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wsm wg972-e4, Workshop Manual

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CONTENTS

1. TROUBLESHOOTING.................................................................................................................1-S1

[1] FOR GENERAL.....................................................................................................................1-S1
[2] FOR GASOLINE FUEL [WG972-GL, WG972-G] ..................................................................1-S5
[3] FOR GAS FUEL [WG972-GL, WG972-L, WG972-N]............................................................1-S5

2. SERVICING SPECIFICATIONS ..................................................................................................1-S6
3. TIGHTENING TORQUES..........................................................................................................1-S12

[1] TIGHTENING TORQUES FOR GENERAL USE SCREWS, BOLTS AND NUTS...............1-S12
[2] TIGHTENING TORQUES FOR SPECIAL USE SCREWS, BOLTS AND NUTS.................1-S13

4. CHECKING, DISASSEMBLING AND SERVICING ...................................................................1-S14

[1] CHECKING AND ADJUSTING............................................................................................1-S14

(1) Engine Body ..................................................................................................................1-S14
(2) Lubricating System ........................................................................................................1-S16
(3) Cooling System .............................................................................................................1-S17
(4) Fuel System...................................................................................................................1-S18
(5) Ignition System ..............................................................................................................1-S19
(6) Electrical System ...........................................................................................................1-S21

[2] DISASSEMBLING AND ASSEMBLING ..............................................................................1-S25

(1) Draining Coolant and Engine Oil ...................................................................................1-S25
(2) External Components ....................................................................................................1-S26
(3) Cylinder Head, Valves and Oil Pan ...............................................................................1-S27
(4) Thermostat ....................................................................................................................1-S31
(5) Timing Gear, Camshaft .................................................................................................1-S31
(6) Piston and Connecting Rod...........................................................................................1-S33
(7) Crankshaft .....................................................................................................................1-S34
(8) Starter............................................................................................................................1-S38
(9) Alternator .......................................................................................................................1-S39

[3] SERVICING.........................................................................................................................1-S40

(1) Combustion Chamber....................................................................................................1-S40
(2) Cylinder Head and Valves .............................................................................................1-S41
(3) Timing Gear and Camshaft ...........................................................................................1-S46
(4) Piston and Connecting Rod...........................................................................................1-S49
(5) Crankshaft .....................................................................................................................1-S52
(6) Cylinder .........................................................................................................................1-S56
(7) Oil Pump........................................................................................................................1-S57
(8) Starter............................................................................................................................1-S58
(9) Alternator .......................................................................................................................1-S60

SERVICING

KiSC issued 07, 2015 A

Summary of Contents for wg972-e4

Page 1: ...WORKSHOP MANUAL GASOLINE LPG NATURAL GAS ENGINE WG972 E4 EFI KiSC issued 07 2015 A...

Page 2: ...chanism This section contains information on the structure and the function of the unit Before you continue with the subsequent sections make sure that you read this section Servicing This section con...

Page 3: ...I INFORMATION KiSC issued 07 2015 A...

Page 4: ...ION REGULATION I 7 1 GENERAL I 7 2 IMPORTANT ITEMS OF EXHAUST EMISSION REGULATION I 7 1 Important Notice I 7 2 Emission Related Installation Instructions I 7 4 PERFORMANCE CURVES I 8 5 DIMENSIONS I 12...

Page 5: ...e damage and decrease the engine life WSM000001INI0003US0 SAFETY FIRST This symbol the industry s Safety Alert Symbol is used throughout this manual and on labels on the machine itself to warn of the...

Page 6: ...nnections before you apply the pressure Do not open a fuel system under high pressure The fluid under high pressure that stays in fuel lines can cause serious injury Do not disconnect or repair the fu...

Page 7: ...ons when you discard oil fuel coolant electrolyte and other dangerous waste WSM000001INI0007US0 PREVENT ACID BURNS Keep electrolyte away from your eyes hands and clothing Sulfuric acid in battery elec...

Page 8: ...1 rpm Cylinder Head Overhead Valve Ignition System Full Transistor Battery Ignition Type Governor Electronic Governor Direction of Rotation Counter Clockwise Viewed from flywheel side Spark Plug NGK...

Page 9: ...or Direction of Rotation Counter Clockwise Viewed from flywheel side Spark Plug NGK BKR6E Ignition Timing no load condition 0 70 rad 40 before T D C 3600 min 1 rpm Firing Order 1 2 3 Compression Ratio...

Page 10: ...peed 970 to 1030 min 1 rpm Cylinder Head Overhead Valve Ignition System Full Transistor Battery Ignition Type Governor Electronic Governor Direction of Rotation Counter Clockwise Viewed from flywheel...

Page 11: ...pplicable emissions laws 2 Exhaust System Kubota offers certified catalytic converter catalytic muffler and O2 sensor Catalyst parts and O2 sensor other than Kubota must not be used because other cata...

Page 12: ...TION WG972 E4 WSM I 8 4 PERFORMANCE CURVES WG972 GL E4 9Y1211108INI0007US0 1 Torque 2 B S F C Brake Specific Fuel Consumption 3 Engine Speed 4 Brake Horsepower a Gasoline Use b LPG Use KiSC issued 07...

Page 13: ...INFORMATION WG972 E4 WSM I 9 WG972 G E4 9Y1211108INI0014US0 1 Torque 2 B S F C Brake Specific Fuel Consumption 3 Engine Speed 4 Brake Horsepower KiSC issued 07 2015 A...

Page 14: ...INFORMATION WG972 E4 WSM I 10 WG972 L E4 9Y1211108INI0015US0 1 Torque 2 B S F C Brake Specific Fuel Consumption 3 Engine Speed 4 Brake Horsepower KiSC issued 07 2015 A...

Page 15: ...INFORMATION WG972 E4 WSM I 11 WG972 N E4 9Y1211108INI0016US0 1 Torque 2 B S F C Brake Specific Fuel Consumption 3 Engine Speed 4 Brake Horsepower KiSC issued 07 2015 A...

Page 16: ...INFORMATION WG972 E4 WSM I 12 5 DIMENSIONS WG972 GL E4 9Y1211108INI0008US0 WG972 GL E4 A 516 mm 20 3 in B 393 mm 15 5 in C 503 mm 19 8 in KiSC issued 07 2015 A...

Page 17: ...INFORMATION WG972 E4 WSM I 13 WG972 G E4 9Y1211108INI0009US0 WG972 G E4 A 453 mm 17 8 in B 393 mm 15 5 in C 503 mm 19 8 in KiSC issued 07 2015 A...

Page 18: ...INFORMATION WG972 E4 WSM I 14 WG972 L E4 WG972 N E4 9Y1211108INI0010US0 WG972 L E4 WG972 N E4 A 516 mm 20 3 in B 393 mm 15 5 in C 503 mm 19 8 in KiSC issued 07 2015 A...

Page 19: ...INFORMATION WG972 E4 WSM I 15 6 WIRING DIAGRAM WG972 GL E4 KiSC issued 07 2015 A...

Page 20: ...INFORMATION WG972 E4 WSM I 16 KiSC issued 07 2015 A...

Page 21: ...INFORMATION WG972 E4 WSM I 17 WG972 G E4 KiSC issued 07 2015 A...

Page 22: ...INFORMATION WG972 E4 WSM I 18 KiSC issued 07 2015 A...

Page 23: ...INFORMATION WG972 E4 WSM I 19 WG972 L E4 WG972 N E4 KiSC issued 07 2015 A...

Page 24: ...INFORMATION WG972 E4 WSM I 20 KiSC issued 07 2015 A...

Page 25: ...G GENERAL KiSC issued 07 2015 A...

Page 26: ...HECK LIST G 6 4 CHECK AND MAINTENANCE G 11 1 DAILY CHECK POINTS G 11 2 CHECK POINTS OF INITIAL 50 HOURS G 13 3 CHECK POINTS OF EVERY 50 HOURS G 14 4 CHECK POINTS OF EVERY 100 HOURS G 16 5 CHECK POINTS...

Page 27: ...engine serial number is an identified number for the engine It is marked after the engine model name It indicates month and year of manufacture as follows Engine Series Year of manufacture To be conti...

Page 28: ...999 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 October U0001 U...

Page 29: ...listed in the appropriate KUBOTA Operator s Manual or in the appropriate E4 KUBOTA Workshop Manual Use of incorrect replacement parts or replacement parts from other emission level engines for example...

Page 30: ...elow catalytic parts Any modifications to the fuel system or any adjustments made on this engine will cause this engine to be in noncompliance with emission regulations NOTE New service catalytic muff...

Page 31: ...emove oil and dirt from parts before you measure Use only KUBOTA genuine parts for replacement to keep the machine performance and to make sure of safety You must replace the gaskets and O rings when...

Page 32: ...soline line Checking fuel leakage of fuel hoses and clamps between gas tank and gas mixer Gas line Checking battery electrolyte level Cleaning spark plug if necessary Adjusting spark plug if necessary...

Page 33: ...operating under dusty conditions 3 Replace the element after 6 times cleaning 9Y1211108GEG0005US0 Item Service Interval Every 8 hrs Daily Every 50 hrs Weekly Every 100 hrs Every 200 hrs Every 1000 hr...

Page 34: ...cking and Cleaning each part Checking and filling engine oil Checking and filling radiator coolant Checking air cleaner element if necessary Cleaning air cleaner primary element if necessary Checking...

Page 35: ...xer Checking battery electrolyte level Cleaning spark plug if necessary Adjusting spark plug if necessary Checking fan belt tension and damage Adjusting fan belt tension if necessary Replacing engine...

Page 36: ...the new engine oil Fuel Fuel is flammable and can be dangerous You should handle fuel carefully Gasoline WG972 GL E4 WG972 G E4 Use unleaded gasoline and E10 only DO NOT USE gasoline blended with met...

Page 37: ...l before adding the new engine oil Never mix two different types of oil Engine oil should have properties of API classification SL or higher Change the type of engine oil according to the ambient temp...

Page 38: ...olant air must be vented from the engine coolant passages The air vents by jiggling the radiator upper and lower hoses Be sure to close the radiator cap securely If the cap is loose or improperly clos...

Page 39: ...gine for approx 5 minutes 2 Place an oil pan underneath the engine 3 To drain the used oil remove the drain plug 1 at the bottom of the engine and drain the oil completely 4 Screw the drain plug 1 5 F...

Page 40: ...his will get rid of large particles of dust and dirt 2 Wipe the inside air cleaner clean with cloth if it is dirty or wet 3 To clean the element use clean dry compressed air on the inside of the eleme...

Page 41: ...if the fuel hose and clamp are found to be damaged or deteriorate before one year passes replace or repair them at once 9Y1211108GEG0024US0 Checking Fuel Leakage of Fuel Pipes and Clamps Gas Line WG97...

Page 42: ...NT If the spark plug electrode or its insulator is soiled or is covered with deposited carbon it may cause engine trouble When reassembling Put the high tension cord cap inside the spark plug terminal...

Page 43: ...ations adjust the fan belt tension 9Y1211108GEG0030US0 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 belt is worn and sun...

Page 44: ...ufficiently oil can be hot and cause burns 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...

Page 45: ...ition Gas Line WG972 GL WG972 L WG972 N 1 Check that LPG or CNG fuel tank is installed firmly 2 Be sure that the fill up valve and liquid withdrawal valve of the LPG or CNG fuel tank can be opened and...

Page 46: ...gradation baseline 0 position turn the adjustment screw until it matches 5 When zero adjustment is complete wipe the prism and cover surface with a soft cloth or tissue paper Measurement of test flui...

Page 47: ...nside the spark plug terminal firmly Make sure that the cylinder number is corresponding to the high tension cord number Wrong connection causes high temperature on catalytic muffler converter 9Y12111...

Page 48: ...end plate so that the No 1 piston comes to the overlap position 6 Check the following valve clearance marked with using a feeler gauge 7 If the clearance is not within the factory specifications adjus...

Page 49: ...y engaged with the grooves Make sure that the cylinder head cover gasket is not damaged Replace the cylinder head gasket with a new one Replace the exhaust manifold gasket with a new one Replace the m...

Page 50: ...oved 9Y1211108GEG0040US0 Replacing Gasoline Fuel Hose Clamps and Fuel Filter Gasoline Line WG972 GL WG972 G 1 Replace the fuel filter 1 with a new one 2 Replace the hose 2 and clamp 3 with new ones CA...

Page 51: ...ody 3 After all coolant is drained close the drain plug 4 Fill with clean water and cooling system cleaner 5 Follow directions of the cleaner instruction 6 After flushing fill with clean water and ant...

Page 52: ...dustrial 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 ra...

Page 53: ...3 The coolant filled to radiator and bleed the air from the gas regulator 2 9Y1211108GEG0048US0 Replacing Balance Hose of Gas Regulator Gas Line WG972 GL WG972 L WG972 N 1 Remove the used balance hose...

Page 54: ...1 Stop the engine and let cool down 2 To drain the coolant open the radiator drain plug 2 and remove the radiator cap 1 Then radiator 1 must be removed to completely drain the coolant And open the dra...

Page 55: ...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 necessit...

Page 56: ...t and press fit the valve guide 9Y1211108GEG0009US0 1 Gauge 2 Cable 3 Threaded Joint 4 Adaptor 1 5 Adaptor 2 6 Adaptor 3 7 Adaptor 4 8 Adaptor 5 A 200 mm 7 87 in B 80 mm 3 1 in C 40 mm 1 6 in D 20 mm...

Page 57: ...0 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 a 6 3 m 250 in b 6 3 m 250 in A 150 mm 5 91 in B 20 mm 0 79 in C 10...

Page 58: ...dia H 43 90 to 43 95 mm dia 1 729 to 1 730 in dia A 130 mm 5 12 in B 72 mm 2 8 in C 40 mm radius 1 6 in radius D 9 mm 0 4 in E 24 mm 0 94 in F 20 mm 0 79 in G 68 mm dia 2 7 in dia H 43 90 to 43 95 mm...

Page 59: ...1 ENGINE KiSC issued 07 2015 A...

Page 60: ...1 M12 2 FUEL FILTER GASOLINE LINE WG972 GL WG972 G 1 M14 3 FUEL PUMP GASOLINE LINE WG972 GL WG972 G 1 M15 4 ELECTRONIC THROTTLE BODY ETB 1 M15 5 INJECTORS AND FUEL INJECTION RAIL GASOLINE LINE WG972 G...

Page 61: ...7 CAMSHAFT POSITION SENSOR 1 M28 8 IGNITION COIL 1 M29 KiSC issued 07 2015 A...

Page 62: ...because each cylinder has its own chamber To increase the rigidity of the cylinder block parts of engine block which support main bearing case has thicker rib for additional rigidness to improve noise...

Page 63: ...stellite alloys 9Y1211108ENM0004US0 4 CRANKSHAFT The crankshaft with the connecting rod converts the reciprocating motion of the piston into rotating motion The crankshaft 2 has oil passages drilled s...

Page 64: ...that is upper and lower rails and one spacer being held between two rails This function is particularly effective in preventing oil up because of high boost at the time of engine coasting 9Y1211108EN...

Page 65: ...rotates The bearing and journals are force lubricated 9Y1211108ENM0010US0 9 ROCKER ARM ASSEMBLY The rocker arm assembly includes the rocker arms 2 and adjusting screws 1 the end of which rests on the...

Page 66: ...Also a rotor is attached to the flywheel and the rotor 2 has some holes Some of these holes are different form from the other ones Crank position sensor is sensing piston position and engine speed by...

Page 67: ...to the crankshaft the connecting rods the idle gear the camshaft and the rocker arm shaft through the oil passage in the cylinder block and the shafts to lubricate the bearings Some oil splashed by t...

Page 68: ...ect acting type and is best suited for low pressures When the pressure of the oil forced by the pump exceeds the specified value the oil pushes back the ball 2 and escapes to the oil pan 9Y1211108ENM0...

Page 69: ...ating oil passage When the oil pressure falls below the specified value the oil pressure warning lamp lights 9Y1211108ENM0019US0 1 Terminal 2 Insulator 3 Spring 4 Rubber Gasket 5 Contact Rivet 6 Conta...

Page 70: ...e closed 9Y1211108ENM0020US0 2 COOLING FIN 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 9Y12...

Page 71: ...water jacket escapes to the radiator through the leak hole of the thermostat At high temperature higher than valve opening temperature opened completely As the coolant temperature rises the wax in th...

Page 72: ...temperature rises and the pressure in the radiator increases above the specified pressure the pressure valve 1 opens to reduce the internal pressure When the coolant temperature falls and a vacuum for...

Page 73: ...lled by qualified personnel and utilizing recognized procedures and standards WG972 GL E4 This fuel system has 2 ways For gasoline the fuel is fed from the gasoline tank 4 through the fuel filter 3 to...

Page 74: ...s regulator with vaporizer 1 by pressure in the gaseous phase in the tank through the lock off valve 2 including fuel filter The liquid fuel is evaporated in vaporizer 1 and is sent to the LPG mixer 4...

Page 75: ...through the filter element 1 the dirt and impurities in the fuel are filtered allowing only clean fuel to penetrate the inside of the filter element The cleaned fuel flows out from the outlet B 9Y121...

Page 76: ...rator position sensor a foot pedal position sensor is located in the operator s compartment When the engine is operating electrical signals are sent from the accelerator position sensor the foot pedal...

Page 77: ...filter and liquid fuel comes to lock off valve after passing through the filter When applying current the lock off valve closes the fuel passage Lock off valve is assembled to regulator 9Y1211108ENM00...

Page 78: ...assage to evaporate liquid fuel to gaseous fuel Hot Water Line The coolant water of the engine is made to circulate as a heat source to prevent freezing of vaporizer by latent heat of vaporization Pri...

Page 79: ...enerated when liquid changes to gas The coolant water of the engine is made to circulate in evaporator as a heat source to prevent freezing of vaporizer by latent heat of vaporization Outlet of evapor...

Page 80: ...to mixer from regulator after gaseous fuel was filled in secondary chamber There is balance connection chamber on the opposite side of secondary chamber through the membrane secondary stage This bala...

Page 81: ...ne starts the LPG fuel flows out from main jet 1 to venturi a constant amount and is mixed with air quantity corresponding to the opening of the throttle valve and is supplied to the cylinder 9Y121110...

Page 82: ...imizing the emission purification efficiency characteristic with reference to the intake air fuel ratio Because the good balance of carbon hydrogen and oxygen in exhaust gas is necessary to operate th...

Page 83: ...ation of oxygen contained in the atmosphere inside increasing the electromotive force When the air fuel ratio is lean the process is the other way around resulting in a significant drop in the electro...

Page 84: ...e starts and increases its speed While the pinion spins faster than the armature the overrunning clutch 7 allows the pinion to spin independently from the armature The pull in coil 4 is short circuite...

Page 85: ...ted to the 30 terminal 30 from battery AC to regulator oil lamp and accessory 9Y1211108ENM0042US0 2 CHARGING SYSTEM 1 General The function of the charging device is to charge batteries 9Y1211108ENM004...

Page 86: ...complex it is described as M IC circuit Tr1 has the function as the contact point to control field electrical current and as the charging lamp relay to light the charging lamp M IC controls Tr1 and T...

Page 87: ...ive and negative current and change to the direct current 9Y1211108ENM0048US0 Alternator P Terminal P terminal waveform The alternator P terminal outputs rotation signals required by a tachometer etc...

Page 88: ...l the fuel metering and speed control while the engine is operating As well the ECU will provide diagnostic control over the fuel system 9Y1211108ENM0052US0 4 WATER TEMPERATURE SENSOR Ignition timing...

Page 89: ...for calculating airflow pressure The temperature information from the TMAP is used for a density correction in the mass air flow calculation 9Y1211108ENM0054US0 6 CRANKSHAFT POSITION SENSOR The Crank...

Page 90: ...layer thin crude steel plates secondary coil is wound on whose outside in the same direction primary coil is wound The empty space in the case is filled with resin for electric insulation and good hea...

Page 91: ...S16 3 Cooling System 1 S17 4 Fuel System 1 S18 5 Ignition System 1 S19 6 Electrical System 1 S21 2 DISASSEMBLING AND ASSEMBLING 1 S25 1 Draining Coolant and Engine Oil 1 S25 2 External Components 1 S...

Page 92: ...ine Turns Over At Normal Speed But Does Not Start 1 Fuel does not flow Check the fuel tank fuel filter fuel hoses and fuel pump Repair or replace G 15 2 Fuel filter clogged Check and replace G 16 G 17...

Page 93: ...ace 1 S42 11 Excessive wear of rings and liners Check the compression pressure 1 S14 Check and replace 1 S50 1 S56 12 Excessive carbon in engine Remove carbon 1 S40 13 Improper clearance of bearing Ch...

Page 94: ...plug Reconnect 5 Improper input signal to ECU Check the wire harness 6 Clogged air cleaner Clean or replace G 14 G 24 7 Breather tube has separated Attach correctly 1 M5 8 Damaged throttle body Replac...

Page 95: ...e corroded Clean or replace radiator and parts G 25 7 Damaged fan or radiator or radiator cap Replace damaged parts 8 Damaged thermostat Check thermostat and replace 1 S17 9 Damaged temperature sensor...

Page 96: ...ecking Procedure Solution Reference Page Engine Turns Over At Normal Speed But Does Not Start 1 Insufficient gas fuel Fill gas fuel G 10 2 Damaged gas fuel tank valve Check and replace 3 Damaged lock...

Page 97: ...recessing mm 0 012 recessing in Valve Stem to Valve Guide Inlet Valve Stem Valve Guide Valve Stem to Valve Guide Exhaust Valve Stem Valve Guide Clearance O D I D Clearance O D I D 0 030 to 0 060 mm 0...

Page 98: ...7 to 0 70937 in 0 10 mm 0 0039 in Timing Gear Crank Gear to Idle Gear Idle Gear to Cam Gear Crank Gear to Oil Pump Drive Gear Backlash Backlash Backlash 0 0430 to 0 124 mm 0 00170 to 0 00488 in 0 0470...

Page 99: ...g Oil Clearance I D 0 013 to 0 075 mm 0 00052 to 0 0029 in 20 026 to 20 077 mm 0 78843 to 0 79043 in 0 15 mm 0 0059 in Piston Ring Top Ring Second Ring Oil Ring Upper and lower rail Gap Gap Gap 0 15 t...

Page 100: ...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...

Page 101: ...llowable Limit Fan Belt Tension 7 0 to 9 0 mm 98 N 0 28 to 0 35 in 98 N 10 kgf 22 lbf Thermostat Valve Opening Temperature At Beginning Valve Opening Temperature Opened Completely 69 5 to 72 5 C 157 1...

Page 102: ...ory Specification Allowable Limit Starter 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 m...

Page 103: ...NUTS If the tightening torque is not specified refer to the table below for the none specified torques values 9Y1211108ENS0005US0 Indication on top of bolt No grade or 4T 7T Indication on top of nut N...

Page 104: ...crew 2 M7 1 0 27 to 30 2 7 to 3 1 20 to 22 Main bearing case screw 1 M6 1 0 13 to 15 1 3 to 1 6 9 4 to 11 Oil pressure switch PT 1 8 15 to 19 1 5 to 2 0 11 to 14 Spark plug M14 1 25 24 5 to 29 4 2 50...

Page 105: ...ply a small amount of oil to the cylinder wall through the spark plug hole and measure the compression pressure again 8 If the compression pressure is still less than the allowable limit check the top...

Page 106: ...r end plate so that the No 1 piston comes to the overlap position 6 Check the following valve clearance marked with using a feeler gauge 7 If the clearance is not within the factory specifications adj...

Page 107: ...filter cartridge clogged Oil gallery clogged Excessive oil clearance Foreign matter in the relief valve When reassembling After checking the engine oil pressure tighten the engine oil pressure switch...

Page 108: ...ly sunk in the pulley groove replace it 9Y1211108ENS0011US0 Thermostat Valve Opening Temperature 1 Suspend the thermostat in the water by a string with its end inserted between the valve and seat 2 He...

Page 109: ...the pinhole repair with the radiator cement When water leak is excessive replace the radiator 9Y1211108ENS0015US0 4 Fuel System Resistance of Throttle Body 1 Disconnect the connector 2 Measure the re...

Page 110: ...resistance is not with in the factory specifications replace it NOTE This table shows the results of the test conducted by using the Sanwa made testers SP 10 SP 150 analog meter Use of other testers...

Page 111: ...connected Make sure that the removed connectors are correctly connected CAUTION This test is hazardous of electric shocks Never use hand or screwdriver to press the plug to ground it to the engine bod...

Page 112: ...ion causes high temperature on catalytic muffler converter 9Y1211108ENS0116US0 Check Ignition Coil Ignition coil has three pins at connector so you cannot check this type of ignition coil by itself Ch...

Page 113: ...emperature 20 C Specific gravity at 68 F Measured value 0 0004 electrolyte temperature 68 F At an electrolyte temperature of 20 C 68 F 9Y1211108ENS0026US0 Motor Test CAUTION Secure the starter to prev...

Page 114: ...terminal 2 with a circuit tester pushing in the plunger 2 If not continuous or if a certain value is indicated replace the magnet switch 9Y1211108ENS0029US0 Resistance of Water Temperature Sensor 1 Di...

Page 115: ...distance from the engine rotating parts 1 Start the engine 2 When the engine is operating measure the voltage between two battery terminals If the voltage is between 14 2 V and 14 8 V the alternator i...

Page 116: ...ous one remove all of the old oil Never mix two different types of oil Engine oil should have properties of API classification SH Use the proper SAE Engine Oil according to ambient temperature 9Y12111...

Page 117: ...er is installed 9Y1211108ENS0037US0 Gasoline Line WG972 GL WG972 G 1 Disconnect the gasoline hose from the connector 1 9Y1211108ENS0038US0 Gas Line WG972 GL WG972 L WG972 N 1 Remove the coolant hoses...

Page 118: ...1 Remove the rocker arm bracket screws nuts 1 2 Remove the rocker arm assembly 2 3 Remove the push rods 3 When reassembling When putting the push rods 3 onto the tappets 4 check to see if their ends...

Page 119: ...Tighten them uniformly or the head may deform in the long run 9Y1211108ENS0042US0 Tappets 1 Remove the tappets 1 from the crankcase When reassembling Visually check the contact between tappets and cam...

Page 120: ...th a plastic hammer Install a new stem seal on the valve guide 9 vertically with a jig 8 when insert the stem seal 6 See page G 32 Valve Stem Seal Replacing Tool IMPORTANT Be sure stem seal 6 seats fi...

Page 121: ...red 3 5 install the oil strainer by mounting screw IMPORTANT Scrape off the old adhesive completely Wipe the sealing surface clean Now apply new adhesive 3 0 to 5 0 mm 0 12 to 0 19 in thick all over t...

Page 122: ...lley retaining screws And tighten them 9Y1211108ENS0047US0 Gear Case 1 Remove the screw 2 Remove the gear case 1 When reassembling Apply a liquid gasket Three Bond 1215 or equivalent to both sides of...

Page 123: ...g screws And tighten them 9Y1211108ENS0051US0 Oil Pump and Crankshaft Gear 1 Remove the oil pump gear 5 2 Remove the oil pump 6 3 Remove the collar 2 O ring and crankshaft oil slinger 3 When reassembl...

Page 124: ...ting rod to the fuel camshaft When inserting the piston into the cylinder place the gap C of the top compression ring on the opposite side of the slant portion and stagger the gaps A E of the second c...

Page 125: ...rod and the piston so as not to change the combination 9Y1211108ENS0055US0 7 Crankshaft Flywheel 1 Secure the flywheel to keep it from turning using a flywheel stopper 2 Remove all flywheel screws 1 a...

Page 126: ...ng mark UP a on it upward Apply engine oil to the oil seal 5 lip and be careful that it is not rolled when installing Tighten the bearing case cover mounting screws with even force on the diagonal lin...

Page 127: ...er 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...

Page 128: ...Install the bearing with the oil groove c up Match the alignment numbers a on the main bearing case assembly 1 Do the same for the main bearing case assembly 2 2 and the main bearing case assembly 3...

Page 129: ...TE 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 Col...

Page 130: ...move 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 r...

Page 131: ...ber Clean any carbon deposits from the combustion chamber walls including the cylinder head surface surroundings of valve tops and piston top surfaces Check valve seating according to following sectio...

Page 132: ...es and two diagonal as shown in the figure 3 Measure the clearance with a feeler gauge 4 If the measurement exceeds the allowable limit correct it with a surface grinder IMPORTANT Be sure to check the...

Page 133: ...lve on its seat to check the contact 2 If the valve seats all the way around the valve seat the valve seat is correct 3 If the valve does not seat all the way around the valve seat lapping the valve a...

Page 134: ...surface 2 Insert the valve into the valve guide Lap the valve onto its seat with a valve flapper 3 After lapping the valve wash the compound away and apply prussian blue to the contact surface to che...

Page 135: ...ve guide to the specified dimension IMPORTANT Do not hit the valve guide with a hammer during replacement 9Y1211108ENS0071US0 Clearance between valve stem and valve guide Inlet Factory specification 0...

Page 136: ...ween 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...

Page 137: ...limit check the oil clearance of the shafts and the gear 4 If the oil clearance is proper replace the gear 9Y1211108ENS0077US0 Push rod alignment Allowable limit 0 25 mm 0 0098 in Oil clearance betwee...

Page 138: ...t both end journals 2 Set a dial indicator with its tip on the intermediate journal 3 Measure the camshaft alignment 4 If the measurement exceeds the allowable limit replace the camshaft 9Y1211108ENS0...

Page 139: ...g using an idle gear bushing replacing tool When installing 1 Clean a new idle gear bushing and idle gear bore and apply engine oil to them 2 Press in a new bushing using an idle gear bushing replacin...

Page 140: ...shing and bore and apply engine oil to them 2 Using a small end bushing replacing tool press in a new bushing service parts taking due care to see that the connecting rod hole matches the bushing hole...

Page 141: ...surement exceeds the allowable limit replace the piston ring 9Y1211108ENS0088US0 Piston ring gap Top ring Factory specifica tion 0 15 to 0 35 mm 0 0059 to 0 013 in Allowable limit 1 25 mm 0 0492 in Se...

Page 142: ...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 of...

Page 143: ...aft alignment 4 If the measurement exceeds the allowable limit replace the crankshaft 9Y1211108ENS0092US0 Crankshaft side clearance Factory specification 0 15 to 0 31 mm 0 0059 to 0 012 in Allowable l...

Page 144: ...9Y1211108ENS0093US0 Oil clearance between crankpin and crankpin bearing Factory specification 0 020 to 0 051 mm 0 00079 to 0 0020 in Allowable limit 0 15 mm 0 0059 in Crankpin O D Factory specificati...

Page 145: ...e figure 9Y1211108ENS0095US0 Oil Clearance between crankshaft journal and crankshaft bearing 1 Factory specification 0 0340 to 0 106 mm 0 00134 to 0 00417 in Allowable limit 0 20 mm 0 0079 in Cranksha...

Page 146: ...gure NOTE Be sure not to move the crankshaft while the bearing case screws are tightened To be continued Oil clearance between crankshaft journal and crankshaft bearing 2 Factory specification 0 028 t...

Page 147: ...40 040 US Crankshaft bearing 2F 04 1G460 07540 Crankshaft bearing 3 04 1G460 07590 040 US Crankshaft bearing 3F 04 1G460 07640 Undersize 0 2 mm 0 008 in 0 4 mm 0 02 in Dimension A 1 8 to 2 2 mm radius...

Page 148: ...e exceeds the factory specifications replace the oil pump rotor assembly 9Y1211108ENS0100US0 Clearance between Rotor and Cover 1 Put a strip of plastigage onto the rotor face with grease 2 Install the...

Page 149: ...owable limit correct the commutator on a lathe to the factory specification 5 Measure the mica undercut 6 If the undercut is less than the allowable limit correct if with a saw blade and chamfer the s...

Page 150: ...If it conducts replace the armature 3 Check the continuity across the segments of the commutator with an ohmmeter 4 If it does not conduct replace the armature 9Y1211108ENS0106US0 Field Coil 1 Check t...

Page 151: ...ring and core with resistance range of circuit tester 4 If infinity is not indicated replace it 9Y1211108ENS0110US0 Slip Ring 1 Check the slip ring for score 2 If scored correct with an emery paper o...

Page 152: ...in one direction and does not conduct in the reverse direction 9Y1211108ENS0113US0 IC Regulator 1 Check the continuity across the B terminal 2 and the F terminal 1 of IC regulator with resistance rang...

Page 153: ...VICE LTD 64 ISHIZU KITAMACHI SAKAI KU SAKAI CITY OSAKA 590 0823 JAPAN PHONE 81 72 241 1129 FAX 81 72 245 2484 E mail ks_g ksos pub kubota com KUBOTA Corporation 2015 05 S EI EI engusa Printed in Japan...

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