Kubota Z402-EB-ONAN-1 Workshop Manual Download

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Summary of Contents for Z402-EB-ONAN-1

Page 1: ...WORKSHOP MANUAL DIESEL ENG INE Z402 EB ONAN 1...

Page 2: ......

Page 3: ...s and periodic inspection items For each engine section there are Checking and Adjustment Disassembling and Assembling and Servicing which cover procedures precautions factory specificationand allowab...

Page 4: ...atesa potentiallyhazardoussituationwhich if not avoided could result indeath or serious injury c I CAUTION Indicates a potentlally hazardous situation which if not avoided may result in minor l a or m...

Page 5: ...ping 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 pressurebefore removingcompletel...

Page 6: ...away from eyes hands and clothing If you spill electrolyte on yourself flush with water and get medicalattentionimmediately 00000Z00070 DISPOSEOF FLUIDSPROPERLY 1 Do not pour fluids into the ground d...

Page 7: ...jectionorder 400 CC 24 41 cu in 5 5 kW 3000 rpm 7 4 HPl3000rpm 6 3 kW 3000 rpm 8 4 HP 3000 rpm 6 5 kW 3000 rpm 8 7 HP 3000 rpm 5 5 kW13000rpm 7 5 PS 3000 rpm 6 1 kW 3000 rpm 8 3 PS 3000rpm 6 6 kW 3000...

Page 8: ...Pointsof Every 100Hours 5 16 4 Check Pointsof Every200 Hours 5 18 5 Check Pointsof Every800 Hours 5 19 6 Check Pointsof Every 1000 Hours 5 20 8 SPECIAL TOOLS 5 20 0 ENGINE BODY 5 26 CHECKING AND ADJU...

Page 9: ...FUEL SYSTEM 5 54 CHECKING AND ADJUSTING 5 54 i INJECTION PUMP 5 54 2 INJECTION NOZZLE 5 55 DISASSEMBLING AND ASSEMBLING 5 56 I INJECTION NOZZLE 5 56...

Page 10: ...rer always specify your engine model name and serial number 02090510010 2 Cylinder Number The cylinder numbers of 2402 diesel engine are designated as The sequence of cylinder numbers is given as No 1...

Page 11: ...ly KUBOTA genuine parts for parts replacement to maintainengine performanceandto ensuresafety Gaskets and O rings must be replaced during reassembly Apply greaseto new O rings or oil seals beforeassem...

Page 12: ...to 1 15 7 23 to 8 32 M6x 1 0 M8x 1 25 M6 x 1 0 M8x 1 25 M7 x 1 0 MI0 x 1 25 M7x 0 75 M6x 1 0 M6 x 1 0 MI2x 1 5 M6x 1 0 M8 x 1 0 M20 x 1 5 PT 118 MI2 x 1 5 MI2 x 1 5 M8 MI0 MI2 N m 39 2 to 45 1 4 0 to...

Page 13: ...eaner clogged Fuel leak due to loose injectionpipe retaining Injectionpumpmalfunctioning nut Incorrectnozzleopeningpressure Injectionnozzlestuckor clogged Governor malfunctioning Excessive engine oil...

Page 14: ...ient 0 Oil strainer clogged 0 Relief valve stuck with dirt 0 Relief valve spring weaken or broken 0 Excessiveoil clearance of crankshaft bearing 0 Excessiveoil clearance of crankpin bearing 0 Excessiv...

Page 15: ...fective Overload running 0 Head gasket defective 0 Incorrect injectiontiming 0 Unsuitablefuel used Battery electrolyte insufficient 0 Fan belt slips Wiring disconnected Rectifierdefective 0 Alternator...

Page 16: ...5 mm 0 0019 in Close CompressionPressure 0 26 rad 1 5 afterT D C 2 84 to 3 23 MPa 29 0 t o33 0 kgf cm2 412 to 469 psi 2 25 MPa 23 kgflcm2 327 psi Valves IValve Clearance Cold Valve Seat Angle Valve Fa...

Page 17: ...to 0 41410 in Tilt Clearancebetween Tappet and Guide 0 016 to 0 052 mm 0 00063 to 0 00205 in 0 10 mm 0 0039 in Tappet Guide I D RockerArm Shaft O D 18 000 to 18 018 mm 0 70866 to 0 70939 in 10 473 to...

Page 18: ...ebetweenIdle Gear Shaft and Idle Gear Bushing IdleGear BushingI D Idle Gear Shaft O D IdleGear Side Clearance Piston PistonRing FactorySpecification 0 043 to 0 124 mm 0 00169 to 0 00488 in 0 047 t o0...

Page 19: ...kshaftand Crankshaft Bearing3 CrankshaftO D Crank bearing3 I D Oil Clearancebetween Crank Pinand Crank Pin Bearing Crank PinO D Crank PinBearingI D Crankshaft Side Clearance 0 0 3 4to 0 106 mm 0 0013...

Page 20: ...kgf cm2 1 4psi ClearancebetweenOuter Rotorand Pump Body End Clearancebetween Inner Rotorand Cover 0 0 3to 0 14mm 0 0012 to 0 0055 in 0 07to 0 15 mm 0 0028to 0 0059in 0 075 to 0 135 mm 0 0029to 0 0053...

Page 21: ...i the valve seat must be fuel tightness When the pressure is InjectionTiming I FuelTitghtnesso f Pump Element FuelTightnessof DeliveryValve 0 31 to 0 35 rad 18to 20 BeforeT D C Allowable Limit 14 7 MP...

Page 22: ...ningair filter element 72 Cleaningfuel filter element Checkingfan belt tension anddamage Checkingwater pipesand clamps Changingoilfilter element Changingfuel filter cartridge Checkingvalve clearance a...

Page 23: ...two differenttypes of oil IMPORTANT 01640S10050 Checking and ReplenishCoolingWater 1 Removethe radiator cap andcheck to seethat the coolingwater 2 If low addcleanwater andantifreeze A CAUTION Do not r...

Page 24: ...pipe and the clamp have been changed bleedthe fuel system A CAUTION Stop the engine when attempting the check and change 1 Clamp 2 Fuel Pipe prescribedabove 01640S10070 When bleedingfuel system 4 1 Fi...

Page 25: ...operties o f API classification CD CE grades temperature 0 C to 25 C 32 Fto 77O F SAE 20 or 1OW 30 Below 0 C 32 F SAE 1OW or 1OW 30 Above 25 C 77O F SAE 30 or 1OW 30 02090510230 Checking Fan Belt Tens...

Page 26: ...re to cleanthe fuel filter cup periodically 1 CockBody 4 FilterElement 2 Air Vent Plug 3 FilterCock 6 RetainingRing 5 FilterCup 01640S10120 Cleaning Air Cleaner 1 The air cleaner uses a dry element Ne...

Page 27: ...rdenedor cracked 3 Replace hoses and clamp bands every 2 years or earlier if checkedand foundthat hoses areswollen hardenedor cracked 02090510070 Changing EngineOil FilterCartridge 1 Removethe oil fil...

Page 28: ...59 to 0 0073 in I Number of cylinders Valve arrangement Adjustablecylinder Locationof piston 1 When No 1pistonIsat top Ist dead centercompression 2nd overlapposition 2nd 1 When No 1pistonisatthe I ISt...

Page 29: ...Slowly movethetester handleto measurethe pressureat which fuel beginsjetting out from the nozzle 3 If the measurement is not within the factory specifications disassemble the injection nozzle and cha...

Page 30: ...pressure 00000F00230 I 01640S10220 ConnectingRod AlignmentTool Code No 07909 31661 Application Use for checkingthe connecting rodalignment Applicable range Connectingrodbig end I D 30to 75 mrn 1 18to...

Page 31: ...hem referring to the figure D I I cI 11790F00451 I G k J 11790F00461 01640810250 01640510910 Valve Guide Replacing Tool Application Use to press out and press fit the valve guide I A I 20 rnrndia 0 79...

Page 32: ...ressuregaugefull scale Morethan 0 4724 to 0 4732 in dia 100mm 3 94 in M12xP1 5 I B I Comeraasket I C D I Flange Material Steel I Hex nut27 mm 1 06 in across the plat E I Injectionpipe F I PF 112 1 15m...

Page 33: ...uin A B C 150rnrn 5 91 in 20 rnrn 0 79 in 100rnrn 13 94 in E F a b 19 90 to 19 95 rnrn 0 7835 to 0 7854 in 21 90 to 21 95 rnrn 0 8622 to 0 8642 in DIA 25 rnrn 0 98 in 6 3 prn 250 pin 6 3 urn 250 uin 1...

Page 34: ...Press Out E F G A B I 135 mrn 5 31i n I 72mrn 2 83i n 24rnrn 0 9 5i n 20mm dia 0 79in d i a 68mrn dia 2 68 in d i a 39 90t o39 95mm dia I C I 1 57 rad 4 0 1 I 1i110mrn 0 39in 1 22mrn 0 87 i n 20 rnrn...

Page 35: ...the cylinder piston ring top clearance valve and cylinderhead 6 If the measurement is below the allowable limit apply a small amount of oil to the cylinder wall through the nozzle hole and measurethe...

Page 36: ...197t o 0 0276in 3 7 2to 4 2 1 Nam Factoryspec Top clearance Cylinderhead mounting to 4 3kgf m lighteningtorque bolts 2 7 5to 3 1 1 ft lbs 1 Fuse DrainingCoolingWater and EngineOil A CAUTION Never remo...

Page 37: ...3 Removethe push rods H IMPORTANT 0 After reassembling the rocker arm be sure to adjust the valve clearance When reassembling 0 When putting the push rods onto the tappets check to see if their ends a...

Page 38: ...11900S10082 Valves 1 Removethe valve cap 1 2 Removethe valve springcollet 2 with a valve lifter 3 Removethe valve spring retainer 3 valve spring 4 and valve When reassembling Wash the valve stem and v...

Page 39: ...ng 4 to the lever 5 first and install the speed controlplate 2 0 Be sureto placethe copper washers underneathtwoscrews 1 Positionthe slot 9 on thefork leverjust under the slot 8 on the crankcase 0 Ins...

Page 40: ...out the camshaftwith the gear on 2 Removethe retainingplate 1 3 Remove the screws then draw out the injection pump gear 2 When reassembling Hook the spring to the fork lever 2 4 as shown in the figure...

Page 41: ...Apply liquid gasket Three Bond 1270D or 1270C to the oil pan as shown inthe figure IMPORTANT Scape off the oil adhesive completely Wipe the sealing surfaceclean using waste cloth soakedwith gasoline...

Page 42: ...TANT Do 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 e When insertingthe piston into the cylinder place t...

Page 43: ...joint IO on the oppositeside o f the oil ring gap 11 Apply engine oil to the piston pin When installingthe piston pin immerse the pistonin 80 C 176 O F oil for 10to 15 minutesand insertthe pistonpint...

Page 44: ...shaft Also check it during reassembly 1 Removethe bearingcase cover mounting screws 2 Removethe bearingcase cover 3 Removethe bearingcase screw 2 5 4 Pullout the crankshaft When reassembling IMPORTANT...

Page 45: ...n installing the main bearing case assemblies 1 face the 1 Main Bearing Case Assembly bearingcase assembly 1 mark FLYWHEEL to the flywheel 2 Main Bearing Case Assembly 1 01650S10380 Cylinder Head Surf...

Page 46: ...he allowable limit replace the valve If it still exceeds the allowable limit after replacing the valve correct the valve seat face o f the cylinder head with a valve seat cutter CodeNo 07909 33102 or...

Page 47: ...ating 1 Correct 3 Incorrect 2 Incorrect 11790F10450 0 79 rad 45 0 Factoryspec 0 0 0 11 790F10460 00000F10090 I 7 I 0 26 rad 15 0 79 rad 4 5 I A B I C I 11790S10230 CorrectingValve and Valve Seat NOTE...

Page 48: ...valve guide until it is flush with the cylinder headas shown inthe figure 3 Ream precisely the I D of the valve guide to the specified dimension I IMPORTANT 0 Do not hit the valve guide with a hammer...

Page 49: ...he push rodwith a dial indicator 3 If the measurementexceedsthe allowablelimit replacethe push unusualwear rod 00000s10111 Oil Clearance between Tappet and Tappet Guide Bore 1 Measurethe tappet O D wi...

Page 50: ...OOOOS10183 Cam Height 1 Measurethe heighto fthe camat its highestpoint with an outside 2 If the measurement is less than the allowable limit replace the micrometer camshaft OOOOOS10203 Oil Clearanceo...

Page 51: ...260 000 Piston Pin Bore I D 1 Measure the piston pin bore I D in both the horizontal and 2 If the measurement exceeds the allowable limit replace the vertical directionswith a cylindergauge piston 000...

Page 52: ...s shown in the figure until it is flash with the connectingrod 3 Drill a hole to the bushing with aligning the oil hole 2 of connectingrod using3 5 mm dia 0 138in dia drill 4 NOTE Be sure to chamfer t...

Page 53: ...Key StoneType B 2nd Oil Ring 00000510252 Connecting Rod Alignment NOTE Since the I D o f the connecting rod small end bushing is the basis of this check check the bushing for wear beforehand 1 Remove...

Page 54: ...rringto the table and figure 0 15 to 0 25 mm 0 0059 to 0 0098 in 0 0197 in Factoryspec Allowable limit Crankshaftside clearance Reference 0 Oversizemain bearingcase assembly I I I Mainbearingcaseassem...

Page 55: ...ever insert the plastigage into the crankpin oil hole Be sure not to move the crankshaft while the connecting rod screws are tightened 2 3 to 2 7 mmradius 0 091 to 0 106 in radius A 0 019 to 0 081 mm...

Page 56: ...4 to 39 950 mm 1 57221 to 1 57284 in Factoryspec I 0 034 to 0 106 mm I 0 0013 to 0 0042 in 1 Oil clearance between 1 Factory A B C 1 8 to 2 2 mm radius 0 071 to 0 087in radius 5 mmdia 0 20 in dia 39 7...

Page 57: ...journal O D Factoryspec 1 57221 to 1 57284 in Intermediate 39 978 to 39 993 mm Crankshaftbearing3 I D Factory spec 1 57394 to 1 57453 in 0 034 to 0 092 mrn 0 20 mrn 0 0079 in 43 934 to 43 950 mm 1 729...

Page 58: ...fer to Correcting Cylinder Cylinder1 D 64 500to 64 519mm 2 5394to 2 5401 in Factoryspec I Maximumwear Maximumwear 0 15mm I 0 0059in I Allowable limit 0 15 mm 0 0059in Allowable limit A TOP B Middle C...

Page 59: ...After checking the engine oil pressure tighten the engine oil 0 7 9 16 32031 both idling and ratedspeeds following pressureswitch to the specifiedtorque 02090S10170 SERVICING I OIL PUMP OOOOOF10560 R...

Page 60: ...o 07909 30241 onto the rotor 2 Installthe cover andtighten the screws 3 Remove the cover carefully and measure the amount of the 4 If the clearance exceeds the factory specifications replace oil face...

Page 61: ...e seat 2 Place the thermostat and a thermometer in a container with water and gradually heatthe water 3 Hold the string to suspend the thermostat in the water When the water temperature rises the ther...

Page 62: ...sembling Apply a liquid gasket ThreeBond1215or equivalent only at the c thermostat cover side of the gasket 2 1 ThermostatCover 3 Thermostat Assembly 2 ThermostatCoverGasket 11900510271 Water Pump Ass...

Page 63: ...able in thickness of 0 20 mm 0 0079 in 0 25 mm 0 0098 in and 0 3 0 mm 0 0118 in Combine these shims for adjustments Addition or reduction of shim 0 05 mm 0 0020 in delays or advances the injection tim...

Page 64: ...confirming that there is nobody standing in the directionthe fume goes If the fume from the nozzle directly contacts the human body cells may be destroyed and blood poisoning may be caused f I 1I790S1...

Page 65: ...SEMBLING AND ASSEMBLING I INJECTION NOZZLE I 00000F10700 Nozzle Holder 1 Securethe nozzleretainingnut 7 with a vise 2 Removethe nozzleholder I and take out parts inside When reassembling Assemble the...

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Page 68: ...NERYSERVICE LTD 64 ISHIZU KITAMACHI SAKAI CITY OSAKA JAPAN PHONE 81 722 41 1129 FAX 81 722 45 2484 E mail ksos pub6oa kubota co jp I KUBOTA Corporation Printed in Japan 2000 10 S El El e Code No 97897...

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