Kubota D722-E3B Workshop Manual Download

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SM-E3B SERIES

WORKSHOP MANUAL

DIESEL ENGINE

KiSC issued 03, 2011 A

Summary of Contents for D722-E3B

Page 1: ...SM E3B SERIES WORKSHOP MANUAL DIESEL ENGINE KiSC issued 03 2011 A ...

Page 2: ...ne Mechanism Workshop Manual Code No 9Y021 01876 for the one which has not been described to this workshop manual Q Servicing Information on the troubleshooting servicing specification lists tightening torque checking and adjusting disassembling and assembling and servicing which cover procedures precautions factory specifications and allowable limits All information illustrations and specificatio...

Page 3: ...n 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 to repair or use this unit DANGER Indicates an imminently hazardous situation which if not avoided will result in death or serious injury WARNING Indicates a potentially hazardous situation which if n...

Page 4: ...ise 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 completely Escaping fluid fuel or hydraulic oil under pressure can penetrate the skin causing serious injury Relieve pressure before disconnecting hydraulic or fuel lines Tighten all connections before applying pressur...

Page 5: ...must be running to do some work make sure the area is well ventilated Never run the engine in a closed area The exhaust gas contains poisonous carbon monoxide DISPOSE OF FLUIDS PROPERLY Do not pour fluids into the ground down a drain or into a stream pond or lake Observe relevant environmental protection regulations when disposing of oil fuel coolant electrolyte and other harmful waste PREVENT ACI...

Page 6: ...TY INSTRUCTIONS PREPARE FOR EMERGENCIES Keep a first aid kit and fire extinguisher handy at all times Keep emergency numbers for doctors ambulance service hospital and fire department near your telephone KiSC issued 03 2011 A ...

Page 7: ...irection of Rotation Counter clockwise viewed from flywheel side Injection Nozzle Bosch Throttle type Injection Timing 0 37 rad 21 before T D C 0 35 rad 20 before T D C Firing Order 1 2 Injection Pressure 13 73 MPa 140 0 kgf cm2 1991 psi Compression Ratio 23 5 1 24 1 Lubricating System Forced lubrication by trochoid pump Oil Pressure Indicating Electrical type switch Lubricating Filter Full flow p...

Page 8: ...on Pump Bosch MD type mini pump Governor All speed mechanical governor Direction of Rotation Counter clockwise viewed from flywheel side Injection Nozzle Bosch Throttle type Injection Timing 0 37 rad 21 before T D C 0 30 rad 17 before T D C 0 35 rad 20 before T D C Firing Order 1 2 3 Injection Pressure 13 73 MPa 140 0 kgf cm2 1991 psi Compression Ratio 23 5 1 24 1 Lubricating System Forced lubrica...

Page 9: ...oss 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 Overload Torque 14 Continuous Torque 15 Gross B H P 16 Overload B H P 17 Continuous B H P 18 Overload B S F C KiSC issued 03 2011 A ...

Page 10: ...ngine 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 Torque 12 Gross B H P 13 Overload B H P 14 Overload B S F C KiSC issued 03 2011 A ...

Page 11: ...ittent 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 Torque 14 Continuous Torque 15 Gross B H P 16 Overload B H P 17 Continuous B H P 18 Overload B S F C KiSC issued 03 2011 A ...

Page 12: ...Torque 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 Torque 13 Overload Torque 14 Gross B H P 15 Overload B H P 16 Overload B S F C KiSC issued 03 2011 A ...

Page 13: ...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 Torque 12 Gross B H P 13 Overload B H P 14 Overload B S F C KiSC issued 03 2011 A ...

Page 14: ...12 SM E3B SERIES WSM DIMENSIONS DIMENSIONS Q Z482 E3B KiSC issued 03 2011 A ...

Page 15: ...13 SM E3B SERIES WSM DIMENSIONS Q Z602 E3B KiSC issued 03 2011 A ...

Page 16: ...14 SM E3B SERIES WSM DIMENSIONS Q D722 E3B KiSC issued 03 2011 A ...

Page 17: ...15 SM E3B SERIES WSM DIMENSIONS Q D782 E3B KiSC issued 03 2011 A ...

Page 18: ...16 SM E3B SERIES WSM DIMENSIONS Q D902 E3B KiSC issued 03 2011 A ...

Page 19: ... 4 CHECK POINT OF EVERY 75 HOURS G 12 5 CHECK POINTS OF EVERY 100 HOURS G 13 6 CHECK POINT OF EVERY 150 HOURS G 16 7 CHECK POINTS OF EVERY 200 HOURS G 16 8 CHECK POINTS OF EVERY 400 HOURS G 17 9 CHECK POINTS OF EVERY 500 HOURS G 18 10 CHECK POINTS OF EVERY 1 OR 2 MONTHS G 20 11 CHECK POINT OF EVERY YEAR G 22 12 CHECK POINT OF EVERY 800 HOURS G 23 13 CHECK POINTS OF EVERY 1500 HOURS G 24 14 CHECK P...

Page 20: ...b c d W1011076 Alphabet or Number Year Alphabet or Number Year 6 2006 H 2017 7 2007 J 2018 8 2008 K 2019 9 2009 L 2020 A 2010 M 2021 B 2011 N 2022 C 2012 P 2023 D 2013 R 2024 E 2014 S 2025 F 2015 T 2026 G 2016 V 2027 A Engine Model Name and Serial Number Month Engine Lot Number January A0001 A9999 B0001 BZ999 February C0001 C9999 D0001 DZ999 March E0001 E9999 F0001 FZ999 April G0001 G9999 H0001 HZ...

Page 21: ...mple E2B engines may result in emission levels out of compliance with the original E3B design and EPA or other applicable regulations Please refer to the emission label located on the engine head cover to identify Output classification and Emission Control Information E3B engines are identified with ET at the end of the Model designation on the US EPA label Please note E3B is not marked on the eng...

Page 22: ...attery 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 during reassembly Apply grease to new O rings or oil seals before assembling When reassembling external or internal snap rings position them so that the sharp edge faces against the direction from w...

Page 23: ...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 hrs 1500 hrs 3000 hrs 2 years Checking fuel hoses and clamp bands Changing Engine oil 1 Oil pan depth 101 mm 3 98 in 2 Oil pan depth 121 mm 4 76 in 3 Extended oil pan depth 101 mm 3 98 in Checking fan belt tens...

Page 24: ...nging or inspecting be sure to level and stop the engine 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 hrs 1500 hrs 3000 hrs 2 years Recharging battery Replacing air cleaner element Checking valve clearance Checking injection nozzle condition Checking injection timing Checking injection pump Replacing intake air line Replacing battery Re...

Page 25: ... fuel sulfur content 0 50 5000 ppm to 1 0 10000 ppm is used as a diesel fuel change the engine oil and oil filter at shorter intervals approximately half DO NOT USE Fuels that have sulfur content greater than 1 0 10000 ppm Diesel fuels specified to EN 590 or ASTM D975 are recommended No 2 D is a distillate fuel of lower volatility for engines in industrial and heavy mobile service SAE J313 JUN87 S...

Page 26: ...aker or viscosity from the previous drain old oil Never mix two different types of oil NOTE Q Be sure to inspect the engine locating it on a horizontal place If placed on gradients accurately oil quantity may not be measured Be sure to keep the oil level between upper and lower limits of the dipstick Too much oil may cause a drop in output or excessive blow by gas On the closed breather type engin...

Page 27: ...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 boiling point Then loosen the cap slightly to relieve any excess pressure before removing the cap completely IMPORTANT Q During filling the coolant air must be vented from the engine coolant passages The...

Page 28: ...Engine 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 W1016604 Above 25 C 77 F SAE 30 or SAE 10W 30 SAE 10W 40 0 C to 25 C 32 F to 77 F SAE 20 or SAE 10W 30 SAE 10W 40 Below 0 C 32 F SAE 10W or SAE 10W 30 SAE 10W 40 Oil pan depth Models Engine oil capacity 101 mm 3 98 in 121 mm 4 76 in Z482 E3B 2 1 L 0 55 ...

Page 29: ... replaced 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 specified level IMPORTANT Q To prevent serious damage to the engine replacement element must be highly efficient Use only a KUBOTA genuine filter or its equivalent NOTE Q The oil pan of 101 mm 3 98 ...

Page 30: ...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 air vent cock 5 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 seconds If equipped mechanical fuel feed pump set...

Page 31: ...e proper SAE Engine 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 0 C to 25 C 32 F to 77 F SAE 20 or SAE 10W 30 SAE 10W 40 Below 0 C 32 F SAE 10W or SAE 10W 30 SAE 10W 40 Oil pan depth Models Engine oil capacity 101 mm 3 98 in 121 mm 4 76 in Z482 E3...

Page 32: ...he proper SAE Engine 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 0 C to 25 C 32 F to 77 F SAE 20 or SAE 10W 30 SAE 10W 40 Below 0 C 32 F SAE 10W or SAE 10W 30 SAE 10W 40 Oil pan depth Models Engine oil capacity 101 mm 3 98 in 121 mm 4 76 in Z482 E...

Page 33: ...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 clean dry compressed air on the inside of the element Pressure of compressed air must be under 205 kPa 2 1 kgf cm2 30 psi Maintain reasonable distance between the nozzle and the filter NOTE Q The air ...

Page 34: ...d the fuel system IMPORTANT Q 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 Checking Battery Electrolyte Level 1 Check the battery electrolyte level 2 If the level is below than lower level line 2 and the distilled water to pour level of each cell W1047154 1 Cock Body 2 Air...

Page 35: ...lter 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 the oil filter cartridge 1 with the filter wrench 2 Apply a slight coat of oil onto the new cartridge gasket 3 To install the new cartridge screw it in by hand Over tightening may cause deformation ...

Page 36: ...ious damage 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 filter cartridge So change the filter cartridge every 400 hours service 1 Remove the used filter cartridge with filter wrench 2 Apply a thin film of fuel to the surface of new filter cartridge ga...

Page 37: ...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 recovery tank 4 8 Start and operate the engine for few minutes 9 Stop the engine and let cool Check coolant level of radiator and recovery tank 4 and add coolant if necessary IMPORTANT Q Do not start eng...

Page 38: ...ooling system NOTE Q 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 water only to keep the anti freeze mixing ratio less than 50 In case of leakage add anti freeze and fresh soft water in the specified mixing ratio Anti freeze absorbs moisture Keep unused anti fr...

Page 39: ...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 remove all port caps 4 The electrolyte temperature must not exceed 40 C 104 F during charging If it exceed 40 C 104 F decrease the charging amperage or stop charging for a while 5 When charging several...

Page 40: ...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 0007 with an increase of 1 C 0 0004 with an increase of 1 F in temperature and increases by 0 0007 with a decreases of 1 C 0 0004 with a decrease of 1 F Therefore using 20 C 68 F as a reference the spec...

Page 41: ...EVERY YEAR Replacing Air Cleaner Element 1 Remove used air cleaner element 2 Replace new air cleaner element NOTE Q The air cleaner uses a dry element Never apply oil to it Do not run the engine with filter element removed W1020554 KiSC issued 03 2011 A ...

Page 42: ...ap position 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 compression top dead center position When No 1 piston is at the overlap position NOTE Q The sequence of cylinder numbers is given as No 1 No 2 and No 3 starting from the gear case side After adjusti...

Page 43: ...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 adjust it Reference Pressure variation with 0 025 mm 0 00098 in difference of adjusting washer thickness Approx 590 kPa 6 0 kgf cm2 85 psi W10182100 Nozzle Valve Seat Tightness 1 Set the injection nozzle...

Page 44: ...tion After assembling the nozzle be sure to adjust the fuel injection pressure W1018491 Tightening torque Nozzle holder 35 to 39 N m 3 5 to 4 0 kgf m 26 to 28 lbf ft Overflow pipe retaining nut 20 to 24 N m 2 0 to 2 5 kgf m 15 to 18 lbf ft Nozzle holder assembly 49 to 68 N m 5 0 to 7 0 kgf m 37 to 50 lbf ft 1 Nozzle Holder 2 Adjusting Washer 3 Nozzle Spring 4 Push Rod 5 Distance Piece 6 Nozzle Pie...

Page 45: ...t mark 2 9 If injection timing is out of adjustment readjust the timing with shims Z482 D722 E3B 3600 min 1 rpm spec D782 E3B 3200 min 1 rpm spec Z602 D902 E3B 3600 min 1 rpm spec W1023147 Injection timing Serial No below 7ZZ999 Factory spec 0 3491 to 0 3839 rad 20 00 to 22 00 before T D C Injection timing Serial No above 8A0001 Factory spec 0 3535 to 0 3796 rad 20 25 to 21 75 before T D C Injecti...

Page 46: ...r advances the injection timing by approx 0 0044 rad 0 25 In disassembling and replacing the injection pump be sure to use the same number of new shims with the same thickness The 0 175 mm 0 00689 in thick shim is coated only on the lower face Therefore do not use the 0 175 mm 0 00689 in thick shim as the top shim of the combination injection pump side because this can cause oil leakage Refer to f...

Page 47: ...e fuel jets from the injection nozzle After that turn the flywheel by hands and raise the pressure to approx 13 73 MPa 140 0 kgf cm2 1991 psi 7 Now turn the flywheel back about half a turn to keep the plunger free Maintain the flywheel at this position and clock the time taken for the pressure to drop from 13 73 to 12 75 MPa from 140 0 to 130 0 kgf cm2 from 1991 to 1849 psi 8 Measure the time need...

Page 48: ...ttery 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 Remove the used battery 4 Replace the new battery 5 Tighten the battery holder 6 Connect the positive terminal 7 Connect the negative terminal W1023996 Replacing Radiator Hoses and Clamp Bands CAUTI...

Page 49: ...g when 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 seconds If equipped mechanical fuel feed pump set the stop lever on stop position and crank the engine for 10 to 15 seconds 6 Close securely the air vent cock after air bleeding NOTE Q Always keep the...

Page 50: ...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 Start and operate the engine for few minutes 9 Stop the engine and let cool Check coolant level of radiator and recovery tank 4 and add coolant if necessary IMPORTANT Q Do not start engine without coola...

Page 51: ... mmHg 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 Q 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 water only to keep the anti freeze mixing rati...

Page 52: ... 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 07916 32032 Application Use to measure lubricating oil pressure W1024318 1 Gauge 2 L Joint 3 Adaptor A 4 Adaptor B 5 Adaptor C 6 Adaptor E 7 Adaptor F 8 Adaptor G 9 Adaptor H 10 Adaptor I 11 Adaptor J 1...

Page 53: ... 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 0 241 to 0 244 in dia N 8 0 mm 0 31 in O 4 0 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 mm 0 91 in S 17 mm 0 67 in T 4 0 mm 0 16 in U 12 00 to 12 02 mm dia 0 4725 to 0 4732 in dia V 100 mm 3 94 in W M12 P1 5 X 5 0 mm 0 20 in A 220 mm 8 66 in B 80 mm 3 1 in C 40 mm 1 6 in D 20 mm dia 0 79 ...

Page 54: ...0 8622 to 0 8641 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 01 in a 6 3 μm 250 μin b 6 3 μm 250 μin A 150 mm 5 91 in B 23 mm 0 91 in C 100 mm 3 94 in D 19 90 to 19 95 mm dia 0 7835 to 0 7854 in dia E 21 90 to 21 95 mm dia 0 8622 to 0 8641 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...

Page 55: ...mfer 1 0 mm 0 039 in C2 Chamfer 2 0 mm 0 079 in C0 3 Chamfer 0 3 mm 0 01 in A 130 mm 5 12 in B 72 mm 2 8 in C 40 mm radius 1 6 in radius D 9 0 mm 0 35 in E 24 mm 0 94 in F 20 mm dia 0 79 in dia G 68 mm dia 2 7 in dia H 39 90 to 39 95 mm dia 1 571 to 1 572 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 01 in A 130 mm 5 12 in B 72 mm 2 8 in C 40 mm radius 1 6 in r...

Page 56: ... K 52 mm dia 2 0 in dia L 40 mm dia 1 6 in dia M 10 mm 0 39 in N 33 mm 1 3 in O 20 mm dia 0 79 in dia P 40 mm dia 1 6 in dia Q 63 10 to 63 15 mm dia 2 485 to 2 486 in dia R 64 mm dia 2 5 in dia S 75 mm dia 3 0 in dia C0 3 Chamfer 0 3 mm 0 01 in C1 Chamfer 1 0 mm 0 039 in C5 Chamfer 5 0 mm 0 20 in A 42 mm 1 7 in B 12 mm 0 47 in C 30 mm 1 2 in D M10 Pitch 1 25 E 2 0 mm 0 079 in F 10 mm 0 39 in G 2 0...

Page 57: ...1 ENGINE BODY M 1 1 HALF FLOATING HEAD COVER M 1 2 CLOSED BREATHER M 1 3 PISTON Z602 E3B D782 E3B D902 E3B M 2 4 OIL PAN Z602 E3B D902 E3B M 2 2 COOLING SYSTEM M 3 1 COOLING FIN Z602 E3B D902 E3B M 3 KiSC issued 03 2011 A ...

Page 58: ...inder 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 ...

Page 59: ...e molybdenum 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 E3B D902 E3B The oil pan is extended under the gear case Therefore the height of the engine can be lowered more than so far while securing a necessary amount of oil W1013041 1 Molybdenum Disulfide 1 Cylinder Block 2 Gear Case 3 Oil ...

Page 60: ...OLING SYSTEM 1 COOLING FIN Z602 E3B D902 E3B 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 W1013135 1 Cooling Fin KiSC issued 03 2011 A ...

Page 61: ...ing 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 4 Gear Case and Timing Gears S 35 5 Piston and Connecting Rod S 42 6 Flywheel and Crankshaft S 45 7 Starter S 49 8 Dynamo S 51 9 Alternator S 52 3 SERVICING S 53 1 Cylinder Head and Valves S 53 2 Ti...

Page 62: ... 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 30 31 32 Improper valve timing Correct or replace timing gear S 40 Piston ring and cylinder worn Replace S 43 44 63 Excessive valve clearance Adjust S 14 Stop solenoid malfunctioning Replace S 26 27 2...

Page 63: ...ump 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 Consumption Piston ring s gap facing the same direction Shift ring gap direction S 43 Oil ring worn or stuck Replace S 43 44 Piston ring groove worn Replace piston S 43 44 63 Valve stem and valve guide...

Page 64: ...G 9 Relief valve defective Replace Engine Overheated Engine oil insufficient Replenish G 7 Fan belt broken or elongated Replace or adjust G 14 Coolant insufficient Replenish G 18 19 Radiator net and radiator fin clogged with dust Clean Inside of radiator corroded Clean or replace G 18 Coolant flow route corroded Clean or replace G 18 19 Radiator cap defective Replace Overload running Reduce the lo...

Page 65: ...to 0 10 mm 0 0039 to 0 0039 in 0 30 mm 0 012 in Valve Stem to Valve Guide Intake and Exhaust Valve Stem Valve Guide Clearance O D I D 0 030 to 0 057 mm 0 0012 to 0 0022 in 5 968 to 5 980 mm 0 2350 to 0 2354 in 6 010 to 6 025 mm 0 2367 to 0 2372 in 0 10 mm 0 0039 in Valve Face Intake and Exhaust Angle 0 79 rad 45 Valve Seat Intake and Exhaust Angle Width 0 79 rad 45 2 12 mm 0 0835 in Intake Valve T...

Page 66: ... Gear to Injection Pump Gear Crank Gear to Oil Pump Drive Gear Backlash Backlash Backlash Backlash 0 0430 to 0 124 mm 0 00170 to 0 00488 in 0 0470 to 0 123 mm 0 00185 to 0 00484 in 0 0460 to 0 124 mm 0 00182 to 0 00488 in 0 0410 to 0 123 mm 0 00162 to 0 00484 in 0 15 mm 0 0059 in 0 15 mm 0 0059 in 0 15 mm 0 0059 in 0 15 mm 0 0059 in Idle Gear Side Clearance 0 20 to 0 51 mm 0 0079 to 0 020 in 0 80 ...

Page 67: ...rance I D 0 015 to 0 075 mm 0 00059 to 0 0029 in 20 026 to 20 077 mm 0 78843 to 0 79043 in 0 15 mm 0 0059 in Piston Ring Gap Z482 E3B D722 E3B D782 E3B Top Ring 0 15 to 0 30 mm 0 0059 to 0 011 in 1 20 mm 0 0472 in Second Ring 0 30 to 0 45 mm 0 012 to 0 017 in 1 20 mm 0 0472 in Oil Ring 0 15 to 0 30 mm 0 0059 to 0 011 in 1 20 mm 0 0472 in Piston Ring Gap Z602 E3B D902 E3B Top Ring 0 20 to 0 35 mm 0...

Page 68: ...34 to 0 00417 in 43 934 to 43 950 mm 1 7297 to 1 7303 in 43 984 to 44 040 mm 1 7317 to 1 7338 in 0 20 mm 0 0079 in Crankshaft Journal to Crankshaft Bearing 2 Flywheel Side Crankshaft Journal Crankshaft Bearing 2 Oil Clearance O D I D 0 028 to 0 059 mm 0 0011 to 0 0023 in 43 934 to 43 950 mm 1 7297 to 1 7303 in 43 978 to 43 993 mm 1 7315 to 1 7320 in 0 20 mm 0 0079 in Crankshaft Journal to Cranksha...

Page 69: ...mm 2 8504 in Engine Oil Pressure At Idle Speed At Rated Speed More than 49 kPa 0 50 kgf cm2 7 1 psi 197 to 441 kPa 2 00 to 4 50 kgf cm2 28 5 to 64 0 psi 147 kPa 1 50 kgf cm2 21 3 psi Inner Rotor to Outer Rotor Clearance 0 030 to 0 14 mm 0 0012 to 0 0055 in Outer Rotor to Pump Body Clearance 0 070 to 0 15 mm 0 0028 to 0 0059 in Inner Rotor to Cover Clearance 0 0750 to 0 135 mm 0 00296 to 0 00531 in...

Page 70: ... 75 before T D C Injection Pump Z602 D902 E3B Serial No below 7ZZ999 Serial No above 8A0001 Injection Timing 3600 min 1 rpm 0 3317 to 0 3665 rad 19 00 to 21 00 before T D C 0 3360 to 0 3621 rad 19 25 to 20 75 before T D C Pump Element Fuel Tightness 13 73 MPa 140 0 kgf cm2 1991 psi Delivery Valve Fuel Tightness 10 seconds 13 73 12 75 MPa 140 0 130 0 kgf cm2 1991 1849 psi 5 seconds 13 73 12 75 MPa ...

Page 71: ... in 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 18 in Less than 0 02 mm 0 0008 in 0 50 to 0 80 mm 0 020 to 0 031 in 14 0 mm 0 551 in 29 0 mm 1 14 in 0 05 mm 0 002 in 0 20 mm 0 0079 in 9 0 mm 0 35 in Dynamo No load Regulating Output Voltage Output Voltage AC20V or more at 5200 min 1 rpm 14 to 15 V at 5200 min 1 rpm Altern...

Page 72: ...erial grades are shown by 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 kgf m lbf ft N m kgf m lbf ft M6 7 9 to 9 3 0 80 to 0 95 5 8 to 6 8 9 81 to 11 2 1 00 to 1 15 7 24 to 8 31 M8 18 to 20 1 8 to 2 1 13 to 15 24 to 27 2 4 to 2 8 18 to 20 M10 40...

Page 73: ...27 12 0 to 13 0 86 8 to 94 0 Idle gear shaft mounting screw M6 x 1 9 81 to 11 2 1 00 to 1 15 7 24 to 8 31 Oil pump mounting screw M8 x 1 25 17 7 to 21 5 1 80 to 2 20 13 1 to 15 9 Connecting rod screw M7 x 0 75 27 to 30 2 7 to 3 1 20 to 22 Flywheel screw M10 x 1 25 54 to 58 5 5 to 6 0 40 to 43 Bearing case cover mounting screw M6 x 1 9 81 to 11 2 1 00 to 1 15 7 24 to 8 31 Main bearing case screw 2 ...

Page 74: ...e 6 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 compression pressure again 8 If the compression pressure is still less than the allowable limit check the top clearance valve clearance and cylinder head 9 If the compression pressure increases after ...

Page 75: ...heck 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 compression top dead center position When No 1 piston is at the overlap position NOTE Q The sequence of cylinder numbers is given as No 1 No 2 and No 3 starting from the gear case side After adjusting the valve cl...

Page 76: ...he 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 pulley at specified force 98 N 10 kgf 22 lbf 2 If the measurement is not within the factory specifications loosen the alternator mounting screws and relocate the alternator to adjust W10356670 Engine oil...

Page 77: ... measurement is less than the factory specification replace the radiator cap W1054156 Radiator Water Leakage 1 Pour a specified amount of water into the radiator 2 Set a radiator tester 1 and an adaptor 2 and raise the water pressure to the specified pressure 3 Check the radiator for water leaks 4 For water leak from the pinhole replace the radiator or repair with the radiator cement When water le...

Page 78: ... turn back clockwise the flywheel around 1 6 rad 90 5 Turn the flywheel counterclockwise to set at around 0 44 rad 25 before T D C 6 Slowly turn the flywheel counterclockwise and stop 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 of No 1 cylinder 8 ...

Page 79: ...re do not use the 0 175 mm 0 00689 in thick shim as the top shim of the combination injection pump side because this can cause oil leakage Refer to figure of the shim to check the thickness of the shims The injection timing might be changed by the application W1018986 Injection timing Serial No below 7ZZ999 Factory spec 0 3491 to 0 3839 rad 20 00 to 22 00 before T D C Injection timing Serial No ab...

Page 80: ... 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 0 kgf cm2 1991 psi 7 Now turn the flywheel back about half a turn to keep the plunger free Maintain the flywheel at this position and clock the time taken for the pressure to drop from 13 73 to 12 75 MPa from 140 0 to 130 0 kgf cm2 from 1991 to 1849 ps...

Page 81: ...sure 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 Reference Pressure variation with 0 025 mm 0 00098 in difference of adjusting washer thickness Approx 590 kPa 6 0 kgf cm2 85 psi W10182100 Nozzle Valve Seat Tightness 1 Set the injection nozzle to a nozzle ...

Page 82: ...h oxygen becomes very explosive IMPORTANT Q 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 terminal of battery If this advice is disregarded damage to alternator and regulator may result Battery Voltage 1 Stop the engine 2 Measure the voltage with a circuit tester between the ba...

Page 83: ...drometer 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 with an increase of 1 C 0 0004 with an increase of 1 F in temperature and increases by 0 0007 with a decreases of 1 C 0 0004 with a decrease of 1 F Therefore using 20 C 68 F as a reference the sp...

Page 84: ...t 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 terminal 4 Remove the starter from the engine 5 Connect a jumper lead from the starter S terminal 1 to the battery positive terminal 2 6 Connect a jumper lead momentarily between the starter s body and the...

Page 85: ...witch 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 the measurement is not within the specified values replace the dynamo W1021164 1 C Terminal 2 B Terminal A Electromagnetic Drive Type B Planetary Gear Reduction Type No load output voltage Factory spec...

Page 86: ... unit for the measuring range The judgement should be as below table ON if the indicator moves otherwise OFF Q Check Table ON OFF W1021509 Regulating Voltage 1 Complete the charging circuit with a fully charged battery and operate the dynamo at the specified speed 2 Measure the output voltage with a volt meter 3 If the measurement is not within the specified values replace the dynamo W1022299 Test...

Page 87: ...ltage 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 the wiring harness or main switch is faulty 0000010725E Glow Plug Continuity 1 Remove the glow plug 2 Measure the resistance with a circuit tester between the glow plug terminal and the glow plug ho...

Page 88: ...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 turn off the switch 7 8 If the plunger is not attracted the engine stop solenoid is faulty NOTE Q This solenoid assembly includes reverse polarity protected pulling coil timer module 2 to prevent solen...

Page 89: ...oil up to the upper line on the dipstick 1 IMPORTANT Q Never mix two different types of oil Use the proper SAE Engine Oil according to ambient temperature W1023464 Draining Coolant CAUTION Never remove radiator cap while operating or immediately after stopping Otherwise hot water will spout out from the radiator Wait for more than ten minutes to cool the radiator before opening the cap 1 Prepare a...

Page 90: ...Oil 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 is not defective W1028468 Injection Pipes 1 Loosen the screws to the pipe clamp 2 2 Detach the injection pipes 1 When reassembling Sent compressed air into the pipes to blow out dust Then reassembl...

Page 91: ...ole 2 Turn screw 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 When reassembling Heat seal and injection nozzle gasket must be changed when the injection nozzle is removed for cleaning or for service W1021255 Tightening torque Overflow pipe retainin...

Page 92: ...utting the push rods 3 onto the tappets 4 check to see if their ends are properly engaged with the dimples IMPORTANT Q After installing the rocker arm be sure to adjust the valve clearance W1021437 Tightening torque Rocker arm bracket screw 9 81 to 11 2 N m 1 00 to 1 15 kgf m 7 24 to 8 31 lbf ft 1 Rocker Arm Assembly 2 Rocker Arm Bracket Screws 3 Push Rod 4 Tappet KiSC issued 03 2011 A ...

Page 93: ... and specified sequence a to n or j NOTE Q Do not use O ring on the pin pipe It is not necessary to retighten the cylinder head screw and to readjust valve clearance after engine warmed up W1025645 Tappets 1 Remove the tappets 1 from the crankcase When reassembling Visually check the contact between tappets and cams for proper rotation If defect is found replace tappets Before installing the tappe...

Page 94: ...Assembly 1 Remove the thermostat cover mounting screws 1 and remove the thermostat cover 2 2 Remove the thermostat assembly 4 When reassembling Replace the gasket 3 with a new one W10363950 Water Pump Assembly If necessary 1 Loosen the alternator mounting screws and remove the fan belt 2 Remove the fan and fan pulley 3 Remove the water pump assembly 1 from the gear case cover 3 When reassembling R...

Page 95: ...e hole 5 numbered 3 install the oil strainer by mounting screw IMPORTANT Q Scrape off the old adhesive completely Wipe the sealing surface clean using waste cloth soaked with gasoline Now apply new adhesive 3 0 to 5 0 mm 0 12 to 0 19 in thick all over the contact surface Apply the adhesive also on the center of the flange as well as on the inner wall of each bolt hole Cut the nozzle of the liquid ...

Page 96: ...plate 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 and the pin 11 on the rod engages with the slot 7 on the fork lever as shown in the photo NOTE Q The sealant is applied to both sides of the soft metal gasket shim The liquid gasket is not required f...

Page 97: ...d 4 2 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 1 4 Remove the fuel feed pump 2 5 Disconnect the start spring 8 from the bracket 9 using the specific tool 1 6 Remove the socket head screws and nuts and remove the injection pump 5 W1148604 1 ...

Page 98: ...per 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 Q Be careful not to stretch the start spring 6 too long Otherwise it may get deformed permanently Make sure the start spring 6 is tight on the bracket 3 The sealant is applied to both sides of the soft metal gasket shim The...

Page 99: ... Draw 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 W10181950 Tightening torque Fan drive pulley screw 118 to 127 N m 12 0 to 13 0 kgf m 86 8 to 94 0 lbf ft 1 Alignment Mark KiSC issued 03 2011 A ...

Page 100: ... or equivalent to both sides of the gear case gasket Be sure to set three O rings inside the gear case NOTE Q The gear case for energize to run type stop solenoid and the gear case for one side maintenance are available to meet customer s requirements Option W1029858 1 Screw Inside 2 Start Spring 3 Fork Lever 1 4 Gear Case a Gear Case for Energize to Run Type Stop Solenoid Option b Gear Case for O...

Page 101: ...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 Apply engine oil to the camshaft mounting screws And tighten them W1030808 Tightening torque Idle gear shaft mounting screw 9 81 to 11 2 N m 1 00 to 1 15 kgf m 7 24 to 8 31 lbf ft 1 Idle Gear 2 Idle ...

Page 102: ...aft Gear One 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 E3B D722 E3B D782 E3B 3 Remove the crankshaft gear 1 with a puller When reassembling Install the collar 4 after aligning the marks on the gears See the photo at Idle Gear W10314010 1 Injection Pump Gear 2 Governor Sleeve 3 Fork Lever 1 4 ...

Page 103: ...rd the 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 the threads If the connecting rod screw is still hard to screw in replace it W10275480 Tightening torque Connecting rod screw 27 to 30 N m 2 7 to 3 1 kgf m 20 to 22 lbf ft 1 Connecting Rod Cap a Ma...

Page 104: ...not change 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 the piston rings as shown in the figure Carefully insert the piston using a piston ring compressor 1 Otherwise their chrome plated section may be scratched causing trouble inside the cylinde...

Page 105: ...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 When installing the connecting rod to the piston align the mark 9 on the connecting rod to the fan shaped concave 8 IMPORTANT Q Mark the same number on the connecting rod and the piston so as not to c...

Page 106: ... the 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 it upward Apply engine oil to the oil seal 6 lip and take care that it is not rolled when installing Tighten the bearing case cover mounting screws with even force on the diagonal line W1031168 Ti...

Page 107: ...he second 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 crankshaft When reassembling Clean the oil passage of the crankshaft with compressed air Install the crankshaft assembly aligning the screw hole of main bearing case screw 2 with the screw hole of crankc...

Page 108: ...1 for Z482 E3B and 1 2 for D722 E3B D782 E3B 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 assembly 2 2 and the main bearing case assembly 3 too When installing the main bearing case 1 and 2 face the mark FLYWHEEL to the flywheel Install the thrust bearing 7 with its oil groove facing outward Co...

Page 109: ... bottom 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 and the main bearing case assembly 3 too When installing the main bearing case 1 and 2 face the mark FLYWHEEL to the flywheel Install the thrust bearing 8 with its oil groove facing outward Confir...

Page 110: ...t the armature 10 with the drive lever 3 NOTE Q 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 solenoid switch a Bushing b Drive lever c Collar d Teeth of pinion gear e Armature shaft f W1052309 1 Solenoid Switch Mounting Nut 2 Starter Drive Housing 3 Drive Lever 4 Gasket 5 Solenoid Switch 6 B ...

Page 111: ...ing 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 When reassembling W1012736 1 Magnetic Switch Mounting Nut 2 Housing 3 Magnetic Switch 4 B Terminal Nut 5 C Terminal Nut 6 Drive Lever 7 Shaft Assembly 8 Overrunning Clutch 9 Connecting Lead 10 Mountin...

Page 112: ...otor 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 Bearing 6 Stator 7 Plate 8 Bearing Tightening torque Pulley nut 40 to 44 N m 4 0 to 4 5 kgf m 29 to 32 lbf ft KiSC issued 03 2011 A ...

Page 113: ... 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 7 with a puller When reassembling W1224556 1 Pulley 2 Drive End Frame 3 Stator 4 Bearing 5 Retainer Plate 6 Rotor 7 Bearing 8 Rear End Frame 9 Rectifier 10 IC Regulator 11 Brush Holder 12 Rear End Co...

Page 114: ...the plastigauges 6 If they are out of spec check the oil clearance of the crank pin journal and piston pins W1020190 Cylinder Head Surface Flatness 1 Clean the cylinder head surface 2 Place a straightedge on the cylinder head s four sides and two diagonal as shown in the figure 3 Measure the clearance with a thickness gauge 4 If the measurement exceeds the allowable limit correct it with a surface...

Page 115: ...ce the 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 D with a small hole gauge and calculate the clearance 4 If the clearance exceeds the allowable limit replace the valves If it still exceeds the allowable limit replace the valve guide W10311740 1...

Page 116: ...mmer 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 valve seat or the valve contact is less than 70 correct the valve seating as follows 3 If the valve contact does not comply with the reference value replace the valve or correct the contact of valve s...

Page 117: ...t with a 0 79 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 rate becomes more than 70 of the total contact area W10283500 Valve Lapping 1 Apply compound evenly to the valve lapping surface 2 Insert the valve into the valve guide Lap the valve onto its seat w...

Page 118: ... W11177330 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 clearance 3 If the oil clearance exceeds the allowable limit replace the rocker arm and measure the oil clearance again If it still exceeds the allowable limit replace also the rocker arm sha...

Page 119: ...tappet 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 Allowable limit 0 25 mm 0 0098 in Oil clearance between tappet and tappet guide bore Factory spec 0 016 to 0 052 mm 0 00063 to 0 0020 in Allowable limit 0 10 mm 0 0039 in Tappet O D Factory spec 17 966 to...

Page 120: ...e 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 0430 to 0 124 mm 0 00170 to 0 00488 in Allowable limit 0 15 mm 0 0059 in Backlash between idle gear and cam gear Factory spec 0 0470 to 0 123 mm 0 00185 to 0 00484 in Allowable limit 0 15 mm 0 0059 in Backlash...

Page 121: ...nal 1 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 the allowable limit replace the camshaft W11335580 Camshaft alignment Allowable limit 0 01 mm 0 0004 in Cam height of intake and exhaust Factory spec 26 88 mm 1 058 in Allowable limit 26 83 mm 1 ...

Page 122: ...e 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 piston pin bore I D in both the horizontal and vertical directions with a cylinder gauge 2 If the measurement exceeds the allowable limit replace the piston W11406200 Oil clearance between idle gear...

Page 123: ...ushing 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 the piston pin and move it against the face plate 4 If the gauge does not fit squarely against the face plate measure the space between the pin of the gauge and the face plate 5 If the measurement e...

Page 124: ...ton ring gap Z482 E3B D722 E3B D782 E3B Top ring Factory spec 0 15 to 0 30 mm 0 0059 to 0 011 in Allowable limit 1 20 mm 0 0472 in Second ring Factory spec 0 30 to 0 45 mm 0 012 to 0 017 in Allowable limit 1 20 mm 0 0472 in Oil ring Factory spec 0 15 to 0 30 mm 0 0059 to 0 011 in Allowable limit 1 20 mm 0 0472 in Piston ring gap Z602 E3B D902 E3B Top ring Factory spec 0 20 to 0 35 mm 0 0079 to 0 0...

Page 125: ...he 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 0 012 in Allowable limit 0 50 mm 0 020 in Oversize Bearing Code Number Marking 0 20 mm 0 0079 in Thrust bearing 1 02 15261 23950 020 OS Thrust bearing 2 02 15261 23970 020 OS 0 40 mm 0 016 in Thrust bearing 1 04 15261 23960 040 O...

Page 126: ...ersize dimensions of crankpin W11625390 Oil clearance between crankpin and crankpin bearing Factory spec 0 020 to 0 051mm 0 00079 to 0 0020 in Allowable limit 0 15 mm 0 0059 in Crankpin O D Factory spec 33 959 to 33 975 mm 1 3370 to 1 3375 in Crankpin bearing I D Factory spec 33 995 to 34 010 mm 1 3384 to 1 3389 in Undersize Bearing Code Number Marking 0 20 mm 0 0079 in Crankpin bearing 02 15861 2...

Page 127: ...e of the crankshaft 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 0340 to 0 106 mm 0 00134 to 0 00417 in Allowable limit 0 20 mm 0 0079 in Crankshaft journal O D Factory spec Z482 E3B D722 E3B D782 E3B 39 934 to 39 950 mm 1 5722 to 1 5728 in Z602 E3B D902 E3B 43 934 to 4...

Page 128: ...40 mm 0 016 in Z482 E3B D722 E3B D782 E3B Crankshaft bearing 1 04 15861 23920 040 US Z602 E3B D902 E3B 1G460 23920 Undersize Models 0 20 mm 0 0079 in 0 40 mm 0 016 in Dimension A All models 1 8 to 2 2 mm radius 0 071 to 0 086 in radius 1 8 to 2 2 mm radius 0 071 to 0 086 in radius Dimension B All models 1 0 to 1 5 mm relief 0 040 to 0 059 in relief 1 0 to 1 5 mm relief 0 040 to 0 059 in relief Dim...

Page 129: ... the table and figure NOTE Q 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 0 028 to 0 059 mm 0 0011 to 0 0023 in Allowable limit 0 20 mm 0 0079 in Crankshaft journal O D Flywheel side Factory spec 43 934 to 43 950 mm 1 7297 to 1 7303 in Crankshaft bearing 2...

Page 130: ...E3B Crankshaft bearing 2 04 1G460 23950 Crankshaft bearing 3 04 1G460 23960 Undersize Models 0 20 mm 0 0079 in 0 40 mm 0 016 in Dimension A All models 1 8 to 2 2 mm radius 0 071 to 0 086 in radius 1 8 to 2 2 mm radius 0 071 to 0 086 in radius Dimension B All models 1 0 to 1 5 mm relief 0 040 to 0 059 in relief 1 0 to 1 5 mm relief 0 040 to 0 059 in relief Dimension C Z482 E3B D722 E3B D782 E3B 39 ...

Page 131: ... with a cylinder gauge to find the maximum 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 Cylinder 4 Visually check the cylinder wall for scratches If deep scratches are found the cylinder should be bored Refer to Correcting Cylinder W10360060 1 Crank...

Page 132: ...mbly W10378950 Clearance between Outer Rotor and 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 Cylinder liner I D Factory spec Z482 E3B D722 E3B D782 E3B 67 250 to 67 269 mm 2 6477 to 2 6483 in Z602 E3B D902 E3B 72 250 to 72 269 mm 2 8445 to 2 845...

Page 133: ...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 cranking direction 3 If the pinion slips or does not turn in both directions replace the overrunning clutch assembly NOTE Q Do not wash off the grease in the overrunning clutch with the chemicals or oi...

Page 134: ...imit correct it with a saw blade and chamfer the segment edges W1155802 Commutator O D Factory spec Electromagnetic drive type 28 0 mm 1 10 in Planetary gear reduction type 30 0 mm 1 18 in Allowable limit Electromagnetic drive type 27 0 mm 1 06 in Planetary gear reduction type 29 0 mm 1 14 in Difference of O D s Factory spec Electromagnetic drive type Less than 0 05 mm 0 002 in Planetary gear redu...

Page 135: ... replace 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 the continuity across the segments of the commutator with resistance range of circuit tester 4 If it does not conduct replace the armature W1156507 Brush length A Factory spec Electromagnetic drive...

Page 136: ...h 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 resistance range of circuit tester 4 If infinity is not indicated replace it W1019964 Rotor 1 Measure the resistance across the slip rings 2 If the resistance is not the factory specification replace ...

Page 137: ...1 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 the reverse direction W1020452 IC Regulator 1 Check the continuity across the B terminal 2 and the F terminal 1 of IC regulator with resistance range of circuit tester 2 The IC regulator is normal if ...

Page 138: ...ERY 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 2011 03 S EI EI e Code No 9Y111 00133 2007 03 S EI EI e ...

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