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Mitsubishi Heavy Industries L2 Service Manual

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MITSUBISHI DIESEL ENGINE
SERVICE MANUAL
L2/L3 MODELS
MITSUBISHI HEAVY INDUSTRIES, LTD
08/2004

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Summary of Contents for Mitsubishi Heavy Industries L2

  • Page 1 MITSUBISHI DIESEL ENGINE SERVICE MANUAL L2/L3 MODELS MITSUBISHI HEAVY INDUSTRIES, LTD 08/2004...
  • Page 2 FOREWORD This service manual is written to familiarize you with the maintenance of your L-series Diesel Engine. If the engine is carefully maintained, it will deliver a long productive life and efficient performance marked by power and economy. Before attempting to inspect, disassemble, or repair the engine, read this manual carefully to learn more about the engine and how to care for it properly.
  • Page 3 WARNING SIGNS The following safety related signs are used in this manual to emphasize important and critical instructions: Indicates the most serious specific potential hazard which could result in DANGER serious personal injury or death. Indicates a specific potential hazard which could result in personal injury. WARNING Indicates operating procedures, practices, etc.
  • Page 4 TERMS USED IN THIS MANUAL Before reading this manual, note that the following special terms are used in dimensional 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.
  • Page 5 SUMMARY OF MANUAL CONTENTS Section Contents General Engine model and engine number, external views, features, engine specifications, maintenance, troubleshooting Engine main parts General, rocker arms and rocker shaft, cylinder head, valves and valve springs, inlet manifold and exhaust manifold, gear case and oil pump, timing gear, camshaft (valve camshaft and injection pump camshaft), piston and connecting rod, crankshaft, cylinder block Lubrication system General, oil filter and oil pressure switch...

  • Page 6: Table Of Contents

    ................ 12 Model, classification and use ....................12 Engine model embossment and engine number stamp............12 EXTERNAL VIEW ........................14 Engine L2..........................14 Engine L3..........................15 FEATURES ..........................16 Aim of development ....................... 16 Features of the new series..................... 16 SPECIFICATIONS ........................
  • Page 7 TABLE OF CONTENTS Repair of valve seat ....................... 47 Installation..........................48 VALVES AND VALVE SPRINGS ..................49 10.1 Disassembly........................... 49 10.2 Removal..........................50 10.3 Inspection and repair ......................50 10.4 Installation..........................51 INLET MANIFOLD AND EXHAUST MANIFOLD ............. 52 11.1 Disassembly........................... 52 11.2 Inspection..........................
  • Page 8 GENERAL ............................ 82 18.1 Specification........................... 82 18.2 Special tools........................... 82 OIL FILTER AND OIL PRESSURE SWITCH ..............83 19.1 Disassembly........................... 83 19.2 Removal and installation......................84 19.3 Inspection..........................84 FUEL SYSTEM GENERAL ............................ 86 20.1 Specifications......................... 86 20.2 Disassembly........................... 88 FUEL INJECTION PUMP ......................
  • Page 9 WATER PUMP ......................... 109 27.1 Removal and installation...................... 109 27.2 Inspection..........................109 THERMOSTAT ......................... 110 28.1 Removal and installation...................... 110 28.2 Inspection..........................110 WATER TEMPERATURE GAGE UNIT AND THERMOSWITCH ......111 29.1 Inspection of water temperature gage unit................111 29.2 Inspection of thermoswitch ....................111 AIR CLEANER AIR CLEANER .........................
  • Page 10 36.2 Glow timer..........................141 36.3 Glow relay ..........................141 SERVICE DATA PERIODIC INSPECTION CHART ..................144 37.1 Periodic service chart......................144 SPECIFICATIONS AND MAINTENANCE STANDARDS ..........145 38.1 Engine Main Parts........................ 145 38.2 Lubrication System ......................148 38.3 Fuel System ......................... 148 38.4 Governor System .........................
  • Page 11 10 / 155 ENGLISH Service Manual Mitsubishi L-Series diesel engines Version 08/2004...
  • Page 12 GENERAL ENGLISH 11 / 155 Service Manual Mitsubishi L-Series diesel engines Version 08/2004...

  • Page 13: General

    ENGINE MODEL AND ENGINE NUMBER GENERAL GENERAL ENGINE MODEL AND ENGINE NUMBER Model, classification and use 1.1.1 Engine model Model Application 11,12 - For Agricultural 31, 32 - For Industrial 61, 62 - For Export only Table 1 Engine model and usage 1.1.2 Engine model and application codes L 3 C –...
  • Page 14 GENERAL ENGINE MODEL AND ENGINE NUMBER 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.

  • Page 15: External View

    EXTERNAL VIEW GENERAL GENERAL EXTERNAL VIEW Engine L2 Engine hangers Air vent screw Water pump Fuel injection pump Fuel injector Side oil filler Air inlet cover Coolant drain plug Stop solenoid Oil pressure switch Fuel filter Dipstick Oil filter Oil drain plug...

  • Page 16: Engine L3

    GENERAL EXTERNAL VIEW Engine L3 Engine hangers Air vent screw Water pump Fuel injection pump Fuel injector Side oil filler Air inlet cover Oil pressure switch Stop solenoid Dipstick Fuel filter Coolant drain plug Oil drain plug Oil filter REAR FRONT RIGHT SIDE VIEW Top oil filler...

  • Page 17: Features

    FEATURES GENERAL GENERAL FEATURES Aim of development The L-series designs are compact, lightweight engines suitable for superseding gasoline engines to power lawn mowers, vehicles, etc. The high-speed (3600 min continuous) engines are also available for generators, welders, and marine use. The L series are the smallest and the lightest water-cooled diesel engines in the world.
  • Page 18 GENERAL FEATURES 3.2.4 Multipurpose engine The L-series engine can be equipped with various kinds of optional devices. • Key-OFF stop system (Fuel cutoff valve) • Torque spring • Manual stop lever Figure 4 Nozzle holders and return pipe Service Manual Mitsubishi L-Series diesel engines ENGLISH 17 / 155 Version 08/2004...

  • Page 19: Specifications

    SPECIFICATIONS GENERAL GENERAL SPECIFICATIONS Model System Item Type 4-cycle, water-cooled, vertical, overhead valve, diesel engine Combustion chamber Swirl chamber type No. of cylinders Bore x Stroke (mm) 65x70 70x70 76x70 65x70 70x70 76x70 ENGINE PROPER Total displacement (l) 0.464 0.538 0.635 0.696 0.808...

  • Page 20: Maintenance

    GENERAL MAINTENANCE GENERAL MAINTENANCE Engine oil and oil filter 5.1.1 Checking and correcting the engine oil level Procedure Place the engine horizontally. Check the oil level with the oil level gage. If the oil level has fallen to the lower limit, add oil up to the upper limit.
  • Page 21 MAINTENANCE GENERAL Atm. temperature Viscosity classification Above 20°C [68°F] SAE30 5° to 20°C [41 to SAE20 Class CF 68°F] or CF-4 Below 5°C [41°F] SAE10W-30 All seasons SAE10W-30 Table 4 API classification 5.1.4 Replacing the oil filter When replacing the oil filter, use only the genuine replacement filter.

  • Page 22: Retightening The Cylinder Head Bolts

    [14.47 to 21.70 lbf·ft] M10 bolt 73.5 to 83.4 (7.5 to 8.5) [54.25 to 61.48] Figure 8 Cylinder head bolt tightening sequence (L2) M8 bolt 19.6 to 29.4 (2.0 to 3.0) [14.47 to 21.70] Table 8 Tightening torque M10 bolt: 73.5 to 83.4 N·m (7.5 to 8.5 kgf·m) Rocker stay [54.25 to 61.48 lbf·ft]...

  • Page 23: Adjusting The Valve Clearance

    When setting the top dead center for the No. 2 cylinder and that for the No. 3 cylinder, perform as follows: L2 (Two-cylinder engine) Turn the crankshaft 180° clockwise from TDC (Top Dead Center) of the No. 1 cylinder, to set the No.

  • Page 24: Adjusting The Fan Belt Tension

    GENERAL MAINTENANCE Adjusting the fan belt tension To check if the belt tension is appropriate, press the belt at a midpoint between the alternator pulley and crankshaft pulley with your thumb, and check that the amount of belt deflection is about 10 mm [0.3937 in.] (about 98 N (10 kgf) [22 lbf]).

  • Page 25: Replacing The Fuel Filter

    MAINTENANCE GENERAL Replacing the fuel filter 5.6.1 Cartridge type Replace the cartridge type filter as an assembly if accumulation of dust or water is in its element. Regular replacement interval is every 500 service hours of engine operation. Check the filter every 100 service hours and, if necessary, replace early.
  • Page 26 GENERAL MAINTENANCE Diaphragm type electromagnetic pump The diaphragm type electromagnetic pump should not be disassembled. Like the compact plunger- type pump mentioned above, check the pump for functions and fuel leak. Figure 18 Diaphragm type fuel pump Mechanical type fuel pump This type of fuel pump is installed with an adapter on the rear-end side of the fuel injection pump camshaft.

  • Page 27: Checking And Adjusting Injection Timing

    MAINTENANCE GENERAL Checking and adjusting injection timing To check and adjust injection timing, use the following procedure: Disconnect the No. 1 injection pipe. Remove the No. 1 delivery valve from the injection pump. Put back the valve holder only. CAUTION Figure 20 Removing delivery valve Be sure to shut off the fuel feed before removing the...

  • Page 28: Adjusting The Engine Speeds

    This instant is the real injection timing, which will come approx. 1° later than standard injection timing. Model L2 Model L3 min- Less than 2000 BTDC 15°...

  • Page 29: Checking And Adjustment Of Nozzles

    MAINTENANCE GENERAL After adjustment, perform engine acceleration and deceleration test to confirm that the engine is free from hunting and smoking. Checking and adjustment of nozzles To check and adjust the injection nozzles, use the following procedure: 5.9.1 Injection start pressure Remove the nozzle assembly to be tested from the cylinder head and set the nozzle on the nozzle tester.
  • Page 30 GENERAL MAINTENANCE 5.9.2 Chattering test Operate the tester handle at a speed of about one stroke per second. Needle valve oscillation If the fuel spray shows good atomization, making intermittent sounds, and oscillations of the needle valve are transmitted to the handle, then the noz- zle is considered as normal.
  • Page 31 MAINTENANCE GENERAL Special tool name Part No. Compression gage ST332270 adapter Table 16 Tools Crank the engine with the starting motor until a stable reading of the compression gage is obtained. After reading the gage, remove the compression gage and adapter. Put back the glow plug. Check all cylinders using the same procedure described above.

  • Page 32: Troubleshooting

    GENERAL TROUBLESHOOTING GENERAL TROUBLESHOOTING Hints on using the trouble- diagnosis chart As for diesel engines, trouble symptoms and causes are often so complicated that it will be difficult to locate the root cause by judging from a trouble symptom. For example, trouble symptoms caused by the faulty injection pump, faulty injection nozzles and improper cylinder compression, make the same kind of phenomenon.

  • Page 33: Hard Starting

    TROUBLESHOOTING GENERAL Hard starting 6.2.1 Matters to be checked before diagnosis Clogging of the air cleaner Coagulation of engine oil Use of poor-quality fuel Lowering of cranking speed 6.2.2 Diagnosis Does current flow in glow plug Does preheating system Inspect key switch, wiring and circuit as soon as key switch is operate properly? glow indicator.

  • Page 34: Knocking

    GENERAL TROUBLESHOOTING Knocking Diesel engines are usually accompanied by fuel combustion noise (diesel knocking sounds) because of its inherent mechanism. A trouble should be suspected only when the engine makes abnormally large sounds. 6.3.1 Matters to be checked before diagnosis Clogging of the air cleaner Use of poor-quality fuel (Low cetane number fuel such as used for burner)

  • Page 35: Overheating

    TROUBLESHOOTING GENERAL Overheating 6.4.1 Matters to be checked before diagnosis Lack of coolant and leakage Loosening of fan belt Clogging of radiator fins Wrong concentration of antifreeze solution Clogging of muffler Lack of engine oil and deterioration Lack of cooling air Defective thermostat 6.4.2 Diagnosis Is engine operating condition too heavy?

  • Page 36: Black-Smoky Exhaust

    GENERAL TROUBLESHOOTING Black-smoky exhaust 6.5.1 Matters to be checked before diagnosis Clogging of air cleaner element Use of poor-quality fuel Overload 6.5.2 Diagnosis Is smoke set of injection pump correct? Adjust smoke set. Is engine adjusted properly? Adjust engine. (Check for excessive valve clearance and improper injection timing.) Do injection nozzles operate properly? (Check for improper shape of fuel spray and for excessively high injection Inspect injection nozzles.

  • Page 37: Unsteady Idling

    TROUBLESHOOTING GENERAL Unsteady idling 6.6.1 Matters to be checked before diagnosis Faulty engine control system Too high viscosity of engine oil Use of poor-quality fuel 6.6.2 Diagnosis Is engine adjusted properly? Adjust engine. (Check for idling speed, valve clearance, and injection timing.) Do injection nozzles operate properly? Inspect injection nozzles.

  • Page 38: Low Output

    GENERAL TROUBLESHOOTING Low output 6.7.1 Matters to be checked before diagnosis Seizing of engine moving parts Too high engine oil viscosity Use of poor-quality fuel Clogging of air cleaner element Clogging of muffler Malfunctioning of drive system 6.7.2 Diagnosis Engine without fuel feed pump: Is gravitational flow of fuel normal? Is sufficient fuel flow in fuel...
  • Page 39 TROUBLESHOOTING GENERAL 38 / 155 ENGLISH Service Manual Mitsubishi L-Series diesel engines Version 08/2004...

  • Page 40: Engine Main Parts

    ENGINE MAIN PARTS ENGLISH 39 / 155 Service Manual Mitsubishi L-Series diesel engines Version 08/2004...

  • Page 41: General

    GENERAL ENGINE MAIN PARTS ENGINE MAIN PARTS GENERAL Specifications Model Item Material Special cast iron Combustion chamber type Swirl chamber CYLINDER HEAD Material of chamber Heat-resisting steel (press-fitted in cylinder head) Type of intake and exhaust ports Cross-flow type Heat-resisting steel (3600 min specification engines) VALVE Material...

  • Page 42: Special Tools

    ENGINE MAIN PARTS GENERAL Model Item No. 1 Semi-keystone type PISTON RINGS No. 2 Plain type Oil ring With coil expander Type Gear type OIL PUMP Drive Direct drive by crankshaft Crankshaft gear Number of teeth: 26 Idle gear Number of teeth: 40 TIMING GEARS Injection pump camshaft gear Number of teeth: 52...

  • Page 43: Rocker Arms And Rocker Shaft

    ROCKER ARMS AND ROCKER SHAFT ENGINE MAIN PARTS ENGINE MAIN PARTS ROCKER ARMS AND ROCKER SHAFT Disassembly Figure 30 Rocker system components parts Disassembly sequence Oil filter cap Breather hose Rocker cover Rocker cover gasket Rocker shaft Rocker spring Adjust screw Rocker arm 42 / 155 ENGLISH...

  • Page 44: Removal And Installation

    ENGINE MAIN PARTS ROCKER ARMS AND ROCKER SHAFT Removal and installation 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] CAUTION Stay tightening torque: 14.7 to 21.6N·m Be careful not to confuse proper direction of (1.5 to 2.2 kgf·m) installation of the rocker shaft.

  • Page 45: Cylinder Head

    CYLINDER HEAD ENGINE MAIN PARTS ENGINE MAIN PARTS CYLINDER HEAD Disassembly Cylinder head cross section Figure 33 Cylinder head component parts Disassembly sequence Cylinder head Valve guide Cylinder head bolt (main bolt) Cylinder head bolt (sub-bolt) Seat ring (3600 min specification engine) Water outlet fitting Cylinder head gasket...

  • Page 46: Removal

    Figure 34 Sequence for loosening cylinder head prevent from entering the dust. bolts (L2) Disconnect the glow plug lead wire. Loosen the alternator bracket bolts and dismount the alternator. Disconnect the air breather hose.

  • Page 47: Inspection And Repair

    CYLINDER HEAD ENGINE MAIN PARTS Inspection and Repair Check cylinder head surface for a warpage between bolt holes: Check guide for wear and damage within 0.05 mm [0.0020 in.] Check for cracks, damage, water Check for valve contact, wear, leak and remove oil, sludge, sealant damage, and sink of seat face.

  • Page 48: Service Manual Mitsubishi L-Series Diesel Engines English

    ENGINE MAIN PARTS CYLINDER HEAD Repair of valve seat Valve sinkage If a valve seat is found defective, reface or replace it. Sinkage of valve Seat contact and wear Standard Service limit 0.5 mm [0.0197 in.] 1.5 mm [0.0591 in.] Table 19 Sinkage of valve Figure 39...

  • Page 49: Installation

    Figure 41 Sequence for tightening cylinder head loosen the pipe clamp first. bolts (L2) When tightening the nut at each end of pipe, hold the nozzle holder or delivery valve holder with a wrench to prevent from being turned together with the nut.

  • Page 50: Valves And Valve Springs

    ENGINE MAIN PARTS VALVES AND VALVE SPRINGS ENGINE MAIN PARTS 10 VALVES AND VALVE SPRINGS 10.1 Disassembly (Not installed to agricultural model) Figure 43 Valve system component parts Disassembly sequence Valve stem cap Valve lock Valve spring retainer Valve stem seal Valve spring Valve Service Manual Mitsubishi L-Series diesel engines...

  • Page 51: Removal

    VALVES AND VALVE SPRINGS ENGINE MAIN PARTS 10.2 Removal Dismount the cylinder head assembly. Press the valve spring retainer (to compress the valve spring) and remove the valve lock. Remove the valve and place it cylinder by cylinder. Figure 44 Removing valve and valve spring 10.3 Inspection and repair Wear and...

  • Page 52: Installation

    ENGINE MAIN PARTS VALVES AND VALVE SPRINGS 10.3.1 Repair of valve face If the valve face is found worn, resurface with a valve refacer. If margin of the resurface valve is less than the service limit, replace the valve. 10.3.2 Repair of valve stem end Margin If the valve stem end is indented by wear, flatten with an oil stone.

  • Page 53: Inlet Manifold And Exhaust Manifold

    INLET MANIFOLD AND EXHAUST MANIFOLD ENGINE MAIN PARTS ENGINE MAIN PARTS 11 INLET MANIFOLD AND EXHAUST MANIFOLD 11.1 Disassembly Tightening torque: 7.85 to 9.80 N²m (0.8 to 1.0 kgf²m) [5.79 to 7.23 lbf²ft] Tightening torque: 14.7 to 21.6 N·m (1.5 to 2.2 kgf·m) [10.85 to 15.91 lbf·ft] Figure 49 Manifold component parts...
  • Page 54 INLET MANIFOLD AND EXHAUST ENGINE MAIN PARTS MANIFOLD Check the mounting surfaces to the cylinder head for flatness. The surfaces must be flat within 0.15 mm [0.0059 in.]. Check the manifolds for corrosion, damage and cracks. CAUTION Check the interior of the inlet manifold for dust and dirt.

  • Page 55: Gear Case And Oil Pump

    GEAR CASE AND OIL PUMP ENGINE MAIN PARTS ENGINE MAIN PARTS 12 GEAR CASE AND OIL PUMP 12.1 Disassembly Common to L2 and L3 Figure 50 Gear case component parts Disassembly sequence Bushings Plug Gear case Front oil seal Relief plunger...

  • Page 56: Removal

    ENGINE MAIN PARTS GEAR CASE AND OIL PUMP 12.2 Removal Remove the crankshaft pulley. Remove the fan and fan belt. Remove the tie-rod cover from the side face of the injection pump. Remove the tie-rod and tie-rod spring. Be careful not to let the spring drop to inside of the case.

  • Page 57: Replacement Of Front Oil Seal

    GEAR CASE AND OIL PUMP ENGINE MAIN PARTS Description 1000 4000 Speed, min Opening pressure 0.29 (3.0) — (kgf/cm ) [psi] [43] Relief Closing pressure 0.49 valve (5) [71] — (kgf/cm )[psi] below Table 21 Oil pump performance, oil used: SAE30, 100±5°C [212±9°F] 12.4 Replacement of front oil seal Remove the front oil seal.

  • Page 58: Inspection Of Governor System

    ENGINE MAIN PARTS GEAR CASE AND OIL PUMP 12.6 Inspection of governor system Check the governor system in the gear case. If any Check springs parts are found defective, repair or replace them. for fatigue. Check shaft for flaws. Check sliding sleeve joint for wear and damage.

  • Page 59: Installation Of Gear Case Assembly

    GEAR CASE AND OIL PUMP ENGINE MAIN PARTS 12.8 Installation of gear case Tightening torque: assembly 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...

  • Page 60: Timing Gears

    ENGINE MAIN PARTS TIMING GEARS ENGINE MAIN PARTS 13 TIMING GEARS 13.1 Disassembly Figure 57 Timing gear component parts Disassembly sequence Crankshaft gear Idle gear Camshaft gear Injection pump camshaft gear Service Manual Mitsubishi L-Series diesel engines ENGLISH 59 / 155 Version 08/2004...

  • Page 61: Removal

    TIMING GEARS ENGINE MAIN PARTS 13.2 Removal Remove the snap ring and remove the idle gear. Figure 58 Removing idle gear Since camshaft gear is press-fitted, remove camshaft gear (valve-cam and injection pump cam) only after disassembling the shaft independently. Remove the crankshaft gear as same procedure as camshaft gear.

  • Page 62: Installation Of Timing Gears

    ENGINE MAIN PARTS TIMING GEARS 13.4 Installation of timing gears Press-fit the crankshaft gear onto the shaft. Press-fit the gears to the camshaft (valve camshaft and injection pump camshaft). Install the gears in the following sequence. Turn the crankshaft to set the No. 1 cylinder to top dead center on compression stroke.

  • Page 63: Camshafts (Valve And Injection Pump)

    CAMSHAFTS (VALVE AND INJECTION PUMP) ENGINE MAIN PARTS ENGINE MAIN PARTS 14 CAMSHAFTS (VALVE AND INJECTION PUMP) 14.1 Disassembly Figure 62 Camshaft component parts Disassembly sequence Camshaft (Valve) Camshaft gear Ball bearing (Front) Woodruff key Sunk key Camshaft stopper washer Bolt Tappet Pushrod...

  • Page 64: Removal Of Valve Camshaft

    CAMSHAFTS (VALVE AND INJECTION ENGINE MAIN PARTS PUMP) 14.2 Removal of Valve Camshaft 14.2.1 Remove only the valve camshaft When it is necessary to remove only the valve camshaft, use the following procedure: Dismount the cylinder head assembly. Pull out the pushrods. Pull out the tappets.

  • Page 65: Inspection

    CAMSHAFTS (VALVE AND INJECTION PUMP) ENGINE MAIN PARTS 14.3 Inspection Check the removed parts. If any parts are found defective, repair or replace them. Cam lobe-wear and damage Rod end-wear Bend and damage Journal bearing-wear and damage Each ball bearing-wear and noise Cam contact surface-wear and damage...

  • Page 66: Installation

    CAMSHAFTS (VALVE AND INJECTION ENGINE MAIN PARTS PUMP) 14.4 Installation When installing the camshafts, pay attention to the following: Apply oil to the bearings and cam lobes. Reassembly sequence of the camshaft is the reverse of disassembly. Align the timing marks on the gears to the marks on the idler gear.

  • Page 67: Piston And Connection Rod

    PISTON AND CONNECTION ROD ENGINE MAIN PARTS ENGINE MAIN PARTS 15 PISTON AND CONNECTION ROD 15.1 Disassembly Figure 66 Piston and connecting rod component Disassembly sequence parts Piston ring No. 1 Piston ring No. 2 Oil ring Piston Piston pin Connecting rod Connecting rod bearing Connecting rod cap...

  • Page 68: Removal

    ENGINE MAIN PARTS PISTON AND CONNECTION ROD 15.2 Removal Remove the cylinder head assembly. Remove the oil pan. Remove the oil screen. Mark the cylinder number on the side face of big end of each connecting rod to prevent confusion at reassembly.

  • Page 69: Inspection

    PISTON AND CONNECTION ROD ENGINE MAIN PARTS 15.3 Inspection Inspect the removed parts. If any parts are found defective, replace or repair them. • Wear, seizure and Damage, wear, and ring gap streaks • Clearance between piston and cylinder. • Bend and twist Standard: 0.07 to •...

  • Page 70: Installation

    ENGINE MAIN PARTS PISTON AND CONNECTION ROD CAUTION 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. When replacing rings, make sure to install the new rings having the same size as the piston.
  • Page 71 PISTON AND CONNECTION ROD ENGINE MAIN PARTS Description Standard Pin press-fitting force 1000 ±500 kg (at a normal temperature) [2205 ±1102 lb] Table 30 Pin press-fitting force Pressing Push rod Connecting rod Piston pin Identification mark FRONT mark (arrow) Piston Guide Tool body Base plug...
  • Page 72 ENGINE MAIN PARTS PISTON AND CONNECTION ROD Installation of piston rings Ring set positions: FRONT mark No. 1 ring, No. 2 ring, “T” mark and OS size mark oil ring Rod front mark “T” mark and OS size mark OS size identification paint Align lugs accurately each other.
  • Page 73 PISTON AND CONNECTION ROD ENGINE MAIN PARTS Apply 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.

  • Page 74: Crankshaft

    ENGINE MAIN PARTS CRANKSHAFT ENGINE MAIN PARTS 16 CRANKSHAFT 16.1 Disassembly Figure 77 Crankshaft component parts Disassembly sequence Crankshaft Crankshaft gear Crankshaft pulley Washer Spring washer Flywheel Ring gear 10. Rear oil seal 11. Rear oil seal case 12. Gasket 13.

  • Page 75: Removal

    CRANKSHAFT ENGINE MAIN PARTS 16.2 Removal Loosen the flywheel bolts and remove the flywheel. Unscrew the crankshaft pulley nut and remove the crank pulley. Remove the rear oil seal case assembly. Remove the main bearing caps. Keep each set of removed bearings together with its bearing cap.
  • Page 76 ENGINE MAIN PARTS CRANKSHAFT 16.3.1 Checking the crankshaft for wear To check the crankpins and main journals for cylindricity and roundness, measure the diameter of each crankpin and main journal at two places 1 and 2 in directions “A” and “B” for a total of 4 measurements in the figure at right.

  • Page 77: Replacement Of Crankshaft Rear Oil Seal

    CRANKSHAFT ENGINE MAIN PARTS Description Standard 49.0 to 53.9 (5.0 to 5.5) Main bearing cap bolt [36.17 to 39.78] 31.4 to 34.3 (3.2 to 3.5) Rod bearing cap nut [23.15 to 25.32] Table 33 Tightening torque N·m (kgf·m) [lbf·ft] Description Standard Main bearing 0.10 [0.0039]...

  • Page 78: Installation

    ENGINE MAIN PARTS CRANKSHAFT 16.5 Installation When installing the crankshaft, pay attention to the notes given in the figure below. Cap tightening torque: 49.0 to 53.9 N·m (5.0 to 5.5 kgf·m) Thrust bearing only for No. 2 cap [36.17 to 39.78 lbf·ft] Side seals coated with sealant (THREE-BOND 1212) Direction of...

  • Page 79: Cylinder Block

    CYLINDER BLOCK ENGINE MAIN PARTS ENGINE MAIN PARTS 17 CYLINDER BLOCK 17.1 Disassembly Figure 83 Cylinder block component parts Disassembly sequence Cylinder block Front plate Bearing cap Cover Main bearing Starter bracket Rear oil seal Oil seal case Idler gear shaft 10.

  • Page 80: Inspection

    ENGINE MAIN PARTS CYLINDER BLOCK 17.2 Inspection Inspect the cylinder block. If it is found defective, repair or replace the block. Model Standard Service limit +0.03 +0.7 L2A, L3A +0.0012 [2.5591 [+0.0276] +0.03 +0.7 L2C, L3C +0.0012 [2.7559 [+0.0276] +0.03 +0.7 Figure 84 Measuring cylinder bore...
  • Page 81 CYLINDER BLOCK ENGINE MAIN PARTS 80 / 155 ENGLISH Service Manual Mitsubishi L-Series diesel engines Version 08/2004...

  • Page 82: Lubrication System

    LUBRICATION SYSTEM ENGLISH 81 / 155 Service Manual Mitsubishi L-Series diesel engines Version 08/2004...
  • Page 83 18.1 Specification Description Specification Lubricating system and filtering system Pressure-feed lubricating, full-flow filtering Oil capacity (Upper limit/lower limit): L3: 3.0/1.5, 3.6/1.8 or 4.8/3.0 L2: 2.4/1.4 excluding 0.5 l for oil filter [0.7926/0.3963, 0.9511/0.4756 or [0.6341/0.3699] l [U.S.gal] 1.2682/0.7926] Type Gear type (Inner and outer gears in mesh) enclosed in gear case...
  • Page 84 LUBRICATION SYSTEM OIL FILTER AND OIL PRESSURE SWITCH LUBRICATION SYSTEM 19 OIL FILTER AND OIL PRESSURE SWITCH 19.1 Disassembly Figure 87 Oil filter and pressure switch Disassembly sequence Oil filter Oil pressure switch Service Manual Mitsubishi L-Series diesel engines ENGLISH 83 / 155 Version 08/2004...
  • Page 85 OIL FILTER AND OIL PRESSURE SWITCH LUBRICATION SYSTEM 19.2 Removal and installation Remove the filter by the filter wrench. Remove the oil pressure switch by the special tool named socket wrench. Special tool name Part No. Socket wrench MD998054 Table 38 Special tool Figure 88 Installing oil filter...

  • Page 86: Fuel System

    FUEL SYSTEM ENGLISH 85 / 155 Service Manual Mitsubishi L-Series diesel engines Version 08/2004...
  • Page 87 GENERAL FUEL SYSTEM FUEL SYSTEM 20 GENERAL 20.1 Specifications Specification Description Type In-line type (Bosch NC) Direction of rotation Clockwise (as viewed from driving side) Injection order 1–2 1–3–2 n ≤ 2000 rpm 15° bTDC Fuel injection timing 2000 ≤ n ≤ 3000 rpm if the rated speed "n"...
  • Page 88 FUEL SYSTEM GENERAL Specification Description Type Solenoid pull hold type Rated current, pull Rated current, hold 1.0A FUEL Working voltage 12V, DC CUTT OFF Stroke 13.5 mm [0.5315 in.] VALVE Type Solenoid, push out type Coil resistance 1.6Ω±10% (at 20°C [68°F]) Stroke 10 mm [0.3937 in.] FUEL FILTER...
  • Page 89 GENERAL FUEL SYSTEM 20.2 Disassembly Figure 91 Fuel system component parts Disassembly sequence Injection pump Adjusting shim Injection pipe Injection nozzle Return pipe Fuel filter Fuel cutoff solenoid 88 / 155 ENGLISH Service Manual Mitsubishi L-Series diesel engines Version 08/2004...
  • Page 90 FUEL SYSTEM FUEL INJECTION PUMP FUEL SYSTEM 21 FUEL INJECTION PUMP 21.1 Disassembly Figure 92 Injection pump component parts Disassembly sequence Union collar Air vent screw Delivery valve holder Valve spring Holder stopper Housing O-ring Delivery valve Gasket 10. Seat valve 11.
  • Page 91 FUEL INJECTION PUMP FUEL SYSTEM 21.2 Inspecting the injection pump while operating the engine Never attempt to disassemble the pump unless it is necessary.If the pump is assumed defective, it is recommended to replace the pump assembly. Inspection Item Criteria procedure Measure engine Idling speed...
  • Page 92 FUEL SYSTEM FUEL INJECTION PUMP 21.5 Inspection Inspect all removed parts, if any part is found defective, replace it. O-ring-Cracks and deterioration Wear and scratch Control rack movement Plunger- (uneven) Interference, wear, scratch, rust, seizure Interference, wear Figure 94 Inspection of injection pump 21.6 Reassembly of plunger Insert the plunger barrel into the housing.
  • Page 93 INJECTION NOZZLE FUEL SYSTEM FUEL SYSTEM 22 INJECTION NOZZLE 22.1 Disassembly Figure 97 Nozzle holder assembly component parts Disassembly sequence Body sub-assembly Shim washer Pressure spring Distance piece Nozzle assembly Retaining nut 22.2 Removal Disconnect the injection pipe and fuel return pipe. 92 / 155 ENGLISH Service Manual Mitsubishi L-Series diesel engines...
  • Page 94 FUEL SYSTEM INJECTION NOZZLE Remove the injection nozzle assembly from the cylinder head. CAUTION Attach an identification-number tag to the removed injection nozzle. Plug the openings, to prevent entering of dust, water and other foreign particles into the pipes and combustion chamber. Do not mix the parts of any nozzle assy with others, but keep the parts of each nozzle assembly as a unique combination.
  • Page 95 INJECTION NOZZLE FUEL SYSTEM 22.4 Inspection Never attempt to disassemble the pump unless it is necessary.If the pump is assumed defective, it is recommended to replace the pump assembly. Fatigue and break Wear Deformation and break Poor contact While immersed in kerosene, check for smooth sliding.
  • Page 96 FUEL SYSTEM INJECTION NOZZLE Standard Allowable limit Idling speed Measure engine speed 13.7 MPa (140 kgf/cm 12.7 MPa (130 kgf/cm [1992 psi] [1849 psi] or less Table 42 Injection start pressure 22.7 Installation 49.0 to 58.8 N·m (5.0 to 6.0 kgf·m) [36.17 to 43.40 lbf·ft] Clean the nozzle holder fitting surface of the cylinder head.
  • Page 97 INJECTION NOZZLE FUEL SYSTEM 96 / 155 ENGLISH Service Manual Mitsubishi L-Series diesel engines Version 08/2004...

  • Page 98: Governor System

    GOVERNOR SYSTEM ENGLISH 97 / 155 Service Manual Mitsubishi L-Series diesel engines Version 08/2004...
  • Page 99 GENERAL GOVERNOR SYSTEM GOVERNOR SYSTEM 23 GENERAL 23.1 Specification Governor type Centrifugal flyweight type Table 43 Specification 98 / 155 ENGLISH Service Manual Mitsubishi L-Series diesel engines Version 08/2004...
  • Page 100 GOVERNOR SYSTEM GENERAL 23.2 Disassembly Figure 103 Governor system component parts Disassembly sequence Sealing metal Sealing wire Low and high-speed bolt Governor weight assembly Sliding shaft Stopper Governor spring Governor shaft Governor level 10. Tie-rod 11. Tie-rod clip 12. Tie-rod cover 13.
  • Page 101 TORQUE SPRING GOVERNOR SYSTEM GOVERNOR SYSTEM 24 TORQUE SPRING For installation and For installation and adjustment adjustment 24.1 Installation of torque spring Install and adjust the torque spring set using the Never tamper following procedure: with this screw. Turn in this torque Adjust to Set the speed control lever to the high-idling speed spring set until...
  • Page 102 GOVERNOR SYSTEM TORQUE SPRING Model Number of loosening turns 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 L2C-61DM, L2E-61TM, L2E-62A, L2E-62DA, L2E-61ES, L2E-61RR, L2E-62PL, L2E-61DG, L2E-W261DG, L3E-61EG, L3E-61EG, L3E-61A,...
  • Page 103 TORQUE SPRING GOVERNOR SYSTEM Model Identification color L3A-61TG, L3A-61ES, L3C-61DA, L3C-61ES, L3E-61DA, L3E-31NSA, L3E2-61ES, L3E2-62ES, Green L3E2-63ES, L2E-61GS, L3E2-63ESA, L2A-61DA, L2E–61ES, L2E–61DA L2E–62PL 1520 1520 1500 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, Yellow L2E-61A, L2E-61SC, L2E-61SA, L2E-61WH, L2E–61HMG, L2E–61IR...
  • Page 104 GOVERNOR SYSTEM TORQUE SPRING Check levers for Check springs smooth movements. for fatigue. Check springs for fatigue. Check weight for wear and damage. Check shaft for flaws. Check sliding sleeve for wear, Check sliding sleeve joint damage and for wear and damage. smooth movement.
  • Page 105 TORQUE SPRING GOVERNOR SYSTEM 104 / 155 ENGLISH Service Manual Mitsubishi L-Series diesel engines Version 08/2004...

  • Page 106: Cooling System

    COOLING SYSTEM ENGLISH 105 / 155 Service Manual Mitsubishi L-Series diesel engines Version 08/2004...
  • Page 107 Description Specification FAN BELT Standard type for industrial application LL HM type, length 905 mm [35.6299 in.] L2: Standard type for industrial 4-blade or 5-blade, unequal pitch, pusher or suction type, application ø 290 [11.4173 in.] COOLING FAN L3: Standard type for industrial...
  • Page 108 COOLING SYSTEM GENERAL 25.2 Disassembly Figure 110 Cooling system component parts Disassembly sequence Cooling fan Water pump pulley Water pump assembly V-belt Thermostat Thermostat fitting Thermoswitch Bypass pipe Service Manual Mitsubishi L-Series diesel engines ENGLISH 107 / 155 Version 08/2004...
  • Page 109 FAN AND FAN BELT COOLING SYSTEM COOLING SYSTEM 26 FAN AND FAN BELT Wear of pulley groove 11.8 to 14.7 N·m (1.2 to 1.5 kgf·m) 26.1 Fan belt inspection [8.68 to 10.85 lbf·ft] For fan belt tension, see Maintenance (page xx). 19.6 to 24.5 N·m (2 to 2.5 kgf·m) [14.47 to 18.08 lbf·ft]...
  • Page 110 COOLING SYSTEM WATER PUMP COOLING SYSTEM 27 WATER PUMP 27.1 Removal and installation Remove the fan and fan belt. Remove the water pump. When installing the water pump, take reverse sequence of the removal. 27.2 Inspection Check the water pump for water leak, improper rotation Figure 113 Removing water pump and cracks.
  • Page 111 THERMOSTAT COOLING SYSTEM COOLING SYSTEM 28 THERMOSTAT Water outlet Thermostat 28.1 Removal and installation fitting Renew gasket Never place Pay attention to the following: thermostat Set the thermostat in place. stay in Thermostat direction of Renew the gasket. fitting thermoswitch hole.
  • Page 112 WATER TEMPERATURE GAGE UNIT AND COOLING SYSTEM THERMOSWITCH COOLING SYSTEM 29 WATER TEMPERATURE GAGE UNIT AND THERMOSWITCH 29.1 Inspection of water temperature gage unit If the gage does not function properly, replace it. Gage unit part no. Specification 70°C [158°F]/104±13.5 Ω, MD001380 115°C [239°F]/23.8±2.5 Ω...
  • Page 113 WATER TEMPERATURE GAGE UNIT AND THERMOSWITCH COOLING SYSTEM 112 / 155 ENGLISH Service Manual Mitsubishi L-Series diesel engines Version 08/2004...
  • Page 114 AIR CLEANER ENGLISH 113 / 155 Service Manual Mitsubishi L-Series diesel engines Version 08/2004...
  • Page 115 AIR CLEANER AIR CLEANER AIR CLEANER 30 AIR CLEANER 30.1 Disassembly Figure 118 Air cleaner component parts Disassembly sequence Body assembly Element assembly Dust pan assembly Bolt Partition plate 114 / 155 ENGLISH Service Manual Mitsubishi L-Series diesel engines Version 08/2004...
  • Page 116 AIR CLEANER AIR CLEANER 30.2 Inspection Check the air cleaner body and look for deformation, corrosion, and damage. If any defect is found, repair or replace. If the body and cover (element) are not airtight, dust would enter into the engine, causing the cylinders and pistons to wear early.
  • Page 117 AIR CLEANER AIR CLEANER 116 / 155 ENGLISH Service Manual Mitsubishi L-Series diesel engines Version 08/2004...

  • Page 118: Electrical System

    ELECTRICAL SYSTEM ENGLISH 117 / 155 Service Manual Mitsubishi L-Series diesel engines Version 08/2004...
  • Page 119 GENERAL ELECTRICAL SYSTEM ELECTRICAL SYSTEM 31 GENERAL 31.1 Specifications Specification Description Model M000T60481 M001T68381 Type Solenoid shift type Nominal output 12V-1.2 kW 12V-1.7 kW 11V/90A or less 11V/110A or less STARTER No-load characteristic 2500 rpm or more 2400 rpm or more 7.5V/300A 7.7V/400A 10.5 N·m (1.07 kgf·m) [7.7...
  • Page 120 ELECTRICAL SYSTEM GENERAL Specification Description Model YMS-1 Type Solenoid ETS TYPE STOP Resistance in coil, Ω 1.6 ± 10% at 20°C (68°F) SOLENOID Stroke, mm (in.) 10 ± 0.5 (0.39 ± 0.02) Operating voltage, V DC 10 to 15 Model Rated voltage, V DC 12 Operating voltage, V...
  • Page 121 Safety relay Pilot lamp Glow plug MM130-767 MM201-124 Model Battery 12V-48Ah or more 12V-60Ah or more Themo switch MM432-104 Starter 12V-1.2kW 12V-1.7kW Alternator 12V-40A Pilot lamp Diode MM201-123 Alternator MM434-062 Diode MM434-062 Glow timer Pressure switch MM431-762 Connection of Gow relay 31A90-00100 starter switch MM431-28201...
  • Page 122 Safety relay Pilot lamp Glow plug MM130-767 MM201-124 Model Themo switch Battery 12V-48Ah or more 12V-60Ah or more MC880-900 Starter 12V-1.2kW 12V-1.7kW Alternator 12V-40A Pilot lamp Diode MM201-123 Alternator MM434-062 Diode MM434-062 Glow timer MM431-762 Pressure switch Glow relay Connection of MM130-066 MM431-28201 starter switch...
  • Page 123 STARTER ELECTRICAL SYSTEM ELECTRICAL SYSTEM 32 STARTER 32.1 Structure Figure 119 Starter component parts Disassembly sequence Front bracket assembly Lever assembly Spring set Center bracket assembly Switch assembly Through bolt Armature Rear bearing Pinion 10. Pinion shaft assembly 11. Gear 12.
  • Page 124 ELECTRICAL SYSTEM STARTER 32.2 Inspection (assembly) If any abnormality is assumed by the following tests, adjust the starter or disassemble and repair it. 32.2.1 Pinion gap inspection Push back Connect + terminal of battery (12 V)to starter Lightly Terminal S terminal “S”...
  • Page 125 STARTER ELECTRICAL SYSTEM Attraction test. Connect a battery to the magnetic switch terminal S and M. The pinion must protrude. CAUTION Do not apply battery current for more than 10 seconds. Battery Starter Figure 122 Attraction test Holding test. With a battery connected to the magnetic switch terminal “S”...
  • Page 126 ELECTRICAL SYSTEM STARTER 32.3 Disassembly Disconnect wire from the magnetic switch terminal “M”. Loosen two screws fastening the magnetic switch. Remove the magnetic switch assembly. Remove two through bolts and two screws fastening the brush holder. Remove the rear bracket. With two brushes brought in floating state, remove the yoke-and-brush holder assembly.
  • Page 127 STARTER ELECTRICAL SYSTEM 32.4 Inspection Break and short circuit Wear and chipping One-way mechanism Bearing: Play, noise and rough rotation Insulation Break and short circuit Bearing: Play, noise and rough rotation Figure 127 Inspecting starter Inspect the following: Description Standard Service Limit 0.5 mm 0.2 mm...
  • Page 128 ELECTRICAL SYSTEM STARTER 32.4.1 Inspecting the magnetic switch Check the magnetic switch for continuity between terminal S and M, and between terminal S and body. If zero-ohm is indicated (as an evidence of short circuit), replace the magnetic switch. Body Figure 128 Checking magnetic switch 32.4.2 Inspecting the armature Check the armature with a growler tester.
  • Page 129 STARTER ELECTRICAL SYSTEM 32.4.4 Field coil inspection Check for insulation between one end (brush) of coil and yoke. Check for the continuity between both ends (brushes) of coil. Figure 131 Checking field coil 32.5 Assembly and adjustment Adjusting Gear washer Reassemble the starter in the reverse sequence of disassembly and pay attention to the following: Washer...
  • Page 130 ELECTRICAL SYSTEM ALTERNATOR AND DYNAMO ELECTRICAL SYSTEM 33 ALTERNATOR AND DYNAMO 33.1 Structure Figure 133 Alternator component parts Disassembly sequence Pulley Front bracket assembly Front bearing Rotor assembly Rear bearing Stator Terminal set Regulator assembly Rectifier assembly 10. Rear bracket assembly Service Manual Mitsubishi L-Series diesel engines ENGLISH 129 / 155...
  • Page 131 ALTERNATOR AND DYNAMO ELECTRICAL SYSTEM 33.2 Dynamo Magnet Field coil The dynamo is used for specific engines. This maintenance-free dynamo is the permanent magnet type, light-weight, compact, single-phase AC generator. Alternating current generated by the dynamo is rectified through the separated regulator-and-rectifier unit. Figure 134 Dynamo 33.3 Inspection of the alternator (installed on the engine)
  • Page 132 ELECTRICAL SYSTEM ALTERNATOR AND DYNAMO 33.4 Output inspection Ammeter Disconnect the grounding cable from the battery. Connect an ammeter between the battery and Voltmeter Alternator alternator terminal “B”. Ground the terminal “B” Lamp through a voltmeter. Connect the battery cable to ground. Switch Start the engine.
  • Page 133 ALTERNATOR AND DYNAMO ELECTRICAL SYSTEM Unsolder the stator coil lead wires. Remove the stator assembly. CAUTION Soldering must be done in short time. Never heat the lead wires too long to prevent damage to diodes. Disconnect the capacitor from terminal ìBî. Loosen the rectifier mounting screws and remove the rectifier.
  • Page 134 ELECTRICAL SYSTEM ALTERNATOR AND DYNAMO 33.7.1 Inspecting the diodes Check each built-in diode in the rectifier for continuity as follows: Connect a circuit tester (ohm meter) across the lead wire and case of the diode to be tested. The diode is considered as normal if its resistance is large in either direction and small in the reverse direction.
  • Page 135 ALTERNATOR AND DYNAMO ELECTRICAL SYSTEM 33.7.3 Inspecting the stator coil Check for continuity between lead wires of the stator coil. If there is no continuity, the stator coil is suspected to be broken. Replace the stator coil. Check for continuity between each lead wire and stator core.
  • Page 136 ELECTRICAL SYSTEM ALTERNATOR AND DYNAMO 33.9 Installation Install the alternator in the reverse sequence of removal. 33.9.1 Insertion of spacer When installing the support bolts, insert the spacer in place using the following procedure: Push in the support bolts to the normal position. (Without nuts.) Push the alternator backward.
  • Page 137 ALTERNATOR AND DYNAMO ELECTRICAL SYSTEM Inspecting the regulator alone To judge if the regulator itself is acceptable or not, check the regulator for normal continuity by connecting the circuit tester to the lead wires as Blue lead follows: Red lead Yellow lead Item If abnormal...
  • Page 138 ELECTRICAL SYSTEM GLOW PLUG ELECTRICAL SYSTEM 34 GLOW PLUG 34.1 Removal 14.7 to 19.6 N·m (1.5 to 2.0 kgf·m) [10.85 to 14.47 lbf ·ft] Be careful not to damage the tip of glow plug 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...
  • Page 139 KEY-OFF STOP SYSTEM ELECTRICAL SYSTEM ELECTRICAL SYSTEM 35 KEY-OFF STOP SYSTEM 35.1 General The function of this system is to actuate the fuel cutoff solenoid when the starter key is placed in the OFF position. It also has the emergency engine stop function by actuating the control timer in case of abnormal low oil pressure or abnormal coolant temperature.
  • Page 140 ELECTRICAL SYSTEM KEY-OFF STOP SYSTEM 35.3.2 Solenoid installation procedure Temporarily fit the solenoid 1 and nut 2 to the crankcase. (Coat the effective thread of solenoid with THREE-BOND 1212 or 1211.) Turn in the solenoid so that clearance “C” View P becomes zero at the injection pump rack position zero (stop position).
  • Page 141 KEY-OFF STOP SYSTEM ELECTRICAL SYSTEM Description Specification 13.5±0.5 mm Stroke [0.5315±0.0197 in.] Rated current, pull Rated current, hold 35.4.2 Solenoid installation In this solenoid, under the switch key is turned to the OFF position, the solenoid shaft is pulled in when the solenoid is functioned and the shaft is returned (protruded).
  • Page 142 ELECTRICAL SYSTEM GLOW TIMER SYSTEM ELECTRICAL SYSTEM 36 GLOW TIMER SYSTEM Glow timer 36.1 General The glow plugs are used to help easy start of a cold engine by preheating the combustion chamber. Glow relay In the standard-specification engines, it is necessary to keep the starter key at the “glow”...
  • Page 143 GLOW TIMER SYSTEM ELECTRICAL SYSTEM 142 / 155 ENGLISH Service Manual Mitsubishi L-Series diesel engines Version 08/2004...
  • Page 144 SERVICE DATA ENGLISH 143 / 155 Service Manual Mitsubishi L-Series diesel engines Version 08/2004...
  • Page 145 SERVICE SPECIFICATIONS AND PERIODIC INSPECTION CHART STANDARDS SERVICE SPECIFICATIONS AND STANDARDS 37 PERIODIC INSPECTION CHART 37.1 Periodic service chart ⊗ ο • ····Inspect, adjust or replenish, ····Clean, ····Replace, ∆ ····Drain Service interval Remark Unit and point ⊗ Loose damaged or leakage parts ⊗...
  • Page 146 [356 psi] [313 psi] Difference between cylinders (maximum) 0.25 MPa (2.5 kgf/cm ) [35.6 psi] Fuel injection order L2: 1-2, L3: 1-3-2 Cylinder head Bottom surface distortion (Flatness) Within 0.05 [0.0020] 0.1 [0.0039] Valve guide Inside diameter (IN and EX) 6.6 [0.2598]...
  • Page 147 SPECIFICATIONS AND MAINTENANCE SERVICE SPECIFICATIONS AND STANDARDS STANDARDS Unit: mm (in.) Description Specification or Standard Repair Limit Service Limit Cylinder bore L2A, L3A 65 [2.5591]] +0.2 [0.0079] +0.70 [0.0276] L2C, L3C 70 [2.7559] +0.2 [0.0079] +0.70 [0.0276] L2E, L3E 76 [2.9921] +0.2 [0.0079] +0.70 [0.0276] Oversize finish tolerance...
  • Page 148 SERVICE SPECIFICATIONS AND SPECIFICATIONS AND MAINTENANCE STANDARDS 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]...
  • Page 149 0.37 l [0.0977 U.S.gal]/min (12V, at 20°C [68°F]) Fuel feed pump Type Mechanical drive type Delivery 0.225 l [0.0594 U.S.gal]/min Fuel injection pump For exclusive L2 or L3 use Model Type ND-PFR2NC or ND-PFR3NC Nozzle Type Throttle type Injection start pressure Within Standard +1.0...
  • Page 150 Unit: mm (in.) Description Specification and Standard Repair Limit Service Limit Cooling fan Type uneven pitch, pusher or suction L2: Standard 4-blade or 5-blade, (ø 290 [11.4173]) L3: Standard 5-blade or 6-blade, (ø 320 [12.5984]) Fan belt Type HM type Length (Standard) 890 [35.0393]...
  • Page 151 Glow plug (Quick-heat type) Type Sheath type Model: Y-145T (With hex nut) Voltage–current 10.5V–9.7A 0.2 Ω Resistance Glow plug indicator (Quick-heat type) for L2 Type Red-hot type Model DH-139V-19 Rated current Voltage across terminals (at 19A) 1.5V±0.2V 150 / 155...
  • Page 152 SERVICE SPECIFICATIONS AND SPECIFICATIONS AND MAINTENANCE STANDARDS STANDARDS Unit: mm (in.) Description Specification and Standard Repair Limit Service Limit Glow plug indicator (Quick-heat type) for L3 Type Red-hot type Model DH-139V-29 Rated current Voltage across terminals (at 29A) 1.7V±0.2V Fuel cutoff solenoid Type Electromagnetic ETS push type 1.6 Ω±10% (at 20°C [68°F])

  • Page 153: Tightening Torque Chart And Sealant Chart

    TIGHTENING TORQUE CHART AND SERVICE SPECIFICATIONS AND SEALANT CHART STANDARDS SERVICE SPECIFICATIONS AND STANDARDS 39 TIGHTENING TORQUE CHART AND SEALANT CHART 39.1 Tightening Torque for Main Bolts Size (Width across flat Tightening torque Parts to be tightened of hex. head) N·m (kgf·n) [lbf·ft] Cylinder head bolt, main M10 (14)
  • Page 154 SERVICE SPECIFICATIONS AND TIGHTENING TORQUE CHART AND STANDARDS SEALANT CHART 39.3 Tightening Torque for Common Plugs Unit: N·m(kgf·m)[lbf·ft] Size For aluminium materials For ferrous materials 7.85 to 11.8 NPTF 1/16 — (0.8 to 1.2) [5.79 to 8.68] 7.85 to 11.8 14.7 to 21.6 PT1/8 (0.8 to 1.2)

  • Page 155: Special Tools

    SERVICE SPECIFICATIONS AND SPECIAL TOOLS STANDARDS SERVICE SPECIFICATIONS AND STANDARDS 40 SPECIAL TOOLS Tool No. Toon Name Style Usage ST332400 Piston pin setting tool Removal and installationof (Exclusive use for L series) piston pin Guide LA (92 l) : for L2A, L3A Tool No.
  • Page 156 BLANK PAGE Service Manual Mitsubishi L-Series diesel engines ENGLISH 155 / 155 Version 08/2004...

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