SERVICE MANUAL MITSUBISHI DIESEL ENGINE L-SERIES L2A,L2C,L2E L3A,L3C,L3E APRIL 2001 MITSUBISHI HEAVY INDUSTRIES, LTD.FOREWARD This Service Manual, prepared for the benefit of service mechanics, describes the construc- tion and service procedures of the Mitsubishi diesel engine models L series (L2A, L2C, L2E, L3A, L3C and L3E). We hope that this manual will be helpful for you to make proper and fast service operations, ensuring that the engines are able to keep top performance over an extended period of time, This manual has been prepared on the basis of the latest engines in May 1997 and, therefore, does not contain possible changes in specification to which those engines are subject there- after, Pub. No, 99619-15180MITSUBISHI DIESEL ENGINE L MODELS CONTENTS GENERAL INFORMATION . ENGINE LUBRICATING SYSTEM FUEL SYSTEM .GOVERNOR SYSTEM oO IN |m | . COOLING SYSTEM -AIR CLEANER ELECTRICAL SYSTEM . SERVICE SPECIFICATIONS AND STANDARDSGroup oY? | GENERAL 01 ENGINE MODEL AND ENGINE NUMBER ~ 02 SECTIONAL VIEWS 03 FEATURES - 04 PERFORMANCE CURVES 05 ENGINE SPECIFICATIONS - 06 MAINTENANCE -- 07 TROUBLESHOOTING Tractor Application Excavator Application= G 0-01 ENGINE MODEL AND ENGINE NUMBER Engine Model and Engine Number 0, | Model, Classification, and Use (1) Engine model and Model [Application | Use La [1s Te~ | er For Aericarl vee | | ve |e = For austial La | ise [en = Fer eaport oni + we (2) The engine model number may be broken down as follows : ac-! A , “Lsusivisin of speciation Appliation Pegged 3 nl ieee eae) slider bore egg am.) Nonber of e's, (2: Two, 3: Three) Name of series (L: Lightwoight engine) gine model embossment and engine number stamp | (1) Embossment of engine model and cylinder vol ‘The engine model and cylinder volume are embos- sed on the side of injection pump mounting portion of the cylinder block, (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 as shown Number Engine model to01~ (ALL models) 3G L | 0.80 @ c ) Cc Engine Model and Cylinder Volume P SP SII Q 1001 ‘e—aull gine Number © LC e WwTow ACS we ca (eiOs 0-02 SECTIONAL VIEWS L Cross Section (L3C)ea = 0-02 GJ Sectional Views of Governor (L3C)Ne G 0-02 SECTIONAL VIEWS Oil Pump and Oil Filter.er nd 0-03 FEATURES 0-03 1. Aim of development The L series aim at the through going compact, lightweight engines which are suitable for super- seding gasoline engines to power lawn mowers, vehicles, etc, The high-speed (3600. rpm continuous) specification engines are also avail- able to apply them to the generators, welders, and marine use, The L series are, the smallest ‘and lightest water-cooled diesel engines in the world, 2, Features of the new series c }) Small and lightweight engine The new L series are 10 to 20% smaller in weight and 15 to 20% smaller in contour volume than the same class of engines of competitors, (2) Low noise and economical fuel consumption Low noise and economical fuel consumption are attained by the well designed cylinder block con- struction (having curved side faces), the rearranged combustion chambers, and the small sized fuel injection system, (3) Easy starting ‘The engine can be started instantly only by keep- ing the starting switch key in the ON position for about 6 seconds to allow automatic feeding of current to the glow plugs, eliminating the neces- _Iniection Pump sity of setting the key to the HEAT position, (For engines with the automatic glow plug system, ) The new governor mechanism also contributes to easy engine start, because it increases fuel injection and delays injection timing for ‘easy engine start without necessity of moving the throt- tle lever to the " full throttle” position,or GF 0-03 FEATURES (4) Multipurpose engine The L series engine can be equipped with various kinds of optional devices. Ex. Okey-OFF stop system (Fuel cutoff valve) Torque spring OManual stop lever Nozzle Holders and Return Pipeer vo. Gy 0-04 PERFORMANCE CURVES 0-04 Gy MLZ Series Performance Curves | = 1 he a BA I Mg 4 eee rpe 5 | a é La te ell | A] fl] fe | é | truant i |." Trerniene| cones : — 4] . 6 « | | : uo | eB i | | ir [tl Fi | : ; rr a ed One ae) Bae i ‘tgs sn om tobe toed om WA ae om 6270 = 2 Barometric pressure: 7 . Ti? ‘Ambient temperature: 20°C | E Vapor pressure + 10, Smmig " f i i Z| | amin conn | | § [em | T° foe “Se a8 a8 as oe roe eed om Lec= Gy 0-04 PERFORMANCE CURVES MIL3 Series Performance Curves b 7 SSS f LA e 5 a] yy sS i L g a [| / 8 LA 2 Weel $4 ' con | jo fio & Engine speed rpm = “ Ba ise 1 pwn 6270 ner | ioe he | Barometric pressure: 736mmHg t se | Ambient temperature: 20°C By Vapor pressure 10, 5mmHg * T 2" toxermfnent | i [continue AA — | € con! fr RE he © LETT 5 | se —10—Tas tee Nar Ne 0-05 ENGINE SPECIFICATIONS 0-05 Item ] ee tea} zc | ize | isa | usc | ose Engine type ‘eycle, water-cooled, vertical, diesel General | Compression ratio 2 Combustion chamber Swirl chamber Dry weight 61 5 | Number of cylinders 2 3 | cylinders | Bore x Stroke (mm) 85x70 | 70x70 | 76x70 | 65x70 | 70x70 | 76x70 Total displacement (2) | 0.464 | 0.538 | 0,635 | 0.696 | 0.808 | 0.952 Perfor. | Maximum power " Maximum torque See the engine performance curves, mance Specific fuel consumption List In every direction every 25° continuous 30'in a short time(within 30 min, ) ability | (to lower limit of oil level) Injection pump Bosch NC type Fuel System | Nozze Throttle type veer | Fuel IS No, 2 oF No, 3 diesel fuel Lubri- | Lubricating method Forced lubrication cation | oil filtration Paper-element filter (Full-flow type) system | ot eapciy 8) Upper timt/owe iit feces 0 bir ones) 24/14 3.0/1.5, 3.6/1.8 07 4.8/3.0 Cooling | Cooling method Forced water circulation with pressurized radiator system | S2elant capacity (2) te Ag si (except, rditor and hase) B A ‘Aiternator (V/A) 12/18 oF 12740 eves: : Starting motor (V//AW) 12/1,2 oF 12/1.6 sories Battery (an) 45 _or more 60_or more —n-CE] 0-06 MAINTENANCE MEEngine oil and oil filter 1, Checking and correcting the engine oil level, (1) Place the engine horizontally, (2) Check.the oil level with the oil level gauge, If the oil level has fallen to the lower limit, add cil up to the upper limit, (3) Check the oil level before (everyday) operation of the engine, Ca © Whenever added, check the oil level again after waiting for about 1 minute, © When adding oil, use only the same engine oil as used in the engine. ‘© When checking the oil level in an engine which has been long out of use, run the engine for several minutes, stop the engine, and check the oil level after a while, 2, Oil change intervals Change the oil after initial 50-hour operation of a new engine and, thereafter, every 100 hours of operation, Replace the oil filter after initial 50-hour operation of anew engine and, thereafter, every 200 hours of operation, 3, Engine oil to be used Engine oil must conform to the API classification and viscosity number specified in the table at right, Upper tit | [Normal eve) Lower iit (Checking Oil Level Olt Level Gauge PI classification | Atm, temperature Viscesity ‘Above 200 ‘SAE30 (lass C0 o better S200 ‘SAEZ0 Below 5 ‘SAE1OW-30 cise 09 tr 200 Ne speed speatea || Al seasons 1 tn ene =12-4, When replacing the oil filter, use only the genuine replacement filter. Filter 5. Changing the oil To change, oil, first warm up the engine and remove the drain plug to let oil drain completely. Put back the drain plug and refill the cil pan with fresh engine oll through the oil filler, © Oil pan drain plug tightening torque : 5.0 — 6.0 kfm [49 — 59 N-n} © Oil capacity (Upper limit//Lower limit) Le: 24071ae L3: Ordinary type 3.08//1.52 Deep type 3.62,/1.82 0 4.80,/3,08 (excluding 0.5 2 of oil filter capacity) 6. Replacing the oil filter (1) Remove the oil filter with a filter wrench or the like, (2) Thoroughly clean the filter mounting surface of the filter bracket, Install the new filter with the O-ring coated with engine oil and tighten secur- ely by hand, © Tightening torque 1.0 = 1.3 kofem [9.8 — 12.7 Nal (i Fite Wrenen Caution Be careful not to twist the O-ring. (3) Run the engine for several minutes and make ‘sure that no oil leaks, (4) After stopping the engine, check the oil level, necessary, add oil, =1B-G 0-06 MAINTENANCE © Tightening torque = io bolt ie 5 — 83.4 We al The rocker assembly (the rocker ‘arms, ‘shat, and stays) is to be kept removed when the cylinder (ylinger Head Bolt Tight ing Sequence (L2) 1.5 — 2.2 kofem (14,7 — 21.6 Nem MAdjusting the valve clearance Caution Be sure to retighten the ¢ adjusting the valve clearance, (1). Set the cylinder to be adjusted to the top dead center of compression stroke, © Valve clearance : 0,25 mm (cold) for both Intake and exhaust valves (2) The top dead center of compression stroke can be obtained by aligning the T.0.C. (Top Dead fer head bolts before Center) mark (notch) on the crankshaft pulley Adjusting Valve Clearence with the mark on the gear case. (3). First align the T.D,C, mark for the No, I cylin. der, Confirm that the valves do not move up and down when the crankshaft is turned about 20 in normal direction of rotation and in reverse direction, (4) When setting the top dead center for the No, 2 cylinder and that for the No.3 cylinder, perform as follows : -uea) L2 (Two-cylinder engine) From T.0,C, (Top Dead Center) for the No.1 cylinder, turn the crankshaft 180° clockwise, and the No, 2 cylinder is set to T.D.C, b) 13. (Three-cylinder engine) From T,D.C, for the No, | cylinder, turn the crankshaft 240° clockwise to set the No.3 cylinder T,D,C, Further, turn the crankshaft 240° clockwise, and the No, 2 cylinder is set to T.D.C., WMAdjusting the fan belt tension Move the alternator so that the belt may deflect about 10 mm deep when depressed by thumb force (about 10 kg) at a point mid- way between the alternator pulley and crankshaft pulley. MBleeding air from the fuel system (1) Loosen the air vent screw on the fuel filter, (2) For the engine without fuel pump, in which fuel drops spontaneously and enters the fuel filter, for fuel to overtiow the fuel filter, Then, tighten the air vent screw, (3) For the engine with the electromagnetic fuel pump, turn the starting switch key to the ON position to feed fuel to the fuel filter, Loosen the air vent screw on the filter and, after air escapes, tighten the air vent screw, (4) Loosen the air vent screw on the fuel injection pump to let air escape from the fuel pipe and fuel injection pump, (5) Air in the injection pipes and nozzles is driven out automatically by cranking up of the engine, Mark on eer case TDC mark on crankshaft pulley Timing mark Approx. 10mm (10g of thom force) Ajusting Fan Belt Tension Fuel Filter Air Bleeding Fuel injection Pump air Bleeding —15—tan Ne. 0-06 MAINTENANCE Replacing the fuel filter w (2) @) @ (o) Cartridge type Replace the cartridge type filter as an assembly if accumulation of dust or water in its element is evident, Regular replacement interval is every 400 hours of engine operation, Check the filter every 100 hours and, if necessary, replace early, Separate type filter with cock Close the filter cock, remove the ring aut, ‘and take out the element from the inside of filter, Clean or replace the element, Fuel pump ‘The foolowing three types of fuel pumps are available, Which type of pump is to be used for ‘an engine depends upon engine specification, Plunger type electromagnetic pump The plunger-type pumps are classified as the ‘common, large-sized pump having a filter element or as the compact, light-weight, low-priced pump without filter element, Regardless of classification, check the plun ger-type pump for normal function and make sure that it does not leak fuel, Only on the pump with filter element, remove the cover and clean orrepalce the filter element, Diaphragm type electromagnetic pump The diaphragm type electromagnetic pump should not be disassembled, Like the com- pact plunger-type pump mentioned above, check that the pump funcitons normally and does not leak fuel, Cartridge Type Fiter oS *y Plunger type (Common) Fuel Pump Plunger type (Compact) Fuel pump -16— Brae Magnet CoverNe. 0-06 (c) 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, As the camshaft rotates, the fuel pump cam pushes the tappet to actuate the diaphragm of the fuel pump, This type of fuel pump is provided with 2 priming lever to allow manual feed of fuel, Check the fuel pump for normal function and make sure that it does not leak fuel or make ‘abnormal sound, Adapter camenatt, foe injection pump Fuel Pump Priming lever Mechanical type Fuel Pump Pump type _| Delivery flow _| Shut-off pressure| "tino [887s moe | oan) Prager pe [e/a aoe | 8 ene Diaphragm type [0,371 /nin er mre) © t8t/ow Mechanical type [0,225/nin or more] (3 49t/em At 12V (electromagnetic pumps only) and at 20°C (4) Draining water from the water sedimenter For the engine provided with a water sedimenter, remove the filter ring nut involved and take out the cup, Wipe off water and dust accumulated in the cup, —17-0-06 MAINTENANCE MiChecking and adjusting injection timing To check and adjust injection timing, use the follow- ing procedure (1). Disconnect the No, | injection pipe, (2) Remove the No, | delivery valve from the injec- tion pump, Put back the valve holder only. Caution Be sure to shut off the fuel feed pipe before removing the delivery valve, (3) Remove the tie-rod cover and disconnect the tie rod from the control rack, (4) Set the control rack to a midway position in the working range, (5) Open the fuel feed pipe and make sure that fuel flows from the delivery valve holder. (6) Turn the crankshaft in the direction of normal rotation (clockwise) and find an instant that fuel stops flowing from the delivery valve hol: der, This instant is the real injection timing, Caution The standard injection timing differs with engine specification and engine speed. Check to see whether the real injection timing coincides with the standard injection timing (whether the IT mark on the crankshaft pulley isin alignment with the mark on the gear case). (7) If they do not coincide with each other, adjust thickness of the injection pump mounting shim, Increasing or decreasing thim thickness by 0, 1 mm causes the real injection timing to vary about I", -1 Removing Deliverry Valve Injection Timing Mark Adjusting Shim Thickness(8) To remove the injection pump, first disconnect, the injection pipes and fuel feed pipe from the injection pump, Then, remove the tie-rod cover and tie rod, Dismount the pump assembly. Installation of the pump is the reversal of removal, (9) In the dusty place or when the engine is dirty, removal of a delivery valve may cause intrusion fof dust into the injection pump, Under such circumstances leave the delivery valve installed and check injection timing using the following procedure : (2) Remove the tie-rod cover and disconnect the tie rod from the control rack, (b) Set the contro! rack to a midway position in the working range, Disconnect the injection pipe from the No, | nozzle, Turn the crank- shaft gradually in the direction of rotation Until swelling of fuel is found at the open end of the injection pipe, This instant is the real injection timing, which wi I" late than the standard injection timing, come approx, Adjusting the engine speeds To adjust engine speed, remove the cooling fan and install the safety cover over the fan to prevent getting hurt, For speed adjustment specification, see 8-05, (1) The upper limit of engine speed can be adjusted with the HIGH-SPEED stopper bolt, This stopper bolt has been set properly and sealed in the factory before shipping of the engine, Never tamper with the seal unless it is necessary, —19— © Removing injecto nt Pump Standard Injection Timing model le tom a Upto 2000 | sTOC IS" = ‘ver 2000~ 5 Under 3¢00_ | 87°C i" = over 3800 | TOC is =Caution ton Ne. 0-06 MAINTENANCE (2) The lower limit of engine speed can be adjusted with the LOW-SPEED stopper bolt, (3) Never remove the sealing cap unnecessarily to adjust the torque spring set, For the proper disassembling procedure, see 4-02, Low-sPeeD HIGH-SPEED Warm up the engine (until coolant temperature serbot rises up to 60°C or above) before adjusting engine speeds. HIGH-SPEED and LOW-SPEED Set Bolts (4) During running of the engine for speed adjust- ment, check the engine for gas leak, water leak, oll leak, and fuel leak, (5) After adjustment, perform engine acceleration and deceleration test to confirm that the engine is free from hunting and smoking, MiChecking and adjustment of nozzles To check and adjust the injection nozzles, use the following procedure = Injection start pressure Testing Inlection Start Pressure (1). Remove the nozzle assembly to be tested from the cylinder head and set the nozzle on the nozzle tester, Perform air bleeding by moving the tester han. dle up and down, (2) Operate the handle at a speed of 60 rpm or more and read the gauge pressure of fuel inject- ed from the nozzle, © Injection start pressure :140%:*kgf/em? (13.72! ° Wa] (3) If reading of gauge pressure is not within the specified range, disassemble the nozzle and vary thickness of the adjusting shim, Increasing or decreasing shim thickness by 0, 1 ‘mm will cause injection pressure to vary about 10 kgt/on? [0.98 MPal —29—(4) When installing the nozzle, use the following values of tightening torque : © Nozzle tightening (to cylinder head) torque : 5.0 — 6.0 kgf+m [49 — 59 Nem) © Nozzle retaining nut tightening torque : 3.5 — 4.0 kgf-m [34 — 39 Nea) © Nozzle union collar tightening torque 2.5 — 3.0 kgf-m [25 — 29 Nal 2, Chattering test Operate the tester handle at @ speed of about | stroke per second, (1). Needle valve oscilation Its consedered normal i the nozzle injects fuel mist, making intermittent sounds, and oscillations of the needle valve are transmitted to the handle, (2) State of fuel mist injection The nozzle should inject fuel mist straight in the direction ofits axis, A nozzle is defective if it does not inject steadily or it injects fuel in several separate stripes, ‘A nozzle is defective if it spills fuel accumulated on the bottom of the nozzle after chattering test, However, a very small drop of fuel remaining on the tip of nozzle after chattering test may be regarded as normal, 3, Injection test Operate the tester handle at 2 speed of 4 to 6 strokes per second, © A nozzle should inject fuel mist uniformly in the shape of a cone, 4, Checking the compression pressure (1) Make sure of the following = (@)AII of the engine ol evel, air cleaner, starting motor, and battery are well-conditioned, (b)The engine is preferably warmed up (to a coolant temperature of 50°C or more), ~21- Installing Nozzle Assembly LI LI Good Bad Charttering Test Good Bad LJ Bad Atter-spiling Testing Compression Pressure0-06 MAINTENANCE (2) Measure the compression pressure using the following procedure : (@)Pull the stop lever to the position, (b)Remove the glow plug from the cylinder to be tested, Set the compression gauge adapter to that cylinder and install the gauge, (c)Crank the engine with the starting motor until a ‘non-injection™ stable reading of the compression gauge is obtained, (@after reading the gauge, sion gauge and adapter. plug. (€lCheck all cylinders using the procedure de. scribed above, remove the compres Put back the glow Engine speed 250 — 280 rpm | Compression presure 29 ~ 32 kg/em Pressure dterence between cylinders: Within 3 kg/cm —2—ae No 0-07 TROUBLESHOOTING son 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 @ trouble symptom, For example, trouble symptoms caused by the faulty injection pump, faulty injection nozzles, and improper cylinder compression, respectively, Will be much the same, To pass judgment on such a case, very close examination of the existing trouble symptom is necessary, The trouble-diagnosis charts on the succeeding pages are prepared in such a way of beginning with the most possible or easiest-to-inspect item and then proceeding stepwise to less possible or more compli- cated items, Before troubleshooting you should have a ‘right understanding of the following features about the construction and fuel combustion in the diesel engines, No. 0-07 @Normal engine operation is accompanied by ‘combustion noise (diesel knocking sounds). @A heavy-loaded engine exhausts some black smoke, @When operated singly an engine may vibrate because of high cylinder compression and large ‘output torque, @When an engine is accelerated or decelerated some hunting may occur, quickly, CAUTION Do not attempt to readjust or disassemble the injection pump for the purpose of troubleshooting, without use of a pump tester which is indispensable to measure injection quantity for each cylinder, ‘©To check whether state of combustion in a desired loosen the injection pipe cylinder is normal or not, to cut fuel feed to that cylinder, and find the resulting slowdown of the engine, Compare the degree of slowdown by that cylinder with that by another cylinder, —23—0-07 TROUBLESHOOTING MiHard starting Matters to be checked before diagnosis © Clogging of air cleaner © Coagulation of engine oil © Use of poor-guality fuel Lowering of cranking speed 2, Diagnosis Does preheating Does current tlw in glow plug | 4, | Inspect key _swite, stem operate | N° | circut as soon as key ewitcnis | 8° | wiring, and glow srmally ? turned to” H” (ON). indicator. | 4 yes yess{ Inspect glow plug. Is electric wir. {bees fuel pump, if provided, operate when | jo | Inspect fuel pump ing normal? \key switch is turned to ON? = | and/or wiring tyes Does fuel flow in fuel| jo | Does fuel get out when fuel injection | No cp || 7 ° imp air vent screw is ned ? 7» ded line? ump air vent screw is loosened ? pees Byes | Injection timing » oo Is engine putin order ? { ‘Adjust engine properly. ae oreer and valve timing ° i Ree dyes De neton vas (State of ul mis inecton No [papect mjecton noses. | operate normally? and injection start pressure a Z dyes Inspect valves, Is elinder compression normal? | Ne | pistons, piston rings, and cylinder head gosket, 8 Inspect injection pump, eoNo 0-07 Miknocking Diesel engines are usually accompanied by fuel ‘combustion noise (diesel knocking sounds) because of structural feature, A trouble should be suspected only when the engine makes abnormally large sounds, |, Matters to be checked before diagnosis © Clogging of the air cleaner @Use of poor-quality fuel (Small cetane number fuel such as used for burning) 2, Diagnosis Is injection timing normal ? No ‘Adjust injection timin, (Check for premature injection, ) ° ee dyes Do injection nozzles operate normally 7 x (Check for lowering of injection start pressure 1° | Inspect injection nozzles. £ and improper state of fuel mist injection, ) Syes [in cyngor compression narmar? | No [inspect valves, pistons, piston rings, [1s einer compression norma? = land cylinder head gasket, yes Does injection pump operate normally ? (Check for uniformity of injection quantity. ) ayes Mechanical noise (Worn or damaged main moving parts) —25—0-07 TROUBLESHOOTING Moverheating Matters to be checked before diagnosis @Shortage of coolant and leakage © Clogging of muffler © Loosening of fan belt © Clogging of radiator fins © Too rich antifreeze solution 2, Diagnosis Is engine operating condition moderate? Find the cause of (Check for overload continu: overloat ‘ous running, ) ayes Is cooling system | through, water pump, water for malfunctioning. ) dyes (Check cylinder head gasket for blowing hose, in good order ? | radiator fins for clogging, and thermostat and © Stagnation of cooling air © Defective thermostat No 2 1s injection timing is normal? | NO [ Agjust injection timing, NOTE : Overheating is mostly caused by mis-matching load of the engine. If overheating arises only when the engine drives a load, measure coolant temperature under the working load condition (full open thermostat) to see whether the measurement exceeds a point 60° C higher than atmospheric temperature. If so, it is advised to check for mis-matching of load, too. —26— ‘© Shortage of engine oil and deterioration Repair cooling system,0-07 WMBlack-smoky exhaust Matters to be checked before diagnosis, ‘© Clogging of air cleaner element ©Use of poor-quality fuel © Overload 2, Diagnosis Is smoke set of injection pump No ee NP | Adjust smoke set, Syes put in order ? (Check for excessive valve clearance and improper injec: tion timing, ) Adjust engine, yes Do injection nozzles operate normally ? (Check for improper state of fuel mist injection and for} NO [inspect injection nozzles, excessively large injection start pressure, ) dyes Inspect valves, cylinder head gasket, pistons, and piston rings, Is cylinder compression | No normal ? ° yes Inspect injection pump, 270-07 TROUBLESHOOTING ‘Munsteady 1 |. Matters to be checked before diagnosis ‘Faulty engine control system © To0 high engine oil viscosity © Use of poor quality fuel 2 Diagnosis Is engine adjusted properly ? (Check for idling speed, valve clearance, and injection | siming.) tL Syes | Do injection nozzles operate normally ? (Check for state of fuel mist injection and injection start pressure. ) dyes No 2 No Adjust engine, Inspect injection nozzles. 's cylinder compression normal ? (Check equality between cylinders. ) No 2 Inspect valves, pistons, and piston rings. Byes Inspect injection pump ‘and governor system, | Ca ~28—0-07 Mow output |. Matters to be checked before diagnosis ‘@Seizing of engine moving parts, _@ Clogging of air cleaner eleme! © Too viscous engine oi! © Use of poor-quality fuel 2, Diagnosis Is sufficient fuel flow in fuel line? dyes © Clogging of muffler nt (© Malfunctioning of drive system (Engine without fuel pump) Is spontaneous dropping of fuel nor- mal? (Engine with electromagnetic fuel pump) Does fuel pump feed fuel with key switch placed in ON ? — yes=| Inspect fuel pump, Is engine adjusted properly ? No ‘Adjust engi (Check for valve clearance and injection timing, ) * ——— Byes Do injection nozzles operate normally ? Inspect fuel filter, fuel pipe, and fuel tank, (Check for state of fuel mist iijection and injection start | N° [inspectinjection nozzles, | pressure.) TS Is cylinder compression normal ? yes 8 No * Inspect valves, cylinder head gasket, pistons, and piston rings, Inspect injection pump, —29—Gri coup e | ENGINE } 0 02 ROCKER ARMS AND ROCKER SHAFT 03 CYLINDER HEAD - 04 VALVES AND VALVE SPRINGS --- 05 INTAKE MANIFOLD AND EXHAUST MANIFOLD 06 GEAR CASE AND OIL PUMP «+--+ 07 TIMING GEARS- | GENERAL 08 CAMSHAFT (VALVE CAMSHAFT AND INJECTION PUMP CAMSHAFT) ---53 09 PISTON AND CONNECTING ROD 10 CRANKSHAFT - CYLINDER BLOCK. ~oe 1-01 GENERAL Specifications lem Model 1G B Oylinder head Material Special cast iron Combustion chamber type Swirl chamber Material of chamber Heat-resisting steel (press-fitted in cylinder head) Type of intake and exhaust por rts Cross-flow type | |Heat-resisting steel (3600 rpm spécification engines) Valve seats Material Special cast iron (3000 rpm or less engines) Face angle 4s Valves Intake IN Identification mark Exhaust | EX Valve springs Type Uniformly pitched, single Identification mark fhite paint at top (common to intake and exhaust vaives)| Cylinder head gasket Material Carbon sheet (Graphoil) Material Special steel Cylinder head bolts MIO x6 MIO x8 Size x Number of bolts MB x2 MB x3 Camshaft Valve cam Material Pump cam Carbon steel Arrangement — Drive Side ~ Gear driven Cylinder “block Cylinder bore aa [ee [tae [aA] se |e 5 | 70 | 76 | 65 70 | 76. Cylinder liner type Monoblock type Water jacket type A Full jacket, £: " Siamese” type Material ” Carbon steel Crankshaft Surface treatment Hardening (Induction) Main journal di, x Crankpin dia, 43 x 40 Type * Autothermic™ piston Joint to connecting rod Semi-floating Cooling Oit jet —32—e 1-01 Node hem 2 B om Semi-teystone ype Piston rings Noe Plain bpe jou ne With col expander Type | Gear pe out pump t Drive Direct arive by crankshaft Timing gears | Crankshaft gear Number of teeth : 26 Idle gear ” 240 | injection pump camshat gear ” 182 Valve camshaft gear ” 152 —33—No EI 1-01 GENERAL Special Tools Use Too! name | ‘Sketch Referential page Removal and installation | Piston pin | 56 ~ 58 of piston pin setting tool 7332400 Measurement of cylinder] Compression 20 compression gauge adapter 81332270 Removal and installation | Oil pressure 68 of oil pressure switch | switch socket wrench (26) ‘MD998054 Repair of valve seat | Valve seat | 37 ~ 38 eter ———- Valve seat cutter, 45° Valve seat \ cutter, 60° Nominal angle of eutter Valve seat cutter, 30° 34we ae ie ie EJ 1-02 ROCKER ARMS AND ROCKER SHAFT 1-02 EI Construction of Rocker System component Parts © il filler cap ® Rocker cover gasket ® Breather hose @® Rocker shaft @ Rocker cover © Rocker spring —35— @ Adjust screw ® Rocker arm @ Rocker stayRemoval and Installation Caution 1 2, After installing the rocker shaft, adjust valve clearance. | Minspection 1-02 ROCKER ARMS AND ROCKER SHAFT Be careful not to confuse proper direction of installation of the rocker shaft. @—— tghening toraue: Front dentif- {onthe valve ie) $3 hole 0.5 ~ 0.8 kgfim (4.9 — 7.8 Stay tightening torque: 1.5 — 2.2 ko tar — (2 @ pa Installing Recker Shaft and Recker Cover wal Nea] If any parts are found defective, replace them, Inspecting Rocker Shaft and Rocker Arms =36—te EJ 1-03 CYLINDER HEAD MConstruction a 1-03 ® ® Cylinder head _a cross section Cylinder Head Component Parts oO @ @ @ ® Cylinder head Valve guide Cylinder head boit (Main bolt) Cylinder head bolt (Sub-bolt) Seat ring (3600 rpm specification engine) eee0e8 —37— Water outlet fitting. Cylinder head gasket Mouth piece Thermostat Thermostat fittingio | 1-03 CYLINDER HEAD Removal (1) Remove the injection pipe assembly. Caution ‘© When disconnecting each injection pipe from the injection pump side delivery valve holder, grasp the holder with a wrench to prevent it from loosen- ing. After removing the pipe assembly, plug the nozzle holders and delivery valve holders to prevent intrusion of dust, (2) Disconnect the glow plug lead wire, (3) Loosen’ the alternator bracket bolts and dis- mount the alternator, (4) Disconnect the air breather hose, (5) Remove the rocker cover. (6) Remove the rocker shaft assembly, (7) Loosen the cylinder head mounting bolts in the ‘numerical order illustrated at right and remove the cylinder head assembly (including the intake and exhaust manifold), (8) Remove the cylinder head gasket, Clean the cylinder head and the cylinder block surface from which the gasket has been removed, (9) Remove the nozzle holder assemblies and glow plugs from the cylinder head, (i) Remove the intake manifold and exhaust manifold from the cylinder head, (1) Remove the valve retainers, valve springs, and valves from the cylinder head, Caution ‘© When removing each valve retainer, depress the retainer against the valve spring and remove the retainer lock, Identify each valve by putting a mark indicating the number of cylinder from which the valve is removed, (12) Remove the valve stem seals, Sequence for Loosening Cylinder Head Belts (L2) Removing Valves a38—‘No. 1-03 Minspection and Repair CChack cylinder head surface for warpage between Bolt Roles: within 0. 08mm Cchack guide for ware and damage. Check for valve contac, Check foc cracks, domege, ‘wear, damage, ond sink of seat face. water leak and remove ol sudge Sealant deposit, carbon deposit Inspection of Cylinder Head MReplacement of Valve Guide 1, Removal (96.6738) Press the guide at its upper end and pull it out to the valve seat side, 2, Installation (Press-fitting) Fress-fit the guide from the upper side of the cylinder head to a height of 14 0,5 mm from the valve spring seat face, Pressfitting Valve Guide —39—No. EJ 1-03 CYLINDER HEAD MRepair of Valve Seat Ia valve seat is found defective, reface it or replace the cylinder head, [ Valve sinkage Sinkage of valve Standard Serviee lit 0.5 mm 1.5 mm Caution ‘® When checking valve sinkage, the valve guide must be in the normal condition, ‘@Resurface the valve seat so that it contacts the mid-portion of the valve face, Minstallation Installation of the cylinder head is in the reverse order of removal, Pay attention to the following : (1). Renew the cylinder head gasket, No application of sealant is necessary, On the upper froht of, the gasket is engine model to which that gasket is applicable, gasket for other engine model, (2) tighten the cylinder head bolts in the numerical order shown in the figure at right, going through that order two or three times, Tighten each bolt a little at a time until all are tightened Be careful not to confuse with a to the specified torque, (3) When connecting the injection pipe assembly, loosen the pipe clamp, ‘When tightening the nut at each end of pipe, ‘grip the nozzle holder or delivery valve holder with @ wrench to prevent it from being turned together with the nut, Also, take care not to allow dust to enter the fuel line, Invertace and weer Checking Valve Sinkage Wath of valve contact: 1'3-1.8mm Sequence for Tightening Cylinder Head Bolts (L2) Sequence for Tightening Cylinder Head Bolts (L3) 40se a i in EJ 1-04 VALVES AND VALVE SPRINGS 1-04 | Construction GQ been: Aastra Valve System Component Parts © Valve stem cap @® Valve stem seal © Retainer lock ® Valve spring @ Valve spring retainer ® Vabve —u—om No EJ 1-04 VALVES AND VALVE SPRINGS MRemoval (1) Dismount the cylinder head assembly, (2) Depress the valve retainer (to compress the valve spring) and remove the retainer lock, (3) Remove the valve. Removing Valve and Valve Spring inspection and Repair If any parts are found defective, repair or replace them, ‘Wear and damage (Without for agrcutrat ° 68 8 aoe 0 | ants and waar | + ridge and damage Inspection of Valve and Valve Spring [ Valve fatigue and damage = Iepeston tem | __Standard Serie iit Free length (ee) 40,5 =I H Load te/am) | 5.98/35,5 = 15% Seusrenes z ¥ Margin (na) 1.0 0.5 Valve Spring Tester 4g"es E a Repair of valve face If the valve face is found worn down, resurface with a valve refacer, If margin of the resurfaced valve exceeds service limit, replace the valve, 2, Repair of valve stem end If the valve stem end has been indented by wear, flatten with an oil stone, Inspecting Valve installation (1) Install the valves and valve springs, referring to notes shown in the figure below, (2) Mount the cylinder head assembly, (3) Adjust the valve clearances, Wa eave ees Yo compress ‘ohng, ea Pres tis tte tere oc ey | [ rt t Diving in Instaling sping Intating sing evier Installation of Valve Spring Caution Be careful not to damage the spring and stem seal by excessively compressing the spring wher ling the valve spring, =43—vor EJ 1-05 INTAKE MANIFOLD AND EXHAUST MANIFOLD Construction Tightening torave 1.5 = 2.2 kofem [14.7 — 21.6 Nea) Manifold Component Parts © Intake pipe © Intake manitotd gasket ® Intake cover ® Exhaust manifold gasket @ _ Exhaust manifold —u-No 1-05 inspection Check the following matters, If any defect is found, repair or replace the manifold, (1) Check the mounting surfaces to the cylinder head for flatness, The surfaces must be flat within 0, 15 mm, (2) Check the manifolds for corrosion, damage and cracks, Caution Check the interior of the Intake manifold for dust and dirt, If any dust is found, check the joints to the air cleaner and intake pipe for sealed condition, —45—a We E| 1-06 GEAR CASE AND OIL PUMP Construction Common to L2 and L3 Gear Case Component Parts © Bushings © Relief plunger ® Plug ®© Relief spring ® Gear case ® Oil pump inner gear ® Front oil seal ® il pump outer gear ~46— eeee Oil pump housing Gear case gasket High-pressure pump gear housing Housing gasketMRemoval (1) Remove the crankshatt pulley, (6) Remove the water pump assembly, (2) Remove the fan and fan belt, (7) Remove the alternator. (3) Remove the tie-rod cover from the side face of __—_-(8)_ Remove the pump housing. the injection pump. (9) Remove the gear case assembly. (4) Remove the tie rod and tie rod and tie-rod “spring. Be careful not to let the spring fal into the case, (5) Remove the governor cover assembly. Minspection Check the removed parts. If any parts are found defective, repair or replace them, Cracks anc damage Wear and damage Wear, damage, and clearance Spring fatigue ‘Smooth movement “Thoroughly clean oi lin. Seal surface nterteence Inspection of Gear Case and Oil Pump Oi! Pump Performance Speed, rem | 1000 2000 Description Pressure.kgf/on'twPel [1.500.181 | 2.0 [0.20] Discharge [tow rateé /ain Bor more | 17 of wore ‘Cracking pressure Ko/enwPal | 3.0 10.28) = Relief valve cioingpresurekat/atiral | — | (0,49) or below ‘0/1 used : SAEBO, 100-5 —a7—1-06 GEAR CASE AND OIL PUMP MReplacement of Front Oil Seal (1) Remove the front oil seal, (2) Presscfit the new front oil seal, Cation, a aaa © Apply thin coat of engine oll to the circumference and lip of the oil seal. WReplacement of Governor Shaft Bushings (1) Remove the expansion plug and draw the bush- ings out. (2). Press-fit the new bushings into positions shown in the figure at right, ayy ‘Tobe tush with “To bein contact this plane wth bottom Pressfitting Governor Shaft Bushing inspection of Governor System: Check the governor system parts. If any parts are found defective, repair or replace them, (cheek spines for fatigue gf @ | | PE. Check siding sleeve join for weat and demage. Check weight for wear and damage, =4g—Ne 1-08 MDisassembly and Reassembly of Governor Levers cere ol ener Expansion plug Grooved pin Proition (1) Remove the expansion plug, taking care not to ‘spprex. 2mm scratch the gear case a (2) Pull out the grooved pin. 2, Installation of shaft (1) Install the shaft in the reverse order of removal, Secton Ak (2) After installing the shaft, press-fit the expan- sion plug into the shaft hole in the gear case. Minstallation of Gear Case Assembly —49— Gear case Installing Governor Shaft Tightening torque 0.8 1.0 kof (7.8 = 9.8 Tightening torque: x 4 5 kofm (99 — 49 Hea] ‘Taper plug ghtening torque’ 1.8 = 2.2 kofem (14.7 — 21.6 Wea] ‘Sealant: HERMESEA HY or THREE-BOND 1948 Gear Case Assembly Installing Gear Case Assemblymie 1-07 TIMING GEARS Construction Timing Gear Component Parts © Crankshaft gear @® Camshaft gear @ dle gear ® Injection pump camshaft gear ~50—Removal (1) Pry the snap ring out and remove the idle gear. (2) Remove the valve camshaft and injection pump camshaft on which the respective gears are press-fitted, Remove the gears from the shafts, (3) Remove the crankshaft, Remove the gear from the crankshatt, inspection Check the removed gears, If any gear is found defective, replace it, Idle gear bushing Descrigtion Standard vale | Service limit Carne baween bat! 93 — 0,07 on seas . . . Backlash between gears in mesh Description Standard vale | Service limit (Crankshat-ile Ide-Camstatt | 0,01 = 0,14 0.3 Iee-Fel pump Gear Nor 1-07 Removing Camshaft Gear Injeoton pump camsnah goer Check tooth faces land end surfaces for vat and damage, Valve camshaft gear | Crankshaft gear Inspecting Timing Gears —s1—‘Ne. EJ 1-07 TIMING GEARS installation of Timing Gears (1) Press-fit the crankshaft gear onto the shaft, (2) Press-fit the valve camshaft gear and injection pump camshaft gear onto the respective shafts, (3) Install the gears in the following sequence (2) Turn the crankshaft to set the No, | cylinder to top dead center on compression stroke, (b) Install the vaive camshaft and injection pump camshaft, (c) Install the idle gear so that timing marks on it are in alignment with marks on other gears, (d) Confirm that timing gears are in alignment with each other, Timing Gears in Alignment with Each Other —52—a tas tie te EI 1-08 CAMSHAFTS (Valve and Pump) 1-08 EJ Construction | . os Camshaft Component Parts © Camshaft (Valve) ® Tappet ® Camshaft gear ® Push rod @® Ball bearing ® Camshaft (injection pump) ® Woodrutt key @ Camshatt gear © Sunk key @ Ball bearing (Rear) © Camshaft stopper ® Snap ring @ Bolt —53—Ea 1-08 CAMSHAFTS (Valve and Pump) Removal of Valve Camshaft |, When it is necessary to remove only the valve 2, camshaft, use the following procedure : (1) Dismount the cylinder head assembly, (2) Pull out the push rods, (3) Pull out the tappets, (4) Remove the gear case assembly, (5) Remove the camshaft stopper bolt, (6) Draw the camshaft assembly out, Removal of the injection pump camshaft (1) Disconnect the injection pipes, (2) Remove the injection pump assembly, (3) Remove the gear case assembly, (4) Remove the shaft rear cover. (5) Remove the stopper bolt, (6) Pull out the shaft to the front side, Removing Injection Pump Camshaft 54No. 1-08 ssc 8 2 Ge -S] se: Som, | Each ball a ene hams coupling Wear cam lobe-Weee apd eamage Inspection of Camshafts Major diameter of injection pump cam Major diameter of valve cam ‘Standard value 30 ‘Standard value 2.37 Serviee ti it 0.7 Service limit 1.0 —55—om No. cI 1-08 CAMSHAFTS (Valve and Pump) installation When installing the camshafts, give care to the following (1) Coat the bearings and cam lobes with oil, (2) Install the camshafts in the reverse order of removal, (3) Position the timing marks on the gears in align- ment with the marks on the idler gear. Refer to 1-07 TIMING GEAR, (4) After installation, check and adjust fuel injec- tion timing and vaive clearances, Installing Valve Camshett —56—an oa No No | 1-09 PISTON AND CONNECTING ROD. 1-09 MConstruction cI @—o Piston and Connecting Rod Component parts © Piston ring No. | © Piston pin ® Connecting rod cap ® Piston ring No.2 ©® Connecting rod ® Connecting rod bott ® Oi ring D Connecting rod bearing ® Connecting rod nut ® Piston —s7—1-09 PISTON AND CONNECTING. ROD Removal (1) Remove the cylinder head assembly. (2) Remove the oil pan, (3) Remove the oil screen, (4) Chalk the cylinder number on the side face of big end of each connecting rod to prevent confusion of connecting rods. (5) Remove the connecting rod cap from each piston-and-rod assembly, and draw the assem. bly upward from the cylinder, Take care not to allow the connecting rod to ‘scratch the crankshaft pin and cylinder, Keep the removed parts (connecting rod, rod cap, piston, etc.) classified by cylinders, (6) Remove the rings from each piston with the piston ring pliers, (7) Using the piston setting tool, pull out the piston pin from each piston, Miinspection Inspect the removed parts, If any parts are found defective, replace or repair them, FRONT ark arom Removing Piston Pin Wear, seizure, and steaks “Clearance between piston and cylinder Standard: 0.07~0.115mm = Wear of piston ring grooves 2 Damage, weer, and ring gap — ——— “ Big'end pay Standard: 0.1 ~0.25mm He Fs —— “Faking and fon + Ol cearanee & Standard 6022~0,052mm @ —— damage. Inspection of Piston and Connecting Rod —58—Inspection of piston ring gaps Put each piston ring into the cylinder bore and push the ring with piston to position the ring on. ‘square with the-cylinder wall, Measure the ring gap with a feeler gauge, If the measurement exceeds service limit, replace that piston ring, Caution ‘© When only the replacement of rings is to be made, without reboring (honing) of the cylinder, position the ring to be measured at the least worn place of cylinder skirt. © When replacing rings, install the new rings having. the same size as the piston, ‘© Piston rings available for servicing are sized into three classes : STD, 0.25 0S, and 0,50 OS, 2, Inspection of ring groove in piston Measure the side clearance for each piston ring set in the ring groove in the piston, If the service limit is exceeded, If the clearance still exceeds the service limit, replace the piston with new one, replace the ring with new one, installation When reassembling the piston and connecting rod and installing the piston-and-rod assemblies in the cylinder block, pay attention to the following (1) Reassembling the piston and connecting rod Using the Piston Pin Setting Tool, press the piston pin in to the set position, Description Standard Pin press-fitting force 500k (at a normal temperature) 1000+ 500kg —59— No 1-09 Pion © I cinder —J Ring Ring gees Measuring Ring Gap Ring Standard | Service limit All ings 0, 15~0, 40 1s Measuring Ring Side Clearance Ring Standard | Service limit No. = 0.3 No.2 0. 05~0,08 02 oil 0,03~0,07 a2 Note : No, I ring is of the semi-key stone ype, Installation of Piston and Connecting RodNo. 1-09 PISTON AND CONNECTING. ROD EI Pe FRONT motk (oro) Bese plug Connecting kod th tod Identtication mark LA reer vy Guid "LA" 1920): for 28, L98 Sti “Le 8.80) fo Lae, Le Gee Pressing in Piston Pin (2). Installation of piston rings FRONT mark Fd front mark Align notches accurately with tach other Tightening torque: 3.2 — 3.5 kofm (31 — 34 “Tack an Ring set postions: 2 0S sae mark Not ng, fies ae a ee eyeee ae Color of discrimination: STE 0.25= White 0150-818 Installation of Piston Rings and Connecting Rod Cap —60—No. 1-09 @) (a) 6) Set the piston ring gaps to the proper positions {as shown in the figure at right. Coat the rings and cylinder wall with oil, Using a piston-ring compressor to compress the rings into the grooves, push the piston-and-rod assembly down into the cylinder. Be careful not to break the rings by excessively knocking the head of piston, Note that the front marks on the piston and connecting rod are toward the engine front, Coat the bearing surface of the connecting rod caps with engine oil, Fit each cap to the connecting rod using match marks put before removal as a guide, In the case of a new rod which does not such a match mark, position the notches (provided for preventing the bear- ing from rotating) on the same side. a Front <— 0 ng eo SY 1 fing 929 ‘expander of ot ‘ing Proper Arrangement of Ring Gaps Fitting Cap to Connecting RodNo. EJ 1-10 CRANKSHAFT MConstruction é Crankshaft Component Parts © Key © Washer © Rear oil seal case @® Crankshaft ® Spring washer ® Gasket ® Crankshaft gear © Flywheel @ Flywheel bott ® Crankshaft pulley @® Ring gear ® Nut @ Rear oil seal aRemoval (1) Loosen the flywheel bolts and remove the fiywheel, (2) Loosen the crankshaft pulley nut and remove the pulley. (3) Remove the rear oll seal case assembly. (4) Remove the main bearing caps. Keep each set of bearings removed together with its bearing cap. (5) Take out the crankshaft. Removing Wain Bearing Cap Minspection Inspect the removed parts. If any parts are found defective, repair or replace them, Dameged to tooth face | Damage to en ace Wear and damage Wobble of puley Inspection of Crankshaft and Flywheel —63—id 1-10 CRANKSHAFT Checking the crankshaft for wear To check the crankpins and main journals for tapering wear and out-of-round wear, diameter of each crankpin or main journal should be measured at two places along the crankpin or main journal, in two directions ” A” and” 8” each place, as shown in the figure at right, If necessary, regrind the crankpins and main jour- nals to the next under size, If any crankpin or ‘main journal has been worn out beyond the service limit, replace the crankshaft, Checking Crankshaft for Wear Diameter of crankpin and main journal (mm) Under-size diameters (mm) T Description Standard | Service limit Description Main journal Crankpin, fee 43 0,70 0.25US — |42,715~42, 730] 39, 715~39, 730 Crankpin dia, 40 =0.70 0,50 Us | 42, 465~42, 480|39, 465~39, 480 —64—2, Inspection of crankshaft oll clearance Oil clearance is calculated by subtracting the diameter of main journal or crankpin from the inside diameter of main bearing or rod bearing, To check the main bearings and rod bearings for tapering wear and out-of-round wear, inside diameter of each main bearing or rod bearing should be measured, after its bearing-cap is fastened to the specified torque, at two places along the bearing, in two directions" A” and” B” each place, as shown in the figure at right, If necessary, replace the worn bearing with new one, If oil clearance still exceeds the service limit, regrind the crankshaft to the next under size and replace the bearing with one of the corresponding under size, Caution ‘© A crankshaft which has been sized cannot be re- ground to any under size, Measuring Wain Bearing |. D. Tightening torque kat-m [om] Oil clearance (mm) Description Standard Description. Service limit Main bearing cap bolt so sste~ 9) Main bearing [oto Rod bearing cap nut a2 3soi— 90 Rod bearing 0.15 —65—Ea. 1-10 CRANKSHAFT MReplacement of Crankshaft Rear Oil Seal (1) Pry the oil seal out with 2 screwdriver, (2) Drive in a new oil seal to the oil seal case, installation When installing the crankshaft, pay attention to the notes given in the figure below. Cop ughtening “Tust bearing ony torave 6.0 — 5.5 kof for No.2 cap [49 — 54 Wen) Side seals costed with sealant ITHREE-BOND 1212) 2 Make cap fush with yinder Block and face {common to front and ‘ear end faces) Direction of instataion of ca ef Crank end play 0.08-0.175 Installation of Crankshaft —66—= a 1-11 CYLINDER BLOCK 11 MConstruction © | Cylinder Block Component Parts © Cylinder block © Main bearing @® Idler gear shatt ® Front plate © Starter bracket ® il filter shaft @® Bearing cap © Rear oil seal © Oil level gauge guide ® Cover ® Oil seal case —67—EI 1-11 CYLINDER BLOCK Minspection Inspect the cylinder block, If itis found defective, repair or replace the block, Cylinder bore (mm) Model Standard Service limit LZ, 3A 573m +02 Lac, Lac 70°3% +02 Lae, BE 7678" +02 Measuring Cylinder Bore i Approx. 10mm fom upper end Front Center 4 — tower Direction of Measuring postion Cylinder Bore Measuring Positions WMReboring of Cylinder When reboring a cylinder, use the following proce- dure: (1). Selecting a piston Piston service size 0,25 0S or 0,50 0S (2) Measuring the piston diameter (3) Reboring finish dimension = (Piston 0D] + (Clearance) — (Honing allowance (0, 02 mm)) @ Clearance (between piston and cylinder) Standard : 0,071~0, 084mm (A~D) Cavtion $A ___________ ‘© When it is necessary for a cylinder to be rebored to the next over the remainders must also be rebored to the same over siz Measuring Piston DiameterGroup > | LUBRICATING SYSTEM | Qgiag, O1 GENERAL 02 OIL FILTER AND OIL PRESSURE SWITCINo. 2-01 GENERAL Mispeci | Description Specification Lubricating system and filtering system Pressure-feed lubricating, full-flow filtering [Git capacity (Upper Timit lower Timit) excluding 0,5 for ol filter (BE R071 Shor 3.607188 La: 24/1 ean Type Gear ype laer and outer gers in mesh) enclosed in gear case il pump Driving method Direct drive by crankshaft Relief valve opening pressure 3.0:40.3 kgf/on? {0.30.03 Wa] / 1000 rpm Oil pressure switch closing pressure 0.5:40.1 kgf/on* [0.05:40.01 MPa] Type Paper-element cartridge type Oil filter Relief valve opening pressure 1.0:40.2 kgf/on? (0.1:+0.02 WPa] Mspecial Tools For the oil pump, which is enclosed in the gear case, see Group | ENGINE PROPER, Use Tool name Removal and installation of oil pres- sure switch Oil pressure switch wrench Mp998054 —10-—Construction 2-02 OIL FILTER AND OIL PRESSURE SWITCH woe Ne. 2-02 Oil Filter and Pressure Switch © Oil filter © Oil pressure switch Removal and Installation (1) Coat the O-rings witch engine oil, Take care not to twist the O-rings, (2) Coat the threads with sealant (HERMESEAL HI or THREEBOND 1314), (3), Tightening torque : 1.1 — 1.3 kgf-m [10.8 — 12.7 Nem] (Do not use any wrench, ) Caution @ After instal 1, check for oll leak while the engine is running, Installing Oi! Fier —n— Installing Pressure SwitchNo. Ed 2-02 OIL FILTER AND OIL PRESSURE SWITCH Minspection rr | Inspect the following (1) Oil teak Pressure switch ON pressure : 0.50.1 kgf/on? [0.05:+0.01 MPa] Caution $A $a ‘© Check the oil filter for dirtiness. If necessary, clean the engine int ith flushing oll Inspecting Oil Filter and Switeh —n—Group 5” | FUEL SYSTEM gw 01 GENERAL 02 FUEL INJECTION PUMP + 03 INJECTION NOZZLE ---No. 3-01 GENERAL MSpecifications I Specification Injection pump Injection nozzle Description z =z Type | inline type (Bosch NO) Direction of rotation | Clockwise (as viewed from diving side) Injection order | in2 i-3-2 | | Injection timing | See page 141 Plunger diameter | 66 Number of plungers | 2 3 MS retard | 4° (for crank) Delivery valve | Silt or Bosch Type | Thread type T = | type | Throttie type E | Number of jet | \ Injection pressure 1405s"kgt/ea?_ (13.721 * Wal Fuel pump (optional) Type Electromagnetic diaphragm type Delivery 0,372/min (12 Vv, at 20°C) Type Electromagnetic plunger type Delivery : Common type Compact type | 0.98/ (12¥, at 200) i 0.42 /min (12 Vv, at 20°C) Type | Mechanical drive type Delively | 0.225 & /min | Type | Solenoid pull hold type Hg | Rated current pul SBA : Hold LOA | = | Working voltage lev, DC | B |. Stroke 13,5 mm | 3 | Type Solenoid, push out type | | Coil resistance 1.6.04 10% (at 20°C) stroke 10 a Fuel filter Paper-element ype I See 7-03, —m4—MComponent parts all Fuel System Component Parts © Injection pump © Injection nozzle ® Adjustment shim © Return pipe ® Injection pipe a © Fuel filter @_ Fuel cutott solenoida 3-02 FUEL INJECTION PUMP MConstruction Injection Pump Component Parts ® Union coliar ® Delivery valve @ Plunger ® Air vent screw © Gasket ® Lower seat ® Delivery valve holder ® Seat valve ® Adjusting shim @® Vatve spring @® Plunger barrel @ Tappet rolier ®© Holder stopper @® Sleeve @ Pin © Housing @ Upper seat @ Control rack @ @ @ O-ring Plunger spring Stop wire bracket 16Miinspecting the injection pump while itis mounted on the engine Never attempt to disassemble the pump unless it is necessary, If the pump is assumed defective, itis recommended to replace the pump assembly, Removal (1), Disconnect the fuel injection pipes, (2) Remove the tie-rod clip cover, (3) Remove the tie-rod clip and tie-rod, (4) Remove the injection pump assembly. Disassembly (1) Remove the stopper plate, (2) Unscrew the delivery holder, delivery valve and valve spring, (3) Remove the tappet roller and stopper pin, (4) Remove the tappet, plunger spring, etc, Take out the Caution 1, When replacing the plunger barrel, delivery valve, etc., do not loosen the adjusting screw and plate for each cylinder, When those parts have been replaced, it is necessary to measure fuel injection quantity by using the pump tester and cam box. 3. All parts removed from the pump should be kept classified by cylinders and immersed in clean fuel, No. 3-02 Inspection | _Inspecten procedure Criteria Idling speed | Measure engine speed, | 900° "rom, 1) Quickly accaerate | No remarkably. back smoke exaust permite ftw sme color | erg wit ed 2) pat ere Fue! cutt solenoid Turn gic sch OFF ‘A solenoid acting. [ toma sound, Removing Injection Pump aior GH 3-02 FUEL INJECTION PUMP Minspection MAssembly (1) Insert the plunger barrel into the housing, (2). Install the delivery valve and valve spring. Temporarily tighten the holder, (3). Insert the control rack, (4) Insert the control pinion, Align the matchmark on the rack with that on the pinion, (6) Install the spring upper seat, (6) Insert the plunger spring. (7) Fit the lower seat to the plunger, Insert the plunger into the barrel side, (8) Depress the tappet roller assembly and install the stopper pin, (9) Tighten the delivery holder. tightening torque :3.5 — 3,9 kgm installation Install the injection pump assembly in the reverse order of removal, gq esnwotn &— wa Control rack (Catering) }— Plunger-nterfrence ‘wear, serateh, |— inserterance, 5 ,oN | Sera caution When istaling the phmger baal, ones the dowel pin on the housing side with the groove in the barrel. ‘© Position the plunger so that the part-number stamp on its flange faces the direction opposite to the rack side. (Engage the feed hole with the plunger lead.) After installation, check for proper injection timing. ==No No. 3-03 INJECTION NOZZLE 3-03 MConstruction Nozzle Holder Ass'y Component Parts Body sub-assembly © Distance piece Shim washer © Nozzle assembly Pressure spring © Retaining nut Pin eee80 —19—No 3-03 INJECTION NOZZLE MRemoval (1) Disconnect the injection pipe and fuel return pice. (2) Remove the injection nozzle assembly from the cylinder head. Caution © Attach an identification-number tag to the removed injection nozzle. Plug the openings, from which the pipes are disconnected and the nozzle is removed, to prevent intrusion of dust, water, and other foreign particles into the pipes and combustion chamber. It the removed nozzle assembly is assumed assembly defective, disassemble the assembly and repair or replace the faulty parts, (1). Grip the nozzle holder body in a vise, Loosen the retaining nut. Never vise the retaining nut to prevent deformation, (2) Take out the shim washer, pressure spring, distance piece, and nozzle assembly. Caution © Scrape off carbon deposite with a wooden spatula. Keep the removed parts immersed in washing oil (kerosene). Take special care not to scratch the needle valve in the nozzle assembly. —80—=) Ry 203 Md inspection Inspect the removed parts, If any part is found defective, replace it, MAssembly (1) Insert the nozzle assembly into the retaining nut so that the nozzle is perfectly seated in the nut, (2) Place the distance piece, retaining pin, pres- sure spring, and shim washer on the nozzle assembly, (3) Tighten the nozzle holder body fully by hand, (4) Grip the nozzle holder in a vise, Tighten the retaining nut to the specified torque, (Tightening torque : 3.5 — 4.0 kot (34 — 39 a) Adjustment Adjust injection start pressure by increasing or decreasing the thickness of shim washer to be insert- ed, Varying shim thickness by 0, | mm causes injection start pressure to change 10 kg//em, Available shims IO kinds of shims available from |, 25 mm to 1, 7 mm. in thickness, 0,05 mm step, Injection start pressure Standard woryigtoe (18.725 " wel ‘towable tint ERE or ss —si— © | Poor contact = | ‘® Inspecting Nozzle | ores Fotigue and Deformation and break While immerses icing, Tightening torque 2.5 — 3.0 kgfom [25 = 29 Wen) Tightening toraue: 3.5 — 4.0 kgf-m /\ (34 — 39 Neal ii Return pipe Assembling the Nozzle | \N Testing Nozzle3-03 INJECTION NOZZLE installation (1) Clean the nozzle holder fitting surface of the cylinder head, Install the nozzle holder with a gasket interposed, Tightening torque: 5.0 — 6.0 kgf-m [49 — 59 Nea] (2) Connect the fuel return pipe and injection pibe, Tightening torque = Injection pipe 2.5 — 3.5 kaf-m (25 — 34 Nem] Fuel return pipe 2.5 — 3.0 kgf-m (25 — 29 Nal —3i— Installing Injection PipeGroup 4 GOVERNOR SYSTEM 01 GENERAL 02 TORQUE 03 GOVERNOR - SPRINGBe 4-01 GENERAL Mspecification Centrifugal fyweight type Construction Governor System Component Parts © Sealing metal ® Tierod clip ® Stop lever assembly © Sealing wire ® Tie-rod cover ®@ o-ring © Low: and high-speed @ tie-rod cover gasket @ Snap ring ® Governor spring @ Tension tever ® Stop lever © Sliding shaft @ Start spring @ Grooved pin (3 x 20) © Stopper ® Governor spring lever ® Grooved pin (3x 14) ® Governor spring © Speed control lever assembly ® Torque spring set ® Governor shatt @® Cover assembly @ Sealing cap © Governor lever ® Governor cover gasket @ Tie-rod @ Return springNo 4-02 TORQUE SPRING following procedure : es = 4-02 El (1) Set the speed control lever to the high-idling speed position by adjusting the high-speed set bolt, (2). Turn in the torque spring set until engine speed drops about $0 rpm from high-idling speed. (3) From this postion, turn back the torque spring | Sept stot Sm rom set by the specified number of turns (N.) Lock the torque spring set at that position with the | Sealing cap [Stake after sexing! special nut, (4) Install the torque spring set sealing cap and Never tamper wth this screw. Ture in this torque sping set until engine speed Minstallation of Torque Spring Set [7 Forinstatbton ena ausiment Install and adjust the torque spring set using the | ‘Adjust 10 species ‘number of loosening turns N ‘Number of loosening ung "N stake the cap to prevent loosening. q f Cauthion There are two types of torque spring set : The single spring type and the double-spling type, Since each torque spring set has been abjusted Special aut precisely during asembly, do not tamper with the ) abjust screw unless it is necessary, Toraue spring set Model Number of loosening tums (N) L2A~82A, L2A-620A, L2A-61DM 24 Lsc-63wa 22 L2E-61IR, L9C~81ES 23 L2A-G1A, L2A-6IRR, L2A~62SS, L2A-61SS, L2A-62SDG, L2A-61DA, L2C-62A, L2E-62WM, LA-61A, L9A~62A, LA-61RG, L3C~B1A, 24 L3C-62A, L3C-61DA T2G-61A, L2G-G1CV, L2E-G1SC, L2E-618DG, L2E-61G5, L2E-B1SD, L8A-G1TG, L9A~B1ES, L3C-61TG, L9C-62DA, L3C2-62TG, L3E-81TG, 25 L3E-61RG L2E-61TM, L2E-G2A, L2E-62DA. L2E-61ES, L2E-62PL, L2E-610M, LBE-81A, L3E-61SS, L3E-61SA, L3E-61DS, L3E-G1HMG, L9E-61SHS, 26 LSE-GILS, L9E-61KG, L9E2-62TG L2E-61WM, L2E-61DA, L3C-63WMA, L9E-G1TM, L9E-62A, LE-62DA, a L3E-62WM, L9E-628S, L3E-61SC L2E-61HMG, L2E-61A, L2E-625S, L2E-G15S, L2E~6280G, L2E-61SA, aD L2E-62ES, L2E-61SHG, L2E-61SDH, L9E-61DA, L3E~61KL L2E-61WH, L9A-61WM, L9E-61SDH, L9E2~69ESA 29 LSE-INSA 38 L3E-618D a3 LGE2-61ES, L3E2-62ES, L9E2-63ES 30 —85—No 4-02 TORQUE SPRING Assembling the Torque Spring Set When the torque spring set has been disassembled or its component parts have been replaced, reas- semble and adjust the torque spring set using the following procedure Single spring type When installing the single-spring type torque spring set, use the following steps, (1) Lightly turn in abjust screw © (with a screw. river operated by fingertips ) until a resistance to screw rotation is felt, Lightly lock the screw at that position with locknut @, (2). Set the scale to the zero-point, .Turn in the spring case @ until the value of load “A” shown in table below can be attained, Lock the spring case at that position with special nut @, (3) Temporarily loosen abjust screw @ until the value of load*A"is reduced by about 200 grams, and then retighten the screw until the value of “B" is tattained, Lock the screw at that pos tion with locknut ©, Adjust screw tightening torque : 0,8 to |.2 kg. (4) To inspect the torque spring set for ploperly abjusted spring load, use a testing arrangement such as shown in the figure at right, Gradually push the scale against the torque spring set until the stopper © is moved ( or the pointer of dial gauge deflects). Check that the load ap- plied to the torque spring at that moment coin cides with the value of load “", entiieation Approx. 2 oetore installation) Screw case. Soring Stooper Special Assembling torque spring set ease special seen speci: sion ie @case — \ one Setting of Torque Spring —~86—= z cr Model Ag) Be) Identification Ce) pe T3A-61TG, L9A-G1ES, L30-BIDA, LSG-81ES LBE-61DA, L3E-31NSA, L3E2-61ES, L3E2-62ES, L3E2-63ES, L2E-61G8, L3E2-83ESA, L2A-61DA, L2E-1ES, L2E-81DA, 570% 5708 550°8 Green L2E-62PL 1520 1520.40 1500% Red T3E-61TG, LOA-G1A, LSG-61A, LOC-6ITG, L3E-81A, L3E-61SC, L3E-81SA, L3E-81D8, L3E-61SHS, L3E-61LS, L9E-BIKL, L2A-61A, L2G-81A, L2C-81CV, L2E-61A, L2E-81SC, L2E-61SA, L2E-61WH, L2E~61HMG, L2E-61IR 970% 970% 950°%3 Yellow 1802-827, L3E2-627G, L3A~B1RG, L3E-61RG 1270°9 127050 250% | Purple MICHECKING Replace the gear case and inspect the governor, When removing the gear case, be sure to remove the tie-rod cover by the sidé of the fuel pump and disconnect the tie-rod from the rack, If any parts are found defective, replace them, Caution When the governor is assumed to be malfunction- ing, check the bearing on the gear case side, too, Inspecting Torque Spring —87— Block gauge Dial gauge soniNo Ei 4-03 GOVERNOR forimgie Sheet movement for fatigue as © 2 < Check sings for fatigue A FP \ came Se Check sh \ weer and damage for flaws (Check sing steve for esr, damoge tnd smooth movement Check siding Join for waat and domage Inspection Governor System Parts Removal and Installation (Refer to 1-06 GEAR CASE AND OIL PUMP, ) Removal (1) Removing the levers (@) to remove the levers, pull out the grooved pins which have been driven into the governor lever, stop lever, and speed control lever. (6) Loosen bolts fastening the levers and shatts, (2). Installation ‘Install the levers and shafts, one after another, checking for proper function of them, Caution 1. After press-fitting each grooved pin, check the shaft for smooth rotation, 2. Coat the O-rings with oil before installing them. 3. No deflection exceeding 20 mm is permitted for the governor spring installed, 4, Install the governor spring lever and speed con- trol lever so that play of angle between levers (standard: 5°) is minimized. SSS5 ! Ds: (stander) ‘No play exceeding Instaling Speed Control LeverGroup Fi COOLING SYSTEM 01 GENERAL 02 FAN AND FAN BELT 03 WATER PUMP ---- 04 THERMOSTAT +--+ 05 WATER TEMPERATURE GAUGE UNIT AND THERMOSWITCHTan No 5-01 GENERAL Mspecifications Description Spetification Standard type for industrial appi- Fan belt a a 12,3 LLHM type, length 905 cation L2: Standard type for industrial | 4-blade, unequal pitch, suction type, 2604 application Cooling fan pel LS: Standard type for industrial | 4-blade, unequal pitch, suction type, 2906 | application Water pump Type Centrifugal impeller Type Wax type Standard type Thermostat Valve cracking temperature 16,50 £1,5 Full-opening temperature 80°C (Valve litt 8 mm) Thermoswitch Standard type ‘Switch-ON temperature lire £3 Temperature ‘gauge unit Gauge specification 70°C /104= 13, 50 NSC 723, 842,50 (See page 129) Voltage used 2 volt DC —99-@ voi Miconstruction Cooling System Component Parts @ Cooling fan @ vee ® Thermoswiteh @ Water pump pulley @® Thermostat ® Bypass pipe @® Water pump assembly @® Thermostat fitting —91—5-02 FAN AND FAN BELT Fan Belt Inspection For fan belt tension, see 0.06 MAINTENANCE. 1.21.5 kfm ie oy (11.8 — 14.7 Ne} 5 kgf-m [19.6 — 26.5 Wem Tension Elongavon ng (reer and damage Inspecting Fan Belt ‘an Inspection __ Check the fan for cracks, damaged and deformation, | If any, replace the fan. Inspecting Fan —92—ee Ea 5-03 WATER PUMP MRemoval and Installation (1) Remove the fan and fan belt. (2) Remove the water pump. (3) When installing the water pump, reverse the above-mentioned order of removal, inspection Check the water pump for water leak, rough rota- tion, and cracks, If any, replace the water pump assembly. removing Water Pump —93—No 5-04 THERMOSTAT Removal and Installation Pay attention to the following : faucet joint, (2) Renew the gasket, (1) Never allow the flange to protrude from the) “°9—_ deere inspection If the thermostat does not operate properly, replace | Str up hot water. it, water outlet Renew gasket | Thermostat ting Installing Thermostat Never place thermostat stay in decton of thermositeh hoe 0990999 Inspecting Thermostat | Specification Item +—$,. 76.5 7 Valve crackin © ereenng tise] me temperature Full-open temperature ssc (Lift 8 mm) I o4—‘Nor Ea 5-05 WATER TEMPERATURE GAUGE UNIT AND THERMOSWITCH Miinspection of Water Temperature Gauge Unit If the gauge does not function properly, replace it, Ne. 5-05 (Seog Bee speciation wooo1se0 | 70/0413, 50, 115% 723, 822,50 M435 133 80°C / 118460, HIST /4242, 50 0452510100 | 80°C /29, 542, 50, 106°C /14, 340,50 ‘Caution go 0c 8 Handle hot oil with special care not to cause a scald or a fire, inspection of Thermoswitch | ‘Switch-ON temperature : 111°C =3'C Caution Handle hot oil with special care not to cause a scald ora fi —95— Inspecting Temperature Gauge Unit Inspecting ThermeswitchGroup 6 AIR CLEANER Sw D1 AIR CLEANER ssssssssscssssseseccssssscsssssessenssecessssessessseseesssnvecessseeseenie 98‘ier 6-01 Air Cleaner Construction o— Air Cleaner Component Parts © Body assembly ® Dust pan assembly ® Element assembly © bot © Partition plate —98—6-01 Minspection w 2 @ a 6) © Check the air cleaner body and cbver for defor: mation, corrosion, and damage. If any defect is found, repair or replace. If the body and cover (element) are not airtight, dust would intrude into the engine, causing the cylinders and pistons to wear down early, Check the interior of the body for evidences of intrusion of dust, If any, repair the air-leak part. Check the element and packing for damage and air leak, If any defect is found, replace. Check the element for dirtiness, clogging, and damage, If necessary, clean or replace the element, Check the intake hose for damage and cracks. If necessary, replace the hose. When installing the air cleaner, properly posi- tion it so that the air inlet opening faces sid- eward or downward. Also, install the dust pan with the arrow mark” TOP” indicating top. —99—ELECTRICAL SYSTEM ALTERNATOR AND DYNAMO ~ GLOW PLUG KEY-OFF STOP SYSTEM GLOW TIMER SYSTEMNe 7-01 GENERAL WSpecifications - (CID for apical son [21D contre Deseriotion eIcos 12,3 for coer eppatin | 2, 1D Model| __ MOO2TE2361 002759681 7 Type Solenoid sit type 5 5 Nominal outout tay-t.2kW @® | No-load characteristic 11.5 V/100A or more/3000rpm maximum Load characteristic 71V/8008/0.93kem oF more/880rBm minimum 2 v3 A 8 A 8 Mode . aoorraot71 007TA0171 3 nooorasari | AIOTTAONT! 1 aooorasar | AOO7TAPIT! § Type “Aerator with built-in 1G regulator < Nominal output 12V-40A 12V-40A 12V-40A 12V-40A 147250000 = 21/2600 = Output performance ee a p (Hot) 37A/5000rpm - 37A/5000rpm - Model vast % Type Sheath type, quick heating GS Rated voltage 10.5V DC 3 Current 9.7A+1.0A (when rated voltage is applied for 30 seconds) G | Resistance at normal awe temperatures la ta I Model e DH-1a0v-19 Di-1g0v-29 2 : Type Red-hot type (Quick-heat type) 2 Rated current 19A 298 o Volare between torial tv # ov Lav o2v =102—MGeneral = we Tu | a | MWiring Diagrams Numeral on each wire is a “nominal size” according to JIS, C-3406 Low-voltage Electrical Wiring for Automobiles, (1) For standard type engines with alternator (with builtin IC regulator) or AC dynamo Sane ao) Staring snitch connection Terria] 8 [RR CATS kes Eg |6.[o) 5] a TS1O) oF TS Ow a g e e s OLONSr of [EO F ¥en rina" iM E i 70 2] BT #4) F3 - Regulator & recite 3 = t BF 2 (ammeter when | P 6] “GRW | sea RO[ RED sney | | a: byname tau aw. “Era Arr g Caseanr eat IG repute (2) For L2 engines of " Key-OFF stop” specification (With AC dynamo) Fesamr® emer ay site conection esiee rer Sa TEED aan LOW [B= Ainge oF ts | Serr on | =AEC-Ee START TB=Fe-0-8r Regulator and Timer lead wire Cord olor YEL GAN, REOAWET. RED. BLU. [sik] EER —103—7-01 GENERAL (3) For standard engines of ” Key-OFF stop” specification Disused* x” Mark Wires Model YM 1&—J [control timer Model YM-2 Icontot Fuse 2A 2 ‘ame toe] “Temp. Lamp ae s ine Fue! pune 30 —Faeier iam rons ow! ie * Unt Bronk (win rr 7 ‘rr —[8-(0FF) | ‘on —[e-act-ar [ Cont jner | Se clr cose i press. Ou Pres Unit Gauge (4) For L2, L3 engines with glow timer, key-OFF stop specification OFF ean 0.78 Glow ioral esse emo “| & on Charge mp 5 5 a0 Beery st Control time lead Wire cord color “ofenw w_[Reoran| é aww. Bue(5) Three kinds of wiring diagrams for the engines with the" Key-OFF stop” system are shown ‘above, Machines equipped with those engines may be in need of wiring modification to match with those key-OFF stop system circuits, In such a case, careful attention should be paid to the matters mentioned in the below, Caution 1, Wires G and R (#1 and ¥2) for the contro! timer unit are to be minimized in wire resistance, with the necessary consideration to prevent those wires from being influenced by electric noises (caused by voltage variations, etc.) from other electrical devices. 2, Be careful not to confuse the polarity of the diode (¥v3) interposed between the key switch and alternator terminal" L.” (If that diode is connected in reverse, it will make the "Key-OFF stop” system ineffective. ) (6) Combination of operations of components in” Key-OFF stop” (fuel cutoff solenoid) system circuit [State of Key Olt pressure Fuel outott | etn amp col engine ‘switch ‘switch solenoid ‘rack position uncon oN on oN STOP At start START OFF OFF MS Cranking up ON OFF OFF (ss) ‘Normal running On the run on on [oN stor | Semel OFF OFF on STOP Key-OFF stop (7) Key switch connection for automatic glow system operations Key switch position Connection Remarks OFF B.0FF an aon ee aay Prete (Oe ano HW fred pd wie st meron GFegier hos eran ron (ee Gis Hm) ore ee —105—nd 7-02 STARTER Mconstruction st oO @ @ @ ® Starter Component Parts Front bracket assembly Lever assembly Spring set Center bracket assembly Switch assembly ® @ ® @ ® Through bolt Armature Rear bearing Pinion Pinionshaft assembly —106— @eee Gear Yoke assembly Brush holder assembly Rear bracketNet 7-02 Minspection (Assembly) If any abnormality is assumed by the following tests, adjust the starter or disassemble and repair it (1). Pinion gap inspection (2) Interpose a battery (12 V) between starter and starter body, and the pinion will protrude and stop. terminal” s* Caution Never apply battery voltage for over 10 seconds continuously. (b) Lightly push the pinion back and measure the return stroke (called pinion gap). (6) If the pinion gap is not within the standard range (0,5 to 2,0 mm), adjust it by increasing or decreasing the number of pack- ings on the magnetic switch, The gap is decreased as the number of packings in. creases. (2) Nostoad test (@) Connect the ammeter, voltmeter and battery to the starter as illustrated, (b) When the switch is closed, protrude and the starter must run smoothly (at 3000 rpm or more). If the current or the pinion must starter speed is out of specification, disas- semble the starter and repair it, Caution © Use the thick wires as far as possible for wiring and tighten every terminal securely. © This is a solenoid shift type starter which makes a rotating sound larger than that of a direct-drive type starter. © When detecting starter rotation at the pinion tip, take care of protrusion of the pinion. Push back Lighey Z 0.5~2.0%m Inspecting Pinion Gap Ammeter No-load Test —107—No. | 7-02 STARTER (3) Magnetic switch Perform the following tests, If any test is not satisfied, bly. (a) Disconnect wire from terminal (b) Attraction test Connect a battery to the magnetic switch replace the magnetic switch assem. terminals S and M, protrude, The pinion must ca Do not apply battery current for more than 10 seconds, ‘traction Test (©) Holding test With a battery connected to the magnetic. switch terminal ” S” and to the starter body, ‘manually pull out the pinion fully, The pinion must remain at that position even when released from holding by hand, Cat Do not apply battery current for more than 10 seconds, (a) Return test With a battery connected to the magnetic switch terminal "M” and to the starter body, manually pull out the pinion fully, The pinion must return to its original position when released from holding by hand, Caution Do not apply battery current for more than 10 seconds. MDisassembly (1). Disconnect wire from the magnetic switch termi- ral” M,” (2) Loosen two screws fastening the magnetic switch, Remove the magnetic switch assembly, (3) Remove two through bolts and two screws fas- tening the brush holder, bracket, Remove the rear Holding Test eo Battery Return Test Removing Brush Holder Assembly =108=(a) 6) @ a (@) 9) With two brushes brought in floating state, remove the yoke-and-brush-holder assembly. Then, pull the armature out. Remove the cover, pry the snap ring out, and remove the washer. Unscrew the bolts and remove the center bracket. Atthe same time, washers fr pinion shaft end play adjustment will come off. Pull out the reduction gear lever and lever spring from the front bracket, On the pinion side, pry the snap ring out, and pull out the pinion and pinion shaft. At each end of the armature, remove the ball bearing with @ bearing puller. It is impossible to replace the ball bearing press-ftted in the front bracket. I that bearing has worn off, replace the front bracket assem- biy. Removing Reduction Gear —109—Sa No | ae 7-02 STARTER inspection Break and short eruit, Bearing: Play, noise {and rough rotation Inauiation Bearing: Play, noise, Break and shor circuit ‘and rough tation Inspect about the following Description Standard | Service timit Description Standard | Service limit Depth of undercut 0.5 mm 0,2 mm Height of brush 17 mm 5 mm Commutator 0, 0, 38,7 mm =1.0 mm ‘Soring ressre Ske (1) Inspecting the magnetic switch Check the magnetic switch for conduction between terminals S and M and between termi- nals $ and body, If zero-ohm is indicated (as ‘an evidence of short circuit), replace the magnetic switch, Checking Magnetic Switer| 10—(2) Inspection the armature (2) Check the armature with a growler tester. If short-circuited, replace the armature, Also, ccheck for insulation between the commutator and its shaft. If poorly insulated, replace the armature. (b) Measure the commutator 0. D. and the depth of undercut, Repair or replace if the service limit is exceeded, Also, check the com- mutator outside surface for dirtiness and roughness. If rough, polish the commutator with fine-grain sandpaper. (3) Brush holder inspection (2) Check the brushes. If worn out beyond the service limit, replace the brushes. (b) Check the brush spring tension. If decreased beyond the service limit, replace springs. (C) Check for insulation between the positive brush holder and holder base, If poorly insulated, replace the holder assembly, ‘Also, check the brush holders for proper staking, (4) Field coil inspection (2) Check for insulation between one end (brush) of coil and yoke. (b) Check for conduction between both ends (brushes) of coil. (©) Check the poles and coil for tightness, Assembly and Adjustment Reassemble the starter assembly in the reverse order of disassembly, giving care to the following : (1) Pinion shaft end play adjustment Set the end play (thrust gap) to 0.5 mm or less by inserting an adjusting washer between the center bracket and reduction gear. (@)_ Fit the pinion shaft, reduction gear washer and snap ring to the center bracket, Checking Armature Colt 7-02 Checking Brush Holders (Checking Field Goi ‘Adjusting Gear washer ‘soap 0.5m maximum Adjusting Piion Shaft End Play -ul—ae No 7-02 STARTER (0) Measure end play by moving the pinion shaft inthe axial direction, If end play exceeds 0. 5 mm, increase the number of adjusting washers inserted, (2) Greasing Whenever the starter has been overhauled, apply grease to the following parts Armature shaft gear and reduction gear All bearings Bearing shaft washers and snap rings Bearing sleeves Pinion Sliding portion of lever Caution Never smear the starter fitting surface, terminals, brushes, and commutator with greas —12-ee | ie | 7-03 ALTERNATOR AND DYNAMO Construction = : ro Alternator Component Parts © Palley ® Rear bearing ® ® Front bracket assembly © Stator @ ® Front bearing ©® Terminal set o ® Rotor assembly ® Regulator assembly Dynamo The dynamo is used for so-specified engines, This Field cll maintenancefree dynamo is the permanent magnet type, light-weight, compact, single-phase AC generator, Alternating current generated by the ‘dynamo is rectified through the separate regulator-and: rectifir unit, For dynamo inspection items, see the fend of this section, Dynamo -113— Rectifier assembly Rear bracket assembly Condenser assembly \ta Ne. 7-03 ALTERNATOR AND DYNAMO MOn-tt wo (a) (o) () @ fe ny e) the engine Inspection Precautions for handling Erroneous handling possibly causes damage to the charging circuit and other troubles, Never connect the battery in reverse, Do not use a megger and other high-voltage testers, When recharging the battery, disconnect the battery cable from the alternator, Never disconnect the lead wire from the alternator terminal 8 during running of the engine, Never ground the. alternator terminal B to which battery voltage is always applied, Never short-circuit or ground terminal L, When using a steam cleaner, be careful not to direct steam directly to the alternator, (2) Checking for regulated voltage (@) (b) (©) @ ) Interpose an ammeter between positive termi. nal of battery and terminal B of alternator. Ground the alternator terminal” L" through a voltmeter, Note that the voltmeter indicates zero volt when the key switch is in the OFF position, The voltmeter will indicate a voltage consider- ably lower than battery voltage when the key switch is in the ON positi is at a stop). Short-circuit the ammeter and start the 1A (while the engine engine, Read the voltmeter indication (regulated voltage) under the following test conditions Ammeter indication is below 5 A; engine speed is at 1800 rpm and 2500 rpm; and lamps are switched off, Regulated voltage shows a tendency to decrease as alternator ‘temperature increases, Checking for Regulated Voltage 1(3) Output inspection (a) Disconnect the grounding cable from the meres battery, pO (b) Interpose an ammeter between the battery Alternator +] Vomerer terminal” B” through a voltmeter, (c) Connect the battery grounding cable, {d) Start the engine, (€) Apply all toad including the lamps, (f] Increase engine speed until normal alternator speed is attained, Read the maximum Checking for Output indication of the ammeter at 13.5 V of volt» [Description | 12V%35A (avxa0a | meter indication, Output current must con- form to the specification | 7471200 rom | Alternator | | 30 72500 rom output ati3.sv| | 34/1300 rpm — B | 23.072500 pm | 21 &,72500 rpm |__| (84) 78000rm | 37 4/8000 rpm Removal (1). Disconnect the battery cable, (2) Disconnect lead wire from terminal" 8” ” on the back of alternator, (3) Disconnect the alternator connector, (4) Loosen the alternator brace bolt and support bolt, Push the alternator toward the engine and remove the fan belt, (5) Dismount the alternator, Removing Alternator Disassembly of Alternator (1) Remove three through bolts, (2) Heat the rear bracket around the rear bearing up to §0 to 60°C (with a solder iron) and separate the bracket from the stator coil, Caution |. Pry open the alternator with a screwdriver blade inserted into the clearance between the stator core and front bracket, Be careful not to insert the blade deeply. =lis—o Es 7-03 ALTERNATOR AND DYNAMO- (3) Grip the rotor in a vise, remove the pulley nut, ‘and pull out the pulley, fan and spacer. (4) Pull out the rotor assembly from the front bracket. (5) Unsolder the stator coll lead wires, Remove the stator assembly, Caution ‘Never heat the lead wires long to prevent damage to diodes, (6) Disconnect the capacitor from terminal. 8. (7) Loosen the screws fixing the rectifier and remove the rectifier, =116-= cs 7-03 | a | Miinspection Inspect the disassembled parts, If any part is found defective, replace, Deformation ‘Break and and damage short circuit short cuit 4, / ‘Wear 40 kit oe Inspection of Alternator (1). Inspecting the diodes Check each builtin diode in the rectifier for conduction as follows : (@) Connect a circuit tester (ohm meter) across the lead wire and case of the diode to be tested, The diode is considered normal if its resistance is large in either direction and ‘small in the reverse direction, (b) If there is equal resistance in both directions, the diode is suspected to be defective, Replace the rectifier assembly, (©) Check every diode for conduction, (2) Inspecting the field coil (2) Check for conduction between slip rings, If there is no conduction, the field coll is suspected to be broken, Replace the field coil, (Checking Fielé Gol for Conduction -ur—oo te | ae | 7-03 ALTERNATOR AND DYNAMO (b) Check for conduction between a slip ring and shaft (or core). If any conduction is found, the field coil is suspected to be poor in insula: tion, Replace the field coil, (3) Inspecting the stator coil (2) Check for conduction between lead wires of the stator coil, If there is no conduction, the stator coil is suspected to be broken, Replace the stator coil, (b) Check for conduction between each lead wire and stator core, If any conduction is found, the stator coil is suspected to be poor in insulation, Replace the stator coil, (Checking Stator Coll for Insulation MAssembly of Alternator Reassemble the alternator assembly in the reverse order of disassembly, giving care to the following : (1) The rear bearing has an eccentric groove, Install the snap ring so that its projection fits in with the deepest part of the groove, (2). When installing a new rear bearing, press-fit the bearing with its groove facing the slip ring side, —118—No. 7703 (3) When press-fitting the rear bearing into the rear bracket, heat the bracket, Caution $$ @Pass a wire through the small hole in the rear bracket to lift the brushes before installing the rotor to the rear bracket, Remove the wire after | | the rote Is nstle, i Liting Brushes installation Install the alternator in the reverse order of removal, (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, (Leave the nuts removed from the bolts, ) (b) Push the alternator backward, Measure the clearance between the alternator rear ‘Inserting Spacer bracket and gear case bracket to determine the number of spacers to be inserted into the clearance (0,2 mm maximum), (c) Reinstall the alternator with the necessary ‘spacer inserted in place, tighten the support bolt nuts securely, (d)_ Perform the belt tension adjustment, MDynamo, Regulator and Rectifier |, Specifications For specifications, see 7-01, |, Inspection (1). Checking the unit in service ‘Measure battery voltage across terminals with a circuit tester, It is considered normal if no-load measurement is kept steady at about 15, OV at 5000rpm or more of alternator speed, Chage! lamp Measuring Voltage Across Battery Terminale =119—No. 7-03 ALTERNATOR AND DYNAMO (2) Checking the regulator alone To judge whether the regulator itself is accepta- ble or not, check the regulator for normal BLU toad conduction by connecting the.circuit tester to FED tesa the lead wires as follows, YEL teas [caw teas Lead tobe tested] Normal 1 about Posible jester(+)Tester(—)|_™easurement | cause of eur towble BLK teas ‘BLU teas RED [BLU I | Conduction | Broken diode reo |eu2 ee Lead Outlet Couser Blu 2 | BLK BLU 1 |RED | Non-conduction | Shorted diode” BLU 2 | RED Buk jeLut Shorted diode or Bix | BLU 2 thyristor Note : For testing, use the circuit tester as an ohm- meter, IIL, Installation (1) Heat affects largely on the regulator and rectifier, Position them in a well-ventilated place, Install the regulator in proper direction so that the outlet of leads from the body faces downward, =120—ca a 7-04 GLOW PLUG 7-04 Removal and Installation Glow plug tightening torque: 1,5 ~ 2,0 kgm inspection Check for conduction between the glow plug terminal and body, Ifthe plug is not conductive at all or shows a large resistance, replace the plug, Checking Giow Plug =11-fa 1-05 KEY-OFF STOP SYSTEM MGeneral 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 lowering of cil pressure (and abnormal increase of coolant temperature for special: specification engines), WContro! Timer Unit Description Specteation Wu voge av ~ I5v 0 ss (coil resistance 110 or mere) Wo, | Gord color connect with ® | Bue Solenoid @ Blue Solenoid @ | red | Battery (Key switch” 9°) @ | Green ey switch ~ ON ® | Red/White Starter (Key switch " ST") © | Yeliow it pressure switch © | Black (round) Fuel Cutoff Solenoid (Push type) (1) Specification Description Specification ] Type ETS type (Solenoid push type) Vottate ov = 15v 0 Coll resistance 1.610% (at 200) [stroke +05 | ew Sau reofunt caw Timer Uni ‘Stroke 00.5 Fuel Cutoff Solenoid (Push type)(2) Solenoid installation procedure (2) Temporarily fit the solenoid © and nut @ to the crank case, , (Coat the effective thread of solenoid with THREE-BOND 1212 and ru.) (b) Turn in the solenoid so that clearance” C” becomes zero at the injection pump rack position” 0 (stop position), ” () Turn back the solenoid 30° to 45° (the clearance between the rack and shaft will be 0, 15 to 0,20 mm) and tighten the locknut, (Nut tightening torque : approx, 5 kgm) (d) Start the engine, Confirm that the engine is ‘stopped without fail when the solenoid shaft is pushed in fully, (e) Install the rubber cap arrow mark side top (water drain hole side down), Caution ‘© Be careful not to allow detergent to intrude into the interior (cords and (f) Care after engine assembly 1) Make wiring properly for the ~ key-OFF stop” system, according to the foregoing (See 7-01 GENERAL, ) 2) Start the engine and confirm that the solenoid comes into action to stop the engine when the key switch is placed in the OFF position, 3) Confirm that the engine comes to 2 stop when the oil pressure switch terminal is short-circuited to the switch body, Fuel Cutoff Solenoid (Pull type) (1) Specification wiring diagrams, Rubber cep Water erat 0: hele ®) (A): Keep them absolutly fee from sealant (2): Avoid invasion of detergent ‘rough those gaps. Solencid Installation Type ETR type (Solenoid pull type) Coil resistance | Haig 13.5 210% 135805 Fuel Cutoff Solenoid (Pull type) =123-te | 7-05 KEY-OFF STOP SYSTEM (2) Solenoid installation In this solenoid, the solenoid shaft is pulled in when the solenoid is éxcited and the shaft is returned (protruded) when the switch key is turned to OFF, Install the solenoid while it is not excited (its shaft is protruded), using the same procedure as mentioned before for the push type, so that the specified clearance between the solenoid shaft and injection-pump rack can be obtained, Red O— White Hold 3 Pull =124—No No 7-06 GLOW TIMER SYSTEM 7-06 General Gow umen ‘The glow plugs are used to help easy start of a cold engine by preheating the combustion chamber, In the standard-specification engines, itis necessary to keep the starter key at the” H” position 20 to 30 seconds by hand in order to heat up the ‘glow plugs, The glow timer system eliminates the necessity of keeping the key switch at the " H” position and shortens the glow plug heating time (6 seconds), This system remarkably simplifies the glow plug operation, Unlike the conventional glow plug circuit, this system applies battery voltage directly to the glow plugs, Special care should be taken to prevent short circuit by faulty wiring, Glow Timer Description Specification Model ‘SBINJ Rated voltage Izv oc, Working temperature = 40" to 85°C Initial performance (at normal temperature, normal | 6:0, 7see (*1) humidity, VOC: 12 v) key switch Glow relay a0 40 10) al 3] Glow incisor Vee 3s Opecation enor toe 71 on OFF He oe see] ‘Glow timer NOTE : *1 Using the test circuit shown, measure the time spent until the glow relay trips to ON after the switch S, is closed, MGlow Relay Description Specification Model G7IsP Rated voltage Izv 0c Continuous rating min Coil resistance 13a. Inductance 24 mH (at | KHz) Glow. Timer System ® ®: Intemal wire @ Glow Relay =125—Group 8 SERVICE SPECIFICATIONS AND STANDARDS 01 PERIODIC SERVICE CHART -+---~ 02 SPECIFICATIONS AND STANDARDS 03 TIGHTENING TORQUE CHART+ AND SEALANT CHART 04 SPECIAL TOOLS «-+-e+ssssese-e-++cae | i. cad 8-01 PERIODIC SERVICE CHART MPeriodic Service Chart ‘Ov-Check, adjust or replenish [Clean @--Replace A---Drain Selez Service inerat 38) 28 [S282 /S2|22 23/78/83 /S3 (83/33 Remarks Unit and point Sal" 2/3" (3 |F° se Loose, damaged, or leaky parts} C Exhaust, noise, and vibration} O | Retightening 3 3 & G | valve clearance ° ° Engine idling ° ° Cylinder compression pressure 5° g_ | Engine oit olele ad SE | Oil filter (Cartridge type) ele 2” | oil iter (Disassembly type) o.o] @ © : Replace element, Fuel ° 4 Fuel tank a o é an alite Fog ek pe _reioce element & | Water sedimenter ° Qa B | Fuet pump ao;a Filter Injection pump ° ‘Adjust injection quantity, Nozzle ° cpa | Arcleaner $8 |_Caper-element ype) ole 25 | Air cleaner (Gil-bath type) fo) o.0] @ : Change oil, When no anliirees 16 used, drain 36 | Coolant ole © | 4 | after daity operation, 85 | Fan vert ° ° Instruments (incl, pilot amps) | © SB |reguator an o[o * F Adjust for voltage and current, [BE | clow plug ° it Solenoid switch ° | CCheck for proper function, —128—ag 8-02 SPECIFICATIONS AND STANDARDS Engine | ‘Specification or standard Description Repair limit Cylinder compression pressure 28 kat/ow? [2.7 wl (at 280 rom) 25 kgt/on? Difference between cylinders (maximum) 2.5 kg “em (2.5 wea) Fuel injection order las 12, U3: 132 Cylinder head Bottom surface distortion Within 0,05 ot Valve guide |,D, (IN and EX) 66 Valve seat angle (IN and EX) 4s Valve seat width (IN and EX) L3~h8 25 | Valve seat sinkage | Valve clearance (IN and EX) 0.25 (Cold) | Valves Valvehead cia, (IN) 28,7 | (EX) 24,7 Overall length 98 Stem 0.0, 66 | stem to Guide clearance (IN) 0.10 oo) 0.18 Valve face angle 4s Valve head thickness (Margin width) 1.0 O58 Valve head sinkage 0s (from cylinder head bottom face) Valve spring Free length 40,5 39.3 Preload/Installed length 5.94 kg /35, 5 mm | 15% 14,84 kg//28 ~ 15% Squareness z v Rocker arm Rocker arm |, D, le Rocker arm to Shaft clearance 0.2 Cylinder block Camshaft hole dia, Front No.2 No.3 Rear (42) Ball bearing hole 34 33 (13) 3 =129—No. 8-02 SPECIFICATIONS AND STANDARDS Piston pin to Connecting rod cl Press-fit load : 1000500 kg Unit an ication or standard [Repair limit | Service limit Grinder bore ] LA UA 6s soz | +070 Le, Ue 10 soz | +070 We Le 6 to2 | +070 Oversize finish tolerance 00,03 foreach oversize oytndiity Wain 0,01 en Within 0,05 on | surface distortion | tran | — Solid ype | ater Aumium alloy | 0.0, (hit ena) | L2A, L3A 65 | 20, U3 0 | L2E, L3E 16 | clearance to oyiner 0.2 | oversize | 0.25, 0.50 | Proteusion trom cylinder biock top surtace | og | Pion bin | 1 Type Semisoating type 0.0. tent Piston pinto Piston clearance 0,08 (i st Piston rings Number of rings Compression oil Ring width Compression (No.2) oil Ring side clearance > (te 11 Chrome plated, semikeystone type] No.2 Tapered 1 (Chrome plated ring with coil expander) Compression No, 1 No.2 0,05~0, 03 | 02 Oi ring 0,03~0, 07 0.2 Ring gap 0,15~0, 40 1s Connecting rod | Type | Forged I-beam Bend and twist Within 0,05 0,15 max, Big end thrust clearance 0,1~0,35 0.5 =130—| — 8-02 a Unit Description Specification or standard Repair Umit_| Service lit Connecting rod bearing Type Aluminum metal with back metal Oil clearance ats Under size 0425, 0.50 Crankshaft Type Fly counterbalanced Bena within 0,03 0.05 End play 0,05~0. 175 Journal 0,0, 43 =0,15 0,70 Pin 0.0, 40 -o1s | -07 Under size finishing Journal U8, 0.25 «2, 115~42, 790 0.50 £2, 405~42. 480 Pin U.S, 0.25 38, 715~39, 730 0.50 39, 465~29,c20 ain bearing Type Aluminum metal with back metal Oil clearance (No, 2: Flanged metal) | 0.10 Under size 0.25, 0,50 Canshait Driving method Gear erve Front journal Ball bearing Journal to Cylinder bock hole leranc as Major diameter of cam (WN and &X) 237 =1.0 Oil clearance aus Injection pump camshaft Driving method Gear dive Bearing Ball bearing (Front and rear) Melor diameter of cam | 30 7 Teppet j 0.0, 3 Tappet to Cylinder block clearance 1s Pash rod Bend within 0,3 =131—ag 8-02 SPECIFICATIONS AND STANDARDS MLubricating System Description ‘Specification or standard [Repair limit | Service limit viexsty( $0 20-0 seo 09 = 30 ore secon ~ 33 L2 (standard) + Upper timit/Lower limit 2.4/1.48 (excl, 0,52 in oil filter) L3- (standard) = Upper limit/LomerFimit 3.0/1.52 (excl, 0,52 in oil filter) L3- (large) = Upper timit/Lower limit 3.6/1,.82 (excl, 0,52 in oil filter) + Upper fimit/Low limit 4,873,028 (excl, 0,50 in oil filter) or Check valve opening pressure 3.0:E0. 3kgf/om? (0.30. 03MPa] (1000rpm) Outer rotor to Housing clearance 0, 100~0, 186 03 | Contact closing pressure (Standard type) 0.50.1 kgf/on? [0050.01 wpa] WFuel System Unt ma 1 Description Specification or standard Repair limit | Service limit Fuel specification Diesel fuel AS No, 2 (ES No, 3 in cold weather) te Pur dene e Tie eevanamete doieen vot Delivery 0,372 Amin (12V, at 20°C) Te erevamaeet Png Ye Dewey: Connon ape ost ore’ nin (12, 200) + Compact type 0,42 /min (12V, at 20°C) Delivery 0, 225 Amin Fuel injection pump type. For exclusive L2, U3 use Model NO-PER2NC or ND-PERSNC -132—won No | 7 02 L2 : Standard L3 : Standard uneven pitch, suction ‘blade, (2604) ‘blade, (2906) homed 8 Unit = om Description Specification or standard Repair limit | Service mit Nozze Type Throttle type Injection start pressure stator (13.725 ° we) | tin seanears savas WGovernor System Unit wn Description ‘Specification or standard Reapir limit | Service, limit Governor Type | Centrifugal weight type MCooling System Unit = an Description T Specification or standard Repair limit | Service Cooling fan 1 Type } Option See page Fan belt Type Lengh (Standard) HM type 890 Option See page Water pump Type Centrifugal impeller type Thermostat (76,5 °C specification) Type Wax type Valve cracking temperature 765°C + 15°C Futopening empeate t8 we it 90°C ‘Thermostat (7I°C specification) Type Wax type Valve cranking tomperature mW Fulop temperate atm ae it 95°C Thermo switch Type Bimetal type Model (Part No, ) Fwo6s102G220 (MM432104) Contact closing temperature #30 Temperature gauge unit Type Model (Part No, ) Standard (C,/0) Thermistor type ‘A20-WEu (60001380) 0/104 13,5, 115723, 82,5 —133—— [eal MEME 8-02 SPECIFICATIONS AND STANDARDS Speed Pinion gap) Thrust gap 850 rpm or more 0.5~2,.0 0.5 or less Unit ¢ am Description ‘Specification or standard Repair limit [Service limit Temperature gauge unit Type Thermistor type Model (Part No, ) YM—016—02—Wo=Tu (MM435133) Standard (*C/2) (357670), (507350), 80/1186, (100,763, 5), (105,/54,5), 115/422, 5, (120,/36,2), (140,722) Thermometer unit Type Thermistor type Model (Pert No. ) 51400—Ko02—0 (0452510100) Standard ((C/2) 50/80: 10, 60/56, 35, 80/729, 52.5] 100/16, 52,5, 106/14, 30.5 WMElectrical System Unit : am Description ‘Specification or standard Repair limit | Service limit ‘Starter Type Solenoid shift type Model M2T53681.(MM317604) 2752381 (wMag3i74) Voltage — Output I2v=1.2 kW Direction of rotation Clockwise as viewed from pinion side | Nosload characteristics Terminal voltage u8V Current 100 A or less Speed 3000 rpm or more Load characteristics Terminal voltage 1 Ms Current (torque) 300 A (0,93 kg, m or more) 07 14No_| eed amd 8-02 Unit + mm Description Specification or standard [_ Repair limit | Service timit Alternator Type AC type with built-in IC regulator Mode! ‘ATTAQ171(30A6800800) AOT2537I (MM435752) Output 12V-40 Direction of rotation Output characteristics (Hot) Clockwise as viewed from pulley side Terminal voltage I35Vv Currect/Speed 21472800 rpm 37 &/5000 rpm Regulated voltage 14,740.30 Glow plug (Quick-heat type) Type Sheath type Model : Y-148T (with hex, ut) Voltage Current 10,5 V-3.7A Resistance 0.16.0 | Glow plug indicator (Quicheat ype) for L2 Type Red-hot type Model DH-139V-19| Rated current Iga Votage across terminals (at 19 A) Lsveo2v Glow plug indicator (Quek-heat type) for L3 Type Red-hot type Model DH-I39V-29| Rated current 298 Voltage across terminals (at 29 A) L7ye0.2V Fuel cutoff solenoid Type Coil resistance Working voltage Stroke Temperature range Electromagnetic ETS push type 1,604 10% (at 20°C) lo~I5 v pe 100.5 =30°C to 120°Cce | i 8-02 SPECIFICATIONS AND STANDARDS Unit : mm Description ‘Specification or standard ‘Service limit Fuel cutoff solenoid Type Rated voltage Rated temperature Coil resistance Reted pull current Reted hold current Electromagnetic ETR pull type l2-v 0c zoe Pull 025 210% Hold 135 210% Control timer Working temperature Input voltage 9 V~I5 voc Load Solenoid (Coil resistance 1,70 or more) Working temperature =30°C to 80° low timer Model BINS Rated voltage l2voc Working temperature 40°C ~85°C | Initial characteristic 6+ 0,7'sec (Normal temperature, normal humidity, Vee = 12 ¥) Environmental characteristic 6x 1,3 sec (30°C to 7, Vec=7t0I1SV) | Glow relay Mode! erie Rated voltage lev oc Continuous rating | minute Coil resistance Ba Inductance 24 mH (at 1 kHz) =40'to 100°C (70° to 100°C for 20 sec of less continued use) =136—Injection timing : BT-DC on Compression Stroke (At SS) Ei Model Specification or standard Repair limit L2A-B1DA, L2E-61WM, L2E-61SDG, L2E-61DA, L2E-618D, L3A-61TG, LA-G1WM, L3G-61WM, L3C-61DA, L3C-63WM, L3C~63WMA, L3E-61DA, LE-61WM, L3E-61SD, L3E2-62ES, L3E2-63ESA 18" 1.5" 18" 20° L2A-61A, L2A-BIRR, L2A-61SS, L2A-G2SDG, L2C-61A, L20-61CV, L2E-61HMG, L2E-61A, L2E~61ES, L2E-61SC, L2E-618S, L2E~62SDG, L2E-61SA, L2E-61WH, L2E-62ES, L2E-61GS, L2E-61SHG, L2E-61SDH, LBA-61A, L3A-~61RG, L3A-61ES, L3C-61A, L3C-61TG, L3C-61ES, L3G2-62TG, L9E-61A, L3E-61SS, L3E-61SA, L3E-61SC, L3E-61TG, LSE-61RG, L3E-SINSA, L3E-61DS, L3E-61HMG, L3E-61SHS, L3E-6ILS, LSE-61KG, L3E-61KL, L3E-61SDH, L3E-61SC, L2E2-61ES 1 £15" 17" £20" L2A-G2A, L2A-62DA, L2A-G2SS, L2A-61DM, L2C-62A, L2E-61TM, L2E-62A L2E-62DA, L2E-62WM, L2E-62SS, L2E-62PL, L2E-61DM, L2E-61IR, L3A~ 62A, L3C-62A, L3C-62A, L3C-62WM, L3C~62DA, L9E-61TM, L3E-62A, L3E~ 62DA, L3E-62WM, L3E-62SS, L3E2-62TG 19° E15" 1s" +20" =137—Els 8-03 TIGHTENING TORQUE CHART AND SEALANT CHART Parts to be tightened Size(Width across flat of hex. head) Tightoning torquelN-nl (Cylinder head bolt, main Mio (14) 75~85 (735~833) Cylinder head bolt , sub MB (12) 20~30 [196~29.4) Connecting rod cap nut MB (14) 32~35 (31.3~343] Flywheel bott Mio (17) a5~95 [833~93.1] Grankshaft pulley nut Mi6 (24) 100~120 (980~117.6) Main bearing cap bolt Mio (17) 50~55 [49.0~539] Rocker stay bolt MB (12) 15~22 (a7~218] Rocker cover nut M6 (10) 05~07 (49~s8) Nozzle holder (fitting to engine ) M20 (21) 50~60 [49.0~58.8) Nozzle union color fixing nut m2. (17) 20~30 [9.6~29.4) Nozzle retaining nut Mis (21) 35~40 [343~39.2] Fuel injection pipe nut m2. 17) 25~35 [245~34.3] Delivery valve holder Mie (17) 35~39 (343~38.2) Injection pump hollow screw Mio (14) 1o~1 5 [os~14.7) Injection pump air vent screw M6 (10) 05~07 (49~s8) ‘Solenoid locknut M30 (36) 40~50 [39.2~490] Water temperature gauge joint M16 (23) 20~80 [i96~29.4) Thermoswiteh Mi6 (19) 19~27 (a6~264) Thermo gauge unit M16 (17) 19~27 [1.6~26.4] Oil fiter zo 1i~13 f1o0~12.7] Oil relief plug Mia (22) 40~50 [39.2~490] Oil drain plug Mia (19) 50~60 [49.0~588) Glow plug M10 (12) 15~20 (147~196] Glow plug lead wire fitting nut M4 (7) o1~0.15 (o9~1.4) WTightening Tor que for Common bolts and Nuts Unit: kgm (bff) (Nem) Thread ‘Identification on head diameter a T A O4z01 M6 x03) 6921) | 1iz01 Ms (£02) (og + 1) 21s#035. | M10 (1562.5) 143) 3.6206 T M2 2643) 53+) 621 Mud (327 | (59410) (932415) eS8-03 Ea Tightening Torque for Common Plugs Unit: kgfim (bf) (N-m] Size [__For aluminum materials For ferrous materials j 0652015 T=02 NPTFI/IG gaz 10+2) | 1202 1.85 +035 Pre ath (34295) it fo #2) | 183] | 2.5405 | 4405 PTL/8, NPTFI/4 | (i8 £4) | (2944) 1 (255) (925) 1 | 6.541 PT3/8 | - (4727) | 210) Mseatant Chart Ports eting slant pps Surface Sealant ee | Fuet cutot solenoid ITHREE-BOND 1212 or 1211] Cylinder block B | ater ran jom | cylinder bck g effective serew treads | HERMESEAL H) |__| B | Oil pressure switch or | Gear case | THREE-BOND 1244 aper plug | cylinder block (NPTF 1/16) | aes Geet | Cylinder head and 3 sealing cP cylinder block 3 | Expansion plug Periphery of press-fit part| HERMESEAL 52B zB | Cylinder block 7 | oil tevel gauge guide « | Side seal Periphery ITHREE-BOND 1212 or 1211 z Cylinder block ” | Bearing cap Contact surface with block THREE-BOND 1212 =139—Pe | o Ei 8-04 SPECIAL TOOLS socket wrench (2 6) Too! No. Too! name Sketch Application 81332400 Piston pin setting too Removal and installation | (Exclusive use for of piston pin L series) Guide LA (92.0) for L2A, L3A Guide Lc (89.5.2) Hor L2c, E, 130, E 81332270 Compression gauge Measurement of cylinder adapter compression (Exclusive use for (With “L" mark) L series) | | | | Mosg80sa Oil pressure switch Removal and installation of oil pressure switch In addition to the above, valve seat cutters, valve guide installers, oil filter wrenches, =140— ete, commerciatly available general tools such as bearing pullers, are required,eM a ae MITSUBISHI DIESEL ENGINE L-SERIES rp o, 99619-15180Printed in Japan Pub.No. 99619-15180