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Mitsubishi L Series Service Manual

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SERVICE MANUAL
L2A, L2C, L2E
L3A, L3C, L3E
October 2007
99619-16120
Pub. No.
99619-16120
Printed in Japan
Pub. No.

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Summary of Contents for Mitsubishi L Series

  • Page 1 SERVICE MANUAL L2A, L2C, L2E L3A, L3C, L3E October 2007 99619-16120 Pub. No. 99619-16120 Printed in Japan Pub. No.
  • Page 2      ...
  • Page 3 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.
  • Page 5 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.
  • Page 6 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.
  • Page 7 INTRODUCTION Safety Cautions Fire and explosion Keep flames away Care about fuel, oil and exhaust gas leakage Store fuel and engine oil in a well If any fuel, oil or exhaust gas leakage is found, immedi- ventilated designated area. ately take corrective measures to stop it. Make sure that the caps of fuel and Such leakages, if left uncorrected, can cause fuel or engine oil containers are tightly...
  • Page 8 INTRODUCTION Stay clear of all rotating and moving parts Install protective covers on rotating parts Lockout and Tagout Make sure the protective covers for Be sure to lockout and tagout before starting inspection engine rotating parts are properly and maintenance. installed as intended.
  • Page 9 INTRODUCTION Be careful of burns Be careful of exhaust fume poi- soning Do not touch the engine during or immedi- ately after operation Operate engine in well-ventilated area Do not touch the engine during or If the engine is installed in an en- immediately after operation...
  • Page 10 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.
  • Page 11 INTRODUCTION Service battery When abnormality occurs Handle the battery correctly Stop overheated engine after cooling run • Never use flames or allow sparks Even if the engine comes to overheat, do not stop the to generate near the battery. The engine immediately.
  • Page 12 INTRODUCTION Other cautions Modification of engine prohibited Warming-up operation Unauthorized modification of the engine will void the After starting the engine, run the engine at low idling manufacturer’s warranty. speeds for 5 to 10 minutes for warming-up. Start the Modification of the engine may not only cause engine work after this operation is completed.
  • Page 13 INTRODUCTION problems such as an increase of oil consumption, de- Do not turn off battery switch during opera- tion crease of output, and starting difficulties. For effective removal of dust from intake air, conduct maintenance If the battery switch is turned OFF when the engine is of the air cleaner according to the following instruc- running, not only various meters will stop working but tions.
  • Page 14 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.

  • Page 15: Table Of Contents

    GENERAL CONTENTS Group Name Contents Group No. External view System flow diagrams Engine serial number location General Indication of engine model and total displacement Specifications Tips on disassembling and reassembling Maintenance service data Service data List of tightening torque Basic tools Service tools Special tools Determining overhaul timing...

  • Page 17: General

    GENERAL 1. External view........1-2 1.1 External view of L2A, L2C and L2E ..1-2 1.2 External view of L3A, L3C and L3E ..1-3 2. System flow diagrams .....1-4 2.1 Fuel system - flow diagram ...... 1-4 2.2 Lubrication system - flow diagram ... 1-4 2.3 Cooling system - flow diagram....

  • Page 18: External View

    GENERAL 1. External view 1.1 External view of L2A, L2C and L2E Oil filler Rear hanger Thermostat Alternator Exhaust manifold Front 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...

  • Page 19: External View Of L3A, L3C And L3E

    GENERAL 1.2 External view of L3A, L3C and L3E Oil filler Thermostat Rear hanger Exhaust manifold Alternator Front Rear Starter V-belt Oil pan Left view Flywheel Engine left view Fuel injection nozzle Front hanger Inlet manifold Fuel injection pump Stop solenoid Water pump Fuel filter Rear...

  • Page 20: System Flow Diagrams

    GENERAL 2. System flow diagrams 2.1 Fuel system - flow diagram Fuel leak-off pipe Fuel injection nozzle Fuel injection pipe To fuel tank From fuel pump Fuel injection pump Fuel filter Fuel system - flow diagram 2.2 Lubrication system - flow diagram Rocker shaft Camshaft Oil main gallery...

  • Page 21: Cooling System - Flow Diagram

    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 system - flow diagram Inlet Air breather pipe Exhaust Blow-by gas (blow-by gas reduction) From air cleaner To muffler Inlet cover Exhaust manifold...

  • Page 22: Engine Serial Number Location

    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. Engine serial number Stamp location of engine serial number 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.

  • Page 23: Specifications

    GENERAL 5. Specifications 5.1 Specifications of L2A, L2C and L2E Table 1-1 Specifications of L2A, L2C and L2E (1 / 4) Engine model Type Vertical type, water-cooled, 4 cycle diesel No. of cylinders Combustion type Swirl chamber type Valve mechanism Overhead valve type 65 ×...
  • Page 24 GENERAL Table 1-1 Specifications of L2A, L2C and L2E (2 / 4) Engine model Lubrication system 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.
  • Page 25 Table 1-1 Specifications of L2A, L2C and L2E (3 / 4) Engine model Voltage - polarity 12V - negative (-) ground, 24V - negative (-) ground Type M000T60481 Manufacturer Mitsubishi Electric Corporation Pinion engagement type Pinion shift (reduction type) Starter (1) Output 12V - 1.2 kW Number...
  • Page 26 GENERAL Table 1-1 Specifications of L2A, L2C and L2E (4 / 4) Engine model Working voltage 12V - ETR: 8V or less 100 MΩ or more at DC 500 V megger Insulation resistance Stop (normal temperature, normal relative humidity) solenoid (1) Stroke 13.5 ±...

  • Page 27: Specifications Of L3A, L3C And L3E

    GENERAL 5.2 Specifications of L3A, L3C and L3E Table 1-2 Specifications of L3A, L3C and L3E (1 / 4) Engine model Type Vertical type, water-cooled, 4 cycle diesel No. of cylinders Combustion type Swirl chamber type Valve mechanism Overhead valve type 65 ×...
  • Page 28 GENERAL Table 1-2 Specifications of L3A, L3C and L3E (2 / 4) Engine model 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.
  • Page 29 Table 1-2 Specifications of L3A, L3C and L3E (3 / 4) Engine model Voltage - polarity 12V - negative (-) ground, 24V - negative (-) ground Type M000T60481 Manufacturer Mitsubishi Electric Corporation Pinion engagement type Pinion shift (reduction type) Starter (1) Output 12V - 1.2 kW Number...
  • Page 30 GENERAL Table 1-2 Specifications of L3A, L3C and L3E (4 / 4) Engine model Working voltage 12V - ETR: 8V or less 100 MΩ or more at DC 500V megger Insulation resistance Stop (normal temperature, normal relative humidity) solenoid (1) Stroke 13.5 ±...

  • Page 31: Tips On Disassembling And Reassembling

    This service manual specifies the recommended procedures (1) Wash all engine parts, except such parts as oil seals, O- to be followed when servicing Mitsubishi engines. The rings and rubber sheets, in cleaning oil and dry them manual also specifies the special tools that are required for with compressed air.

  • Page 33: Service Data

    SERVICE DATA 1. Maintenance service data ....2-2 1.1 Engine general......... 2-2 1.2 Basic engine ..........2-2 1.3 Fuel system..........2-5 1.4 Lubrication system ........2-6 1.5 Cooling system ........2-6 1.6 Inlet/Exhaust system........ 2-6 1.7 Electrical system ........2-7 2. List of tightening torque....2-10 2.1 Major bolts and nuts tightening torque...

  • Page 34: Maintenance Service Data

    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 (Varies depending on specification of (rated rotation speed used as reference) Adjusted by the governor.
  • Page 35 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 0.4 to 0.6 Valve sinkage [0.0197] [0.0158 to 0.0236] Valve seat and Valve Valve valve...
  • Page 36 SERVICE DATA Table 2-2 Maintenance service data table - Basic engine(3 / 4) Unit mm [in.] Inspection point Nominal Standard Limit Remark ø 65 64.919 to 64.939 [2.559] [2.5559 to 2.5566] ø 65.25 65.169 to 65.189 0.25 OS [2.569] [2.5657 to 2.5665] ø...

  • Page 37: Fuel System

    SERVICE DATA Table 2-2 Maintenance service data table - Basic engine(4 / 4) Unit mm [in.] Inspection point Nominal Standard Limit Remark ø 43 42.965 to 42.980 Journal outside diameter (STD) [1.69] [1.6915 to 1.6921] -0.70 Repair limit is [-0.0276] -0.15 [-0.0059] ø...

  • Page 38: Lubrication System

    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 ø 75.5 0.100 to 0.196 Replace and oil pump outer gear outside diameter [2.972] [0.0039 to 0.0077] [0.012]...

  • Page 39: Electrical System

    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 0.5 to 2.0 Pinion clearance [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...
  • Page 40 SERVICE DATA Table 2-7 Maintenance service data table - Electrical system(2 / 3) Unit: mm [in.] Inspection point Nominal Standard Limit Remark Pinion shaft end play [0.0197] 0.5 to 2.0 Pinion gap [0.0197 to 0.0787] Brush length [0.709] [0.4331] 34 N 28.9 to 39.1 N 20 N Brush spring load...
  • Page 41 SERVICE DATA Table 2-7 Maintenance service data table - Electrical system(3 / 3) Unit: mm [in.] Inspection point Nominal Standard Limit Remark 0.3 to 0.7 0.15 to 0.20 Clearance of stop solenoid to plunger rack [0.0118 to [0.0059 to 0.0276] 0.0079] 12 V 0.2 Ω...

  • Page 42: List Of Tightening Torque

    SERVICE DATA 2. List of tightening torque 2.1 Major bolts and nuts tightening torque 2.1.1 Basic engines Table 2-8 Tightening torque list - Basic engines Threads Torque Description Dia × Pitch Remark N·m kgf·m lbf·ft (mm) Main M10 × 1.25 73.5 to 83.4 7.5 to 8.5 54.2 to 61.5...

  • Page 43: Lubrication System

    SERVICE DATA 2.1.3 Lubrication system Table 2-10 Tightening torque list - Lubrication system Threads Torque Description Dia × Pitch Remark N·m kgf·m lbf·ft (mm) Oil relief valve M18 × 1.5 39.2 to 49.0 4.0 to 5.0 28.9 to 36.2 Oil pan drain plug M18 ×...

  • Page 44: Standard Bolt And Nut Tightening Torque

    SERVICE DATA 2.2 Standard bolt and nut tightening torque Table 2-14 Standard bolt and nut tightening torque Threads Width Strength classification Description Dia × Pitch across flats 10.9 (mm) (mm) [in.] N·m kgf·m lbf·ft N·m kgf·m lbf·ft M8 × 1.25 12 [0.47] M10 ×...

  • Page 45: Standard Eyebolt Tightening Torque

    SERVICE DATA 2.3 Standard eyebolt tightening torque Table 2-15 Standard eyebolt tightening torque Strength classification Threads Width Dia × Pitch across flats (mm) (mm) [in.] N·m kgf·m lbf·ft M8 × 1.25 12 [0.47] 8 ± 1 0.8 ± 0.1 6 ± 0.7 M10 ×...

  • Page 47: Service Tools

    SERVICE TOOLS 1. Basic tools ........3-2 2. Special tools ........3-3...
  • Page 48 SERVICE TOOLS 1. Basic tools Table 3-1 Basic tools list Tool name Part No. Tool set MM413900 Includes 1 to 5 Width across flats Spanner MK96008010 (8 mm × 10 mm) [0.32 × 0.39 in.] Width across flats Spanner MK96012014 (12 mm ×...
  • Page 49 SERVICE TOOLS 2. Special tools Tool name Part No. Shape 30L91-00030 (L2A, L3A) Piston pin setting 30L91-00020 For pulling out and press fitting tool (L2C, L3C) piston pins 30L91-10010 (L2E, L3E) Compression gauge ST332270 For measuring compression adapter Oil pressure switch socket For removing and installing oil MD998054 wrench (26)

  • Page 51: Determination Of Overhaul

    DETERMINATION OF OVERHAUL 1. Determining overhaul timing ...4-2 2. Testing compression pressure ..4-3...

  • Page 52: Determining Overhaul Timing

    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 affected by other causes, and are not always effective to judge the overhaul timing.
  • Page 53 DETERMINATION OF OVERHAUL 2. Testing compression pressure Compression Compression gauge (a) Be sure to measure the compression pressure for gauge adapter all the cylinders. It is not a good practice to mea- P/N:ST332270 sure the compression pressure for only one cylin- der, and presume the compression for the remaining cylinder.
  • Page 55 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 .......

  • Page 56: Disassembling And Inspecting Cylinder Head And Valve Mechanism

    DISASSEMBLY OF BASIC ENGINE 1. Disassembling and inspecting cylinder head and valve mechanism Clogged oil hole, wear Damage to threaded portion Clogged oil hole, wear Damage to threaded portion Wear and damage on both ends, bend Wear and damage Replace: Stem seal Valve guide wear, damage Crack, damage, coolant leakage, oil leakage, scale, gasket, carbon deposit...

  • Page 57: Removing Rocker Shaft Assembly

    DISASSEMBLY OF BASIC ENGINE 1.1 Removing rocker shaft assembly (1) Loosen the rocker arm adjusting screw by about one Rocker shaft assembly Rocker stay bolt 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.

  • Page 58: Removing Cylinder Head Bolt

    DISASSEMBLY OF BASIC ENGINE 1.3 Removing cylinder head bolt Loosen cylinder head bolts in the numerical order as shown Cylinder head bolt (main) in the illustration. Cylinder head bolt (sub) Loosening order of cylinder head bolt (L2) Cylinder head bolt (main) Cylinder head bolt (sub) Loosening order of cylinder head bolt (L3) 1.4 Removing cylinder head assembly...

  • Page 59: Removing Valves And Valve Spring

    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.

  • Page 60: Disassembling And Inspecting Flywheel

    DISASSEMBLY OF BASIC ENGINE 2. Disassembling and inspecting flywheel Damage to threaded portion Wear, damage, aging of oil seal Replace: Gasket Streak, stepped wear and crack of worn surface and damage and abnormal wear of ring gear Crack, damage, abnormal knock hole Disassembling and inspecting flywheel Disassembling sequence 1 Flywheel...

  • Page 61: Removing Flywheel

    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. (b) The personnel who holds the pulley must pay due attention to safety.

  • Page 62: Disassembling And Inspecting Gear Case, Timing Gear And Camshaft

    DISASSEMBLY OF BASIC ENGINE 3. Disassembling and inspecting gear case, timing gears and camshaft Replace: Wear of cam contact Gasket surface and circumference contact Replace: surface O-ring Replace: Gasket Fatigue and crack Wear and damage of weight Wear and damage of sliding sleeve Damage and wear Wear and damage of...

  • Page 63: Removing Tappet

    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 Pushrod tappet will fall in the oil pan. Tappet Removing tappet 3.2 Removing gear pump housing (1) Remove the bolts and one stud (M8×1.25mm-15mm) Stud (M8 1.25 mm-15 mm) Gear pump...

  • Page 64: Removing Pto Gear

    DISASSEMBLY OF BASIC ENGINE 3.5 Removing PTO gear Pull out the PTO gear together with two ball bearings from PTO gear the gear case. Ball bearing Removing PTO gear 3.6 Removing oil pump Remove the oil pump housing from the gear case, and then Oil pump inner gear remove the oil pump outer gear and oil pump inner gear.

  • Page 65: Measuring Timing Gear Backlash

    DISASSEMBLY OF BASIC ENGINE 3.9 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.

  • Page 66: Removing Camshaft

    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 Removing camshaft (1) (2) Pull out the camshaft together with camshaft gear ball...

  • Page 67: Removing Fuel Injection Pump Camshaft

    DISASSEMBLY OF BASIC ENGINE 3.12 Removing fuel injection pump camshaft Sliding shaft 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.

  • Page 68: Removing Front Plate

    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. Fixing bolts of front plate: 7 Removing front plate 5-14...

  • Page 69: Disassembling And Inspecting Cylinder Block, Crankshaft, Piston And Oil Pan

    DISASSEMBLY OF BASIC ENGINE 4. Disassembling and inspecting cylinder block, crankshaft, piston and oil pan Flaking, scratches, Piston ring wear, Connecting rod bend, seizure damage, end gap twist, big end thrust clearance Piston wear, sticking, streaks, ring groove wear Flaking, Cylinder flaws, scratches, stepped wear...

  • Page 70: Removing Oil Pan

    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.

  • Page 71: Pulling Out Piston

    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.

  • Page 72: Measuring Crankshaft End Play

    DISASSEMBLY OF BASIC ENGINE 4.7 Measuring crankshaft end play Measure the crankshaft end play (difference between the crankshaft 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 [0.0020 to 0.0069 in.] [0.0197 in.]...
  • Page 73 INSPECTION AND REPAIR OF BASIC ENGINE 1. Inspecting and repairing cylinder head 4.6 Measuring connecting rod end play ..6-14 and valve mechanism .....6-2 4.7 Inspecting connecting rod bend and twist6-15 1.1 Measuring clearance between rocker arm 4.8 Measuring clearance between connecting and rocker shaft ........

  • Page 74: Inspecting And Repairing Cylinder Head And Valve Mechanism

    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 Measuring Measure the inside diameter of the rocker arm and outside directions diameter of the rocker shaft. Measuring points Replace the rocker arm or rocker shaft if the clearance...

  • Page 75: Replacing Valve Guide

    INSPECTION AND REPAIR OF BASIC ENGINE 1.3 Replacing valve guide (1) Pull out the valve guide from the bottom to the top face Puller Puller of the cylinder head with a press using a blanking tool. [2.56] [0.79] [0.39] [0.24] Unit mm [in.] Valve guide Pulling out valve guide...

  • Page 76: Inspecting Valve Face

    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 Valve lapper contact condition.

  • Page 77: Measuring Perpendicularity And Free Length Of Valve Spring

    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 Spring perpendicularity (gap) a new one. Item Standard Limit...

  • Page 78: Measuring Distortion Of The Bottom Surface Of The Cylinder Head

    INSPECTION AND REPAIR OF BASIC ENGINE 1.8 Measuring distortion of the bottom surface of the cylinder head Measuring points 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).

  • Page 79: Inspecting And Repairing Flywheel

    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.

  • Page 80: Inspecting And Repairing Gear Case, Timing Gear And Camshaft

    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...

  • Page 81: Measuring Cam Lift

    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 Measuring Measuring bore. Replace the camshaft or cylinder block if the directions points clearance exceeds the limit.

  • Page 82: Inspecting Tappet

    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. Good Inspecting tappets 3.8 Measuring clearance between tappet and Measuring tappet guide hole Measuring directions directions...

  • Page 83: Inspecting And Repairing Cylinder Block, Crankshaft, Piston And Oil Pan

    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.

  • Page 84: Reboring Cylinder

    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 the skirt perpendicular to the piston pins as shown in the angles to piston pin illustration.

  • Page 85: Measuring Piston Ring End Gap

    INSPECTION AND REPAIR OF BASIC ENGINE 4.3 Measuring piston ring end gap (a) When replacing rings without boring (honing), Piston 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.

  • Page 86: Measuring Piston Pin Bore Diameter And Piston Pin Outside Diameter

    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 ø...

  • Page 87: Inspecting Connecting Rod Bend And Twist6-15

    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 0.05 0.0020 check bend and twist of the connecting rod. Straighten 3.94 0.05 0.0020 the connecting rod with a press to meet the standard. 3.94 If the standard is exceeded after correction, replace the connecting rod with a new one.

  • Page 88: Measuring Clearance Between Connecting Rod Bearing And Crankpin

    INSPECTION AND REPAIR OF BASIC ENGINE 4.8 Measuring clearance between connecting rod bearing and crankpin Tightening torque Measuring Measuring 31.4 to 34.3 N m directions points {3.2 to 3.5 kgf m} [23.1 to 25.3 lbf ft] When grinding crank pins, be sure to grind all the pins to the same size.

  • Page 89: Measuring Clearance Between Main Bearing And Crankshaft Journal

    INSPECTION AND REPAIR OF BASIC ENGINE 4.9 Measuring clearance between main bear- ing and crankshaft journal Tightening torque 49.0 to 53.9 N m {5.0 to 5.5 kgf m} [36.2 to 39.8 lbf ft] (a) When grinding crank journals, be sure to grind all the journals to the same size.

  • Page 90: Measuring Crankshaft Runout

    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 center journal using a dial gauge. If the runout deviates from the standard only slightly, grind the crankshaft to repair.

  • Page 91: Measuring Distortion Cylinder Block Top Surface

    INSPECTION AND REPAIR OF BASIC ENGINE 4.12 Measuring distortion cylinder block top surface Measuring points and directions 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).
  • Page 93 REASSEMBLY OF BASIC ENGINE 1. Reassembling cylinder block, 4.6 Installing cylinder head assembly ..7-18 crankshaft, piston and oil pan ..7-2 4.7 Tightening cylinder head bolts ....7-19 1.1 Installing main bearing ......7-2 4.8 Inserting push rod ........7-19 1.2 Installing crankshaft .........

  • Page 94: Reassembling Cylinder Block, Crankshaft, Piston And Oil Pan

    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 the crankcase, and install the bearing (lower) without groove to the main bearing cap.

  • Page 95: Installing Main Bearing Cap

    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. Front (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.

  • Page 96: Installing Main Bearing Cap Bolt

    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 53.9 N m {5.0 to 5.5 kgf m} [36.2 to 39.8 lbf ft] Tightening main bearing cap bolt Checking crankshaft for rotation...

  • Page 97: Reassembling Piston And Connecting Rod

    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 piston and connecting rod (1)

  • Page 98: Installing Piston

    REASSEMBLY OF BASIC ENGINE 1.8 Installing piston Every piston ring has a top mark such as “R” near the No.1 Top face mark compression ring end gap. Install all piston rings with this mark facing upward. No.2 If the rings are installed upside down, it could cause compression ring malfunctions such as excessive oil consumption or an engine seizing.

  • Page 99: Installing Connecting Rod Cap

    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 pressing the piston head. (2) Fit the connecting rod bearing (lower) to the rod cap with the lug aligned with the lug groove.

  • Page 100: Installing Oil Screen

    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. Installing oil screen 1.12 Installing oil pan (1) Install new oil pan gasket.

  • Page 101: Reassembling Gear Case, Timing Gears And Camshaft

    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 aligning to the dowel pin, install the gasket and the front plate.

  • Page 102: Installing Camshaft

    REASSEMBLY OF BASIC ENGINE 2.4 Installing camshaft Apply engine oil. Be careful not to damage camshaft journals, cams and camshaft holes during insertion. (1) Apply engine oil to the camshaft journals and cams. (2) Slowly insert the camshaft assembly. (3) Install the camshaft stopper. (4) Make sure that the camshaft rotates freely.

  • Page 103: Inspecting And Adjusting Timing Gear After Installation

    REASSEMBLY OF BASIC ENGINE 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. Measuring timing gear backlash 2.7 Installing governor weights and sliding shaft...

  • Page 104: Installing Speed Control Lever And Governor Shaft

    REASSEMBLY OF BASIC ENGINE 2.8 Installing speed control lever and governor shaft Speed control Governor shaft cover (1) Insert the governor shaft into the gear case with the lever Tension lever governor lever and the tension lever positioned in Grooved pin B place.

  • Page 105: Installing Pto Gear

    REASSEMBLY OF BASIC ENGINE 2.11 Installing PTO gear Install ball bearings on both sides of PTO gear, and install PTO gear the PTO gear into the gear case. Ball bearing Installing PTO gear 2.12 Installing timing gear case (1) Apply sealant to the gasket to prevent it from displacing Bolts on front: 8 pcs.

  • Page 106: Installing Gear Pump Housing

    REASSEMBLY OF BASIC ENGINE 2.14 Installing gear pump housing (1) Install the gear pump housing to the stud bolts on the Stud (M8 1.25 mm-15 mm) Gear pump gear case. housing (2) Tighten the gear pump housing bolt. (3) Install the last stud bolt to the gear pump housing. Bolt Installing gear pump housing 2.15 Installing tappet...

  • Page 107: Reassembling Flywheel

    REASSEMBLY OF BASIC ENGINE 3. Reassembling flywheel 3.1 Installing oil seal case 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.

  • Page 108: Installing Flywheel

    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.

  • Page 109: Reassembling Cylinder Head And Valve Mechanism

    REASSEMBLY OF BASIC ENGINE 4. Reassembling cylinder head and valve mechanism Reassemble the cylinder head and valve mechanisms in the reverse order 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.

  • Page 110: Installing Valve Lock

    REASSEMBLY OF BASIC ENGINE 4.4 Installing valve lock 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.

  • Page 111: Tightening Cylinder Head Bolts

    REASSEMBLY OF BASIC ENGINE 4.7 Tightening cylinder head bolts Cylinder head bolt (main) In the numerical order as shown in the illustration, tighten 73.5 to 83.4N m cylinder head bolts progressively to the specified torque. {7.5 to 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 21.7lbf ft]...

  • Page 112: Reassembling Rocker Shaft Assembly

    REASSEMBLY OF BASIC ENGINE 4.9 Reassembling rocker shaft assembly Install the rocker shaft assembly in the reverse order of the Rocker arm disassembly sequence, observing the followings: Rocker stay (1) Apply engine oil to the rocker shaft. Rocker shaft spring (2) Install the rocker shaft assembly in the same position as Rocker shaft it was.

  • Page 113: Adjusting Valve Clearance

    REASSEMBLY OF BASIC ENGINE 4.11 Adjusting valve clearance Adjust the valve clearance. For adjusting procedures, refer to "Adjustment and Operation." Adjusting valve clearance Model Ignition order Rotation angle Mark on gear case side TDC mark on crankshaft pulley side Timing mark 4.12 Installing rocker cover (1) Make sure that the gasket is firmly installed into the rocker cover.
  • Page 115 FUEL SYSTEM 1. Removing fuel system.....8-2 2.9.2 Reassembling torque spring set, 1.1 Removing fuel pipe and fuel injection double spring type ........8-22 nozzle............8-2 2.10 Inspecting fuel pump ......8-23 1.1.1 Removing fuel injection pipe ......8-3 2.11 Disassembling, inspecting and 1.1.2 Removing fuel injection nozzle....8-3 reassembling fuel filter 1.2 Removing fuel filter ........

  • Page 116: Removing Fuel System

    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: Fuel return gasket Replace: Holder gasket Removing fuel pipe and fuel injection nozzle Removing sequence 1 No.

  • Page 117: Removing Fuel Injection Pipe

    FUEL SYSTEM 1.1.1 Removing fuel injection pipe Remove the fuel injection pipe and fuel return pipe. Removing fuel injection pipe 1.1.2 Removing fuel injection nozzle Using a wrench, loosen the nozzle, and remove the fuel injection nozzle and holder gasket. Note: Using a wire or screwdriver remove the holder gasket.

  • Page 118: Removing Fuel Filter

    FUEL SYSTEM 1.2 Removing fuel filter Removing fuel filter Removing sequence 1 Fuel hose 2 Fuel filter 3 Fuel filter support...

  • Page 119: Removing Governor

    FUEL SYSTEM 1.3 Removing governor Replace Replace Fatigue and crack Replace Wear and damage of weight Fatigue and crack Wear and damage of sliding sleeve Replace Damage Wear and damage of sliding shaft contact and wear Removing governor Removing sequence 1 Tie rod cover 7 Tension lever 13 Governor lever...

  • Page 120: Disconnecting Tie Rod From Control Rack

    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. Tie rod clip Tie rod Control rack Disconnecting tie rod from control rack 1.3.2 Removing governor shaft and speed con- trol lever...

  • Page 121: Removing Fuel Injection Pump

    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...

  • Page 122: Disassembling, Inspecting And Reassembling Fuel System

    FUEL SYSTEM 2. Disassembling, inspecting and reassembling fuel system 2.1 Disassembling and inspecting fuel injection nozzles Wear Fatigue and perpendicularity 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...

  • Page 123: Inspecting And Adjusting Fuel Injection Valve Opening Pressure

    FUEL SYSTEM 2.1.1 Inspecting and adjusting fuel injection valve opening pressure Nozzle tester 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.

  • Page 124: Inspecting Fuel Spray Pattern Of Fuel Injection Nozzle

    FUEL SYSTEM 2.1.2 Inspecting fuel spray pattern of fuel injec- tion nozzle Defective spray pattern (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: ·...

  • Page 125: Reassembling Fuel Injection Nozzles

    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 lbf ft] Tightening torque 49.0 to 58.8 N m {5.0 to 6.0 kgf m} [36.2 to 43.4 lbf ft] Reassembling fuel injection nozzles 8-11...

  • Page 126: Inspecting Fuel Injection Pump On Engine8-12

    FUEL SYSTEM 2.3 Inspecting fuel injection pump on engine Do not disassemble the fuel injection pump unless it is absolutely necessary. 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) Observe exhaust color during sudden acceleration under No remarkable black smooke is...

  • Page 127: Removing Swivel Nipple

    FUEL SYSTEM 2.4.1 Removing swivel nipple (1) Grab the plunger of the pump housing with a vise. Pump housing Swivel nipple (2) Remove the swivel nipple from the pump housing. Vise Removing swivel nipple 2.4.2 Removing tappets (1) Turn the pump housing upside down and grab the Control rack Stop wire bracket housing with a vise.

  • Page 128: Removing Delivery Valve

    FUEL SYSTEM 2.4.4 Removing delivery valve Lock plate Pump (a) The delivery valve, plunger and plunger barrel are housing 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.

  • Page 129: Reassembling Fuel Injection Pump

    FUEL SYSTEM 2.5 Reassembling fuel injection pump 3.2 to 4.0 N m {0.3 to 0.4 kgf m} 4.9 to 6.9 N m 34.3 to 38.2 N m [2.2 to 2.9 lbf ft] {0.5 to 0.7 kgf m} {3.5 to 3.9 kgf m} [3.6 to 5.1 lbf ft] [25.3 to 28.2 lbf ft] 9.8 to 14.7 N m...

  • Page 130: Assembling Delivery Valve

    FUEL SYSTEM 2.5.2 Assembling delivery valve Delivery valve holder (a) Do not reuse the O-ring. O-ring (b) Install a new O-ring so that it is not cut with threads of the valve holder. Delivery valve spring Assemble the delivery valve, delivery valve gasket and delivery valve spring.

  • Page 131: Installing Tappet

    FUEL SYSTEM 2.5.5 Installing tappet (1) Install the tappet shim plate. Groove (2) Install the tappet so that its groove is positioned to face Tappet the tappet guide pin hole. Tappet shim plate Tappet guide pin hole (3) Push down the tappet, and install the tappet guide pin. Installing tappet Tappet Tappet...

  • Page 132: Tightening Delivery Valve Holder

    FUEL SYSTEM 2.5.7 Tightening delivery valve holder (1) Place the pump housing upright, and grab the housing 34.3 to 38.2 N m {3.5 to 3.9 kgf m} with a vise. [25.3 to 28.2 lbf ft] (2) Tighten the delivery valve holder to the specified Delivery valve Pump housing torque.

  • Page 133: Disassembling And Inspecting Governor Cover

    FUEL SYSTEM 2.6 Disassembling and inspecting governor cover Fatigue and crack Replace: O-ring 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...

  • Page 134: Disassembling And Inspecting Torque Spring Set

    FUEL SYSTEM 2.8 Disassembling and inspecting torque spring set (Single spring type) Fatigue and crack (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...
  • Page 135 FUEL SYSTEM 2.9.1 Torque spring set, single spring type Reassemble the torque spring set of the single spring type as Adjusting Lock nut described in the following: screw Torque spring case (1) To lightly tighten adjusting screw, turn the adjusting screw with a screwdriver until you feel resistance.

  • Page 136: Reassembling Torque Spring Set, Double Spring Type

    FUEL SYSTEM 2.9.2 Reassembling torque spring set, double spring type Lock nut 7.8 to 11.8 N m Special nut Reassemble the torque spring set of the double spring type {0.8 to 1.2 kgf m} Torque spring case as described in the following. [5.8 to 8.7 lbf ft] Spring stopper (1) Screw in the adjusting screw so that the end of the...

  • Page 137: Inspecting Fuel Pump

    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.

  • Page 138: Disassembling, Inspecting And Reassembling Fuel Filter (Cock Switch Type, Push Botton)

    FUEL SYSTEM 2.11 Disassembling, inspecting and reassembling fuel filter (cock switch type, push botton) Air vent button Do not evulse Wash in a gas oil: Every 100 hrs Replace : Every 400 hrs Replace Replace Check for clogging (water and dust) Disassembling, inspecting and reassembling fuel filter (cock switch type, push botton) Disassembling sequence 1 Ring nut...

  • Page 139: Disassembling, Inspecting And Reassembling Fuel Filter (Cock Switch Type, Changover)

    FUEL SYSTEM 2.12 Disassembling, inspecting and reassembling fuel filter (cock switch type, changeover) Replace Do not evulse Replace Wash in a gas oil: Every 100 hrs Replace : Every 400 hrs Replace Check for clogging (water and dust) Disassembling, inspecting and reassembling fuel filter (cock switch type, changeover) Disassembling sequence 1 Ring nut 5 O-rings...

  • Page 140: Installing Fuel System

    FUEL SYSTEM 3. Installing fuel system 3.1 Installing fuel injection pump Installing fuel injection pump 8-26...

  • Page 141: Installing Governor

    FUEL SYSTEM 3.2 Installing governor Replace 14.7 to 24.5N m {1.5 to 2.5kgf m} Replace [10.8 to 18.1lbf ft] Fatigue and crack Replace Wear and damage of weight Fatigue and crack Wear and damage of sliding sleeve Replace Damage Wear and damage of sliding shaft contact and wear Installing governor 8-27...

  • Page 142: Installing Speed Control Lever And Governor Shaft

    FUEL SYSTEM 3.2.1 Installing speed control lever and governor shaft Speed control Governor shaft cover (1) Insert the governor shaft into the gear case while lever Tension lever placing the governor lever and the tension lever. Grooved pin B (2) Drive the grooved pin A into the gear case. Governor spring lever Sealing cap (3) Drive new sealing cap into the gear case.

  • Page 143: Installing Torque Spring Set (Single Spring, Double Spring)

    FUEL SYSTEM 3.2.3 Installing torque spring set (Single spring, double spring) For installation and adjustment The torque spring set is properly adjusted at the fac- tory before shipment. Do not work on the torque spring set unless absolutely necessary. Do not wrok on this screw Adjust and reassemble the torque spring set as described in unless absolutely necessary.

  • Page 144: Installing Rack Set Screw

    FUEL SYSTEM 3.2.5 Installing rack set screw Torque set nut 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.

  • Page 145: Installing Fuel Filter

    FUEL SYSTEM 3.3 Installing fuel filter Installing fuel filter 8-31...

  • Page 146: Installing Fuel Pipe And Fuel Injection Nozzles

    FUEL SYSTEM 3.4 Installing fuel pipe and fuel injection nozzles 24.5 to 29.4 N m 20.6 to 24.5 N m {2.5 to 3.0 kgf m} {2.1 to 2.5 kgf m} [18.1 to 21.7 lbf ft] [15.2 to 18.1 lbf ft] Installing fuel pipe and fuel injection nozzles 3.4.1 Installing fuel injection nozzle...
  • Page 147 LUBRICATION SYSTEM 1. Removing lubrication system ..9-2 1.1 Removing oil filter, relief valve and oil pressure switch ........9-2 1.1.1 Removing oil filter........9-3 1.1.2 Removing relief valve .........9-3 1.1.3 Removing oil pressure switch ....9-3 1.2 Removing oil pump, oil pan and oil screen9-4 1.2.1 Removing oil pump ........9-4 2.

  • Page 148: Removing Lubrication System

    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...

  • Page 149: Removing Oil Filter

    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. Oil filter Removing oil filter 1.1.2 Removing relief valve Remove the plug from the gear case and take out the relief spring and relief plunger.

  • Page 150: Removing Oil Pump, Oil Pan And Oil Screen9-4

    LUBRICATION SYSTEM 1.2 Removing oil pump, oil pan and oil screen Replace 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 1.2.1 Removing oil pump...

  • Page 151: Disassembling, Inspecting And Reassembling Lubrication System

    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...

  • Page 152: Inspecting Relief Valve

    LUBRICATION SYSTEM 2.2 Inspecting relief valve (1) Check the relief valve and its seat for contact. Check Oil pump inner gear Oil pump housing the spring for fatigue and damage. If faulty, replace the Relief relief valve with new one. spring (2) Measure the relief valve opening pressure.

  • Page 153: Installing Lubrication System

    LUBRICATION SYSTEM 3. Installing lubrication system 3.1 Installing oil pump, oil pan and oil screen 7.8 to 9.8N m Replace {0.8 to 1.0kgf m} [5.8 to 7.2 lbf ft] Replace Installing oil pump, oil pan and oil screen 3.1.1 Installing oil pump Install the oil pump inner gear, oil pump outer gear and oil Oil pump inner gear Oil pump housing...

  • Page 154: Installing Oil Filter, Relief Valve And Oil Pressure

    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 lbf ft] 39.2 to 49.0 N m {4.0 to 5.0 kgf m} [29 to 36 lbf ft] Installing oil filter, relief valve and oil pressure 3.2.1 Installing oil pressure switch...

  • Page 155: Installing Oil Filter

    LUBRICATION SYSTEM 3.2.3 Installing oil filter (1) Apply a light coating of engine oil to the filter 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.
  • Page 157 COOLING SYSTEM 1. Removing cooling system .....10-2 1.1 Removing cooling fan, fan pulley, V-belt, thermostat, thermoswitch and water pump ..........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 ...... 10-4 2.4 Inspecting thermoswitch ......

  • Page 158: Removing Cooling System

    COOLING SYSTEM 1. Removing cooling system 1.1 Removing cooling fan, fan pulley, V-belt, thermostat, thermoswitch and water pump Replace Replace 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...

  • Page 159: Disassembling, Inspecting And Reassembling Cooling System

    COOLING SYSTEM 2. Disassembling, inspecting and reassembling cooling system 2.1 Disassembling and inspecting thermostat Replace Disassembling and inspecting thermostat Disassembling sequence 1 Thermostat cover 2 Thermostat 3 Thermostat case 2.2 Inspecting thermostat Stir hot water well. Be careful of burns or a fire when measuring tempera- ture, as it involves a high-temperature and open flame.

  • Page 160: Reassembling Thermostat

    COOLING SYSTEM 2.3 Reassembling thermostat 8 to 10 N m {0.8 to 1.0 kgf m} [5.8 to 7.2 lbf 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.

  • Page 161: Installing Cooling System

    COOLING SYSTEM 3. Installing cooling system 3.1 Installing cooling fan, fan pulley, V-belt, thermostat, thermoswitch and water pump Replace Replace Replace 19.6 to 29.4 N m {2.0 to 3.0 kgf m} [14 to 22 lbf m] Installing cooling fan, fan pulley, V-belt, thermostat, thermoswitch and water pump 10-5...
  • Page 163 INLET AND EXHAUST SYSTEMS 1. Removing inlet and exhaust systems ......11-2 1.1 Removing inlet cover and exhaust manifold........11-2 2. Disassembling, inspecting and reassembling inlet and exhaust systems ......11-3 2.1 Inspecting inlet cover and exhaust manifold........11-3 2.2 Measuring distortion of inlet and exhaust manifold........

  • Page 164: Removing Inlet And Exhaust Sysytems

    INLET AND EXHAUST SYSTEMS 1. Removing inlet and exhaust systems 1.1 Removing inlet cover and exhaust manifold Replace Replace Replace Replace Replace Replace Replace Replace Removing inlet cover and exhaust manifold Removing sequence 1 Inlet pipe 2 Inlet cover 3 Exhaust manifold 4 Exhaust elbow 11-2...

  • Page 165: Disassembling, Inspecting And Reassembling Inlet And Exhaust Systems

    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 Crack, damage corrosion and corrosion Crack, damage and corrosion Crack, damage, contamination, dirt adhesion and corrosion Inspecting inlet cover and exhaust manifold 2.2 Measuring distortion of inlet and exhaust...

  • Page 166: Installing Inlet And Exhaust Systems

    INLET AND EXHAUST SYSTEMS 3. Installing inlet and exhaust systems 3.1 Installing inlet cover and exhaust manifold Replace 7.8 to 9.8N m {0.8 to 1.0kgf m} Replace [6 to 7 lbf ft] Replace Replace Replace Replace 7.8 to 9.8N m Replace {0.8 to 1.0kgf m} Replace...
  • Page 167 ELECTRICAL SYSTEM 1. Removing electrical system ..12-2 2.4.14 Inspecting insulation of magnetic switch 1.1 Removing starter........12-2 (between M terminal and B terminal)..12-17 1.2 Inspection before removing alternator 2.5 Reassembling starter (A007TA0171B (12V-40A), (M000T60481 (12V-1.2kW), A007TA8271A (24V-25A)) ..... 12-3 M001T68381 (12V-1.7kW))....
  • Page 168 ELECTRICAL SYSTEM 2.8.15 Inspecting continuity of magnetic switch 3.4 Installing stop solenoid (ETS type) ..12-50 (between M terminal and case) .....12-33 3.4.1 Procedure for installing stop solenoid 2.8.16 Inspecting insulation of magnetic switch (ETS type) ..........12-50 (between M terminal and B terminal) ..12-33 3.4.2 Verification after reassembly (ETS type)12-51 2.9 Reassembling starter 3.5 Installing alternator .......12-52...

  • Page 169: Removing Electrical System

    ELECTRICAL SYSTEM 1. Removing electrical system 1.1 Removing starter Removing starter Removing sequence 1 Harness 2 Starter 12-3...

  • Page 170: Inspection Before Removing Alternator (A007Ta0171B (12V-40A), A007Ta8271A (24V-25A))

    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.

  • Page 171: Inspecting Regulated Voltage

    ELECTRICAL SYSTEM 1.2.3 Inspecting regulated voltage (1) Disconnect the battery (+) terminal, and connect an ammeter. Ammeter (2) Connect a volt meter to terminal L ground line. Alternator (3) Make sure that the volt meter indicates 0 when the Lamp starter switch is OFF position.

  • Page 172: Removing Alternator

    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...

  • Page 173: Removing Glow Plug

    ELECTRICAL SYSTEM 1.5 Removing glow plug Removing glow plug Removing sequence 1 Glow plug plate 2 Glow plug 12-7...

  • Page 174: Disassembling, Inspecting And Reassembling Electrical System

    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 Battery Disconnect the lead illustration.
  • Page 175 ELECTRICAL SYSTEM 2.1.2 Inspecting magnetic switch 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 Connect the starter to the circuit as shown in the...

  • Page 176: No Load Test

    ELECTRICAL SYSTEM 2.1.3 No load test Switch Use as thick a wire as possible and firmly tighten each Ammeter terminal. When detecting the rotation at the tip of the pinion, be Voltmeter careful, as the pinion pops out during operation. Battery (1) Connect the starter to the circuit as shown in the Starter...

  • Page 177: Disassembling And Inspecting Starter (M000T60481 (12V-1.2Kw), M001T68381 (12V-1.7Kw))

    ELECTRICAL SYSTEM 2.2 Disassembling and inspecting starter (M000T60481 (12V-1.2kW), M001T68381 (12V-1.7kW)) Looseness, abnormal Broken wire, short Broken coil wire noise and rotation circuit and ground of condition of bearing coil, roughness and wear of commutator, and damage and wear of gear Wear Pinion gear wear...

  • Page 178: Preparation Before Disassembling

    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. Preparatory work before disassembly 2.3.1 Removing pinion set The starter generates heat if it is left with current being applied.

  • Page 179: Removing Rear Bracket

    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 Screw Through bolt Removing rear bracket 2.3.4 Removing brush holder and brush assem- Apply a socket (of the same diameter as the commutator) to Socket the commutator of the armature.

  • Page 180: Removing Overrunning Clutch

    ELECTRICAL SYSTEM 2.3.6 Removing overrunning clutch Pull out the internal gear, gear shaft, overrunning clutch and Lever lever as an assembly from the front bracket, and remove the Overrunning clutch lever. Internal gear Gear shaft Front bracket Removing overrunning clutch 2.3.7 Removing gear shaft (1) Remove the stopper ring and then the stopper.

  • Page 181: Inspecting And Repairing Starter (M000T60481 (12V-1.2Kw), M001T68381 (12V-1.7Kw))

    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. Measure the length of the Item...

  • Page 182: Measuring Commutator Radial Runout

    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. 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.

  • Page 183: Checking Armature Coil

    ELECTRICAL SYSTEM 2.4.7 Checking armature coil (1) Inspect the armature coil using a growler. Iron plate Growler Hold a piece of iron plate against the armature core. If 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).

  • Page 184: Inspecting Overrunning Clutch

    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. Inspecting overrunning clutch 2.4.10 Inspecting pinion Check the pinion for wear and damage.

  • Page 185: Reassembling Starter (M000T60481 (12V-1.2Kw), M001T68381 (12V-1.7Kw))

    ELECTRICAL SYSTEM 2.5 Reassembling starter (M000T60481 (12V-1.2kW), M001T68381 (12V-1.7kW)) 4.1 to 7.6 N m 8.8 to 12.7 N m {0.42 to 0.77 kgf m} {0.90 to 1.30 kgf m} [7 to 9 lbf ft] Apply Multemp PS2 [7 to 8 lbf ft] (Kyodo Yushi made) 4.4 to 7.1 N m or equivalent.

  • Page 186: Installing Pinion

    ELECTRICAL SYSTEM 2.5.2 Installing pinion Stopper Stopper ring Before assembling, apply grease to the inner race Shaft of groove of the front bracket bearing. overrunning clutch Be sure to use a new stopper ring. Do not reuse the Pinion stopper ring that has been removed. (1) Put the overrunning clutch through the front bracket.

  • Page 187: Installing Yoke And Armature

    ELECTRICAL SYSTEM 2.5.4 Installing yoke and armature (1) Install the planetary gears on the gear shaft. Packing (2) Install the packing on the internal gear. Plate (3) Install the plate and packing. (4) Install the yoke on the front bracket. (5) Apply grease to the armature shaft end and install a ball Armature on it.
  • Page 188 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 Battery Disconnect the lead illustration. with a terminal (2) When the switches SW1 and SW2 are turned ON, the connected to pinion springs out to the cranking position and the terminal M.

  • Page 189: 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. Disconnect the lead (1) Connect the starter to the circuit as shown in the with a terminal connected to illustration.
  • Page 190 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) Disconnect the connector of M terminal. Battery (2) Pull-in test Connect the starter to the circuit as shown in the Disconnect the connector.

  • Page 191: No Load Test

    ELECTRICAL SYSTEM 2.6.3 No load test Use as thick a wire as possible and firmly tighten each Ammeter terminal. When detecting the rotation at the tip of the pinion, be careful, as the pinion pops out during operation. Starter (1) Connect the starter to the circuit as shown in the illustration.

  • Page 192: Disassembling And Inspecting Starter (M002T66071 (24V-3.2Kw))

    ELECTRICAL SYSTEM 2.7 Disassembling and inspecting starter (M002T66071 (24V-3.2kW)) Broken coil wire Wear Looseness, abnormal noise and rotation condition of bearing Metal wear Wear and damage of gear Pinion gear wear Wear and damage of gear Rotation condition Replace: Stopper ring Wear of brushes, rust and deterioration of spring and Rotation...

  • Page 193: Preparation Before Disassembling

    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. Preparation before disassembling 2.7.2 Removing magnetic switch Disconnect the leads, and remove the magnetic switch. Connector Magnetic switch...

  • Page 194: Removing Brushes, Brush Holder, Yoke And Armature

    ELECTRICAL SYSTEM 2.7.4 Removing brushes, brush holder, yoke and armature While lifting the two brushes, remove the yoke and brush Brush Brush holder holder assembly. Then, pull out the armature. Yoke Armature Removing brushes, brush holder, yoke and armature 2.7.5 Removing ball bearing Remove the bearings from both ends of the armature using a Rear bearin...

  • Page 195: Removing Center Bracket

    ELECTRICAL SYSTEM 2.7.7 Removing center bracket Remove the screw, then remove the center bracket. Once the Center bracket center bracket is removed, the adjusting washer that adjusts the pinion shaft end play can be removed. Adjusting washer Screw Removing center bracket 2.7.8 Removing reduction gear and spring set...

  • Page 196: Inspecting And Repairing Starter (M002T66071 (24V-3.2Kw))

    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...

  • Page 197: Measuring Commutator Radial Runout

    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.

  • Page 198: Checking Armature Coil

    ELECTRICAL SYSTEM 2.8.7 Checking armature coil (1) Inspect the armature coil using a growler. Iron plate Growler Hold a piece of iron plate against the armature core. If tester the iron plate vibrates, replace the armature with a new one. Checking armature coil for short circuit (2) Check that there is no continuity between the commutator and the shaft (core).

  • Page 199: Inspecting Continuity Of Yoke Assembly

    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. Checking field coils for breaks 2.8.9 Inspecting insulation between yoke body and brush...

  • Page 200: Inspecting Overrunning Clutch

    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. Inspecting overrunning clutch 2.8.12 Inspecting pinion Check the pinion for wear and damage.

  • Page 201: (M002T66071 (24V-3.2Kw))

    ELECTRICAL SYSTEM 2.9 Reassembling starter (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.

  • Page 202: Installing Lever And Pinion Shaft

    ELECTRICAL SYSTEM 2.9.2 Installing lever and pinion shaft Reassemble the lever to the pinion shaft and insert them into the front bracket. Front bracket Pinion shaft Lever Installing lever and pinion shaft 2.9.3 Installing pinion (1) Install the spring, pinion and pinion stopper on the pinion shaft.

  • Page 203: Adjusting Pinion Shaft End Play

    ELECTRICAL SYSTEM 2.9.6 Adjusting pinion shaft end play Adjust the end play (thrust gap) to 0.5 mm [0.0197 in.] or Adjusting Reduction gear less by inserting adjusting washers between the center washer bracket and reduction gear. (1) Install the pinion shaft, reduction gear, washer and snap Washer ring onto the center bracket.

  • Page 204: Installing Rear Bracket

    ELECTRICAL SYSTEM 2.9.9 Installing rear bracket Install the rear bracket to the yoke, and tighten the through Through bolt 4.4 to 7.1N m bolt and the brush holder screws. {0.45 to 0.72kgf m} [3 to 5lbf ft] Screw 2.4 to 4.4N m {0.24 to 0.45kgf m} [2 to 3lbf ft] Installing rear bracket...

  • Page 205: Disassembling And Inspecting Alternator12-38

    ELECTRICAL SYSTEM 2.10 Disassembling and inspecting alternator Rotation condition Dirt, damage and seizure of slip ring and coil resistance Crack, damage Crack, damage Rotation condition Deformation and damage Rotation condition Short circuit and open circuit Sliding state and wear of brushes Broken wire and ground of coil Disassembling and inspecting alternator Disassembling sequence...

  • Page 206: Separating Front Bracket From Stator

    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.

  • Page 207: Removing Stator

    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. Stator core Rectifier Soldering Removing stator 2.10.6 Removing regulator assembly Remove the screws of the regulator assembly and then Screws remove the regulator assembly.

  • Page 208: Inspecting And Repairing Alternator

    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.

  • Page 209: Inspecting Stator

    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.

  • Page 210: Replacing Brushes

    ELECTRICAL SYSTEM 2.11.5 Replacing brushes (1) To remove the brush and the spring, unsolder the brush lead. Soldering Brush holder Replacing brushes (2) To install a new brush, push the brush into the brush holder as shown in the illustration, and then solder the Brush lead to the brush.

  • Page 211: Reassembling Alternator

    ELECTRICAL SYSTEM 2.12 Reassembling alternator Reassembling alternator 12-45...

  • Page 212: Installing Rectifier Assembly And Regulator Assembly

    ELECTRICAL SYSTEM 2.12.1 Installing rectifier assembly and regulator assembly Regulator Install the rectifier assembly and regulator assembly on the 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.

  • Page 213: Installing Rear Bearing

    ELECTRICAL SYSTEM 2.12.4 Installing rear bearing Press-fit the rear bearing to the rotor. Rotor Rear bearing Installing 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. Front bracket (2) Install the spacer and pulley, and secure the pulley with a nut.

  • Page 214: Inspecting Glow Plug

    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 0.2 Ω 12 V Resistance value 4.5 Ω...

  • Page 215: Installing Electrical System

    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 lbf ft] 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...

  • Page 216: Installing Stop Solenoid

    ELECTRICAL SYSTEM 3.3 Installing stop solenoid (ETR type) These areas must be free from sealants. Control rack Cylinder block 39.2 to 49.0 N m {4.0 to 5.0 kgf m} [28.9 to 36.2 lbf ft] Approx. 0.3 to 0.7 mm Stop solenoid [0.012 to 0.028 in.] Threaded portion: Apply sealant.
  • Page 217 ELECTRICAL SYSTEM 3.4 Installing stop solenoid (ETS type) These areas must be Cylinder block free from a sealant. 39.2 to 49.0N m Control rack {4.0 to 5.0kgf m} [28.9 to 36.2lbf ft] Do not allow wash fluid to enter the inside of the solenoid from the clearance.
  • Page 218 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.
  • Page 219 ELECTRICAL SYSTEM 3.5 Installing alternator Installing alternator 3.6 Installing starter Installing starter 12-53...
  • Page 221 ADJUSTMENT AND OPERATION 1. Inspection and adjustment of engine ...........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 .......13-3 1.2 Inspecting fuel injection timing ....13-4 1.3 Adjusting fuel injection timing....13-5 1.4 Inspecting and adjusting low idle speed and high idle speed........

  • Page 222: Inspection And Adjustment Of Engine

    ADJUSTMENT AND OPERATION 1. Inspection and adjustment of engine 1.1 Inspecting and adjusting valve clearance 1.1.1 Preparation for valve clearance inspection Cylinder head bolt (main) (1) Inspect and adjust the valve clearance when the engine 73.5 to 83.4N m is cold. {7.5 to 8.5kgf m}[54.2 to 61.5lbf ft] (2) Slightly loosen cylinder head bolts and tighten them to the specified torque in the order as shown in the...

  • Page 223: Inspecting Valve Clearance

    ADJUSTMENT AND OPERATION 1.1.2 Inspecting valve clearance (1) Set No. 1 cylinder to the top dead center in compression Model Ignition order Rotation angle 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 Mark on gear...

  • Page 224: Inspecting Fuel Injection Timing

    ADJUSTMENT AND OPERATION 1.2 Inspecting fuel injection timing Valve To prevent the outflow of fuel, stop the fuel supply before removing the delivery valve. Delivery Valve seat valve The fuel injection timing varies with the output, speed and other engine specifications. Be sure to check the engine's specification sheet.

  • Page 225: Adjusting 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.

  • Page 226: 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 by Mitsubishi are authorized to perform checking and adjustment of these settings.

  • Page 227: Bleeding Fuel System

    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 closest to the fuel tank: the fuel filter the first and the fuel injection pump the last.

  • Page 228: Bleeding Air From Fuel Injection Pump

    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. Air vent screw Note: Air in the fuel injection pipe and fuel injection nozzle is automatically discharged by cranking of the engine.

  • Page 229: Adjusting V-Belt Tension

    ADJUSTMENT AND OPERATION 1.6 Adjusting V-belt tension (1) Loosen the adjusting bolt and fixing bolt of the Water pump Adjusting bolt pulley alternator. Loop the V-belt over the water pump pulley, Alternator pulley alternator pulley and crankshaft pulley. Approx. (2) With the alternator pushed toward the V-belt tension 10 mm [0.39 in.] side, tighten the adjusting bolt at an appropriate...

  • Page 230: Break-In Operation

    ADJUSTMENT AND OPERATION 2. Break-in operation 2.3 Break-in operation time After the engine is overhauled, couple the engine to the dynamometer, and run the engine for break-in operation and The relationship between the load in break-in operation and inspection. the operation time is as shown below. 2.1 Starting up Break-in operation time (1) Before starting the engine, check the levels of coolant,...

  • Page 231: Performance Test (Jis Standard)

    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 D0006-2)."...

  • Page 232: Calculation Of Corrected Power

    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.
  • Page 233 TROUBLESHOOTING 1. Troubleshooting ......14-2 1.1 Before troubleshooting......14-2 1.2 Starting trouble........14-3 1.2.1 Check items before troubleshooting..14-3 1.2.2 Problem: Starting trouble ......14-3 1.3 Knocking ..........14-4 1.3.1 Check items before troubleshooting..14-4 1.3.2 Problem: Knocking ........14-4 1.4 Overheating ........... 14-5 1.4.1 Check items before troubleshooting..14-5 1.4.2 Problem: Overheating ......14-5 1.5 Excessive black smoke......

  • Page 234: Troubleshooting

    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. (b) 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...

  • Page 235: Starting Trouble

    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 Is power applied to the glow plug Is the preheating Inspect key switch, wire immediately after the key...

  • Page 236: Knocking

    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...

  • Page 237: Overheating

    TROUBLESHOOTING 1.4 Overheating 1.4.1 Check items before troubleshooting (1) Quantity and leakage of coolant (2) Loosening of fan belt (3) Clogging of radiator fins (4) Concentration of LLC (5) Clogging of muffler (6) Quantity and degradation of engine oil (7) Swirling of cooling air (8) Thermostat malfunction 1.4.2 Problem: Overheating...

  • Page 238: Excessive Black Smoke

    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 Is the smoke set amount of Adjust smoke set the fuel injection pump normal? Is the engine correctly adjusted Adjust engine (valve clearance excessive,...

  • Page 239: Idling Malfunction

    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 Is the engine correctly adjusted Adjust engine (engine idle speed, valve clearance and fuel injection timing)? Are fuel injection nozzles normal (spray state, Inspect fuel injection nozzles...

  • Page 240: Low Output

    TROUBLESHOOTING 1.7 Low output 1.7.1 Check items before troublshooting (1) Seizure of engine moving parts (2) Viscosity of engine oil too high (3) Use of poor quality fuel (4) Clogging of air cleaner element (5) Clogging of muffler (6) Powertrain malfunction 1.7.2 Problem: Low output Does fuel including the fuel amount...
  • Page 241 SUPPLEMENT INSPECTION RECORD SHEET（L-SERIES） No.1 Measurement of Cylinder Inside Diameter ····························································Supplement- 2 No.2 Measurement of Valve Guide Inside Diameter and Valve Stem Outside Diameter···································································································Supplement- 3 No.3 Measurement of Valve Seat Angle, Valve Sinkage and Valve Margin ···················Supplement- 4 No.4 Measurement of Distortion of Cylinder Head Bottom Surfaces ·····························Supplement- 5 No.5 Measurement of Clearance Between Connecting Rod Bearing Inside Diameter and Crankshaft Pin Outside···················································································Supplement- 6 No.6 Measurement of Rocker Arm Inside Diameter and Rocker Shaft...
  • Page 242 No.1 INSPECTION RECORD SHEET Engine Model Company Date Serial No. Inspection Measurement of Cylinder Inside Diameter Unit mm [in.] Point Measuring Positions Standard Nominal Remarks Standard Limit Value φ65 65.00 to 65.03 L2A, L3A [2.5591 to 2.5602] [2.56] Cylinder Repair. limit: φ70 +0.7 70.00 to 70.03...
  • Page 243 No.2 INSPECTION RECORD SHEET Engine Model Company Date Serial No. Measurement of Valve Guide Inside Diameter and Valve Inspection Unit mm [in.] Point Stem Outside Diameter Measuring Positions Standard Nominal Standard Limit Value φ6.6 6.600 to 6.615 Inlet – [0.260] [0.2598 to 0.2604] Valve Guide Inside Diameter...
  • Page 244 No.3 INSPECTION RECORD SHEET Engine Model Company Date Serial No. Measurement of Valve Seat Angle, Valve Sinkage and Inspection Unit mm [in.] Point Valve Margin Measuring Positions Standard Standard Limit Valve Seat Angle 44° – 0.4 to 0.6 Valve Sinkage –...
  • Page 245 No.4 INSPECTION RECORD SHEET Engine Model Company Date Serial No. Measurement of Distortion of Cylinder Head Bottom Inspection Unit mm [in.] Point Surfaces Measuring Positions Standard Standard Limit Distortion of 0.05 or less 0.10 Cylinder Head [0.0020] [0.0039] Bottom Surfaces Measured Values Part Name Distortion of Cylinder Head Bottom Surfaces...
  • Page 246 No.5 INSPECTION RECORD SHEET Engine Model Company Date Serial No. Measurement of Clearance Between Connecting Rod Inspection Unit mm [in.] Point Bearing Inside Diameter and Crankshaft Pin Outside Measuring Positions Standard Nominal Value Standard Limit φ40 40.008 to 40.036 Connecting Rod Bearing Inside Diameter –...
  • Page 247 No.6 INSPECTION RECORD SHEET Engine Model Company Date Serial No. Measurement of Rocker Arm Inside Diameter and Rocker Inspection Unit mm [in.] Point Shaft Outside Diameter Measuring Positions Standard Nominal Standard Limit Value φ12 Rocker Arm Inside 12.013 to 12.035 –...
  • Page 248 No.7 INSPECTION RECORD SHEET Engine Model Company Date Serial No. Measurement of Piston Pin Bore Diameter and Piston Pin Inspection Unit mm [in.] Point Outside Diameter Measuring Positions Standard Nominal Value Standard Limit φ18 18.013 to 18.019 L2A, L3A – L2C, L3C [0.71] [0.7092 to 0.7094]...
  • Page 249 No.8 INSPECTION RECORD SHEET Engine Model Company Date Serial No. Inspection Measurement of Valve Clearance Unit mm [in.] Point Measuring Positions Standard Standard 0.25 Inlet [0.0098] Valve Clearance (Cold Setting) 0.25 Exhaust [0.0098] Measured Values Valve Clearance Inlet Exhaust Before Adjustment After Adjustment Before Adjustment After Adjustment...
  • Page 250 No.9 INSPECTION RECORD SHEET Engine Model Company Date Serial No. Measurement of Valve Opening Pressure of Fuel Injection Inspection Unit {kgf/cm Point Nozzle [psi] Measuring Positions Standard Nominal Value Standard 13.73 13.73 to 14.73 Valve Opening {140} {140 to 150} Pressure [1992] [1992 to 2134]...
  • Page 251 No.10 INSPECTION RECORD SHEET Engine Model Company Date Serial No. Measurement of Camshaft Journal Outside Diameter to Inspection Unit mm [in.] Point Cylinder Block Camshaft Bore Clearance (L2) Measuring Positions Standard Nominal Standard Limit Value φ34 33.925 to 33.950 No.2 –...
  • Page 252 No.11 INSPECTION RECORD SHEET Engine Model Company Date Serial No. Measurement of Camshaft Journal Outside Diameter to Inspection Unit mm [in.] Point Cylinder Block Camshaft Bore Clearance (L3) Measuring Positions Standard Nominal Standard Limit Value φ34 33.925 to 33.950 No.2 –...
  • Page 253 No.12 INSPECTION RECORD SHEET Engine Model Company Date Serial No. Inspection Measurement of Crankshaft End Play Unit mm [in.] Point Measuring Positions Standard Standard Limit 0.050 to 0.175 0.500 Crankshaft End Play [0.0020 to 0.0069] [0.0197] Measured Values Disassembling During Reassembling Approved Checked Measured...
  • Page 254      ...

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