Mitsubishi L series Diesel Engines Service Manual
TABLE OF CONTENTS:
Mitsubishi L series Diesel Engines Service Manual
BINDING.................................................................................................................... 1 INTRODUCTION............................................................................................................... 3 How to use this manual................................................................................................. 5 Methods of presentation............................................................................................ 5 Terms used in this manual.......................................................................................... 6 Abbreviations...................................................................................................... 6 Units of measurement............................................................................................... 6 Safety Cautions........................................................................................................ 7 Fire and explosion................................................................................................. 7 Keep flames away............................................................................................... 7 Keep surrounding area tidy and clean........................................................................... 7 Avoid accessing crankcase until engine cools................................................................... 7 Care about fuel, oil and exhaust gas leakage................................................................... 7 Use explosion-proof lighting apparatus......................................................................... 7 Prevent electrical wires from short-circuiting................................................................. 7 Keep fire extinguishers and first-aid kit handy................................................................ 7 Stay clear of all rotating and moving parts........................................................................ 8 Install protective covers on rotating parts.................................................................... 8 Ensure safety of neighboring people before starting engine..................................................... 8 Stay clear of moving parts during engine running............................................................... 8 Lockout and Tagout............................................................................................. 8 Keep engine stopped during servicing........................................................................... 8 Always restore engine turning tools after use.................................................................. 8 Be careful of burns................................................................................................ 9 Do not touch the engine during or immediately after operation.................................................. 9 Slowly and carefully open radiator cap......................................................................... 9 Add coolant only after the coolant temperature dropped......................................................... 9 Never remove heat shields...................................................................................... 9 Be careful of exhaust fume poisoning............................................................................... 9 Operate engine in well-ventilated area......................................................................... 9 Protect ears from noises........................................................................................... 9 Wear ear plugs................................................................................................. 9 Be careful of falling down......................................................................................... 10 Lift engine correctly.......................................................................................... 10 Do not climb onto the engine................................................................................... 10 Establish firm scaffold during work............................................................................ 10 Be careful of handling fuel, engine oil and LLC.................................................................... 10 Use only specified fuel, engine oil and long- life coolant (LLC)............................................... 10 Handle LLC (long life coolant) carefully....................................................................... 10 Proper disposal of waste oil and coolant (LLC)................................................................. 10 Service battery.................................................................................................... 11 Handle the battery correctly................................................................................... 11 When abnormality occurs............................................................................................ 11 Stop overheated engine after cooling run....................................................................... 11 Avoid immediate restart after abnormal stop.................................................................... 11 Avoid continuous engine operation with too low oil pressure.................................................... 11 Stop the engine immediately if the fan belt breaks............................................................. 11 Other cautions..................................................................................................... 12 Modification of engine prohibited.............................................................................. 12 Never break the seals.......................................................................................... 12 Pre-operational check and periodic inspection/maintenance...................................................... 12 Break-in operation............................................................................................. 12 Warming-up operation........................................................................................... 12 Avoid engine operations in a overload condition................................................................ 12 Cooling operation before stopping engine....................................................................... 12 Protection of engine against water entry....................................................................... 12 Maintenance of air cleaner or pre-cleaner...................................................................... 12 Observe safety rules at work site.............................................................................. 13 Work clothing and protective gear.............................................................................. 13 Use of tools optimum for each work............................................................................. 13 Avoidance of prolonged time of starter operation............................................................... 13 Do not turn off battery switch during operation................................................................ 13 Cautionary instructions for transporting engine................................................................ 13 Avoid continuous engine operation in a low load condition...................................................... 13 Ventilation of engine room..................................................................................... 13 Avoid contact with high-pressured fuel......................................................................... 13 About warning labels............................................................................................... 14 Maintenance of warning labels.................................................................................. 14 GENERAL CONTENTS........................................................................................................... 15 GENERAL.................................................................................................................... 17 1. External view....................................................................................................... 18 1.1 External view of L2A, L2C and L2E.............................................................................. 18 1.2 External view of L3A, L3C and L3E.............................................................................. 19 2. System flow diagrams................................................................................................ 20 2.1 Fuel system - flow diagram..................................................................................... 20 2.2 Lubrication system - flow diagram.............................................................................. 20 2.3 Cooling system - flow diagram.................................................................................. 21 2.4 Inlet and exhaust system - flow diagram........................................................................ 21 3. Engine serial number location....................................................................................... 22 4. Indication of engine model and total displacement................................................................... 22 5. Specifications...................................................................................................... 23 5.1 Specifications of L2A, L2C and L2E............................................................................. 23 5.2 Specifications of L3A, L3C and L3E............................................................................. 27 6. Tips on disassembling and reassembling.............................................................................. 31 6.1 Disassembling.................................................................................................. 31 6.2 Reassembling................................................................................................... 31 SERVICE DATA............................................................................................................... 33 1. Maintenance service data............................................................................................ 34 1.1 Engine general................................................................................................. 34 1.2 Basic engine................................................................................................... 34 1.3 Fuel system.................................................................................................... 37 1.4 Lubrication system............................................................................................. 38 1.5 Cooling system................................................................................................. 38 1.6 Inlet/Exhaust system........................................................................................... 38 1.7 Electrical system.............................................................................................. 39 2. List of tightening torque........................................................................................... 42 2.1 Major bolts and nuts tightening torque......................................................................... 42 2.1.1 Basic engines............................................................................................ 42 2.1.2 Fuel system.............................................................................................. 42 2.1.3 Lubrication system....................................................................................... 43 2.1.4 Cooling system........................................................................................... 43 2.1.5 Inlet and exhaust systems................................................................................ 43 2.1.6 Electrical system........................................................................................ 43 2.2 Standard bolt and nut tightening torque........................................................................ 44 2.3 Standard eyebolt tightening torque............................................................................. 45 2.4 Standard union nut tightening torque........................................................................... 45 2.5 High-pressure fuel injection pipe tightening torque............................................................ 45 SERVICE TOOLS.............................................................................................................. 47 1. Basic tools......................................................................................................... 48 2. Special tools....................................................................................................... 49 DETERMINATION OF OVERHAUL.................................................................................................. 51 1. Determining overhaul timing......................................................................................... 52 2. Testing compression pressure........................................................................................ 53 DISASSEMBLY OF BASIC ENGINE................................................................................................ 55 1. Disassembling and inspecting cylinder head and valve mechanism...................................................... 56 1.1 Removing rocker shaft assembly................................................................................. 57 1.2 Disassembling rocker shaft assembly............................................................................ 57 1.3 Removing cylinder head bolt.................................................................................... 58 1.4 Removing cylinder head assembly................................................................................ 58 1.5 Removing valves and valve spring............................................................................... 59 1.6 Removing valve stem seal....................................................................................... 59 2. Disassembling and inspecting flywheel............................................................................... 60 2.1 Removing flywheel.............................................................................................. 61 2.2 Removing flywheel housing...................................................................................... 61 2.3 Removing oil seal case......................................................................................... 61 3. Disassembling and inspecting gear case, timing gears and camshaft................................................... 62 3.1 Removing tappet................................................................................................ 63 3.2 Removing gear pump housing..................................................................................... 63 3.3 Removing crankshaft pulley..................................................................................... 63 3.4 Removing timing gear case...................................................................................... 63 3.5 Removing PTO gear.............................................................................................. 64 3.6 Removing oil pump.............................................................................................. 64 3.7 Removing relief valve.......................................................................................... 64 3.8 Removing governor shaft and speed control lever................................................................ 64 3.9 Measuring timing gear backlash................................................................................. 65 3.10 Removing idler gear........................................................................................... 65 3.11 Removing camshaft............................................................................................. 66 3.12 Removing fuel injection pump camshaft......................................................................... 67 3.13 Removing front plate.......................................................................................... 68 4. Disassembling and inspecting cylinder block, crankshaft, piston and oil pan......................................... 69 4.1 Removing oil pan............................................................................................... 70 4.2 Removing oil screen............................................................................................ 70 4.3 Removing connecting rod cap.................................................................................... 70 4.4 Pulling out piston............................................................................................. 71 4.5 Removing piston ring........................................................................................... 71 4.6 Removing piston pin............................................................................................ 71 4.7 Measuring crankshaft end play.................................................................................. 72 4.8 Removing main bearing cap...................................................................................... 72 4.9 Removing crankshaft............................................................................................ 72 INSPECTION AND REPAIR OF BASIC ENGINE...................................................................................... 73 1. Inspecting and repairing cylinder head and valve mechanism.......................................................... 74 1.1 Measuring clearance between rocker arm and rocker shaft........................................................ 74 1.2 Measuring valve stem outside diameter and valve guide inside diameter.......................................... 74 1.3 Replacing valve guide.......................................................................................... 75 1.4 Inspecting valve face.......................................................................................... 76 1.5 Refacing valve face............................................................................................ 76 1.6 Measuring perpendicularity and free length of valve spring..................................................... 77 1.7 Lapping valve and valve seat................................................................................... 77 1.8 Measuring distortion of the bottom surface of the cylinder head................................................ 78 1.9 Measuring push rod runout...................................................................................... 78 2. Inspecting and repairing flywheel................................................................................... 79 2.1 Measuring flatness of flywheel................................................................................. 79 2.2 Inspecting ring gear........................................................................................... 79 2.3 Replacing ring gear............................................................................................ 79 2.3.1 Removing ring gear....................................................................................... 79 2.3.2 Installing ring gear..................................................................................... 79 3. Inspecting and repairing gear case, timing gear and camshaft........................................................ 80 3.1 Measuring timing gear backlash................................................................................. 80 3.2 Measuring clearance between idler gear and idler shaft......................................................... 80 3.3 Replacing idler shaft.......................................................................................... 80 3.4 Measuring clearance between camshaft journal and cylinder block bore........................................... 81 3.5 Measuring cam lift............................................................................................. 81 3.6 Measuring cam height of fuel injection pump camshaft........................................................... 81 3.7 Inspecting tappet.............................................................................................. 82 3.8 Measuring clearance between tappet and tappet guide hole....................................................... 82 4. Inspecting and repairing cylinder block, crankshaft, piston and oil pan............................................. 83 4.1 Measuring cylinder inside diameter............................................................................. 83 4.2 Reboring cylinder.............................................................................................. 84 4.2.1 Measuring piston outside diameter........................................................................ 84 4.2.2 Boring finish dimension.................................................................................. 84 4.3 Measuring piston ring end gap.................................................................................. 85 4.4 Measuring clearance between piston ring groove and piston ring................................................. 85 4.5 Measuring piston pin bore diameter and piston pin outside diameter............................................. 86 4.6 Measuring connecting rod end play.............................................................................. 86 4.7 Inspecting connecting rod bend and twist....................................................................... 87 4.8 Measuring clearance between connecting rod bearing and crankpin................................................ 88 4.9 Measuring clearance between main bearing and crankshaft journal................................................ 89 4.10 Measuring crankshaft runout................................................................................... 90 4.11 Replacing crankshaft gear..................................................................................... 90 4.11.1 Removing crankshaft gear................................................................................ 90 4.11.2 Installing crankshaft gear.............................................................................. 90 4.12 Measuring distortion cylinder block top surface............................................................... 91 REASSEMBLY OF BASIC ENGINE................................................................................................. 93 1. Reassembling cylinder block, crankshaft, piston and oil pan......................................................... 94 1.1 Installing main bearing........................................................................................ 94 1.2 Installing crankshaft.......................................................................................... 94 1.3 Installing main bearing cap.................................................................................... 95 1.4 Inserting side seal............................................................................................ 95 1.5 Installing main bearing cap bolt............................................................................... 96 1.6 Measuring crankshaft end play.................................................................................. 96 1.7 Reassembling piston and connecting rod......................................................................... 97 1.8 Installing piston.............................................................................................. 98 1.9 Installing piston and connecting rod........................................................................... 98 1.10 Installing connecting rod cap................................................................................. 99 1.11 Installing oil screen.........................................................................................100 1.12 Installing oil pan............................................................................................100 2. Reassembling gear case, timing gear and camshaft....................................................................101 2.1 Installing front plate.........................................................................................101 2.2 Rotating crankshaft............................................................................................101 2.3 Installing fuel injection pump camshaft........................................................................101 2.4 Installing camshaft............................................................................................102 2.5 Installing idler gear..........................................................................................102 2.6 Inspecting and adjusting timing gear after installation........................................................103 2.6.1 Inspecting backlash......................................................................................103 2.7 Installing governor weights and sliding shaft..................................................................103 2.8 Installing speed control lever and governor shaft..............................................................104 2.9 Installing relief valve........................................................................................104 2.10 Installing oil pump...........................................................................................104 2.11 Installing PTO gear...........................................................................................105 2.12 Installing timing gear case...................................................................................105 2.13 Installing crankshaft pulley..................................................................................105 2.14 Installing gear pump housing..................................................................................106 2.15 Installing tappet.............................................................................................106 3. Reassembling flywheel...............................................................................................107 3.1 Installing oil seal case.......................................................................................107 3.2 Installing flywheel housing....................................................................................107 3.3 Installing flywheel............................................................................................108 4. Reassembling cylinder head and valve mechanism......................................................................109 4.1 Cleaning cylinder head bottom surface..........................................................................109 4.2 Installing valve stem seal.....................................................................................109 4.3 Installing valve spring........................................................................................109 4.4 Installing valve lock..........................................................................................110 4.5 Installing cylinder head gasket................................................................................110 4.6 Installing cylinder head assembly..............................................................................110 4.7 Tightening cylinder head bolts.................................................................................111 4.8 Inserting push rod.............................................................................................111 4.9 Reassembling rocker shaft assembly.............................................................................112 4.10 Installing rocker shaft assembly..............................................................................112 4.11 Adjusting valve clearance.....................................................................................113 4.12 Installing rocker cover.......................................................................................113 4.13 Installing torque spring set..................................................................................113 FUEL SYSTEM................................................................................................................115 1. Removing fuel system................................................................................................116 1.1 Removing fuel pipe and fuel injection nozzle...................................................................116 1.1.1 Removing fuel injection pipe.............................................................................117 1.1.2 Removing fuel injection nozzle...........................................................................117 1.2 Removing fuel filter...........................................................................................118 1.3 Removing governor..............................................................................................119 1.3.1 Disconnecting tie rod from control rack..................................................................120 1.3.2 Removing governor shaft and speed control lever..........................................................120 1.4 Removing fuel injection pump...................................................................................121 2. Disassembling, inspecting and reassembling fuel system..............................................................122 2.1 Disassembling and inspecting fuel injection nozzles............................................................122 2.1.1 Inspecting and adjusting fuel injection valve opening pressure...........................................123 2.1.2 Inspecting fuel spray pattern of fuel injection nozzle...................................................124 2.1.3 Cleaning and replacing faulty nozzle.....................................................................124 2.2 Reassembling fuel injection nozzles............................................................................125 2.3 Inspecting fuel injection pump on engine.......................................................................126 2.4 Disassembling and inspecting fuel injection pump...............................................................126 2.4.1 Removing swivel nipple...................................................................................127 2.4.2 Removing tappets.........................................................................................127 2.4.3 Removing plunger.........................................................................................127 2.4.4 Removing delivery valve..................................................................................128 2.5 Reassembling fuel injection pump...............................................................................129 2.5.1 Installing plunger barrel................................................................................129 2.5.2 Assembling delivery valve................................................................................130 2.5.3 Assembling control sleeve................................................................................130 2.5.4 Assembling plunger.......................................................................................130 2.5.5 Installing tappet........................................................................................131 2.5.6 Installing control rack..................................................................................131 2.5.7 Tightening delivery valve holder.........................................................................132 2.5.8 Inspecting control rack for smooth operation.............................................................132 2.5.9 Installing lock plate....................................................................................132 2.5.10 Installing swivel nipple................................................................................132 2.6 Disassembling and inspecting governor cover....................................................................133 2.7 Reassembling governor cover....................................................................................133 2.8 Disassembling and inspecting torque spring set.................................................................134 2.9 Reassembling torque spring set.................................................................................134 2.9.1 Torque spring set, single spring type....................................................................135 2.9.2 Reassembling torque spring set, double spring type.......................................................136 2.10 Inspecting fuel pump..........................................................................................137 2.11 Disassembling, inspecting and reassembling fuel filter (cock switch type, push botton)........................138 2.12 Disassembling, inspecting and reassembling fuel filter (cock switch type, changeover).........................139 3. Installing fuel system..............................................................................................140 3.1 Installing fuel injection pump.................................................................................140 3.2 Installing governor............................................................................................141 3.2.1 Installing speed control lever and governor shaft........................................................142 3.2.2 Connecting tie rod.......................................................................................142 3.2.3 Installing torque spring set (Single spring, double spring)..............................................143 3.2.4 Installing torque set spring (Double spring, two point control)..........................................143 3.2.5 Installing rack set screw................................................................................144 3.3 Installing fuel filter.........................................................................................145 3.4 Installing fuel pipe and fuel injection nozzles................................................................146 3.4.1 Installing fuel injection nozzle.........................................................................146 3.4.2 Installing fuel return pipe and fuel injection pipe......................................................146 LUBRICATION SYSTEM.........................................................................................................147 1. Removing lubrication system.........................................................................................148 1.1 Removing oil filter, relief valve and oil pressure switch......................................................148 1.1.1 Removing oil filter......................................................................................149 1.1.2 Removing relief valve....................................................................................149 1.1.3 Removing oil pressure switch.............................................................................149 1.2 Removing oil pump, oil pan and oil screen......................................................................150 1.2.1 Removing oil pump........................................................................................150 2. Disassembling, inspecting and reassembling lubrication system.......................................................151 2.1 Inspecting oil pump............................................................................................151 2.1.1 Measuring clearance between oil pump housing inside diameter and oil pump outer gear outside diameter....151 2.1.2 Measuring the end clearance between oil pump outer gear width and oil pump housing depth.................151 2.2 Inspecting relief valve........................................................................................152 2.3 Inspecting oil pressure switch.................................................................................152 3. Installing lubrication system.......................................................................................153 3.1 Installing oil pump, oil pan and oil screen....................................................................153 3.1.1 Installing oil pump......................................................................................153 3.2 Installing oil filter, relief valve and oil pressure...........................................................154 3.2.1 Installing oil pressure switch...........................................................................154 3.2.2 Installing relief valve..................................................................................154 3.2.3 Installing oil filter....................................................................................155 COOLING SYSTEM.............................................................................................................157 1. Removing cooling system.............................................................................................158 1.1 Removing cooling fan, fan pulley, V-belt, thermostat, thermoswitch and water pump..............................158 2. Disassembling, inspecting and reassembling cooling system...........................................................159 2.1 Disassembling and inspecting thermostat........................................................................159 2.2 Inspecting thermostat..........................................................................................159 2.3 Reassembling thermostat........................................................................................160 2.4 Inspecting thermoswitch........................................................................................160 2.5 Inspecting water pump..........................................................................................160 2.5.1 Checking water pump for smooth rotation..................................................................160 3. Installing cooling system...........................................................................................161 3.1 Installing cooling fan, fan pulley, V-belt, thermostat, thermoswitch and water pump............................161 INLET AND EXHAUST SYSTEMS..................................................................................................163 1. Removing inlet and exhaust systems..................................................................................164 1.1 Removing inlet cover and exhaust manifold......................................................................164 2. Disassembling, inspecting and reassembling inlet and exhaust systems................................................165 2.1 Inspecting inlet cover and exhaust manifold....................................................................165 2.2 Measuring distortion of inlet and exhaust manifold.............................................................165 3. Installing inlet and exhaust systems................................................................................166 3.1 Installing inlet cover and exhaust manifold....................................................................166 ELECTRICAL SYSTEM..........................................................................................................167 1. Removing electrical system..........................................................................................169 1.1 Removing starter...............................................................................................169 1.2 Inspection before removing alternator (A007TA0171B (12V-40A), A007TA8271A (24V-25A))...........................170 1.2.1 Inspecting alternator operation..........................................................................170 1.2.2 Handling precaution......................................................................................170 1.2.3 Inspecting regulated voltage.............................................................................171 1.2.4 Inspecting output........................................................................................171 1.3 Removing alternator............................................................................................172 1.4 Removing stop solenoid.........................................................................................172 1.5 Removing glow plug.............................................................................................173 2. Disassembling, inspecting and reassembling electrical system........................................................174 2.1 Inspection before disassembling starter (M000T60481 (12V-1.2kW), M001T68381 (12V-1.7kW)).......................174 2.1.1 Inspecting pinion clearance..............................................................................174 2.1.2 Inspecting magnetic switch...............................................................................175 2.1.3 No load test.............................................................................................176 2.2 Disassembling and inspecting starter (M000T60481 (12V-1.2kW), M001T68381 (12V-1.7kW))..........................177 2.3 Preparation before disassembling...............................................................................178 2.3.1 Removing pinion set......................................................................................178 2.3.2 Removing magnetic switch.................................................................................178 2.3.3 Removing rear bracket....................................................................................179 2.3.4 Removing brush holder and brush assembly.................................................................179 2.3.5 Removing armature and yoke...............................................................................179 2.3.6 Removing overrunning clutch..............................................................................180 2.3.7 Removing gear shaft......................................................................................180 2.4 Inspecting and repairing starter (M000T60481 (12V-1.2kW), M001T68381 (12V-1.7kW))..............................181 2.4.1 Inspecting brushes for wear..............................................................................181 2.4.2 Measuring brush spring load..............................................................................181 2.4.3 Inspecting brush holder for insulation...................................................................181 2.4.4 Measuring commutator radial runout.......................................................................182 2.4.5 Measuring commutator outside diameter....................................................................182 2.4.6 Measuring undercut depth.................................................................................182 2.4.7 Checking armature coil...................................................................................183 2.4.8 Inspecting rear bracket..................................................................................183 2.4.9 Inspecting overrunning clutch............................................................................184 2.4.10 Inspecting pinion.......................................................................................184 2.4.11 Inspecting front bracket................................................................................184 2.4.12 Inspecting gears of starter.............................................................................184 2.4.13 Inspecting continuity of magnetic switch (between M terminal and case)..................................184 2.4.14 Inspecting insulation of magnetic switch (between M terminal and B terminal)............................184 2.5 Reassembling starter (M000T60481 (12V-1.2kW), M001T68381 (12V-1.7kW))..........................................185 2.5.1 Applying grease..........................................................................................185 2.5.2 Installing pinion........................................................................................186 2.5.3 Installing gear shaft....................................................................................186 2.5.4 Installing yoke and armature.............................................................................187 2.5.5 Installing brush holder and brush assembly...............................................................187 2.5.6 Installing rear bracket..................................................................................187 2.5.7 Installing magnetic switch...............................................................................187 2.5.8 Inspecting pinion clearance..............................................................................188 2.6 Inspection before disassembling starter (M002T66071 (24V-3.2kW))...............................................189 2.6.1 Inspecting pinion clearance..............................................................................189 2.6.2 Inspecting magnetic switch...............................................................................190 2.6.3 No load test.............................................................................................191 2.7 Disassembling and inspecting starter (M002T66071 (24V-3.2kW))..................................................192 2.7.1 Preparation before disassembling.........................................................................193 2.7.2 Removing magnetic switch.................................................................................193 2.7.3 Removing rear bracket....................................................................................193 2.7.4 Removing brushes, brush holder, yoke and armature........................................................194 2.7.5 Removing ball bearing....................................................................................194 2.7.6 Removing cover set.......................................................................................194 2.7.7 Removing center bracket..................................................................................195 2.7.8 Removing reduction gear and spring set...................................................................195 2.7.9 Removing pinion set......................................................................................195 2.7.10 Removing lever and pinion shaft.........................................................................195 2.8 Inspecting and repairing starter (M002T66071 (24V-3.2kW))......................................................196 2.8.1 Inspecting brushes for wear..............................................................................196 2.8.2 Measuring brush spring load..............................................................................196 2.8.3 Inspecting brush holder for insulation...................................................................196 2.8.4 Measuring commutator radial runout.......................................................................197 2.8.5 Measuring commutator outside diameter....................................................................197 2.8.6 Measuring undercut depth.................................................................................197 2.8.7 Checking armature coil...................................................................................198 2.8.8 Inspecting continuity of yoke assembly...................................................................199 2.8.9 Inspecting insulation between yoke body and brush........................................................199 2.8.10 Inspecting center bracket...............................................................................199 2.8.11 Inspecting overrunning clutch...........................................................................200 2.8.12 Inspecting pinion.......................................................................................200 2.8.13 Inspecting front bracket................................................................................200 2.8.14 Inspecting gears of starter.............................................................................200 2.8.15 Inspecting continuity of magnetic switch (between M terminal and case)..................................200 2.8.16 Inspecting insulation of magnetic switch (between M terminal and B terminal)............................200 2.9 Reassembling starter (M002T66071 (24V-3.2kW))..................................................................201 2.9.1 Applying grease..........................................................................................201 2.9.2 Installing lever and pinion shaft........................................................................202 2.9.3 Installing pinion........................................................................................202 2.9.4 Installing spring set and reduction gear.................................................................202 2.9.5 Installing center bracket................................................................................202 2.9.6 Adjusting pinion shaft end play..........................................................................203 2.9.7 Installing bearing.......................................................................................203 2.9.8 Installing armature, yoke, brush and brush holder........................................................203 2.9.9 Installing rear bracket..................................................................................204 2.9.10 Installing magnetic switch..............................................................................204 2.9.11 Inspecting pinion clearance.............................................................................204 2.10 Disassembling and inspecting alternator.......................................................................205 2.10.1 Separating front bracket from stator....................................................................206 2.10.2 Removing pulley.........................................................................................206 2.10.3 Removing rear bearing...................................................................................206 2.10.4 Removing front bearing..................................................................................206 2.10.5 Removing stator.........................................................................................207 2.10.6 Removing regulator assembly.............................................................................207 2.10.7 Removing rectifier assembly.............................................................................207 2.11 Inspecting and repairing alternator...........................................................................208 2.11.1 Inspecting rectifier....................................................................................208 2.11.2 Inspecting rotor........................................................................................208 2.11.3 Inspecting stator.......................................................................................209 2.11.4 Inspecting brushes for wear.............................................................................209 2.11.5 Replacing brushes.......................................................................................210 2.12 Reassembling alternator.......................................................................................211 2.12.1 Installing rectifier assembly and regulator assembly....................................................212 2.12.2 Installing stator.......................................................................................212 2.12.3 Installing front bearing................................................................................212 2.12.4 Installing rear bearing.................................................................................213 2.12.5 Installing pulley.......................................................................................213 2.12.6 Assembling stator and front bracket.....................................................................213 2.13 Inspecting glow plug..........................................................................................214 3. Installing electrical system........................................................................................215 3.1 Installing glow plug...........................................................................................215 3.2 Installing stop solenoid.......................................................................................215 3.3 Installing stop solenoid (ETR type)............................................................................216 3.3.1 Procedure for installing stop solenoid (ETR type)........................................................216 3.3.2 Verification after reassembling (ETR type)...............................................................216 3.4 Installing stop solenoid (ETS type)............................................................................217 3.4.1 Procedure for installing stop solenoid (ETS type)........................................................217 3.4.2 Verification after reassembly (ETS type).................................................................218 3.5 Installing alternator..........................................................................................219 3.6 Installing starter.............................................................................................219 ADJUSTMENT AND OPERATION...................................................................................................221 1. Inspection and adjustment of engine.................................................................................222 1.1 Inspecting and adjusting valve clearance.......................................................................222 1.1.1 Preparation for valve clearance inspection...............................................................222 1.1.2 Inspecting valve clearance...............................................................................223 1.2 Inspecting fuel injection timing...............................................................................224 1.3 Adjusting fuel injection timing................................................................................225 1.4 Inspecting and adjusting low idle speed and high idle speed....................................................226 1.4.1 Preparation..............................................................................................226 1.4.2 Adjusting low idle speed.................................................................................226 1.4.3 Adjusting high idle speed................................................................................226 1.5 Bleeding fuel system...........................................................................................227 1.5.1 Bleeding air from fuel filter............................................................................227 1.5.2 Bleeding air from fuel injection pump....................................................................228 1.6 Adjusting V-belt tension.......................................................................................229 2. Break-in operation..................................................................................................230 2.1 Starting up....................................................................................................230 2.2 Inspecting engine condition after starting up..................................................................230 2.3 Break-in operation time........................................................................................230 2.4 Inspection and adjustment after break-in operation.............................................................230 3. Performance test (JIS standard).....................................................................................231 3.1 Engine equipment condition.....................................................................................231 3.2 Test items and purposes........................................................................................231 3.2.1 Operation load test......................................................................................231 3.2.2 Continuous load test.....................................................................................231 3.2.3 Low idle test............................................................................................231 3.3 Other inspections..............................................................................................231 3.4 Engine output adjustment.......................................................................................231 3.4.1 Standard atmospheric conditions:.........................................................................231 3.4.2 Calculation of corrected power...........................................................................232 TROUBLESHOOTING............................................................................................................233 1. Troubleshooting.....................................................................................................234 1.1 Before troubleshooting.........................................................................................234 1.2 Starting trouble...............................................................................................235 1.2.1 Check items before troubleshooting.......................................................................235 1.2.2 Problem: Starting trouble................................................................................235 1.3 Knocking.......................................................................................................236 1.3.1 Check items before troubleshooting.......................................................................236 1.3.2 Problem: Knocking........................................................................................236 1.4 Overheating....................................................................................................237 1.4.1 Check items before troubleshooting.......................................................................237 1.4.2 Problem: Overheating.....................................................................................237 1.5 Excessive black smoke..........................................................................................238 1.5.1 Check items before troubleshooting.......................................................................238 1.5.2 Problem: Excessive black smoke...........................................................................238 1.6 Idling malfunction.............................................................................................239 1.6.1 Check items before troubleshooting.......................................................................239 1.6.2 Problem: Unstable idling.................................................................................239 1.7 Low output.....................................................................................................240 1.7.1 Check items before troublshooting........................................................................240 1.7.2 Problem: Low output......................................................................................240 INSPECTION RECORD SHEET....................................................................................................241
DESCRIPTION:
Mitsubishi L series Diesel Engines Service Manual
INTRODUCTION :
- This service manual describes the specifications, maintenance and service procedures for Mitsubishi diesel engines. To maintain the performance of the engine for many years and to ensure safe operation, it is important to use the engine correctly and conduct regular inspection and maintenance, and also to take necessary measures which involves the disassembly, inspection, repair and reassembly of the engine and engine parts.
- Read this manual carefully and understand the work procedures fully before disassembling, inspecting, repairing or reassembling the engine. The contents of the manual are based on the engine models that are being produced at the time of publication. Due to improvements made thereafter, the actual engine that you work on may differ partially from the one described in this manual.
How to use this manual:
- This service manual consists of several Groups, which are arranged so as to allow you to make reference quickly to specifications, maintenance standards, adjustment procedures and service procedures including methods for disassembly, inspection, repair and reassembly of the Mitsubishi Diesel Engine (standard model for land use). A short summary describing the content of each Group is given in the General Contents page, and there is also a detailed table of contents at the beginning of each Group.
- Regarding the procedures for operation and periodical maintenance of the engine, refer to the Operation and Maintenance Manual. For information on the engine components and ordering of service parts, refer to the Parts Catalogue. Structure and function of the engine are described in the relevant training manuals.
VIDEO PREVIEW OF THE MANUAL:
IMAGES PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the same manual used by the DEALERSHIPS to SERVICE your vehicle.
- The manual can be all yours – Once payment is complete, you will be taken to the download page from where you can download the manual. All in 2-5 minutes time!!
- Need any other service / repair / parts manual, please feel free to contact us at heydownloadss @gmail.com . We may surprise you with a nice offer