wsm V3307-DI-T-E2B Workshop Manual Download Page 73

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S-4

V3307-DI-T-E2B, WSM

ENGINE

W1168623

Symptom

Probable Cause

Solution

Reference
Page

High Oil Pressure

Different type of oil

Use specified type of
oil

G-6, 9

Relief valve defective

Replace

S-46, 76

Engine Overheated

Engine oil insufficient

Replenish

G-7, 9

Fan belt broken or elongated

Replace or adjust

G-12, 15

Coolant insufficient

Replenish

G-8, 15

Radiator net and radiator fin clogged with dust

Clean

–

Inside of radiator corroded

Clean or replace

G-15

Coolant flow route corroded

Clean or replace

G-15

Radiator cap defective

Replace

S-18

Overload running

Reduce the load

–

Head gasket defective

Replace

S-33, 34

Incorrect injection timing

Adjust

S-20

Unsuitable fuel used

Use specified fuel

G-6

Battery Quickly
Discharged

Battery electrolyte insufficient

Replenish distilled
water and charge

G-18, 19

Fan belt slips

Adjust belt tension or
replace

G-12, 15

Wiring disconnected

Connect

–

Rectifier defective

Replace

S-26, 56

Alternator defective

Replace

S-26, 56

Battery defective

Replace

G-27,

S-23, 24

KiSC issued 01, 2009 A

Summary of Contents for V3307-DI-T-E2B

Page 1: ...WORKSHOP MANUAL DIESEL ENGINE V3307 DI T E2B KiSC issued 01 2009 A...

Page 2: ...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...

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...

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 Escapin...

Page 5: ...ust 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 PREVENT ACID BURNS Sulfuric acid in batter...

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 teleph...

Page 7: ...Type Injection Timing 0 0087 rad 0 50 after T D C Firing Order 1 3 4 2 Injection Pressure 1st stage 18 63 MPa 190 0 kgf cm2 2702 psi 2nd stage 22 56 MPa 230 0 kgf cm2 3271 psi Compression Ratio 20 0 L...

Page 8: ...WSM PERFORMANCE CURVES PERFORMANCE CURVES Q V3307 DI T E2B 1 Brake Horsepower 2 Engine Speed 3 B S F C 4 Torque 5 Gross Intermittent Torque 6 Gross Intermittent B H P 7 Gross Intermittent B S F C KiSC...

Page 9: ...7 V3307 DI T E2B WSM DIMENSIONS DIMENSIONS Q V3307 DI T E2B KiSC issued 01 2009 A...

Page 10: ...2 CHECK POINTS OF INITIAL 50 HOURS G 9 3 CHECK POINT OF EVERY 50 HOURS G 11 4 CHECK POINTS OF EVERY 250 HOURS G 12 5 CHECK POINTS OF EVERY 500 HOURS G 14 6 CHECK POINT OF EVERY 1000 HOURS G 17 7 CHECK...

Page 11: ...e 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 W10...

Page 12: ...9 F0001 FZ999 April G0001 G9999 H0001 HZ999 May J0001 J9999 K0001 KZ999 June L0001 L9999 M0001 MZ999 July N0001 N9999 P0001 PZ999 August Q0001 Q9999 R0001 RZ999 September S0001 S9999 T0001 TZ999 Octob...

Page 13: ...ecuted the improvement of the engine according to this regulation In order to discriminate the engines conforming to Tier 1 Phase 1 requirements and those conforming to Tier 2 Phase 2 requirements we...

Page 14: ...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 replace...

Page 15: ...y 250 hrs Every 500 hrs Every 1000 hrs Every 1 or 2 months Every 1500 hrs Every 3000 hrs Every 1 year Every 2 years Changing engine oil Replacing oil filter cartridge Checking fuel hoses and clamp ban...

Page 16: ...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 grea...

Page 17: ...e previous one 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 measu...

Page 18: ...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 1 until coolant temperature is below its boi...

Page 19: ...emove 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 deformat...

Page 20: ...lternator mounting screws 1 and relocate the alternator to adjust W1208957 Checking Fan Belt Damage and Wear 1 Check the fan belt for damage 2 If the fan belt is damaged replace it 3 Check if the fan...

Page 21: ...ibed above When bleeding fuel system 1 Fill the tank with fuel and open the cock 2 Loosen the air vent coupling bolt of fuel filter a few turns 3 When there is no more air bubbles in the fuel coming o...

Page 22: ...an 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 cleaner elemen...

Page 23: ...de of rubber and tends to age It must be replaced every two years Also replace the clamp band and tighten it securely W1029518 Checking Battery Electrolyte Level for Refillable Battery s only 1 Check...

Page 24: ...emove 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 deformat...

Page 25: ...e removed to completely drain the coolant And open the drain cock of engine body 3 After all coolant is drained close the drain plug 2 4 Fill with clean water and cooling system cleaner 5 Follow direc...

Page 26: ...eric 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...

Page 27: ...push rod side and insert the feeler gauge between the rocker arm and the head of valve bridge arm Set the adjusting screw 3 to the specified value then tighten the lock nut Adjustment unnecessary typ...

Page 28: ...ld 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...

Page 29: ...hold the 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 dec...

Page 30: ...2 Slowly move the 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 injection nozzle ass...

Page 31: ...sor cover 6 to see if there is no air leak 2 If any air leak is found change the clamp band 7 and or inlet hoses 9 3 Check the intake hose 8 and the clamp band 7 to see if there is not loose or crack...

Page 32: ...begins to come up to get the present injection timing 8 Check to see the degree on flywheel The flywheel has mark 1TC for the crank angle before the top dead center of No 1 piston 9 If the injection t...

Page 33: ...injection nozzle 2 After that turn the flywheel by the hand and raise the pressure to approx 18 63 MPa 190 0 kgf cm2 2702 psi 7 Now turn the flywheel back about half a turn to keep the plunger free M...

Page 34: ...ent types of oil Engine oil should have properties of API classification CD CE CF See page G 6 Use the proper SAE Engine Oil according to ambient temperature W1036031 Replacing Air Cleaner Element 1 R...

Page 35: ...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 recov...

Page 36: ...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...

Page 37: ...ump Otherwise the engine may stall W1020090 Replacing Intake Air Line 1 Loosen the clamp bands 2 2 Remove the intake air hose 1 and clamp bands 2 3 Replace new intake air hose 1 and new clamp bands 2...

Page 38: ...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 Joint 3 Adaptor A 4 Adaptor B 5 Adaptor C 6 Adapto...

Page 39: ...terial Steel E Hex nut 27 mm 1 1 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 0 mm dia 0 31 in dia K 1 0 mm 0 039 i...

Page 40: ...in dia P0 5 N 17 0 mm 0 669 in D 13 0 mm dia 0 512 in dia O 61 5 mm 2 42 in E 9 5 mm dia 0 37 in dia P 15 0 mm 0 591 in F M8 x 1 0 Q 10 0 mm 0 394 in G 6 50 to 6 70 mm dia 0 256 to 0 263 in dia R 100...

Page 41: ...74 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 0 mm 0 5512 in C 120 mm 4 7244 in D 27 4 mm dia 1 0787 in dia E 42 000 mm dia 1 653...

Page 42: ...E 11 7 to 11 9 mm dia 0 461 to 0 468 in dia F 6 50 to 6 60 mm dia 0 256 to 0 259 in dia G 25 mm dia 0 98 in dia H 6 70 to 7 00 mm dia 0 264 to 0 275 in dia I 5 0 mm 0 20 in J 20 mm dia 0 79 in dia K...

Page 43: ...in dia H 78 900 to 79 100 mm dia 3 1063 to 3 1141 in dia I 57 971 to 57 990 mm dia 2 2824 to 2 2830 in dia J 50 0 mm dia 1 97 in dia K 15 0 mm dia 0 591 in dia L 30 0 mm dia 1 18 in dia M 15 0 mm 0 5...

Page 44: ...90 to 101 10 mm dia 3 9725 to 3 9803 in dia I 86 966 to 86 988 mm dia 3 4239 to 3 4247 in dia J 79 0 mm dia 3 11 in dia K 15 0 mm dia 0 591 in dia L 30 0 mm dia 1 18 in dia M 13 0 mm 0 512 in N 90 0...

Page 45: ...a 0 30 mm radius 0 012 in radius C0 5 Chamfer 0 50 mm 0 020 in C1 Chamfer 1 0 mm 0 039 in C2 Chamfer 2 0 mm 0 079 in 1 Material SS400 A 30 0 mm 1 18 in B 30 0 mm dia 20 0 mm depth 1 18 in dia 0 79 in...

Page 46: ...6 0 mm 0 24 in V 8 0 mm dia 0 31 in dia G 23 5 mm 0 925 in W 33 475 to 33 525 mm 1 3180 to 1 3198 in H 29 5 mm 1 16 in a Ra 1 6 a I 58 0 mm 2 28 in b 0 50 mm radius 0 020 in radius J 95 0 mm 3 74 in...

Page 47: ...F 15 mm 0 59 in G 59 mm 2 3 in H 14 mm dia 0 55 in dia I 80 mm radius 3 1 in radius J 70 mm 2 8 in K 460 mm 18 1 in L 270 mm 10 6 in M 6 0 mm 0 24 in N 70 mm 2 8 in C10 Chamfer 10 mm 0 39 in 1 Materi...

Page 48: ...in dia G 77 0 mm dia 3 03 in dia H 57 0 mm dia 2 24 in dia I 35 0 mm dia 1 38 in dia J 30 0 mm dia 1 18 in dia K 84 0 mm dia 3 31 in dia L 3 5 mm 0 14 in M 3 0 mm 0 12 in N 6 60 to 6 80 mm 0 260 to 0...

Page 49: ...1 582 in dia E 35 90 to 36 10 mm dia 1 414 to 1 421 in dia F 2 09 rad 120 G M8 x P1 25 H 9 0 mm dia 0 35 in dia I 19 0 mm dia 0 748 in dia J 12 0 mm 0 472 in K 15 0 mm 0 591 in L 27 5 mm 1 08 in M 31...

Page 50: ...6 a F 7 0 mm 0 28 in AA Governor housing side G 6 0 mm 0 24 in BB Press in side H 80 0 mm 3 15 in a 0 60 mm radius 0 024 in radius I 27 95 to 28 05 mm 1 101 to 1 104 in b 1 0 mm radius 0 039 in radiu...

Page 51: ...SYSTEM E CDIS M 6 7 GEAR TRAIN CONFIGURATION M 7 8 PISTON M 7 9 BUILT IN DYNAMIC BALANCER BALANCER MODEL ONLY M 7 3 LUBRICATING SYSTEM M 8 1 OIL COOLER M 8 4 COOLING SYSTEM M 9 1 THERMOSTAT M 9 2 BOTT...

Page 52: ...th the new E CDIS The 07 series DI engine newly adopted ladder frame crankshaft support structure gear train located at flywheel side and coolant evenness distribution type cooling jacket Thus this en...

Page 53: ...2 2 which supports the crankcase 1 1 The following benefits are in the ladder frame structure 1 Minimizing parts 2 Noise reduction 3 Reduction of loss and dispersion on friction thanks to accuracy of...

Page 54: ...hrough the main gallery 3 in the jacket mold core 2 W1013000 3 HALF FLOATING HEAD COVER The rubber packing 2 is fitted in to maintain the head cover 0 5 mm 0 02 in or so off the cylinder head This arr...

Page 55: ...4 CYLINDER HEAD This engine employs four valve system the cylinder head is provided with double intake passage in order to ensure appropriate air suction and give an optimum swirl W1013336 1 Intake 2...

Page 56: ...mbled from the top and bottom to the crankcase 1 3 with each of 10 screws The following objectives are in the 4 screws per each cylinder assembling structure 1 Reduce the load share rate of combustion...

Page 57: ...er combustion performance In other words cleaner emission higher power output lower fuel consumption lower operating noise and higher start up performance have been achieved W11094950 The 07 series DI...

Page 58: ...t like a Graphite or Teflon This material helps resist metal wears even with little lube oil W1015665 9 BUILT IN DYNAMIC BALANCER BALANCER MODEL ONLY Engines are sure to vibrate by piston s reciprocat...

Page 59: ...il but also warms the cool engine oil shortly 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 thereby...

Page 60: ...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 3 and undershoo...

Page 61: ...eld closed and the coolant is allowed to flow through the bypass pipe and to circulate in the engine When the temperature exceeds the thermostat 1 valve opening level the thermostat 1 fully opens itse...

Page 62: ...chanical 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 governo...

Page 63: ...compress 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 2 to keep rated rotation and rated output When th...

Page 64: ...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 manually move the extern...

Page 65: ...iciently to move the needle valve through its full lift This gives the following features Improved engine stability at low and intermediate speeds Decreased engine hunting and surge Decreased noise at...

Page 66: ...the needle valve is again lifted and main injection can begin Second opening pressure is represented by point F in the bottom left hand figure and B C in the above figure 3 INJECTION PUMP WITH F S P...

Page 67: ...urface 2 opens when the fuel pressure becomes more than the delivery valve set pressure Q At after injection The delivery valve 1 the steel ball 5 and the snapper valve 6 are moved down and the delive...

Page 68: ...rn more fuel thereby producing more horsepower In applications where the boost pressure is relatively low the turbocharger is capable of reducing the smoke concentration the concentration in the cylin...

Page 69: ...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 31 4 Thermostat S 35 5 Injection Pump Unit S 36 6 Wat...

Page 70: ...ing nut S 31 Incorrect injection timing Adjust S 20 Fuel camshaft worn Replace S 41 Injection nozzle clogged Repair or replace S 22 32 Injection pump malfunctioning Repair or replace S 21 43 Seizure o...

Page 71: ...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 engine...

Page 72: ...ove worn Replace piston S 52 53 69 Valve stem and valve guide worn Replace S 35 61 Crankshaft bearing and crank pin bearing worn Replace S 52 53 70 to 72 Oil leaking due to defective seals or packing...

Page 73: ...de of radiator corroded Clean or replace G 15 Coolant flow route corroded Clean or replace G 15 Radiator cap defective Replace S 18 Overload running Reduce the load Head gasket defective Replace S 33...

Page 74: ...haust 0 65 to 0 85 mm 0 026 to 0 033 in 1 20 mm 0 0472 in Valve Stem to Valve Guide Intake and Exhaust Valve Stem Valve Guide Clearance O D I D 0 055 to 0 085 mm 0 0022 to 0 0033 in 6 960 to 6 975 mm...

Page 75: ...0 3568 in 0 15 mm 0 0059 in Push Rod Alignment 0 25 mm 0 0098 in Tappet to Tappet Bore Tappet Tappet Bore Oil Clearance O D I D 0 020 to 0 050 mm 0 00079 to 0 0019 in 9 965 to 9 980 mm 0 3924 to 0 392...

Page 76: ...025 mm 1 3780 to 1 3789 in 43 934 to 43 950 mm 1 7297 to 1 7303 in 44 000 to 44 025 mm 1 7323 to 1 7332 in 0 15 mm 0 0059 in Piston Pin Bore I D 28 000 to 28 013 mm 1 1024 to 1 1028 in 28 05 mm 1 104...

Page 77: ...to 0 35 mm 0 0059 to 0 013 in 0 50 mm 0 020 in Crankshaft Alignment 0 02 mm 0 0008 in Crank Pin to Crank Pin Bearing Crank Pin Oil Clearance O D 0 017 to 0 048 mm 0 00067 to 0 0018 in 49 980 to 49 991...

Page 78: ...Rotor to Pump Body Clearance 0 100 to 0 184 mm 0 00394 to 0 00724 in 0 30 mm 0 012 in Rotor to Cover Clearance 0 025 to 0 075 mm 0 00099 to 0 0029 in 0 225 mm 0 00886 in Relief Valve Spring Free Lengt...

Page 79: ...livery Valve Fuel Tightness 10 seconds 18 63 17 65 MPa 190 0 180 0 kgf cm2 2702 2560 psi 5 seconds 18 63 17 65 MPa 190 0 180 0 kgf cm2 2702 2560 psi Fuel Injection Nozzle Injection Pressure 1st stage...

Page 80: ...ush Yoke O D Undercut Length Resistance Resistance Resistance Resistance Resistance 32 0 mm 1 26 in 0 50 mm 0 020 in 18 0 mm 0 709 in Infinity Infinity 0 0 Infinity 31 4 mm 1 24 in 0 20 mm 0 0079 in 1...

Page 81: ...l 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 Speci...

Page 82: ...to 27 2 4 to 2 8 18 to 20 Overflow pipe assembly retaining screw M6 x 1 0 9 81 to 11 2 1 00 to 1 15 7 24 to 8 31 Lubricating oil pipe mounting screw M10 x 1 25 16 to 19 1 6 to 2 0 12 to 14 Governor h...

Page 83: ...5 40 to 44 4 0 to 4 5 29 to 32 Front cover mounting screw 7T M8 x 1 25 24 to 27 2 4 to 2 8 18 to 20 Front cover mounting screw 10T M8 x 1 25 30 to 34 3 0 to 3 5 22 to 25 Flywheel housing mounting scr...

Page 84: ...in 1 rpm with the starter 4 Read the maximum pressure Measure the pressure more than twice NOTE Q Check the compression pressure with the specified valve clearance Always use a fully charged battery f...

Page 85: ...rt the feeler gauge between the rocker arm and the head of valve bridge arm Set the adjusting screw 3 to the specified value then tighten the lock nut Adjustment unnecessary type of valve bridge arm 3...

Page 86: ...specified torque W10349520 3 Cooling System Fan Belt Tension 1 Measure the deflection A depressing the fan belt 2 halfway between the fan drive pulley and alternator pulley at specified force 98 N 10...

Page 87: ...surement 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...

Page 88: ...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 read th...

Page 89: ...begins to come up to get the present injection timing 8 Check to see the degree on flywheel The flywheel has mark 1TC for the crank angle before the top dead center of No 1 piston 9 If the injection...

Page 90: ...the fuel jets from the injection nozzle 2 After that turn the flywheel by the hand and raise the pressure to approx 18 63 MPa 190 0 kgf cm2 2702 psi 7 Now turn the flywheel back about half a turn to k...

Page 91: ...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 injection nozzle assembly or repair at...

Page 92: ...n gas mixed with 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 engi...

Page 93: ...hold the 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 decr...

Page 94: ...able 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...

Page 95: ...2 is faulty NOTE Q Adjust the direction of the ditch to the terminal side when the seal 1 is installed in the glow plug 2 W1036945 Engine Stop Solenoid 1 Remove the engine stop solenoid from the engi...

Page 96: ...k the inlet hose 4 of the compressor cover 1 to see if there is no air leak 2 Check for loose connections or cracks in the suction side of the intake hose 3 3 If any air leak is found change the clamp...

Page 97: ...1 Open the radiator drain plug and remove the radiator cap 2 Remove the radiator hose 1 from engine body W1023496 2 External Components Air Cleaner Muffler and Others 1 Remove the air cleaner and muff...

Page 98: ...starting the engine make sure that air cleaner is in position Oil Pipe and Intake Hose 1 Remove the joint bolt 1 bolt 3 and clamp band 4 2 Disconnect the oil pipe 1 2 and oil pipe 2 5 3 Remove the int...

Page 99: ...ary 4 Remove the exhaust port 5 and exhaust manifold 2 If necessary When reassembling Replace the gasket 8 with new one NOTE Q Be careful not to damage the O ring 10 W1078106 Tightening torque Oil pip...

Page 100: ...of the injection pipes 1 See the figure Adjust the direction of the ditch to the terminal side when the seal 6 is installed in the glow plug 3 After installing the glow plug 3 confirm that the seal 6...

Page 101: ...d with the grooves When installing the valve bridge arm 3 apply engine oil to the valve bridge shaft sufficiently and check whether to move smoothly IMPORTANT Q After reassembling the rocker arm 1 be...

Page 102: ...andling the gasket not to damage it Install the cylinder head Tighten the cylinder head screw gradually in the order of 1 to 10 after applying engine oil Be sure to adjust the valve clearance See the...

Page 103: ...as shown in figure 2 Select the suitable cylinder head gasket 1 refer to the table below W1022965 Notch of Cylinder Head Gasket Thickness of cylinder head gasket Part Code Piston Head s protrusion or...

Page 104: ...ch 8 end downward at the cylinder head side B W1053044 4 Thermostat Thermostat Assembly 1 Remove the thermostat cover mounting screws and remove the thermostat cover 1 2 Remove the thermostat assembly...

Page 105: ...s not move any longer 5 Tighten the lower fuel camshaft lock screw 9 until it comes into contact with the fuel camshaft NOTE Q Never overtighten the lock screws when they have come into contact with t...

Page 106: ...e 1 6 Tighten the injection pump unit mounting nut 5 to the specified torque 7 Reconnect the lubricating oil pipe 7 and place the injection pump unit support 8 and the window cover of the injection pu...

Page 107: ...pin 6 tighten the nut with the specified torque with using the jig for keeping the governor connecting rod 4 horizontal See the Replacing Injection Pump Assembly After tightening the nut hook the star...

Page 108: ...e governor housing 5 When reassembling After reassembling the governor housing assembly check the movement of the governor fork lever assembly the speed control lever and the stop lever NOTE Q When as...

Page 109: ...e governor housing 4 Remove the start spring 6 W1142375 Stop Lever 1 Remove the spring pin 3 2 Remove the stop lever 2 and the return spring 1 3 Remove the stop lever shaft 4 W1143531 1 Return Spring...

Page 110: ...en removing the governor weight mounting nut 3 Otherwise the lock screws or injection pump housing might get damage IMPORTANT Q This injection pump gear mounting nut 5 has left handed screw To loose t...

Page 111: ...ting screws 2 with the specified torque Install the injection pump gear and mounting nut to the fuel camshaft and temporarily tighten nut Install the injection pump unit to the crankcase 1 and tempora...

Page 112: ...ernor connecting rod 6 from the rack pin 8 of injection pump assembly 10 7 Remove the injection pump mounting screws and nuts and take out the injection pump assembly 10 NOTE Q Be careful not to drop...

Page 113: ...njection pump unit 1 Refer to 5 SPECIAL TOOLS at GENERAL section 5 Make sure the permanent magnet at the tip of the service jig 6 is attracted to the governor connecting rod 4 6 Slightly tighten the l...

Page 114: ...the fan drive pulley 3 When reassembling Tighten the crankshaft screw 4 to specified torque after applying engine oil W1185033 6 Water Pump and Oil Cooler Water Pump If necessary 1 Remove the water pu...

Page 115: ...kcase 1 3 and crankcase 2 2 W1189218 Relief Valve 1 Remove the relief valve retaining screw 5 2 Remove the relief valve 2 the spring 3 and the packing 4 W1081251 Tightening torque Oil cooler joint scr...

Page 116: ...housing 1 2 Remove the PTO cover 1 3 with PTO gear assembly 5 from the flywheel housing 1 When reassembling Be sure to place the O ring 4 NOTE Q Be careful not to damage the O ring 4 W1124264 1 Flywh...

Page 117: ...lywheel 2 using jack up screws 5 When reassembling Apply engine oil to the flywheel screws 3 Before fitting the flywheel 2 and the crankshaft gear together wipe oil dust and other foreign substances o...

Page 118: ...am between crankcase 1 8 and crankcase 2 9 Assemble the adhesive applied parts within ten minutes For Side PTO Model Option Install the inside roller bearing 12 of the camshaft 11 in the outside rolle...

Page 119: ...When reassembling When installing the idle gear 2 and cam gear 4 be sure to place the 4th cylinder piston at the top dead center in compression then align all mating marks on each gear to assemble the...

Page 120: ...o fit them to the mating parts Assemble the adhesive applied parts within ten minutes To avoid uneven tightening tighten mounting screws 1 in diagonal order from the center After cleaning the oil stra...

Page 121: ...the cylinder apply enough engine oil to the cylinder When inserting the piston into the cylinder face the mark 4 on the connecting rod to the injection pump IMPORTANT Q Do not change the combination o...

Page 122: ...the piston pin 7 to the piston 5 Assemble the piston 5 to the connecting rod 6 with the mark 8 and the connecting rod numbering mark 9 facing same side The end faces of the oil ring 3 are plated with...

Page 123: ...and crankcase 2 flange screw in the order of Z to A 2 Remove the crankcase 2 1 from the crankcase 1 2 3 Remove the crankshaft 3 To be continued W1037243 1 Crankcase 2 2 Crankcase 1 3 Crankshaft a Fron...

Page 124: ...oosely after applying engine oil Tighten up the jig 7 to the specified torque same as the flywheel housing screw Refer to 5 SPECIAL TOOLS at GENERAL section This helps to minimize the level difference...

Page 125: ...e setup bolt Apply grease to the gears bearings shaft s sliding part and ball 7 NOTE Q Do not damage to the brush and commutator When reassembling Apply grease DENSO CO No 50 or equivalent to the part...

Page 126: ...ve the 4 screws and detach the bearing retainer 2 Temporarily install the nut on the pulley screw and detach the rotor W1074920 Brush 1 When the rotor is detached the 2 brushes are found to stretch ou...

Page 127: ...4 0 mm 0 16 in hex wrench to push the brushes into place Using a pin pointed 2 0 mm 0 079 in punch keep the brushes from popping out 2 Match the tally line of the front section with that of the rear s...

Page 128: ...e cylinder head and measure squeezed fuse wires 1 for thickness 6 If the measurement is not within the specified value check the oil clearance of the crankpin journal and the piston pin W1049122 Cylin...

Page 129: ...llowable limit after replacing the valve replace the cylinder head W1061543 Valve Lapping 1 Apply compound evenly to the valve lapping surface 2 Insert the valve into the valve guide Lap the valve ont...

Page 130: ...tion When installing 1 Clean a new valve 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 figur...

Page 131: ...way around W10283500 Free Length and Tilt of Valve Spring 1 Measure the free length B with vernier calipers If the measurement is less than the allowable limit replace it 2 Put the spring on a surfac...

Page 132: ...outside micrometer and then calculate the oil clearance 3 If the clearance exceeds the allowable limit replace the valve bridge arm 1 and measure the oil clearance again If it still exceeds the allow...

Page 133: ...D with an outside micrometer 2 Measure the I D of the tappet bore at the most wear part with a small hole gauge 3 If the oil clearance exceeds the allowable limit or the tappet is damaged replace the...

Page 134: ...nce exceeds the allowable limit replace the bushing W1064968 Backlash between crank gear and cam gear Factory spec 0 0410 to 0 139 mm 0 00162 to 0 00547 in Allowable limit 0 22 mm 0 0087 in Backlash b...

Page 135: ...with V block on the surface plate and set a dial indicator with its tip on the intermediate journal at right angle 2 Rotate the camshaft 1 on the V blocks and get the misalignment half of the measure...

Page 136: ...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 W1065759 Oil clearance between camshaft journal a...

Page 137: ...necting rod W1066057 Connecting Rod Alignment NOTE Q Since the I D of the connecting rod small end bushing is the basis of this check check the bushing for wear beforehand 1 Remove the piston pin from...

Page 138: ...the allowable limit replace the piston ring 4 If the clearance still exceeds the allowable limit with new ring replace the piston W1066183 Top ring Factory spec 0 25 to 0 40 mm 0 0099 to 0 015 in Allo...

Page 139: ...on the intermediate journal at right angle 2 Rotate the crankshaft on the V block and get the misalignment half of the measurement value 3 If the misalignment exceeds the allowable limit replace the...

Page 140: ...sions of crankpin W1067389 Crankpin O D Factory spec 49 980 to 49 991 mm 1 9678 to 1 9681 in Oil clearance between crankpin and crankpin bearing Factory spec 0 017 to 0 048 mm 0 00067 to 0 0018 in All...

Page 141: ...T E3B V3307 DI T E3B W1261077 Crankshaft journal O D Factory spec 79 977 to 79 990 mm 3 1487 to 3 1492 in Oil clearance between crankshaft journal and crankshaft bearing Factory spec 0 030 to 0 073 m...

Page 142: ...ered surface facing outward Keep the space a between the edge of the crankshaft gear 1 and the crankshaft sleeve 2 W1262151 Replacing Flywheel Housing Oil Seal 1 Remove the used oil seal 2 2 Clean the...

Page 143: ...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...

Page 144: ...tigage onto the rotor face with grease 2 Install the cover and tighten the screws with the specified torque 3 Remove the cover carefully and measure the amount of the flattening with the scale and get...

Page 145: ...place the overrunning clutch assembly 3 Check that the pinion turns freely and smoothly in the overrunning direction and does not slip in the cranking direction 4 If the pinion slips or does not rotat...

Page 146: ...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 allowable l...

Page 147: ...k 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 conduct...

Page 148: ...eter 4 If infinity is not indicated replace it W1076422 Slip Ring 1 Check the slip ring for score 2 If scored correct with an sand paper or on a lathe 3 Measure the O D of slip ring with vernier calip...

Page 149: ...L MACHINERY 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 2008 11 S...

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