Kubota V3300-E2B Workshop Manual Download Page 106

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S-43

V3300-E2B, V3300-T-E2B, WSM

DIESEL ENGINE

Installing Procedure of Injection Pump Assembly

1. Install the fuel injection pump assembly (1) in its unit (2), and

hook the governor connecting rod to the rack pin of the fuel
injection pump assembly.

2. Place the service jig (3) in the stop solenoid mounting hole of the

fuel injection pump unit.

3. Make sure the permanent magnet at the tip of the service jig is

attracted to the governor connecting rod (4). To do this, turn the
jig a little clockwise and counterclockwise and look into the fuel
injection pump unit sight hole to see if the governor connecting
rod (4) moves right and left accordingly.

4. Slightly tighten the anti-rotation nut of the governor connecting

rod.

5. Holding down the service jig (3) by hand, tighten up the anti-

rotation nut (5) to the specified torque.

6. Hook the start spring (6) to the rack pin (7).

W1069371

(1) Fuel Injection Pump Assembly
(2) Fuel Injection Pump Unit
(3) Service Jig
(4) Governor Connecting Rod

(5) Anti-rotation Nut
(6) Start Spring
(7) Rack Pin

KiSC issued 06, 2006 A

Summary of Contents for V3300-E2B

Page 1: ...WORKSHOP MANUAL DIESEL ENGINE V3300 E2B V3300 T E2B KiSC issued 06 2006 A...

Page 2: ...gine 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 tightenin...

Page 3: ...and 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 att...

Page 4: ...opping 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 compl...

Page 5: ...regulations 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 ca...

Page 6: ...Minimum Bare Idling Speed 700 to 750 min 1 rpm Combustion Chamber Spherical Type E TVCS Fuel Injection Pump Bosch Type Mini Pump Governor All speed mechanical governor Direction of Rotation Counter c...

Page 7: ...RVES 1 Brake Horsepower 2 Engine Speed 3 B S F C 4 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 Conti...

Page 8: ...ke Horsepower 2 Engine Speed 3 B S F C 4 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...

Page 9: ...7 V3300 E2B V3300 T E2B WSM DIMENSIONS DIMENSIONS KiSC issued 06 2006 A...

Page 10: ...2 CHECK POINTS OF INITIAL 50 HOURS G 8 3 CHECK POINT OF EVERY 50 HOURS G 9 4 CHECK POINTS OF EVERY 250 HOURS G 10 5 CHECK POINTS OF EVERY 500 HOURS G 12 6 CHECK POINT OF EVERY 1000 HOURS G 15 7 CHECK...

Page 11: ...gine 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 manufacture...

Page 12: ...ing 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 sale s...

Page 13: ...e battery 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 repl...

Page 14: ...hrs Every 3000 hrs Every 1 year Every 2 years Changing engine oil Replacing oil filter cartridge Checking fuel hoses and clamps Cleaning air filter element Replace the element after 6 times cleanings...

Page 15: ...an off road vehicle engine runs on a high sulfur fuel it is advisable to employ the CF CD or CE lubricating oil with a high total base number If the CF 4 or CG 4 lubricating oil is used with a high su...

Page 16: ...iscosity from the previous one 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 quantity ma...

Page 17: ...olant 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...

Page 18: ...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 car...

Page 19: ...mps have been changed bleed the fuel system CAUTION Stop the engine when attempting the check and change prescribed above When bleeding fuel system 1 Fill the tank with fuel and open the cock 2 Loosen...

Page 20: ...heck if the fan belt 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 c...

Page 21: ...r line on the dipstick 2 IMPORTANT When using an oil of different maker or viscosity from the previous one remove all of the old oil Never mix two different types of oil Engine oil should have propert...

Page 22: ...gasket 3 To install the new cartridge screw it in by hand Over tightening may cause deformation of rubber gasket 4 After the new cartridge has been replaced the engine oil normally decrease a little T...

Page 23: ...rections of the cleaner 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...

Page 24: ...eric 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 standards that ne...

Page 25: ...top of valve stem then tighten the lock nut 6 Loosen the lock nut 4 of adjusting screw 3 push rod side and insert the thickness gauge between the rocker arm and the bridge head Set the adjusting screw...

Page 26: ...should 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 charg...

Page 27: ...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...

Page 28: ...he tester 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 hol...

Page 29: ...r assembling 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...

Page 30: ...of the compressor cover 10 to see if there is no air leak 2 If any air leak is found change the clamp 8 and or inlet hoses 3 Check the intake hose 7 and the clamp to see if there is not loose or crack...

Page 31: ...egins to come up to get the present injection timing 8 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 piston 9 If the in...

Page 32: ...arter when the fuel jets from the injection nozzle After that turn the flywheel by the hand and raise the pressure to approx 13 73 MPa 140 kgf cm2 1991 psi 7 Now turn the flywheel back about half a tu...

Page 33: ...m the previous one remove all of the old oil Never mix two different types of oil Engine oil should have properties of API classification CD CE CF CF 4 CG 4 Use the proper SAE Engine Oil according to...

Page 34: ...5 Follow directions of the cleaner 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 coo...

Page 35: ...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...

Page 36: ...l injection pump Otherwise the engine may stall W1020090 Replacing Intake Air Line 1 Loosen the clamp 2 2 Remove the intake air hose 1 and clamp 2 3 Replace new intake air hose 1 and new clamp 2 4 Tig...

Page 37: ...to measure diesel engine compression and diagnosis of need for major overhaul W1024200 Oil Pressure Tester Code No 07916 32032 Application Use to measure lubricating oil pressure W1024318 1 Gauge 2 L...

Page 38: ...ange Material Steel E Hex nut 27 mm 1 06 in across the plat F Adhesive application G Fillet welding on the enter circumference H Retaining nut I 17 mm dia 0 67 in dia J 8 mm dia 0 31 in dia K 1 0 mm 0...

Page 39: ...ia 0 7874 in dia a 6 3 m 250 in b 6 3 m 250 in C1 Chamfer 1 0 mm 0 039 in C2 Chamfer 2 0 mm 0 079 in A 157 mm 6 181 in B 14 5 mm 0 571 in C 120 mm 4 7244 in D 30 0 mm dia 1 1811 in dia E 42 000 mm dia...

Page 40: ...B 50 mm 1 9685 in C 18 8 mm 0 7401 in D 13 7 to 13 9 mm 0 5394 to 0 5472 in E 11 mm 0 433 in F 18 mm dia 0 7087 in dia G 38 mm dia 1 4961 in dia H 45 mm dia 1 7716 in dia I 57 9 to 58 1 mm dia 2 2795...

Page 41: ...5 to 12 8 mm dia 0 492 to 0 504 in dia L 8 9 to 9 1 mm 0 350 to 0 358 in 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 225 mm 8 86 in B 80 mm 3 15 in C 40 mm 1...

Page 42: ...2 mm 0 4724 in F 7 9 to 8 1 mm 0 3110 to 0 3189 in G 20 mm 0 7874 in H 130 mm dia 5 1181 in dia I 99 4 to 99 6 mm dia 3 9134 to 3 9213 in dia J 95 05 to 95 20 mm dia 3 7421 to 3 7480 in dia K 3 mm dia...

Page 43: ...ia 1 61 in dia P 32 mm dia 1 26 in dia Q 33 96 to 34 0 mm dia 1 3370 to 1 3386 in dia R 18 mm dia 0 71 in dia S 19 967 to 20 0 mm dia 0 7861 to 0 7874 in dia U 3 mm 0 12 in V 149 1 to 149 4 mm 5 8701...

Page 44: ...094 in dia G 50 421 to 50 44 mm dia 1 9851 to 1 9858 in dia H 8 mm 0 31 in I 2 mm 0 08 in J 35 mm dia 1 38 in dia K 5 mm 0 20 in L 0 26 rad 15 A 35 mm 1 38 in B 33 mm 1 30 in C Chamfer 0 5 mm 0 02 in...

Page 45: ...eplacing Tool Components Parts 1 Bracket W1167794 No Name of Part Q ty 1 Bracket 1 2 Flange Nut 1 3 Washer 1 4 Shaft 1 5 Piece 1 1 6 Clevis 1 7 Washer 1 8 Cotter Pin 1 9 Joint 1 1 10 Piece 2 1 11 Join...

Page 46: ...70 mm 2 76 in O 19 5 mm 0 77 in P 12 mm 0 47 in Q 0 8 mm 0 03 in R 6 mm 0 24 in A 26 mm 1 02 in B 18 mm 0 71 in C 16 5 to 17 0 mm 0 6496 to 0 6693 in D 1 5 mm 0 06 in E 54 0 to 54 2 mm dia 2 1260 to...

Page 47: ...o 0 6693 in D 1 5 mm 0 06 in E 53 5 to 53 7 mm dia 2 1063 to 2 1142 in dia F 50 05 to 50 25 mm dia 1 9705 to 1 9783 in dia G 16 mm 0 63 in H Chamfer 1 mm 0 04 in I 8 5 mm dia 0 33 in dia J 0 4 mm 0 01...

Page 48: ...3 in dia J 0 4 mm 0 0157 in K 3 mm 0 12 in L 19 mm 0 75 in M Chamfer 0 5 mm 0 02 in N 36 mm 1 42 in O 45 mm dia 1 77 in dia P 0 78 rad 45 Q 11 5 mm 0 45 in A 10 mm dia 0 39 in dia B M16 Pitch 1 5 C 19...

Page 49: ...10 in H 95 mm 3 74 in I 14 mm dia 0 55 in dia J 40 mm radius 1 57 in radius K 210 mm 8 27 in L 190 mm 7 48 in M 100 mm 3 94 in N 6 mm 0 24 in O 6 mm 0 24 in P 25 mm dia 0 98 in dia C10 Chamfer 10 mm 0...

Page 50: ...1 mm radius 0 0394 in radius H Chamfer 0 2 mm 0 0079 in I 8 mm radius 0 3150 in radius J 1 mm radius 0 0394 in radius K 1 mm radius 0 0394 in radius L Chamfer 0 2 mm 0 0079 in M Chamfer 0 2 mm 0 0079...

Page 51: ...NDER HEAD M 3 4 PISTON AND PISTON RINGS M 3 5 BUILT IN DYNAMIC BALANCER BALANCER MODEL ONLY M 4 3 LUBRICATING SYSTEM M 5 1 OIL COOLER M 5 4 COOLING SYSTEM M 6 1 THERMOSTAT M 6 2 BOTTOM BYPASS SYSTEM M...

Page 52: ...ys the three valve system two inlet valves with double ports and one exhaust valve with the new E TVCS VERSION II Thus this engine achieves high combustion efficiency and complies with various regulat...

Page 53: ...u can easily assemble disassemble it The cylinder is a linerless type which enables good cooling operation less strain and good abrasion resistance W1013119 2 HALF FLOATING HEAD COVER The rubber packi...

Page 54: ...nal models The profile and the offset of piston are optimized to reduce slapping noises The oil jet at the small end of the connecting rod reduces heat load of the piston Three rings are installed in...

Page 55: ...er engines are much less prone to cause vibration than four cylinder ones second inertia etc However any engine has many moving parts in addition to its pistons and cannot be completely free from vibr...

Page 56: ...ot oil but also warms the cool engine oil shoftly after start up As shown in the figure the oil flows inside the connected cooler plate whereas coolant is kept circulating outside the cooler plate the...

Page 57: ...o Too much water cooled by the radiator flows through the water passage which suddenly closes the valve below the thermostat s preset valve closing temperature A repeated cycle of such overshoot and u...

Page 58: ...thermostat is held closed and the coolant is allowed to flow through the bypass pipe and to circulate in the engine When the temperature exceeds the thermostat valve opening level the thermostat fully...

Page 59: ...es a mechanical governor that controls the fuel injection rate at all speed ranges from idling to maximum speed by utilizing the balance between the flyweight s centrifugal force and spring tension A...

Page 60: ...s the torque spring and move the fork lever 1 in the direction of the arrow A The fork lever 2 moves until it reaches the output limiting bolt to keep rated rotation and rated output When the engine i...

Page 61: ...oid is turned off the spring tension of the solenoid is released the rod extrudes and the stop lever moves the control rack in the direction of the arrow B which stops the engine To stop the engine ma...

Page 62: ...r than working pressure of the boost actuator 1 it prevents oversupply of fuel to reduce transient smoke When the boost pressure is higher than working pressure of the boost actuator 1 it controls the...

Page 63: ...cal System S 23 6 Turbocharger S 27 2 DISASSEMBLING AND ASSEMBLING S 28 1 Draining Oil and Coolant S 28 2 External Components S 28 3 Cylinder Head and Valves S 30 4 Thermostat S 34 5 Injection Nozzle...

Page 64: ...ining nut S 30 Incorrect injection timing Adjust S 20 Fuel camshaft worn Replace S 40 Injection nozzle clogged Clean or replace S 22 23 30 Injection pump malfunctioning Repair or replace S 21 42 Seizu...

Page 65: ...ace the turbocharger assembly S 27 29 Turbocharger fin or other part damaged due to foreign matters Replace the turbocharger assembly S 27 29 Either White or Blue Exhaust Gas Is Observed Excessive eng...

Page 66: ...ton ring groove worn Replace piston S 49 50 68 Valve stem and valve guide worn Replace S 33 59 Crankshaft bearing and crank pin bearing worn Replace S 50 53 69 71 Oil leaking due to defective seals or...

Page 67: ...an Inside of radiator corroded Clean or replace G 13 Coolant flow route corroded Clean or replace G 13 Radiator cap defective Replace S 18 Overload running Reduce the load Head gasket defective Replac...

Page 68: ...1 rpm 626 psi 250 min 1 rpm 3 92 MPa 250 min 1 rpm 40 kgf cm2 250 min 1 rpm 569 psi 250 min 1 rpm 3 26 MPa 250 min 1 rpm 33 2 kgf cm2 250 min 1 rpm 472 psi 250 min 1 rpm 2 99 MPa 250 min 1 rpm 30 5 kg...

Page 69: ...0039 in 0 1 mm 0 0039 in Valve Clearance Cold 0 23 to 0 27 mm 0 0091 to 0 0106 in Intake Valve Timing Open Close 0 24 rad 14 before T D C 0 61 rad 36 after B D C Exhaust Valve Timing Open Close 0 79...

Page 70: ...9 032 mm 0 3552 to 0 3556 in 0 15 mm 0 0059 in Push Rod Alignment 0 25 mm 0 0098 in Tappet to Tappet Guide Tappet Guide Bore Tappet Clearance I D O D 0 020 to 0 062 mm 0 0008 to 0 0024 in 24 000 to 24...

Page 71: ...2 Bushing Idle Gear 1 2 Bushing Idle Gear 1 2 Shaft Oil Clearance I D O D 0 050 to 0 091 mm 0 0020 to 0 0036 in 45 025 to 45 050 mm 1 7726 to 1 7736 in 44 959 to 44 975 mm 1 7700 to 1 7707 in 0 10 mm...

Page 72: ...11 mm 1 1813 to 1 1815 in 30 031 to 30 046 mm 1 1823 to 1 1829 in 0 15 mm 0 0059 in Crankshaft Side Clearance Alignment 0 15 to 0 31 mm 0 0059 to 0 0122 in 0 50 mm 0 0197 in 0 02 mm 0 00079 in Cranksh...

Page 73: ...0063 in 0 3 mm 0 0118 in Outer Rotor to Pump Body Clearance 0 100 to 0 184 mm 0 0039 to 0 0072 in 0 3 mm 0 0118 in Inner Rotor to Cover Clearance 0 025 to 0 075 mm 0 0010 to 0 0030 in 0 225 mm 0 0089...

Page 74: ...m2 1991 1849 psi Fuel Injection Nozzle Injection Pressure Valve Seat Tightness 13 73 to 14 71 MPa 140 to 150 kgf cm2 1991 to 2134 psi When the pressure is 12 75 MPa 130 kgf cm2 1849 psi the valve seat...

Page 75: ...n 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...

Page 76: ...6 to 24 5 2 0 to 2 5 14 5 to 18 1 Oil switch taper screw R 1 8 14 7 to 19 6 1 5 to 2 0 10 8 to 14 5 Oil cooler joint screw 39 2 to 44 1 4 0 to 4 5 28 9 to 32 5 Oil pump cover screw 7 9 to 9 3 0 80 to...

Page 77: ...00 to 1 15 7 23 to 8 32 Anti rotation nut M5 x 0 8 2 8 to 4 0 0 29 to 0 41 2 1 to 3 0 Balancer shaft set screw Balancer model only M8 x 1 25 23 5 to 27 5 2 4 to 2 8 17 4 to 20 3 Bearing case cover mo...

Page 78: ...on rings 7 If the compression pressure is still less than the allowable limit check the top clearance valve and cylinder head NOTE Check the compression pressure with the specified valve clearance Alw...

Page 79: ...em then tighten the lock nut 6 Loosen the lock nut 4 of adjusting screw 3 push rod side and insert the thickness gauge between the rocker arm and the bridge head Set the adjusting screw to the specifi...

Page 80: ...gine 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 a...

Page 81: ...1 Set a radiator tester on the radiator cap 2 Set a radiator tester Apply the specified pressure of 88 kPa 0 9 kgf cm2 13 psi 3 Check if the pressure drop to less than 59 kPa 0 6 kgf cm2 9 psi in 10...

Page 82: ...water When the water temperature rises the thermostat valve will open allowing it to fall down from the string Read the temperature at this moment on the thermometer 4 Continue heating the water and r...

Page 83: ...he fuel begins to come up to get the present injection timing 8 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 piston 9...

Page 84: ...e starter when the fuel jets from the injection nozzle After that turn the flywheel by the hand and raise the pressure to approx 13 73 MPa 140 kgf cm2 1991 psi 7 Now turn the flywheel back about half...

Page 85: ...ndle 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 adjus...

Page 86: ...becomes 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 insulat...

Page 87: ...hydrometer 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...

Page 88: ...ative 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 fr...

Page 89: ...lternator and check the each component part for finding out the failure See the DISASSEMBLING AND ASSEMBLING and SERVICING for alternator 0000010745E Glow Plug Lead Terminal Voltage 1 Turn the key swi...

Page 90: ...olenoid is faulty IMPORTANT Never apply the current for pulling coil more than two seconds when inspecting W1020600 6 Turbocharger Turbine Side 1 Check the exhaust port 3 and inlet port 5 side of turb...

Page 91: ...adiator 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 bu...

Page 92: ...bolt 5 and clamp 4 and take off the pipe 1 2 2 Remove the bolts 1 and release the clamp 6 3 Disconnect the oil pipe 2 7 and pipe 4 3 When reassembling Pour fresh engine oil through the oil filler por...

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: ...ing When putting the push rods onto the tappets 2 check to see if their ends are properly engaged with the grooves IMPORTANT After reassembling the rocker arm be sure to adjust the valve clearance W10...

Page 95: ...ratches and dust Take care for handling the gasket not to damage it Install the cylinder head Tighten the cylinder head screw gradually in the order of 1 to 18 after applying engine oil Be sure to adj...

Page 96: ...nd valve guide hole and apply engine oil sufficiently After installing the valve spring collets lightly tap the stem to assure proper fit with a plastic hammer W1053044 Notch Mark of Cylinder Head Gas...

Page 97: ...ve the nozzle holder 1 and take out parts inside When reassembling Assemble the nozzle in clean fuel oil Install the push rod 4 noting its direction After assembling the nozzle be sure to adjust the f...

Page 98: ...es not move any longer 5 Tighten the lower fuel cam shaft lock screw 5 until it comes into contact with the fuel cam shaft NOTE Never overtighten the lock screws when they have come into contact with...

Page 99: ...or plugging 7 Loose the injection pump unit mounting nuts 7 for aligning the injection timing 8 Moving the injection pump unit clockwise viewed from gear case side align the injection timing marks 6 o...

Page 100: ...in tighten the nut with the specified torque with using the jig for keeping the governor connecting rod horizontal See the Replacing Injection Pump Assembly After tightening the nut hook the start spr...

Page 101: ...ed control lever and the stop lever NOTE When assembling the inside parts put the oil on each inside part slightly Be careful not to deform the start spring W1139749 Boost Arms If equipped Boost Compe...

Page 102: ...y 4 from the governor housing 3 Remove the start spring 5 and the stop spring 3 W1142375 Stop Lever 1 Remove the stop lever 1 and the return spring 2 2 Remove the stop lever shaft 3 W1143531 1 Speed C...

Page 103: ...governor weight mounting nut Otherwise the lock bolts or injection pump housing might get damage When reassembling Press the bearings into the fuel camshaft Set the cir clip at the gear side s bearin...

Page 104: ...of the governor sleeve NOTE Be careful not to damage the O ring Be careful the direction of the governor sleeve When reassembling the inside parts put the oil on each inside part slightly W1146489 Ti...

Page 105: ...ff the governor connecting rod 8 from the rack pin of injection pump assembly 7 Remove the injection pump mounting screws and nuts and take out the injection pump assembly 5 NOTE Be careful not to dro...

Page 106: ...the governor connecting rod 4 To do this turn the jig a little clockwise and counterclockwise and look into the fuel injection pump unit sight hole to see if the governor connecting rod 4 moves right...

Page 107: ...into place W1069772 Fan Drive Pulley 1 Set the stopper to the flywheel 2 Remove the crankshaft screw 2 3 Draw out the fan drive pulley 1 When reassembling W1185033 Tightening torque Anti rotation nut...

Page 108: ...t mounting the O ring and not to let it out of position W1187742 Oil Cooler 1 Remove the water pipe 1 2 Remove the oil filter cartridge 2 and the oil cooler joint screw 3 3 Remove the oil cooler 4 W10...

Page 109: ...idle gear 1 2 2 Remove two set screws of the camshaft stopper and draw out the camshaft When reassembling Set the crankshaft at the top dead center of No 1 and 4 cylinder and the camshaft key to the...

Page 110: ...ancer shaft 1 2 3 Remove the balancer shaft 2 set screws and draw out the balancer shaft 2 6 When reassembling When install the balancer shaft 1 and 2 be sure to place the 4th cylinders piston at the...

Page 111: ...y liquid gasket Three Bond 1217D to the oil pan as shown in the figure Confirm that the liquid gasket coating surface is free of water dust and oil in order to maintain sealing effect Carefully apply...

Page 112: ...rd by lightly tapping it from the bottom of the crankcase with the grip of a hammer When reassembling Before inserting the piston into the cylinder apply enough engine oil to the cylinder When inserti...

Page 113: ...insert the piston pin to the piston Assemble the piston to the connecting rod with the aligning the direction of the fan shaped concave 8 of piston head and the mark 9 of connecting rod The end faces...

Page 114: ...the oil seal use caution when installing the seal in the bearing case cover as not to install it tilted The seal should be flush with the cover Confirm that the liquid gasket coating surface is free o...

Page 115: ...e the adhesive applied parts within ten minutes W1060825 Crankcase 1 and Crankcase 2 When reassembling Match the crankcase 1 and 2 referring to the flywheel housing s contoured face Tighten the crankc...

Page 116: ...W SIDE on the main bearing case facing towards the flywheel side Reassemble the thrust bearing 2 with the oil groove facing outside into both side of the fourth main bearing case 1 Apply oil to the be...

Page 117: ...bearings shaft s sliding part and ball NOTE Do not damage to the brush and commutator When reassembling Apply grease DENSO CO No 50 or equivalent to the parts indicated in the figure W1074237 12 Alter...

Page 118: ...th its sliding face in the clockwise direction when viewed from front IMPORTANT Be sure to keep the 2 brushes deep in the brush holder Otherwise the rotor and the rear section can not be fitted into t...

Page 119: ...ng the piston to its middle position install the cylinder head and tighten the cylinder head screws to specification Head gasket must be changed to new one 4 Turn the crankshaft until the piston excee...

Page 120: ...sure to check the valve recessing after correcting W1061323 Cylinder Head Flaw 1 Prepare an air spray red check 2 Clean the surface of the cylinder head with detergent 2 3 Spray the cylinder head surf...

Page 121: ...a valve flapper or screwdriver 3 After lapping the valve wash the compound away and apply oil then repeat valve lapping with oil 4 Apply prussian blue to the contact surface to check the seated rate I...

Page 122: ...guide and apply engine oil to it 2 Using a valve guide replacing tool press in a new valve guide until it is flush with the cylinder head as shown in the figure 3 Ream precisely the I D of the valve...

Page 123: ...and with a 0 262 rad 15 valve seat cutter to exhaust valve seat so that the width is close to specified valve seat width 2 12 mm 0 0835 in 3 After resurfacing the seat inspect for even valve seating a...

Page 124: ...tside micrometer and then calculate the oil clearance 3 If the clearance exceeds the allowable limit replace the rocker arm and measure the oil clearance again If it still exceeds the allowable limit...

Page 125: ...D of the 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 W1063847 Push rod align...

Page 126: ...pper W1064307 Backlash between crank gear and idle gear 1 Factory spec 0 049 to 0 193 mm 0 0019 to 0 0076 in Allowable limit 0 22 mm 0 0087 in Backlash between idle gear 1 and cam gear Factory spec 0...

Page 127: ...mshaft Journal 1 Measure the camshaft journal O D with an outside micrometer 2 Measure the cylinder block bore I D for camshaft with an inside micrometer 3 If the clearance exceeds the allowable limit...

Page 128: ...moving the balancer shaft to the front and rear 3 If the measurement exceeds the allowable limit replace the balancer shaft W1065273 Balance Shaft Alignment 1 Support the balancer shaft with V blocks...

Page 129: ...g rod small end with a cylinder gauge Calculate the oil clearance 3 If the clearance exceeds the allowable limit replace the bushing If it still exceeds the allowable limit replace the piston pin W106...

Page 130: ...on the connecting rod alignment tool 4 Put a gauge over the piston pin and move it against the face plate 5 If the gauge does not fit squarely against the face plate measure the space between the pin...

Page 131: ...shaft journal wear replace it with an oversize one referring to the table and figure Reference Oversize dimensions of crankshaft journal W1066738 Factory spec Second ring 0 093 to 0 120 mm 0 0037 to 0...

Page 132: ...g rod screws to the specified torque and remove the cap again 4 Measure the amount of the flattening with the scale and get the oil clearance 5 If the oil clearance exceeds the allowable limit replace...

Page 133: ...0 0591 in Without color 56 00 to 56 01 mm 2 2047 to 2 2051 in S 1C020 22331 1 491 to 1 496 mm 0 0587 to 0 0589 in Undersize 0 2 mm 0 008 in 0 4 mm 0 016 in Dimension A 2 8 to 3 2 mm radius 0 1102 to...

Page 134: ...the crankshaft as shown in figure 4 Press fit the sleeve using the auxiliary socket for pushing 4 NOTE Mount the sleeve with its largely chamfered surface facing outward W1069911 Crankshaft journal O...

Page 135: ...in ones NOTE When the oversize cylinder is worn beyond the allowable limit replace the cylinder block with a new one W10344480 6 Oil Pump Rotor Lobe Clearance 1 Measure the clearance between lobes of...

Page 136: ...eplace oil pump rotor assembly and the cover W1148218 7 Starter Overrunning Clutch 1 Inspect the pinion for wear or damage 2 If there is any defect replace the overrunning clutch assembly 3 Check that...

Page 137: ...ment edges W1075277 Brush Wear 1 If the contact face of the brush is dirty or dusty clean it with emery paper 2 Measure the brush length A with vernier calipers 3 If the length is less than the allowa...

Page 138: ...1 Check the continuity across the lead 1 and brush 2 with an ohmmeter 2 If it does not conduct replace the yoke assembly 3 Check the continuity across the brush 2 and yoke 3 with an ohmmeter 4 If it...

Page 139: ...on a lathe 3 Measure the O D of slip ring with vernier calipers 4 If the measurement is less than the allowable limit replace it W1076592 Brush Wear 1 Measure the brush length A with vernier calipers...

Page 140: ...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 2005 12 S EI EI e C...

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