacing valve seat Both inlet and exhaust valves Seat contact and wear Valve sinkage Width of valve contact 1 3 to 1 8 mm 0 0512 to 0 0709 in Sinkage of valve Standard Service limit 0 5 mm 0 0197 in 1 5 mm 0 0591 in Table 19 Sinkage of valve CAUTION a When checking valve sinkage the valve guide must be in the normal condition b Resurface the valve seat so that it contacts the mid p...

Page 49: ...r engine model 2 Tighten the cylinder head bolts in the numerical order shown in the figure at right Tighten each bolt a little two or three times in total until all are tightened to the specified torque 3 When connecting the injection pipe assembly loosen the pipe clamp first When tightening the nut at each end of pipe hold the nozzle holder or delivery valve holder with a wrench to prevent from ...

Page 50: ...E SPRINGS ENGLISH ENGINE MAIN PARTS ENGINE MAIN PARTS 10 VALVES AND VALVE SPRINGS 10 1 Disassembly Disassembly sequence 1 Valve stem cap 2 Valve lock 3 Valve spring retainer 4 Valve stem seal 5 Valve spring 6 Valve Not installed to agricultural model Figure 43 Valve system component parts ...

Page 51: ...ce them Figure 44 Removing valve and valve spring Figure 45 Inspection of valve and valve spring Figure 46 Valve spring tester Wear and damage Not installed to agricultural model Fatigue and damage Margin Dents and wear Ridge and damage Valve fatigue and damage Inspection item Standard Service limit Free length 61SG 63SG Others mm in 40 5 1 5945 40 0 1 5748 1 0 0394 Set force Set length 61SG 63SG ...

Page 52: ...y wear flatten with an oil stone 10 4 Installation 1 Reassemble the valves and valve springs referring to the illustrations shown below 2 Mount the cylinder head assembly 3 Adjust the valve clearances Figure 47 Inspecting valve Margin Press the retainer and push the spring to install retainer lock Press this surface Driving in stem seal ø14 8 mm 0 5827 in Installing spring Installing spring retain...

Page 53: ...ly sequence 1 Inlet pipe 2 Inlet manifold 3 Exhaust manifold 4 Inlet manifold gasket 5 Exhaust manifold gasket 11 2 Inspection Check the following matters If any defect is found repair or replace the manifold Tightening torque 7 85 to 9 80 N m 0 8 to 1 0 kgf m 5 79 to 7 23 lbf ft Tightening torque 14 7 to 21 6 N m 1 5 to 2 2 kgf m 10 85 to 15 91 lbf ft 1 2 2 4 4 5 5 3 3 L2 L2 L3 L3 Figure 49 Manif...

Page 54: ...S 1 Check the mounting surfaces to the cylinder head for flatness The surfaces must be flat within 0 15 mm 0 0059 in 2 Check the manifolds for corrosion damage and cracks CAUTION a Check the interior of the inlet manifold for dust and dirt b If any dust is found check the joints of the air cleaner and inlet pipe for sealed condition ...

Page 55: ...TS 12 GEAR CASE AND OIL PUMP 12 1 Disassembly Common to L2 and L3 Disassembly sequence 1 Bushings 2 Plug 3 Gear case 4 Front oil seal 5 Relief plunger 6 Relief spring 7 Oil pump inner gear 8 Oil pump outer gear 9 Oil pump housing 10 Gear case gasket 11 High pressure pump gear housing 12 Housing gasket Figure 50 Gear case component parts ...

Page 56: ...emove the water pump assembly 7 Remove the alternator 8 Remove the pump housing 9 Remove the gear case assembly 12 3 Inspection Check the removed parts If any parts are found defective repair and replace them Wear damage and clearance Cracks and damage Wear and damage Seal surface interference Thoroughly clean oil line Spring fatigue Smooth movement Figure 51 Inspection of gear case and oil pump D...

Page 57: ... bushings out 2 Press fit the new bushings into the positions shown at right Relief valve Opening pressure MPa kgf cm2 psi 0 29 3 0 43 Closing pressure MPa kgf cm2 psi 0 49 5 71 or below CAUTION Apply thin coat of engine oil to the periphery and lip of the oil seal Description Speed min 1 1000 4000 Table 21 Oil pump performance oil used SAE30 100 5 C 212 9 F Figure 52 Press fitting governor shaft ...

Page 58: ...1 Remove the expansion plug paying attention not to scratch the gear case 2 Pull out the grooved pin 12 7 2 Reassembling Shaft 1 Reassemble the shaft in the reverse sequence of disassembly 2 After reassembling the shaft press fit the expansion plug into the shaft hole in the gear case Figure 53 Check governor system Check sliding sleeve joint for wear and damage Check springs for fatigue Checkshaf...

Page 59: ...se assembly Figure 55 Gear case assembly Figure 56 Installing gear case assembly Tightening torque 7 85 to 9 80 N m 0 8 to 1 0 kgf m 5 79 to 7 23 lbf ft Tightening torque 39 2 to 49 0 N m 4 0 to 5 0 kgf m 28 93 to 36 17 lbf ft Taper plug tightening torque 14 7 to 21 6 N m 1 5 to 2 2 kgf m 10 85 to 15 91 lbf ft Sealant HERMESEAL H1 or THREE BOND 1344 ...

Page 60: ... engines Version 08 2004 TIMING GEARS ENGLISH ENGINE MAIN PARTS ENGINE MAIN PARTS 13 TIMING GEARS 13 1 Disassembly Disassembly sequence 1 Crankshaft gear 2 Idle gear 3 Camshaft gear 4 Injection pump camshaft gear Figure 57 Timing gear component parts ...

Page 61: ... any gear is found defective replace it Figure 58 Removing idle gear Figure 59 Removing camshaft gear Figure 60 Inspecting timing gears Injection pump camshaft gear Idle gear Crankshaft gear Valve camshaft gear Check tooth faces and end surfaces for wear and damage Description Standard Value Service Limit Clearance between bushing and shaft 0 03 to 0 07 0 0012 to 0 0028 0 2 0 0079 Table 22 Idle ge...

Page 62: ...e gears to the camshaft valve camshaft and injection pump camshaft 3 Install the gears in the following sequence a Turn the crankshaft to set the No 1 cylinder to top dead center on compression stroke b Install the valve camshaft and injection pump camshaft c Install the idle gear aligning with the timing marks of other gears d Confirm the positions of timing gears again Figure 61 Timing gears in ...

Page 63: ...FTS VALVE AND INJECTION PUMP 14 1 Disassembly Disassembly sequence 1 Camshaft Valve 2 Camshaft gear 3 Ball bearing Front 4 Woodruff key 5 Sunk key 6 Camshaft stopper washer 7 Bolt 8 Tappet 9 Pushrod 10 Camshaft Injection pump 11 Camshaft gear 12 Ball bearing Rear 13 Snap ring 1 1 2 3 4 5 6 6 7 7 8 9 10 10 11 12 13 L2 L3 L2 L3 Figure 62 Camshaft component parts ...

Page 64: ...rocedure 1 Dismount the cylinder head assembly 2 Pull out the pushrods 3 Pull out the tappets 4 Remove the gear case assembly 5 Remove the camshaft stopper bolt 6 Draw out the camshaft assembly 14 2 2 Removal of the injection pump camshaft 1 Disconnect the injection pipes 2 Remove the injection pump assembly 3 Remove the gear case assembly 4 Remove the shaft rear cover 5 Remove the stopper bolt 6 ...

Page 65: ...them Cam lobe wear and damage Bend Cam contact surface wear and damage Cam lobe wear and damage Journal bearing wear and damage Each ball bearing wear and noise Oldham s coupling wear Rod end wear and damage Figure 64 Inspection of camshafts Standard value Service limit Major diameter of injection pump cam 30 1 1811 0 7 0 0276 Major diameter of valve cam 27 37 1 0776 1 0 0 0394 Table 24 Inspection...

Page 66: ...hen installing the camshafts pay attention to the following 1 Apply oil to the bearings and cam lobes 2 Reassembly sequence of the camshaft is the reverse of disassembly 3 Align the timing marks on the gears to the marks on the idler gear 4 After installation check and adjust fuel injection timing and valve clearances Figure 65 Installing valve camshaft ...

Page 67: ...NE MAIN PARTS 15 PISTON AND CONNECTION ROD 15 1 Disassembly Disassembly sequence 1 Piston ring No 1 2 Piston ring No 2 3 Oil ring 4 Piston 5 Piston pin 6 Connecting rod 7 Connecting rod bearing 8 Connecting rod cap 9 Connecting rod bolt 10 Connecting rod nut 1 2 3 4 5 6 7 8 9 10 Figure 66 Piston and connecting rod component parts ...

Page 68: ...rod to scratch the crankshaft pin and cylinder Place the removed parts connecting rod rod cap piston etc classifying by each cylinder 6 Remove the rings from each piston by the piston ring pliers 7 Using the piston pin setting tool push out the piston pin from each piston Figure 67 Removing connecting rod and piston Figure 68 Removing piston pin Pressing Pushrod Connecting rod Piston pin Identific...

Page 69: ...ing Damage wear and ring gap Journal bearing wear and damage Bend and twist Big end play Standard 0 1 to 0 35 mm 0 0039 to 0 0138 in Damage Contact and seizure Flaking and fusion Oil clearance Standard 0 028 to 0 071 mm 0 0011 to 0 0028 in Damage and wear Wear seizure and streaks Clearance between piston and cylinder Standard 0 07 to 0 115 mm 0 0028 to 0 0045 in Wear of piston ring grooves Damage ...

Page 70: ...pin setting tool press the piston pin into the set position CAUTION a When only the replacement of rings are to be made without reboring honing of the cylinder measure the ring at less worn portion of the cylinder bore b When replacing rings make sure to install the new rings having the same size as the piston c Piston rings available for servicing are sized by three classes STD 0 25 OS and 0 50 O...

Page 71: ...iption Standard Pin press fitting force at a normal temperature 1000 500 kg 2205 1102 lb Table 30 Pin press fitting force Guide LA 92 l for L2A L3A Guide LC 89 5 l for L2C L2E L3C L3E Tool body Identification mark Connecting rod Push rod Pressing Piston pin Base plug Guide Piston FRONT mark arrow Figure 73 Reassembling piston pin ...

Page 72: ...by knocking the head of piston excessively Note that the front marks on the piston and connecting rod are in direction of the engine front FRONT mark Rod front mark Align lugs accurately each other Tightening torque 31 4 to 34 3 N m 3 2 to 3 5 kgf m 23 15 to 25 32 lbf ft Ring set positions No 1 ring No 2 ring oil ring T mark and OS size mark T mark and OS size mark OS size identification paint Col...

Page 73: ...engine oil to the bearing surface of the connecting rod caps Fit each cap to the connecting rod using match marks placed before removal as a guide In the case of a new rod which does not have such a match mark position the lugs provided for preventing the bearing from rotating on the same side Figure 76 Fitting cap to connecting rod ...

Page 74: ...E MAIN PARTS 16 CRANKSHAFT 16 1 Disassembly Disassembly sequence 1 Key 2 Crankshaft 3 Crankshaft gear 4 Crankshaft pulley 5 Nut 6 Washer 7 Spring washer 8 Flywheel 9 Ring gear 10 Rear oil seal 11 Rear oil seal case 12 Gasket 13 Flywheel bolt 1 1 1 1 13 5 7 6 12 10 11 9 8 2 2 5 4 Figure 77 Crankshaft component parts ...

Page 75: ...move the main bearing caps Keep each set of removed bearings together with its bearing cap 6 Remove the crankshaft 16 3 Inspection Inspect the removed parts If any parts are found defective repair or replace them Figure 78 Removing main bearing cap Damage to tooth face Wear and damage Damage to tooth face Journals and pins damage and uneven wear Cracks clogging of oil hole and bend Wear of journal...

Page 76: ...wear and out of round wear inside diameter of each main bearing and rod bearing should be measured after its bearing cap is fastened to the specified torque at two places along the bearing in two directions A and B each place as shown in the figure at right If necessary replace the worn bearing with new one If oil clearance still exceeds the service limit regrind the crankshaft to the next under s...

Page 77: ... assemblies in the cylinder block pay attention to the following 1 Pry the oil seal out with a screwdriver 2 Drive in a new oil seal to the oil seal case Description Standard Main bearing cap bolt 49 0 to 53 9 5 0 to 5 5 36 17 to 39 78 Rod bearing cap nut 31 4 to 34 3 3 2 to 3 5 23 15 to 25 32 Table 33 Tightening torque N m kgf m lbf ft Description Standard Main bearing 0 10 0 0039 Rod bearing 0 1...

Page 78: ...tes given in the figure below Place cap flush with the end face of cylinder block Round end down Side seals coated with sealant THREE BOND 1212 Thrust bearing only for No 2 cap Cap tightening torque 49 0 to 53 9 N m 5 0 to 5 5 kgf m 36 17 to 39 78 lbf ft Crankshaft end play 0 05 to 0 175 mm 0 0020 to 0 0069 in Direction of cap installation Front Figure 82 Installation of crankshaft ...

Page 79: ...TS 17 CYLINDER BLOCK 17 1 Disassembly Disassembly sequence 1 Cylinder block 2 Front plate 3 Bearing cap 4 Cover 5 Main bearing 6 Starter bracket 7 Rear oil seal 8 Oil seal case 9 Idler gear shaft 10 Oil filter shaft 11 Oil level gage guide 1 1 7 6 10 11 9 8 2 3 5 4 5 5 5 3 3 3 3 3 3 5 5 5 Figure 83 Cylinder block component parts ...

Page 80: ...gure 84 Measuring cylinder bore Model Standard Service limit L2A L3A 65 2 5591 0 7 0 0276 L2C L3C 70 2 7559 0 7 0 0276 L2E L3E 76 2 9921 0 7 0 0276 Table 35 Cylinder bore mm in Figure 85 Cylinder bore measuring positions Approx 10 mm 0 40 in from upper end Front Direction of measuring Measuring position Center Lower Figure 86 Measuring piston diameter Description Standard Clearance between piston ...

Page 81: ...80 155 Service Manual Mitsubishi L Series diesel engines Version 08 2004 ENGLISH CYLINDER BLOCK ENGINE MAIN PARTS ...

Page 82: ...81 155 Service Manual Mitsubishi L Series diesel engines Version 08 2004 ENGLISH LUBRICATION SYSTEM ...

Page 83: ... 5 l for oil filter l U S gal L2 2 4 1 4 0 6341 0 3699 L3 3 0 1 5 3 6 1 8 or 4 8 3 0 0 7926 0 3963 0 9511 0 4756 or 1 2682 0 7926 Oil pump Type Gear type Inner and outer gears in mesh enclosed in gear case Driving method Direct drive by crankshaft Relief valve opening pressure 0 3 0 03 MPa 3 0 0 3 kgf cm2 42 68 4 27 psi Lamp lighting and valve opening pressure Differential pressure 0 05 0 01 MPa 0...

Page 84: ...ines Version 08 2004 OIL FILTER AND OIL PRESSURE SWITCH ENGLISH LUBRICATION SYSTEM LUBRICATION SYSTEM 19 OIL FILTER AND OIL PRESSURE SWITCH 19 1 Disassembly Disassembly sequence 1 Oil filter 2 Oil pressure switch Figure 87 Oil filter and pressure switch ...

Page 85: ... threads of the oil pressure switch before installation 5 Install the oil filter by hands 19 3 Inspection Inspect the following 19 3 1 Oil leak Figure 88 Installing oil filter Figure 89 Installing pressure switch Special tool name Part No Socket wrench MD998054 Table 38 Special tool CAUTION After installation check for oil leak while the engine is running Figure 90 Inspecting oil filter and oil pr...

Page 86: ...85 155 Service Manual Mitsubishi L Series diesel engines Version 08 2004 ENGLISH FUEL SYSTEM ...

Page 87: ...0 n 3000 rpm 17 bTDC n 3600 rpm 19 bTDC Plunger diameter ø 6 mm 0 2362 in Number of plungers 2 3 MS retard 4 for crank Delivery valve Silt or Bosch INJECTION NOZZLE Type Thread type Nozzle type Throttle type Nozzle number of jets 1 Injection pressure 13 7 MPa 140 kg cm2 1991 5 psi FUEL PUMP optional Type Electromagnetic diaphragm type Delivery 0 37 l 0 0977 U S gal min 12V at 20 C 68 F Type Electr...

Page 88: ...Rated current pull Rated current hold 55A 1 0A Working voltage 12V DC Stroke 13 5 mm 0 5315 in Type Solenoid push out type Coil resistance 1 6Ω 10 at 20 C 68 F Stroke 10 mm 0 3937 in FUEL FILTER Paper element type a Please refer to the applicable engine model specification sheet for actual data Description Specification L2 L3 Table 40 Specifications ...

Page 89: ... 08 2004 ENGLISH GENERAL FUEL SYSTEM 20 2 Disassembly Disassembly sequence 1 Injection pump 2 Adjusting shim 3 Injection pipe 4 Injection nozzle 5 Return pipe 6 Fuel filter 7 Fuel cutoff solenoid 2 2 3 4 5 3 6 7 L2 L3 1 1 L3 L2 Figure 91 Fuel system component parts ...

Page 90: ...assembly sequence 1 Union collar 2 Air vent screw 3 Delivery valve holder 4 Valve spring 5 Holder stopper 6 Housing 7 O ring 8 Delivery valve 9 Gasket 10 Seat valve 11 Plunger barrel 12 Sleeve 13 Upper seat 14 Plunger spring 15 Plunger 16 Lower seat 17 Adjusting shim 18 Tappet roller 19 Pin 20 Control rack 21 Stop wire bracket Figure 92 Injection pump component parts ...

Page 91: ...e spring 3 Remove the tappet roller and stopper pin 4 Remove the tappet plunger spring etc Item Inspection procedure Criteria Idling speed Measure engine speed 900 rpm Exhaust smoke color 1 Quickly accelerate engine without load 2 Apply load to No remarkably blacksmoke exhaust permitted Fuel cut off solenoid Turn ignition switch to OFF from ON A solenoid acting sound Table 41 Inspection injection ...

Page 92: ...appet roller assembly and install the stopper pin 9 Tighten the delivery holder 21 7 Reassembly of delivery valve Reassemble the injection pump in the reverse sequence of removal Figure 94 Inspection of injection pump Control rack movement uneven O ring Cracks and deterioration Wear and scratch Plunger Interference wear scratch rust seizure Interference wear Figure 95 Direction of reassembly of pl...

Page 93: ...L SYSTEM FUEL SYSTEM 22 INJECTION NOZZLE 22 1 Disassembly Disassembly sequence 1 Body sub assembly 2 Shim washer 3 Pressure spring 4 Pin 5 Distance piece 6 Nozzle assembly 7 Retaining nut 22 2 Removal 1 Disconnect the injection pipe and fuel return pipe Figure 97 Nozzle holder assembly component parts ...

Page 94: ...to prevent deformation 2 Remove the shim washer pressure spring distance piece and nozzle assembly CAUTION a Attach an identification number tag to the removed injection nozzle b Plug the openings to prevent entering of dust water and other foreign particles into the pipes and combustion chamber c Do not mix the parts of any nozzle assy with others but keep the parts of each nozzle assembly as a u...

Page 95: ...ed torque 22 6 Adjustment Adjust injection starting pressure by increasing or decreasing the thickness of inserting shim washer Varying shim thickness by 0 1 mm 0 0039 in causes injection start pressure to change 0 98 MPa 10 kgf cm2 142 3 psi Available shims 10 kinds of shims available from 1 25 mm to 1 7 mm 0 0492 to 0 0669 in in thickness in increment of 0 05 mm 0 0020 in Figure 98 Inspecting no...

Page 96: ...n pipe and injection pipe Standard Allowable limit Idling speed Measure engine speed 13 7 MPa 140 kgf cm2 1992 psi 12 7 MPa 130 kgf cm2 1849 psi or less Table 42 Injection start pressure Figure 101 Installing nozzle holder 49 0 to 58 8 N m 5 0 to 6 0 kgf m 36 17 to 43 40 lbf ft Figure 102 Installing injection pipe Fuel return pipe 24 5 to 29 4 N m 2 5 to 3 0 kgf m 18 08 to 21 70 lbf ft Injection p...

Page 97: ...96 155 Service Manual Mitsubishi L Series diesel engines Version 08 2004 ENGLISH INJECTION NOZZLE FUEL SYSTEM ...

Page 98: ...97 155 Service Manual Mitsubishi L Series diesel engines Version 08 2004 ENGLISH GOVERNOR SYSTEM ...

Page 99: ... Service Manual Mitsubishi L Series diesel engines Version 08 2004 ENGLISH GENERAL GOVERNOR SYSTEM GOVERNOR SYSTEM 23 GENERAL 23 1 Specification Governor type Centrifugal flyweight type Table 43 Specification ...

Page 100: ... 7 Governor spring 8 Governor shaft 9 Governor level 10 Tie rod 11 Tie rod clip 12 Tie rod cover 13 Tie rod cover gasket 14 Tension lever 15 Start spring 16 Governor spring lever 17 Speed control lever assembly 18 Cover assembly 19 Governor cover gasket 20 Return spring 21 Stop lever assembly 22 O ring 23 Snap ring 24 Stop lever 25 Grooved pin 3 x 20 26 Grooved pin 3 x 16 27 Torque spring set 28 S...

Page 101: ...using the procedure mentioned below Figure 104 Torque spring set For installation and adjustment For installation and adjustment Never tamper with this screw Turn in this torque spring set until engine speed drops about 50 min 1 from high idling speed For installation and adjustment For installation and adjustment Adjust to specified number of loosening turns N CAUTION There are two types of torqu...

Page 102: ...ment coincides with the value of load C shown in the table L2C 61A L2C 61CV L2C2 61CV L2E 61R L2E 61SC L2E 61SDG L2E 61GS L2E W264SGHM L2E 61DPH L2E 61DPHA L2E W261DPH L2E W261DPHA L2E W262SDH L2E W262WMG L2E 62APH2 L3A 61TG L3A 61ES L3C 61TG L3C 62DA L3C2 62TG L3E 61R L3E 61TG L3E W261TG L3E 61RG L3E W264SGHM L3E 61DPH L3E 61DPHA L3E W261DPH L3E W261SPHA L3E 62APH L3E 62APH2 2 5 L2C 61DM L2E 61TM...

Page 103: ... 61ES L3E2 62ES L3E2 63ES L2E 61GS L3E2 63ESA L2A 61DA L2E 61ES L2E 61DA 570 570 550 Green L2E 62PL 1520 1520 1500 Red L3E 61TG L3A 61A L3C 61A L3C 61TG L3E 61A L3E 61SC L3E 61SA L3E 61DS L3E 61SHS L3E 61LS L3E 61KL L2A 61A L2C 61A L2C 61CV L2E 61A L2E 61SC L2E 61SA L2E 61WH L2E 61HMG L2E 61IR 970 970 950 Yellow L3C2 62TG L3E2 62TG L3A 61RG L3E 61RG 1270 1270 1250 Purple Table 44 Applying loads NO...

Page 104: ... Check levers for smooth movements Check shaft for flaws Check springs for fatigue Check sliding sleeve joint for wear and damage Check sliding sleeve for wear damage and smooth movement Check weight for wear and damage Figure 108 Inspection governor system parts Figure 109 Installing speed control lever 5 degrees Standard No play exceeding 5 degrees permitted CAUTION a After press fitting each gr...

Page 105: ...104 155 Service Manual Mitsubishi L Series diesel engines Version 08 2004 ENGLISH TORQUE SPRING GOVERNOR SYSTEM ...

Page 106: ...105 155 Service Manual Mitsubishi L Series diesel engines Version 08 2004 ENGLISH COOLING SYSTEM ...

Page 107: ...4 blade or 5 blade unequal pitch pusher or suction type ø 290 11 4173 in L3 Standard type for industrial application 5 blade or 6 blade unequal pitch pusher or suction type ø320 mm 12 5984 in WATER PUMP Type Centrifugal impeller THERMOSTAT Type Wax pellet type Valve opening temperature 76 5 1 5 C 169 7 2 7 F Full opening temperature 90 C 194 F Valve lift 6 mm 0 2362 in THERMOSWITCH Standard type B...

Page 108: ...es Version 08 2004 GENERAL ENGLISH COOLING SYSTEM 25 2 Disassembly Disassembly sequence 1 Cooling fan 2 Water pump pulley 3 Water pump assembly 4 V belt 5 Thermostat 6 Thermostat fitting 7 Thermoswitch 8 Bypass pipe Figure 110 Cooling system component parts ...

Page 109: ...tion For fan belt tension see Maintenance page xx I 26 2 Fan inspection Check the fan for cracks damage and deformation If any replace the fan Figure 111 Inspecting fan belt Wear of pulley groove 11 8 to 14 7 N m 1 2 to 1 5 kgf m 8 68 to 10 85 lbf ft Elongation aging wear and damage 19 6 to 24 5 N m 2 to 2 5 kgf m 14 47 to 18 08 lbf ft Tension Figure 112 Inspecting fan ...

Page 110: ...EM 27 WATER PUMP 27 1 Removal and installation 1 Remove the fan and fan belt 2 Remove the water pump 3 When installing the water pump take reverse sequence of the removal 27 2 Inspection Check the water pump for water leak improper rotation and cracks If any replace the water pump assembly Figure 113 Removing water pump ...

Page 111: ...f the thermostat does not operate properly replace it Figure 114 Installing thermostat Thermostat Never place thermostat stay in direction of thermoswitch hole Water outlet fitting Renew gasket Thermostat fitting Figure 115 Inspecting thermostat Stir up hot water Item Specification 76 5 C 169 7 F 71 C 159 8 F Valve cranking temperature 76 5 1 5 C 169 7 2 7 F 71 C 159 8 F Full open temperature lift...

Page 112: ...e unit Gage unit part no Specification MD001380 70 C 158 F 104 13 5 Ω 115 C 239 F 23 8 2 5 Ω MM435133 80 C 176 F 118 6 Ω 115 C 239 F 42 2 5 Ω 0452510100 80 C 176 F 29 5 2 5 Ω 106 C 222 8 F 14 3 0 5 Ω 05204 05300 67 C 152 6 F 44 6 Ω 110 C 230 F 12 8 Ω Table 47 Inspecting temperature gage unit CAUTION Take special care when handling hot oil in order not to cause burns or fire Figure 117 Inspecting t...

Page 113: ...112 155 Service Manual Mitsubishi L Series diesel engines Version 08 2004 ENGLISH WATER TEMPERATURE GAGE UNIT AND THERMOSWITCH COOLING SYSTEM ...

Page 114: ...113 155 Service Manual Mitsubishi L Series diesel engines Version 08 2004 ENGLISH AIR CLEANER ...

Page 115: ...iesel engines Version 08 2004 ENGLISH AIR CLEANER AIR CLEANER AIR CLEANER 30 AIR CLEANER 30 1 Disassembly Disassembly sequence 1 Body assembly 2 Element assembly 3 Dust pan assembly 4 Bolt 5 Partition plate Figure 118 Air cleaner component parts ...

Page 116: ...and pistons to wear early Check interior of the body for evidences of dust entering If any repair the air leak part 3 Check the element and packing for damage and air leak If any defect is found replace 4 Check the element for contamination clogging and damage If necessary clean or replace the element 5 Check the intake hose for damage and cracks If necessary replace the hose 6 When installing the...

Page 117: ...116 155 Service Manual Mitsubishi L Series diesel engines Version 08 2004 ENGLISH AIR CLEANER AIR CLEANER ...

Page 118: ...117 155 Service Manual Mitsubishi L Series diesel engines Version 08 2004 ENGLISH ELECTRICAL SYSTEM ...

Page 119: ...ore 7 7V 400A 16 0 N m 1 63 kgf m 11 8 lbf ft or more 740 rpm or more ALTERNATOR Model L2 L3 A B A B A000T25371 A007TA01718 NEW TYPE A000T25371 A007TA01718 NEW TYPE Type Alternator with built in IC regulator Nominal output 12V 40A 12V 40A Output performance hot 21A 2500 rpm 37A 5000 rpm 21A 2500 rpm 37A 5000 rpm GLOW PLUG Model Y 145T Type Sheath type quick heating Rated voltage 10 5V DC Current 9...

Page 120: ...Resistance in coil Ω 1 6 10 at 20 C 68 F Stroke mm in 10 0 5 0 39 0 02 Operating voltage V DC 10 to 15 GLOW TIMER Model QGS Rated voltage V DC 12 Operating voltage V 7 to 15 Operating temperature range C F 30 to 70 22 to 158 Storage temperature range C F 40 to 80 40 to 176 Pre glow time second 6 2 0 7 Description Specification L2 L3 Table 49 Specifications ...

Page 121: ...o switch MM432 104 Safety relay MM130 767 Model Battery Starter Alternator Gow relay MM431 28201 Pilot lamp MM201 123 Glow timer MM431 762 Diode MM434 062 Pressure switch 31A90 00100 Charge pilot MM201 122 Alternator Starter switch 30890 05200 Pilot lamp MM201 124 Control timer I6A11 14000 Solénoid ETS Connection of starter switch Terminal Position Fuel pump 30A60 00200 Starter relay 32A66 19100 S...

Page 122: ... Alternator Glow relay MM431 28201 Pilot lamp MM201 123 Glow timer MM431 762 Diode MM434 062 Pressure switch MM130 066 Charge pilot MM201 122 Alternator Starter switch 30890 05200 Pilot lamp MM201 124 Control timer I6A12 02001 Connection of starter switch Terminal Position Fuel pump 30A60 00200 Starter relay 32A66 19100 Starter Battery switch 05125 00102 Battery 0 85 mm2 or more 60 mm2 or more 3 m...

Page 123: ... 1 Structure Disassembly sequence 1 Front bracket assembly 2 Lever assembly 3 Spring set 4 Center bracket assembly 5 Switch assembly 6 Through bolt 7 Armature 8 Rear bearing 9 Pinion 10 Pinion shaft assembly 11 Gear 12 Yoke assembly 13 Brush holder assembly 14 Rear bracket 12 4 6 13 14 3 2 1 5 11 10 8 9 7 Figure 119 Starter component parts ...

Page 124: ... ammeter voltmeter and battery to the starter as illustrated 2 When the switch is closed the pinion must protrude and the starter must run smoothly at 3000 rpm or more If the current or starter speed is out of specification disassemble the starter and repair it 32 2 3 Magnetic switch Perform the following tests If any defect is found replace the magnetic switch assembly 1 Disconnect wire from term...

Page 125: ...osition when released from holding by hand 4 Return test With a battery connected to the magnetic switch terminal M and to the starter body manually pull out the pinion fully The pinion must return to its original position when released from holding by hand Figure 122 Attraction test Starter Battery CAUTION Do not apply battery current for more than 10 seconds Figure 123 Holding test Body Battery ...

Page 126: ...rmature out 5 Remove the cover pry the snap ring out and remove the washer 6 Unscrew the bolts and remove the center bracket At the same time washers for opinion shaft end play adjustment will be removed 7 Pull out the reduction gear lever and lever spring from the front bracket 8 On the pinion side pry the snap ring out and pull out the pinion and pinion shaft 9 At each end of the armature remove...

Page 127: ...noise and rough rotation One way mechanism Break and short circuit Wear and chipping Bearing Play noise and rough rotation Figure 127 Inspecting starter Description Standard Service Limit Depth of under cut 0 5 mm 0 0197 in 0 2 mm 0 0079 in Commutator O D 38 7 mm 1 5236 in 1 0 mm 0 0394 in Height of brush 17 mm 0 6693 in 6 mm 0 2362 in Spring pressure 29 4 N 3 kgf 6 61 lbf Table 50 Inspection ...

Page 128: ...easure the outside dimension of the commutator and the depth of undercut Repair or replace if exceed the service limit Also check the commutator outside surface for dirtiness and roughness If it is rough polish the commutator with fine grain sandpaper 32 4 3 Brush holder inspection 1 Check the brushes If worn out nearly to the service limit replace the brushes 2 Check the brush spring tension If a...

Page 129: ...acket and reduction gear 1 Reassemble the pinion shaft reduction gear washer and snap ring to the center bracket 2 Measure the end play by moving the pinion shaft in the axial direction If the end play exceeds 0 5 mm 0 0197 in increase the number of adjusting washers 32 5 2 Greasing Whenever the starter has been overhauled apply grease to the following parts 1 Armature shaft gear and reduction gea...

Page 130: ...SYSTEM ELECTRICAL SYSTEM 33 ALTERNATOR AND DYNAMO 33 1 Structure Disassembly sequence 1 Pulley 2 Front bracket assembly 3 Front bearing 4 Rotor assembly 5 Rear bearing 6 Stator 7 Terminal set 8 Regulator assembly 9 Rectifier assembly 10 Rear bracket assembly 4 6 3 2 1 5 10 8 9 7 Figure 133 Alternator component parts ...

Page 131: ...he ON position while the engine stops 4 Short circuit the ammeter terminals to start the engine 5 Read the voltmeter indication regulated voltage under the following test conditions Ammeter indication is below 5 A engine speed is at 1800 rpm and 2500 rpm and lamps are switched off Regulated voltage shows a tendency to decrease as the alternator temperature increases Figure 134 Dynamo Field coil Ma...

Page 132: ...connector 4 Loosen the alternator brace bolt and support bolt Push the alternator toward the engine and remove the fan belt 5 Dismount the alternator 33 6 Disassembly of alternator 1 Remove three through bolts 2 Heat the rear bracket around the rear bearing portion up to 50 to 60 C 122 to140 F with a solder iron and separate the bracket from the stator coil 3 Grip the rotor in a vise remove the pu...

Page 133: ...l ìBî 7 Loosen the rectifier mounting screws and remove the rectifier 33 7 Inspection Inspect the disassembled parts If any part is found defective replace CAUTION a Soldering must be done in short time b Never heat the lead wires too long to prevent damage to diodes Break and short circuit Crack and damage Crack and damage Break and short circuit Wear Wear to limit line Wear and roughness Figure ...

Page 134: ...the reverse direction 2 If there is equal resistance in both directions the diode is suspected to be defective Replace the rectifier assembly 3 Check every diode for continuity 33 7 2 Inspecting the field coil 1 Check continuity between slip rings If there is no continuity the field coil is suspected to be broken Replace the field coil 2 Check for continuity between a slip ring and shaft or core I...

Page 135: ...mble the alternator in the reverse sequence of disassembly and pay attention to the following 1 The rear bearing has an eccentric groove Install the snap ring so that its protrusion fits to the deepest part of the groove 2 When installing a new rear bearing press fit the bearing with its groove facing to the slip ring side 3 When press fitting the rear bearing into the rear bracket heat the bracke...

Page 136: ...of spacers to be inserted into the clearance 0 2 mm 0 0079 in maximum 3 Reinstall the alternator with the necessary spacer inserted in place Tighten the support bolt nuts securely 4 Perform the belt tension adjustment 33 10Alternator and regulator 33 10 1Specifications For specifications refer to 8 2 33 10 2Inspection 1 Inspecting the unit in service Measure battery voltage between terminals with ...

Page 137: ... is necessary to install them in a well ventilated area reassemble the regulator in the proper direction by positioning the head of the outlet leads downward Figure 147 Lead outlet coupler Blue lead Red lead Yellow lead Green lead Blue lead Black lead Item Normal measure ment If abnormal possible cause of regulator trouble Tester Tester Red Blue 1 Continuity Broken diode Red Blue 2 Blue 1 Black Bl...

Page 138: ...lug when removing Glow plug tightening torque 14 7 to 19 6 N m 1 5 to 2 0 kgf m 10 85 to 14 47 lbf ft 34 2 Inspection Check for continuity between the glow plug terminal and body If there is no continuity at all or large resistance replace the plug 34 3 Installation Tighten the glow plug to the specified torque Figure 148 Checking glow plug 14 7 to 19 6 N m 1 5 to 2 0 kgf m 10 85 to 14 47 lbf ft ...

Page 139: ...Fuel cutoff solenoid ETS type 35 3 1 Specification Figure 149 Timer unit BLK YEL BLU BLU GRN RED WHT RED Description Specification Input voltage 9V to 15V DC Load Solenoid Coil resistance 1 7 Ω or more Table 53 Control timer unit No Cord Color Connect with 1 Blue Solenoid 2 Blue Solenoid 3 Red Battery Key switch B 4 Green Key switch ON 5 Red White Starter Key switch ST 6 Yellow Oil pressure switch...

Page 140: ... to the foregoing wiring diagrams Refer to GENERAL 2 Start the engine and confirm that the solenoid comes into action to stop the engine when the key switch is placed in the OFF position 3 Confirm that the engine comes to stop when the oil pressure switch terminal is short circuited to the switch body 35 4 Fuel cutoff solenoid ETR type 35 4 1 Specification Figure 151 Solenoid installation A Keep t...

Page 141: ...d Install the solenoid while it is not functioned its shaft is protruded using the same procedure as mentioned before for the push type so that the specified clearance between the solenoid shaft and injection pump rack can be obtained Stroke 13 5 0 5 mm 0 5315 0 0197 in Rated current pull 55A Rated current hold 1A Description Specification Figure 153 Fuel cutoff solenoid ETR type diagram Red Hold ...

Page 142: ...lug heating time 6 seconds This system remarkably simplifies the glow plug operation 36 2 Glow timer 36 3 Glow relay Figure 154 Glow timer system Glow indicator Glow relay Battery Glow timer Key switch Glow plugs Glow timer Operation chart Glow relay Test circuit Description Specification Model p n MM431762 Rated voltage 12V DC Working temperature 20 C 68 F Initial performance at normal temperatur...

Page 143: ...142 155 Service Manual Mitsubishi L Series diesel engines Version 08 2004 ENGLISH GLOW TIMER SYSTEM ELECTRICAL SYSTEM ...

Page 144: ...143 155 Service Manual Mitsubishi L Series diesel engines Version 08 2004 ENGLISH SERVICE DATA ...

Page 145: ...ts Exhaust noise and vibration Retightening bolts and nuts Valve clearance Engine idling Cylinder compression pressure Lubricating system Engine lube oil Oil filter cartridge type Oil filter disassembly type Fuel system Fuel Fuel tank ο Fuel filter element ο Water sedimeter Fuel feed pump filter element Fuel injection nozzle Intake system Air cleaner Paper element type ο Air cleaner Oil bath type ...

Page 146: ...1 0 0394 Valve clearance IN and EX 0 25 0 0098 Cold Valve Valve head diameter IN 26 7 1 0512 EX 24 7 0 9724 Overall length 94 3 7008 Stem Outside diameter 6 6 0 2598 Stem to Guide clearance IN 0 10 0 0039 EX 0 15 0 0059 Valve face angle 45 Valve head thickness Margin width 1 0 0 0394 0 5 0 0197 Valve head sinkage from cylinder head bottom face 0 5 0 0197 Valve spring Free length p n MM432 668 whit...

Page 147: ... Oversize 0 25 0 0098 0 50 0 0197 Protrusion from crankcase top surface 0 9 0 0354 Piston pin Type Semi floating type Outside diameter Outside diameter Piston pin to piston clearance 0 08 0 0031 Piston pin to connecting rod clearance Press fit load 1000 500 kg 2204 6 1102 3 lb Within standard range Piston ring Number of rings Compression 2 No 1 Chrome plated semi keystone type No 2 Tapered Oil 1 C...

Page 148: ... 1 6718 to 1 6724 Pin U S 0 25 0 0098 39 715 to 39 730 1 5636 to 1 5642 0 50 0 0197 39 465 to 39 480 1 5537 to 1 5543 Main bearing Type Aluminum metal with back metal No 2 Flanged metal Oil clearance 0 10 0 0039 Undersize 0 25 0 0098 0 50 0 0197 Camshaft Driving method Gear drive Front journal Ball bearing Journal to cylinder block hole clearance 0 15 0 0059 Major diameter of cam IN and EX 27 37 1...

Page 149: ...mp Type Gear type Check valve opening pressure 0 3 0 03 MPa 3 0 0 3 kgf cm2 42 68 4 27 psi 1000 RPM Outer rotor to Housing clearance 0 100 to 0 196 0 0039 to 0 0077 0 3 0 0118 Outer rotor thrust clearance 0 04 to 0 10 0 0016 to 0 0039 0 25 0 0098 Oil pressure switch Contact closing pressure Standard type 0 05 0 01 MPa 0 5 0 1 kgf cm2 7 11 1 42 psi Description Specification and Standard Repair Limi...

Page 150: ...ing temperature 76 5 1 5 C 169 7 2 7 F Full opening temperature at 6 mm 0 2362 in valve lift 90 C 194 F Thermostat 71 C specification Type Wax type Valve cranking temperature 71 C 159 8 F Full opening temperature at 6 mm 0 2362 in valve lift 85 C 185 F Thermo switch Type Bimetal type Model Part No FW065102G220 MM432104 Contact closing temperature 111 3 5 C 231 8 6 3 F Temperature gage unit Type Th...

Page 151: ...ype Model M001T68381 30L66 10500 Voltage output 12V 1 7 kW Direction of rotation Clockwise as viewed from pinion side No load characteristics Terminal voltage 11V Current 110A or less Speed 2400 RPM or more Load characteristics Terminal voltage 7 7V 11 5 0 4528 Current torque 400A 16 0 N m 1 63 kgf m 11 8 lbf ft or more 0 7 0 0276 Speed 740 RPM or more Pinion gap 0 5 to 2 0 0 0197 to 0 0787 Thrust...

Page 152: ... solenoid Type Electromagnetic ETR pull type Rated voltage 12V DC Rated temperature 20 C 68 F Coil resistance Pull 0 25 Ω 10 Hold 13 5 Ω 10 Rated pull current 55A Rated hold current 1A Control timer Input voltage 9V to 15V DC Load Solenoid Coil resistance 1 7 Ω or more Working temperature 30 to 80 C 22 to176 F Glow timer Model S81NJ Rated voltage 12V DC Working temperature 40 to 85 C 40 to 185 F I...

Page 153: ...0 21 49 0 to 58 8 5 0 to 6 0 36 17 to 43 40 Nozzle union collar fixing nut M12 17 19 6 to 29 4 2 0 to 3 0 14 47 to 21 70 Nozzle retaining nut M16 21 34 3 to 39 2 3 5 to 4 0 25 32 to 28 93 Fuel injection pipe nut M12 17 24 5 to 29 4 2 5 to 3 0 18 08 to 21 70 Delivery valve holder M16 17 34 3 to 38 2 3 5 to 3 9 25 32 to 28 21 Injection pump hollow screw M10 14 9 8 to 14 7 1 0 to 1 5 7 23 to 10 85 In...

Page 154: ... to 29 4 2 0 to 3 0 14 47 to 21 70 34 3 to 44 1 3 5 to 4 5 25 32 to 32 55 Parts requiring sealant application Surface Sealant Where sealant coated parts to be mounted Threaded parts Fuel cutoff solenoid Effective screw threads THREE BOND 1212 or 1211 Crankcase Water drain joint HERMESEAL H1 or THREE BOND 1344 Crankcase Oil pressure switch Crankcase Tapper plug NPTF 1 16 Crankcase Press fit part Se...

Page 155: ...llers oil filter wrenches etc are required Tool No Toon Name Style Usage ST332400 Piston pin setting tool Exclusive use for L series Removal and installationof piston pin Guide LA 92 l for L2A L3A Guide LC 89 5 l for L2C E L3C E ST332270 Compression gage adapter Exclusive use for L series Measurement of cylinder compression With L mark MD998054 Oil pressure switch socket wrench 26 Removal and inst...

Page 156: ...155 155 Service Manual Mitsubishi L Series diesel engines Version 08 2004 ENGLISH 155 BLANK PAGE ...

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