Kubota D662-E2B Workshop Manual Download Page 60

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M-1

SM-E2B SERIES, WSM

DIESEL ENGINE

1. ENGINE BODY

[1] HALF-FLOATING HEAD COVER

The rubber packing is fitted in to maintain the cylinder

head cover 0.5 mm (0.02 in.) or so off the cylinder head.
This arrangement helps reduce noise coming from the
cylinder head.

W1013327

[2] CLOSED BREATHER

Closed breather system has been adopted to prevent

the release of blow-by gas into the atmosphere.

After its oil content is filtered by oil shield (4), the blow-

by gas is fed back to the intake manifold through breather
valve (3) to be used for re-combustion.

W1012956

(1) Cylinder Head Cover

(2) Rubber Packing

(1) Cylinder Head Cover
(2) Breather Hose
(3) Breather Valve

(4) Oil Shield
(5) Rubber Packing

KiSC issued 06, 2006 A

Summary of Contents for D662-E2B

Page 1: ...SM E2B SERIES WORKSHOP MANUAL DIESEL ENGINE KiSC issued 06 2006 A...

Page 2: ...Mechanism Workshop Manual Code No 9Y021 01870 for the one which has not been described to this workshop manual Servicing Information on the troubleshooting servicing specification lists tightening tor...

Page 3: ...on labels on the machine itself to warn of the possibility of personal injury Read these instructions carefully It is essential that you read the instructions and safety regulations before you attempt...

Page 4: ...ng Otherwise hot water will spout out from radiator Only remove radiator cap when cool enough to touch with bare hands Slowly loosen the cap to first stop to relieve pressure before removing completel...

Page 5: ...lations when disposing of oil fuel coolant electrolyte and other harmful waste PREVENT ACID BURNS Sulfuric acid in battery electrolyte is poisonous It is strong enough to burn skin clothing and cause...

Page 6: ...zzle Bosch Throttle type Injection Timing 0 35 rad 20 before T D C 0 31 rad 18 before T D C 0 35 rad 20 before T D C Firing Order 1 2 Injection Pressure 13 73 MPa 140 kgf cm2 1991 psi Compression Rati...

Page 7: ...ide Injection Nozzle Bosch Throttle type Injection Timing 0 35 rad 20 before T D C Firing Order 1 2 3 Injection Pressure 13 73 MPa 140 kgf cm2 1991 psi Compression Ratio 23 1 23 5 1 Lubricating System...

Page 8: ...ion Nozzle Bosch Throttle type Injection Timing 0 30 rad 17 before T D C 0 31 rad 18 before T D C 0 35 rad 20 before T D C Firing Order 1 2 3 Injection Pressure 13 73 MPa 140 kgf cm2 1991 psi Compress...

Page 9: ...s Intermittent Torque 6 Net Intermittent Torque 7 Net Continuous Torque 8 Gross Intermittent B H P 9 Net Intermittent B H P 10 Net Continuous B H P 11 Net Intermittent B S F C 12 Gross Torque 13 Overl...

Page 10: ...s Intermittent Torque 6 Net Intermittent Torque 7 Net Continuous Torque 8 Gross Intermittent B H P 9 Net Intermittent B H P 10 Net Continuous B H P 11 Net Intermittent B S F C 12 Gross Torque 13 Overl...

Page 11: ...ower 2 Engine Speed 3 B S F C 4 Torque 5 Gross Intermittent Torque 6 Net Intermittent Torque 7 Gross Intermittent B H P 8 Net Intermittent B H P 9 Net Intermittent B S F C 10 Gross Torque 11 Overload...

Page 12: ...ttent Torque 6 Net Intermittent Torque 7 Net Continuous Torque 8 Gross Intermittent B H P 9 Net Intermittent B H P 10 Net Continuous B H P 11 Net Intermittent B S F C 12 Gross Torque 13 Overload Torqu...

Page 13: ...ttent Torque 6 Net Intermittent Torque 7 Net Continuous Torque 8 Gross Intermittent B H P 9 Net Intermittent B H P 10 Net Continuous B H P 11 Net Intermittent B S F C 12 Gross Torque 13 Overload Torqu...

Page 14: ...rque 5 Gross Intermittent Torque 6 Net Intermittent Torque 7 Net Continuous Torque 8 Gross Intermittent B H P 9 Net Intermittent B H P 10 Net Continuous B H P 11 Net Intermittent B S F C 12 Gross Torq...

Page 15: ...ss Intermittent Torque 6 Net Intermittent Torque 7 Net Continuous Torque 8 Gross Intermittent B H P 9 Net Intermittent B H P 10 Net Continuous B H P 11 Net Intermittent B S F C 12 Gross Torque 13 Over...

Page 16: ...power 2 Engine Speed 3 B S F C 4 Torque 5 Gross Intermittent Torque 6 Net Intermittent Torque 7 Gross Intermittent B H P 8 Net Intermittent B H P 9 Net Intermittent B S F C 10 Gross Torque 11 Overload...

Page 17: ...15 SM E2B SERIES WSM DIMENSIONS DIMENSIONS Z482 E2B KiSC issued 06 2006 A...

Page 18: ...16 SM E2B SERIES WSM DIMENSIONS Z602 E2B KiSC issued 06 2006 A...

Page 19: ...17 SM E2B SERIES WSM DIMENSIONS D662 E2B D722 E2B KiSC issued 06 2006 A...

Page 20: ...18 SM E2B SERIES WSM DIMENSIONS D782 E2B KiSC issued 06 2006 A...

Page 21: ...19 SM E2B SERIES WSM DIMENSIONS D902 E2B KiSC issued 06 2006 A...

Page 22: ...4 CHECK POINT OF EVERY 75 HOURS G 11 5 CHECK POINTS OF EVERY 100 HOURS G 12 6 CHECK POINT OF EVERY 150 HOURS G 15 7 CHECK POINTS OF EVERY 200 HOURS G 15 8 CHECK POINTS OF EVERY 400 HOURS G 16 9 CHECK...

Page 23: ...ced Engine Serial Number The engine serial number is an identified number for the engine It is marked after the engine model number It indicates month and year of manufacture as follows Year of manufa...

Page 24: ...conforming to Tier 1 Phase 1 requirements and those conforming to Tier 2 Phase 2 requirements we have adopted E2B as a new model name for the engines conforming Tier 2 Phase 2 regulations In the after...

Page 25: ...ttery first Remove oil and dirt from parts before measuring Use only KUBOTA genuine parts for parts replacement to maintain engine performance and to ensure safety Gaskets and O rings must be replaced...

Page 26: ...ance of the required maintenance on the engine according to the above instruction W1029462 Item Service Interval Every 50 hrs 75 hrs 100 hrs 150 hrs 200 hrs 400 hrs 500 hrs 1 or 2 months 1 year 800 hr...

Page 27: ...or CE lubricating oil with a high total base number If the CF 4 or CG 4 lubricating oil is used with a high sulfur fuel change the lubricating oil at shorter intervals Lubricating oil recommended when...

Page 28: ...ker or viscosity from the previous drain old oil Never mix two different types of oil NOTE Be sure to inspect the engine locating it on a horizontal place If placed on gradients accurately oil quantit...

Page 29: ...t brand cannot be identified drain out all of the remaining coolant and refill with a totally new brand of coolant mix CAUTION Do not remove the radiator cap until coolant temperature is below its boi...

Page 30: ...ing to ambient temperature Upon an oil change be sure to replace the gasket with new one 101 mm 3 98 in oil pan depth is optional W1016604 Above 25 C 77 F SAE 30 or SAE 10W 30 SAE 10W 40 0 C to 25 C 3...

Page 31: ...laced the engine oil normally decrease a little Thus see that the engine oil does not leak through the seal and be sure to read the oil level on the dipstick Then replenish the engine oil up to the sp...

Page 32: ...ing fuel system 1 Fill the tank with fuel and open the cock 4 B only 2 Loosen the air vent plug 3 of the fuel filter a few turns 3 Screw back the plug when bubbles do not come up any more 4 Open the a...

Page 33: ...ne Oil according to ambient temperature Upon an oil change be sure to replace the gasket with new one 101 mm 3 98 in oil pan depth is optional W1017177 Above 25 C 77 F SAE 30 or SAE 10W 30 SAE 10W 40...

Page 34: ...ine Oil according to ambient temperature Upon an oil change be sure to replace the gasket with new one 101 mm 3 98 in oil pan depth is optional W1017548 Above 25 C 77 F SAE 30 or SAE 10W 30 SAE 10W 40...

Page 35: ...is worn and sunk in the pulley groove 4 If the fan belt is nearly worn out and deeply sunk in the pulley groove replace it W1209480 Cleaning Air Cleaner Element 1 Remove the air cleaner element 2 Use...

Page 36: ...d the fuel system IMPORTANT If dust and dirt enter the fuel the fuel injection pump and injection nozzle will wear quickly To prevent this be sure to clean the fuel filter cup 5 periodically W1046058...

Page 37: ...ter or its equivalent W1018457 7 CHECK POINTS OF EVERY 200 HOURS Replacing Oil Filter Cartridge for Standard Depth Oil Pans CAUTION Be sure to stop the engine before changing filter cartridge 1 Remove...

Page 38: ...mage to the engine keep out any dust inside the intake air line W1029631 8 CHECK POINTS OF EVERY 400 HOURS Replacing Fuel Filter Cartridge Cartridge Type Water and dust in fuel are collected in the fi...

Page 39: ...r instruction 6 After flushing fill with clean water and anti freeze until the coolant level is just below the port Install the radiator cap 1 securely 7 Fill with coolant up to FULL A mark on the rec...

Page 40: ...g system NOTE The above data represents industrial standards that necessitate a minimum glycol content in the concentrated anti freeze When the coolant level drops due to evaporation add fresh soft wa...

Page 41: ...d be slightly lower than the specified level to prevent overflow 2 Connect the battery to the charging unit following the manufacture s instructions 3 As the electrolyte generates gas while charging r...

Page 42: ...eter at eye level The hydrometer reading must be taken at the highest electrolyte level Reference Specific gravity slightly varies with temperature To be exact the specific gravity decreases by 0 0007...

Page 43: ...EVERY YEAR Replacing Air Cleaner Element 1 Remove used air cleaner element 2 Replace new air cleaner element NOTE The air cleaner uses a dry element Never apply oil to it Do not run the engine with fi...

Page 44: ...n 6 Check the following valve clearance marked with using a feeler gauge 7 If the clearance is not within the factory specifications adjust with the adjusting screw When No 1 piston is at the compress...

Page 45: ...er handle to measure the pressure at which fuel begins jetting out from the nozzle 3 If the measurement is not within the factory specifications replace the adjusting washer 1 in the nozzle holder to...

Page 46: ...sembling the nozzle be sure to adjust the fuel injection pressure W1018491 Tightening torque Nozzle holder 34 3 to 39 2 N m 3 5 to 4 0 kgf m 25 3 to 28 9 ft lbs Overflow pipe retaining nut 19 6 to 24...

Page 47: ...he flywheel has mark 1TC 10 and 20 for the crank angle before the top dead center of No 1 cylinder 8 Check to see if the timing angle on the flywheel is aligned with the alignment mark 2 9 If injectio...

Page 48: ...same thickness Refer to figure of the shim to check the thickness of the shims The injection timing might be changed by the application Reference Injection Timing Map before T D C W1022861 Model Rated...

Page 49: ...er when the fuel jets from the injection nozzle After that turn the flywheel by hands and raise the pressure to approx 13 73 MPa 140 kgf cm2 1991 psi 7 Now turn the flywheel back about half a turn to...

Page 50: ...ery start with the positive terminal first Never check battery charge by placing a metal object across the posts 1 Disconnect the negative terminal and positive terminal 2 Remove the battery holder 3...

Page 51: ...hen bubbles do not come up any more 4 Open the air vent cock on top of the fuel injection pump 5 If equipped electrical fuel feed pump turn the key to AC position and pump the fuel up for 10 to 15 sec...

Page 52: ...fter flushing fill with clean water and anti freeze until the coolant level is just below the port Install the radiator cap 1 securely 7 Fill with coolant up to FULL A mark on the recovery tank 4 8 St...

Page 53: ...pressure atmospheric A higher boiling point is obtained by using a radiator pressure cap which permits the development of pressure within the cooling system NOTE The above data represents industrial...

Page 54: ...No 07909 39081 Assembly 07909 31301 L 07909 31291 K 07909 31311 M Application Use to measure diesel engine compression and diagnosis of need for major overhaul W1025289 Oil Pressure Tester Code No 079...

Page 55: ...mm dia 0 31 in dia K 1 0 mm 0 039 in L 17 mm dia 0 67 in dia M 6 10 to 6 20 mm dia 0 2402 to 0 2441 in dia N 8 mm 0 31 in O 4 mm 0 16 in P 11 97 to 11 99 mm dia 0 4713 to 0 4720 in dia Q PF 1 2 R 23 m...

Page 56: ...ia 0 8622 to 0 8642 in dia F 25 mm dia 0 98 in dia C1 Chamfer 1 0 mm 0 039 in C2 Chamfer 2 0 mm 0 079 in C0 3 Chamfer 0 3 mm 0 012 in a 6 3 m 248 in b 6 3 m 248 in A 150 mm 5 91 in B 23 mm 0 91 in C 1...

Page 57: ...mfer 1 0 mm 0 039 in C2 Chamfer 2 0 mm 0 079 in C0 3 Chamfer 0 3 mm 0 012 in A 130 mm 5 12 in B 72 mm 2 83 in C 40 mm radius 1 57 in radius D 9 mm 0 35 in E 24 mm 0 95 in F 20 mm dia 0 79 in dia G 68...

Page 58: ...n dia K 52 mm dia 2 05 in dia L 40 mm dia 1 57 in dia M 10 mm 0 39 in N 33 mm 1 30 in O 20 mm dia 0 79 in dia P 40 mm dia 1 57 in dia Q 63 10 to 63 15 mm dia 2 484 to 2 486 in dia R 64 mm dia 2 52 in...

Page 59: ...SM 1 ENGINE BODY M 1 1 HALF FLOATING HEAD COVER M 1 2 CLOSED BREATHER M 1 3 PISTON Z602 E2B D902 E2B M 2 4 OIL PAN Z602 E2B D902 E2B M 2 2 COOLING SYSTEM M 2 1 COOLING FIN Z602 E2B D902 E2B M 3 KiSC i...

Page 60: ...nder head W1013327 2 CLOSED BREATHER Closed breather system has been adopted to prevent the release of blow by gas into the atmosphere After its oil content is filtered by oil shield 4 the blow by gas...

Page 61: ...bdenum disulfide 1 serves as a solid lubricant like a Graphite or Teflon This material helps resist metal wears even with little lube oil W1013114 4 OIL PAN Z602 E2B D902 E2B The oil pan is extended u...

Page 62: ...LING SYSTEM 1 COOLING FIN Z602 E2B D902 E2B The cooling fin is set up around the oil passage in the gear case Therefore the temperature of oil is decreased by the wind generated by the cooling fan W10...

Page 63: ...ng System S 15 4 Fuel System S 17 5 Electrical System S 21 2 DISASSEMBLING AND ASSEMBLING S 28 1 Draining Engine Oil and Coolant S 28 2 External Components S 29 3 Cylinder Head Valves and Oil Pan S 29...

Page 64: ...of crankshaft camshaft piston cylinder or bearing Repair or replace S 40 to 48 S 64 to 71 Compression leak from cylinder Replace head gasket tighten cylinder head screw glow plug and nozzle holder S 3...

Page 65: ...mp malfunctioning Repair or replace S 19 35 36 37 Deficient nozzle injection Repair or replace nozzle S 20 21 Compression leak Check the compression pressure and repair S 13 Excessive Lubricant Oil Co...

Page 66: ...8 Relief valve defective Replace Engine Overheated Engine oil insufficient Replenish G 6 Fan belt broken or elongated Replace or adjust G 13 Coolant insufficient Replenish G 17 18 Radiator net and ra...

Page 67: ...mm 0 0197 to 0 0276 in Cylinder Head Surface Flatness 0 05 mm 0 0020 in Valve Recessing Intake and Exhaust 0 10 to 0 10 mm 0 0039 to 0 0039 in 0 30 mm 0 0118 in Valve Stem to Valve Guide Valve Stem Va...

Page 68: ...r to Injection Pump Gear Crank Gear to Oil Pump Drive Gear Backlash Backlash Backlash Backlash 0 043 to 0 124 mm 0 00169 to 0 00488 in 0 047 to 0 123 mm 0 00185 to 0 00484 in 0 046 to 0 124 mm 0 00181...

Page 69: ...0 015 to 0 075 mm 0 00059 to 0 00295 in 20 026 to 20 077 mm 0 78843 to 0 79043 in 0 15 mm 0 0059 in Piston Ring Gap Z482 E2B D662 E2B D722 E2B D782 E2B Top Ring 0 15 to 0 30 mm 0 0059 to 0 0118 in 1...

Page 70: ...00417 in 43 934 to 43 950 mm 1 72968 to 1 73031 in 43 984 to 44 040 mm 1 73165 to 1 73386 in 0 20 mm 0 0079 in Crankshaft Journal to Crankshaft Bearing 2 Flywheel Side Crankshaft Journal Crankshaft Be...

Page 71: ...269 mm 2 52953 to 2 53027 in 64 400 mm 2 53543 in Cylinder Liner Oversize 0 25 mm 0 0098 in Z482 D722 D782 E2B I D 67 250 to 67 269 mm 2 64764 to 2 64839 in 67 400 mm 2 65354 in Cylinder Liner Oversiz...

Page 72: ...ing 3600 min 1 rpm 0 33 to 0 37 rad 19 to 21 before T D C Injection Pump D782 E2B Injection Timing 3200 min 1 rpm 0 28 to 0 31 rad 16 to 18 before T D C Injection Pump Z602 D902 E2B Injection Timing 3...

Page 73: ...n 10 5 mm 0 413 in Starter Planetary Gear Reduction Type Commutator Difference Mica Brush O D O D Undercut Length 30 0 mm 1 181 in Less than 0 02 mm 0 0008 in 0 50 to 0 80 mm 0 0197 to 0 0315 in 14 0...

Page 74: ...numbers punched on the screw and bolt heads Prior to tightening be sure to check out the numbers as shown below W1012705 Grade Nominal Unit Diameter Standard Screw and Bolt Special Screw and Bolt N m...

Page 75: ...to 94 0 Idle gear shaft mounting screw M6 x 1 9 8 to 11 3 1 00 to 1 15 7 2 to 8 3 Oil pump mounting screw M8 x 1 25 17 7 to 21 6 1 80 to 2 20 13 0 to 15 9 Connecting rod screw M7 x 0 75 26 5 to 30 4 2...

Page 76: ...Repeat steps 4 and 5 for each cylinder 7 If the measurement is below the allowable limit apply a small amount of oil to the cylinder wall through the glow plug hole or nozzle hole and measure the com...

Page 77: ...ollowing valve clearance marked with using a feeler gauge 7 If the clearance is not within the factory specifications adjust with the adjusting screw When No 1 piston is at the compression top dead ce...

Page 78: ...the engine oil pressure switch to the specified torque W10349520 3 Cooling System Fan Belt Tension 1 Measure the deflection A depressing the belt halfway between the fan drive pulley and alternator pu...

Page 79: ...d measure the time for the pressure to fall to 59 kPa 0 6 kgf cm2 9 psi 3 If the measurement is less than the factory specification replace the radiator cap W1054156 Radiator Water Leakage 1 Pour a sp...

Page 80: ...op turning when the fuel begins to come up to get the present injection timing 7 Check to see the degree on flywheel The flywheel has mark 1TC 10 and 20 for the crank angle before the top dead center...

Page 81: ...e same thickness Refer to figure of the shim to check the thickness of the shims The injection timing might be changed by the application Reference Injection Timing Map before T D C W1018986 Model Rat...

Page 82: ...ressure 6 Stop the starter when the fuel jets from the injection nozzle After that turn the flywheel by hands and raise the pressure to approx 13 73 MPa 140 kgf cm2 1991 psi 7 Now turn the flywheel ba...

Page 83: ...measure the pressure at which fuel begins jetting out from the nozzle 3 If the measurement is not within the factory specifications replace the adjusting washer 1 in the nozzle holder to adjust it Re...

Page 84: ...omes very explosive IMPORTANT If the machine is to be operated for a short time without battery using a slave battery for starting use additional current lights while engine is running and insulate te...

Page 85: ...ometer at eye level The hydrometer reading must be taken at the highest electrolyte level Reference Specific gravity slightly varies with temperature To be exact the specific gravity decreases by 0 00...

Page 86: ...switch W1019297 Magnetic Switch Test 1 Disconnect the battery negative cable from the battery 2 Disconnect the battery positive cable from the battery 3 Disconnect the leads from the starter B termin...

Page 87: ...itch 0000010771E No load Dynamo Output 1 Disconnect the lead wires from the dynamo 2 Start the engine and operate the dynamo at the specified speed 3 Measure the output voltage with a volt meter If th...

Page 88: ...it for the measuring range The judgement should be as below table ON if the indicator moves otherwise OFF Check Table ON OFF W1021509 Regulating Voltage 1 Complete the charging circuit with a fully ch...

Page 89: ...tage 1 Turn the key switch to the GLOW or PREHEAT position and measure the voltage with a circuit tester between the lead terminal and the engine body 2 If the voltage differs from the battery voltage...

Page 90: ...d body and then the plunger comes out within approximately 1 2 seconds 7 Turn on the switch 8 then turn on the switch 7 the plunger pull into the solenoid body and it keeps in holding position after t...

Page 91: ...oil up to the upper line on the dipstick 1 IMPORTANT Never mix two different types of oil Use the proper SAE Engine Oil according to ambient temperature W1023464 Draining Coolant CAUTION Never remove...

Page 92: ...Pan Cylinder Head Cover 1 Disconnect the breather hose 1 2 Remove the cylinder head cover screws 2 3 Remove the cylinder head cover 3 When reassembling Check to see if the cylinder head cover gasket i...

Page 93: ...rew driver three or four times each way 3 While turning the screw driver slowly pull the heat seal 4 out together with the injection nozzle gasket 3 4 If the heat seal drops repeat the above procedure...

Page 94: ...putting the push rods 3 onto the tappets 4 check to see if their ends are properly engaged with the dimples IMPORTANT After installing the rocker arm be sure to adjust the valve clearance W1021437 Tig...

Page 95: ...e long run Retighten the cylinder head screws after running the engine for 30 minutes W1025645 Thermostat Assembly 1 Remove the thermostat cover mounting screws 1 and remove the thermostat cover 2 2 R...

Page 96: ...move the water pump flange 1 5 Press out the water pump shaft 2 with the impeller 6 on it 6 Remove the impeller from the water pump shaft 7 Remove the mechanical seal 5 When reassembling A Apply a liq...

Page 97: ...SM E2B SERIES WSM DIESEL ENGINE S 32b rev 001 5 01 07 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 98: ...ve spring collet 3 pushing the valve spring retainer 2 by valve spring replacer 1 3 Remove the valve spring retainer 2 valve spring 5 and valve stem seal 6 4 Remove the valve 7 When reassembling Wash...

Page 99: ...g the hole 5 numbered 3 install the oil strainer by mounting screw IMPORTANT Scrape off the old adhesive completely Wipe the sealing surface clean using waste cloth soaked with gasoline Now apply new...

Page 100: ...late 2 Position the slot 7 on the fork lever just under the slot 6 on the crankcase Insert the injection pump 1 so that the control rod 10 should be pushed by the idling adjusting spring 9 at its end...

Page 101: ...Remove the screws and separate the speed control plate 6 taking care not to damage the governor spring 7 3 Disconnect the governor spring 7 and remove the speed control plate 6 using the specific tool...

Page 102: ...er of the speed control plate 7 Install the engine stop solenoid rod 15 to the guide hole of cylinder block 10 and fix the engine stop solenoid 16 with socket head screws NOTE Be careful not to stretc...

Page 103: ...aw out the fan drive pulley with a puller When reassembling Install the pulley to crankshaft aligning the mark 1 on them Apply engine oil to the fan drive pulley retaining screw And tighten it W101819...

Page 104: ...or equivalent to both sides of the gear case gasket Be sure to set three O rings inside the gear case NOTE The gear case for energize to run type stop solenoid and the gear case for one side maintena...

Page 105: ...to the photo W1030437 Camshaft 1 Remove the camshaft mounting screws 1 and draw out the camshaft with gear 2 on it When reassembling When install the camshaft apply engine oil to the camshaft journals...

Page 106: ...e side Maintenance Type 1 Remove the oil pump mounting screw 6 and the oil pump 5 2 Remove the collar 4 O ring 3 and crankshaft oil slinger 2 For Z482 E2B D662 E2B D722 E2B D782 E2B 3 Remove the crank...

Page 107: ...e injection pump Apply engine oil to the connecting rod screws and lightly screw it in by hand then tighten it to the specified torque If the connecting rod screw won t be screwed in smoothly clean th...

Page 108: ...e the combination of cylinder and piston Make sure of the position of each piston by marking For example mark 1 on the No 1 piston When installing the piston into the cylinder place the gaps of all of...

Page 109: ...e oil ring gap 11 Apply engine oil to the piston pin When installing the connecting rod to the piston immerse the piston in 80 C 176 F oil for 10 to 15 minutes and insert the piston pin to the piston...

Page 110: ...bearing case cover 5 When reassembling Fit the bearing case gasket 3 and the bearing case cover gasket 4 with correct directions Install the bearing case cover 5 to position the casting mark UP a on...

Page 111: ...cond cylinder to the bottom dead center Draw out the crankshaft until the crankpin of the first cylinder comes to the center of the third cylinder 4 Repeat the above steps to draw out all the cranksha...

Page 112: ...r Z482 E2B and 1 2 for D662 E2B D722 E2B D782 E2B from the gear case side Refer to the figure Match the alignment numbers a on the main bearing case assembly 1 1 Do the same for the main bearing case...

Page 113: ...tom of the crankshaft bearing 3 5 9 Install the bearing with the oil groove c up Match the alignment numbers a on the main bearing case assembly 1 1 Do the same for the main bearing case assembly 2 2...

Page 114: ...t the armature 10 with the drive lever 3 NOTE Do not damage to the brush and commutator When reassembling Apply grease DENSO CO LTD No 50 or equivalent to the parts indicated in the figure Joint of so...

Page 115: ...g the spring up 5 Remove the brush holder 13 6 Draw out the armature 11 and yoke 12 from the housing 7 Draw out the shaft assembly 7 with the drive lever 6 and overrunning clutch 8 from the housing Wh...

Page 116: ...3 3 Unscrew the screws and remove the stator 6 When reassembling Take care the direction of the collar 4 the flat side should face to the pulley side W1224556 1 Shaft 2 Pulley 3 Rotor 4 Collar 5 Beari...

Page 117: ...drive end frame 2 9 Remove the retainer plate 5 10 Press out the bearing 4 from drive end frame 2 with a press and jig 11 Lightly secure the rotor with a vise to prevent damage and remove the bearing...

Page 118: ...ions check the oil clearance between the crankpin and crankpin bearing and between the piston pin and small end bushing NOTE After checking the top clearance be sure to assemble the cylinder head with...

Page 119: ...he cylinder head W10768800 Clearance between Valve Stem and Valve Guide 1 Remove carbon from the valve guide section 2 Measure the valve stem O D with an outside micrometer 3 Measure the valve guide I...

Page 120: ...r during replacement W10314690 Valve Seating 1 Coat the valve face lightly with prussian blue and put the valve on its seat to check the contact 2 If the valve does not seat all the way around the val...

Page 121: ...ith a 0 785 rad 45 valve seat cutter again and visually recheck the contact between the valve and seat 5 Repeat steps 3 and 4 until the correct contact is achieved 6 Continue lapping until the seated...

Page 122: ...30 Oil Clearance between Rocker Arm and Rocker Arm Shaft 1 Measure the rocker arm shaft O D with an outside micrometer 2 Measure the rocker arm I D with an inside micrometer and then calculate the oil...

Page 123: ...appet guide bore with a cylinder gauge and calculate the oil clearance 3 If the oil clearance exceeds the allowable limit or the tappet is damaged replace the tappet W11231410 Push rod alignment Allow...

Page 124: ...by moving the cam gear to the font and rear 3 If the measurement exceeds the allowable limit replace the camshaft stopper W11299720 Backlash between idle gear and crank gear Factory spec 0 043 to 0 1...

Page 125: ...Measure the camshaft journal O D with an outside micrometer 2 Measure the cylinder block bore I D for camshaft with a inside micrometer and calculate the oil clearance 3 If the oil clearance exceeds...

Page 126: ...oil to them 2 Press in a new brushing using an idle gear bushing replacing tool until it is flush with the end of the idle gear W11373220 3 Piston and Connecting Rod Piston Pin Bore I D 1 Measure the...

Page 127: ...ng is the basis of this check check bushing for wear beforehand 1 Install the piston pin into the connecting rod 2 Install the connecting rod on the connecting rod alignment tool 3 Put a gauge over th...

Page 128: ...gap Z482 E2B D662 E2B D722 E2B D782 E2B Top ring Factory spec 0 15 to 0 30 mm 0 0059 to 0 0118 in Allowable limit 1 20 mm 0 0472 in Second ring Factory spec 0 30 to 0 45 mm 0 0118 to 0 0177 in Allowa...

Page 129: ...e the crankshaft alignment 4 If the measurement exceeds the allowable limit replace the crankshaft W11613530 Crankshaft side clearance Factory spec 0 15 to 0 31 mm 0 0059 to 0 0122 in Allowable limit...

Page 130: ...dimensions of crankpin W11625390 Oil clearance between crankpin and crankpin bearing Factory spec 0 020 to 0 051mm 0 00079 to 0 00201 in Allowable limit 0 15 mm 0 0059 in Crankpin O D Factory spec 33...

Page 131: ...kshaft journal wear replace it with an undersize one referring to the table and the figure W10323470 Oil Clearance between crankshaft journal and crankshaft bearing 1 Factory spec 0 034 to 0 106 mm 0...

Page 132: ...E2B D662 E2B D722 E2B D782 E2B Crankshaft bearing 1 04 15861 23920 040 US Z602 E2B D902 E2B 1G460 23920 Undersize Models 0 2 mm 0 008 in 0 4 mm 0 016 in Dimension A All models 1 8 to 2 2 mm radius 0 0...

Page 133: ...igure NOTE Be sure not to move the crankshaft while the bearing case screws are tightened W10344030 Oil clearance between crankshaft journal and crankshaft bearing 2 crankshaft bearing 3 Factory spec...

Page 134: ...rankshaft bearing 2 04 1G460 23950 Crankshaft bearing 3 04 1G460 23960 Undersize Models 0 2 mm 0 008 in 0 4 mm 0 016 in Dimension A All models 1 8 to 2 2 mm radius 0 071 to 0 087 in radius 1 8 to 2 2...

Page 135: ...m and minimum I D s 2 Get the difference Maximum wear between the maximum and the minimum I D s 3 If the wear exceeds the allowable limit bore and hone to the oversize dimension Refer to Correcting Cy...

Page 136: ...Pump Body 1 Measure the clearance between the outer rotor and the pump body with a thickness gauge 2 If the clearance exceeds the factory specifications replace the oil pump rotor assembly W10381420...

Page 137: ...tarter Overrunning Clutch 1 Check the pinion and if worn or damage replace the clutch assembly 2 Check that the pinion turns freely and smoothly in the overrunning direction and does not slip in the c...

Page 138: ...correct it with a saw blade and chamfer the segment edges W1155802 Commutator O D Factory spec Electromagnetic drive type 28 0 mm 1 102 in Planetary gear reduction type 30 0 mm 1 181 in Allowable lim...

Page 139: ...eplace the brush holder W1156895 Armature Coil 1 Check the continuity across the commutator and armature coil core with resistance range of circuit tester 2 If it conducts replace the armature 3 Check...

Page 140: ...ch lead of the stator coil with resistance range of circuit tester 2 If the measurement is not within factory specification replace it 3 Check the continuity across each stator coil lead and core with...

Page 141: ...Check the continuity across each diode of rectifier with resistance range of circuit tester 2 The rectifier is normal if the diode in the rectifier conducts in one direction and does not conduct in th...

Page 142: ...RY SERVICE LTD 64 ISHIZU KITAMACHI SAKAI KU SAKAI CITY OSAKA 590 0823 JAPAN PHONE 81 72 241 1129 FAX 81 72 245 2484 E mail ksos pub kubota co jp KUBOTA Corporation Printed in Japan 2006 02 S EI EI e C...

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