Kubota 05 Service Manual

KUBOTA

Toro Part No. 01090SL

REPAIRMATE

Workshop Manual

05 Series

Diesel Engine

Reprinted from KUBOTA Workshop Manual, 05 Series Diesel Engine (English language only)

E KUBOTA Corporation 1996

TO

THE READER

This Workshop Manual has been prepared to provide information SERIES. It each section.

•

Mechanism

Information on the construction and function are included part should servicing.

• Disassembling

Under the heading of servicing specifications and periodic inspection items. For each engine section, there are

"Checking

cover procedures, precautions, factory specification and

All engines.

The mark

All the latest production information available at the time of publication.

The right is reserved to make changes

Due to covering many models of this manual,

been specified as one model.

on

the mechanism, service and maintenance of

is

divided into two parts,

be

understood before proceeding with troubleshooting, disassembling and

and Servicing

"General"

and Adjustment",

the engines that have been manufactures since January of

[E]

in

the WSM refers to the said clean engine.

information,

illustrations

"Mechanism"

section comes general precautions, troubleshooting, lists

"Disassembling

and specifications contained

in

and

"Disassembling

and Assembling", and

allowable limits.

all

information at any time without notice.

illustration

serv1cmg

KUBOTA

for each engine section. This

1994

in

this manual are based

or picture being used have not

personnel with

Diesel Engines

and

Servicing"

"Servicing"

are clean exhaust

05

for

which

on

©

KUBOTA Corporation

1996

May

'96

01640Z00040

SAFETY

~h¥m"~~.IW.MW~.IW~~

INSTRUCTIONS

05

SERIES WSM, 01640

~

This

~

the engine

~

It

is essential that you read the instructions and safety regulations before you attempt

~

use this unit.

symbol,

itself

the

industry's

to

warn

of

the

A

SAFETY FIRST

"Safety Alert Symbol",

possibility

of

personal injury. Read these instructions

is

used

throughout

~.IWH~UHH'~~~~UHH'H//H"A

A

DANGER :Indicates

or

serious injury.

A

WARNING:Indicates

or

serious injury.

A

CAUTION :Indicates a

or

moderate injury.

• IMPORTANT :Indicates followed.

an imminently hazardous situation which,

a

potentially

that

equipment

hazardous situation which,

or

property damage

if

could result

if

this

manual and decals on

carefully.

to

if

not

avoided, will result in death

not

avoided, could result in death

not

avoided, may result in minor

if

instructions are

repair

or

not

~

OOOOOF00010

:Gives

helpful

information.

BEFORE SERVICING

(1)

Read

all

instructions and safety instructions in this

manual and

(2)

Clean

(3)

Place

(4)

allow

(5)

Stop

the engine, and remove the key.

(6)

Disconnect the battery negative

on

your engine safety

the work area and engine.

the engine on a firm and

the engine to

cool before proceeding.

AND

REPAIRING

decals.

level

cable.

I

OOOOOZ00011

ground.

OOOOOZ00021

05

SERIES WSM,

01640

SAFETY

INSTRUCTIONS

SAFETY STARTING

(1)

Do not start the engine by shorting across starter terminals.

(2)

Unauthorized modifications to the engine may impair the function and

I

or safety and affect engine life.

OOOOOF00021

OOOOOF00030

OOOOOZ00031

SAFETY WORKING

(1)

Do

not work of alcohol, medication, or other substances or while fatigued.

(2)

Wear

appropriate to the job.

(3)

Use tools appropriate to the work. Makeshift tools, parts, and procedures are not recommended.

(4)

When servicing is performed together by two or more persons, take care to perform

(5)

Do

not touch the rotating or hot parts while the engine

is

running.

(6)

Never remove the radiator cap while the engine is running, or immediately after stopping. Otherwise, hot water radiator cap when cool enough to touch with bare hands. Slowly loosen the cap to first stop to relieve pressure before removing completely.

(7)

Escaping fluid (fuel or hydraulic oil) under pressure can penetrate the skin causing serious injury. Relieve pressure before disconnecting hydraulic or fuel lines. Tighten pressure.

(8)

Wear a suitable hearing protective device such earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.

on

the engine while under the influence

close fitting clothing and safety equipment

all

work safely.

will spout out from radiator.

all connections before applying

Only

remove

as

OOOOOFOOOSO

+

I

-

AVOID FIRES

(1)

Fuel

is

extremely flammable and explosive under certain conditions. sparks in your working area.

(2)

To avoid sparks from always disconnect the battery negative cable first and connect

(3)

Battery gas can explode. Keep sparks and open flame away from the top of battery, especially when charging the battery.

(4)

Make sure that no fuel has been spilled engine.

2

it

last.

Do

not smoke or allow flames or

an

accidental short circuit,

OOOOOZ00041

on

the

OOOOOZ00050

SAFETY

INSTRUCTIONS

05 SERIES WSM, 01640

VENTILATE

the engine must

If

{1)

sure the area

a

in poisonous carbon monoxide.

PREVENT

Sulfuric

{1)

strong enough to

blindness away from eyes, hands and electrolyte medical

WORK AREA

be

well

is

closed area. The exhaust gas contains

ACID BURNS

battery

in

acid

splashed

if

yourself, flush

on

attention immediately.

same

running to

ventilated.

electrolyte

burn

into eyes. Keep

do

run

Never

poisonous.

is

skin, clothing and cause

clothing. If with water, and get

make

work,

engine

the

OOOOOZ00060

is

It

electrolyte

spill

you

OOOOOZ00070

DISPOSE OF

not pour

Do

(1)

into a stream, pond, or lake. Observe relevant environmental

oil,

of waste.

PREPARE FOR

a first

Keep

(1)

times.

Keep

(2)

service, telephone.

FLUIDS PROPERLY

into the ground,

fluids

protection

fuel, coolant, electrolyte

regulations

down

when

and other harmful

EMERGENCIES

fire extinguisher handy

and

kit

aid

emergency numbers for doctors,

fire department near your

hospital

and

a drain, or

OOOOOZOOOBO

ambulance

disposing

all

at

OOOOOF00090

OOOOOZ00090

3

05 SERIES WSM, 01640

SPECIFICATIONS

Model Number

of

cylinders

Type Bore

x

stroke

Total displacement

SAE

net

cont.

SAE

net kW/rpm

intermittent (HP/rpm)

~

0

SAEgross

a.

(I)

intermittent (HP/rpm)

~

0

DIN6271-NA kW/rpm

J:

(I)

-a

DIN6271-NB kW/rpm

m

DIN70020

Maximum Minimum idling speed rpm Maximum torque

Combustion Fuel Governor Direction Injection nozzle

bare

injection

of

Chamber

pump

rotation

mm{in.)

3

cm

kW/rpm (HP/rpm)

kW/rpm

(ps/rpm)

(ps/rpm) kW/rpm

(ps/rpm)

speed

N·m/rpm 53.8/2000 52.8/2400 kgf·m/rpm 5.49/2000 ft-lbs/rpm

Without

Injection timing

I

Firing order Injection pressure Compression ratio Lubricating system Oil pressure indicating Lubricating filter Cooling

system

Starting

system

Starting

support device

Battery Dynamo Fuel

Lubricating

Lubricating capacity

Weight

(Dry)

tor

charging

oil

With

timer

125

mm

(4.92in.) 101

mm

(3.97in.)

kg (lbs)

0905·8

{E)

72

X

73.6

{2.83

X

2.90)

(cu. in.)

rpm

timer

898 (54.86)

12.713000 15.3/3600 14.2J3000 16.8/3600 17.2/3000 20.1/3600 21.6/3000

(17.0/3000) (20.5/3600) (19.013000) (22.&/3600) (23.0/3000) (27.0/3600)

14.9/3000 17.5/3600 16.813000 19.4/3600 20.1/3000 23.5/3600 25.4/3000 29.8/3600 22.4/3000

(20.0/3000)

16.8/3000 19.4/3600 16.713000

(22.5/3000) (26.0/3600) (25.013000)

12.5/3000 15.1/3600

(17.0/3000) (20.5/3600) (19.0/3000) (22.5/3000)

14.3/3000 16.5/3600 15.813000 18.4/3600 19.1/3000 22.1/3600 24.3/3000 28.3/3600 21.3/3000 24.6/3600

(19.5/3000) (22.5/3600)

15.4/3000 18.4/3600

(21

3200

39.71/2000 38.91/2400

18

(0.31

0.35 rad.) before before T.D.C.

a to (0.14 to

0.17 before before T.D.C.

(23.5/3600)

.0/3000) (25.0/3600) (23.5/3000) (27.5/3600)

3800

5.38/2400 6.18/2000 5.95/2400 7.41/2000 7.21/2400

to

20'

21

to

10'

rad.)

12

V,

12V,

MIL-L-46152,

5.1

4.0

23'

(0.37to

0.40 rad.) T.D.C.

Stoll'

(0.16

to

0.19

rad.)

T.D.C. T.D.C.

1-2-3

Pressurized radiator,

0.9

kW

12

V,

65

AH,

150W

MIL-L-2104C,

L (5.39 U.S.qts.,

L (4.23 U.S.qts.,

93.0 (205.0)

01005-8

{E)

3

Vertical,

water-cooled, 4-cycle diesel engine

76

X

73.6 72

(2.99

X

2.90)

1001 (61.08)

{22.513000)

14.013000

(21.5,/3000)

17.313000

60.6/2000

44.712000

18

(0.31

0.35 before before T.D.C. T.D.C.

8 (0.1410 (0.16

0.17 rad.) before before before before before

equivalent

4.49 lmp.qts.)

3.52lmp.qts.)

(26.0/3600) (27.0/3000) (31.5/3600) (34.0/3000) (40.0/3600) (30.0/3000)

21.613600

(29.0/3600)

16.5/3600 16.9/3000 19.9/3600 21.3/3000 25.4/3600 18.8/3000 22.1/3600

(25.0/3600) (26.0/3000)

20.2/3600 21.0/3000 24.3/3600 26.513000 31.3/3600 23.2/3000 26.8/3600

3200

to

rad.)

to

12V,

3800

58.4/2400

43.0/2400

Counter-clockwise (viewed from flywheel side)

20'

21

to

(0.37

0.40 rad.)

10'

9to

0.19 rad.) T.D.C.

forced

1.0kW

22.4/3000 26.1/3600

{30.0/3000) (35.0/3600) (37.5/3000)

(23.0/3000)

(28.5/3000)

72.7/2000 70.7/2400

53.60/2000 52.15/2400 67.46/2000 66.18/2400 59.60/2000

Bosch

Centrifugal mechanical governor

Mini nozzle (DNOPD)

to

23'

18

to

(0.31

0.35 before before T.D.C. T.D.C.

11'

8to

to

(0.14

0.17 rad.) T.D.C. T.D.C.

140

kgf/cm"

Forced lubrication by

Electrical type switch

Full

flow

paper

circulation with water

Electric starting with starter

.

By

glow plug in combustion

I

Diesel

fuel

quality better than

CD

6.0

L (6.34

4.7 L (4.97

V1205-B

{E)

V1205-

T

-B

4

X

73.6 76

(2.83

X

2.90)

1198

(73.10)

(29.0/3000) (34.5/3600) (25.5/3000)

28.0/3000 32.813600 25.0/3000

(27

.0/3600)

(29.0/3000) (34.5/3600) (25.5/3000)

(30.0/3600)

(33.0/3600) (36.0/3000) (42.5/3600) (31.5/3000)

3200

600

Spherical

type

MD

type mini pump

to

20'

21

to

(0.37

rad.)

0.40

10'

9to

to

(0.16

0.19 rad.)

(13.73 MPa, 1991

22:

1

(33.0/3000) (38.5/3600) (29.0/3000) (33.5/3600)

3800

to

rad.)

11'

3200 3800

91.5/2000

9.33{2000

18

23'

(0.31

to

0.35 before before before before T.D.C.

8to (0.14

to

0.17 rad.) T.D.C.

psi)

25.7/3600

(44.0/3600)

89.7/2400 80.8/2000 77.4/2400

9.15/2400 8:24/2000

to

20'

21

to

(0.37to

rad.)

0.40 T.D.C. T.D.C. T.D.C.

10'

9to11'

to

(0.16to

0.19 rad.) before T.D.C.

1-3-4-2

pump

filter

(caltridge type)

pump

(not

included

in

the

12V,1.2kw

chamber

12

V,

70

AH, equivalent

12V,

360W

No. 2-D

(ASTM

D975)

class

U.S.qts.,

lmp.qts.)

U.S.qts., 4.14

lmp.qts.)

110.0

(242.5)

(API)

Quality better than CE

class (API)

5.28 6.7 L

5.90

114.0

(7.08 U.S.qts.,

lmp.qts.)

-

(251.3)

{E)

19.0/3000 22.4/3600

(33.5/3000) (38.5/3600)

3200

to23'

18

to20'

(0.31

rad.)

0.35

8to (0.14to

0.17 rad.) before

T.D.C.

basic engine)

Quality better than

6.0

5.28 lmp.qts.)

4.7

4.141mp.qts.)

110.0

V1305-B

(2.99

1335

to

rad.)

10'

class

L (6.34

L (4.97

{E)

X

73.6

X

2.90)

(81.46)

(30.0/3600)

25.7/3600

(34.5/3600)

28.7/3600

(30.0/3600)

{36.5/3600)

3800

7.89/2400

57.07/2400

21

to

(0.37to

0.40 rad.)

9to (0.16to

0.19

rad.) before T.D.C.

(API)

U.S.qts.,

(242.5)

23'

11'

CD

12

01640Z00070

SPECIFICATIONS

05 SERIES WSM, 01643

Model 01105-B (E) Number

of

cylinders Type Bore x stroke Total displacement

net

SAE cont. (HP/rpm)

net

SAE interrrittent

lii

3:

0

SAE gross kW/rpm

0..

Q)

intermittent (HP/rpm)

~

0

DIN6271-NA kW/rpm

.c

Q)

.><

DIN6271-NB kW/rpm

!!!

CD

DIN70020 kW/rpm

Maximum bare speed rpm Minimum idling speed rpm Maximum torque N·m/rpm 68.3/2000

Combustion chamber Fuel

injection pump

Governor Centrifugal mechanical governor

of

Direction Injection nozzle

Injection timing

Firing order Injection pressure Compression ratio Lubricating system Forced lubrication by pump Oil pressure indicating Electrical type switch

Lubricating filter

Cooling system

Starting system

Starting support device Battery Dynamo for charging Fuel Lubricating

Lubricating capacity

Weight (Dry) kg (lbs) 93.0 (205.0)

rotation

oil

mm(in.)

cm3 (cu. in.)

kW/rpm

(HP/rpm)

(ps/rpm)

kgf·m/rpm 6.96/2000

ft-lbs/rpm 50.3/2000

Without timer With timer

125mm (4.92 in.) (5.39 U.S.qts.,4.491mp.qts.)

101

mm

(3.97 in.) (4.23 U.S.qts.,3.52 lmp.qts.) (4.97 U.S.qts. ,4.14 lmp.qts.) (4.23 U.S.qts.,3.52 lmp.qts.)

16.4/3000 (22.0/3000)

18.7/3000 (25.0/3000)

20.9/3000 (28.0/3000)

16.2/3000 (22.0/3000)

17.6/3000 (24.0/3000)

19.5/3000 (26.5/3000)

0.14to

12

MIL-L-46152, MIL-L-2104C, quality better

3

1123 (68.53)

0.17 rad.

(8to

before T.D.C.

1-2-3

12

V,

V, 65 AH, equivalent

5.1

4.0L

10•)

Pressurized radiator, forced circulation

1.0 kW

L

22:

V1505-B (E)

4

Vertical, water-cooled, 4-cycle diesel engine

78 X 78.4 (3.07 X 3.09)

1498 (91.41) 1123 (68.53)

21

6/3000

(29.0/3000) 20.5/3000 (27.5/3000)

25.013000 (33.5/3000) 23.5/3000 (31.5/3000)

28.013000 (37.5/3000) 26.1/3000 (35.0/3000) 34.7/3000 (46.5/3000)

21.3/3000 (29.0/3000) 20.2/3000 (27.5/3000) 26.8/3000 (36.5/3000)

23.!W300() (32.0/3000) 22.4/3000 (30.5/3000) 29.8/3000 (40.5/3000)

26.1/3000 (35.5/3000) 24.6/3000 (33.5/3000) 32.7/3000 (44.5/3000)

850to950

91.5/2000 86.0/2000 114.7/2000

9.33/2000 8.77/2000 11.7/2000

67.5/2000 63.4/2000 84.6/2000 Spherical type (E-TVCE)

MD

Bosch

Counter-<:lockwise (viewed from flywheel side)

Mini nozzle (DNOPD)

to

0.35 rad. (18 to 20•) before T.D.C.

0.31

0.21 to 0.24 rad. (12 to 14.) before T.D.C.

1-3-4-2

13.73 MPa (140 kgf/cm

1

Full flow paper filter (cartridge type)

with water pump (not included in the basic engine)

Electric starting with starter

12V,

1.2kW

By

glow plug in combustion chamber

12 V, 70 AH, equivalent

12V,

Diesel fuel

!han

(6.34 U.S.qiS., 5.281mp.qts.) (5.39 U.S.qts., 4.49 lmp.qts.) (7.08 U.S.qts.,5.90 lmp.qts.)

6.0L

4.7 L 4.0 L

110.0 (242.5) 97.0 (213.8) 114.0 (251.3)

No

CD

class (API) Quality better than CE class (API)

01105-

3200

type mini pump

0.14 to 0.17 rad. (8 to 10•) before T.D.C. 1-2-3

2

,

1991 psi)

12V,1.0kW

12 V, 65 AH, equivalent

360W

.. 2-D (ASTM D975)

5.1

T-B (E)

3 4

22.5:

L 6.7 L

V1505-T-B (E)

1498 (91.41)

27.2/3000 (36.5/3000)

31.3/3000 (42.0/3000)

1-3-4-2

1

12V,

1.2

kW

56 AH

-

01640Z00100

13

'

MECHANISM

CONTENTS

• FEATURE .........................................................................................................

• ENGINE BODY ................................................................................................ M-3

[1]

CYLINDER BLOCK .................................................................................... M-3

[2]

CYLINDER HEAD ...................................................................................... M-3

[3]

CRANKSHAFT ............................................................................................ M-5

[4] PISTON AND PISTON RINGS ................................................................ M-5

[5] CONNECTING ROD .................................................................................. M-7

[6] ROCKER ARM ........................................................................................... M-7

[7] CAMSHAFT ................................................................................................ M-7

[8]

FUEL CAMSHAFT ..................................................................................... M-9

[9]

FLYWHEEL.. ............................................................................................... M-9

• LUBRICATING SYSTEM ...............................................................................

[1]

GENERAL. ................................................................................................

[2]

OIL PUMP ................................................................................................ M-13

[3]

RELIEF VALVE ........................................................................................ M-13

[4]

OIL FILTER CARTRIDGE. ...................................................................... M-15

[5]

OIL PRESSURE SWITCH ...................................................................... M-15

• COOLING SYSTEM ....................................................................................... M-17

[1]

GENERAL. ................................................................................................ M-17

[2]

WATER PUMP ......................................................................................... M-17

[3]

THERMOSTAT ......................................................................................... M-19

[4]

RADIATOR (not included

[5] RADIATOR CAP ...................................................................................... M-21

in

the basic engine) ......................................... M-19

M-1

M-11 M-11

D INTAKE I EXHAUST SYSTEM ...................................................................... M-23

[1] AIR CLEANER (not included [2]

MUFFLER (not included

• FUEL SYSTEM .............................................................................................. M-25

[1]

GENERAL. ................................................................................................ M-25

[2]

INJECTION PUMP ................................................................................... M-25

(1)

Pump Element... .................................................................................. M-27

(2)

Delivery Valve ..................................................................................... M-27

(3)

Dumping Valve .................................................................................... M-29

(4)

Injection Control .................................................................................. M-29

[3]

INJECTION NOZZLE ...............................................................................

[4]

FUEL FILTER (not included

[5] GOVERNOR ............................................................................................. M-33

[6]

AUTOMATIC ADVANCE TIMER (not included

B ELECTRICAL SYSTEM .................................................................................

[1]

CHARGING SYSTEM ..............................................................................

(1)

Alternator .............................................................................................

(2)

IC Regulator ........................................................................................

• TURBO CHARGER SYSTEM ....................................................................... M-43

(1)

Mechanism .......................................................................................... M-45

(2)

Turbine ................................................................................................ M-47

(3)

Compressor ......................................................................................... M-47

(4)

Bearing ................................................................................................ M-49

(5)

Seals (Piston Rings) ...........................................................................

in

the basic engine) .................................. M-23

in

the basic engine) .......................................... M-23

in

the basic model) .....................................

in

the basic model) ...... M-37

M-31 M-31

M-41 M-41 M-41 M-41

M-51

DIESEL ENGINE

II

FEATURE

05

SERIES

The

05 SERIES ENGINE are

cycle diesel

They are incorporated KUBOTA's foremost technologies. Combustion System}, injection pump and the greater power, low fuel quiet operation .

• NOTE

•

Since January 1994,

engines.

With KUBOTA's

well-known Bosch MD type

well-balanced

consumption,

the combustion chamber

of

traditional

E-

TVCS was developed

N-

TVCS.

exhaust gas which

vertical, water-cooled,

E-TVCS

designs, they give

little

E-

TVCS has been used

of

our

products instead

with an eye toward

is

more environmentally

WSM,

(Three

vibration and

freindly.

The combustion chamber hereinafter refers Model

of

combustion chamber :

to

E-

TVCS.

models

mentioned

N-TVCS (Engine Serial

Number ;

489290

or

lower) E-TVCS (Engine

Serial

Number ;

489291

or

higher)

01642

4

Vortex

for

clean

01640F10070

01640F10080

11900M10011

M-1

DIESEL ENGINE

0 ENGINE BODY

[1]

CYLINDER BLOCK

SERIES WSM, 01640

05

The engine has a high durability tunnel-type cylinder

block

in

which the crank bearing component is a

constructed body.

Furthermore, liner less type, allow effective cooling,

less distortion, and greater wear-resistance.

The noise level is reduced to a minimum because

each cylinder has its own chamber.

11900F10020

[2]

CYLINDER HEAD

11900F1 0030

11900M1 0020

The cross-flow type intake I exhaust ports in this

engine have their openings at both sides of the cylinder

head. Because overlaps

smaller than

in

ports of other types which have openings

of

intake I exhaust ports are

on one side, the suction air can be protected from being heated and expanded by heated exhaust air. The cool,

high density suction air has high volume efficiency and raises the power of the engine. Furthermore, distortion of the cylinder head by heated exhaust gas is reduced because intake ports are arranged alternately.

The combustion chamber is

of

KUBOTA's exclusive

E-TVCS combustion chamber type. Suction air is

whirled to be mixed effectively with fuel, prompting

combustion and reducing fuel consumption.

In

the combustion chamber are installed throttle type injection nozzle and rapid heating sheathed type glow plug. This glow plug assures easier than ever engine starts even at

-15

·c

(5

·F).

11790F1 0040

(1)

Combustion Chamber (7) Depression

(2)

Intake Port

(3)

Exhaust Port

(4)

Nozzle Assembly {A)

(5)

Glow Plug

(6)

Cylinder Head

(8)

Compressed Air

Connect Chamber

to

Combustion

11790F10050

M-3

(A)

11900M10031

DIESEL ENGINE

[3]

CRANKSHAFT

11790F10060

[4]

PISTON AND PISTON RINGS

05 SERIES WSM, 01642

The crankshaft with the connecting rod converts the reciprocating motion of the piston into the rotating motion.

The crankshaft is made of tough special alloy steel, and the journals, pins and oil seal sliding portions are induction hardened to increase the hardness for higher wear resistance.

The front journal is supported by a solid type bearing, the intermediate journal by a split type, and the rear journal by a split type with thrust bearings.

The crankshaft is provided with an oil gallery, through

oil

is

fed

which engine lubricates

it.

to the crankpin portion, and

11790M10040

11790F10070

The piston has a slightly oval shape when cold

(in consideration of thermal expansion) and a concave head.

in

Three rings are installed

(1)

The top ring

is a keystone type, which can stand

grooves

against heavy loads, and the barrel face

in

the piston.

on

the ring fits

well to the cylinder wall.

The second ring

effectively prevents the oil from being carried

The oil ring

{3)

(2)

is

an

undercut type, which

up.

has chamfered contact faces and

an expander ring, which increase the pressure of the oil ring against the cylinder wall.

on

Several grooves are cut

dissipate

(1) (2) (3)

and

Top

Ring Second Ring Oil Ring

to prevent scuffing.

the top land to help heat

(4)

Depression

(5)

Valve Recess

11900F10040

11900M10041

M-5

DIESEL ENGINE

[5]

CONNECTING ROD

05 SERIES WSM, 01640

11790F1 0090

[6]

ROCKER

11900F10060

[7]

CAMSHAFT

ARM

The connecting rod

(2)

is

used to connect the piston

with the crankshaft.

The big end of the connecting rod has a crankpin

bearing bushing

(1) (2)

(1

(3)

(split

type) and the small

(1)

(solid

type).

Small

End

Connecting Rod

Bushing

(3)

Crankpin Bearing

The rocker arm assembly includes

),

rocker arm brackets

(4)

and rocker arm shaft

end has a

small

11790M 10060

the rocker arms

end

(5), and converts the reciprocating movement of the push rods to exhaust

rocker arm shaft, which serves as a rocker arm and the entire system are

an

open

valves.

Lubricating

I

close

movement

oil

pressurized through the bracket to the

of

the intake and

fulcrum

so that the

lubricated

sufficiently.

(1)

Rocker Arm

(2)

Lock Nut

(3)

Adjusting Screw

(4)

Rocker Arm Bracket

(5)

Rocker Arm Shaft

11900M10070

11900F10010

The camshaft

journal

(1) (2)

and cam sections are

The

journal

Cam Gear Camshaft Stopper

(3)

is made of

sections are

special

chilled

cast iron, and the

to resist wear.

force-lubricated.

(3)

Camshaft

11900M10050

M-7

DIESEL ENGINE

[8]

FUEL CAMSHAFT

05 SERIES WSM, 01640

01640F10090

[9]

FLYWHEEL

The fuel camshaft

of

movement

the injection pump.

The fuel camshaft is made

(2)

controls the reciprocating

of

carbon steel and the cam sections are quenched and tempered to provide greater wear resistance.

(1)

Injection Pump Gear

(2)

Fuel Camshaft

(3)

Automatic Advance Timer (not included in the basic model)

(A) Without Timer (B) With Timer

11900M10061

11790F10140

The flywheel stores the rotating force

in

the combustion stroke as inertial energy, reduces crankshaft rotating speed fluctuation and maintains the smooth rotating conditions.

is

The flywheel periphery

inscribed with the marks showing fuel injection timing angle lines and top dead center mark TC.

The flywheel has gear teeth around its outer rim,

which mesh with the drive pinion

(1) Crankshaft (2) Aywheel

of

the starter.

(3) Flywheel Screw

11900M10081

M-9

DIESEL ENGINE

fJ

LUBRICATING SYSTEM

[1]

GENERAL

05 SERIES WSM, 01640

Rocker Arm

(1)

Oil

Pressure Switch

(2)

Rocker Arm

(3)

Valve

(4) (5)

Governor Idle

(6)

Crankshaft

(7)

Oil

(8)

Oil Strainer

(9)

Relief Valve

(10)

Push Rod

(11) (12) Tappet

Camshaft

(13)

Piston

(14)

Connecting Rod

(15)

Oil Filter

(16)

Shaft

Gear

Pump

Cartridge

Shaft

11900F10070

This engine's lubricating strainer cartridge

through the cartridge, where it

forced

The

(9),

(16)

oil

pump sucks

oil

to

crankshaft

oil

pump

and

oil

strainer

pressure switch

is

(7),

system consists of

(8),

relief valve

lubricating

and

the

oil

flows

further

filtered.

connecting rods

(2).

oil

from the

down

(1

0),

oil

to

the filter

Then the

(15),

idle

oil

filter

pan

oil

gear

oil

(6),

governor shaft

shaft

(3)

to

lubricate each part.

Some

leaking

part of

and

these parts : pistons

is

connecting exhaust

rods,

valves

M-11

(5),

camshaft

oil, splashed

(13)

and

by the crankshaft or

dropping from gaps of each part,

(14),

cylinders, small

tappets

(4)

(12),

and

timing gears.

push rods

(11),

rocker

arm

lubricates

ends of

inlet

and

11900M10090

DIESEL ENGINE

[2]

OIL

11900F10080

PUMP

(A)

(B)

The

oil

pump

Inside

eccentrically

the pump body, the 1

engaged with the

The inner rotor

in

this engine

is

driven

05 SERIES

is

a trochoid pump.

0 lobe

11

lobe

by

the crankshaft, which

WSM,

inner rotor

outer rotor

01640

(2}

in

turn

is

(1).

rotate the outer rotor.

When the inner rotor rotates, the outer rotor rotates differences space between

the

in

the same direction. The two rotors have

in

lobe

number and center, which generates

lobes

as

At position (A), there

inlet

port.

As

the rotor rotates towards position, the

shown

is

little

in

the figure.

space between

also

lobes

in

space between the lobes becomes larger, creating a negative pressure which sucks

Outside the space between the and

oil

pressure increases. At position

inlet

port, as shown

lobes becomes

in

oil.

in

position (8), the

gradually smaller,

(C),

oil

discharged from the outlet port.

(1)

Outer

(2)

Inner

Rotor

(3) (4)

Inlet Port

Outlet

Port

11900M10101

is

[3]

RELIEF

11900F10090

VALVE

The relief valve lubricating system due valve

is a

ball

type direct acting relief valve,

suited for

(2)

low

pressures.

When

oil

pressure exceeds the upper limit, the

is pushed back

escapes.

(1)

Spring

(2)

Steel Ball

prevents the damage of the

to

high

oil

by

the pressure

(3)

pressure. This

oil

Valve

Seat

and

relief

and

is

best

the

11900M10111

ball

oil

M-13

DIESEL ENGINE

[4]

OIL FILTER CARTRIDGE

05 SERIES WSM, 01640

11900F10100

Impurities components chemical properties of the in

force-fed engine

removal

When the filter element pressure

in

engine

as

they pass through the filter element

in

inlet line builds

oil

well

as

oil

are absorbed

can

cause to wear

impairing the physical

oil

itself. Impurities contained

on

the filter paper for

is

clogged

up

by

98

kPa (1.0 kgf/cm

and

psi) more than the outlet line, the bypass valve and

the

oil

flows from inlet to outlet bypassing the filter

element.

(1)

Filter Element

(2)

Bypass Valve

and

(1).

(2)

seize

and

the

2

,

opens

oil

14

01

11900F1

[5]

l

11790F10180

01

OIL PRESSURE SWITCH

{A)

l

{B)

The

oil

block,

to

pressure

If the psi), the operator.

pressure switch

warn the operator that the lubricating

is

poor.

oil

pressure falls below 49 kPa (0.5 kgf/cm

oil

warning lamp will light

In

this case, stop the engine immediately

is

mounted

check the cause of pressure drop.

Terminal

(1)

(2) Insulator

Spring

(3) (4) Rubber Gasket

(5)

Contact Rivet

(6) Contact

(7)

Oil Switch Body

(A)

(B)

At (0.5 At

Oil

Pressures

kgf/cm

Proper

11900M10120

on

the cylinder

up,

warning the

2

7

psi)

,

Oil

Pressure

11790M10152

of

49 kPa

or

2

and

Less

oil

,

7

M-15

DIESEL ENGINE

II

COOLING SYSTEM

[1]

GENERAL

05

SERIES WSM, 01640

Radiator

(1)

Water Pump

(2)

Suction

(3)

Thermostat

(4)

Cylinder Head

(5)

Cylinder Block

(6}

Fan

11900F10110

The cooling

included

in

suction fan

The water is fan set behind the radiator core to improve

system consists of a radiator

the basic engine), centrifugal

(3)

and thermostat

cooled

through the radiator core, and the

pulls cooling

cooling.

The water pump sucks the cooled the cylinder block

(2]

WATER PUMP

11900F1

0441

and draws out the hot water. Then the

water pump

(4).

air through the

water, forces it into

(1)

(not

cooling of water, a thremostat is provided

(2),

is repeated. Furthermore, to control

in

the system. When the thermostat opens, the water moves radiator, but when it

closes,

the water moves toward the water pump through the bypass between thremostat and water pump. The opening temperature of thermostat is approx.

belt. water pump from its center of the water pump into the water jacket

(1) (2)

71

·c

(160

"F).

The water pump is driven

Water

cooled

in

the radiator

lower portion and is sent from the

impeller

in

the crankcase.

Bearing Unit

Water Pump Body

by

the crankshaft via a V

is

sucked into the

(4)

radially outward

(3)

Mechanical

(4)

Water Pump

Seal

temperature

directly

11900M10131

Impeller

11900M10141

to

M-17

DIESEL ENGINE

[3]

THERMOSTAT

05

SERIES

WSM, 01640

11790F10210

(A)

(B)

The thermostat maintains the temperature. KUBOTA's engine uses a wax thermostat. Wax solid at

low

temperatures, expands

(A) At low

temperature

As the thermostat in

the engine through the water return pipe without

running through

(B) At high temperature (higher than

to

the radiator.

Air

in

the water jacket escapes to the radiator side

leak hole

is

enclosed

temperatures, but turns

and

(lower than

is

closed, cooling water

(8)

of the thermostat.

When the temperature of

·c

(160

·F),

wax

in

the pellet Because the the valve cooling

(1)

Seat

(2)

Valve

(3)

Pellet

(4)

Spindle

(5)

Synthetic Rubber

(2)

water

spindle

is

(4)

is fixed, the pellet

is

separated from the seat

sent to the radiator.

cooling

in

the

opens the

cooling

turns liquid

(6)

Wax (7) (8) (9)

(Solid) Spring Leak Wax (Liquid)

water at correct

pellet

pellet.

The wax

liquid at high

valve.

71

oc,

160

circulates

71

OC,

160

water exceeds

and expands.

(3)

is

lowered,

(1

),

and

Hole

11790M10182

type

is

OF)

71

then

[4]

RADIATOR

11790F10220

(not included

in

the basic engine)

The radiator core consists of water carrying tubes

and

fins

water

in fins. KUBOTA's engine uses corrugated fin type core which has a Clogging

(1)

Cooling

(2)

Tube

{3)

at a right

the tubes

is

minimized by the

Air

light

is

weight

angle

to the tubes

{2).

Heat of hot

radiated from the tube walls

and

high heat transfer rate.

louverless

(3)

Fin

corrugated fins.

11790M10191

(2)

and

M-19

DIESEL ENGINE

[5]

RADIATOR CAP

05 SERIES

WSM,

01640

11790F1

(A)

(B)

0230

The radiator cap pressure of the kPa (0.9 kgf/cm

cooling system at the specified

is

for sustaining the internal

2

,

13

psi) when the engine

operation. The cap consists of a pressure

vacuum

steam, air bubbles

water lowers the

(1) (2)

valve

(2),

Cooling water

and

as its boiling temperature rises, generation of

will

Pressure Vacuum

Valve

valve springs, gasket, etc.

is

pressurized by thermal expansion of

be

suppressed. (Air bubbles

cooling effect.)

(A) When radiator

pressure

(B) When radiator

pressure

is

level

valve

in

cooling

internal

high

internal

negative

11790M10201

is

(1)

88

in

a

M-21

DIESEL ENGINE

II

INTAKE

[1]

AIR

CLEANER (not included

I

EXHAUST SYSTEM

in

the basic engine}

05 SERIES WSM, 01640

01640F10100

[2]

MUFFLER (not included

The air maintenance. Sucked air is caused to flow

way with fin (1). As a circulate

in

the

(5).

absorbed by the entering the engine.

(1)

Fin

(2)

Air Cleaner

(3)

Air

in

the basic engine}

High temperature and high pressure exhaust gas is intermittently pressure waves inside the exhaust pipe which

in

noise.

The

This and outer tube The

glass wool placed main body, absorbs the exhaust noise of higher frequency.

cleaner

around the circumference and enter the

baffle

cover

Minute dust, while circulating

Body

Filter Element

discharged by

muffler

is

a dry-cyclone

result,

(6)

and accumulate

element

is used to reduce this noise.

consists of a perforated inner tube (3),

glass wool

between the outere tube and

heavier dust

{3)

and thus prevented from

(4)

To

(5)

Dust Cup

(6)

Baffle Cover

fuel

combustion generating

(2), main body

type for easy

in

the air flow, is

Cylinder

in

a whirling

particles

holes

the dust cup

01640M10010

will result

(4)

(1),

etc.

01640F10110

(1)

Main Body

(2)

Glass Wool

(3) (4)

Outer

Inner

Tube

01640M10020

M-23

DIESEL ENGINE

II

FUEL SYSTEM

[1]

GENERAL

05

SERIES

(1)

Fuel (2) (3) (4) (5) (6) (7)

Tank

Fuel Filter Injection Injection Injection Nozzle Fuel Overflow Pipe Fuel

Feed Pump

WSM,

Pump Pipe

01640

01640F10540

Fuel

from the

filter

(2),

and

impurties such

The

fuel

opening pressure (13.73 to

2

cm

,

1991

fuel

tank

(1)

passes through the

then enters the injection pump

as

dirt, water,

etc.

are removed.

pressurized by the injection pump to the

14.71

MPa,

to 2133 psi), of the injection nozzle

injected into the combustion chamber.

[2]

INJECTION

PUMP

140

(3)

to

150 kgf/

fuel

after

(5)

Part

of the

lubricates

fuel fed to the injection

the moving parts of the nozzle, then returns to the overflow pipe

(6)

holder.

is

A Bosch

pump.

The the tappet causing the

(1)

Control

(2)

Tappet Roller

(3)

Dumping

(4)

Delivery Valve Holder

MD

type mini pump

It

is

small, lightweight

plunger

(7) roller fuel

to

Rack

Valve

plunger inside the

fuel

tank through the

from the upper part of the

11900M10151

is

used for the injection

and

with a

(2)

by

be

delivered

easy to

left-hand lead

means of the

into the injection

(5)

Delivery Valve

(6)

Cylinder

(7)

Plunger

handle.

reciprocates via

fuel

nozzle

camshaft,

nozzle.

(5)

fuel

11900F10150

11900M10170

M-25

DIESEL ENGINE

(1) Pump Element

05

SERIES WSM,

01640

11790F1 0260

(2)

Delivery Valve

11790F10270

The pump

and cylinder

The sliding

maintain injection pressure at engine

the driving face

(3)

is rotated by the movement of the

increase or decrease of

As

described above, the plunger

have the

(1) Pump Element (2)

Cylinder

(3)

Plunger

(4)

Feed

Hole

The

delivery valve

4

A

2

and delivery valve

The

delivery valve performs the following functions.

1.

Reverse

If

the when the delivery avoid this, the interruption by flow, thus keeping

element

(1)

is consist of the

(2).

surfaces are super-precision machined to

low

speeds.

(7)

fits

in

the

control sleeve,

control

fuel delivery.

(3)

is machined to

slot

(5)

and the

flow

fuel flow

plunger lowers, the time

start and the

delivery

delivery valve

control

consists of the

seat

(2).

groove

(5)

Slot

(6)

Control

(7)

Driving Face

(6).

Groove

delivery valve

preventing function

reverse from the injection

lag

between the next

nozzle

injection start increases. To

chamber to injection pipe

(1)

prevents this reverse

fuel always filled

in

the

plunger

(3)

Since

the

plunger

rack to

11790M10231

(1)

nozzle

side

and

pipe.

2.

Suck-back function

After

completing the lowers, delivery valve seat surface

and the relief plunger

seat

(3) During this time, the amount of is

sucked back from inside the injection pipe, the pressure inside the pipe is reduced, thus improved injection shut off and preventing after

(2).

seats

fuel delivery,

The

valve further lowers until

firmly

the

(4)

end contacts the

the

delivery valve

fuel corresponding to

leading

its

seat.

(A)

to an

leakage

dribbling.

(1)

Delivery Valve

(2)

Delivery Valve Seat

(3)

Seat Surface

(4)

Relief Plunger

11790M10241

M-27

DIESEL ENGINE

05

SERIES

WSM,

01640

(3) Dumping

11790F10280

Valve

(4) Injection Control

1.

At

fuel

injection

2

Since

spring,

as without dumping

dumping

fuel

is pressure-fed to injection

valve

is pushed up to press

valve.

nozzle

the

the same

2. At suck-back

At

suck-back returns through dumping injection is apt to occur reaction

of

suck-back

As a result perfectly clogging, durability

1.

No

fuel delivery

At

the engine stop position lengthwise slot (1) on the hole

(5). And the

hole

during the entire stroke

The

pressure in the delivery

up

and no

2.

Fuel delivery

The

plunger

by

delivery valve

valve orifice.

by

after fuel

reflex

injection fuel

Generally

second

pressure due to

sudden pressure drop when changing into

by

delivery valve

of

by

dumping valve and

of

delivery

fuel

can be forced to the injection

(2) is rotated (see figure)

from high injection pressure.

preventing this second injection

dissolving nozzle

injection

nozzle

of

the

control

plunger

(2)

aligns

chamber (4) is

of

the

plunger.

chamber does not

is improved.

11790M10251

rack (3), the

with the feed

led

to the feed

build

nozzle.

by

the

control

rack (3).

When the closed. up and forcefeeds the

the

control

The

plunger

The pressure

groove

amount

of

(6)

the

is pushed up, the feed hole

in

the delivery

fuel

to

meets the feed

fuel

corresponds to

the

injection

chamber (4)

nozzle until

hole

(5).

the

distance

(5) is

builds

"A".

(1)

(2) (3)

Slot

Plunger

Control

Rack

(4)

Delivery

(5)

Feed

(6)

Control Groove

Chamber

Hole

11900F10160

11900M10181

M-29

DIESEL ENGINE

(3]

INJECTION NOZZLE

05 SERIES WSM, 01640

11790F1

(4]

0300

FUEL

FILTER (not included

in

the basic

This nozzle

is

throttle-type. The needle valve pushed against the nozzle body via the

push

rod

(5).

Fuel

pressurized by the injection pump pushes the needle valve into the sub-combustion chamber.

Excessive flow

through the eye joint

passes from nozzle holder center

and

the fuel

fuel tank.

The injection pressure is 13.73 to

kgf/cm

Filter

Rod

2

,

1991

to 2133 psi),

(3).

Body

(6) (7)

(8)

(9)

(10)

150

adjusting washers

( 1 )

Bar

(2)

Nozzle Holder

(3)

Adjusting Washer

(4)

Nozzle Spring

(5)

Push

model)

(7)

by

the nozzle spring

up

and then

is

overflow pipe to the

14.71

MPa

and

is

adjusted with

Retaining Nut Nozzle

Body

Needle

Valve Heat Seal Gasket

11790M1

(8)

is

injected

(140

to

0272

01640F10120

(B)

Each

moving part of the injection pump and nozzle extremely precision machined, and clearances of their sliding parts are extremely small. Fuel itself serves lubricating to completely remove water

This fuel serves accumulated

Air vent

oil.

For this reason, it

is

and

dirt contained

extremely important

filter, which uses very fine filter paper,

to

separate

in

plug

and

filter dirt

in

fuel

the tank.

is

fitted to the cock body. Before

in

and

as

fuel.

water

starting or after disassembling and reassembling, loosen

this plug

(1)

(2) (3) (4)

(5)

and

bleed the air

Cock Body (A) Inlet Filter Element Filter

Cup

Retaining Ring

Fuel

Cock

in

the fuel

(B)

Outlet

system.

01640M10030

is

M-31

DIESEL ENGINE

[5]

GOVERNOR

05 SERIES WSM, 01640

This mechanism maintains engine speed at a constant stable idling and regulates controlling

the fuel

maximum speed)

flyweight's

level

even under fluctuating

the

fuel

injection

This engine uses a

injection rate at

by

centrifugal

loads,

maximum engine speed by

rate.

mechanical

all

speed ranges (from utilizing force

and

governor that

the

balance

spring tension.

provides

between the

A governor shaft for monitoring engine speed independent of the injection pump shaft twice the speed of

response to load fluctuation

conventional

types, providing better

and

delivering

rotates at

engine output.

(1)

Start

(2)

(3)

(4)

(5)

Spring Governor Spring 1 Governor Spring 2 Fork Lever 1 Fork Lever 2

Fork Lever

(6)

Flyweight

(7)

Torque Spring

(8)

Governor

(9)

(10) Governor

Shaft

Shaft Sleeve

controls idling

to

is

greater

11900F1 0170

11900M10190

M-33

DIESEL ENGINE

11900F10180

05 SERIES WSM, 01640

•

At

Start

As

no

centrifugal tension of start spring the starting position,

force

is

applied to flyweight

(1)

permits control

supplying

rack to move to

the amount of

required to start the engine .

•

At

Idling

Setting during engine rotation permits the governor spring 2

(12)

speed control lever

(3),

start spring

(11)

to the

(1)

and

idling

low

tension of

idle limit

to balance the centrifugal force of flyweight without activating high tension governor spring 1 this

way,

the

fuel

injection rate

ensure

•

injection fuel setting

stable

idling.

At High

Speed Running with Overload

Governor spring 1

rate.

To maintain the required engine speed,

is

supplied and

load

according

by

balancing

(2)

springs 1 and 2 with the centrifugal

In

addition,

idle limit spring

can

be

controlled

and

2

(3)

control the

to

the speed control

the tension of governor

force of flyweight

(12)

provides

engine rotation.

(7),

low

fuel

position

spring

(7)

(2).

In

to

fuel

lever

(7).

stable

11900F10190

•

During

At

Overload

load increases, the engine speed decreases, reducing the flyweight's centrifugal force. Governor springs 1 and

2

(2)

and

(5),

increasing the

2

(3},

therefore,

fuel

pull

fork

levers

1

injection rate and

(4)

maintaining engine speed.

If

engine speed decreases due to a further increase

in

load, fork

limit bolt,

lever

2

(5)

will

come

in

stopping a further increase

contact with the

in

the

fuel

injection

fuel

rate.

Torque spring

moves the

lever

increase, thereby boosting torque

(8)

incorporated

in

the direction of

in

fork

lever 1

fuel

injection rate

and

providing greater

(4)

engine output.

(1)

Start

(2) (3) (4) (5)

(6) (7)

Spring Governor Spring Governor Spring

Fork Lever 1 Fork Lever 2 (12) Fork Lever Ayweight

1

2

Shaft

Torque

(8)

Governor

(9)

Governor

(10)

Speed Control Lever

(11)

Idle

Limit

Fuel

(13)

(14)

Limit Adjust

Control Rack Pin

Spring

Shaft Sleeve

Spring

Bolt

11900M1

0200

M-35

DIESEL ENGINE

[6]

AUTOMATIC

01640F10090

01640F10130

ADVANCE

TIMER

05

SERIES WSM,

(not included

Fuel

fed by the injection pump passes through the

injection pipe to the injection nozzle.

for

fuel

to flow from the injection pump to the almost required for injected maximum pressure is

of

ignition timing is delayed, and vice verse.

constant, irrespective

engine speed. Therefore, as engine speed increases,

in

the basic

model)

The time required

of

enginespeed. The time

fuel

to ignite, burn and reach the

also virtually constant, irrespective

If

fuel

nozzle

injection

timing is fixed, it is impossible to provide optimum injection timing

at

each engine speed.

To

solve

problem, an automatic injection advance timer is used to

control fuel

injection timing automatically. This engine uses a mechanical timer for this purpose which utilizes the

balance

(generated by engine rotation) and

The structure

between the flyweight's centrifugal force

spring tension.

of

the timer is

as

illustrated

figure.

Hub bolt

side

of

(1)

by key and nut. Driving pump gear (2). Driving is in contact with the curved surface

Timer

hub

bolt

(8)

is inserted into the hole located

flyweight (6). Hub

spring

(5)

is installed

(8).

(7)

is secured to

plate

(3)

bolt

(4)

securing driving plate

between driving

is

bolted

of

fuel cemshaft

to injection

flyweight (6).

bolt

Therefore, torque is transmitted from the crankshaft

to the

fuel

Crank gear gear (2) Flyweight

camshaft via the

(9)

- Idle gear 1

Driving plate

(6)

-

Hub

follwoing route :

(3)

bolt

(8)

-

(1

0) -

- Driving

Hub

(7)

Injection pump

bolt

- Fuel

camshaft

(1)

01641

is

this

in the

on one

(3)

(4) and

(4)

-

(1) (2) (3) (4) (5) (6)

M-37

Fuel

Camshaft lnejction Pump Gear Driving

Plate

Driving

Bolt Timer Spring Flyweight

(7)

Hub

(8)

Hub

(9)

Crank Gear

(1

0}

Idle

(11}

Idle

(12}

Governor Gear

Bolt

Gear 1 Gear 2

01640M10040

DIESEL ENGINE

01640F10140

-

05

SERIES

•

During

As

small, spring force presses the flyweight inward, permitting driving flyweight at the position shown

(4)Driving

•

During medium- to high-speed travel

As

applied to hub

the position (where driving bolt

flyweight

Therefore, since the injection pump gear angle

(6)Fiyweight

low-speed travel

the

centrifugal

Bolt

engine speed increases, the

flyweight

bolt

(8)

in

the direction of the arrow, thereby rotating

(6))

through

0,

injection timing

force

applied

bolt

(4)

to come

(8)Hub

(6)

increases, expanding it around

angle 0 as shown

fuel

(2)

in the rotational direction through

is

advanced.

to flyweight

in

the figure.

Bolt

(4)

is in contact with

camshaft rotates from

WSM,

in

contact with

01640M10050

centrifugal

in

the figure.

01641

(6)

force

is

01640F10150

01640M10060

M-39

DIESEL ENGINE

II

ELECTRICAL SYSTEM

[1]

CHARGING SYSTEM

(1) Alternator

05

SERIES

WSM,

01640

01640F10160

(2)

IC

Regulator

01640F10170

A compact alternator with an IC

having the

•

Approximately 26 % lighter and standard alternator.

•

Cooling performance and safety have been improved by incorporating the fan

• IC

•

The rectifier, easy alternator.

An

othere semiconductor elements instead of the relays in a conventional regulator. Stable achieved by cutting off the field current.

IC

•

The control voltage does not change over time, so the need for readjustment is eliminated. Since

are no moving parts,

durable and resistant

•

The overheat compensation characteristics ensure that the control voltage is reduces as the temperature

rises, so the battery is charged at just the right level.

The internal circuitry of the

the diagram.

monolighic is extremely complex, so it is shown as simply

circuit".

Tn

and

flashing

The

the alternator output voltage, and detacts any drop in terminal voltage or breaks in the rotor coil.

(1)

IC

following

combining the cooling fan with the rotor and

regulator is fitted inside the alternator.

to

remove, making it easier to service the

IC

regulator uses solid state transistors, chips or

regulators have the

I

C.

acts as the contacts

Tr2

acts as the charge lamp relay controlling

of

the charge lamp.

M.IC

Regulator

characteristics:

I

rotor unit inside the alternator.

IC

regulator and similar components are

following

IC

regulators are extremely

to

vibration.

It

consists

(The internal circuitry of the monolithic

circuit controls

of

a hybrid

controlling

Tr1

regulator is used,

17

%

smaller than a

01640M90010

characteristics are

characteristics:

IC

regulator is shown in

IC incorporating a

the field current,

and

Tr2,

and monitors

01640M90020

there

IC

"M.IC

the

L

M-41

DIESEL ENGINE

6

TURBO

CHARGER

SYSTEM

05

SERIES WSM,

01640

01640F10180

(1)

Actuator

(2)

Turbine Housing

(3)

Snap

(4)

Ring

Lock Nut

This turbo charger consists compressor mounted on a flow turbine driven by exhaust

The turbo charger is to

the engine than for a non-supercharged engine, which

(5) (6)

(7)

(8)

common

gas

capable

Compressor Turbine Wheel

Piston Ring

Bearing

basically

of

Wheel

a

shaft with a

from the engine.

of

supplying

centrifugal

double

far

more air

is without such a charger.

In applications low, the turbo charger is

where the

capable

boost

of

pressure is

relatively

reducing the smoke

(9)

Snap

(10) (11) (12)

Ring

Snap

Ring

Piston Ring

Oil

Deflector

(TD025) (14)

concentration, the concentration

(13)

Thrust

0-ring

(15)

Thrust Bearing

(16)

Thrust Ring

in

Sleeve

the

cylinder, fuel consumption, and deterioration in performance elevated

terrain

by

increasing the

amount

of

air

engine.

In applications charger is engine output by increasing the engine, in addition

where the

capable

to

boost

pressure is high, the

of

providing a

large

amount

increase in

of

air into the

the above mentioned advantages.

01640M10070

to

at

the

M-43

DIESEL ENGINE

(1) Mechanism

(r

01640F10190

c

___

I

_l

__

_

05 SERIES WSM, 01640

•

Turbocharger Works

While the engine is running, exhaust gas passes

through the exhaust manifold to rotate the turbine wheel

(3)

of

the turbocharger

Rotation wheel on the same shaft. As the compressor wheel rotates, air is sucked in, compressed, and sent into the cylinder.

The higher density of the compressed air per cylinder volume results in increased output compared with nonturbocharged engines of the same displacement.

•

Advantages

Turbocharged engine have the following advantages:

1.

Despite the increase in output, there is little increase in friction loss. Therefore, good mechanical efficiency is insured.

2.

During overlap (when both the suction and exhaust valves are open), compresed air forces out exhaust gas and fills the cylinder with fresh air. This increases combustion efficiency.

3.

Improvements in mechanical and combustion efficiency lead to a lower fuel consumption.

(1)

Air

(2)

Turbocharger

(3)

Turbine

(4)

Waste Gate

(5)

Exhaust

of

the turbine wheel rotates the compressor

(7)

at the same speed because both wheels are

Cleaner

Wheel

Valve

(2)

at high speed.

(6)

Intake Valve

(7)

Compressor

(a)

Air

(b) Exhaust Gas

Wheel

01640M10080

M-45

DIESEL ENGINE

(2)

Turbine

05 SERIES

WSM,

01641

01640F10200

(b)

This is a radial flow The turbine

wheel

and shaft is designed to

turbine.

wheel assembly

(3) uniting the turbine

balance

even at high

speeds.

The turbine housing

As

the passage becomes

gas flow rate increases so that the turbine

(2)

has a vortex gas passage.

smaller (from

"A"

to

"B"},

is

rotated at

the

high speeds.

The turbine back

housing and bearing (floating metal)

plate

(1)

prevents the bearing

inside from being

directly exposed to the heat of the exhaust gas on the

turbine

(1) Turbine Back

(2)

(3) Turbine

wheel

side.

Turbine Housing

Plate

Wheel Assembly

(a)

From Cylinder

(b)

To

Exhaust

Muffler

01640F10210

(3)

Compressor

01640F10220

01640M1

A

radial flow

compressor is used.

The compressor consists of a cast compressor

0090

wheel

(1}, bearing housing (3}, insert (2), compressor cover (4).

Air is sucked at high speed by the compressor

As

it passes through the spiral

its speed is reduced to the proper

the

cylinder.

The compressor

wheel is a precision-cast component, which maintains the proper high speeds.

Its blades

are curved backward to ensure

passage in the housing,

level

and forced into

balance even at

wheel.

the highest performance.

The compressor housing is designed to

air flow drawn by the

(1) Compressor (2)

Insert

(3)

Bearing Housing

(4) Compressor Cover

Wheel

wheel

and increase its pressure.

(a)

To

Cylinder

(b) From

the

Air

regulate the

Cleaner

01640M10100

M-47

DIESEL ENGINE

(4) Bearing

01640F10230

05 SERIES WSM, 01640

The shaft rotates at a very high speed-tens of

thousands of revolutions per minute. To withstand high

(5)

speeds, the bearings

on

bearings float housing

(4)

a film

and

rotate to reduce the sliding friction.

The shaft also receives thrust force

on

direction)

the compressor side from both the turbine

and compressor wheels. This load

(3)

bearing ring

fitted between the thrust sleeve

(2)

which

is

secured to the shaft

use floating metals. These

oil

between the shaft

is

borne by the thrust

and

(in

(1)

and

turns together

the axial

and

bearing

thrust

with the shaft. ·

Lubricating

fed from the engine's

oil

pump enters

oil

the bearing section through the top of the bearing

and

housing

passes through the internal passages,

lubricating the bearings. After that, it returns to the

engine from the bottom of the bearing housing.

(1)

Thrust Sleeve

(2)

Thrust Ring

(3)

Thrust Bearing

{4) Bearing Housing

(5)

Bearing

(a)

(b)

From

To

the

Engine

Oil

Pump

01640M10110

M-49

DIESEL ENGINE

(5) Seals (Piston Rings)

05 SERIES WSM, 01640

01640F10240

\

@

When lubricating oil leaks on the turbine compressor wheel side, it will adhere housing. the oil carbon. Such contamination will destroy the balance the rotating shaft and prevent normal operation.

To

prevent this problem, lubricating oil is sealed

the follwoing parts:

the

On

* A piston ring (1} is placed *

The

shaft itself has an oil fling portion (2}.

On the compressor wheel side

* A piston ring (3} is placed

may

then be contaminated with dust

turbine wheel side

over

to

the wheel

the shaft.

the thrust sleever (5}.

or or or of

by

* The oil deflector (4}, which is placed on the thrust

sleeve (5}, prevents oil from leaking to the piston ring side.

In addition, oil is prevented from leaking to the

outside by a seal ring (square rubber ring} placed

between the center housing and the back plate.

(1)

Piston Ring (on

the Turbine Side)

(2)

Oil Fling Portion

(3)

Piston Ring (Compressor Side)

Oil Deflector

(4)

Thrust Sleeve

(5) (6)

Thrust Ring

01640F10250

01640M10120

M-51

SERVICING

CONTENTS

• GENERAL .........................................................................................................

[1]

ENGINE IDENTIFICATION ........................................................................

(1)

Model Name and Engine Serial Number ...............................................

(2)

Cylinder Number ...................................................................................

[2]

GENERAL PRECAUTION ......................................................................... S-3

[3]

TIGHTENING TORQUES .......................................................................... S-5

(1)

Tightening torques for special use screws, bolts and nuts .................... S-5

(2)

Tightening torques for general use screws, bolts and nuts ................... S-5

[4]

TROUBLESHOOTING ................................................................................ S-8

[5]

SERVICING SPECIFICATIONS .............................................................. S-19

(1)

Engine Body ........................................................................................ S-19

(2)

Lubricating System .............................................................................. S-25

(3)

Cooling System ................................................................................... S-25

(4)

Fuel System ........................................................................................ S-26

(5)

Electrical System ................................................................................. S-27

[6]

MAINTENANCE CHECK LIST.. .............................................................. S-44

[7]

CHECK AND MAINTENANCE ................................................................ S-47

(1)

Daily Check Points .............................................................................. S-47

(2)

Check Point of Every 50 hours ............................................................ S-49

(3)

Check Point of Every 100 hours ..........................................................

(4)

Check Point of Every 800 hours .......................................................... S-57

(5)

Check Point of 1500 hours (Serial

[8]

SPECIAL TOOLS ..................................................................................... S-59

• ENGINE BODY .............................................................................................. S-73

CHECKING AND ADJUSTING ..................................................................... S-73

DISASSEMBLING AND ASSEMBLING ........................................................ S-75

[1]

DRAINING WATER AND OIL.. .............................................................. S-77

[2]

EXTERNAL COMPONENTS ................................................................... S-77

[3]

CYLINDER HEAD AND VALVES .......................................................... S-79

[4]

GEAR CASE ............................................................................................ S-83

[5]

PISTON AND CONNECTING ROD ....................................................... S-95

[6]

LYWHEEL AND CRANKSHAFT ...........................................................

SERVICING .................................................................................................. S-105

[1]

CYLINDER HEAD .................................................................................. S-105

[2]

TIMING GEAR AND CAMSHAFT ........................................................ S-115

[3]

PISTON AND CONNECTING ROD ..................................................... S-119

[4]

CRANKSHAFT ........................................................................................ S-125

[5]

CYLINDER .............................................................................................. S-137

• LUBRICATING SYSTEM .............................................................................

CHECKING ...................................................................................................

SERVICING ..................................................................................................

[1]

OIL PUMP ..............................................................................................

• COOLING SYSTEM ..................................................................................... S-145

CHECKING ................................................................................................... S-145

(1]

FAN

BELT .............................................................................................. S-145

[2]

RADIATOR ............................................................................................. S-145

DISASSEMBLING AND ASSEMBLING ...................................................... S-147

No:-

489290) .............................. S-59

S-1 S-1 S-1 S-1

S-51

S-101

S-141 S-141 S-141 S-141

D FUEL SYSTEM .............................................................................................

CHECKING AND ADJUSTING ....................................................................

[1]

INJECTION PUMP .................................................................................

[2]

INJECTION NOZZLE. ............................................................................. S-155

DISASSEMBLING AND ASSEMBLING ...................................................... S-157

[1]

INJECTION PUMP ................................................................................. S-157

[2]

INJECTION NOZZLE .............................................................................. S-159

B ELECTRICAL SYSTEM ................................................................................

CHECKING ....................................................................................................

[1]

STARTER ................................................................................................

[2]

GLOW PLUG .......................................................................................... S-163

DISASSEMBLING AND ASSEMBLING ...................................................... S-163

[1]

STARTER ................................................................................................ S-163

[2]

ALTERNATOR. ........................................................................................ S-165

SERVICING ...................................................................................................

[1]

STARTER ................................................................................................

[2]

ALTERNATOR ......................................................................................... S-175

• TURBO CHARGER SYSTEM .....................................................................

CHECKING ....................................................................................................

DISASSEMBLING AND ASSEMBLING ...................................................... S-185

S-151 S-151

S-151

S-161 S-161 S-161

S-171 S-171

S-181 S-181

DIESEL ENGINE

BJ

GENERAL

[1]

ENGINE IDENTIFICATION

05 SERIES WSM, 01640

(1) Model

(2)

Cylinder

Name and Engine Serial

Number

8888

Number

When contacting the manufacturer,

model name and

The

cylinder

designated as shown

The sequence of cylinder

3

and

No.

4 starting from the gear case side.

serial

number.

numbers of

in

05

SERIES diesel engine are

the figure.

numbers is given as

always

specify

No.

~rour

engine

01640510010

1,

No.

2,

No.

01640F10260

01640510020

S-1

DIESEL ENGINE

[2]

GENERAL

(A)

11790F00051

PRECAUTION

(B)

•

During

disassembly, carefully area to prevent confusion be

replaced

in

their

05 SERIES

arrange removed parts

later.

Screws,

bolts

original position to prevent reassembly

WSM,

in

and nuts

errors.

•

When

special tools tools. Special tools make according

•

Before always

• Remove

•

Use

disassembling

disconnect the grounding cable

oil

and

only KUBOTA genuine parts for parts

maintain engine performance

•

Gaskets and Apply

grease

•

When reassembling external them

so

that the sharp edge faces against the direction from

which force

•

Be

sure to perform run-in the serviced

Do

not attempt to give heavy load

may

A

CAUTION

•

Certain components used gasket, exhaust gasket, etc.) contain asbestos. Handle with care according to safety regulation.

(1)

Grease (A)

(2)

Force

(3)

Place Direction of Force

result

the

Sharp

is

to the engine.

are required, use

which are not

to

the drawings provided.

or servicing

KUBOTA

frequently used

live

from the battery first.

dirt from parts before measuring.

and

to ensure safety.

0-rings

to new

must

0-rings

be

or

replaced

oil

seals

or

internal

before

applied.

or

at once, or serious damage

in

this engine

External Snap Ring

(B)

Edge against the

Internal Snap

genuine

should

wires, make sure to

replacement

during

reassembly.

assembling.

snap rings, position

reassembled

{cylinder

Ring

engine.

01640510030

01640

a clean

should

special

be

to

head-

S-3

DIESEL ENGINE

TIGHTENING TORQUES

[3]

Screws, bolts and nuts must be tightened to the specified torque using a torque wrench, several screws, bolts

proper sequence and at the proper torque.

tightened

and nuts such as those used on the cylinder head must

(1) Tightening torques for

NOTE

•

removing and

• In

employed,

if

tool,

marked screws,

"*"

• For

tightening.

letter "M"

The

•

nominal

the threads.

Cylinder head cover cap nuts

*

Cylinder head screws

*

Main bearing case screws 1

*

Main bearing case screws 2

*

Flywheel screws

*

Connecting rod screws

*

Rocker arm bracket nuts

*

gear shaft screws

Idle

*

Crankshaft (Serial

*

end bolt Bearing case cover screws

*

Glow plugs

Nozzle holder assembly

Oil switch taper screw Injection Overflow pipe assembly retaining nuts Starter's terminal

pipe retaining nuts

applying

must be used with enough care not to get them seized.

Size

in

outside diameter in mm

Item

(Serial

mounting nut

B

(2) Tightening torques for

When the tightening torques are not specified, tighten the screws, bolts and nuts according to the table below.

special

bolts

the

and nuts on the table, apply

bolts

Pitch means that the screw,

x

- 604086)

No:

604087

No:

No: - 489290)

No: 489291

general

use screws,

and nuts marked with

the threads. The pitch is the

of

Size

M7

M10

M8 M9

M10

M8 M7

M6 M14x1.5 M14

-) M6

M10x1.25

-)

M8

M20

PT 1/8 M12 M12

use screws,

Standard Screw and

be

bolts

bolt

Pitch

x

1.0

X

1.25 63.7to.68.6 6.5 to

X

1.25 29.4 to 34.3

X

1.25

X

1.25

X

1.0

X

1.0

X

1.0

X

1.5 235.4 to 245.2

X

1.0

X

1.0

X

1.5

X

1.5 24.5 to 34.3

X

1.5 19.6 to 24.5

X

M8

bolts

Bolt

in

and nuts

a pneumatic wrench or

"*",

engine

nut dimension stands for metric. The size is

or

6.9 to 8.8

49.0

53.9 to 58.8

41.2 to

21.6 to 26.5

9.8 to 11.3

142.2 to

9.8 to 11.3

19.6 to 24.5

7.8 to 14.7

49.0

14.7 to 19.6 1.5 to

8.8 to11.8

oil to their threads and seats before

nominal

N·m

to 53.9

46.1

152.0

to 68.6

distance

kgf·m

0.7 to 0.9

3.0 to 3.5 21.7 to 25.3

5.0 to 5.5 36.2 to 39.8

5.5 to 6.0

4.2 to 4.7

2.2 to 2.7

1.00to

14.5 to 15.5

24.0 to

1.00

2.0

0.8

5.0

2.5 to 3.5

2.0 to 2.5 14.5 to

0.9

and nuts

Special

@

05 SERIES WSM, 01640

01640810760

similar

in

7.0 47.0

1.15

25.0 173.6 to to 1.15 7.2 to 8.3 to 2.5 to 1.5

7.0

to

2.0

to 1.2

Screw

pneumatic

mm between two

ft-lbs

to 6.5

5.1 to

39.8 to 43.4 to

30.4

15.9 to 19.5

7.2 to 8.3

104.9to

14.5 to

5.8 to

36.2 to 50.6

10.8to14.5

18.1

6.5 to 8.7

11790810643

Bolt

and.·

(j)

50.6

34.0

112.1

180.8

18.1

10.8

to 25.3

18.1

~

M6 M8

M10

M12

Screw

tightening, be sure to check out the numbers as shown below.

Punched number

and bolt material grades are shown by numbers punched

None or 4 Standard screw and bolt

7 Special

N·m kgf·m

to 0.95

45.1

0.80

1.8 to to 4.6

4.0

SS41

S43C, S48C

7.9 to 9.3

17.7to20.6

39.2 to

62.8 to 72.6 6.4 to 7.4

and bolt material grade

Screw

screw and bolt

2.1

S20C

,

(Refined)

S-5

ft-lbs

5.8 to 6.9 9.8 to 11.3 to 15.2

13.0

28.9 to 33.3

46.3 to 53.5 77.5 to

N·m

23.5 to 27.5 to 55.9 4.9 to 5.7 35.4 to 41.2

48.1

the screw and bolt heads. Prior to

on

90.2

kgf·m

to 1.15

1.00

2.4 to 2.8

7.9 to 9.2

ft-lbs

7.23 to 8.32

20.3

17.4 to

to 66.5

57.1

01640810040

SERIES WSM, 01640

05

TROUBLESHOOTING

[4]

DIESEL ENGINE

Symptom

Engine Does Not Start

Cause Solution

Replenish Vent air S-49 Change fuel and

fuel

No

• Air in the

• Water

•

Probable

fuel system

the fuel system

in

repair system

clogged Clean

• Fuel

• Fuel filter clogged

•

pipe

fuel or engine

Excessively high viscosity

temperature

low

at

with low cetane number Use specified

• Fuel

leak due to

loose

of

injection pipe retaining

oil

Clean or change

Use specified engine

Tighten retaining nut

nut

• Incorrect injection timing Adjust

• Fuel

camshaft worn

• Injection nozzle clogged

• Injection

• Seizure cylinder Compression

•

pump malfunctioning Repair or replace

crankshaft, camshaft, piston,

of

or bearing

from

leak

cylinder

Replace Clean S-155,

Repair or replace

Replace head gasket, tighten cylinder glow holder

• Improper

valve timing

Correct timing gear

Piston ring and

•

Excessive

•

cylinder

clearance Adjust

valve

worn Replace

fuel

replace

or

oil

head screw,

plug and

replace

or

fuel

fuel or

fuel

nozzle

Reference Page

-

S-53

S-51

-

S-151,

S-89

S-87, 153, S-155

S-73, S-81

153

157

-

79,

S-95 S-121, 123 ,

S-137 S-57

(Starter

Does Not

Run)

Engine Revolution Not Smooth

Either White or Blue

Exhaust Gas

Is

Observed

Battery discharged

•

• Starter Key switch malfunctioning Repair or replace

•

malfunctioning

• Wiring disconnected

Is

Fuel filter clogged or dirty

•

Air cleaner

•

• Fuel leak nut

• Injection

• Incorrect

• Injection

Governor

• Excessive engine oil Reduce

•

Piston ring

•

• Incorrect

Deficient compression

•

Charge Repair or

replace

Connect

change

or

Clean

change

or

clogged

due to loose

injection pipe retaining Tighten retaining nut

pump malfunctioning Repair or

Clean

replace

nozzle opening pressure Adjust

nozzle stuck or clogged Repair or replace

malfunctioning

Repair

specified

to

level

liner worn or stuck Repair or replace

and

injection timing

Adjust

Adjust top clearance S-73

-

S-53 S-55

-

S-87, 153, S-155

91

151

11

90

7

157 157

51

, 153

51055

S-155, S-155, S-

S-47,

S-121, 123, S-137 S-

S-8

DIESEL ENGINE

05 SERIES WSM, 01640

Symptom Probable

Overload

or Dark

Black

Either Gray Exhaust Gas Observed

Deficient Output

Excessive Lubricant

Consumption

Oil

• Low grade fuel used Use specified fuel

•

Is

Fuel filter clogged Clean or change

• Air cleaner clogged Clean or change

• Deficient nozzle injection Repair or replace

•

• Incorrect Engine's moving parts seem to be seizing Repair or replace

• Uneven fuel injection Repair or replace

•

Deficient nozzle injection Repair or replace

•

Compression leak Replace head

•

• Piston ring's gap facing the same direction

ring worn or stuck

• Oil

• Piston

• Valve

ring groove worn

stem and valve guide worn

• Carnkshaft bearing, and crank pin bearing worn

leaking due to defective seals or packing

• Oil

Mixed into

Fuel Lubricant

Oil

• Injection pump's plunger worn

Deficient nozzle injection Repair or replace

•

• Injection pump broken

Head gasket defective

Water Mixed Into Lubricant Oil •

Pressure

Oil

Low

Pressure

Oil

High

• Cylinder block or cylinder head flawed

Engine oil insufficient Replenish

•

strainer clogged Clean

• Oil Relief valve stuck with dirt Clean

• Relief valve spring weaken or broken

•

Excessive oil clearance of crankshaft bearing Replace

•

Excessive oil clearance of crankpin bearing Replace

• Excessive oil clearance of rocker arm bearing Replace

•

passage clogged Clean

• Oil

Different type of oil

•

pump defective Repair or replace

• Oil Different type of oil Use specified type of

•

Relief valve defective

•

Cause

Lessen load

nozzle

injection timing Adjust

injection pump

nozzle

gasket, tighten cylinder head screw,

glow plug and nozzle holder

Shift direction

Replace

Replace piston Replace Replace

Replace Replace

element or injection pump

nozzle Replace

Replace Replace

Replace

Use specified type

oil

·Replace

Solution

ring gap

pump

Reference Page

S-53 S-55 S-155,

S-151,

S-87, S-153 S-155,

S-73, 79, S-81

S-97

S-99, S-123 S-99,

S-107, 109 S-133,

S-87,

S-155

S-79,

S-87

S-81

S-107

S-47, S-95

S-129, S-133 S-127 S-113

of

S-141,

-

157

153

-

151,

157

121,

123

135

-

153,

159

51

-

11790S

131,

143

10562

•

S-9

05 SERIES WSM, 01640

DIESEL ENGINE

Symptom

Engine Overheated

Battery Quickly Discharge

Probable Cause

Engine oil insufficient

• Fan belt broken or elongated

• Cooling water insufficient

• Radiator net and radiator

•

fin clogged with dust

• Inside of radiator corroded Cooling water flow route corroded

•

• Radiator cap defective

Overload running

• Head gasket defective

•

• Incorrect injection timing

• Unsuitable fuel used Battery electrolyte insufficient

•

Fan belt slips

•

Wiring disconnected

•

• Rectifier defective Alternator defective

•

Battery

•

defective

Solution

Replenish Replace or adjust Replenish Clean Clean or replace Clean or replace

Replace Loosen load Replace

Adjust

Use specified fuel Replenish

distilled

water and charge

Adjust belt tension or change Correct Replace Replace

Change

Reference Page

51

S-47, S-53

-

S-147

-

S-81 S-151, 153

-

S-53

-

S-179

S-175, 177, S-179

-

11790510571

S-10

DIESEL ENGINE

[5]

SERVICING SPECIFICATIONS

(1) Engine Body

05 SERIES WSM,

01642

Cylinder

Top

Compression Pressure

Variance Among

Head

Clearance

Surface Flatness

Cylinders

Valves

Valve Clearance (Cold)

Valve Seal Width

Valve

Seat Angle IN.

Item

IN.

EX.

Factory Specification

-

0.55

to

0.75 mm

0.0217

29.0

0.145

0.0057

to

0.0295

2.84 to 3.23 MPa to

33.0

412 to

4S9 psi

-

to

0.185

to

0.0072

2.12 mm

0.0835 in

2.12 mm

0.0835

1.047

in.

kgf/cm

mm

in.

rad.

2

so·

Allowable

0.05

mm

0.0019

-

2.25 MPa

23 kgf/cm

327 psi

10%

or

-

Limit

in.

2

less

Valve

Face Angle IN.

Valve

Recessing

Clearance

between

Valve Stem

and

Valve

EX.

Guide

0.785

1.047

0.785

-

0.05

0.0020

0.035

0.0014

S.9SO

0.2741

7.010

0.2760

rad.

45"

rad.

so·

rad.

45"

to

0.25 mm

to

0.0060

to

0.065 mm

to

0.0025

to S.975 mm

to

0.2764

to

7.025

to

0.2765

in.

mm

in.

-

0.4mm

0.01S in.

0.1

mm

0.0039

-

01640510450

in.

S-19

05 SERIES WSM, 01642

Valve Timing

Intake Valve

Open

Close

Exhaust Valve

Open

Close

Item

0905-B 01005-B V1205-B

(E)

(E) V1205-T-B V1305-B

(E) 011 05-B V1505-B

(E) 011 05-T-B

V1505-T-B 0905-B

(E) 01005-B V1205-B

(E) V1205-T-B V1305-B

(E) 011 05-B V1505-B

01105-T-B

V1505-T-B

0905-B

(E) 01005-B V1205-B V1205-T-B V1305-B 011 05-B V1505-B

011 05-T-B V1505-T

0905-B

-8

(E) 01005-B V1205-B V1205-T-B V1305-B

011 05-B

V1505-B

01105-T-B

V1505-T -B

(E)

(E) (E)

(E)

(E) (E)

(E) (E) (E)

(E)

(E) (E)

(E)

DIESEL ENGINE

Factory Specification Allowable Limit

0.24 rad. (14°)

-

before T.O.C.

0.38 rad.

(22°)

-

before T.O.C.

0.52 rad.

(30°)

-

after B.O.C.

0.82 rad.

(4n

-

after B.O.C.

0.96 rad.

(55°)

-

before B.O.C.

0.91

rad.

(52°)

-

before B.O.C.

0.24 rad. (14

°)

-

after T.D.C.

0.30 rad. (17")

-

after T.O.C.

Valve Spring

Free Length

Setting Load

Tilt

I Setting Length

S-20

37.0 to 37.5 mm

36.5 mm

1.457 to 1.476 in. 1.437 in.

11.97 kgf

117.4NI31.0mm

26.4 lbs

I 31.0 mm 10.2 kgf I 31.0 mm

100.0 N I 31.0 mm

I 1.22 in. 22.5 lbs I 1.22 in.

-

1.0mm

0.039 in.

01642510460

DIESEL ENGINE

Rocker Arm

Item

Clearance between Rocker Arm Shaft and Rocker Arm

Factory Specification

mm

0.045

to

0.016

0.0006

0.0018

to

in.

SERIES

05

Allowable

0.10

0.0039

WSM, 01640

Limit

mm

in.

Rocker Arm Shaft

O.D.

Rocker Arm I.D. 12.000 to 12.018 mm

Tappet

Clearance between Tappet and Guide

Tappet

Tappet Guide

O.D.

D.

I.

Camshaft

Camshaft Side

Camshaft

Cam Height

Clearance

Alignment

IN.

11.973 to 11.984 mm

0.4714 to 0.4718 in.

0.4724 to 0.4731 in.

0.0024

19.980 7866

0.

20.021

0.7882

0.0087

-

mm

in.

mm

in.

mm

in.

to 0.062

0.020

0.0008

19.959 to 7858 to

0.

20.000

to

0.7874

to 0.22 mm

0.07

0.0028

28.80

to

1.1339in.

-

0.07 mm

0.0028

in.

-

0.3mm

mm

0.01

0.0004

in.

0.0118

28.75 mm

1.1319 in.

Oil Clearance

Camshaft

Camshaft Bearing

of Camshaft

Journal O.D.

EX.

29.00 mm

1.1417in. to

0.050

0.0020 to

35.934 to

0.091

0.0036

35.050

mm

in.

mm

28.95mm

1.1398 in. mm

0.12

0.0047

in.

-

1.4147 to 1.3799 mm

-

01640510470

.41

83

mm

in.

36.025

1

.41

73

to

to 1

D.

I.

36.000

S-21

05 SERIES

WSM, 01641

Timing Gear

Clearance between

Backlash

Crank Gear-Idle

Gear 1-Cam Gear

Idle

Gear 1-lnjection

Idle

Gear 1-ldle Gear 2

Idle

Idle Gear 2-Governor Gear

Idle Gear 1

Gear Shaft

Idle

Item

Gear 1

Pump Gear

and

Gear Bushing

Idle

Factory Specification

mm

0.115

to

0.032

0.0013.to 0.0045

0.114

to

0.036

0.0045

to 0.116

0.034

to

0.030

0.020 to

to

to 0.0046

0.117

to to 0.0046

0.117

to 0.0046

0.054

0.0021

to

0.0014

0.0013

0.0033

0.0013

0.0012

0.0008

in.

mm

in.

mm

in.

mm

in.

mm

in.

mm

in.

DIESEL ENGINE

Allowable

0.15

0.0059

0.15

0.0059

0.15

0.0059

0.15

0.0059

0.15

0.0059

0.10

0.0039

Limit

mm

in.

mm

in.

mm

in.

mm

in.

mm

in.

mm

in.

Idle

Gear Bushing

Idle

Gear

Idle

Gear 2

Idle

Idle Gear Bushing

Gear

Idle

Side Clearance

Gear

Gear 1

Idle

Gear 2

Idle

Shaft

1

2

I.D.

O.D.

D.

I.

O.D.

26.000 to 26.021

1.0236 to 1.0244

mm

in.

25.967 to 25.980 mm

1.0223 to 1.0228

to 0.054

0.020

0.0021

0.0008

26.000

to

to 26.021 mm

1.0236 to 1.0244

in.

mm 0.10

in.

25.967 to 25.980 mm

1.0223 to 1.0228 in.

mm

0.51

to

0.20

0.0079

0.20

0.0079

0.0200

to

0.51

to

to 0.0200

in.

mm

in.

-

mm

0.0039

-

0.8mm

0.0315

0.8mm

0.315

01640510480

in.

S-22

DIESEL ENGINE

05 SERIES WSM,

01642

Piston

Piston Pin Bore

Clearance

Clerance between

Ring Gap

· Piston Ring

between Compression Ring 2 and Ring Groove

Compression Ring 1

Compression Ring 2

Oil

Ring

Item

Oil

Ring and Ring Groove

Factory Specification

22.000

0.8661

0.085

0.0033

0.020

0.0008

0905-B

V1205-B

01005-B V1305-B 011 V1505-B

01105-T-B V1205-T V1505-T

0905-B V1205-B

01005-B V1305-B (E) 0.0118 011 05-B

V1505-B V1205-T-B

01105-T-B V1505-T-B

0905-B 01005-B

V1205-B V1205-T -B V1305-B

01105-B

V1505-B (E)

01105-T-B {E) V1505-T-B

05-B

(E)

-8

-B

(E)

(E) (E)

(E) (E) (E)

(E)

(E) (E)

(E)

0.25

0.0098

0.30

0.0118

0.20

0.0079

0.25

0.0098

0.30

0.20

0.0079

0.40

0.0157

0.25

0.0098

0.30

0.0118

to 22.013 mm

to

0.8687 in.

to

0.112 mm

to

0.0044 in.

to

0.055 mm

to

0.0021 in.

to

0.40

mm 1.25 mm

to

0.0157

to

0.45

to

0.0170

to

0.35

to

0.0138

to

0.40

to

0.0157 in.

to

0.45

to

0.0170 in.

to

0.35

to

0.0138

to

0.55

to

0.0217 in.

to

0.40

to

0.0157 in.

to

0.55

to

0.0217 in.

in.

mm 1.25 mm

in.

mm

in.

mm 1.25 mm

mm

in.

mm

mm 1.25 mm

Allowable

22.03

0.8673 in.

0.20mm

0.0079 in.

0.15

mm

0.0059 in.

0.0492 in.

0.0492

1.20

mm

0.047

0.0492 in.

1.20

mm

0.047

1.20

mm

0.047

0.0492 in.

Limit

mm

in.

Connecting Rod

Connecting Rod Alignment

Clearance between Piston Pin and

Piston Pin

Small

O.D.

End Bushing

1.0.

Small end Bushing

S-23

-

0.014

to

0.038 mm

0.0006

22.002

0.8662 to 0.8666 in.

22.025 to

0.8671 to 0.8677 in.

to

0.0015 in.

to 22.011 mm

22.040

mm

0.05

mm

0.0020

0.15

0.0059 in.

in.

mm

-

01642510490

05 SERIES WSM, 01642

DIESEL ENGINE

Crankshaft

Item Factory Specification Allowable Limit

Crankshaft Alignment

Oil Clearance between Crankshaft and Crankshaft Bearing 1 0.034 to 0.114 mm 0.20 mm

0.0013 to 0.0045 in.

-

0.02 mm

0.0008 in.

0.0079 in.

Crankshaft O.D. 47.934 to 47.950 mm

-

1.8872 to 1.8878 in.

Crankshaft Bearing 1 I.D.

47.984 to 48.084 mm

-

1.8891 to 1.8917 in.

Oil Clearance between Crankshaft and Crankshaft Bearing 2 0.034 to 0.095 mm 0.20 mm

0.0013 to 0.0037 in.

Crankshaft O.D. 47.934 to 47.950 mm

0.0079 in.

-

1.8872 to 1.8878 in.

Crankshaft Bearing 2 I.D.

47.984 to 48.029 mm

-

1.8891 to 1.8909 in.

Oil Clearance between Crankshaft and Crankshaft Bearing 3

0.034 to 0.098 mm

0.20 mm

0.0013 to 0.0039 in. 0.0079 in.

Crankshaft O.D. 51.921 to 51.940 mm

-

2.0441 to 2.0449 in.

Crank bearing 3

I.

D.

51.974 to 52.019 mm

-

2.0462 to 2.0480 in.

Oil Clearance between Crank Pin and Crank Pin Bearing 0.029 to 0.091 mm

0.0011 to 0.0036 in.

0.20 mm

0.0079 in.

Crank Pin O.D. 39.959 to 39.975 mm

1.5732 to 1.5738 in.

Crank Pin Bearing I.D.

40.004 to 40.050 mm

1.5750 to 1.5768 in.

Crankshaft Side Clearance 0.15 to

0.0059 to 0.0122 in. 0.0197 in.

Cylinder Liner

Cylinder Liner I.D. D905-B

V1205-B (E) 2.8346 to 2.8354 in. 0.0059 in. V1205-T-B

D1005-B

V1305-B (E) 2.9921 to 2.9929 in. 0.0059 in.

D1105-B D11 V1505-B V1505-T-B

Oversized Cylinder Liner

I.

D.

(E)

05-T-B

(E)

72.000 to 72.019 mm

76.000 to 76.019 mm + 0.15 mm

78.000 to 78.019 mm + 0.15 mm

3.0709 to 3.0716 in. 0.0059 in.

+ 0.0197 in. 0.0059 in.

-

0.31

mm 0.50 mm

+ 0.15 mm

+ 0.5 mm + 0.15 mm

01642$10500

S-24

DIESEL ENGINE

(2)

Lubricating System

Oil

Pump

Engine

Oil

Pressure

At

Idle Speed

Item

Factory Specification

49kPa

0.5 kgf/cm 7 psi

2

05 SERIES

Allowable

WSM,

Limit

01642

At Rated

Clearance

End Clearance between

(3)

Cooling System

between

Speed

Inner

Outer

Rotor and

Rotor and Pump Body

Inner

Thermostat

Thermostat's

Temperature at Which Thermostat

Valve

Opening Temperature

Radiator

Radiator Water Tightness

Radiator Cap Air Leakage

Fan

Belt

Tension

Outer

Rotor

Rotor and Cover

Completely Opens

196.0

to

441.0

kPa 147.1 kPa

2.0

to 4.5 kgkf/cm

28.0

to

64.0

psi 21.3 psi

0.06

to

0.18

mm

0.0024

0.0039

0.0098 to

(1.4 kgf/cm

1

to

0.0071

0.100 to

0.025

157.1 to 162.5

Water tightness at specified pressure

0

0.9-0.6

0

o

0.394 to

0.180

to

0.0071

to

0.75 mm

0.0295

69.5 to 72.5

85

·c

185

OF

137 kPa

2

,

seconds

88

13-9

to

to 12 mm

or

.....

59 kPa

kgf/cm

psi

12 mm

/1

0.472

22.1 lbs.)

mm

·c

20 psi)

more

I

98 N

o

in.

•F

2

in.

2

kgf

I

1.5 kgf/cm

01642510510

2

S-25

01640810520

05 SERIES WSM, 01643

(4)

Fuel System

DIESEL ENGINE

Injection

Pump

Timing

Without Timer

With Timer

Fuel

Titghtness of Pump Element

Fuel

Tightness of Delivery Valve

Injection Nozzle

Fuel Injection Pressure

Fuel Titghtness of

Nozzle Valve Seat

Item

3000

rpm

3600

rpm

3000

rpm

V1505-B

3600

rpm

(E)

Factory specification

0.31

to

0.35

rad. (18 to

20")

Before T.D.C.

0.37 to

0.21

0.40

23")

Before T.D.C.

0.14 to

0.16 to

0.17

10")

Before T.D.C.

to

0.24

14")

Before T.D.C.

0.19

11")

Before T.D.C.

More 1

14.7--+

150

--+

-

0

seconds

13.7

140

2133--+ 1990

13.73 to 14.71 140

to 150

1991

to 2133 psi

rad.

(21

rad.

(8

rad. (12 to

rad.

(9

MPa

2

kgf/cm

psi

MPa

2

kgf/cm

When the pressure is

12.75

MPa (130

2

kgf/cm

valve

,

1849 psi), the

seat must be

fuel

tightness

to

Allowable

-

14.7

MPa

150

kgf/cm

2133 psi

5 seconds

14.7

--+13.7 MPa

150

--+140

kgf/cm

2133 --+1990

-

01642510530

Limit

.

2

psi

S-26

DIESEL ENGINE

SERIES WSM,

05

01640

Electrical

(5) Starter

Commutator

Mica Undercut

Brush Length

Alternator

No-load Voltage

Resistance

Stator Rotor Resistance

O.D.

Ring

Slip

Brush Length

Glow Plug

Resistance

A

System

0.0.

Item

Factory Specification

mm

30.0

0.8

0.0315

to

mm

13.0

5000 rpm

Vat

2.9Q

14.4 mm

0.5669 mm

10.0

0.3937

1.0

in.

mm

Q

in.

to 1.2

in.

Q

1.1811

0.5 to

0.0197

0.5118 in.

13.5 Less than 1

Approx.

Allowable

29.0mm

1.1417

0.2mm

0.079

8.5mm

0.3346 in.

-

14mm

0.5512

1.5mm

0.0591

-

Limit

in.

B

Approx.

0.9 Q A : S

S

:

B

489290

N

I

N 489291

I

-

below

&

above

&

01640510540

S-27

05

SERIES WSM,

[6]

MAINTENANCE CHECK

01642

DIESEL ENGINE

LIST

To maintain long-lasting and safe engine performance, make it a

the table below.

75

(1)

hrs

*

Every

100 150 hrs hrs

(2)1<

*

-:.

*

construction

Item

Checking

*Changing

Cleaning air filter element Cleaning fuel filter element

Checking fan

Checking water pipes and clamps *Changing

Changing fuel filter cartridge Cleaning Changing radiator coolant (L.L.C)

**

Changing air filter element Cheking Changing water pipes and clamps Changing

(1), (3), (4) For generators (1800 (5), (7), (8) For generators (1800

fuel

pipes and clamps

(1), (3)

engine oil

oil filter cartridge

radiator interior

Checking injection nozzle

valve

fuel

(2)

For generators

(6)

For generators

(2), (4)

belt

tension and damage

(5),

(6),

clearance

pipes and clamps

Oil

pan depth (101

Oil

pan depth (125 mm)

(7)

Oil

pan depth (101 mm)

(B)

Oil

pan depth (125 mm)

(3000

Every Every

50

hrs

-:.

mm

I

3600

rpm)

I

1500

rpm) and

I

3600

rpm) and general construction

I

1500

rpm)

general

Every

(3)

*

(5)1<

rule

to

carry out

Service

Every Every

200

300

hrs

hrs hrs

(4)-:.

regular

Interval

Every Every Every Every

400

inspections

500

hrs hrs hrs

800

1500

by

Every

one

year

*

(7)

*

(6)

*

(8)

*

I

industrial

I

industrial machinery and farm equipment

machinery and farm equipment

following

Every

two

years

*

* *

*

Change engine

**

Maintenance inetrvals as per EPA instructions.

A

CAUTION

•

When changing

oil and oil cartridge after the first

or

inspecting, be sure to

50

hours

of

operation.

level

and stop the engine.

S-44

01640510730

DIESEL ENGINE

[7] CHECK AND MAINTENANCE

(1)

Daily

Check Points

Checking Engine Oil Level

1.

2.

3.

• IMPORTANT

•

Level the engine. To check the reinsert Check to see that the If

the level

When using an previous one, drain oil.

oil

level,

it,

and draw it out again.

is

too low, add new

oil

05 SERIES WSM, 01640

draw out the dipstick, wipe it

oil level lies

of

different maker

old

oil.

between the two notches.

oil to the specified

or

viscosity

Never

mix

two

different types

clean,

level.

from the

of

01640510050

Checking and

1 . Remove the radiator cap and check to see that the

level

2.

If low,

A

CAUTION

• Do

• IMPORTANT

• Be sure to

•

not temperature slightly cap

completely

loose engine Do

not

time.

Replenish Cooling

is

just

bellow

the port.

add

clean water and antifreeze.

remove the radiator cap

is

below

its

to

relieve any excess pressure before removing the

.

close

the radiator cap

or

improperly closed,

could

overheat.

use

an

antifreeze and

boiling

water may

Water

until cooling water

point. Then

securely.

scale

inhibitor

leak

cooling

loosen

the cap

If

the cap

out

and the

at the same

01640510060

water

is

S-47

DIESEL ENGINE

05 SERIES

WSM,

01640

(2) Check Point of Every

01640F10270

50

hours

Checking Fuel Pipe

1.

If

the clamp

(1)

is

loose, apply

oil

to the threads and securely

retighten it.

2.

The fuel pipe period

of

(2)

service.

is made

of

rubber and ages regardless

Change the fuel pipe together with the clamp every two years.

3.

However,

if

the fuel pipe and clamp are found to be damaged or

deteriorate earlier than two years, then change or remedy.

4.

After the fuel pipe and the clamp have been changed, bleed the fuel system.

A

CAUTION

•

Stop the engine when attempting the check and change prescribed above.

(1)

Clamp

(2)

Fuel

Pipe

01640510070

of

the

01640F10490

(When bleeding fuel system)

1.

Fill

the fuel tank with fuel, and open the fuel cock (1).

2.

Loosen the air vent plug

3.

Screw back the plug when bubbles do not come up any more.

4.

Open

the air vent cock on top of the fuel injection pump.

5.

Retighten the plug when bubbles do not come. up any more .

• NOTE

• Always keep the air vent plug on the fuel injection pump

closed except when air is vented, or it may cause the engine

to stop.

(1)

Fuel Cock

(2)

of

the fuel filter a few turns.

(2)

Air

Vent Plug

01640510080

S-49

DIESEL ENGINE

(3)

Check

Point

of

Every 100

05 SERIES WSM, 01642

hours

Changing Engine

1.

After warming up, stop the engine.

2.

To change the used oil,

Oil

remove the drain plug at the bottom

the engine and drain off the

3.

Reinstall

4.

Fill

the drain

the new oil

plug.

up to the upper notch on the dipstick. (See

S-47.)

• IMPORTANT

•

Engine properties

•

Change the type

oil

should

of

API

be

MIL-L-46152

classification

of

engine according

temperature.

Above 25 oc (77 0

octo

25 oc

Below 0

oc (32

~

0905-B

(E) 01005-B 01105-B(E) 01105-T-B

V1205-B V1305-B V1505-B

V1205-T-B V1505-T-B

(E)

(E) (E) (E)

(E) (E)

epth

°F}

..................••

(32

oF

to

°F}

.....•.••••....•.....•

77

125 mm (4.92 in.)

5.1

L

5.39 U.S.qts.

4.49

lmp.qts

6.0

L

6.34 U.S.qts.

5.28

lmp.qts.

6.7 L

7.08

U.S.qts.

5.90 lmp.qts.

oil completely.

CD

ICE

SAE 30

°F}

.•...•

SAE 20

SAE

I

MIL-L-2104C

grades.

to

or

10W-30

or

10W-30

1

OW

or

1

OW-30

Capacity

101

mm (3.97 in.)

4.0

L

4.23 U.S.qts.

3.52

lmp.qts

4.7 L

4.97 U.S.qts.

4.141mp.qts.

of

page

or

have

the ambient

-

Changing Engine

1.

Remove the

2.

Apply

engine

3.

Screw

the

Oil Filter

Cartridge

oil filter cartridge with a

oil

to the rubber gasket on the

new

cartridge

in

by hand. (See

• NOTE

•

Over-tightening may cause deformation

•

After

cartridge has been

replaced, decreases a little. Check the oil level

and

add new

oil

filter

wrench.

new

page S-44.)

of

engine

to

the specified

01640510090

cartridge.

rubber gasket.

oil normally

level.

01640510100

S-51

DIESEL ENGINE

05

SERIES

WSM, 01640

OOOOOF10621

OOOOOF10631

01640F10280

(A)

OOOOOF10641

(B)

Checking Fan Belt

1 . Press the fan

(1

0

kgf,

22

Check

if

the fan

2.

If

the

deflection

with the tension

(A)

Good

Checking

1 .

Check the fan

2.

Check if the fan

3.

Replace the fan and

Fan

deeply

Tension

belt

between fan

pulley

and

lbs).

belt deflection

is

10

to

12

is not within the factory specifications, adjust

pulley

Belt

belt

sunk in

adjusting

Damage

for damage.

is worn and

belt

if the

the

pulley

bolts.

(B)

sunk

belt

is damaged

groove.

Bad

in

Cleaning Fuel Filter

1.

Close

the

fuel filter cock (3).

2. Unscrew the retaining ring (6) and remove the inside with kerosene.

3.

Take

out

4.

the element

After

cleaning, reassemble the

(4)

and dip it

in

the kerosene

fuel filter,

dirt.

5.

Bleed the

fuel

system .

• IMPORTANT

• If

dust and dirt enter the injection to

(1)

Cock Body

(2)

Air Vent

(3)

Filter

clean

nozzle will

the

Plug

Cock

fuel filter

wear

cup

fuel,

the

fuel

quickly.

To prevent this, be sure

periodically.

(4)

Filter Element

(5)

Filter Cup

(6)

Retaining Ring

pulley

at force

mm

(0.394

the

pulley

or

nearly

the

cup (5), and rinse

of

to

0.472

01640510110

groove.

worn

00000510461

to

rinse.

keeping out dust and

injection pump and

01640510120

98

in.).

N

out

S-53

DIESEL ENGINE

05 SERIES

WSM,

01640

01640F10290

Cleaning

1.

The air

2.

Remove and with dust.

3. When the air

Air

Cleaner

cleaner

uses a dry

clean

filter element

element.

out the dust cup before it becomes

is dusty, clean

• NOTE

•

Change the

element

once a year

or

• IMPORTANT

• Install

Cleaning

• When

Air pressure at the nozzle must not exceed

the air cleaner

rear

of

the cup in the upside.

If

the

dust

cup

is collect element will

Use

100 psi). Maintain

in the cup, and direct attachment

cause

Air

Filter Element

dry

dust

adheres

clean dry compressed air on the inside of the element.

reasonable

dust

cup

with

mounted

its

distance between the

life

time

incorrectly,

to

shorten

Never apply oil

it.

every 6th

to it.

half full

cleaning .

"TOP" indicated on the

dust

or

dirt

does

of

the

dust

to

a great extent.

01640510130

690 kPa

nozzle

(7

and the

kgf/cm

filter.

not

the

2

,

01640F10300

01640510140

S-55

DIESEL ENGINE

(4)

Check Point

01640F10310

of

Every 800

hours

05 SERIES WSM, 01643

Checking Valve Clearance

.IMPORTANT

• Valve clearance

must

be checked and adjusted when engine

is cold.

1. Remo

2. Align

3. Check the following valve clearance marked with

4. If

ve

the head cover.

the

"1TC" mark

housing

ove

feeler gauge.

the

Valve clearance

so

that the No. 1 piston comes

rlap top dead center.

clearance, adj

on

the

ust

with

Factory spec.

flywheel and projection {1) on the

to

the compression or

"-t:c"

using a

the

adjusting screw.

0.145

to 0.185

0.0057

to

0.0072 in .

mm

• NOTE "TC"

• The there Is

marking

no

"TC" marking

• No. 1 piston comes

marking Is aligned

on

with

the

flywheel

for

the

to

the

T.D.

the projection

is

just for No. 1 cylinder.

other cylinders.

C.

position when the "TC"

in

the window

flywheel-housing. Turn the flywheel 0.26 rad. (15")

clockwise and counter-clockwise

the compression

Now referring clearance. {The piston

the

IN. and

EX.

top

' dead center

to

the table below, readjust

is

at

valves

do

not

the

to

see

If

the

piston

or

the overlap

the

top

dead center when both

move;

it

Is

at the overlap

position.

position when both the valves move.

• Finally

marking and

tu

rn

the

flywheel 6.28 rad. (360") and aligne the "TC"

the

projection perfectly.

Adjust

the other valve

clearance as required.

• After turning the flywheel counterclockwise

times, recheeck

• After adjusting the valve clearance,

nut

of

the

valve clearance.

adjusting screw.

firmly

twice

tighten

or

the

on

is

at

valve

three

lock

Number Valve arrangement Adjustable cylinder

Location

When No. 1 piston is compression top dead center

When No. 1 piston is overlap position

(1) Projection

(2)

TC

of

Mark

S-57

cylinders

piston

Une

IN.

1st 2nd 3rd 4th 1

st 2nd 3rd 4th

* * * *

*

(3) Valve Clearance

3 cylinder

EX

4 cylinder

IN.

* *

*

-{:(

EX

* *

01640510150

DIESEL ENGINE

{5)

Check Point

of

1500

hours

(Serial

05

SERIES

No:

-

489290)

A

CAUTION

• Check the nozzle injection pressure and condition after

confirming that there is nobody standing fume goes. human body, cells may be destroyed and blood poisoning may

be

If the fume from the nozzle directly contacts the

caused.

in

WSM,

01640

the direction the

01640510160

OOOOOF10690

01640F10500

[8]

SPECIAL TOOLS

Checking Nozzle

1.

Set the injection nozzle to the nozzle tester (Code

31361).

2.

Slowly move the tester handle to measure the pressure at which fuel begins jetting out from the nozzle.

3.

If

the measurement

disassemble the injection nozzle, and change adjusting washer

(1)

until the proper injection pressure

159.)

4.

If

the spraying condition

(Reference)

• Pressure adjusting washer thickness.

Approx. 59

(1)

Adjusting Washer

Flywheel Puller

Code

No:

Application: Use to remove the flywheel.

Injection Pressure

is

variation with

kPa

{6

kgf/cm

07916-32011

No:

not within the factory specifications,

is

obtained. (See page

is

defective, replace the nozzle piece.

0.025

2

mm

(0.001

,

85

psi)

in.)

difference

01640510170

07909-

S-

of

OOOOOF00170

01640510180

S-59

DIESEL ENGINE

05

SERIES

WSM,

01640

~

I

.

OOOOOF00240

~

Special-use Puller

Code

No:

07916-09032

Application:

Valve

Code Application:

Diesel

Code Application:

Use

for

Seat

Cutter Set

No:

07909-33102 Use

for correcting valve

Engine Compression Tester

No:

07909-30207 Use pressure.

Set

pulling

out bearings, gears

for measureing

seats.

diesel

and

other parts.

01640510190

01640510200

engine compression

"'

I~

gs

rrc

!=',

D

·~

=c___j

R=-

"

~

j

®

.------~

-=dJ

0

~

~·~~~

OOOOOF00230

®

~

®

~

®

~

©

Oil

Pressure Tester

Code

No:

Application:

S-61

07916-32031 Use for measureing

lubricating

oil

pressure.

01640510210

01640510220

DIESEL

ENGINE

05

SERIES

WSM,

01640

OOOOOF10310

OOOOOF00250

Connecting Rod

Alignment Tool

Code No: 07909-31661 Application: Use for checking the connecting rod alignment. Applicable range: Connecting rod big end

2.95 in.dia.). Connecting rod length 65 to 330

I.

D.

30

to 75 mm (1.18 to

mm

(2.56 to 12.99 in.).

01640510230

Press Gauge

Code No:

07909-30241

Application: Use for checking the oil crearance between crankshaft

and bearing, etc.

Measureing: Green

range

Red -------0.051 Blue-------- 0.102

---- 0.025 (0.001

(0.002

(0.004

to

0.076

mm

to

0.003

in.)

to 0.152 mm

to 0.006

in.)

to 0.229 mm

to 0.009

in.)

01640510240

Red Check (Crack Check Liquid)

Code No: 07909-31371 Application: Use for checking cracks

on

cylinder head, cylinder

block, etc.

S-63

01640510250

DIESEL ENGINE

• NOTE

•

The

following special tools

2

c

11790F00451

G

A

are

not provided, so make them referring to the figure.

Valve

Guide Replacing Tool

D

V'iZ_

E

F

,............._

Application:

A

8

c

C1

C0.3

8

c

1

J

K

D

E

F

G

H

I

J

K 12.5

L C1 C2

C0.3

05

SERIES WSM,

Use

to

press out and press fit

the

valve guide.

20

mm

dia. (0.79 in. dia.)

11.7 to 11.9

0.460 to 0.468 in. dia.

6.5 to 6.6

0.256 to 0.259 in. dia. 225 70

mm

45

mm 25 mm (0.98 in.) 5 mm (0.197 in.)

6.7 20

mm dia. (0.787 in. dia.)

8.9 to Chamfer 1.0 mm (0.039 in.) Chamfer 2.0 mm (0.079 in.) Chamfer 0.3 mm (0.012 in.)

mm

dia.

mm

dia.

mm

(8.86 in.) (2.76 in.) (1.77 in.)

to

7.0 mm dia. (0.263

to

12.8

mm

dia. (0.492

9.1

mm {0.350

to

0.358 in.)

01640

01640510910

0.275 in. dia.)

to

0.504 in. dia.)

11790F00461

L

11790G00622

S-65

DIESEL

F

B

c

D

a

b

E

ENGINE

B

Jt=$

M~

G

R

Q

s

u

c

p

05 SERIES WSM, 01640

Injection Pump Pressure Tester

Application: Use to check fuel tightness

injection pumps.

Pressure gauge

A

29.4 MPa

B

Copper gasket Flange (Material

c

Hex. nut 27 mm

D

E

Injection pipe

F PF 1/2

5 mm

G

17 mm dia.

H

I

8 mm dia.

1.0

J

K

L

M N

0

p

Q

R

s

T

u

v

a b

mm

17 mm dia.

6.10

0.2402 8 mm 4 mm (0.16

11.97to

0.4713 PF 1/2 23 mm 17 mm (0.67 4 mm

12.00

0.4724 100

mm (3.94 in.)

M12xP1.5

Adhesive

Fillet welding

(0.20

to

(0.31

to

(0.16

to

full scale

(300

kgf/cm

:

(1

in.)

(0.67

(0.31

in. dia.)

(0.039

in.)

(0.67

6.20 mm dia. to 0.2441 in. dia.

in.) in.)

11.99 mm dia.

0.4721 in. dia.

(0.91

in.) in.)

in.)

12.02 mm dia.

0.4732 in. dia.

application

on the enter circumference

2

,

4267 psi)

Steel)

,06

in.) across the

in. dia.)

: More than

plat

of

11790F00500

11790GOOB11

S-67

DIESEL ENGINE

05 SERIES WSM, 01640

a

11900F00410

B

Bushing

Replacing Tool

Application: Use to press out and to press

A

1.

For small end bushing

c

A

B

c

F

C2

b

D

E

F

a

b

2.

For idle gear bushing

A

B

c

D

E

F

a

b 6.3

fit the bushing.

157mm(6.1811 24 mm (0.9449 in.) 120

mm (4.7244 in.)

21.8

to

21.9 mm

(0.8583 to 0.8622 in.)

24.8

to

24.9

(0.9764

20

mm (0.7874 in.)

6.3

11m

(250

6.3

11m

(250

196 mm (7.7165 in.)

26 mm (1.0236 in.)

150

mm

25.8 to 25.9 mm (1.0157 to 1.0197 in.)

28.8

to

28.9 mm

(1.0157 20

mm (0.7874 in.)

6.3

11m

(250

11m

(250

mm

to

0.9803

11in.) 11in.)

(5.9055 in.)

to

1.0197 in.)

11in.) 11in.)

in.)

DIA.

D

E

11790F00490

11900G00441

Flywheel

Stopper

Application: Use to loosen and tighten the

flywheel screw.

200

A

B

c

D

E

F

G

mm (7.87 in.)

30

mm (1.18 in.)

20

mm (0.79

15 mm

(0.59

15 mm

(0.59 8 mm (0.31 10

mm

DIA. (0.39

in.)

in.) in.) in.)

in.

DIA.)

11790GOOB01

S-69

DIESEL ENGINE

05 SERIES WSM, 01640

11900F00420

Crankshaft Bearing 1

Application:

Use to press out and to press

fit the crankshaft bearing 1.

[Press

Out]

A

135 mm (5.31 in.} 72

8

40.

c

D

10

E

20

F

20

56.80

G

2.2362

51.80

H

2.0393

mm

(2.83 in.}

(1.57 rad.}

mm

(0.39

mm

(0.79

mm

(0.79

to

56.90

to

2.2402

to

51.90

to

2.0433

in.}

in.} in.}

mm dia.

mm

[Press Fit]

A

130

mm

(5.12 in.}

8

72

mm

(2.83 in.}

40.

c

D

E

F

G

H

(1.57 rad.} 9 mm (0.35 24 20 68

47.38 to 47.48

1.865

in.)

mm (0.95

mm

dia.

(0.79

mm

dia. (2.68 in. dia.}

to

1.869 in. dia.

in.}

mm

Replacing Tool

in. dia.

dia.

in. dia.

in. dia.)

dia.

D D

~~"':

-

E

&

01640F10320

··-c--·-

Governor Gear

Application:

1-F

~-Gl---·-·

1--

~

"'-D

c

A

188 mm (7.4 in.}

A

18 mm

8

150

c

D

C1

E 73.9

69.8

F

30

G

H

C2 : Chamfer

11900600451

Holder

Bushing

Replacing Tool

Use to press out and to press fit the governor gear

holder bushing.

(0.7

in.}

mm (5.9 in.)

: Chamfer

to

mm dia. (1.181 in. dia.}

1.0

mm

(0.039 in.}

to

74.0

mm dia.

(29.09 to 29.13 in. dia.}

69.9 mm dia. (2.748 to 2.751 in. dia.}

2.0

mm

(0.079 in.}

01640510260

S-71

DIESEL ENGINE

D

ENGINE BODY

05 SERIES

WSM

, 01640

CHECKING AND

ADJUSTING

Compression Pressure

1. After warming up the engine, stop it and remove the air cleaner, the muffler and

2.

Install

a compression tester (Code N

all

nozzle holders.

o:

07909-30204)

for diesel

engines to nozzle holder hole.

3. After making sure that the speed control lever is set

position (Non-in

je

ction

),

run

the engine

at

200

to

at

300

the stop

rpm with

the starter.

4. Read the maximum pressure. Measure the pressure more than twice.

5.

If

the measurement is below the

cylinde

6.

If amount

r,

piston ring, top clearance, valve and

the measurement is below the

of

oil to the

cylinder wall

allowable

limit,

cylinder

check the

head.

allowable limit, apply a small

through the nozzle hole and

measure the compression pressure again.

7.

If

the compression pressure is

still

less than the allowable limit,

check the top clearance, valve and cylinder head.

8.

If

the compression pressure increases after applying oil, check

the cylinder

wall and piston rings .

• NOTE

• Check the compression pressure with the specified valve

clearance.

•

Always use a

•

Variances in

fully

charged battery

cylinder

compression values should

for

performing this

be

test

under

10%.

Compression pressure

Factory spec.

Allowable limit

2.

84

to 3.24

29

to

412

to

2.26

MPa

23

kgf/cm

327 psi

33

kgf/cm

469 psi

2

MPa

2

11900510011

S-73

DIESEL ENGINE

OOOOOF10510

OOOOOF10520

05

SERIES WSM, 01640

Top

Clearance

1.

Remove the

cylinder

head (remove the cylinder

head gasket

completely).

2.

Bring the piston to its top dead center fasten 1.5 mm dia. 5 to 7 mm

long

fuse wires to 3 to 4 spots on the piston top with grease

so

as

to avoid the intake and exhaust valves

and the combustion

chamber ports.

3.

Bring the piston to its and tighten the gasket must

4.

Turn the crank shaft

5.

Remove the cylinder head, and measure squeezed fuse wires

be

middle

cylinder

position,

head

bolts

changed to new one.)

until

the piston exceeds its top dead center.

install

the

cylinder

to specification. (Head

for thickness.

6.

If

the measurement is not within the specified

clearance

Top

clearance

Tightening torque

(1) Fuse

of the crankpin

Factory spec.

Cylinder bolts

journal

head mounting

and the piston pin.

value,

0.55

to

0.0217

63.7

to

6.5 to

47.0

to

check the

0.75

mm

to

0.0295

68.6

N·m

7.0 kgf·m

50.6 ft-lbs

01640510270

in.

head,

oil

DISASSEMBLING

AND ASSEMBLING

• NOTE

•

The

cylinder partially introduction

For

replacing the choose the right one in reference to its

heads with

modified

of

the

serial numbers 489291 and on are

in

configuration because of the

nozzle heat

cylinder

seal.

head, see the parts

serial

number.

list

and

01640510280

S-75

DIESEL

[1]

DRAINING

ENGINE

WATER AND

OIL

05 SERIES

WS

M, 01640

[2] EXTERNAL COMPONENTS

Draining Cooling Water and Engine

A

CAUTION

•

Never remove radiator cap until cooling water temperature is

below

stop

its

boiling point. Then loosen cap

to

relieve any excess pressure before removing cap

011

slightly

completely.

1.

Prepare a bucket.

2. Prepare an oil pan. Remove the the

pan.

Air

Cleaner and Muffler

1. Remove the air cleaner.

2. Remove

muffler

Open

the drain cock to drain cooling water.

retaining nuts

dra

in plug to drain engine oil in

to

remove the muffler.

01640510290

{When reassembling)

• Install the muffler gasket

so

that

its steel side face the muffler.

01640510300

to

the

01640P10040

Alternator and Fan Belt

1. Remove the al

2. Remo

ve

te

rnator (1).

the fan belt (2) . .

{When reassembling)

• Check

to

see th

at

there are no cracks on the belt surface .

• IMPORTANT

•

After

reassembling

belt tension.

(1)

Alternator

·

the

fan belt, be sure

(2)

Fan Belt

to

adjust

01640510310

the

fan

S-77

DIESEL ENGINE

[3]

CYLINDER

11900F10500

HEAD AND VALVES

Nozzle Holder Assembly

1. Loosen the

2. Remove the injection pipes.

3. Remove the

4. Loosen the lock

5. Remove the copper gaskets

6. Remove the

(1) Nozzle

Cylinder Head Cover

1 . Remove the

2. Remove the

(When reassembling)

•

Check to

Holder

see

05 SERIES WSM, 01640

sc

r

ews

on the pipe

fuel

overflow pipes.

nuts, and remove the nozzle holder assemblies.

nozzle

Assembly

head cylinder

heat

cover

head cover

if the cylinder

clamps.

on

the seats.

seal. (See

cap

nuts.

head cover gasket

(1

page

).

S-83.)

is

01640510320

not

defective.

(1) Head Cover

Rocker Arm and Push Rod

1. Remove t

2. Detach the rocker arm as a unit.

3. Remove the push rods .

he

rocker arm bracket mounting nuts.

• IMPORTANT

• After reassembling the rocker arm,

valve

clearance.

(When reassembling)

•

When their ends

(1)

putting t

Rocker Arm Assembly

he

are

properly engaged with

push rods onto t

(2)

he

the

Push

01640510330

be

sure

to

adjust the

tappets, check to see

grooves.

Rod

11900510061

if

S-79

DIESEL ENG INE

05 SERIES

WSM,

01640

(B)

11900F10280

Cylinder

Head

1. Loosen the pipe band, and remove the water return pipe.

2. Remove the cylinder head screws in the order and remove the

3. Remove the cylinder head gasket and

cylinder

h

ea

d.

0-ri

ng.

of

(14,

18

(When reassembling)

•

Replace the head gasket with a

• Install

•

(A) Gear

the cylinder head, using

Tig

ht

{14,

en the

18)

cylinder head

after applying engine

Retighten the cylinder head screws after runn

30

minutes.

Case Side

new

one.

ca

re

not

to damage the 0-ring.

screwsgradually

oil.

(B) Flywheel Side

in the order

ing

the

engine for

11900510072

Tappets

1. Remove the tappets

(When

• Before

•

reassembling)

installing the tappets,

lMPORTANT

Mark. the cylinder number

(1)

fr

om the crankcase.

app

ly

to

engine

the

oil

thi n

ly

tappets

around them .

to

interchanging.

(1)

Tappet

) to

(1

),

of

(1)

to

prevent

11900P10080

•

11900510081

Valves

1. Remove the valve cap (2).

2.

Remove the valve spring collet

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

(3) with a valve

sp

lifter.

ring

(5)

and

va

l

ve

(7).

(When reassembling)

•

sufficiently

•

After installing

the

va

lve

assure proper fit with a plastic hammer.

(1)

Valve

Wash the valve stem and valve

(2) (3) (4)

Ufter

Valve

Cap Valve Spring Collet Valve

Spring

Re

tainer

guide hole, and

sp

ring

collets,

(5) (6)

(7)

lightly tap

Valve Spring

Valve Stem Seal Valve

apply

engine oil

the stem to

11900510091

S-81

DIESEL ENGINE

05

SERIES

WS

M,

01640

11790F10410

Nozzle Heat

Seal

Service Removal Procedure

(Engine Serial Number : 489291 and beyond

.IMPORTANT

•

Use a plus

Is

bigger than the heat seal hole

1. Drive screw driver lightly into

2.

Tu

m screw driver t

3.

While turning the screw driver, together

If

the heat seal drops, repeat the above

(phillips

with

th

head) screw driver that has a

hr

ee or four times each way.

e injection nozzle gasket.

(Approx. 6 mm) 1/4

the

he

at

seal hole.

slowly pull the

pr

ocedu and injection nozzle gasket must be changed when nozzle

(1) (2)

is

removed for cleaning or for service.

Plus

Screw Driver (3)

Injection Nozzle (4) Heat

Injection Nozzle

Seal

Dla.

heat seal

re

.

Heat

the

Packin

11790510131

which

ln.

out

seal

injection

(4]

GEAR CASE

01640P10070

Fuet

Feed Pump and Hour Meter Gear

Case

1 . Loosen the pipe clamp and remove the fuel pipe from

injection pump side.

2. Remo

ve

the fuel feed pump mounting nuts.

3. Remove the fuel feed pump (1).

(When

•

(1)

reassembling)

App

ly

a liquid gasket (Three Bond 1215

both sides

Fuel

Feed Pump

of

fuel feed pump gasket a

or

eq

ui

va

lent) to

nd

hour meter gear case .

01640510340

Water Pump

1. Remove the water pump flange.

(When

•

reassembling)

Apply a liquid gasket (Three Bond

both sides

of

water pump flange gasket.

12

15

or

equivalent}

to

the

S-83

01640510350

DIESEL ENGINE

Fan Drive Pulley

1. Set the stopper to the flywheel.

2. Remove the crankshaft screw

3. Draw out the fan drive pulley

{2)

(When reassembling)

• Install the pulley {D905, aligning the marks

Tightening torque

(1) Crankshaft Screw (2) Fan Drive Pulley

Gear

Case

1.

Remove the gear case.

{3)

Crankshaft screw (Serial

D1

on them.

No

: - 604086)

No

: 604087

(When reassembling)

• Apply a liquid gasket (Three sides

of

the gear case gasket.

• Grease thi n

ly

to

the oil seal, and install it, ensuring the lip does

not come off.

{1)

.

with a puller.

005,

D11

-)

(3)

Aligning Marks

Bond

1215

OS

SERIES WSM, 01642

05)

to

the crankshaft,

to

142.2 14

104.9

235.4

24

173.6

or

152.0 N·m

.5 to 15.5 kgf·m

to

112.1 ft-lbs

to

245.2 N·m

.0 to 25.0

kgf

to

180.8 ft-lbs

01640510360

equivalent) to both

·m

11900F1 0300

Length

ofthe

gear case mounting bolts {refer to the figure) A : 45 mm E : 68 mm B : 50 mm

F : 80 mm

C : 55 mm G : Nut

D:59mm

01640510370

Engine Stop Solenoid and Speed Control Plate

1. Remove the eng ine stop solenoid

{1).

2. Remove the speed control plate with the governor springs 1

(When reassembling)

• Apply a liquid gasket {Three Bond 1215 or equivalent) sides

of

the solenoid cover gasket and control plate gasket.

• Be careful not

(1) Engine Stop Solenoid

to

drop the governor springs 1 into the crankcase.

(2) Governor Spring 1

to

{2).

both

S-85

11900510121

DIE

SEL

ENGINE

05 SERIES WSM, 01640

Injection Pump

1. Align the control rack pin (3) with the notch (1) on the crankcase, and remove the injection pu

2. Rem

3.

ov

e the injection pump shims.

In prin ciple, the injection pu

mp

(2).

should

not

be disassembled.

(When reassembling) .

•

Wh

en installing the injection pump, insert

firmly into the groove of the

• NOTE

fo

rk l

eye

the

con

tro

l rack pin (3)

r and thrust lever .

(Engine serial number : - 489290)

• Insert the same number crank case and pum

• Addition advances

•

Apply liquid to

both

or

reduction

the

injection ti

-type gasket (Three

sides

of

p.

of

the

of

shims

shim ming

injection

as used before between

(0.15

mm

, 0.0059 in.) del

by

approx. 0.026 rad.

Bons

1215

or

its

pump

shim

ays

or

(1.5)

.

equivalent)

before

reassembling.

(Engine serial number :

• The sealant

is

applied

shim. The liquid gasket

•

Addit

ion

or

reduction of

advances

the

Injecti

• In disassembling and replacing, be sure number

of

new gasket

489291 - )

to

both

is

not

shim

on

timi

ng

shims with

sides

of the

soft

metal gasket

required for assembling.

(0.05 mm, 0.0020

by

approx. 0.0087 rad. (0.5

the

same thickness.

in

.) delays

to

use the same

or

j.

(1)

Notch

(2)

Injection Pump

(3)

Control Rack Pin

11900510131

S-87

DIESEL ENGINE

05

SERIES

WSM,

Fuel Camshaft

1.

Remove the fuel camshaft stopper (2).

2. Draw out the fuel camshaft

(3)

and injection pump gear (1).

(When reassembling)

• Apply engine oil thinly to the fuel camshaft before installation.

(3)

(1)

Injection Pump Gear

(2)

Fuel Camshaft Stopper

Fuel Camshaft

01640

11900F10320

01640F10330

11900810140

Timer

• IMPORTANT

•

If

there are not problems with the timer, there is no need to

separate it from the fuel camshaft.

• Hammers and similar tools should not be used if the timer is

to be separated from the shaft.

(1)

Fuel Camshaft

(2)

Timer Mounting Nut

01640510380

S-89

DIESEL ENGINE

Governor Shaft

1.

Remove the

2.

Remove the governor shaft (2).

(When

•

reassembling)

Make s

shaft.

•

Che

ck the governor shaft for smooth rotation .

• IMPORTANT

•

When fit

the ball (Three Bond 132 fasten the screw circumferential end

(1)

External

(2) Governor

external

ur

e assembling t

replacing

the

bearing (3)

Snap

Ring

Shaft

48

s

nap

ball

or

until

of

ring (1) from

he

external

bearing

to

the crankcase, apply

equivalent)

its

the

ball

beari

(3)

(4)

the

snap ring of the govern

of

governor shaft, securely

to

the set screw

tapered part contacts

ng

.

Ball

Bearing

Set

Screw

05

SERIES WSM, 01640

governor shaft.

an adhesive

(4),

a

nd

the

or

11900F10330

11900$10151

S-

91

DIESEL ENGINE

11900F10340

OS

SERIES WSM,

Fork Lever

1. Remove the start spring

(7).

2. Remove the fork lever shaft cover (1).

3. Remove the fork lever shaft {

4)

.

4. Remove the spacer (2), bearing (3) and fork lever

(When reassembling)

•

Apply a liquid gasket (Three Bond 1215 sides

of

the fork lever shaft cover.

•

to

assembling the fork lever shaft cover

"

UP

"

on it upwards.

•

Ma

ke sure assembling the start spring .

or

equivale

to

position the mark

• IMPORTANT

•

To

assembling

bolts as shown

(1)

Fork Lever

(2)

Spacer

(3)

Bearing

(4)

Fork

Lever

the fork lever 2 to the right side

In

the figure.

Shaft Cover

Shaft

(5)

Fork Lever

(6)

Fork Lever 1

(7)

Start Spring

(8)

Fuel

Um

it

2

Bolt

1,

of

2.

nt

) to both

fuel

01640

limit

11900F10350

11900510161

S-93

DIESEL ENGINE

05

SER

I

ES

WSM, 01643

(For EU]

01640F10181

Cam Gear and

1.

Remove the external snap ring.

Idle Gear 1, 2

2. Remove the idle gear 2 (7).

3. Remove the idle gear 1 (4).

4. Remove the camshaft stopper mounting bolt.

5. Rem

ove

the camshaft (6) .

• IMPORTANT

•

When installing

the

idle gear,

be

sure

to

align

the

alignment

marks on gears.

•

Make sure assembling the external snap ring and stopper.

(1)

Injection

(2)

Governor Gear

(3) Crank

{4)

Idle

Gear

Pump

1

Gear

(5)

Cam Gear

(6)

Camshaft

(7)

Idle

Gear

2

11900F10360

[5]

PISTON AND CONNECTING

11900F1

0370

11900510171

ROD

Oil

Pan and

1.

Remove the oil pan mounting screws.

2.

Remove the oil pan by lightly tapping the rim wooden hammer.

3. Remove the oil strainer

(When reassembling)

•

Apply a liqu sides

•

To avoid uneven tightening, tighten mounting screws in diagonal order from

•

After cleaning the oil s

• Install the oil strainer

(1)

Oil

Strainer

id

gasket (Three Bond 1215

of

the oil pan gasket.

the

center.

Strainer

(1).

or

equivalent)

tr

ainer,

install

it.

(1),

using care not to damage the

of

the pan with a

to

0-

11900510181

rin

both

g.

S-95

DIESEL ENGINE

01640P10140

(a)

05

SERIES

WSM,

Connecting Rod Cap

1. Remove the connecting rod screws from connecting rod cap.

2. Remove

the

connecting rod caps.

(When reassembling)

•

Align the marks (a) with each other. (Face the marks toward the injection pump.)

• Apply engine in by hand, then tighten If

the

connecting rod screw

the threads.

If

the

connecting rod

ligh

tening torque

(a) Mark

oil

to

the connecting rod screws

it

to the specified torque.

won't

screw

is

still

Connecting

rod

screw

and

lightly screw

be screwed in smoothly, clean

hard

to

screw

41

4.2 30

.2 to

to

.3

in, replace

46

.1

4.7

kgf·m

to

33.9 ft-lbs

it.

N·m

01643

it

11900F10380

0.79

rad.

(45")

Piston

--

1. Turn the flywheel and bring the No. 1 piston

2.

(When reassembling)

•

• IMPORTANT

•

(1)

0.79 rad. (A)

(45")

11900510191

to

the center. Pull

out

the piston upward by

the crankcase

wit

h the grip

Before inserting the piston into the

lightly tapping

of

a

hammer

cylinder,

it

from the bottom

.

apply enough engine

oil to the cylinder.

When

inserting the piston into the cylinder, face the

co

nnecting r

Do

not Make sure example, mark "1" When inserting the piston

od

to

the injection

pump

change the combination

of

the

position

on

the

of

No.1

into

each

piston.

the

.

mark

of

cylinder and piston.

piston

by

marking. For

cylinder, place the gap

the compression ring 1 on the opposite side combustion chamber and stagger compression ring 2 and

the

gap

of

the

compression

Carefully

(1

). Otherwis

Insert

the e,

scratched, causing trouble

Piston Ring

Top

Ring

Compressor

Gap

oil

pistons

their

ring making a

ring

1.

us

ing a piston ri

chrome-plated section may be

Inside

(B)

(C)

(D)

the

Seco

011

Pl

Ring

eton

the

liner.

nd

Ring Gap

Gap

right

Hole

gaps

angle from

ng

compressor

top dead

of

on

the

of

the

of

the

11900F10390

(D)

11900510201

S-97

DIESEL ENGINE

05

SERIES

WSM,

01640

11900F10400

11900F10410

t)

Rod

the piston as shown

on

(8)

tool.

figure.

in

(7)

Piston Ring and Connecting

Remove the piston rings using a piston ring

1. the casting mark (

Put

2.

3. Remove the piston pin (1}, and separate the connecting rod from the piston (2).

(When

• When

reassembling)

installing

the ring, assemble

the rings so that the

manufacturer's mark (12) near the gap faces the top

of

the

piston.

the expander

ring onto the piston,

oil

• When

• Apply

•

installing

0)

(1

joint

engine

installing the piston pin, immerse the piston in 80

When

for 1

oil

"F)

• When installing on the connecting rod to the casting mark

(9)

the

the opposite side of the oil ring gap

on

to the piston pin.

oil

to 15 minutes and insert the piston pin to the piston.

o

the connecting rod to the piston,

place

(11

.

(8)

).

align

(176

·c

the mark

• IMPORTANT

the connecting rod and the

Mark the same number

•

to

not

as

piston

(1) Piston Pin (2) Piston (3) Piston Pin (4)

(5)

(6)

so

Compression Compression Oil

Snap

Ring

Ring Ring 1 Ring 2

change the combination.

on

(10) (11) (12)

Connecting

(7)

Casting

(8)

Mark

(9)

Expander

Ring

Oil Manufacturer's

Rod

Mark

Joint

Gap

Mark

I

0500

11790F1

11790F10510

C)

11900810211

S-99

DIESEL ENGINE

[6]

FLYWHEEL AND CRANKSHAFT

. , I

01640P10170

OS

SERIES

WSM

, 01640

Starter

1.

Remove the starter

(1)

Starter

(1

}.

01640510390

Aywheel

1. Lock the flywheel not

to

turn using the flywheel stopper.

2. Remove the flywheel screws, except for two which must be loosened and left as they are.

3.

Set

a flywheel

puller

(Code No: 07916 -32011

),

and remove the

flywheel.

(When reassembling)

•

Apply engine

oil

to the flywheel screws.

016405 10400

S-101

DIESEL ENGINE

05 SERIES WSM, 01640

Bearing Case Cover and Crankshaft

• NOTE

• Before disassembling, crankshaft

1 . Remove

2.

Screw cover

3. Remove

4. Pull

out

the

two

to

remove i

the

..

Also

check

bearing

removed

t.

bearing

crankshaft.

case screws

case

check

it

during

cover

into

screw

reassembly.

mounting screws.

the

2 (5).

the

side clearance

screw

hole

of

(When reassembling)

• IMPORTANT sub

• Install the crankshaft of

main bearing case 2 (2)

block

{1).

Apply

• screw

engine

oil

to

2 (5) and tightening it.

• Install the bearing case mark

"UP;;

(4) on

It

upward.

• Tighten force

(1) Cylinder Block (4) Top Mark (2) Main Bearing Case 2 (5) Bearing Case Screw 2 (3) Bearing Case Cover

on

the

bearing case

the

diagonal line.

assembly,

with

the

seat and thread cover

cover

aligning

the

screw

(3)

to

position

mounting

"UP"

the

hole

of

bearing case

screws

bearing

case

screw hole of

cylinder

the

casting

with

even

of

01640510410

S-103

DIESEL ENGINE

05 SERIES

WSM,

01640

Main Bearing Case Assembly

1 . Remove the two main bearing case screws 1 , and remove the

main bearing case assembly (2), being careful with the thrust bearing (3) and crankshaft bearing 2.

2.

Remove the main bearing case assembies

1,

2 and 3 as above.

(When reassembling)

in

• Clean the oil passage

• Apply clean engine oil

the main bearing case.

on

the crankshaft bearing 2 and thrust

bearings.

• Since diameters of

makings (A, B, C) from the gear case side.

• When installing the main bearing case assemblies

of

main bearing case vary, install them

1,

in

order

2 and

3,

face the mark "FLYWHEEL" to the flywheel.

• Be sure to install the thrust bearing with its oil groove facing outward.

(1)

Main

Bearing Case Assembly

and

3

1, 2 (2)

(3)

Main Bearing Case Assembly Thrust Bearing

11790F10530

SERVICING (1]

CYLINDER HEAD

OOOOOF10010

11900510251

Cylinder Head Surface Flatness

1.

Thoroughly clean the cylinder head surface.

2. Place a straightedge on the cylinder head's four sides and two

diagonal as shown in the figure. Measure the clearance with a feeler gauge.

3.

If

the measurement exceeds the allowable limit, correct it with a

surface grinder .

• IMPORTANT

• Do not place the straight edge on the combustion chamber.

• Be sure to check the valve recessing after correcting.

OOOOOF10020

00000510011

S-105

DIESEL ENGINE

05

SERIES

WSM,

01640

RC-AA

8

OOOOOF10030

Cylinder

1.

2.

3.

4.

5.

6.

{1) {2)

Valve

1.

2.

3.

4.

Head

Flaw

Prepare Clean Spray the

(1). Wash away the red permeative liquid surface with the detergent

Spray the cylinder head surface with white developer (3).

If

Red Detergent

Clean

Insert

Measure the valve recessing with a depth gauge.

If valve.

If it

correct the valve seat face of the cylinder head with a valve seat

cutter (Code No. 07909-331 Then, correct the cylinder head surface with a surface grinder, or

replace the cylinder head.

an

air spray red check (Code

the surface of the cylinder head with detergent (2).

cylinder

Leave it five to ten minutes after spraying.

flawed, it can be identified as red marks.

Permeative Liquid

Recessing

the cylinder head, the valve face and seat.

the valve into the valve guide.

the measurement exceeds the

still

exceeds the

head surface with the red permeative liquid

(2).

allowable

02)

No.

07909-31371

on

the cylinder head

{3)

White

Developer

allowable limit,

limit after replacing the valve,

or valve seat grinder.

).

00000510020

replace the

00000510031

+

OOOOOF10050

OOOOOF10060

Clearance

1.

Remove carbon from the valve guide section.

2.

Measure the valve stem

3.

Measure the valve guide

wear part as shown And calculate the clearance.

4.

If

between

the clearance exceeds the allowable limit, replace the valves. it still

exceeds the allowable limit, replace the valve guide.

S-107

Valve Stem

in

the figure below with a

and

0.0.

with

an

1.0.

of the cylinder head at the most

Valve

Guide

outside micrometer.

small

hole gauge.

00000510042

DIESEL ENGINE

11790F10450

Valve

Seating

1.

Coat the on

2.

If

the valve contact is follows.

3.

If replace

(1)

Correct

(2)

Incorrect

valve

face

its seat to check the contact.

valve

does not seat

less

the

valve

contact does not

the

valve

or correct the contact of

05

lightly with prussian blue

all

the way around the

than

70

%,

correct the

comply

with the reference

(3)

Incorrect

valve

SERIES

WSM,

and put the

valve

seat or the

valve

seating as

seating.

01640

valve

value,

0

11790F10460

OOOOOF10090

OOOOOF10100

0

®

Correcting Valve

• NOTE

•

1)

1.

2)

1.

2.

0.785

rad.

(45")

or

1.047

rad.

Ul--t:--=:--~

(60")

0.523 (30")

0.262

(15")

or

3.

4. Check the valve

rad

(b)

rad.

and

Valve Seat

Before correcting the and the necessary. After correcting the recessing. Correcting

Correct the

Correcting

Slightly correct the seat surface with a valve) 07909-331 02).

Resurface the seat surface with a 0.523 cutter to intake valve cutter to exhaust valve After resurfacing the seat, inspect for even thin and fit them with valve lapping tool.

surface should show good contact

(a)

Identical Valve Seat

I.D.

of

Valve

valve

Valve

or

0.785

rad. (45") (exhaust

seat width (2.12

film

of compound between the valve

Dimensions

Width

valve

and seat, check the

the

valve

guide section, and repair them

valve seat, be sure

with a

valve

refacer.

Seat

valve) seat cutter (Code No.

seat and with a 0.262

valve

seat so that the width

mm,

0.0835

seating with prussian

(A) (B) (C)

in.).

all

Check Correct Check

to

check the

1.047

rad. (60") (intake

rad.

(30") valve

rad. (15")

is

close

valve

seating,

face and

blue. The

the way around.

Contact

Seat

Contact

valve

Width

11790510230

valve

stem

valve

seat

valve seat

to specified

apply a

valve

seat,

seating

if

c

~(~

OOOOOF1011~

( )

00000810070

S-109

DIESEL ENGINE

OOOOOF10080

05

SERIES

WSM,

01640

Valve Lapping

1 . Apply compound evenly to the valve lapping surface.

2. Insert the valve into the valve guide. Lap the valve onto its seat with a valve flapper or screwdriver.

3. After lapping the valve, wash the compound away and apply oil, then repeat valve lapping with oil.

4.

Apply prussian blue to the contact surface to check the seated rate. If it is less than

70%,

repeat valve lapping again .

• IMPORTANT

• When valve lapping

performed, be

sure

to

check the valve

is

recessing and adjust the valve clearance after assembling

the valve.

00000510060

Replacing Valve Guide {When removing)

1.

Using a valve guide replacing tool (see page S-65), press out the used valve guide.

{When installing)

1.

Clean a new valve guide, and apply engine oil to it.

2.

Using a valve guide replacing tool, press

until it is flush with the cylinder head as shown in the figure.

3.

Ream precisely the 1.0.

dimension .

of

the valve guide to the specified

in

a new valve guide

• IMPORTANT

• Do

not

hit

the valve

guide

with

a hammer, etc.

during

replacement.

(A) When Removing

(B) When Installing

OOOOOF10070

(A)

(B)

Ja~~wM~w~~'l

OOOOOF10120

(A)

00000510052

Free Length and Tilt

1.

Measure the free length (A) with vernier calipers. If the measurement is less than the allowable limit, replace it.

2.

Put the spring on a surface plate, place a square on the side the spring, and check to see if the entire side is the square. Rotate the spring and measure the maximum (B). If the measurement exceeds the allowable limit, replace.

3. Check the entire surface any.

S-111

of

Valve Spring

of

the spring for scratches. Replac it, if

in

contact with

00000510082

of

DIESEL ENGINE

05

SERIES

WSM,

01640

Valve Spring Setting Load

1. Place the valve spring on a tester and compress it to the same

length it is actually compressed in the engine.

2.

Read the compression load on the gauge.

3.

If the measurement is less than the allowable limit, replace it.

OOOOOF10130

OOOOOF10140

OOOOOF10150

00000510092

Oil Clearance between Rocker Arm Shaft and Beraing

1. Measure the rocker arm bearing

2.

Measure the rocker arm shaft O.D. with an outside micrometer,

I.

D.

with an inside micrometer.

and then calculate the oil clearance.

3.

If the clearance exceeds the allowable limit, replace the rocker

arm and measure the oil clearance again.

If

it still exceeds the

allowable limit, replace also the rocker arm shaft.

00000510102

Push Rod Alignment

1 . Check the both end

of

the push rod for cracks, damage and

unusual wear.

2.

Measure the bending

of

the push rod with a dial indicator.

3. If the measurement exceeds the allowable limit, replace the push rod.

00000510111

Oil Clearance between Tappet and Tappet Guide Bore

1.

Measure the tappet O.D. with an outside micrometer

2.

Measure the

I.

D.

of

the tappet guide bore with a cylinder gauge,

and calculate the oil clearance.

3.

If the oil clearance exceeds the allowable limit

or

the tappet is

damaged, replace the tappet.

OOOOOF10160

00000510122

S-113

DIESEL ENGINE

[2]

TIMING

GEAR AND CAMSHAFT

Timing Gear Backlash

1. Set a dial indicator (lever type) with its tip on the gear tooth.

2. Move

3.

If

the backlash exceeds

clearance

4.

If

the

Idle Gear

1.

Set a dial

2.

Measure the side clearance by moving the idle

and rear.

3.

If

the

gear

the

gear

to

measure the backlash,

the

allowable limit, check the oil

of

the shafts and the gear.

oil

clearance is proper, replace

Side Clearance

indicator with its tip on the

measurement exceeds the allowable

collar.

the

idle

05 SERIES

ho

lding its mating gear.

gear.

limit, replace the idle

gear

WSM

00000510132

to

the front

, 01640

11900P10220

Camshaft Side Clearance

1

. Set a

2. Measure the

3.

dial

indicator with its tip on the camshaft.

side clearance

and rear.

If

the measurement exceeds the allowable limit,

camshaft stopper.

by

moving the cam gear to the front

00000510142

replace the

00000510182

S-115

DIESEL ENGINE

05

SERIES

WSM,

01640

Camshaft Alignment

1 . Support the camshaft with V blocks on the surface plate and set

a dial indicator with its tip on the intermediate journal at right angle.

2. rotate the camshaft on the V blocks and get the misalignment (half of the measurement).

3. if the misalignment exceeds the allowable limit, replace the

camshaft.

OOOOOF10240

OOOOOF10250

01640F10350 01640F10530

~

Q).

0

.v

(

00000510191

Cam Height

1.

Measure the height of the cam at its highest point with micrometer.

2.

If the measurement is less than the allowable limit, replace the camshaft.

Oil Clearance

1.

Measure the camshaft journal O.D. with an outside micrometer

2.

Measure the cylinder block bore micrometer. Calculate the oil clearance.

3. If the clearance exceeds the allowable limit, replace the camshaft.

Oil Clearance between Idle Gear Shaft and Idle Gear Bushing

1.

Measure the idle gear shaft O.D. with

2.

Measure the idle gear bushings and calculate the oil clearance.

3. If the oil clearance exceeds the allowable limit, replace the

bushing.

of

Camshaft Journal

I.

D.

for camshaft with

an

outside micrometer.

J.D.

with an inside micrometer,

an

outside

00000510202

an

inside

00000510172

OOOOOF10190

00000510152

S-117

DIESEL

ENGINE

05

SERIES

WSM,

01640

(B)

OOOOOF10200

[3]

PISTON AND CONNECTING

OOOOOF10260

~

._

Replacing Idle Gear Bushing

(A) (When removing)

1. Using an idle out

the

gear

bushing replacing tool (see page S-69), press

used bushing.

(B) (When installing)

1. Clean a

engine oil

2. Using

bushing (service parts)

new

idle gear bushing and idle

to

them.

an

idle gear bushing replacing tool, press in a

to

the

specified dimension. (See figure.)

gear

bore,

and

00000510161

ROD

Piston Pin Bore I.D.

1. Measure the piston pin bore I.D. in both vertical directions with a cylinder gauge.

2. If

the

measurement

piston.

exceeds

the

allowable limit, replace

Oil Clearance between Piston Pin and Small End Bushing

1. Measure the O.D.

with an outside micrometer.

2. Measure

small end with a cylilnder gauge. Calculate

3.

If

the

If it still exceeds

the

clearance exceeds

of

the

piston pin

I.

D.

of

the

piston pin bushing

oil clearance.

the

allowable limit, replace

where

allowable limit, replace

the

horizontal and

it contacts

at

the

connecting rod

the

piston pin.

OODDDS10212

the

apply

new

the

bushing

bushing.

S-119

00000510222

DIESEL ENGINE

(A)

OOOOOF10280

(B)

05

SERIES

WSM,

Replacing Small End Bushing (When removing)

1.

Press out the used bushing using a small end bushing replacing

tool.

(When installing)

1.

Clean a new small end bushing and bore, and apply engine oil to them.

2.

Insert a new bushing onto the tool and press-fit it with a press so

that the seam

(1)

of

bushing positions as shown in the figure,

until it is flash with the connecting rod.

3.

Drill a hole to the bushing with aligning the oil hole connecting rod using 4.0 mm dia. (0.157 in. dia.) drill.

• NOTE

• Be sure

to

chamfer the oil hole circumference with an oil

stone.

(1) (2)

Seam Oil Hole

(A) When Removing (B) When

Installing

01640

(2)

of

OOOOOF10740

00000510231

Piston Ring Gap

1.

Insert the piston ring into the lower part

of

the liner (the least

worn out part) with the piston.

2.

Measure the ring gap with a feeler gauge.

3.

If the gap exceeds the allowable limit, replace the piston ring.

00000510242

S-121

DIESEL ENGINE

05

SERIES

WSM,

01640

[A]

01640F10360

[B)

OOOOOF10300

OOOOOF10310

Clearance between Piston Ring and Groove

1.

Remove carbon from the ring grooves.

2.

Measure the feeler

gauge or depth gauge.

3.

If

the

clearance

compression

4.

If

the

clearance still

the ring, replace

I

Factory

spec:

{A)

Top

Ring {Key Stone

Connecting Rod

clearance

between the ring and the groove with a

exceeds allowable limit, replace

leak

and

oil

shortage result.

exceeds

the

allowable limit

the piston.

I

A

Type)

More than 0.2 mm

{B) 2nd, Oil

Alignment

0.079

Ring

• NOTE

•

Since the basis

1.

Remove the crankpin bearing, and

of

I.

D.

of

the connecting rod

this

check, check the bushing

small

end bushing

for

install

the connecting rod

cap.

2.

Install

3.

the piston pin

Install

the connecting rod on the connecting rod

in

the connecting rod.

(Code No. 07909-31661).

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

the space between the pin of the gauge and the face

6.

If

the measurement exceeds

the

allowable limit, replace

connecting rod.

the ring since

after

replacing

in.

00000510252

is

the

wear beforehand.

alignment tool

plate,

measure

plate.

the

00000510261

S-123

DIESEL ENGINE

[4]

CRANKSHAFT

05 SERIES WSM, 01642

11900P10240

OOOOOF10350

B

Crankshaft Si

1

.

Set

a dial indicator with its tip on

2. Measure the side clearance

de

Clearance

the

by

moving the crankshaft to the front

and rear.

3.

If

the measurement exceeds the allowable

thrust bearings.

4.

If

the same size bearing is useless because

journal wear, replace it with

an

oversize one referring

and figure.

Factory

spec

Crankshaft side clearance

Allowable limit

.

(Reference)

•

Oversize thrust bearing

Oversize Bearing

0.2

mm

o.oosin.

0.4mm

0.016

•

Oversize dimensions

Thrust bearing 1 02 15 Thrust bearing 2 Thrust bearing 1

in.

Thrust bearing 2

02 04 04

of

crankshaft journal

521 19202-23971 1552119202-23981

end

of

the crankshaft.

0.15

0.0059

0.50mm

0.0197 in.

Code Number

-23951

2396

1

limit, replace

of

the crankshaft

to

the

to

0.31

mm

to

0.0122

in.

Marking

0200S

0200S 0400S 04005

the

table

OOOOOF1

0330

0.2mm 0.4mm

e

~

n

A

B

c

The

crankshaft journal must be fine-finished

Crankshaft

1

.

Support

0.008 in.

28.20 to

1.1102 to 1.1122 in. 1. 51

.5 to 51.7

2.

028

to

2.3 to 2.7

0.

091

to

Alignment

the crankshaft with a dial indicator with its tip angle.

2. Ro

ta

te the crankshaft on the

(half

of

t

he

measurement).

3.

If

the

misalignment exceeds the allowable

crankshaft.

28

.25

mm

2.035

in.

mm

radius 2.3 to 2.7

0.106

ln. radius

to

higher than

V

blocks

on

V

on

the

intermediate journal at right

blocks and

O.Q16

in

.

28.40 to 28.45 1181

51

.6

to

2.

031

to

0.091

to

mm

to 1.1201 in .

51.8

mm

2.039

in.

mm

ra

dius

0.

106

in. radius

(0.8·5)

vvvv

.

00000510291

t

he

surface plate and set

get

the misalignment

limit,

replace the

OOOOOS10281

S-125

DIESEL ENGINE

05 SERIES WSM, 01640

OOOOOF10400

A

Oil Clearance

1.

Clean the crankpin and crankpin bearing.

2.

Put a strip of

between Crankpin and Crankpin Bearing

plastigage (Code

No. 07909-30241) on the center

of the crankpin.

3.

Install

the connecting

rod

cap and tighten the connecting rod

screws to the specified torque, and remove the

4.

Measure the amount of the

flattening

with the

oil clearance.

5.

If

the oil clearance

exceeds the

allowable limit, replace the

crankpin bearing.

6.

If

the same size bearing is useless

wear,

replace

it with

an

undersize one referring to the

because of the crankpin

figure .

• NOTE

•

Never insert the

•

Be sure not to move the crankshaft while

plastigage

into the crankpin

rod screws are tightened.

Oil clearance crankpin and crankpin bearing

Crankpin

Crankpin bearing

between

0.0.

1.0.

Factory spec.

Allowable limit

Factory spec.

cap

again.

scale,

oil hole.

the connecting

0.029

to

0.091

0.00114

to

0.00358

0.20mm

0.0079

in.

39.959

to

1.57319to

40.004

1.57496

39.975 mm

1.57382 in.

to

40.050

to

1.57677 in.

and get the

table

and

mm

in.

mm

(Reference)

•

Undersize crankpin bearing

Undersize Bearing

0.2mm

0.008

0.4mm

0.016

•

Undersize dimensions of

~

The crankpin must be fine-finished

in.

n

A

8

c

Crankpin bearing

0.2mm

0.008

in.

2.8

to

3.2 mm radius 2.8 to 3.2 mm radius

0.1102

to

1.0

to 1.5 mm radius

0.0394

to

39.759

to

1.56531

Code

Number

02

16241-22971

04

16241-22981

crankpinl

0.4mm O.D16

0.1260

in.radius

0.0591

in. radius 0.0394

39.775 mm 39.559

to

1.56594 in. 1.557 44

to

higher than

0.1102

1.0

(0.8-S)

vvvv

Marking

020US

040US

in.

to

0.1260

in.radius

to 1.5 mm radius

to

0.0591

in. radius

to

39.575 mm

to

1.55807 in.

.

00000810321

S-127

DIESEL ENGINE

OOOOOF10410

05 SERIES WSM, 01640

Oil Clearance between Crankshaft Journal and Crankshaft Bearing 1

1.

Measure the

0.0.

of the crankshaft front journal with

an

outside

micrometer.

2.

Measure the micrometer,

3.

If the

oil

crankshaft bearing

4.

If the same size bearing

journal wear, replace it with

and

table

Oil clearance between crankshaft journal and crankshaft bearing 1

Crankshaft journal

Crankshaft bearing 1

1.0.

of the crankshaft bearing 1 with

and

calculate the

oil

clearance.

an

clearance exceeds the allowable limit, replace the

1. is

useless because of the crankshaft

an

undersize one referring to the

figure.

0.034 to 0.114 mm to

0.00134

0.20mm

0.0079 in.

47.934

1.88716

47.984

1.88913

0.00449 in.

to

47.950 mm

to

1.88779 in.

to

48.048 mm

to

1.89165 in.

0.0.

I.

Factory spec.

Allowable limit

Factory spec.

D.

Factory spec.

inside

OOOOOF10420

OOOOOF10430

(Reference)

• Undersize crankshaft bearing 1

Undersize Bearing Code Number

0.2mm

0.008 in.

0.4mm

0.016 in.

Crankshaft bearing 1 02

Crankshaft bearing 1 04

16241-23911

16241-23921

• Undersize dimensions of crankshaft journal

0.2mm 0.4mm

~

n

A

8

c

The crankshaft journal must be fine-finished

0.008 in.

2.3 to 2.7 mm radius 2.3 to 2.7 mm radius

0.0906

to

0.1063 in.radius 0.0906

1.0

to

1.5 mm radius 1.0

0.0394

to

0.0591 in. radius 0.0394

47.734

to

1.87929

47.750 mm

to

1.87992

in.

to

higher than

O.D16

47.534

1.87142

in.

to

0.1063 in.radius

to

1.5 mm radius to

0.0591 in. radius

to

47.550 mm

to

1.87204 in.

{0.8-S)

VVVV

Marking

020US

040US

.

00000510331

S-129

DIESEL ENGINE

OOOOOF10440

Replacing Crankshaft Bearing 1 (When removing)

1 . Press out the

bearing 1

used

crankshaft bearing using a crankshaft

replacing tool.

(When installing)

1.

Clean

a new crankshaft bearing 1

and

apply

engine

2.

Using a crankshaft bearing 1 bearing 1 manifold

Dimension (A)

(1)

Seam

(2)

Crankshaft Bearing 1

side.

(2)

so

(See

oil

to them.

that its

figure)

Factory spec.

seam

05 SERIES WSM, 01640

and

crankshaft

replacing tool,

(1)

directs toward the exhaust

Oto 0.3 0

to 0.0118

(3)

Cylinder Block

journal

press

mm

in.

bore,

in

a new

00000510341

S-131

DIESEL ENGINE

OOOOOF10450

B

OOOOOF10460

05

SERIES WSM, 01640

Oil

Clearance between Crankshaft Journal and Crankshaft

Bearing 2 (Crankshaft Bearing 3)

1 . Put a strip of plastigage (Code No.

of the

journal.

2.

Install

the bearing case and tighten the bearing case screws 1 to

07909-30241)

the specified torque, and remove the bearing case again.

3.

Measure the amount of the flattening with the

oil

clearance.

4.

If

the oil clearance exceeds the allowable limit, replace

scale,

crankshaft bearing 2 (crankshaft bearing 3).

5.

If the same size bearing is journal table

wear,

replace

and figure .

it with

useless

an

because of the crankshaft

undersize one referring to the

• NOTE

• Be sure not to move the crankshaft

while

the bearing case

screws are tightened.

0.034

to

0.00134

0.20mm

0.0079 in.

47.934

to

47.984

to

1.88913

0.095 mm to

to

I.

D.

Factory spec.

Allowable

Factory spec.

limit

Oil

clearance between crankshaft journal and crankshaft bearing 2

CrankshaftjournaiO.D.

(Intermediate) 1.88716

Crankshaft bearing 2

on

the center

and get the

0.00374 in.

47.950 mm

1.88779 in.

48.029 mm

1.89091 in.

the

0.034

0.00134

0.20mm

0.0079 in.

51.921

51.974

2.04622

I.

D.

Factory spec.

Allowable limit

Factory spec.

Oil

clearance between

crankshaft journal and

crankshaft bearing 3

Crankshaft journal

(Flywheel side) 2.04413

Crankshaft bearing 3

O.D.

to

0.098 mm

to

0.00386 in.

to

51.940 mm

to

2.04488 in.

to

52.019 mm

to

2.04799 in.

00000510351

S-133

DIESEL ENGINE

05 SERIES WSM, 01640

Oil

Clearance between Crankshaft Journal and Crankshaft

Bearing 2 and 3 (Continue) (Reference)

•

Undersize crankshaft bearing 2 and 3

Undersize Bearing Code Number

0.2mm

0.008 in.

0.4mm

0.016

•

Undersize dimensions

~

•

The crankpin

Crankshaft bearing 2 Crankshaft bearing 3 Crankshaft bearing 2

in.

Crankshaft bearing 3

n

A

B

c

D

journal

0.2mm 0.4mm

0.008

2.3 to 2.7 mm radius

0.0906

1.0

0.0394

47.734 to 47.750 mm 47.534

1.87929

51.721

2.03626

of

crankshaft

in.

to

0.1063

to

1.5 mm radius to

0.0591

to

1.87992 in. 1.87141

to

51.740 mm 51.521

to

2.03700

must be fine-finished

16241-23931

02

16241-23861

02

16241-23941

04

16241-23871

04

journal

0.016

in. radius

in. 2.02838

2.3 to 2.7 mm radius

0.0906

1.0

0.0394

to

higher than

in.

to

0.1063

to 1.5 mm radius

to

0.0591

to

47.550 mm

to

1.87204

to

51.540

to

2.02913 in.

vvvv

Marking 020US 020US 040US 040US

in.radius

in.

mm

(0.8 S).

radius

in.

00000510352

S-135

DIESEL ENGINE

[5]

CYLINDER

(A)

(B)

(C)

:::-:-:

OOOOOF10~80

05 SERIES WSM, 01642

Cylinder Wear

1.

Measure the I.D.

with a

cylinder gauge to find the maximum and minimum

2.

Get the difference {Maximum wear) between the maximum and the minimum

3.

If the wear exceeds the

oversize dimension. {Refer to

4.

Visually

check the cylinder wall

are found, the

of the

cylinder

I.D.'s

cylinder should

at the six positions {see figure)

I.

D.'s.

allowable limit, bore and hone to the

"Correcting

for scratches.

be

bored. {Refer to "Correcting

Cylinder".)

If

deep scratches

Cylinder".)

0905-8

(E) V1205-8 V1205-

Cylinder 1.0.

Maximum

-

wear

(A) Top

(B)

Middle

(C)

Bottom

Factory spec.

Allowable limit

(Skirt)

01005-8

V1305-8

01105-8 01105-T-8 V1505-8 V1505-

(E)

T-8

(E) (E)

(E)

T-8

(a)

Right-angled

(b)

Piston Pin Direction

(E)

(E) (E)

72.000

2.8346

76.000

2.9921

78.000

3.0709

0.15

mm

0.0059

to

72.019

to

to 76.019mm to

to

in.

Piston Pin

mm

2.8353 in.

2.9929 in.

78.019

mm

3.0716

in.

01642510362

S-137

DIESEL ENGINE

..

-

OOOOOF10490

CD

®

I

I I I

I

I I

••

,.......

.......

-

05 SERIES WSM, 01642

Correcting Cylinder

1

. When the

hone

Cylinder 1.0. Factory spec. V1305-B

f-

Maximum wear

Finishing

2.

Replace

Part Name

Piston

Piston ring assembly

cylinder

is worn beyond the

allowable limit,

it to the specified dimension.

0905-B

Allowable limit

(E) V1205-B V1205-T-B

01005-B

01105-B 011 05-T-B (E) V1505-B (E) V1505-

Hone

to

(E)

(E) (E)

T-8

1.2

72.500

2.8346 to 2.8551 in .

(E)

76.500

3.0118

78.500

3.0906

(E)

0.15mm

0.0059

to

2.0

J.LR

max.

--

(0.00047

to

0.00079

in.R max.)

the piston and piston rings with oversize (0.5

Model

0905-B

(E), V1205-B (E)

V1205-

T-B (E)

01005-B

01105-B (E), V1505-B

01105-T-B V1505-

0905-B V120501005-B 01105-B 01105-T-B

V1505-T-B (E)

(E), V1305-B

(E)

T-8

(E)

(E), V1205-B (E)

T-8

(E)

(E), V1305-B (E)

(E), V1505-B (E)

(E)

Code Number Marking 16224-2191-0 16295-2191-0 16050-2191-0

(E)

16060-2191-0

16292-2191-0

15901-2109-0 16269-2109-0 16271-2109-0 16261-2109-0

16292-21 09-0

bore and

to 72.519 mm

to 76.519mm

to

3.0126

in.

to

78.519

3.0913

mm in.

to

in.

mm) ones.

05

OS

• NOTE

•

When the oversize cylinder is worn beyond the limit, replace

(1)

Cylinder

the cylinder block

1.0.

(Before Correction) (2) Oversize Cylinder 1.0.

with a new one.

S-139

allowable

01642510372

Kubota 05 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

SAFETY FIRST

SPECIFICATIONS

MECHANISM

FEATURE

0 ENGINE BODY

LUBRICATING SYSTEM

COOLING SYSTEM

FUEL SYSTEM

ELECTRICAL SYSTEM

SERVICING

GENERAL

TIGHTENING TORQUES

TROUBLESHOOTING

SPECIAL TOOLS

ENGINE BODY

GEAR CASE

FLYWHEEL AND CRANKSHAFT

CYLINDER HEAD

CRANKSHAFT

CYLINDER