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S-35

05-E3B, 05-E3BG, WSM

DIESEL ENGINE

Valves

1. Remove the valve caps (2).
2. Remove the valve spring collet (3), pushing the valve spring

retainer (4) by valve spring replacer (1).

3. Remove the valve spring retainer (4), valve spring (5) and valve

stem seal (6).

4. Remove the valve (7).
(When reassembling)

• Wash the valve stem and 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.

IMPORTANT

■

• Don’t change the combination of valve and valve guide.

W10211070

Thermostat Assembly

1. Remove the thermostat cover mounting screws (1), and remove

the thermostat cover (2).

2. Remove the thermostat assembly (4).
(When reassembling)

• Apply a liquid gasket (Three Bond 1215 or equivalent) only at the

thermostat cover side of the gasket (3).

W10363950

(4) Gear Case and Timing Gears

Oil Pan and Oil Strainer (for Extended Oil Pan)

1. Remove the oil pan mounting screws.
2. Remove the oil pan (2).
3. Remove the oil strainer (1).
(When reassembling)

• After cleaning the oil strainer, check to see that the filter mesh in

clean, and install it.

• Visually check the O-ring, apply engine oil, and install it.
• Securely fit the O-ring to the oil strainer.
• To avoid uneven tightening, tighten oil pan mounting screws in

diagonal order form the center.

IMPORTANT

■

• Scrape off the old adhesive completely. Wipe the sealing

surface clean using waste cloth soaked with gasoline. Now
apply new adhesive 3.0 to 5.0 mm (0.12 to 0.19 in.) thick all
over the contact surface. Apply the adhesive also on the
center of the flange as well as on the inner wall of each screw
hole.

• Cut the nozzle of the “liquid gasket” container at its second

notch. Apply “liquid gasket” about 5.0 mm (0.19 in.) thick.
Within 20 minutes after the application of fluid sealant,
reassemble the components. Wait then for about 30
minutes, and pour oil in the crankcase.

W10236610

(1) Valve Spring Replacer
(2) Valve Cap
(3) Valve Spring Collet
(4) Valve Spring Retainer

(5) Valve Spring
(6) Valve Stem Seal
(7) Valve

(1) Thermostat Cover Mounting Screw
(2) Thermostat Cover

(3) Thermostat Cover Gasket
(4) Thermostat Assembly

(1) Oil Strainer

(2) Oil Pan

KiSC issued 12, 2007 A

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Содержание N3.30

Страница 1: ...N3 30 Starting serial number KTD08090423 WORK SHOP MANUAL ENGINE BASE NANNI INDUSTRIES S A S Zone Industrielle 11 avenue MARIOTTE B P 107 33260 LA TESTE FRANCE 60300187...

Страница 2: ...chanism Workshop Manual Code No 9Y021 01875 for the one which has not been described to this workshop manual Servicing Information on the troubleshooting servicing specification lists tightening torqu...

Страница 3: ...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 attemp...

Страница 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...

Страница 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...

Страница 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...

Страница 7: ...p nuts 0 7 to 0 9 Nm Cylinder head bolts 6 5 to 7 0 Nm Flywheel bolts 5 5 to 6 0 Nm Connecting rod bolts 4 2 to 4 7 Nm Rocker arm bracket nuts 2 2 to 2 7 Nm Main bearing caps bolts M8 3 0 to 3 5 Nm M9...

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Страница 14: ...3 CHECK POINTS OF EVERY 50 HOURS G 11 4 CHECK POINTS OF EVERY 100 HOURS G 12 5 CHECK POINTS OF EVERY 200 HOURS G 14 6 CHECK POINTS OF EVERY 400 HOURS G 16 7 CHECK POINTS OF EVERY 500 HOURS G 17 8 CHEC...

Страница 15: ...er 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 W1010477 Alphabe...

Страница 16: ...999 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 Oct...

Страница 17: ...xample E2B engines may result in emission levels out of compliance with the original E3B design and EPA or other applicable regulations Please refer to the emission label located on the engine head co...

Страница 18: ...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...

Страница 19: ...hrs 3000 hrs 2 years Checking fuel hoses and clamp bands Changing engine oil Oil pan depth 110 mm 4 33 in 125 mm 4 92 in 130 mm 5 12 in Cleaning air cleaner element Replace the element after 6 times...

Страница 20: ...strongly recommended If high sulfur 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...

Страница 21: ...or viscosity from the previous 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...

Страница 22: ...t brand cannot be identified drain out all of the remaining coolant and refill with a totally new brand of coolant mix CAUTION Do not remove the radiator cap until coolant temperature is below its boi...

Страница 23: ...of API classification See page G 6 Use the proper SAE Engine Oil according to ambient temperature Upon an oil change be sure to replace the gasket with new one W1016604 Above 25 C 77 F SAE 30 or SAE...

Страница 24: ...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 Thus see that the engine oil does not leak through...

Страница 25: ...ve When bleeding fuel system 1 Fill the tank with fuel and open the cock 4 2 Loosen the air vent plug 3 of the fuel filter a few turns 3 Screw back the plug when bubbles do not come up any more 4 Open...

Страница 26: ...with kerosene 3 Take out the element 4 and dip it in the kerosene to rinse 4 After cleaning reassemble the fuel filter keeping out dust and dirt 5 Bleed the fuel system IMPORTANT If dust and dirt ent...

Страница 27: ...k in the pulley groove 4 If the fan belt is nearly worn out and deeply sunk in the pulley groove replace it W1209480 Checking Battery Electrolyte Level 1 Check the battery electrolyte level 2 If the l...

Страница 28: ...of API classification See page G 6 Use the proper SAE Engine Oil according to ambient temperature Upon an oil change be sure to replace the gasket with new one W1018298 Above 25 C 77 F SAE 30 or SAE...

Страница 29: ...e filter or its equivalent W1018617 Checking Radiator Hoses and Clamp Bands 1 Check to see if the radiator hoses are properly fixed every 200 hours of operation or every six months whichever comes fir...

Страница 30: ...before screwing on 3 Then tighten enough by hand 4 Loosen the air vent plug to let the air out 5 Start engine and check for fuel leakage W1050548 Replacing Fuel Filter Element Element Type 1 Close the...

Страница 31: ...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 FULL A ma...

Страница 32: ...oling system NOTE The above data represents industrial standards that necessitate a minimum glycol content in the concentrated anti freeze When the coolant level drops due to evaporation add fresh sof...

Страница 33: ...uld 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...

Страница 34: ...varies with temperature To be exact the specific gravity decreases by 0 0007 with an increase of 1 C 0 0004 with an increase of 1 F in temperature and increases by 0 0007 with a decreases of 1 C 0 000...

Страница 35: ...and alignment mark 2 on the rear 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...

Страница 36: ...ressure 1 Set the injection nozzle to a nozzle tester 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 fa...

Страница 37: ...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 4...

Страница 38: ...ne these shims for adjustments Addition or reduction of shim 0 025 mm 0 00098 in delays or advances the injection timing by approx 0 0044 rad 0 25 In disassembling and replacing the injection pump be...

Страница 39: ...fuel jets from the injection nozzle After that turn the flywheel by the hand and raise the pressure to approx 13 73 MPa 140 0 kgf cm2 1991 psi 7 Now turn the flywheel back about half a turn to keep t...

Страница 40: ...ery start with the positive terminal first Never check battery charge by placing a metal object across the posts 1 Disconnect the negative terminal and positive terminal 2 Remove the battery holder 3...

Страница 41: ...hen bubbles do not come up any more 4 Open the air vent cock on top of the fuel injection pump 5 If equipped electrical fuel feed pump turn the key to AC position and pump the fuel up for 10 to 15 sec...

Страница 42: ...ion 6 After flushing fill with clean water and anti freeze until the coolant level is just below the port Install the radiator cap 1 securely 7 Fill with coolant up to FULL A mark on the recovery tank...

Страница 43: ...mmHg pressure atmospheric A higher boiling point is obtained by using a radiator pressure cap which permits the development of pressure within the cooling system NOTE The above data represents industr...

Страница 44: ...No 07909 39081 Assembly 07909 31301 L 07909 31291 K 07909 31311 M Application Use to measure diesel engine compression and diagnosis of need for major overhaul Adaptor L for 05 series W1025289 Oil Pre...

Страница 45: ...dia 0 31 in dia K 1 0 mm 0 039 in L 17 mm dia 0 67 in dia M 6 10 to 6 20 mm dia 0 241 to 0 244 in dia N 8 0 mm 0 31 in O 4 0 mm 0 16 in P 11 97 to 11 99 mm dia 0 4713 to 0 4720 in dia Q PF 1 2 R 23 m...

Страница 46: ...62 in dia E 24 8 to 24 9 mm dia 0 977 to 0 980 in dia F 20 mm dia 0 79 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 196 mm 7 72 in B 26 mm 1 0 in C 150...

Страница 47: ...in dia H 47 30 to 47 50 mm dia 1 863 to 1 870 in dia C1 Chamfer 1 0 mm 0 039 in C2 Chamfer 2 0 mm 0 079 in C0 3 Chamfer 0 30 mm 0 012 in A 135 mm 5 31 in B 72 mm 2 8 in C 40 mm radius 1 6 in radius D...

Страница 48: ...2 0 in dia L 40 mm dia 1 6 in dia M 10 mm 0 39 in N 33 mm 1 3 in O 20 mm dia 0 79 in dia P 40 mm dia 1 6 in dia Q 72 10 to 72 15 mm dia 2 839 to 2 840 in dia R 73 mm dia 2 9 in dia S 83 mm dia 3 3 in...

Страница 49: ...CONTENTS MECHANISM 1 ENGINE BODY M 1 1 CLOSED BREATHER M 1 2 HALF FLOATING HEAD COVER D1305 E3B E3BG M 1 3 GOVERNOR M 2 4 BOOST COMPENSATOR M 4 KiSC issued 12 2007 A...

Страница 50: ...intake manifold through breather valve 3 to be used for re combustion W1012956 2 HALF FLOATING HEAD COVER D1305 E3B E3BG The rubber packing is fitted in to maintain the cylinder head cover 0 5 mm 0 02...

Страница 51: ...to a slide plate and holds the control rack in the direction of the full fuel position Fork lever 2 9 and the floating lever are installed in fork lever 1 6 with the fork lever shaft 4 The max torque...

Страница 52: ...uous fuel supply and suppresses the generation of black smoke W1013023 Two Lever Type Fork Lever for BG Series The engine speed of BG engine 1800 min 1 rpm specification The fork lever assembly of BG...

Страница 53: ...ing the engine startup and acceleration The rod of actuator 2 is pushed out by the rise of boost pressure and the plate 3 moves in the direction of the fuel increase around the fulcrum A W1013615 1 Bo...

Страница 54: ...S 18 4 Fuel System S 21 5 Electrical System S 24 6 Turbocharger S 29 2 DISASSEMBLING AND ASSEMBLING S 30 1 Draining Oil and Coolant S 30 2 External Components S 30 3 Cylinder Head and Valve S 31 4 Ge...

Страница 55: ...g nut Incorrect injection timing Adjust S 21 Fuel camshaft worn Replace S 40 Injection nozzle clogged Clean or replace S 23 24 Injection pump malfunctioning Repair or replace S 22 39 Seizure of cranks...

Страница 56: ...eplace the turbocharger assembly S 30 Turbocharger fin or other part damaged due to foreign matters Replace the turbocharger assembly S 30 Either White or Blue Exhaust Gas Is Observed Excessive engine...

Страница 57: ...2 43 Piston ring groove worn Replace piston S 41 to 43 Valve stem and valve guide worn Replace S 35 52 Crankshaft bearing and crank pin bearing worn Replace S 46 Oil leaking due to defective seals or...

Страница 58: ...ust Clean Inside of radiator corroded Clean or replace G 17 Coolant flow route corroded Clean or replace G 17 19 Radiator cap defective Replace Overload running Reduce the load Head gasket defective R...

Страница 59: ...psi 10 or less Top Clearance D1005 E3B E3BG D1105 E3B E3BG D1105 T E3B V1505 E3B E3BG V1505 T E3B D1305 E3B E3BG 0 55 to 0 75 mm 0 022 to 0 029 in 0 80 to 1 0 mm 0 032 to 0 039 in Cylinder Head Surfac...

Страница 60: ...Tappet Guide Clearance O D I D 0 020 to 0 062 mm 0 00079 to 0 0024 in 19 959 to 19 980 mm 0 78579 to 0 78661 in 20 000 to 20 021 mm 0 78740 to 0 78822 in 0 07 mm 0 003 in Timing Gear Crank Gear to Id...

Страница 61: ...0 020 in 0 20 to 0 51 mm 0 0079 to 0 020 in 0 80 mm 0 031 in 0 80 mm 0 031 in Camshaft Side Clearance Alignment 0 070 to 0 22 mm 0 0028 to 0 0086 in 0 30 mm 0 012 in 0 01 mm 0 0004 in Cam Height Intak...

Страница 62: ...nd Ring 0 30 to 0 45 mm 0 012 to 0 017 in 1 25 mm 0 0492 in Oil Ring 0 30 to 0 55 mm 0 012 to 0 021 in 1 25 mm 0 0492 in Piston Ring to Piston Ring Groove D1005 E3B E3BG Second Ring Oil Ring Clearance...

Страница 63: ...g 2 Oil Clearance O D I D 0 034 to 0 095 mm 0 0014 to 0 0037 in 47 934 to 47 950 mm 1 8872 to 1 8877 in 47 984 to 48 029 mm 1 8892 to 1 8908 in 0 20 mm 0 0079 in Crankshaft to Crankshaft Bearing 2 D13...

Страница 64: ...3 077 in Cylinder Oversized D1005 E3B E3BG D1105 E3B E3BG D1105 T E3B D1305 E3B E3BG V1505 E3B E3BG V1505 T E3B 76 500 to 76 519 mm 3 0119 to 3 0125 in 78 500 to 78 519 mm 3 0906 to 3 0912 in 76 65 m...

Страница 65: ...o 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 to 162 5 F 85 C 185 F Radiator Cap Pressure Falling Time...

Страница 66: ...7 to 0 3097 rad 16 25 to 17 75 before T D C 0 3360 to 0 3621 rad 19 25 to 20 75 before T D C 0 2575 to 0 2836 rad 14 75 to 16 25 before T D C 0 2487 to 0 2748 rad 14 25 to 15 75 before T D C Pump Elem...

Страница 67: ...n 0 20 mm 0 0079 in 10 5 mm 0 413 in Starter Electromagnetic Drive Type Commutator Difference Mica Brush O D O D Undercut Length 28 0 mm 1 10 in Less than 0 05 mm 0 002 in 0 50 to 0 80 mm 0 020 to 0 0...

Страница 68: ...rial 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 Sp...

Страница 69: ...nnecting rod screw M8 x 1 0 42 to 46 4 2 to 4 7 31 to 33 Rocker arm bracket nut D1005 E3B E3BG D1105 E3B E3BG D1105 T E3B V1505 E3B E3BG V1505 T E3B M7 x 1 0 22 to 26 2 2 to 2 7 16 to 19 Rocker arm br...

Страница 70: ...o the cylinder wall through the glow plug hole or nozzle hole and measure the compression pressure again 8 If the compression pressure is still less than the allowable limit check the top clearance va...

Страница 71: ...1TC mark 1 on the flywheel and alignment mark 2 on the rear 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 NOTE...

Страница 72: ...ne oil pressure switch to the specified torque W10349520 3 Cooling System Fan Belt Tension 1 Measure the deflection A depressing the belt halfway between the fan drive pulley and alternator pulley at...

Страница 73: ...si 3 If the measurement is less than the factory specification replace the radiator cap W1054156 Radiator Water Leakage 1 Pour a specified amount of water into the radiator 2 Set a radiator tester 1 a...

Страница 74: ...temperature when the valve opens and leaves the string 3 Continue heating and read the temperature when the valve opens approx 8 mm 0 3 in 4 If the measurement is not within the factory specification...

Страница 75: ...in Combine these shims for adjustments Addition or reduction of shim 0 025 mm 0 00098 in delays or advances the injection timing by approx 0 0044 rad 0 25 In disassembling and replacing the injection...

Страница 76: ...top the 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 0 kgf cm2 1991 psi 7 Now turn the flywheel back abo...

Страница 77: ...measure the pressure at which fuel begins jetting out from the nozzle 3 If the measurement is not within the factory specifications replace the adjusting washer 1 in the nozzle holder to adjust it Re...

Страница 78: ...th oxygen 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 an...

Страница 79: ...ometer at eye level The hydrometer reading must be taken at the highest electrolyte level Reference Specific gravity slightly varies with temperature To be exact the specific gravity decreases by 0 00...

Страница 80: ...switch W1019297 Magnetic Switch Test 1 Disconnect the battery negative cable from the battery 2 Disconnect the battery positive cable from the battery 3 Disconnect the leads from the starter B termin...

Страница 81: ...e is operating measure the voltage between two battery terminals If the voltage is between 13 8 V and 14 8 V the alternator is operating normally 3 If the results of alternator on unit test are not wi...

Страница 82: ...h 3 to the battery positive terminal 4 Connect the jumper leads from the engine stop solenoid body to the battery negative terminal 5 When switch 4 is turn on the plunger pull into the solenoid body a...

Страница 83: ...er 4 to see if there is no air leak 2 If any air leak is found change the clamp 2 and or inlet hoses 3 Check the intake hose 1 and the clamp to see if there is no loose or crack 4 If any loose or crac...

Страница 84: ...lt 2 3 Remove the starter 3 When reassembling Check to see that there are no cracks on the belt surface IMPORTANT After reassembling the fan belt be sure to adjust the fan belt tension W1021324 Turboc...

Страница 85: ...the injection pipes 2 When reassembling Send compressed air into the pipes to blow out dust Then reassemble the pipes in the reverse order W1028640 Tightening torque Cylinder head cover screw 7 to 8 N...

Страница 86: ...e 2 Turn screw driver three or four times each way 3 While turning the screw driver slowly pull the heat seal 4 out together with the injection nozzle gasket 3 4 If the heat seal drops repeat the abov...

Страница 87: ...PORTANT After installing the rocker arm be sure to adjust the valve clearance D1005 E3B E3BG D1105 E3B E3BG D1105 T E3B V1505 E3B E3BG V1505 T E3B D1305 E3B E3BG W1021437 Tightening torque Rocker arm...

Страница 88: ...of screws tighten them in several steps and specified sequence a to n or r NOTE Do not use O ring on the pin pipe It is not necessary to retighten the cylinder head screw and to readjust valve cleara...

Страница 89: ...trainer 1 When reassembling After cleaning the oil strainer check to see that the filter mesh in clean and install it Visually check the O ring apply engine oil and install it Securely fit the O ring...

Страница 90: ...t the fan drive pulley with a puller When reassembling Install the pulley to crankshaft aligning the mark 1 on them 3 cylinder engine Apply engine oil to the fan drive pulley retaining screw And tight...

Страница 91: ...030917 1 Gear Case A Gear Case for Standard Oil Pan B Gear Case for Extended Oil Pan C Gear Case for BG Type Without D1305 E3BG a Bolt Length 45 mm 1 8 in b Bolt Length 50 mm 2 0 in c Bolt Length 55 m...

Страница 92: ...embling 1 Install the stop solenoid mounting bolt 3 in boost compensator assembly 2 and assemble it to the boost compensator installation position at the same time 2 Tighten the boost compensator moun...

Страница 93: ...sembling When installing the injection pump insert the control rack pin 2 firmly into the groove 7 of the thrust lever of fork lever NOTE Addition or reduction of shim 0 05 mm 0 0020 in delays or adva...

Страница 94: ...xternal snap ring of the governor shaft Check the governor shaft for smooth rotation IMPORTANT There is a model of idle gear 1 4 and idle gear 2 7 by the difference of the method of transmission the p...

Страница 95: ...so on the center of the flange as well as on the inner wall of each screw hole Cut the nozzle of the liquid gasket container at its second notch Apply liquid gasket about 5 0 mm 0 19 in thick Within 2...

Страница 96: ...mark on the connecting rod to the injection pump IMPORTANT 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 pist...

Страница 97: ...the oil ring gap 11 Apply engine oil to the piston pin When installing the connecting rod to the piston immerse the piston in 80 C 176 F oil for 10 to 15 minutes and insert the piston pin to the pist...

Страница 98: ...the bearing case gasket 3 and the bearing case cover gasket 4 with correct directions Install the bearing case cover 6 to position the casting mark UP on it upward Apply engine oil to the oil seal 5 l...

Страница 99: ...e crankshaft by 2 09 rad 120 counterclockwise to set the crankpin of the second cylinder to the A Draw out the crankshaft until the crankpin of the first cylinder comes to the center of third cylinder...

Страница 100: ...order of makings b A B C from the gear case side Match the alignment numbers a on the main bearing case assembly 1 When installing the main bearing case 1 and 2 face the mark FLYWHEEL to the flywheel...

Страница 101: ...drive end frame 2 9 Remove the retainer plate 5 10 Press out the bearing 4 from drive end frame 2 with a press and jig 11 Lightly secure the rotor with a vise to prevent damage and remove the bearing...

Страница 102: ...he armature 10 with the drive lever 3 NOTE 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 solen...

Страница 103: ...9 Remove the idle gear 7 and the overrunning clutch 6 10 Remove the magnet switch cover 10 11 Remove the plunger 11 NOTE Do not damage to the brush and commutator When reassembling Apply grease DENSO...

Страница 104: ...ankpin bearing and between the piston pin and small end bushing NOTE After checking the top clearance be sure to assemble the cylinder head with a new cylinder head gasket W1020190 Cylinder Head Surfa...

Страница 105: ...lve replace the cylinder head W10768800 Clearance between Valve Stem and Valve Guide 1 Remove carbon from the valve guide section 2 Measure the valve stem O D with an outside micrometer 3 Measure the...

Страница 106: ...mer during replacement W10278890 Valve Seating 1 Coat the valve face lightly with prussian blue and put the valve on its seat to check the contact 2 If the valve does not seat all the way around the v...

Страница 107: ...and fit them with valve lapping tool 4 Check the valve seating with prussian blue The valve seating surface should show good contact all the way around W10283500 Valve Lapping 1 Apply compound evenly...

Страница 108: ...360 Oil Clearance between Rocker Arm and Rocker Arm Shaft 1 Measure the rocker arm shaft O D with an outside micrometer 2 Measure the rocker arm I D with an inside micrometer and then calculate the oi...

Страница 109: ...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 W1051412 Push rod alignment Allo...

Страница 110: ...0 0320 to 0 115 mm 0 00126 to 0 00452 in Allowable limit 0 15 mm 0 0059 in Backlash between idle gear 1 and cam gear Factory spec 0 0360 to 0 114 mm 0 00142 to 0 00448 in Allowable limit 0 15 mm 0 005...

Страница 111: ...easure the camshaft alignment 4 If the measurement exceeds the allowable limit replace the camshaft W10296710 Cam Height 1 Measure the height of the cam at its highest point with an outside micrometer...

Страница 112: ...ear bushing using an idle gear bushing replacing tool See page SPECIAL TOOLS 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 us...

Страница 113: ...en installing 1 Clean a new small end bushing 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 conn...

Страница 114: ...od 2 Install the connecting rod on the connecting rod alignment tool 3 Put a gauge over the piston pin and move it against the face plate 4 If the gauge does not fit squarely against the face plate me...

Страница 115: ...0 mm 0 0099 to 0 015 in Allowable limit 1 25 mm 0 0492 in Piston ring gap D1105 E3B E3BG D1105 T E3B V1505 E3B E3BG V1505 T E3B Top ring Factory spec 0 20 to 0 35 mm 0 0079 to 0 014 in Allowable limit...

Страница 116: ...m 0 008 in Oil ring Factory spec 0 020 to 0 055 mm 0 00079 to 0 0021 in Allowable limit 0 15 mm 0 0059 in Clearance between piston ring and piston ring groove D1105 E3B E3BG D1105 T E3B V1505 E3B E3BG...

Страница 117: ...e plate at both end journals 2 Set a dial indicator with its tip on the intermediate journal 3 Measure the crankshaft alignment 4 If the measurement exceeds the allowable limit replace the crankshaft...

Страница 118: ...t while the connecting rod screws are tightened Reference Undersize dimensions of crankpin W10331060 Oil clearance between crankpin and crankpin bearing Factory spec 0 029 to 0 091 mm 0 0011 to 0 0036...

Страница 119: ...Oil clearance between crankshaft journal and crankshaft bearing 1 Factory spec 0 0340 to 0 114 mm 0 00134 to 0 00448 in Allowable limit 0 20 mm 0 0079 in Crankshaft journal O D Factory spec 47 934 to...

Страница 120: ...ory spec 0 0340 to 0 119 mm 0 00134 to 0 00468 in Allowable limit 0 20 mm 0 0079 in Crankshaft journal O D Factory spec 51 921 to 51 940 mm 2 0442 to 2 0448 in Crankshaft bearing 1 I D Factory spec 51...

Страница 121: ...n Allowable limit 0 20 mm 0 0079 in Crankshaft journal O D Intermediate Factory spec 47 934 to 47 950 mm 1 8872 to 1 8877 in Crankshaft bearing 2 I D Factory spec 47 984 to 48 029 mm 1 8892 to 1 8909...

Страница 122: ...ry spec 51 921 to 51 940 mm 2 0442 to 2 0448 in Crankshaft bearing 2 I D Factory spec 51 974 to 52 024 mm 2 0463 to 2 0481 in Oil clearance between crankshaft journal and crankshaft bearing 3 Factory...

Страница 123: ...yond the allowable limit replace the cylinder block with a new one W10344480 Cylinder I D Factory spec D1005 E3B E3BG 76 000 to 76 019 mm 2 9922 to 2 9929 in D1105 E3B E3BG D1105 T E3B D1305 E3B E3BG...

Страница 124: ...attening with the scale and get the clearance 4 If the clearance exceeds the factory specifications replace the oil pump rotor assembly W10357320 7 Starter Overrunning Clutch 1 Check the pinion and if...

Страница 125: ...lean it with emery paper 2 Measure the brush length A with vernier caliper 3 If the length is than the allowable limit replace the yoke assembly and brush holder W1156360 Commutator O D Factory spec E...

Страница 126: ...tester 2 If it conducts replace the armature 3 Check the continuity across the segments of the commutator with resistance range of circuit tester 4 If it dose not conduct replace the armature W1156507...

Страница 127: ...e continuity across the slip ring and core with resistance range of circuit tester 4 If infinity is not indicated replace it W1020094 Slip Ring 1 Check the slip ring for score 2 If scored correct with...

Страница 128: ...ctifier conducts in one direction and does not conduct in the reverse direction W1020452 IC Regulator 1 Check the continuity across the B terminal 2 and the F terminal 1 of IC regulator with resistanc...

Страница 129: ...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 2007 12 S EI EI e C...

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