Kubota 05-E2B, 05-E2BG Service Manual

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Page 1

WORKSHOP MANUAL

KiSC issued 06, 2011 A

DIESEL ENGINE

05-E2B SERIES,

05-E2BG SERIES

Page 2

TO THE READER

KiSC issued 06, 2011 A

This Workshop Manual has been prepared to provide servicing personnel with information on the mechanism, service and maintenance of 05-E2B and 05-E2BG series. It is divided into three parts, “General”, “Mechanism” and “Servicing”.

Q General

Information on the engine identification, the general precautions, maintenance check list, check and maintenance and special tools are described.

Q Mechanism

Information on the construction and function are included. This part should be understood before proceeding with troubleshooting, disassembling and servicing.

Refer to Diesel Engine Mechanism Workshop Manual (Code No. 9Y021-01870) for the one which has not been described to this workshop manual.

Q Servicing

Information on the troubleshooting, servicing specification lists, tightening torque, checking and adjusting, disassembling and assembling, and servicing which cover procedures, precautions, factory specifications and allowable limits.

All information illustrations and specifications contained in this manual are based on the latest product information available at the time of publication.

The right is reserved to make changes in all information at any time without notice.

Do to covering many models of this manual, information or picture being used have not been specified as one model.

August 2005

Page 3

05-E2B, 05-E2BG, WSM

SAFETY FIRST

KiSC issued 06, 2011 A

SAFETY INSTRUCTIONS

This symbol, the industry’s “Safety Alert Symbol”, is used throughout this manual and on labels on

the machine itself to warn of the possibility of personal injury. Read these instructions carefully.

It is essential that you read the instructions and safety regulations before you attempt to repair or use

this unit.

DANGER : Indicates an imminently hazardous situation which, if not avoided, will result in

death or serious injury.

WARNING : Indicates a potentially hazardous situation which, if not avoided, could result in

death or serious injury.

CAUTION : Indicates a potentially hazardous situation which, if not avoided, may result in

minor or moderate injury.

Q IMPORTANT : Indicates that equipment or property damage could result if instructions are not

followed.

Q NOTE : Gives helpful information.

BEFORE SERVICING AND REPAIRING

• Read all instructions and safety instructions in this manual and on your engine safety decals.

• Clean the work area and engine.

• Park the machine on a firm and level ground.

• Allow the engine to cool before proceeding.

• Stop the engine, and remove the key.

• Disconnect the battery negative cable.

• Hang a “DO NOT OPERATE” tag in operator station.

Page 4

05-E2B, 05-E2BG, WSM

KiSC issued 06, 2011 A

SAFETY INSTRUCTIONS

SAFETY STARTING

• Do not start the engine by shorting across starter terminals or bypassing the safety start switch.

• Unauthorized modifications to the engine may impair the function and / or safety and affect engine life.

SAFETY WORKING

• Do not work on the machine while under the influence of alcohol, medication, or other substances or while fatigued.

• Wear close fitting clothing and safety equipment appropriate to the job.

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

• When servicing is performed together by two or more persons, take care to perform all work safely.

• Do not touch the rotating or hot parts while the engine is running.

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

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

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

AVOID FIRES

• Fuel is extremely flammable and explosive under certain conditions. Do not smoke or allow flames or sparks in your working area.

• To avoid sparks from an accidental short circuit, always disconnect the battery negative cable first and connect it last.

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

• Make sure that no fuel has been spilled on the engine.

Page 5

05-E2B, 05-E2BG, WSM

KiSC issued 06, 2011 A

SAFETY INSTRUCTIONS

VENTILATE WORK AREA

• If the engine must be running to do some work, make sure the area is well ventilated. Never run the engine in a closed area. The exhaust gas contains poisonous carbon monoxide.

DISPOSE OF FLUIDS PROPERLY

• Do not pour fluids into the ground, down a drain, or into a stream, pond, or lake. Observe relevant environmental protection regulations when disposing of oil, fuel, coolant, electrolyte and other harmful waste.

PREVENT ACID BURNS

• Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, clothing and cause blindness if splashed into eyes. Keep electrolyte away from eyes, hands and clothing. If you spill electrolyte on yourself, flush with water, and get medical attention immediately.

PREPARE FOR EMERGENCIES

• Keep a first aid kit and fire extinguisher handy at all times.

• Keep emergency numbers for doctors, ambulance service, hospital and fire department near your telephone.

Page 6

05-E2B, 05-E2BG, WSM

KiSC issued 06, 2011 A

SPECIFICATIONS

Model D905-E2B D1005-E2B V1305-E2B

Number of Cylinders 3 4

Type Vertical, Water-cooled, 4 cycle diesel engine

Bore × Stroke mm (in.) 72 × 73.6 (2.83 × 2.90) 76 × 73.6 (2.99 × 2.90)

Total Displacement cm

ISO Net Continuous kW/min (HP/min

ISO/SAE Net Intermittent kW/min

SAE Gross Intermittent kW/min

Maximum Bare Speed (min

Minimum Bare Idling Speed (min

Combustion Chamber Spherical type (E-TVCS)

Fuel Injection Pump Bosch MD type mini pump

Governor All speed mechanical governor

Direction of Rotation Counter-clockwise (viewed from flywheel side)

Injection Nozzle Mini Nozzle (DNOPD)

Injection Timing

Firing Order 1-2-3 1-3-4-2

Injection Pressure 13.73 MPa (140 kgf/cm

Compression Ratio 23 : 1 24 : 1

Lubricating System Forced lubrication by trochoid pump

Oil Pressure Indicating Electrical type switch

Lubricating Filter Full flow paper filter (Cartridge type)

Cooling System Pressurized radiator, forced circulation with water pump

Starting System Electric Starting with Starter

Starting Motor 12 V, 0.9 kW 12 V, 1.0 kW

Starting Support Device By glow plug in combustion chamber

Battery 12 V, 60 AH, equivalent

Charging Alternator 12 V, 150 W 12 V, 360 W

Fuel Diesel Fuel No.2-D (ASTM D975)

Lubricating Oil

Lubricating Oil Capacity (Oil Pan Depth 125 mm (4.92 in.))

Weight (Dry) kg (lbs) 93.0 (205.0) 110.0 (242.5)

* The specification described above is of the standard engine of each model. * Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW

-1

(rpm) (HP/min-1 (rpm))

-1

(rpm) (HP/min-1 (rpm))

(cu.in.) 898 (54.80) 1001 (61.08) 1335 (81.46)

-1

(rpm)

-1

(rpm))

-1

(rpm)) 3200 3800 3200 3800 3200 3800

-1

(rpm))

13.0 / 3000

(17.4 / 3000)

14.9 / 3000

(20.0 / 3000)

15.5 / 3000

(20.8 / 3000)

0.31 rad

(18 °) before

T. D. C .

If this class of lubricating oil is not available, preferably use Class CD or CE lubricating oil.

15.2 / 3600

(20.4 / 3600)

17.5 / 3600

(23.5 / 3600)

18.5 / 3600

(24.8 / 3600)

0.37 rad

(21 °) before

T. D. C .

Class CF lubricating oil as per API classification is recommended.

For details on recommended lubricating oils, see page G-5, 8.

5.1 L (1.35 U.S.gals) 6.0 L (1.59 U.S.gals)

14.5 / 3000

(19.5 / 3000)

16.8 / 3000

(22.5 / 3000)

17.5 / 3000

(23.5 / 3000)

0.31 rad

(18 °) before

T. D. C .

16.8 / 3600

(22.5 / 3600)

19.4 / 3600

(26.0 / 3600)

20.4 / 3600

(27.3 / 3600)

900

0.37 rad

(21 °) before

T.D.C.

, 1991 psi)

19.0 / 3000

(26.0 / 3000)

22.4 / 3000

(30.0 / 3000)

23.4 / 3000

(31.4 / 3000)

0.31 rad

(18 °) before

T.D.C.

22.4 / 3600

(30.0 / 3600)

25.7 / 3600

(34.5 / 3600)

27.2 / 3600

(36.5 / 3600)

0.37 rad

(21 °) before

T.D.C.

W10275180

Page 7

05-E2B, 05-E2BG, WSM

KiSC issued 06, 2011 A

SPECIFICATIONS

Model D1105-E2B V1505-E2B D1105-T-E2B V1505-T-E2B

Number of Cylinders 3 4 3 4

Type Vertical, Water-cooled, 4 cycle diesel engine

Bore × Stroke mm (in.) 78 × 78.4 (3.07 × 3.09)

Total Displacement cm

ISO Net Continuous kW/min (HP/min

ISO/SAE Net Intermittent kW/min

SAE Gross Intermittent kW/min

-1

(rpm) (HP/min-1 (rpm))

-1

(rpm) (HP/min-1 (rpm))

Maximum Bare Speed (min

Minimum Bare Idling Speed (min

(cu.in.) 1123 (68.53) 1498 (91.41) 1123 (68.53) 1498 (91.41)

-1

(rpm)

-1

(rpm))

-1

(rpm)) 3200

-1

(rpm))

16.2 / 3000

(21.7 / 3000)

18.7 / 3000

(25.0 / 3000)

19.4 / 3000

(26.0 / 3000)

21.7 / 3000

(29.1 / 3000)

25.0 / 3000

(33.5 / 3000)

26.5 / 3000

(35.5 / 3000)

900

20.4 / 3000

(27.4 / 3000)

23.5 / 3000

(31.5 / 3000)

24.5 / 3000

(32.8 / 3000)

27.2 / 3000

(36.4 / 3000)

31.3 / 3000

(42.0 / 3000)

33.0 / 3000

(44.2 / 3000)

Combustion Chamber Spherical type (E-TVCS)

Fuel Injection Pump Bosch MD type mini pump

Governor All speed mechanical governor

Direction of Rotation Counter-clockwise (viewed from flywheel side)

Injection Nozzle Mini Nozzle (DNOPD)

Injection Timing 0.31 rad (18 °) before T.D.C.

Firing Order 1-2-3 1-3-4-2 1-2-3 1-3-4-2

Injection Pressure 13.73 MPa (140 kgf/cm

, 1991 psi)

Compression Ratio 24 : 1 23 : 1

Lubricating System Forced lubrication by trochoid pump

Oil Pressure Indicating Electrical type switch

Lubricating Filter Full flow paper filter (Cartridge type)

Cooling System Pressurized radiator, forced circulation with water pump

Starting System Electric Starting with Starter

Starting Motor 12 V, 1.0 kW 12 V, 1.2 kW 12 V, 1.0 kW 12 V, 1.2 kW

Starting Support Device By glow plug in combustion chamber

Battery

12 V, 65 AH

equivalent

12 V, 75 AH

equivalent

12 V, 65 AH

equivalent

12 V, 56 AH

equivalent

Charging Alternator 12 V, 360 W

Fuel Diesel Fuel No.2-D (ASTM D975)

Class CF lubricating oil as per API classification is recommended.

Lubricating Oil

If this class of lubricating oil is not available, preferably use Class CD or CE lubricating oil.

For details on recommended lubricating oils, see page G-5, 8.

Lubricating Oil Capacity (Oil Pan Depth 125 mm (4.92 in.))

5.1 L (1.35 U.S.gals) 6.0 L (1.59 U.S.gals) 5.1 L (1.35 U.S.gals) 6.7 L (1.77 U.S.gals)

Weight (Dry) kg (lbs) 93.0 (205.0) 110.0 (242.5) 97.0 (213.8) 114.0 (251.3)

* The specification described above is of the standard engine of each model. * Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW

W10316890

Page 8

05-E2B, 05-E2BG, WSM

KiSC issued 06, 2011 A

SPECIFICATIONS

Model

D905-E2BG D1005-E2BG V1305-E2BG

BG1 BG1 BG1

Number of Cylinders 3 4

Type Vertical, Water-cooled, 4 cycle diesel engine

Bore × Stroke mm (in.) 72 × 73.6 (2.83 × 2.90) 76 × 73.6 (2.99 × 2.90)

Total Displacement cm

STANDBY

NET CONT.

ISO 3046 kW/min

SAE J-1349 (HP/min

ISO 3046 kW/min

SAE J-1349 (HP/min

(cu.in.) 898 (54.86) 1001 (61.08) 1335 (81.46)

-1

(rpm) 8.9 / 1800 9.8 / 1800 13.1 / 1800

-1

(rpm)) 11.9 / 1800 13.7 / 1800 17.5 / 1800

-1

(rpm) 7.8 / 1800 8.6 / 1800 11.6 / 1800

-1

(rpm)) 10.5 / 1800 11.6 / 1800 15.5 / 1800

Governor Regulation Less than 5 %

Combustion Chamber Spherical type (E-TVCS)

Fuel Injection Pump Bosch type

Governor All speed mechanical governor

Direction of Rotation Counter-clockwise (viewed from flywheel side)

Injection Nozzle Bosch “Throttle” type

Injection Timing 0.29 rad (16.5 °) before T.D.C.

Firing Order 1-2-3 1-3-4-2

Injection Pressure 13.73 MPa (140 kgf/cm

, 1991 psi)

Compression Ratio 23 : 1 24 : 1

Lubricating System Forced lubrication by trochoid pump

Oil Pressure Indicating Electrical type switch

Lubricating Filter Full flow paper filter (Cartridge type)

Cooling System Pressurized radiator, forced circulation with water pump

Starting System Electric Starting with Starter

Starting Motor 12 V, 0.9 kW 12 V, 1.0 kW 12 V, 1.2 kW

Starting Support Device By glow plug in combustion chamber

Battery 12 V, 35 AH equivalent 12 V, 65 AH equivalent 12 V, 75 AH equivalent

Charging Alternator 12 V, 360 W

Fuel Diesel Fuel No.2-D (ASTM D975)

Class CF lubricating oil as per API classification is recommended.

Lubricating Oil

If this class of lubricating oil is not available, preferably use Class CD or CE lubricating oil.

For details on recommended lubricating oils, see page G-5, 8.

Lubricating Oil Capacity (Oil Pan Depth)

5.1 L (1.35 U.S.gals) (125 mm, 4.92 in.)

6.7 L (1.77 U.S.gals) (130 mm 5.12 in.)

Weight kg (lbs) 89 (196.2) 106 (233.7)

* The specification described above is of the standard engine of each model. * Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW

W10336300

Page 9

05-E2B, 05-E2BG, WSM

KiSC issued 06, 2011 A

SPECIFICATIONS

Model

D1105-E2BG V1505-E2BG

BG1 BG1

Number of Cylinders 3 4

Type Vertical, Water-cooled, 4 cycle diesel engine

Bore × Stroke mm (in.) 78 × 78.4 (3.07 × 3.09)

Total Displacement cm

STANDBY

NET CONT.

ISO 3046 kW/min

SAE J-1349 (HP/min

ISO 3046 kW/min

SAE J-1349 (HP/min

(cu.in.) 1123 (68.53) 1498 (91.41)

-1

(rpm) 11.5 / 1800 15.1 / 1800

-1

(rpm)) 15.4 / 1800 20.2 / 1800

-1

(rpm) 10.1 / 1800 13.4 / 1800

-1

(rpm)) 13.6 / 1800 17.9 / 1800

Governor Regulatiln Less than 5 %

Combustion Chamber Spherical type (E-TVCS)

Fuel Injection Pump Bosch type

Governor All speed mechanical governor

Direction of Rotation Counter-clockwise (viewed from flywheel side)

Injection Nozzle Bosch “Throttle” type

Injection Timing 0.29 rad (16.5 °) before T.D.C.

Firing Order 1-2-3 1-3-4-2

Injection Pressure 13.73 MPa (140 kgf/cm

, 1991 psi)

Compression Ratio 24 : 1

Lubricating System Forced lubrication by trochoid pump

Oil Pressure Indicating Electrical type switch

Lubricating Filter Full flow paper filter (Cartridge type)

Cooling System Pressurized radiator, forced circulation with water pump

Starting System Electric Starting with Starter

Starting Motor 12 V, 1.0 kW 12 V, 1.2 kW

Starting Support Device By glow plug in combustion chamber

Battery 12 V, 65 AH equivalent 12 V, 70 AH equivalent

Charging Alternator 12 V, 360 W

Fuel Diesel Fuel No.2-D (ASTM D975)

Class CF lubricating oil as per API classification is recommended.

Lubricating Oil

If this class of lubricating oil is not available, preferably use Class CD or CE lubricating oil.

For details on recommended lubricating oils, see page G-5, 8.

Lubricating Oil Capacity (Oil Pan Depth)

5.1 L (1.35 U.S.gals) (125 mm, 4.92 in.)

6.7 L (1.77 U.S.gals) (130 mm 5.12 in.)

Weight kg (lbs) 89 (196.2) 106 (233.7)

* The specification described above is of the standard engine of each model. * Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW

W10362750

Page 10

05-E2B, 05-E2BG, WSM

KiSC issued 06, 2011 A

PERFORMANCE CURVES

(1) Gross Int. (2) Net Int. (3) Net Cont.

(4) Brake Horsepower (5) Engine Speed (6) Specified Fuel

(7) Torque (8) Gross

(9) Overload

(10) Continuous

Page 11

05-E2B, 05-E2BG, WSM

KiSC issued 06, 2011 A

PERFORMANCE CURVES

(1) Gross Int. (2) Net Int. (3) Net Cont.

(4) Brake Horsepower (5) Engine Speed (6) Specified Fuel

(7) Torque (8) Gross

(9) Overload

(10) Continuous

Page 12

05-E2B, 05-E2BG, WSM

KiSC issued 06, 2011 A

PERFORMANCE CURVES

(1) Gross Int. (2) Net Int. (3) Net Cont.

(4) Brake Horsepower (5) Engine Speed (6) Specified Fuel

(7) Torque (8) Gross

(9) Overload

(10) Continuous

Page 13

05-E2B, 05-E2BG, WSM

KiSC issued 06, 2011 A

DIMENSIONS

Unit : mm (in.)

D905-E2B D1005-E2B D1105-E2B D1105-T-E2B

A 497.8 (19.60) 497.8 (19.60) 497.8 (19.60) 497.8 (19.60)

B 230 (9.06) 230 (9.06) 230 (9.06) 230 (9.06)

C 320 dia. (12.6 dia.) 330 dia. (12.99 dia.) 330 dia. (12.99 dia.) 330 dia. (12.99 dia.)

D 396 (15.59) 396 (15.59) 396 (15.59) 396 (15.59)

E 194 (7.64) 194 (7.64) 194 (7.64) 194 (7.64)

F 608.7 (23.96) 608.7 (23.96) 608.7 (23.96) 608.7 (23.96)

G 233.5 (9.19) 233.5 (9.19) 233.5 (9.19) 233.5 (9.19)

H 200 (7.87) 200 (7.87) 200 (7.87) 200 (7.87)

J 56 (2.20) 56 (2.20) 56 (2.20) 56 (2.20)

250.81 to 251.12 dia. (9.874 to 9.887 dia.)

W1038971

Page 14

05-E2B, 05-E2BG, WSM

KiSC issued 06, 2011 A

DIMENSIONS

Unit : mm (in.)

V1305-E2B V1505-E2B V1505-T-E2B

A 583.8 (22.98) 591.3 (23.28) 591.3 (23.28)

B 230 (9.06) 230 (9.06) 230 (9.06)

C 350 dia. (13.78 dia.) 370 dia. (14.57 dia.) 370 dia. (14.57 dia.)

D 396 (15.59) 396 (15.59) 396 (15.59)

E 194 (7.64) 194 (7.64) 194 (7.64)

F 613.7 (24.16) 613.7 (24.16) 629.3 (24.16)

G 238.5 (9.39) 238.5 (9.39) 238.5 (9.39)

H 200 (7.87) 200 (7.87) 200 (7.87)

J 56 (2.20) 56 (2.20) 56 (2.20)

250.81 to 251.12 dia. (9.874 to 9.887 dia.)

W1039589

Page 15

05-E2B, 05-E2BG, WSM

KiSC issued 06, 2011 A

DIMENSIONS

Unit : mm (in.)

D905-E2BG

A 546.6 (21.52) 546.6 (21.52) 546.6 (21.52) 634.3 (24.97) 634.3 (24.97)

C 608.7 (23.96) 608.7 (23.96) 608.7 (23.96) 613.7 (24.16) 613.7 (24.16)

D 360 (14.17) 360 (14.17) 360 (14.17) 360 (14.17) 360 (14.17)

E 333.38 dia. (13.13 dia.) 333.38 dia. (13.13 dia.) 333.38 dia. (13.13 dia.) 333.38 dia. (13.13 dia.) 333.38 dia. (13.13 dia.)

F 200.02 dia. (7.87 dia.) 200.02 dia. (7.87 dia.) 200.02 dia. (7.87 dia.) 200.02 dia. (7.87 dia.) 200.02 dia. (7.87 dia.)

G 356 dia. (14.02 dia.) 356 dia. (14.02 dia.) 356 dia. (14.02 dia.) 356 dia. (14.02 dia.) 356 dia. (14.02 dia.)

H 290 dia. (11.42 dia.) 290 dia. (11.42 dia.) 290 dia. (11.42 dia.) 290 dia. (11.42 dia.) 290 dia. (11.42 dia.)

I 184.2 dia. (7.25 dia.) 184.2 dia. (7.25 dia.) 184.2 dia. (7.25 dia.) 184.2 dia. (7.25 dia.) 184.2 dia. (7.25 dia.)

J 98 dia. (3.86 dia.) 98 dia. (3.86 dia.) 98 dia. (3.86 dia.) 98 dia. (3.86 dia.) 98 dia. (3.86 dia.)

4-3/8-16 UNC-2B

Depth 16 (0.63)

D1005-E2BG D1105-E2BG V1305-E2BG V1505-E2BG

4-3/8-16 UNC-2B

Depth 16 (0.63)

4-3/8-16 UNC-2B

Depth 16 (0.63)

4-3/8-16 UNC-2B

Depth 16 (0.63)

4-3/8-16 UNC-2B

Depth 16 (0.63)

W1040012

Page 16

GENERAL

KiSC issued 06, 2011 A

CONTENTS

1. ENGINE IDENTIFICATION ............................................................................. G-1

[1] MODEL NAME AND ENGINE SERIAL NUMBER ................................ G-1

[2] E2B ENGINE............................................................................................. G-2

[3] CYLINDER NUMBER ............................................................................... G-2

2. GENERAL PRECAUTIONS ............................................................................ G-3

3. MAINTENANCE CHECK LIST ....................................................................... G-4

4. CHECK AND MAINTENANCE ....................................................................... G-6

[1] DAILY CHECK POINTS........................................................................... G-6

[2] CHECK POINTS OF INITIAL 50 HOURS ............................................. G-8

[3] CHECK POINTS OF EVERY 50 HOURS........................................... G-10

[4] CHECK POINTS OF EVERY 100 HOURS......................................... G-11

[5] CHECK POINTS OF EVERY 200 HOURS......................................... G-13

[6] CHECK POINTS OF EVERY 400 HOURS......................................... G-14

[7] CHECK POINTS OF EVERY 500 HOURS......................................... G-15

[8] CHECK POINTS OF EVERY 1 OR 2 MONTHS ............................... G-17

[9] CHECK POINTS OF EVERY YEAR .................................................... G-18

[10]CHECK POINTS OF EVERY 800 HOURS ......................................... G-19

[11]CHECK POINTS OF EVERY 1500 HOURS ....................................... G-20

[12]CHECK POINTS OF EVERY 3000 HOURS ....................................... G-21

[13]CHECK POINTS OF EVERY 2 YEARS.............................................. G-24

5. SPECIAL TOOLS.......................................................................................... G-28

Page 17

05-E2B, 05-E2BG, WSM

KiSC issued 06, 2011 A

1. ENGINE IDENTIFICATION

[1] MODEL NAME AND ENGINE SERIAL NUMBER

When contacting the manufacture, always specify your engine

model name and serial number.

The engine model and its serial number need to be identified

before the engine can be serviced or parts replaced.

Q Engine Serial Number

The engine serial number is an identified number for the engine.

It is marked after the engine model number.

It indicates month and year of manufacture as follows.

• Year of manufacture

Alphabet or

Number

1 2001 F 2015

2 2002 G 2016

3 2003 H 2017

4 2004 J 2018

5 2005 K 2019

6 2006 L 2020

7 2007 M 2021

8 2008 N 2022

9 2009 P 2023

A 2010 R 2024

B 2011 S 2025

C 2012 T 2026

D 2013 V 2027

E 2014

Year

Alphabet or

Number

G GENERAL

Yea r

(1) Engine Label (2) Emission Label

(3) Engine Model (4) Serial Number

W1010477

G-1

Page 18

05-E2B, 05-E2BG, WSM

KiSC issued 06, 2011 A

G GENERAL

• Month of manufacture

Month

January A0001 ~ A9999 B0001 ~

February C0001 ~ C9999 D0001 ~

March E0001 ~ E9999 F0001 ~

April G0001 ~ G9999 H0001 ~

May J0001 ~ J9999 K0001 ~

June L0001 ~ L9999 M0001 ~

July N0001 ~ N9999 P0001 ~

August Q0001 ~ Q9999 R0001 ~

September S0001 ~ S9999 T0001 ~

October U0001 ~ U9999 V0001 ~

November W0001 ~ W9999 X0001 ~

December Y0001 ~ Y9999 Z0001 ~

0001 ~ 9999 10000 ~

Engine Serial Number

e.g. D1105-4A0001 “4” indicates 2004 and “A” indicates January.

So, 4A indicates that the engine was manufactured in January,

2004.

W1011076

[2] E2B ENGINE

[ex. Model Name D1105-E2B] The emission controls that have been put into effect in various countries to prevent air pollution will be stepped up.

The time to enforce the regulations differs depending on the engine output classifications.

Kubota has been supplying the diesel engines conforming to the emission regulations in respective countries. Exhaust emissions regulations shift to the second stage. Kubota executed the improvement of the engine according to this regulation.

In order to discriminate the engines conforming to Tier 1 / Phase 1 requirements and those conforming to Tier 2 / Phase 2 requirements, we have adopted E2B as a new model name for the engines conforming Tier 2 / Phase 2 regulations.

In the after-sale services for 05-E2B and 05-E2BG series engines, only use the dedicated parts for E2B models and carry out the maintenance services accordingly.

[3] CYLINDER NUMBER

The cylinder numbers of kubota diesel engine are designated as

shown in the figure.

The sequence of cylinder numbers is given as No.1, No.2, No.3

and No.4 starting from the gear case side.

W1011077

G-2

Page 19

05-E2B, 05-E2BG, WSM

KiSC issued 06, 2011 A

2. GENERAL PRECAUTIONS

• During disassembly, carefully arrange removed parts in a clean area to prevent confusion later. Screws, bolts and nuts should be replaced in their original position to prevent reassembly errors.

• When special tools are required, use KUBOTA genuine special tools. Special tools which are not frequently used should be made according to the drawings provided.

• Before disassembling or servicing live wires, make sure to always disconnect the grounding cable from the battery first.

• Remove oil and dirt from parts before measuring.

• Use only KUBOTA genuine parts for parts replacement to maintain engine performance and to ensure safety.

• Gaskets and O-rings must be replaced during reassembly. Apply grease to new O-rings or oil seals before assembling.

• When reassembling external or internal snap rings, position them so that the sharp edge faces against the direction from which force is applied.

• Be sure to perform run-in the serviced or reassembled engine. Do not attempt to give heavy load at once, or serious damage may result to the engine.

(1) Grease (2) Force (3) Place the Sharp Edge against the

Direction of Force

G GENERAL

(A) External Snap Ring (B) Internal Snap Ring

W1011734

G-3

Page 20

05-E2B, 05-E2BG, WSM

KiSC issued 06, 2011 A

G GENERAL

3. MAINTENANCE CHECK LIST

To maintain long-lasting and safe engine performance, make it a rule to carry out regular inspections by following

the table below.

Service Interval

Item

* Checking fuel hoses and clamp bands ,

* Changing engine oil

(Oil pan depth : 125 mm (4.92 in.), 130 mm (5.12 in.)) * Cleaning air cleaner element

(Replace the element after 6 times cleaning)

Cleaning fuel filter element ,

Check fan belt tension and damage ,

Checking battery electrolyte level ,

* Replacing oil filter cartridge

(Oil pan depth : 125 mm (4.92 in.), 130 mm (5.12 in.))

Checking radiator hoses and clamp bands ,

* Checking intake air line ,

Replacing fuel filter cartridge ,

Cleaning water jacket and radiator interior ,

Replacing fan belt ,

Recharging battery ,

* Replacing air cleaner element ,

Checking valve clearance ,

* Checking injection nozzle pressure ,

* Checking turbocharger

Checking injection pump ,

Checking injection timing ,

Changing radiator coolant (L.L.C.) ,

Replacing radiator hoses and clamp bands ,

* Replacing fuel hoses and clamps ,

* Replacing intake air line ,

Replacing battery ,

hrs

100 hrs

200 hrs

400

hrs

+ Change engine oil and replace oil filter cartridge after the first 50 hours of operation.

* The items listed above (* marked) are registered as emission related critical parts by KUBOTA in the U.S. EPA

nonroad emission regulation. As the engine owner, you are responsible for the performance of the required

maintenance on the engine according to the above instruction.

500 hrs

Every 1 or 2

months

1 year

800 hrs

1500

hrs

3000

hrs

2 years

W1029462

G-4

Page 21

05-E2B, 05-E2BG, WSM

CAUTION

KiSC issued 06, 2011 A

G GENERAL

• When changing or inspecting, be sure to level and stop the engine. Q NOTE Lubricating Oil

With the emission control now in effect, the CF-4 and CG-4 lubricating oils have been developed for use of a lowsulfur fuel on-road vehicle engines. When an off-road vehicle engine runs on a high-sulfur fuel, it is advisable to employ the CF, CD or CE lubricating oil with a high total base number. If the CF-4 or CG-4 lubricating oil is used with a high-sulfur fuel, change the lubricating oil at shorter intervals.

• Lubricating oil recommended when a low-sulfur or high-sulfur fuel is employed.

Fuel

Lubricating

Low sulfur

(0.5 % ≥)

High sulfur Remarks

oil class

CF PPTBN ≥ 10

CF-4 P X

CG-4 P X

P : Recommendable X : Not recommendable

W1035555

G-5

Page 22

05-E2B, 05-E2BG, WSM

IMPORTANTQ

NOTEQ

KiSC issued 06, 2011 A

4. CHECK AND MAINTENANCE

[1] DAILY CHECK POINTS

Checking Engine Oil Level

1. Level the engine.

2. To check the oil level, draw out the dipstick (1), wipe it clean, reinsert it, and draw it out again. Check to see that the oil level lies (A) between the two notches.

3. If the level is too low, add new oil to the specified level.

• When using an oil of different maker or viscosity from the previous, drain old oil. Never mix two different types of oil.

• Be sure to inspect the engine, locating it on a horizontal place. If placed on gradients, accurately, oil quantity may not be measured.

• Be sure to keep the oil level between upper and lower limits of the dipstick. Too much oil may cause a drop in output or excessive blow-by gas. On the closed breather type engine in which mist is sucked through port, too much oil may caused oil hammer. While too little oil, may seize the engine’s rotating and sliding parts.

(1) Dipstick A : Oil Level

G GENERAL

W1016222

G-6

Page 23

05-E2B, 05-E2BG, WSM

CAUTION

IMPORTANTQ

KiSC issued 06, 2011 A

G GENERAL

Checking and Replenish Coolant

1. Without recovery tank : Remove the radiator cap (1) and check to see that the coolant level is just below the port. With recovery tank (2) : Check to see that the coolant level lies between FULL (A) and LOW (B).

2. If coolant level is too low, check the reason for decreasing coolant. (Case 1) If coolant is decreasing by evaporation, replenish only fresh, soft water. (Case 2) If coolant is decreasing by leak, replenish coolant of the same manufacture and type in the specified mixture ratio (fresh, soft water and L.L.C.). If the coolant brand cannot be identified, drain out all of the remaining coolant and refill with a totally new brand of coolant mix.

• Do not remove the radiator cap until coolant temperature is below its boiling point. Then loosen the cap slightly to relieve any excess pressure before removing the cap completely.

• During filling the coolant, air must be vented from the engine coolant passages. The air vents by jiggling the radiator upper and lower hoses.

• Be sure to close the radiator cap securely. If the cap is loose or improperly closed, coolant may leak out and the engine could overheat.

• Do not use an antifreeze and scale inhibitor at the same time.

• Never mix the different type or brand of L.L.C..

(1) Radiator Cap (2) Recovery Tank

A: FULL B: LOW

W1035779

G-7

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05-E2B, 05-E2BG, WSM

CAUTION

IMPORTANTQ

KiSC issued 06, 2011 A

[2] CHECK POINTS OF INITIAL 50 HOURS

Changing Engine Oil

• Be sure to stop engine before changing engine oil.

1. Start and warm up the engine for approx. 5 minutes.

2. Place an oil pan underneath the engine.

3. To drain the used oil, remove the drain plug (1) at the bottom of the engine and drain the oil completely.

4. Screw the drain plug (1).

5. Fill new oil up to upper line on the dipstick.

• When using an oil of different maker or viscosity from the previous one, remove all of the old oil.

• Never mix two different types of oil.

• Engine oil should have properties of API classification CD/ CE/CF/CF-4/CG-4.

• Use the proper SAE Engine Oil according to ambient temperature.

• Upon an oil change, be sure to replace the gasket with new one.

Above 25 °C (77 °F)

0 °C to 25 °C (32 °F to 77 °F)

Below 0 °C (32 °F)

G GENERAL

SAE 30 or SAE 10W-30 SAE 10W-40

SAE 20 or SAE 10W-30 SAE 10W-40

SAE 10W or SAE 10W-30 SAE 10W-40

Oil pan depth

Models

D905-E2B / E2BG D1005-E2B /E2BG D1105-E2B /E2BG D1105-T-E2B

V1305-E2B V1505-E2B

V1305-E2BG V1505-E2BG

V1505-T-E2B –

Drain plug with

Tightening torque

(1) Drain Plug

copper gasket

Drain plug with rubber coated gasket

125 mm (4.92 in.) 130 mm (5.12 in.)

1.35 U.S.gals

1.59 U.S.gals

M12 × 1.25

M22 × 1.5

5.1 L

6.0 L

–

Capacity

–

6.7 L

1.77 U.S.gals

6.7 L

1.77 U.S.gals

32.4 to 37.3 N·m

3.3 to 3.8 kgf·m

23.9 to 27.5 ft-lbs

63.7 to 73.5 N·m

6.5 to 7.5 kgf·m

47.0 to 54.2 ft-lbs

44.1 to 53.9 N·m

4.5 to 5.5 kgf·m

32.5 to 39.8 ft-lbs

W1016604

G-8

Page 25

05-E2B, 05-E2BG, WSM

CAUTION

IMPORTANTQ

KiSC issued 06, 2011 A

G GENERAL

Replacing Oil Filter Cartridge

• Be sure to stop the engine before changing filter cartridge.

1. Remove the oil filter cartridge with the filter wrench.

2. Apply a slight coat of oil onto the new cartridge gasket.

3. To install the new cartridge, screw it in by hand. Over tightening may cause deformation of rubber gasket.

4. After the new cartridge has been replaced, the engine oil normally decrease a little. Thus see that the engine oil does not leak through the seal and be sure to read the oil level on the dipstick. Then, replenish the engine oil up to the specified level.

• To prevent serious damage to the engine, replacement element must be highly efficient. Use only a KUBOTA genuine filter or its equivalent.

W1017137

G-9

Page 26

05-E2B, 05-E2BG, WSM

CAUTION

NOTEQ

KiSC issued 06, 2011 A

[3] CHECK POINTS OF EVERY 50 HOURS

Checking Fuel Hose

1. If the clamp (2) is loose, apply oil to the threads and securely retighten it.

2. The fuel hose (1) is made of rubber and ages regardless of the period service. Change the fuel hose together with the clamp every two years.

3. However, if the fuel hose and clamp are found to be damaged or deteriorate earlier than two years, then change or remedy.

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

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

(When bleeding fuel system)

1. Fill the tank with fuel and open the cock (4).

2. Loosen the air vent plug (3) of the fuel filter a few turns.

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

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

5. If equipped electrical fuel feed pump, turn the key to AC position

and pump the fuel up for 10 to 15 seconds. If equipped mechanical fuel feed pump, set the stop lever on stop position and crank the engine for 10 to 15 seconds.

6. Close securely the air vent cock after air bleeding.

G GENERAL

• Always keep the air vent cock on the fuel injection pump closed except when air is vented, or it may cause the engine to stop.

(1) Fuel Hose (2) Clamp (3) Air Vent Plug (4) Fuel Cock

[A] Cartridge Type [B] Element Type

W1035921

G-10

Page 27

05-E2B, 05-E2BG, WSM

NOTEQ

IMPORTANTQ

KiSC issued 06, 2011 A

[4] CHECK POINTS OF EVERY 100 HOURS

Cleaning Air Cleaner Element

1. Remove the air cleaner element.

2. Use clean dry compressed air on the inside of the element. Pressure of compressed air must be under 205 kPa (2.1 kgf/cm 30 psi). Maintain reasonable distance between the nozzle and the filter.

• The air cleaner uses a dry element. Never apply oil to it.

• Do not run the engine with filter element removed.

• Change the element once a year or every 6th cleaning.

Cleaning Fuel Filter (Element Type only)

1. Close the fuel cock (3).

2. Unscrew the retaining ring (6) and remove the filter cup (5), and rinse the inside with kerosene.

3. Take out the element (4) and dip it in the kerosene to rinse.

4. After cleaning, reassemble the fuel filter, keeping out dust and dirt.

5. Bleed the fuel system.

G GENERAL

W1045746

• If dust and dirt enter the fuel, the fuel injection pump and injection nozzle will wear quickly. To prevent this, be sure to clean the fuel filter cup (5) periodically.

(1) Cock Body (2) Air Vent Plug (3) Fuel Cock

(4) Filter Element (5) Filter Cup (6) Retaining Ring

W1046058

Fan Belt Tension

1. Measure the deflection (A), depressing the belt halfway between

the fan drive pulley and alternator pulley at specified force 98 N (10 kgf, 22 lbs).

2. If the measurement is not within the factory specifications, loosen the alternator mounting screws and relocate the alternator to adjust.

Deflection (A) Factory spec.

(A) Deflection

7.0 to 9.0 mm

0.28 to 0.35 in.

W1208957

G-11

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KiSC issued 06, 2011 A

G GENERAL

Fan Belt Damage and Wear

1. Check the fan belt for damage.

2. If the fan belt is damaged, replace it.

3. Check if the fan belt is worn and sunk in the pulley groove.

4. If the fan belt is nearly worn out and deeply sunk in the pulley groove, replace it.

(A) Good (B) Bad

W1209480

Checking Battery Electrolyte Level

1. Check the battery electrolyte level.

2. If the level is below than lower level line (2), and the distilled water to pour level of each cell.

(1) Upper Level Line (2) Lower Level Line

W1047154

G-12

Page 29

05-E2B, 05-E2BG, WSM

CAUTION

IMPORTANTQ

KiSC issued 06, 2011 A

[5] CHECK POINTS OF EVERY 200 HOURS

Changing Engine Oil

• Be sure to stop engine before changing engine oil.

1. Start and warm up the engine for approx. 5 minutes.

2. Place an oil pan underneath the engine.

3. To drain the used oil, remove the drain plug (1) at the bottom of the engine and drain the oil completely.

4. Screw the drain plug (1).

5. Fill new oil up to upper line on the dipstick.

• When using an oil of different maker or viscosity from the previous one, remove all of the old oil.

• Never mix two different types of oil.

• Engine oil should have properties of API classification CD/ CE/CF/CF-4/CG-4.

• Use the proper SAE Engine Oil according to ambient temperature.

• Upon an oil change, be sure to replace the gasket with new one.

Above 25 °C (77 °F)

0 °C to 25 °C (32 °F to 77 °F)

Below 0 °C (32 °F)

G GENERAL

SAE 30 or SAE 10W-30 SAE 10W-40

SAE 20 or SAE 10W-30 SAE 10W-40

SAE 10W or SAE 10W-30 SAE 10W-40

Oil pan depth

Models

D905-E2B / E2BG D1005-E2B /E2BG D1105-E2B /E2BG D1105-T-E2B

V1305-E2B V1505-E2B

V1305-E2BG V1505-E2BG

V1505-T-E2B –

Drain plug with

Tightening torque

(1) Drain Plug

copper gasket

Drain plug with rubber coated gasket

125 mm (4.92 in.) 130 mm (5.12 in.)

1.35 U.S.gals

1.59 U.S.gals

M12 × 1.25

M22 × 1.5

5.1 L

6.0 L

–

Capacity

–

6.7 L

1.77 U.S.gals

6.7 L

1.77 U.S.gals

32.4 to 37.3 N·m

3.3 to 3.8 kgf·m

23.9 to 27.5 ft-lbs

63.7 to 73.5 N·m

6.5 to 7.5 kgf·m

47.0 to 54.2 ft-lbs

44.1 to 53.9 N·m

4.5 to 5.5 kgf·m

32.5 to 39.8 ft-lbs

W1018298

G-13

Page 30

05-E2B, 05-E2BG, WSM

CAUTION

IMPORTANTQ

KiSC issued 06, 2011 A

G GENERAL

Replacing Oil Filter Cartridge

• Be sure to stop the engine before changing filter cartridge.

1. Remove the oil filter cartridge with the filter wrench.

2. Apply a slight coat of oil onto the new cartridge gasket.

3. To install the new cartridge, screw it in by hand. Over tightening may cause deformation of rubber gasket.

• To prevent serious damage to the engine, replacement element must be highly efficient. Use only a KUBOTA genuine filter or its equivalent.

W1018617

Checking Radiator Hoses and Clamp Bands

1. Check to see if the radiator hoses are properly fixed every 200 hours of operation or every six months, whichever comes first.

2. If the clamp is loose, apply oil to the threads and retighten it securely.

3. The water hose is made of rubber and tens to age. It must be replaced every two years. Also replace the clamp and tighten it securely.

(1) Upper Hose (2) Lower Hose

W1029518

Checking Intake Air Line

1. Check to see if the intake air hose(s) are properly fixed every 200 hours of operation.

2. If the clamp is loose, apply oil to the threads and retighten it securely.

3. The intake air hose(s) is made of rubber and tends to age. It must be changed every two years. Also change the clamp and tighten it securely.

• To prevent serious damage to the engine, keep out any dust inside the intake air line.

(1) Intake Air Hose (2) Clamp

[6] CHECK POINTS OF EVERY 400 HOURS

Replacing Fuel Filter Cartridge (Cartridge Type)

Water and dust in fuel are collected in the filter cartridge. So,

change the filter cartridge every 400 hours service.

1. Remove the used filter cartridge with filter wrench.

2. Apply a thin film of fuel to the surface of new filter cartridge gasket before screwing on.

3. Then tighten enough by hand.

4. Loosen the air vent plug to let the air out.

5. Start engine and check for fuel leakage.

(1) Fuel Filter Cartridge

W1029631

W1050548

G-14

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05-E2B, 05-E2BG, WSM

CAUTION

IMPORTANTQ

KiSC issued 06, 2011 A

Replacing Fuel Filter Element (Element Type)

1. Close the fuel cock (3).

2. Unscrew the retaining ring (6) and remove the filter cup (5), and rinse the inside with kerosene.

3. Replace the filter element (4).

4. Reassemble the fuel filter, keeping out dust and dirt.

5. Bleed the fuel system.

(1) Cock Body (2) Air Vent Plug (3) Fuel Cock

[7] CHECK POINTS OF EVERY 500 HOURS

Cleaning Water Jacket and Radiator Interior

• Do not remove the radiator cap when the engine is hot. Then loosen cap slightly to the stop to relieve any excess pressure before removing cap completely.

1. Stop the engine and let cool down.

2. To drain the coolant, open the radiator drain plug (2) and remove the radiator cap (1). Then radiator cap (1) must be removed to completely drain the coolant. And open the drain cock of engine body.

3. After all coolant is drained, close the drain plug.

4. Fill with clean water and cooling system cleaner.

5. Follow directions of the cleaner instruction.

6. After flushing, fill with clean water and anti-freeze until the coolant level is just below the port. Install the radiator cap (1) securely.

7. Fill with coolant up to “FULL” (A) mark on the recovery tank (3).

8. Start and operate the engine for few minutes.

9. Stop the engine and let cool. Check coolant level of radiator and recovery tank (3) and add coolant if necessary.

G GENERAL

(4) Filter Element (5) Filter Cup (6) Retaining Ring

W1050583

• Do not start engine without coolant.

• Use clean, fresh, soft water and anti-freeze to fill the radiator and recovery tank.

• When the anti-freeze is mixed with fresh, soft water, the antifreeze mixing ratio must be less than 50 %.

• Securely tighten radiator cap. If the cap is loose or improperly fitted, water may leak out and the engine could overheat.

(1) Radiator Cap (2) Drain Plug (3) Recovery Tank

A : Full B : Low

W1038102

G-15

Page 32

05-E2B, 05-E2BG, WSM

IMPORTANTQ

NOTEQ

KiSC issued 06, 2011 A

G GENERAL

Anti-Freeze

• There are two types of anti-freeze available: use the permanent type (PT) for this engine.

• Before adding anti-freeze for the first time, clean the radiator interior by pouring fresh, soft water and draining it a few times.

• The procedure for mixing water and anti-freeze differs according to the make of the anti-freeze and the ambient temperature. Basically, it should be referred to SAE J1034 standard, more specifically also to SAE J814c.

• Mix the anti-freeze with fresh, soft water, and then fill into the radiator.

• When the anti-freeze is mixed with fresh, soft water, the antifreeze mixing ratio must be less than 50 %.

Vol %

anti-freeze

40 –24 –11.2 106 222.8

50 –37 –34.6 108 226.4

Freezing point Boiling point*

°C °F °C °F

* At 1.013 × 100000 Pa (760 mmHg) pressure (atmospheric). A

higher boiling point is obtained by using a radiator pressure cap which permits the development of pressure within the cooling system.

• The above data represents industrial standards that necessitate a minimum glycol content in the concentrated anti-freeze.

• When the coolant level drops due to evaporation, add fresh, soft water only to keep the anti-freeze mixing ratio less than 50 %. In case of leakage, add anti-freeze and fresh, soft water in the specified mixing ratio.

• Anti-freeze absorbs moisture. Keep unused anti-freeze in a tightly sealed container.

• Do not use radiator cleaning agents when anti-freeze has been added to the coolant. (Anti-freeze contains an anti-corrosive agent, which will react with the radiator cleaning agent forming sludge which will affect the engine parts.)

W1039218

Replacing Fan Belt

1. Remove the alternator.

2. Remove the fan belt (1).

3. Replace new fan belt.

4. Install the alternator.

5. Check the fan belt tension.

7.0 to 9.0 mm / 98 N

Deflection (A) Factory spec.

0.28 to 0.35 in. / 98 N (10 kgf, 22 lbs)

(1) Fan Belt (A) Deflection

W1052220

G-16

Page 33

05-E2B, 05-E2BG, WSM

CAUTION

KiSC issued 06, 2011 A

[8] CHECK POINTS OF EVERY 1 OR 2 MONTHS

Recharging

• When the battery is being activated, hydrogen and oxygen gases in the battery are extremely explosive. Keep open sparks and flames away from the battery at all times, especially when charging the battery.

• When charging battery, remove battery vent plugs.

• When disconnecting the cable from the battery, start with the negative terminal first. When connecting the cable to the battery, start with the positive terminal first.

• Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.

1) Slow Charging

1. Add distilled water if the electrolyte level is low. When charging, the amount of electrolyte should be slightly lower than the specified level to prevent overflow.

2. Connect the battery to the charging unit, following the manufacture’s instructions.

3. As the electrolyte generates gas while charging, remove all port caps.

4. The electrolyte temperature must not exceed 40 °C (104 °F) during charging. If it exceed 40 °C (104 °F), decrease the charging amperage or stop charging for a while.

5. When charging several batteries in series, charg at the rate of the smallest battery in the line.

2) Quick Charging

1. Determine the proper charging current and charging time with the tester attached to the quick charger.

2. Determine the proper charging current as 1/1 of the battery capacity. If the battery capacity exceeds 50 Ah, consider 50 A as the maximum.

Q Precaution for Operating a Quick Charger

• Operate with a quick charger differs according to the type. Consult the instruction manual and use accordingly.

G GENERAL

W1052658

G-17

Page 34

05-E2B, 05-E2BG, WSM

NOTEQ

KiSC issued 06, 2011 A

G GENERAL

Battery Specific Gravity

1. Check the specific gravity of the electrolyte in each cell with a hydrometer.

2. When the electrolyte temperature differs from that at which the hydrometer was calibrated, correct the specific gravity reading following the formula mentioned in (Reference).

3. If the specific gravity is less than 1.215 (after it is corrected for temperature), charge or replace the battery.

4. If the specific gravity differs between any two cells by more than

0.05, replace the battery.

• Hold the hydrometer tube vertical without removing it from the electrolyte.

• Do not suck too much electrolyte into the tube.

• Allow the float to move freely and hold the hydrometer at eye level.

• The hydrometer reading must be taken at the highest electrolyte level.

(Reference)

• Specific gravity slightly varies with temperature. To be exact, the specific gravity decreases by 0.0007 with an increase of 1 °C (0.0004 with an increase of 1 °F) in temperature, and increases by 0.0007 with a decreases of 1 °C (0.0004 with a decrease of 1 °F). Therefore, using 20 °C (68 °F) as a reference, the specific gravity reading must be corrected by the following formula :

- Specific gravity at 20 °C = Measured value + 0.0007 ×

(electrolyte temperature : 20 °C)

- Specific gravity at 68 °F = Measured value + 0.0004 ×

(electrolyte temperature : 68 °F)

Specific Gravity State of Charge

1.260 Sp. Gr. 100 % Charged

1.230 Sp. Gr. 75 % Charged

1.200 Sp. Gr. 50 % Charged

1.170 Sp. Gr. 25 % Charged

1.140 Sp. Gr. Very Little Useful Capacity

1.110 Sp. Gr. Discharged

At an electrolyte temperature of 20 °C (68 °F)

(a) Good (b) Bad

W1012763

[9] CHECK POINTS OF EVERY YEAR

Replacing Air Cleaner Element

1. Remove used air cleaner element.

2. Replace new air cleaner element.

• The air cleaner uses a dry element. Never apply oil to it.

• Do not run the engine with filter element removed.

W1020554

G-18

Page 35

05-E2B, 05-E2BG, WSM

IMPORTANTQ

NOTEQ

KiSC issued 06, 2011 A

[10] CHECK POINTS OF EVERY 800 HOURS

Checking Valve Clearance

• Valve clearance must be checked and adjusted when engine is cold.

1. Remove the cylinder head cover and the glow plugs.

2. Align the “1TC” mark (1) on the flywheel and alignment mark (2)

on the rear end plate so that the No. 1 piston comes to the compression top dead center.

3. Check the following valve clearance marked with “,” using a thickness gauge.

4. If the clearance is not within the factory specifications, adjust with the adjusting screw.

5. Then turn the flywheel 6.28 rad (360 °), and align the “1TC” mark (1) on the flywheel and alignment mark (2) on the rear end plate so that the No. 1 piston comes to the overlap position.

6. Check the following valve clearance marked with “,” using a feeler gauge.

7. If the clearance is not within the factory specifications, adjust with the adjusting screw.

Number of cylinders Valve arrangement

G GENERAL

3 cylinder 4 cylinder

Adjustable cylinder location of piston

1st ,,,,

When No. 1 piston is compression top dead center

When No. 1 piston is overlap position

Valve clearance Factory spec.

2nd ,,

3rd ,,

4th

1st

2nd ,,

3rd ,,

4th ,,

IN. EX. IN. EX.

0.145 to 0.185 mm

0.00571 to 0.00728 in.

• The sequence of cylinder numbers is given as No. 1, No. 2, No. 3 and No. 4 starting from the gear case side.

• After adjusting the valve clearance, secure the adjusting screw with the lock nut.

(1) “1TC” Mark (2) Alignment Mark

W10113200

G-19

Page 36

05-E2B, 05-E2BG, WSM

CAUTION

KiSC issued 06, 2011 A

G GENERAL

[11] CHECK POINTS OF EVERY 1500 HOURS

• Check the injection pressure and condition after confirming that there is nobody standing in the direction the fume goes. If the fume from the nozzle directly contacts the human body, cells may be destroyed and blood poisoning may be caused.

Nozzle Spraying Condition

1. Set the injection nozzle to a nozzle tester, and check the nozzle spraying condition.

2. If the spraying condition is defective, replace the nozzle piece.

(a) Good (b) Bad

W10411400

Fuel Injection Pressure

1. Set the injection nozzle to a nozzle tester.

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

3. If the measurement is not within the factory specifications, replace the adjusting washer in the nozzle holder to adjust it.

Fuel injection pressure Factory spec.

13.73 to 14.71 MPa 140 to 150 kgf/cm 1991 to 2134 psi

W10408820

Valve Seat Tightness

1. Set the injection nozzle to a nozzle tester.

2. Raise the fuel pressure, and keep at 12.75 MPa (130 kgf/cm 1849 psi) for 10 seconds.

3. If any fuel leak is found, replace the nozzle piece.

No fuel leak at

Valve seat tightness Factory spec.

12.75 MPa 130 kgf/cm 1849 psi

W10412730

G-20

Page 37

05-E2B, 05-E2BG, WSM

KiSC issued 06, 2011 A

[12] CHECK POINTS OF EVERY 3000 HOURS

Checking Turbocharger (Turbine Side)

1. Check the exhaust port (3) and inlet port (5) side of turbine housing (1) to see if there is no exhaust gas leak.

2. If any gas leak is found, retighten the bolts and nuts or replace the gasket (2) / (4) / (6) with new one.

(Compressor Side)

1. Check the inlet hose (9) of the compressor cover (10) to see if there is no air leak.

2. If any air leak is found, change the clamp (8) and / or inlet hoses.

3. Check the intake hose (7) and the clamp to see if there is not loose or crack.

4. If any loose or crack is found, tighten the cramp or change the hose to prevent dust from entry.

(Radial Clearance)

1. If the wheel contact to the housing, replace the turbocharger assembly with new one.

(1) Turbine Housing (2) Gasket (3) Exhaust Port (4) Gasket (5) Inlet Port

G GENERAL

(6) Gasket

(7) Intake Hose

(8) Clamp

(9) Inlet Hose

(10) Compressor Cover

W1022082

G-21

Page 38

05-E2B, 05-E2BG, WSM

NOTEQ

KiSC issued 06, 2011 A

G GENERAL

Injection Timing

1. Remove the injection pipes.

2. Remove the engine stop solenoid.

3. Turn the flywheel counterclockwise (viewed from flywheel side) until the fuel fills up to the hole of the delivery valve holder (3) for No. 1 cylinder.

4. After the fuel fills up to the hole of the delivery valve holder for No. 1 cylinder, turn back (clockwise) the flywheel around 1.57 rad (90 °).

5. Turn the flywheel counterclockwise to set at around 0.44 rad (25 °) before T.D.C..

6. Slowly turn the flywheel counterclockwise and stop turning when the fuel begins to come up, to get the present injection timing.

7. Check to see the degree on flywheel. The flywheel gas mark “1TC”, “10” and “20” for the crank angle before the top dead center of No. 1 cylinder.

8. If injection timing is out of adjustment, readjust the timing with shims.

Injection timing (3000 min

Injection timing (3600 min

Injection timing for BG type (1800 min

-1

(rpm))

-1

(rpm))

-1

(rpm))

Factory spec.

0.30 to 0.33 rad (17 to 19 °) before T.D.C.

0.35 to 0.39 rad (20 to 22 °) before T.D.C.

0.27 to 0.31 rad (15.5 to

17.5 °) before T.D.C.

• The liquid gasket is not required for assembling.

• Shims are available in thickness of 0.20 mm (0.0079 in.), 0.25 mm (0.0098 in.) and 0.30 mm (0.0118 in.). Combine these shims for adjustments.

• Addition or reduction of shim (0.05 mm, 0.0020 in.) delays or advances the injection timing by approx. 0.0087 rad (0.5 °).

• In disassembling and replacing the injection pump, be sure to use the same number of new shims with the same thickness.

(1) Timing Line (2) Alignment Mark (3) Delivery Valve Holder (4) Shim (Soft Metal Gasket Shim)

(5) Two-holes : 0.20 mm (0.0079 in.) (6) One-hole : 0.25 mm (0.0098 in.) (7) Without hole : 0.30 mm (0.0118 in.)

W1023147

G-22

Page 39

05-E2B, 05-E2BG, WSM

NOTEQ

KiSC issued 06, 2011 A

G GENERAL

Checking Injection Pump (Fuel Tightness of Pump Element)

1. Remove the engine stop solenoid.

2. Remove the injection pipes and glow plugs.

3. Install the injection pump pressure tester to the injection pump.

4. Install the injection nozzle (2) jetted with the proper injection pressure to the injection pump pressure tester (1). (Refer to the photo.)

5. Set the speed control lever to the maximum speed position.

6. Run the starter to increase the pressure.

7. If the pressure can not reach the allowable limit, replace the pump with new one or repair with a Kubota-authorized pump service shop.

(Fuel Tightness of Delivery Valve)

1. Remove the engine stop solenoid.

2. Remove the injection pipes and glow plugs.

3. Set a pressure tester to the fuel injection pump.

4. Install the injection nozzle (2) jetted with the proper injection pressure to the injection pump pressure tester (1).

5. Run the starter to increase the pressure.

6. Stop the starter when the fuel jets from the injection nozzle. After that, turn the flywheel by the hand and raise the pressure to approx. 13.73 MPa (140 kgf/cm

, 1991 psi).

7. Now turn the flywheel back about half a turn (to keep the plunger free). Maintain the flywheel at this position and clock the time taken for the pressure to drop from 13.73 to 12.75 MPa (from 140 to 130 kgf/cm

8. Measure the time needed to decrease the pressure from 13.73 to

12.75 MPa (140 to 130 kgf/cm

, from 1991 to 1849 psi).

, 1991 to 1849 psi).

9. If the measurement is less than allowable limit, replace the pump with new one or repair with a Kubota-authorized pump service shop.

Fuel tightness of pump element

Fuel tightness of delivery valve

Allowable limit

Factory spec.

Allowable limit

13.73 MPa 140 kgf/cm 1991 psi

10 seconds

13.73 → 12.75 MPa 140 → 130 kgf/cm 1991 → 1849 psi

5 seconds

13.73 → 12.75 MPa 140 → 130 kgf/cm 1991 → 1849 psi

• Never try to disassemble the injection pump assembly. For repairs, you are strongly requested to contact a Kubotaauthorized pump service shop.

(1) Injection Pump Pressure Tester (2) Injection Nozzle

(3) Protection Cover for Jetted Fuel

W1022357

G-23

Page 40

05-E2B, 05-E2BG, WSM

NOTEQ

CAUTION

KiSC issued 06, 2011 A

[13] CHECK POINTS OF EVERY 2 YEARS

Replacing Intake Air Line

1. Loosen the clamp (2).

2. Remove the intake air hose (1) and clamp (2).

3. Replace new intake air hose (1) and new clamp (2).

4. Tighten the clamp (2).

• To prevent serious damage to the engine, keep out any dust inside the intake air line.

(1) Intake Air Hose (2) Clamp

Replacing Battery

• When charging battery, remove battery vent plugs.

• When disconnecting the cable from the battery, start with the negative terminal first. When connecting the cable to the battery, start with the positive terminal first.

• Never check battery charge by placing a metal object across the posts.

1. Disconnect the negative terminal and positive terminal.

2. Remove the battery holder.

3. Remove the used battery.

4. Replace the new battery.

5. Tighten the battery holder.

6. Connect the positive terminal.

7. Connect the negative terminal.

Replacing Radiator Hoses and Clamp Bands

G GENERAL

W1023867

W1023996

• Do not remove the radiator cap when the engine is hot. Then loosen cap slightly to the stop to relieve any excess pressure before removing cap completely.

1. Drain the coolant.

2. Loosen the clamp bands.

3. Remove the upper hose (1) and lower hose (2).

4. Replace new upper / lower hose (1), (2) and clamp bands.

5. Tighten the clamp bands.

6. Fill with clean water and anti-freeze until the coolant level is just below the port. Install the radiator cap securely.

(1) Upper Hose (2) Lower Hose

W1024178

G-24

Page 41

05-E2B, 05-E2BG, WSM

CAUTION

NOTEQ

KiSC issued 06, 2011 A

G GENERAL

Replacing Fuel Hoses and Clamp Bands

1. Loosen the clamp (2) and remove the fuel hose (1).

2. Replace new fuel hose (1) and new clamp (2).

3. Tighten the clamp (2).

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

(When bleeding fuel system)

1. Fill the tank with fuel and open the cock (4).

2. Loosen the air vent plug (3) of the fuel filter a few turns.

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

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

5. If equipped electrical fuel feed pump, turn the key to AC position

and pump the fuel up for 10 to 15 seconds. If equipped mechanical fuel feed pump, set the stop lever on stop position and crank the engine for 10 to 15 seconds.

6. Close securely the air vent cock after air bleeding.

• Always keep the air vent cock on the fuel injection pump closed except when air is vented, or it may cause the engine to stop.

(1) Fuel Hose (2) Clamp (3) Air Vent Plug (4) Fuel Cock

[A] Cartridge Type [B] Element Type

W1024305

G-25

Page 42

05-E2B, 05-E2BG, WSM

CAUTION

IMPORTANTQ

KiSC issued 06, 2011 A

G GENERAL

Changing Radiator Coolant (L.L.C.)

• Do not remove the radiator cap when the engine is hot. Then loosen cap slightly to the stop to relieve any excess pressure before removing cap completely.

1. Stop the engine and let cool down.

3. After all coolant is drained, close the drain plug.

4. Fill with clean water and cooling system cleaner.

5. Follow directions of the cleaner instruction.

6. After flushing, fill with clean water and anti-freeze until the coolant level is just below the port. Install the radiator cap (1) securely.

7. Fill with coolant up to “FULL” (A) mark on the recovery tank (3).

8. Start and operate the engine for few minutes.

9. Stop the engine and let cool. Check coolant level of radiator and recovery tank (3) and add coolant if necessary.

• Do not start engine without coolant.

• Use clean, fresh, soft water and anti-freeze to fill the radiator and recovery tank.

• When the anti-freeze is mixed with fresh, soft water, the antifreeze mixing ratio must be less than 50 %.

• Securely tighten radiator cap. If the cap is loose or improperly fitted, water may leak out and the engine could overheat.

(1) Radiator Cap (2) Drain Plug (3) Recovery Tank

A : Full B : Low

W1024599

G-26

Page 43

05-E2B, 05-E2BG, WSM

IMPORTANTQ

NOTEQ

KiSC issued 06, 2011 A

G GENERAL

Changing Radiator Coolant (L.L.C.) (Continued) (Anti-freeze)

• There are two types of anti-freeze available: use the permanent type (PT) for this engine.

• Before adding anti-freeze for the first time, clean the radiator interior by pouring fresh, soft water and draining it a few times.

• Mix the anti-freeze with fresh, soft water, and then fill into the radiator.

• When the anti-freeze is mixed with fresh, soft water, the antifreeze mixing ratio must be less than 50 %.

Vol %

anti-freeze

40 –24 –11.2 106 222.8

50 –37 –34.6 108 226.4

Freezing point Boiling point*

°C °F °C °F

* At 1.013 × 100000 Pa (760 mmHg) pressure (atmospheric). A

higher boiling point is obtained by using a radiator pressure cap which permits the development of pressure within the cooling system.

• The above data represents industrial standards that necessitate a minimum glycol content in the concentrated anti-freeze.

• Anti-freeze absorbs moisture. Keep unused anti-freeze in a tightly sealed container.

W1024852

G-27

Page 44

05-E2B, 05-E2BG, WSM

KiSC issued 06, 2011 A

5. SPECIAL TOOLS

G GENERAL

Diesel Engine Compression Tester (for Nozzle Hole)

Code No: 07909-30208 (Assembly) 07909-31251 (G)

07909-30934 (A to F) 07909-31271 (I) 07909-31211 (E and F) 07909-31281 (J) 07909-31231 (H)

Application: Use to measure diesel engine compression and

diagnosis of need for major overhaul.

Adaptor : H for 05-E2B series.

(1) Gauge (2) L Joint (3) Adaptor A (4) Adaptor B (5) Adaptor C (6) Adaptor E

(7) Adaptor F (8) Adaptor G

(9) Adaptor H (10) Adaptor I (11) Adaptor J

W1024200

Diesel Engine Compression Tester (for Glow Plug Hole)

Code No: 07909-39081 (Assembly) 07909-31301 (L)

07909-31291 (K) 07909-31311 (M)

Application: Use to measure diesel engine compression and

diagnosis of need for major overhaul.

Adaptor : L for 05-E2B series.

(1) Gauge (2) L Joint (3) Adaptor K

(4) Adaptor L (5) Adaptor M

W1025289

Oil Pressure Tester

Code No: 07916-32032 Application: Use to measure lubricating oil pressure.

(1) Gauge (2) Cable (3) Threaded Joint (4) Adaptor 1

(5) Adaptor 2 (6) Adaptor 3 (7) Adaptor 4 (8) Adaptor 5

W1024318

G-28

Page 45

05-E2B, 05-E2BG, WSM

NOTEQ

KiSC issued 06, 2011 A

• The following special tools are not provided, so make them referring to the figure.

Injection Pump Pressure Tester

Application: Use to check fuel tightness of injection pumps.

Pressure gauge full scale : More than 29.4 MPa (300 kgf/cm

psi)

B PF 1/2

C Copper gasket

D Flange (Material : Steel)

E Hex. nut 27 mm (1.06 in.) across the plat

F Adhesive application

G Fillet welding on the enter circumference

H Retaining nut

I 17 mm dia. (0.67 in. dia.)

J 8 mm dia. (0.31 in. dia.)

K 1.0 mm (0.039 in.)

L 17 mm dia. (0.67 in. dia.)

M 6.10 to 6.20 mm dia. (0.2402 to 0.2441 in. dia.)

N 8 mm (0.31 in.)

O 4 mm (0.16 in.)

P 11.97 to 11.99 mm dia. (0.4713 to 0.4720 in. dia.)

Q PF 1/2

R 23 mm (0.91 in.)

S 17 mm (0.67 in.)

T 4 mm (0.16 in.)

U 12.00 to 12.02 mm dia. (0.4724 to 0.4732 in. dia.)

V 100 mm (3.94 in.)

W M12 × P1.5

X 5 mm (0.20 in.)

Valve Guide Replacing Tool

Application: Use to press out and press fit the valve guide.

A 225 mm (8.86 in.)

B 70 mm (2.76 in.)

C 45 mm (1.77 in.)

D 20 mm dia. (0.79 in. dia.)

E 11.7 to 11.9 mm dia. (0.461 to 0.469 in. dia.)

F 6.5 to 6.6 mm dia. (0.256 to 0.260 in. dia.)

G 25 mm (0.98 in.)

H 6.7 to 7.0 mm dia. (0.264 to 0.276 in. dia.)

I 5 mm (0.197 in.)

J 20 mm dia. (0.787 in. dia.)

K 12.5 to 12.8 mm dia. (0.492 to 0.504 in. dia.)

L 8.9 to 9.1 mm (0.350 to 358 in.)

C1 Chamfer 1.0 mm (0.039 in.)

C2 Chamfer 2.0 mm (0.079 in.)

C0.3 Chamfer 0.3 mm (0.012 in.)

G GENERAL

, 4267

W10252400

W10250170

G-29

Page 46

05-E2B, 05-E2BG, WSM

KiSC issued 06, 2011 A

G GENERAL

Bushing Replacing Tool

Application: Use to press out and press fit the bushing.

1. For small end bushing

A 157 mm (6.1811 in.)

B 24 mm (0.9449 in.)

C 120 mm (4.7244 in.)

D 21.8 to 21.9 mm dia. (0.8583 to 0.8622 in. dia.)

E 24.8 to 24.9 mm dia. (0.9764 to 0.9803 in. dia.)

F 20 mm dia. (0.7874 in. dia.)

a 6.3 μm (250 μin.)

b 6.3 μm (250 μin.)

2. For idle gear bushing

A 196 mm (7.7165 in.)

B 26 mm (1.0236 in.)

C 150 mm (5.9055 in.)

D 25.8 to 25.9 mm dia. (1.0157 to 1.0197 in. dia.)

E 28.8 to 28.9 mm dia. (1.1339 to 1.1378 in. dia.)

F 20 mm dia. (0.7874 in. dia.)

a 6.3 μm (250 μin.)

b 6.3 μm (250 μin.)

W12358870

Flywheel Stopper

Application: Use to loosen and tighten the flywheel screw.

A 20 mm (0.79 in.)

B 15 mm (0.59 in.)

C 10 mm dia. (0.39 in. dia.)

D 30 mm (1.18 in.)

E 8 mm (0.31 in.)

F 200 mm (7.87 in.)

W10259480

G-30

Page 47

05-E2B, 05-E2BG, WSM

KiSC issued 06, 2011 A

G GENERAL

Crankshaft Bearing 1 Replacing Tool

Application: Use to press out and press fit the crankshaft bearing 1.

[Press Out]

A 135 mm (5.31 in.)

B 72 mm (2.83 in.)

C 40 mm radius (1.57 in. radius)

D 10 mm (0.39 in.)

E 24 mm (0.95 in.)

F 20 mm dia. (0.79 in. dia.)

G 51.2 to 51.4 mm dia. (2.0157 to 2.0236 in. dia.)

H 47.3 to 47.5 mm dia. (1.862 to 1.870 in. dia.)

C1 Chamfer 1.0 mm (0.039 in.)

C2 Chamfer 2.0 mm (0.079 in.)

C0.3 Chamfer 0.3 mm (0.012 in.)

[Press Fit]

A 135 mm (5.31 in.)

B 72 mm (2.83 in.)

C 40 mm radius (1.57 in. radius)

D 10 mm (0.39 in.)

E 24 mm (0.95 in.)

F 20 mm dia. (0.79 in. dia.)

G 68 mm dia. (2.68 in. dia.)

H 47.3 to 47.5 mm dia. (1.862 to 1.870 in. dia.)

C1 Chamfer 1.0 mm (0.039 in.)

C2 Chamfer 2.0 mm (0.079 in.)

C0.3 Chamfer 0.3 mm (0.012 in.)

W10261390

Governor Gear Holder Bushing Replacing Tool

Application: Use to press out and to press fit the governor gear

holder bushing.

A C1 : Chamfer 1.0 mm (0.039 in.)

B 73.9 to 74.0 mm dia. (29.09 to 29.13 in. dia.)

C 69.8 to 69.9 mm (2.748 to 2.751 in. dia.)

D 30 mm dia. (1.181 in. dia.)

E C2 : Chamfer 2.0 mm (0.079 in.)

F 18 mm (0.7 in.)

G 150 mm (5.9 in.)

H 188 mm (7.4 in.)

W1023337

G-31

Page 48

05-E2B, 05-E2BG, WSM

KiSC issued 06, 2011 A

G GENERAL

Crank Sleeve Setter

Application: Use to fix the crankshaft sleeve.

(1) Auxiliary Socket for Pushing

A 130 mm (5.12 in.)

B 112 mm (4.41 in.)

C 107 mm (4.21 in.)

D 82 mm (3.23 in.)

E 72 mm (2.83 in.)

F 67 mm (2.64 in.)

G 47 mm (1.85 in.)

H 36.0 to 36.2 mm (1.417 to 1.425 in.)

I 17 mm (0.67 in.)

J 5 mm dia. (0.20 in. dia.)

K 52 mm dia. (2.05 in. dia.)

L 40 mm dia. (1.57 in. dia.)

M 10 mm (0.39 in.)

N 33 mm (1.30 in.)

O 20 mm dia. (0.79 in. dia.)

P 40 mm dia. (1.57 in. dia.)

Q 72.10 to 72.15 mm dia. (2.840 to 2.841 in. dia.)

R 73 mm dia. (2.87 in. dia.)

S 83 mm dia. (3.27 in. dia.)

C0.3 Chamfer 0.3 mm (0.01 in.)

C1 Chamfer 1 mm (0.04 in.)

C5 Chamfer 5 mm (0.2 in.)

(2) Sleeve Guide

A 42 mm (1.65 in.)

B 12 mm (0.47 in.)

C 30 mm (1.18 in.)

D M10 × Pitch 1.25

E 2 mm (0.08 in.)

F 10 mm (0.39 in.)

G 2.0 mm (0.08 in.)

H 17.90 to 17.95 mm dia. (0.700 to 0.707 in. dia.)

I 8 mm dia. (0.31 in. dia.)

J 1.8 mm (0.07 in.)

K 0.09 rad (5 °)

C0.5 Chamfer 0.5 mm (0.02 in.)

W1026961

G-32

Page 49

MECHANISM

KiSC issued 06, 2011 A

CONTENTS

1. ENGINE BODY ............................................................................................... M-1

[1] CLOSED BREATHER (NATURAL ASPIRATION TYPE ONLY)........... M-1

[2] GOVERNOR .............................................................................................. M-2

[3] BOOST COMPENSATOR ........................................................................ M-4

Page 50

05-E2B, 05-E2BG, WSM

KiSC issued 06, 2011 A

1. ENGINE BODY

[1] CLOSED BREATHER (NATURAL ASPIRATION TYPE ONLY)

Closed breather system has been adopted to prevent

the release of blow-by gas into the atmosphere.

After its oil content is filtered by oil shield (4), the blowby gas in fed back to the intake manifold through breather valve (3) to be used for re-combustion.

(1) Breather Tube (2) Cylinder Head Cover (3) Breather Valve

(4) Oil Shield (5) Rubber Packing

DIESEL ENGINE

W1012956

M-1

Page 51

05-E2B, 05-E2BG, WSM

KiSC issued 06, 2011 A

[2] GOVERNOR

DIESEL ENGINE

Q Three Lever Type Fork Lever (for General)

The governor system is a mechanical governor that

used the flyweight (5).

The flyweight (5) is mounted on the governor shaft

that rotates at the same speed as the crankshaft.

Because the feature of this mechanism takes out the engine speed directly as a centrifugal force of weight, the speed control that the change in the engine rotational speed is sensitively transmitted to fork lever assembly (A) and accuracy is high is enabled.

The fork lever assembly of this engine is composed of fork lever 1 (6), for lever 2 (9), and the floating lever (7). A slide plate is installed in fork lever 1. The governor spring (3) is hooked to fork lever 2 (9).

The floating lever (7) installs the torque pin (8) of the output drop prevention at the overload. The start spring (2) is hooked to a slide plate, and holds the control rack in the direction of the full fuel position.

Fork lever 2 (9) and the floating lever are installed in fork lever 1 (6) with the fork lever shaft (4). The max torque limitation (1) device limits the amount of the fuel exhalation at the overload with the torque pin.

(1) Max Torque Limiter (2) Start Spring (3) Governor Spring (4) Fork Lever Shaft (5) Flyweight (6) Fork Lever 1

(7) Floating Lever (8) Torque Pin (9) Fork Lever 2

(A) Fork Lever Assembly

W1012753

(At Rated Operation)

When the engine is running, the fork lever 2 (9) and the floating lever (7) are moving with the fork lever 1 (6) due to the tension of the governor spring (3).

During the time, the torque pin (8) is pressed into the floating lever by centrifugal force of the governor weight (5).

The fork lever 2 (9) comes in contact with the fuel limitation bolt (10), and the fuel injection pump supplies a fuel necessary for rated operation.

(1) Max Torque Limiter (6) Fork Lever 1 (7) Floating Lever

(9) Fork Lever 2

(10) Fuel Limitation Bolt

W1012924

M-2

Page 52

05-E2B, 05-E2BG, WSM

KiSC issued 06, 2011 A

DIESEL ENGINE

(Overloaded Operation)

The amount of the movement of the fork lever assembly is limited with the fuel limitation bolt (10) and can not be moved in the direction of the fuel increase.

As overload reduces the centrifugal force of the governor weight, which is pressing the torque pin (8) into the floating lever (7), the floating lever pushes the fork lever 1 (6) in the way to increase the fuel supply with the help of the torque spring tension.

The fuel supply increases (b) in relation to the degree of the torque pin motion, thus preventing the engine speed from dropping.

At the time, the maximum torque limiter (1) prevents superfluous fuel supply and suppresses the generation of black smoke.

(1) Max Torque Limiter (6) Fork Lever 1 (7) Floating Lever (8) Torque Pin (9) Fork Lever 2

(10) Fuel Limitation Bolt

(a) Distance to which torque

pin (8) pushes fork lever 1 (6) out

(b) Increase of fuel

W1013023

Q Two Lever Type Fork Lever (for BG Series)

The engine speeds of BG engine are 1500 min (rpm) and 1800 min-1 (rpm) specifications.

The fork lever assembly of BG series is composed of fork lever 1 (3), fork lever 2 (4).

A slide plate is installed in fork lever 1. The governor spring (5) is hooked to fork lever 2 (4).

The start spring is hooked to a slide plate, and holds the control rack in the direction of full fuel position.

Fork lever 2 (4) and fork lever 1 (3) are installed with the fork lever shaft (4).

(1) Idle Speed Adjust Bolt (2) Slide Plate (3) Fork Lever 1

(4) Fork Lever 2 (5) Governor Spring (6) Fork Lever Shaft

W1013377

-1

M-3

Page 53

05-E2B, 05-E2BG, WSM

KiSC issued 06, 2011 A

[3] BOOST COMPENSATOR

DIESEL ENGINE

(1) Boost Compensator

Assembly (2) Actuator (3) Plate (4) Injection Pump Assembly (5) Guide (6) Stop Solenoid

A : Fulcrum

W1013537

Boost compensator is the device that reduces black

smoke during the engine startup and acceleration.

The rod of actuator (2) is pushed out by the rise of

boost pressure, and the plate (3) moves in the direction of the fuel increase around the fulcrum (A).

W1013615

M-4

Page 54

SERVICING

KiSC issued 06, 2011 A

CONTENTS

1. TROUBLESHOOTING ......................................................................................S-1

2. SERVICING SPECIFICATIONS ......................................................................S-5

3. TIGHTENING TORQUES ..............................................................................S-13

[1] TIGHTENING TORQUES FOR GENERAL USE SCREWS, BOLTS

AND NUTS...............................................................................................S-13

[2] TIGHTENING TORQUES FOR SPECIAL USE SCREWS, BOLTS

AND NUTS...............................................................................................S-14

4. CHECKING, DISASSEMBLING AND SERVICING......................................S-15

[1] CHECKING AND ADJUSTING ...............................................................S-15

(1) Engine Body........................................................................................S-15

(2) Lubricating System .............................................................................S-17

(3) Cooling System ...................................................................................S-17

(4) Fuel System ........................................................................................S-19

(5) Electrical System ................................................................................ S-22

(6) Turbocharger ......................................................................................S-26

[2] DISASSEMBLING AND ASSEMBLING..................................................S-27

(1) Draining Oil and Coolant .....................................................................S-27

(2) External Components .........................................................................S-27

(3) Cylinder Head and Valve ....................................................................S-28

(4) Gear Case and Timing Gears .............................................................S-32

(5) Piston and Connecting Rod ................................................................S-37

(6) Flywheel and Crankshaft ....................................................................S-40

(7) Starter .................................................................................................S-42

(8) Alternator ............................................................................................S-44

[3] SERVICING ..............................................................................................S-45

(1) Cylinder Head and Valves ..................................................................S-45

(2) Timing Gears, Camshaft and Governor Gear .....................................S-51

(3) Piston and Connecting Rod ................................................................S-54

(4) Crankshaft...........................................................................................S-58

(5) Cylinder ...............................................................................................S-63

(6) Oil Pump .............................................................................................S-64

(7) Starter .................................................................................................S-65

(8) Alternator ............................................................................................S-68

Page 55

05-E2B, 05-E2BG, WSM

KiSC issued 06, 2011 A

1. TROUBLESHOOTING

DIESEL ENGINE

Symptom Probable Cause Solution

Engine Does Not Start

Starter Does Not Run Battery discharged Charge –

No fuel Replenish fuel G-10

Air in the fuel system Vent air G-10

Water in the fuel system Change fuel and

repair or replace fuel system

Fuel pipe clogged Clean or replace G-10

Fuel filter clogged Replace G-14, 15

Excessively high viscosity of fuel or engine oil at low temperature

Fuel with low cetane number Use specified fuel –

Fuel leak due to loose injection pipe retaining nut Tighten retaining nut –

Incorrect injection timing Adjust S-19

Fuel camshaft worn Replace S-36

Injection nozzle clogged Clean or replace S-21, 22

Injection pump malfunctioning Repair or replace S-20, 35

Seizure of crankshaft, camshaft, piston, cylinder or bearing

Compression leak from cylinder Replace head

Improper valve timing Correct or replace

Piston ring and cylinder worn Replace S-37, 38,

Excessive valve clearance Adjust S-16

Stop solenoid malfunctioning Replace S-34

Starter malfunctioning Repair or replace S-27, 65,

Key switch malfunctioning Replace –

Wiring disconnected Connect –

Use specified fuel or engine oil

Repair or replace S-58 to 64

gasket, tighten cylinder head screw, glow plug and nozzle holder

timing gear

Reference Page

4, G-8

S-36 to 39

S-29, 30,

S-36

66, 67

W1014322

–

S-1

Page 56

05-E2B, 05-E2BG, WSM

KiSC issued 06, 2011 A

DIESEL ENGINE

Symptom Probable Cause Solution

Engine Revolution Is Not Smooth

Fuel filter clogged or dirty Replace G-14, 15

Air cleaner clogged Clean or replace G-11, 14,

Fuel leak due to loose injection pipe retaining nut Tighten retaining nut –

Injection pump malfunctioning Repair or replace S-20, 35

Incorrect nozzle opening pressure Adjust S-21

Injection nozzle stuck or clogged Repair or replace S-21, 22

Governor malfunctioning Repair S-35, 36

Turbocharger bearing worn out Replace the

turbocharger assembly

Turbocharger shaft bent Replace the

turbocharger assembly

Turbocharger fin or other part damaged due to foreign matters

Replace the turbocharger assembly

Either White or Blue Exhaust Gas Is Observed

Excessive engine oil Reduce to specified

level

Piston ring and cylinder worn or stuck Repair or replace S-38, 39,

Incorrect injection timing Adjust S-19

Oil Leak into Exhaust Pipe or Suction Pipe

Waste oil pipe clogged or deformed Repair or replace S-28

Piston ring seal faulty Replace the

turbocharger assembly

Either Black or Dark Gray Exhaust Gas Is Observed

Overload Lessen the load –

Low grade fuel used Use specified fuel 4

Fuel filter clogged Replace G-14, 15

Air cleaner clogged Clean or replace G-11, 14,

Deficient nozzle injection Repair or replace

nozzle

Reference Page

S-28

–

S-28

S-21, 22

W1014322

S-2

Page 57

05-E2B, 05-E2BG, WSM

KiSC issued 06, 2011 A

DIESEL ENGINE

Symptom Probable Cause Solution

Reference Page

Deficient Output Incorrect injection timing Adjust S-19

Engine’s moving parts seem to be seizing Repair or replace –

Injection pump malfunctioning Repair or replace S-20, 35

Deficient nozzle injection Repair or replace

S-21, 22

nozzle

Compression leak Check the

S-15 compression pressure and repair

Gas leak from exhaust system Repair or replace S-26, 28

Air leak from compressor discharge side Repair or replace S-26, 28

Air cleaner dirty or clogged Clean or replace G-11, 14,

Compressor wheel turning heavily Replace the

S-28 turbocharger assembly

Excessive Lubricant Oil Consumption

Piston ring’s gap facing the same direction Shift ring gap

direction

S-38

Oil ring worn or stuck Replace S-38, 39

Piston ring groove worn Replace piston S-37 to 39

Valve stem and valve guide worn Replace S-31, 47

Crankshaft bearing and crank pin bearing worn Replace S-41

Oil leaking due to defective seals or packing Replace –

Fuel Mixed into Lubricant Oil

Injection pump’s plunger worn Repair or replace S-20, 35

Deficient nozzle injection Repair or replace

S-21, 22

nozzle

Injection pump broken Replace S-35

Water Mixed into Lubricant Oil

Head gasket defective Replace S-30, 31

Cylinder block or cylinder head flawed Replace S-30, 31

Low Oil Pressure Engine oil insufficient Replenish G-8

Oil strainer clogged Clean S-37

Relief valve stuck with dirt Clean –

Relief valve spring weaken or broken Replace –

Excessive oil clearance of crankshaft bearing Replace S-40

Excessive oil clearance of crankpin bearing Replace S-40

Excessive oil clearance of rocker arm Replace S-29

Oil passage clogged Clean –

Different type of oil Use specified type of

G-8

oil

Oil pump defective Replace –

W1014322

S-3

Page 58

05-E2B, 05-E2BG, WSM

KiSC issued 06, 2011 A

DIESEL ENGINE

Symptom Probable Cause Solution

High Oil Pressure Different type of oil Use specified type of

Reference Page

G-8

oil

Relief valve defective Replace –

Engine Overheated Engine oil insufficient Replenish G-8

Fan belt broken or elongated Replace or adjust G-11, 12

Coolant insufficient Replenish G-15, 16

Radiator net and radiator fin clogged with dust Clean –

Inside of radiator corroded Clean or replace G-15

Coolant flow route corroded Clean or replace G-15, 16

Radiator cap defective Replace –

Overload running Reduce the load –

Head gasket defective Replace S-30, 31

Incorrect injection timing Adjust S-19

Unsuitable fuel used Use specified fuel 4

Battery Quickly Discharged

Battery electrolyte insufficient Replenish distilled

water and charge

Fan belt slips Adjust belt tension or

G-12

G-11, 12

replace

Wiring disconnected Connect –

Rectifier defective Replace –

Alternator defective Replace –

Battery defective Replace –

W1014322

S-4

Page 59

05-E2B, 05-E2BG, WSM

KiSC issued 06, 2011 A

2. SERVICING SPECIFICATIONS

ENGINE BODY

Item Factory Specification Allowable Limit

Valve Clearance (Cold) 0.145 to 0.185 mm

0.00571 to 0.00728 in.

Compression Pressure

D905-E2B / E2BG D1005-E2B / E2BG D1105-E2B / E2BG V1305-E2B / E2BG V1505-E2B / E2BG

3.72 to 4.12 MPa 38 to 42 kgf/cm

539 to 596 psi

DIESEL ENGINE

–

2.25 MPa

23.0 kgf/cm

327 psi

D1105-T-E2B V1505-T-E2B

3.14 to 3.53 MPa 32 to 36 kgf/cm

454 to 511 psi

Difference among Cylinders

–

Top Clearance 0.55 to 0.70 mm

2.25 MPa

23.0 kgf/cm 327 psi

10 % or less

–

0.0217 to 0.0276 in.

Cylinder Head Surface Flatness – 0.05 mm

0.0020 in.

Valve Recessing Intake and Exhaust −0.05 to 0.25 mm

−0.0020 to 0.0098 in.

Valve Stem to Valve Guide

Clearance

0.035 to 0.065 mm

0.0014 to 0.0025 in.

Valve Stem

O.D.

6.960 to 6.975 mm

0.40 mm

0.0157 in.

0.10 mm

0.0039 in.

–

0.2741 to 0.2746 in.

Valve Guide

I.D.

7.010 to 7.025 mm

–

0.2760 to 0.2765 in.

Valve Face Angle (Intake)

1.047 rad

–

60 °

Angle (Exhaust)

0.785 rad

–

45 °

Valve Seat Angle (Intake)

1.047 rad

–

60 °

Valve Spring Free Length

Angle (Exhaust)

Width

Tilt

Setting Load

S-5

0.785 rad 45 °

2.12 mm

0.0835 in.

37.0 to 37.5 mm

1.457 to 1.476 in.

–

117.4 N / 31.0 mm

11.97 kgf / 31.0 mm

26.4 lbs / 1.22 in.

–

36.5 mm

1.437 in.

1.0 mm

0.039 in.

100.0 N / 31.0 mm

10.2 kgf / 31.0 mm

22.5 lbs / 1.22 in.

W10138740

Page 60

05-E2B, 05-E2BG, WSM

KiSC issued 06, 2011 A

ENGINE BODY (Continued)

Rocker Arm Shaft to Rocker Arm

DIESEL ENGINE

Item Factory Specification Allowable Limit

Clearance

0.016 to 0.045 mm

0.00063 to 0.00177 in.

0.10 mm

0.0039 in.

Rocker Arm Shaft

O.D.

11.973 to 11.984 mm

–

0.4714 to 0.4718 in.

Rocker Arm

I.D.

12.000 to 12.018 mm

–

0.4724 to 0.4731 in.

Push Rod Alignment – 0.25 mm

0.0098 in.

Tappet to Tappet Guide

Tappet

Clearance

O.D.

0.020 to 0.062 mm

0.0008 to 0.0024 in.

19.959 to 19.980 mm

0.07 mm

0.0028 in.

–

0.7858 to 0.7866 in.

Tappet Guide

I.D.

20.000 to 20.021 mm

–

0.7874 to 0.7882 in.

Timing Gear

Crank Gear to Idle Gear 1

Idle Gear 1 to Cam Gear

Idle Gear 1 to Injection Pump Gear

Backlash

0.032 to 0.115 mm

0.0013 to 0.0045 in.

0.036 to 0.114 mm

0.0014 to 0.0045 in.

0.034 to 0.116 mm

0.0013 to 0.0046 in.

0.15 mm

0.0059 in.

0.15 mm

0.0059 in.

0.15 mm

0.0059 in.

Idle Gear 1 to Idle Gear 2

Idle Gear 2 to Governor Gear

Governor Gear

Governor Gear to Injection Pump Gear

Backlash

0.033 to 0.117 mm

0.0013 to 0.0046 in.

Backlash

0.030 to 0.117 mm

0.0012 to 0.0046 in.

Backlash 0.030 to 0.117 mm

0.0012 to 0.0046 in.

0.15 mm

0.0059 in.

0.15 mm

0.0059 in.

0.15 mm

0.0059 in.

W1013874

S-6

Page 61

05-E2B, 05-E2BG, WSM

KiSC issued 06, 2011 A

ENGINE BODY (Continued)

Idle Gear Shaft to Gear Bushing

Idle Gear 1

DIESEL ENGINE

Item Factory Specification Allowable Limit

Clearance

0.020 to 0.054 mm

0.0008 to 0.0021 in.

0.10 mm

0.0039 in.

Idle Gear Bushing

Idle Gear Shaft 1

Idle Gear 2

Idle Gear Bushing

Idle Gear Shaft 2

I.D.

O.D.

Clearance

I.D.

O.D.

Idle Gear

Idle Gear 1

Idle Gear 2

Side Clearance

Camshaft Side Clearance

Alignment

Cam Height Intake

26.000 to 26.021 mm

1.0236 to 1.0244 in.

25.967 to 25.980 mm

1.0223 to 1.0228 in.

0.020 to 0.054 mm

0.0008 to 0.0021 in.

26.000 to 26.021 mm

1.0236 to 1.0244 in.

25.967 to 25.980 mm

1.0223 to 1.0228 in.

0.20 to 0.51 mm

0.0079 to 0.0201 in.

0.20 to 0.51 mm

0.0079 to 0.0201 in.

0.07 to 0.22 mm

0.0028 to 0.0087 in.

–

28.80 mm

1.1339 in.

–

0.10 mm

0.0039 in.

–

0.80 mm

0.0315 in.

0.80 mm

0.0315 in.

0.30 mm

0.0118 in.

0.01 mm

0.0004 in.

28.75 mm

1.1319 in.

Exhaust

29.0 mm

1.1417 in.

Camshaft Journal to Cylinder Block Bore

Oil Clearance

0.050 to 0.091 mm

0.00197 to 0.00358 in.

Camshaft Journal

O.D.

35.934 to 35.950 mm

1.4147 to 1.4153 in.

Cylinder Block Bore

I.D.

36.000 to 36.025 mm

1.4173 to 1.4183 in.

Piston Pin Bore I.D. 22.000 to 22.013 mm

0.8661 to 0.8667 in.

Piston Pin to Small End Bushing

Clearance

0.014 to 0.038 mm

0.00055 to 0.00150 in.

Piston Pin

O.D.

22.002 to 22.011 mm

0.8662 to 0.8666 in.

Small End Bushing

I.D.

22.025 to 22.040 mm

0.8671 to 0.8677 in.

28.95 mm

1.1398 in.

0.15 mm

0.0059 in.

–

22.03 mm

0.8673 in.

0.15 mm

0.0059 in.

–

W10138740

S-7

Page 62

05-E2B, 05-E2BG, WSM

KiSC issued 06, 2011 A

ENGINE BODY (Continued)

Piston Ring Gap

[D905-E2B]

Piston Ring Gap

[D1005-E2B] [V1305-E2B] [D1105-E2B] [V1505-E2B]

Piston Ring Gap

[D1105-T-E2B] [V1505-T-E2B]

Piston Ring Gap

[D905-E2BG] [D1005-E2BG] [V1305-E2BG]

Piston Ring Gap

[D1105-E2BG] [V1505-E2BG]

Piston Ring to Piston Ring Groove

Second Ring

DIESEL ENGINE

Item Factory Specification Allowable Limit

Top Ring 0.25 to 0.40 mm

0.0098 to 0.0157 in.

Second Ring 0.25 to 0.40 mm

0.0098 to 0.0157 in.

Oil Ring 0.25 to 0.40 mm

0.0098 to 0.0157 in.

Top Ring 0.30 to 0.45 mm

0.0118 to 0.0177 in.

Second Ring 0.30 to 0.45 mm

0.0118 to 0.0177 in.

Oil Ring 0.25 to 0.40 mm

0.0098 to 0.0157 in.

Top Ring 0.20 to 0.35 mm

0.0079 to 0.0138 in.

Second Ring 0.40 to 0.55 mm

0.0157 to 0.0217 in.

Oil Ring 0.30 to 0.55 mm

0.0118 to 0.0217 in.

Top Ring 0.25 to 0.40 mm

0.0098 to 0.0157 in.

Second Ring 0.25 to 0.40 mm

0.0098 to 0.0157 in.

Oil Ring 0.25 to 0.40 mm

0.0098 to 0.0157 in.

Top Ring 0.30 to 0.45 mm

0.0118 to 0.0177 in.

Second Ring 0.30 to 0.45 mm

0.0118 to 0.0177 in.

Oil Ring 0.25 to 0.40 mm

0.0098 to 0.0157 in.

Clearance

0.085 to 0.112 mm

0.0033 to 0.0044 in.

1.25 mm

0.0492 in.

1.25 mm

0.0492 in.

1.25 mm

0.0492 in.

1.25 mm

0.0492 in.

1.25 mm

0.0492 in.

1.25 mm

0.0492 in.

1.20 mm

0.0472 in.

1.20 mm

0.0472 in.

1.25 mm

0.0492 in.

1.25 mm

0.0492 in.

1.25 mm

0.0492 in.

1.25 mm

0.0492 in.

1.25 mm

0.0492 in.

1.25 mm

0.0492 in.

1.25 mm

0.0492 in.

0.2 mm

0.0079 in.

Oil Ring

Connecting Rod Alignment – 0.05 mm

Crankshaft Alignment – 0.02 mm

Crankshaft to Crankshaft Bearing 1

Crankshaft

Crankshaft Bearing 1

Clearance

Oil Clearance

O.D.

I.D.

S-8

0.020 to 0.055 mm

0.0008 to 0.0021 in.

0.034 to 0.114 mm

0.0013 to 0.0045 in.

47.934 to 47.950 mm

1.8872 to 1.8878 in.

47.984 to 48.048 mm

1.8891 to 1.8916 in.

0.15 mm

0.0059 in.

0.0020 in.

0.0008 in.

0.20 mm

0.0079 in.

–

W10138740

Page 63

05-E2B, 05-E2BG, WSM

KiSC issued 06, 2011 A

ENGINE BODY (Continued)

Item Factory Specification Allowable Limit

Crankshaft to Crankshaft Bearing 2

Oil Clearance

0.034 to 0.095 mm

0.0013 to 0.0037 in.

DIESEL ENGINE

0.20 mm

0.0079 in.

Crankshaft Journal

O.D.

47.934 to 47.950 mm

1.8872 to 1.8878 in.

Crankshaft Bearing 2

I.D.

47.984 to 48.029 mm

1.8891 to 1.8909 in.

Crankshaft to Crankshaft Bearing 3

Oil Clearance

0.034 to 0.098 mm

0.0013 to 0.0039 in.

Crankshaft Journal

O.D.

51.921 to 51.940 mm

2.0441 to 2.0449 in.

Crankshaft Bearing 3

I.D.

51.974 to 52.019 mm

2.0462 to 2.0480 in.

Crankpin to Crankpin Bearing

Oil Clearance

0.029 to 0.091 mm

0.0011 to 0.0036 in.

Crankpin

O.D.

39.959 to 39.975 mm

1.5732 to 1.5738 in.

Crankpin Bearing

I.D.

40.004 to 40.050 mm

1.5750 to 1.5768 in.

Crankshaft Side Clearance 0.15 to 0.31 mm

0.0059 to 0.0122 in.

Cylinder Liner I.D. D905-E2B / E2BG

72.000 to 72.019 mm

2.8346 to 2.8354 in.

–

0.20 mm

0.0079 in.

–

0.20 mm

0.0079 in.

–

0.50 mm

0.0197 in.

72.15 mm

2.8406 in.

D1005-E2B / E2BG V1305-E2B / E2BG

D1105-E2B / E2BG D1105-T-E2B V1505-E2B / E2BG V1505-T-E2B

Cylinder (Oversized) D905-E2B / E2BG

D1005-E2B / E2BG V1305-E2B / E2BG

D1105-E2B / E2BG D1105-T-E2B V1505-E2B / E2BG V1505-T-E2B

76.000 to 76.019 mm

2.9921 to 2.9929 in.

78.000 to 78.019 mm

3.0709 to 3.0716 in.

72.500 to 72.519 mm

2.85433 to 3.85507 in.

76.500 to 76.519 mm

3.0118 to 3.0126 in.

78.500 to 78.519 mm

3.0906 to 3.0913 in.

76.15 mm

2.9980 in.

78.15 mm

3.0768 in.

72.65 mm

2.8602 in.

76.65 mm

3.0177 in.

78.65 mm

3.0965 in.

W10138740

S-9

Page 64

05-E2B, 05-E2BG, WSM

KiSC issued 06, 2011 A

LUBRICATING SYSTEM

Item Factory Specification Allowable Limit

Engine Oil Pressure At Idle Speed

More than 49 kPa

0.5 kgf/cm

7 psi

DIESEL ENGINE

–

At Rated Speed

196 to 441 kPa

2.0 to 4.5 kgf/cm 28 to 64 psi

Inner Rotor to Outer Rotor Clearance 0.06 to 0.18 mm

0.0024 to 0.0071 in.

Outer Rotor to Pump Body Clearance 0.100 to 0.180 mm

0.0039 to 0.0071 in.

Inner Rotor to Cover Clearance 0.025 to 0.075 mm

0.0010 to 0.0030 in.

COOLING SYSTEM

Fan Belt Tension 7.0 to 9.0 mm / 98 N

0.28 to 0.35 in. / 98 N (10 kgf, 22 lbs)

Thermostat Valve Opening

Temperature

69.5 to 72.5 °C

157.1 to 162.5 °F

(At Beginning)

Valve Opening Temperature

85 °C

185 °F (Opened Completely)

Radiator Cap Pressure Falling

Time

10 seconds or more

88 → 59 kPa

0.9 → 0.6 kgf/cm 13 → 9 psi

Radiator Water Leakage

Test Pressure

No leak at specified

pressure

137 kPa

1.4 kgf/cm

20 psi

147 kPa

1.5 kgf/cm

21 psi

–

W10139730

–

W10135990

S-10

Page 65

05-E2B, 05-E2BG, WSM

KiSC issued 06, 2011 A

FUEL SYSTEM

Item Factory Specification Allowable Limit

Injection Pump Injection Timing

(3000 min

-1

(rpm))

0.30 to 0.33 rad (17 to 19°)

before T.D.C.

DIESEL ENGINE

–

Injection Timing (3600 min

-1

(rpm))

0.35 to 0.39 rad (20 to 22°)

–

before T.D.C.

Injection Pump (BG Type) Injection Timing

(60 Hz / 1800 min (rpm))

-1

0.27 to 0.31 rad

(15.5 to 17.5 °)

before T.D.C.

–

Pump Element Fuel Tightness – 13.73 MPa

140 kgf/cm

1991 psi

Delivery Valve Fuel Tightness 10 seconds

13.73 → 12.75 MPa 140 → 130 kgf/cm

1991 → 1849 psi

Injection Nozzle Injection Pressure 13.73 to 14.71 MPa

140 to 150 kgf/cm

5 seconds

13.73 → 12.75 MPa 140 → 130 kgf/cm

1991 → 1849 psi

–

1991 to 2134 psi

Injection Nozzle Valve Seat Valve Seat

Tightness

When the pressure is

12.75 MPa

(130 kgf/cm

, 1849 psi),

–

the valve seat must be

fuel tightness.

W10139730

S-11

Page 66

05-E2B, 05-E2BG, WSM

KiSC issued 06, 2011 A

DIESEL ENGINE

ELECTRICAL SYSTEM

Item Factory Specification Allowable Limit

Glow Plug Resistance Approx. 0.9 Ω –

Starter (Planetary Gear Reduction Type)

Commutator

O.D.

30.0 mm

1.181 in.

29.0 mm

1.142 in.

Difference

Mica

Brush

Starter (Electromagnetic Drive Type)

Commutator

Difference

Mica

Brush

Alternator

Stator

Rotor

O.D.

Undercut

Length

O.D.

Undercut

Length

Resistance

Less than 0.02 mm

0.0008 in.

0.50 to 0.80 mm

0.0197 to 0.0315 in.

16.0 mm

0.630 in.

28.0 mm

1.102 in.

Less than 0.05 mm

0.0002 in.

0.50 to 0.80 mm

0.0197 to 0.0315 in.

16.0 mm

0.630 in.

Less than 1.0 Ω

2.9 Ω

0.05 mm

0.0020 in.

0.20 mm

0.0079 in.

10.5 mm

0.413 in.

27.0 mm

1.063 in.

0.4 mm

0.016 in.

0.20 mm

0.0079 in.

10.5 mm

0.413 in.

–

Slip Ring

Brush

O.D.

Length

14.4 mm

0.5669 in.

10.0 mm

0.3937 in.

14.0 mm

0.5512 in.

8.4 mm

0.331 in.

W1013973

S-12

Page 67

05-E2B, 05-E2BG, WSM

KiSC issued 06, 2011 A

DIESEL ENGINE

3. TIGHTENING TORQUES

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

nuts such as those used on the cylinder head must be tightened in proper sequence and the proper torque.

[1] TIGHTENING TORQUES FOR GENERAL USE SCREWS, BOLTS AND

NUTS

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

Grade

Nominal Unit Diameter

M6 7.9 to 9.3 0.80 to 0.95 5.8 to 6.9 9.8 to 11.3 1.00 to 1.15 7.23 to 8.32

M8 17.7 to 20.6 1.8 to 2.1 13.0 to 15.2 23.5 to 27.5 2.4 to 2.8 17.4 to 20.3

M10 39.2 to 45.1 4.0 to 4.6 28.9 to 33.3 48.1 to 55.9 4.9 to 5.7 35.4 to 41.2

M12 62.8 to 72.6 6.4 to 7.4 46.3 to 53.5 77.5 to 90.2 7.9 to 9.2 57.1 to 66.5

Screw and bolt material grades are shown by numbers punched on the screw and bolt heads. Prior to tightening, be sure to check out the numbers as shown below.

Punched number Screw and bolt material grade

None or 4 Standard screw and bolt SS41, S20C

7 Special screw and bolt S43C, S48C (Refined)

Standard Screw and Bolt

N·m kgf·m ft-lbs N·m kgf·m ft-lbs

Special Screw and Bolt

W10371750

W1012705

S-13

Page 68

05-E2B, 05-E2BG, WSM

NOTEQ

KiSC issued 06, 2011 A

DIESEL ENGINE

[2] TIGHTENING TORQUES FOR SPECIAL USE SCREWS, BOLTS AND

NUTS

• For “*” marked screws, bolts and nuts on the table, apply engine oil to their threads and seats before tightening.

• The letter “M” in Size x Pitch means that the screw, bolt or nut dimension stands for metric. The size is the nominal outside diameter in mm of the threads. The pitch is the nominal distance in mm between two threads.

Item Size x Pitch N·m kgf·m ft-lbs

*Cylinder head cover screw M7 x 1.0 6.9 to 8.8 0.7 to 0.9 5.1 to 6.5

*Cylinder head screw M10 x 1.25 63.7 to 68.6 6.5 to 7.0 47.0 to 50.6

*Main bearing case screw 1 M8 x 1.25 29.4 to 34.3 3.0 to 3.5 21.7 to 25.3

*Main bearing case screw 2 M9 x 1.25 49.0 to 53.9 5.0 to 5.5 36.2 to 39.8

*Flywheel screw M10 x 1.25 53.9 to 58.8 5.5 to 6.0 39.8 to 43.4

*Connecting rod screw M8 x 1.0 41.2 to 46.1 4.2 to 4.7 30.4 to 34.0

*Rocker arm bracket nuts M7 x 1.0 21.6 to 26.5 2.2 to 2.7 15.9 to 19.5

*Idle gear shaft screws M6 x 1.0 9.8 to 11.3 1.00 to 1.15 7.2 to 8.3

*Fan drive pulley screw M14 x 1.5 235.4 to 245.2 24.0 to 25.0 173.6 to 180.8

*Bearing case cover mounting screw M6 x 1.0 9.8 to 11.3 1.00 to 1.15 7.2 to 8.3

Glow plugs M8 x 1.0 7.8 to 14.7 0.8 to 1.5 5.8 to 10.8

Nozzle holder assembly M20 x 1.5 49.0 to 68.6 5.0 to 7.0 36.2 to 50.6

Nozzle holder – 34.3 to 39.2 3.5 to 4.0 25.3 to 28.9

Oil pressure switch PT 1/8 14.7 to 19.6 1.5 to 2.0 10.8 to 14.5

Injection pipe retaining nuts M12 x 1.5 24.5 to 34.3 2.5 to 3.5 18.1 to 25.3

Overflow pipe assembly retaining screw M12 x 1.5 19.6 to 24.5 2.0 to 2.5 14.5 to 18.1

Starter’s terminal B mounting nut (Electromagnetic drive type)

Starter’s terminal B mounting nut (Planetary gear reduction type)

Alternator’s pulley nut – 58.3 to 78.9 5.95 to 8.05 43.0 to 58.2

Drain plug with copper gasket M12 x 1.25 32.4 to 37.3 3.3 to 3.8 23.9 to 27.5

Drain plug with copper gasket M22 x 1.5 63.7 to 73.5 6.5 to 7.5 47.0 to 54.2

Drain plug with rubber coated gasket M22 x 1.5 44.1 to 53.9 4.5 to 5.5 32.5 to 39.8

M8 7.8 to 9.8 0.8 to 1.0 5.8 to 7.2

M8 5.9 to 11.8 0.6 to 1.2 4.3 to 8.7

W1013236

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NOTEQ

KiSC issued 06, 2011 A

DIESEL ENGINE

4. CHECKING, DISASSEMBLING AND SERVICING

[1] CHECKING AND ADJUSTING

(1) Engine Body

Compression Pressure

1. Run the engine until it is warmed up.

2. Stop the engine.

3. Remove the air cleaner, the muffler and all glow plugs (or nozzles).

4. Set a compression tester with the adaptor to the glow plug hole (or nozzle hole). Nozzle hole : Adaptor H (07909-31231) Glow plug hole : Adaptor L (07909-31301)

5. After making sure that the stop lever is set at the stop position (non-injection), run the engine with the starter and measure the compression pressure.

6. Repeat steps 4 and 5 for each cylinder.

7. If the measurement is below the allowable limit, apply a small amount of oil to the cylinder wall through the glow plug hole (or nozzle hole) and measure the compression pressure again.

8. If the compression pressure is still less than the allowable limit, check the top clearance, valve clearance and cylinder head.

9. If the compression pressure increases after applying oil, check the cylinder wall and piston rings.

• Check the compression pressure with the specified valve clearance.

• Always use a fully charged battery for performing this test.

• Variances in cylinder compression values should be under 10 %.

Compression pressure

D905-E2B / E2BG D1005-E2B / E2BG D1105-E2B / E2BG V1305-E2B / E2BG V1505-E2B / E2BG

D1105-T-E2B V1505-T-E2B

Factory spec.

Allowable limit

Factory spec.

Allowable limit

3.72 to 4.12 MPa 38 to 42 kgf/cm 539 to 596 psi

2.25 MPa

23.0 kgf/cm 327 psi

3.14 to 3.53 MPa 32 to 36 kgf/cm 454 to 511 psi

2.25 MPa

23.0 kgf/cm 327 psi

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IMPORTANTQ

NOTEQ

KiSC issued 06, 2011 A

DIESEL ENGINE

Valve Clearance

• Valve clearance must be checked and adjusted when engine is cold.

1. Remove the cylinder head cover and the glow plugs.

2. Align the “1TC” mark (1) on the flywheel and alignment mark (2)

on the rear end plate so that the No. 1 piston comes to the compression top dead center.

3. Check the following valve clearance marked with “,” using a thickness gauge.

4. If the clearance is not within the factory specifications, adjust with the adjusting screw.

5. Then turn the flywheel 6.28 rad (360 °), and align the “1TC” mark (1) on the flywheel and alignment mark (2) on the rear end plate so that the No. 1 piston comes to the overlap position.

6. Check the following valve clearance marked with “,“ using a feeler gauge.

Number of cylinders Valve arrangement

3 cylinder 4 cylinder

Adjustable cylinder location of piston

1st ,,,,

When No. 1 piston is at compression top dead center

When No. 1 piston is at overlap position

Valve clearance Factory spec.

2nd ,,

3rd ,,

4th

1st

2nd ,,

3rd ,,

4th ,,

IN. EX. IN. EX.

0.145 to 0.185 mm

0.00571 to 0.00728 in.

• The sequence of cylinder numbers is given as No. 1, No. 2, No. 3 and No. 4 starting from the gear case side.

• After adjusting the valve clearance, secure the adjusting screw with the lock nut.

(1) “1TC” Mark (2) Alignment Mark

W10155550

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KiSC issued 06, 2011 A

(2) Lubricating System

DIESEL ENGINE

Engine Oil Pressure

1. Remove the engine oil pressure switch, and set an oil pressure tester.

2. Start the engine. After warming up, measure the oil pressure of both idling and rated speeds.

3. If the oil pressure is less than the allowable limit, check the following.

• Engine oil insufficient

• Oil pump defective

• Oil strainer clogged

• Oil filter cartridge clogged

• Oil gallery clogged

• Excessive oil clearance

• Foreign matter in the relief valve

More than 49 kPa

0.5 kgf/cm 7 psi

196 to 441 kPa

2.0 to 4.5 kgf/cm 28 to 64 psi

147 kPa

1.5 kgf/cm 21 psi

Engine oil pressure

At idle speed

At rated speed

Factory spec.

Allowable limit

(When reassembling)

• After checking the engine oil pressure, tighten the engine oil pressure switch to the specified torque.

Tightening torque Oil pressure switch

14.7 to 19.6 N·m

1.5 to 2.0 kgf·m

10.8 to 14.5 ft-lbs

(3) Cooling System

W10349520

Fan Belt Tension

1. Measure the deflection (A), depressing the belt halfway between

the fan drive pulley and alternator pulley at specified force 98 N (10 kgf, 22 lbs).

2. If the measurement is not within the factory specifications, loosen the alternator mounting screws and relocate the alternator to adjust.

Deflection (A) Factory spec.

(A) Deflection

7.0 to 9.0 mm

0.28 to 0.35 in.

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CAUTION

KiSC issued 06, 2011 A

DIESEL ENGINE

Fan Belt Damage and Wear

1. Check the fan belt for damage.

2. If the fan belt is damaged, replace it.

3. Check if the fan belt is worn and sunk in the pulley groove.

4. If the fan belt is nearly worn out and deeply sunk in the pulley groove, replace it.

(A) Good (B) Bad

W1016443

• When removing the radiator cap, wait at least ten minutes after the engine has stopped and cooled down. Otherwise, hot water may gush out, scalding nearby people.

Radiator Cap Air Leakage

1. Set a radiator tester (1) and an adaptor (2) on the radiator cap.

2. Apply the specified pressure 88 kPa (0.9 kgf/cm

, 13 psi), and measure the time for the pressure to fall to 59 kPa (0.6 kgf/cm 9 psi).

3. If the measurement is less than the factory specification, replace the radiator cap.

More than 10 seconds

Pressure falling time Factory spec.

(1) Radiator Tester (2) Adaptor

for pressure fall from 88 to 59 kPa (from 0.9 to 0.6 kgf/cm from 13 to 9 psi)

W1054156

Radiator Water Leakage

1. Pour a specified amount of water into the radiator.

2. Set a radiator tester (1) and an adaptor (2) and raise the water pressure to the specified pressure.

3. Check the radiator for water leaks.

4. For water leak from the pinhole, repair with the radiator cement. When water leak is excessive, replace the radiator.

Radiator water leakage test pressure

Factory spec.

137 kPa

1.4 kgf/cm 20 psi

(1) Radiator Tester (2) Adaptor

W1016903

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NOTEQ

KiSC issued 06, 2011 A

(4) Fuel System

DIESEL ENGINE

Thermostat Valve Opening Temperature

1. Suspend the thermostat in the water by a string with its end inserted between the valve and seat.

2. Heating the water gradually, read the temperature when the valve opens and leaves the string.

3. Continue heating and read the temperature when the valve opens approx. 8 mm (0.315 in.).

4. If the measurement is not within the factory specifications, replace the thermostat.

Thermostat’s valve opening temperature

Temperature at which thermostat completely opens

Factory spec.

69.5 to 72.5 °C

157.1 to 162.5 °F

85 °C 185 °F

W1035849

Injection Timing

1. Remove the injection pipes.

2. Remove the engine stop solenoid.

3. Turn the flywheel counterclockwise (viewed from flywheel side) until the fuel fills up to the hole of the delivery valve holder (3) for No. 1 cylinder.

4. After the fuel fills up to the hole of the delivery valve holder for No. 1 cylinder, turn back (clockwise) the flywheel around 1.57 rad (90 °).

5. Turn the flywheel counterclockwise to set at around 0.44 rad (25 °) before T.D.C..

6. Slowly turn the flywheel counterclockwise and stop turning when the fuel begins to come up, to get the present injection timing.

7. Check to see the degree on flywheel. The flywheel gas mark “1TC”, “10” and “20” for the crank angle before the top dead center of No. 1 cylinder.

8. If injection timing is out of adjustment, readjust the timing with shims.

Injection timing (3000 min

Injection timing (3600 min

Injection timing for BG type (1800 min

-1

(rpm))

-1

(rpm))

-1

(rpm))

Factory spec.

0.30 to 0.33 rad (17 to 19 °) before T.D.C.

0.35 to 0.39 rad (20 to 22 °) before T.D.C.

0.27 to 0.31 rad (15.5 to

17.5 °) before T.D.C.

• The liquid gasket is not required for assembling.

• Shims are available in thickness of 0.20 mm (0.0079 in.), 0.25 mm (0.0098 in.) and 0.30 mm (0.0118 in.). Combine these shims for adjustments.

• Addition or reduction of shim (0.05 mm, 0.0020 in.) delays or advances the injection timing by approx. 0.0087 rad (0.5 °).

• In disassembling and replacing the injection pump, be sure to use the same number of new shims with the same thickness.

(1) Timing Line (2) Alignment Mark (3) Delivery Valve Holder (4) Shim (Soft Metal Gasket Shim)

(5) Two-holes : 0.20 mm (0.0079 in.) (6) One-hole : 0.25 mm (0.0098 in.) (7) Without hole : 0.30 mm (0.0118 in.)

W1017170

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KiSC issued 06, 2011 A

DIESEL ENGINE

Fuel Tightness of Pump Element

1. Remove the engine stop solenoid.

2. Remove the injection pipes and glow plugs.

3. Install the injection pump pressure tester to the injection pump.

4. Install the injection nozzle (2) jetted with the proper injection pressure to the injection pump pressure tester (1). (Refer to the photo.)

5. Set the speed control lever to the maximum speed position.

6. Run the starter to increase the pressure.

7. If the pressure can not reach the allowable limit, replace the pump with new one or repair with a Kubota-authorized pump service shop.

Fuel tightness of pump element

Allowable limit

13.73 MPa 140 kgf/cm 1991 psi

• Never try to disassemble the injection pump assembly. For repairs, you are strongly requested to contact a Kubotaauthorized pump service shop.

(1) Injection Pump Pressure Tester (2) Injection Nozzle

(3) Protection Cover for Jetted Fuel

W1017430

Fuel Tightness of Delivery Valve

1. Remove the engine stop solenoid.

2. Remove the injection pipes and glow plugs.

3. Set a pressure tester to the fuel injection pump.

4. Install the injection nozzle (2) jetted with the proper injection pressure to the injection pump pressure tester (1).

5. Run the starter to increase the pressure.

6. Stop the starter when the fuel jets from the injection nozzle. After that, turn the flywheel by the hand and raise the pressure to

approx. 13.73 MPa (140 kgf/cm

, 1991 psi).

7. Now turn the flywheel back about half a turn (to keep the plunger free). Maintain the flywheel at this position and clock the time taken for the pressure to drop from 13.73 to 12.75 MPa (from 140

to 130 kgf/cm

, from 1991 to 1849 psi).

8. Measure the time needed to decrease the pressure from 13.73 to

12.75 MPa (140 to 130 kgf/cm

, 1991 to 1849 psi).

9. If the measurement is less than allowable limit, replace the pump with new one or repair with a Kubota-authorized pump service shop.

10 seconds

Factory spec.

Fuel tightness of delivery valve

Allowable limit

13.73 → 12.75 MPa 140 → 130 kgf/cm 1991 → 1849 psi

5 seconds

13.73 → 12.75 MPa 140 → 130 kgf/cm 1991 → 1849 psi

• Never try to disassemble the injection pump assembly. For repairs, you are strongly requested to contact a Kubotaauthorized pump service shop.

(1) Injection Pump Pressure Tester (2) Injection Nozzle

(3) Protection Cover for Jetted Fuel

W1017786

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CAUTION

KiSC issued 06, 2011 A

DIESEL ENGINE

• Check the nozzle injection pressure and condition after confirming that there is nobody standing in the direction the fume goes. If the fume from the nozzle directly contacts the human body, cells may be destroyed and blood poisoning may be caused.

Nozzle Spraying Condition

1. Set the injection nozzle to a nozzle tester, and check the nozzle spraying condition.

2. If the spraying condition is defective, replace the nozzle piece.

(a) Good (b) Bad

W10181310

Fuel Injection Pressure

1. Set the injection nozzle to a nozzle tester.

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

3. If the measurement is not within the factory specifications, replace the adjusting washer (1) in the nozzle holder to adjust it.

(Reference)

• Pressure variation with 0.01 mm (0.0004 in.) difference of adjusting washer thickness.

Approx. 235 kPa (2.4 kgf/cm

Fuel injection pressure Factory spec.

, 34 psi)

13.73 to 14.71 MPa 140 to 150 kgf/cm 1991 to 2134 psi

(1) Adjusting Washer

W10182100

Valve Seat Tightness

1. Set the injection nozzle to a nozzle tester.

2. Raise the fuel pressure, and keep at 12.75 MPa (130 kgf/cm 1849 psi) for 10 seconds.

3. If any fuel leak is found, replace the nozzle piece.

No fuel leak at

Valve seat tightness Factory spec.

12.75 MPa 130 kgf/cm 1849 psi

W10183690

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CAUTION

IMPORTANTQ

KiSC issued 06, 2011 A

DIESEL ENGINE

Nozzle Holder

1. Secure the nozzle retaining nut (7) with a vise.

2. Remove the nozzle holder (1), and take out parts inside.

(When reassembling)

• Assemble the nozzle in clean fuel oil.

• Install the push rod (4), noting its direction.

• After assembling the nozzle, be sure to adjust the fuel injection pressure.

34.3 to 39.2 N·m

Tightening torque

Nozzle holder

Overflow pipe retaining nut

Nozzle holder assembly

3.5 to 4.0 kgf·m

25.3 to 28.9 ft-lbs

19.6 to 24.5 N·m

2.0 to 2.5 kgf·m

14.5 to 18.1 ft-lbs

49.0 to 68.6 N·m

5.0 to 7.0 kgf·m

36.2 to 50.6 ft-lbs

(1) Nozzle Holder (2) Adjusting Washer (3) Nozzle Spring (4) Push Rod

(5) Distance Piece (6) Nozzle Piece (7) Nozzle Retaining Nut

W1018491

(5) Electrical System

• To avoid accidental short circuit, be sure to attach the positive cable to the positive terminal before the negative cable is attached to the negative terminal.

• Never remove the battery cap while the engine is running.

• Keep electrolyte away from eyes, hands and clothes. If you are spattered with it, wash it away completely with water immediately.

• Keep open sparks and flames away from the battery at all times. Hydrogen gas mixed with oxygen becomes very explosive.

• If the machine is to be operated for a short time without battery (using a slave battery for starting), use additional current (lights) while engine is running and insulate terminal of battery. If this advice is disregarded, damage to alternator and regulator may result.

Battery Voltage

1. Stop the engine.

2. Measure the voltage with a circuit tester between the battery terminals.

3. If the battery voltage is less than the factory specification, check the battery specific gravity and recharge the battery.

Battery voltage Factory spec. More than 12 V

(1) Positive Terminal (2) Negative Terminal

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NOTEQ

KiSC issued 06, 2011 A

DIESEL ENGINE

Battery Specific Gravity

1. Check the specific gravity of the electrolyte in each cell with a hydrometer.

2. When the electrolyte temperature differs from that at which the hydrometer was calibrated, correct the specific gravity reading following the formula mentioned in (Reference).

3. If the specific gravity is less than 1.215 (after it is corrected for temperature), charge or replace the battery.

4. If the specific gravity differs between any two cells by more than

0.05, replace the battery.

• Hold the hydrometer tube vertical without removing it from the electrolyte.

• Do not suck too much electrolyte into the tube.

• Allow the float to move freely and hold the hydrometer at eye level.

• The hydrometer reading must be taken at the highest electrolyte level.

(Reference)

- Specific gravity at 20 °C = Measured value + 0.0007 ×

(electrolyte temperature : 20 °C)

- Specific gravity at 68 °F = Measured value + 0.0004 ×

(electrolyte temperature : 68 °F)

Specific Gravity State of Charge

1.260 Sp. Gr. 100 % Charged

1.230 Sp. Gr. 75 % Charged

1.200 Sp. Gr. 50 % Charged

1.170 Sp. Gr. 25 % Charged

1.140 Sp. Gr. Very Little Useful Capacity

1.110 Sp. Gr. Discharged

At an electrolyte temperature of 20 °C (68 °F)

(a) Good (b) Bad

W1019017

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CAUTION

NOTEQ

KiSC issued 06, 2011 A

DIESEL ENGINE

Motor Test

• Secure the starter to prevent it from jumping up and down while testing the motor.

1. Disconnect the battery negative cable from the battery.

2. Disconnect the battery positive cable from the battery.

3. Disconnect the leads from the starter B terminal.

4. Remove the starter from the engine.

5. Connect a jumper lead from the starter C terminal (1) to the

battery positive terminal (2).

6. Connect a jumper lead momentarily between the starter’s body and the battery negative terminal (3).

7. If the motor does not run, starter is failure. Repair or replace the starter.

• B terminal : It is the terminal which connects the cable from the battery to the starter.

• C terminal : It is the terminal which connects the cable from the motor to the magnet switch.

(1) C Terminal (2) Positive Terminal (3) Negative Terminal

[A] Electromagnetic Drive Type [B] Planetary Gear Reduction Type

W1019297

Magnetic Switch Test

1. Disconnect the battery negative cable from the battery.

2. Disconnect the battery positive cable from the battery.

3. Disconnect the leads from the starter B terminal.

4. Remove the starter from the engine.

5. Connect a jumper lead from the starter S terminal (1) to the

battery positive terminal (2).

6. Connect a jumper lead momentarily between the starter’s body and the battery negative terminal (3).

7. If the pinion gear does not pop out, the magnetic switch is failure. Repair or replace the starter.

• B terminal : It is the terminal which connects the cable from the battery to the starter.

• S terminal : It is the terminal which connects the cable from the starter switch to the magnet switch.

(1) S Te r m i n a l (2) Positive Terminal (3) Negative Terminal

[A] Electromagnetic Drive Type [B] Planetary Gear Reduction Type

0000010743E

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NOTEQ

KiSC issued 06, 2011 A

DIESEL ENGINE

Magnet Switch Continuity Test

1. Check the continuity across the C terminal (1) and the B terminal

(2) with a circuit tester, pushing in the plunger.

2. If not continuous or if a certain value is indicated, replace the magnet switch.

(1) C Ter m i n a l (2) B Ter m i n a l

[A] Electromagnetic Drive Type [B] Planetary Gear Reduction Type

0000010771E

Alternator on Unit Test (Before testing)

• Before alternator on unit test, check the battery terminal connections, circuit connection, fan belt tension, charging indicator lamp, fuses on the circuit, and abnormal noise from the alternator.

• Prepare full charged battery for the test.

• Be careful not to touch the rotating engine parts while engine is running. Keep safety distance from the engine rotating parts.

1. Start the engine.

2. When the engine is operating measure the voltage between two battery terminals. If the voltage is between 13.8 V and 14.8 V, the alternator is operating normally.

3. If the results of alternator on unit test are not within the specifications, disassemble the alternator and check the each component part for finding out the failure. See the “DISASSEMBLING AND ASSEMBLING” and “SERVICING” for alternator.

Regulating voltage at no load

Factory spec.

13.8 to 14.8 V at 25 °C (77 °F)

0000010745E

Glow Plug Lead Terminal Voltage

1. Turn the key switch to the “GLOW (or PREHEAT)” position, and measure the voltage with a circuit tester between the lead terminal and the engine body.

2. If the voltage differs from the battery voltage, the wiring harness or main switch is faulty.

Main switch key at

Voltage

GLOW (or PREHEAT)

Approx. battery voltage

0000010725E

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IMPORTANTQ

KiSC issued 06, 2011 A

DIESEL ENGINE

Glow Plug Continuity

1. Remove the glow plug.

2. Measure the resistance with a circuit tester between the glow plug terminal and the glow plug housing.

3. If the factory specification is not indicated, glow plug is faulty.

Resistance Factory spec. Approx. 0.9 Ω

0000010726E

Engine Stop Solenoid

1. Remove the engine stop solenoid from the engine.

2. Connect the jumper leads from the pulling coil P terminal to the switch (3), and from switch (3) to the battery positive terminal.

3. Connect the jumper leads from the holding coil H terminal to the switch (4), and from switch (4) to the battery positive terminal.

4. Connect the jumper leads from the engine stop solenoid body to the battery negative terminal.

5. When switch (4) is turn on, the plunger pull into the solenoid body and then turn off the switch (4), the plunger comes out.

6. Turn on the switch (3) then turn on the switch (4), the plunger pull into the solenoid body and it keep in holding position after turn off the switch (4).

7. If the plunger is not attracted, the engine stop solenoid is faulty.

(6) Turbocharger

• Never apply the current for pulling coil more than two seconds when inspecting.

(1) Connector (2) Battery (3) Switch for Holding Coil (4) Switch for Pulling Coil

P : Terminal for Pulling Coil H : Terminal for Holding Coil

W1020600

Turbine Side

1. Check the exhaust port (3) and inlet port (5) side of turbine housing (1) to see if there is no exhaust gas leak.

2. If any gas leak is found, retighten the bolts and nuts or replace the gasket (2) / (4) / (6) with new one.

(1) Turbine Housing (2) Gasket (3) Exhaust Port

(4) Gasket (5) Inlet Port (6) Gasket

W1076917

Compressor Side

1. Check the inlet hose (3) of the compressor cover (4) to see if there is no air leak.

2. If any air leak is found, change the clamp (2) and / or inlet hoses.

3. Check the intake hose (1) and the clamp to see if there is no loose or crack.

4. If any loose or crack is found, tighten the clamp or change the hose to prevent dust from entry.

(1) Intake Hose (2) Clamp

(3) Inlet Hose (4) Compressor Cover

W1077032

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CAUTION

IMPORTANTQ

KiSC issued 06, 2011 A

Radial Clearance

1. If the wheel contact to the housing, replace the turbocharger assembly with new one.

[2] DISASSEMBLING AND ASSEMBLING

(1) Draining Oil and Coolant

Draining Oil and Coolant

• Never remove radiator cap until coolant temperature is below its boiling point. Then loosen cap slightly to the stop to relieve any excess pressure before removing cap completely.

1. Prepare a bucket. Open the drain cock to drain coolant.

2. Prepare an oil pan. Remove the drain plug to drain engine oil in the pan.

DIESEL ENGINE

W1077353

W1021151

(2) External Components

Air Cleaner and Muffler

1. Remove the air cleaner.

2. Remove muffler retaining nuts to remove the muffler.

(When reassembling)

• Install the muffler gasket so that its steel side face the muffler.

W1021239

Alternator and Fan Belt

1. Remove the alternator (1).

2. Remove the fan belt (2).

3. Remove the starter (3).

(When reassembling)

• Check to see that there are no cracks on the belt surface.

• After reassembling the fan belt, be sure to adjust the fan belt tension.

(1) Alternator (2) Fan Belt

(3) Starter

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CAUTION

NOTEQ

KiSC issued 06, 2011 A

DIESEL ENGINE

Turbocharger (equipped with Turbocharger Model)

• While the engine is running and or just after it stops, the turbocharger is hot, be careful not to touch the turbocharger.

• When detaching and attaching the turbocharger assembly, be very careful not to allow dust, dirt and other foreign matters in the oil pipes.

• When the turbocharger assembly has been replaced, pour fresh engine oil through the oil filter port of the turbocharger.

• Before starting the engine, make sure that the air cleaner position.

1. Disconnect the intake hose (3).

2. Remove the oil switch (1).

3. Disconnect the pipe band (2).

4. Remove the exhaust manifold with turbocharger.

(1) Oil Switch (2) Pipe Band

(3) Intake Hose

W1021474

(3) Cylinder Head and Valve

Cylinder Head Cover

1. Disconnect the breather hose (1).

2. Remove the cylinder head cover screw (2).

3. Remove the cylinder head cover (3).

(When reassembling)

• Check to see if the cylinder head cover gasket is not defective.

6.9 to 8.8 N·m

Tightening torque Cylinder head cover screw

(1) Breather Hose (2) Cylinder Head Cover Screw

(3) Cylinder Head Cover

0.7 to 0.9 kgf·m

5.1 to 6.5 ft-lbs

W1028468

Injection Pipes

1. Loosen the screws to the pipe clamp (1).

2. Detach the injection pipes (2).

(When reassembling)

• Sent compressed air into the pipes to blow out dust. Then, reassemble the pipes in the reverse order.

24.5 to 34.3 N·m

Tightening torque Injection pipe retaining nut

(1) Pipe Clamp (2) Injection Pipe

2.5 to 3.5 kgf·m

18.1 to 25.3 ft-lbs

W1028640

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IMPORTANTQ

KiSC issued 06, 2011 A

DIESEL ENGINE

Nozzle Heat Seal Service Removal Procedure

• Use a plus (phillips head) screw driver (1) that has a diameter which is bigger than the heat seal hole (Approx. 6 mm (1/4 in.)).

1. Drive screw driver (1) lightly into the heat seal hole.

2. Turn screw driver three or four times each way.

3. While turning the screw driver, slowly pull the heat seal (4) out together with the injection nozzle gasket (3).

4. If the heat seal drops, repeat the above procedure.

(When reassembling)

• Heat seal and injection nozzle gasket must be changed when the injection nozzle is removed for cleaning or for service.

(1) Plus Screw Driver (2) Nozzle Holder

(3) Injection Nozzle Gasket (4) Heat Seal

W1021255

Rocker Arm and Push Rod

1. Remove the rocker arm bracket screws.

2. Detach the rocker arm assembly (1).

3. Remove the push rods (2).

(When reassembling)

• When putting the push rods (2) onto the tappets (3), check to see if their ends are properly engaged with the dimples.

• After installing the rocker arm, be sure to adjust the valve clearance.

21.6 to 26.5 N·m

Tightening torque Rocker arm bracket screw

(1) Rocker Arm Assembly (2) Push Rod

(3) Tappet

2.2 to 2.7 kgf·m

15.9 to 19.5 ft-lbs

W1021437

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DIESEL ENGINE

Cylinder Head and Cylinder Head Gasket (To be continued)

1. Loosen the pipe clamps (1), and remove the water return pipe (2).

2. Remove the cylinder head screw in the order of (n or r) to (a) and remove the cylinder head.

3. Remove the cylinder head gasket.

4. Remove the O-ring. (Carbon gasket type only.)

• Material of cylinder head gasket has been changed from carbon to metal. When replacing a cylinder head gasket, be sure to check with the following table and notes to chose a correct part.

• The carbon gasket can be used for the engine with the metal gasket specified using the O-ring (15221-33700).

• The metal gasket cannot be used for the carbon type specification engine.

• Engine serial number and cylinder head gasket.

Model Type of Gasket Parts Number Serial Number

D905-E2B / E2BG

D1005-E2B / E2BG

D1105-E2B / E2BG D1105-T-E2B

V1305-E2B / E2BG

V1505-E2B / E2BG V1505-T-E2B

Carbon gasket 16221-03310 4R0300 and below

Metal gasket 1G032-03310 4R0301 and above

Carbon gasket 16231-03310 4Z0452 and below

Metal gasket 1G040-03310 4Z0453 and above

Carbon gasket 1E010-03310 4J0010 and below

Metal gasket 1G063-03310 4J0011 and above

Carbon gasket 16271-03310 5E0009 and below

Metal gasket 1G078-03310 5E0010 and above

Carbon gasket 16292-03310 4E9455 and below

Metal gasket 16394-03310 4E9456 and above

Tightening torque Cylinder head screw

(1) Clamp (2) Return Pipe

63.7 to 68.6 N·m

6.5 to 7.0 kgf·m

47.0 to 50.6 ft-lbs

(A) 3 Cylinder (B) 4 Cylinder n or r to a : To Loosen a to n or r : To Tighten

W10205250

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IMPORTANTQ

KiSC issued 06, 2011 A

DIESEL ENGINE

Cylinder Head and Cylinder Head Gasket (Continued) (When reassembling the carbon gasket type)

• Replace the cylinder head gasket with new one.

• Securely fit the O-ring (1) to the pin pipe (2).

• When mounting the gasket, set it to the pin pipe holes. Take care not to mount it reversely.

• The cylinder head should be free of scratches and dust.

• Install the cylinder head, using care not to damage the gasket.

• After applying engine oil to the thread of screws, tighten them in several steps and specified sequence (a) to (n or r).

• Retighten the cylinder head screws after running the engine for 30 minutes and after cooling, adjust valve clearance.

(When reassembling the metal gasket type)

• Replace the cylinder head gasket with new one.

• When mounting the gasket, set it to the pin pipe holes. Take care not to mount it reversely.

• The cylinder head should be free of scratches and dust.

• Install the cylinder head, using care not to damage the gasket.

• After applying engine oil to the thread of screws, tighten them in several steps and specified sequence (a) to (n or r).

• Do not use O-ring on the pin pipe.

• It is not necessary to retighten the cylinder head screw and to readjust valve clearance after engine warmed up.

(1) O-ring (2) Pin Pipe

[A] Carbon Gasket Type [B] Metal Gasket Type

W1030042

Tappets

1. Remove the tappets (1) from the crankcase.

(When reassembling)

• Visually check the contact between tappets and cams for proper rotation. If defect is found, replace tappets.

• Before installing the tappets, apply engine oil thinly around them.

• Do not change the combination of tappet and tappet guide.

(1) Tappet

W10209700

Valves

1. Remove the valve caps (2).

2. Remove the valve spring collet (3), pushing the valve spring retainer (4) by valve spring replacer (1).

3. Remove the valve spring retainer (4), valve spring (5) and valve stem seal (6).

4. Remove the valve (7).

(When reassembling)

• Wash the valve stem and valve guide hole, and apply engine oil sufficiently.

• After installing the valve spring collets, lightly tap the stem to assure proper fit with a plastic hammer.

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

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

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

W10211070

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(4) Gear Case and Timing Gears

DIESEL ENGINE

Thermostat Assembly

1. Remove the thermostat cover mounting screws (1), and remove the thermostat cover (2).

2. Remove the thermostat assembly (4).

(When reassembling)

• Apply a liquid gasket (Three Bond 1215 or equivalent) only at the thermostat cover side of the gasket (3).

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

(3) Thermostat Cover Gasket (4) Thermostat Assembly

W10363950

Fan Drive Pulley

1. Secure the flywheel to keep it from turning.

2. Remove the fan drive pulley screw.

3. Draw out the fan drive pulley with a puller.

(When reassembling)

• Install the pulley to crankshaft, aligning the mark (1) on them (3cylinder engine).

• Apply engine oil to the fan drive pulley retaining screw. And tighten it.

235.4 to 245.2 N·m

Tightening torque Fan drive pulley screw

24.0 to 25.0 kgf·m

173.6 to 180.8 ft-lbs

(1) Aligning Mark

W10181950

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DIESEL ENGINE

Gear Case

1. Remove the gear case.

(When reassembling)

• Grease thinly to the oil seal, and install it, ensuring the lip does not come off.

• Measure (L) when the gear case mounting bolt is inserted in the gear case bolt hole and judge the installation position of the mounting bolt when you do not understand the installation position of the mounting bolt.

A : L = 18 mm (0.71 in.) (Pipe Pin Position) B : L = 13 mm (0.51 in.) (Water Pipe Mounting) C : L = 10 mm (0.39 in.) D : Nut

(1) Gear Case

W1030917

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IMPORTANTQ

NOTEQ

KiSC issued 06, 2011 A

DIESEL ENGINE

Boost Compensator (equipped with Turbocharger Model)

• Use the stop solenoid mounting bolt (3) for the dropout prevention of boost compensator (2) and the damage prevention of the guide (6) when detach the boost compensator.

• The guide (6) of boost compensator and the control rack (7) should be made the level when you install boost compensator assembly.

1. Disconnect the hose (4).

2. Remove the stop solenoid mounting bolt (M6 × 87 mm) (3).

3. Remove the stop solenoid (1).

4. Install the stop solenoid mounting bolt (3) in an original position again.

5. Remove the boost compensator mounting bolt (5).

6. Detach the boost compensator assembly (2).

7. Remove the stop solenoid mounting bolt (3) with boost compensator assembly (2).

(When reassembling)

1. Install the stop solenoid mounting bolt (3) in boost compensator assembly (2) and assemble it to the boost compensator installation position at the same time.

2. Tighten the boost compensator mounting bolt (5).

3. Remove the stop solenoid mounting bolt (3).

4. Install the stop solenoid (1) and tighten the mounting bolt (3).

• Apply a liquid gasket (Three Bond 1217D or equivalent) to the boost compensator body.

(1) Stop Solenoid (2) Boost Compensator Assembly (3) Stop Solenoid Mounting Bolt (4) Hose

(5) Boost Compensator Mounting Bolt (6) Guide (7) Control Rack

W1031295

Speed Control Plate

1. Remove the engine stop solenoid (without turbocharger model).

2. Remove the speed control plate (1).

(When reassembling)

• Apply a liquid gasket (Three Bond 1215 or equivalent) to both sides of the solenoid cover gasket and control plate gasket.

• Be careful not to drop the governor spring (2) into the crankcase.

(1) Speed Control Plate (2) Governor Spring

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DIESEL ENGINE

Injection Pump

1. Disconnect the start spring (4) on the thrust lever side (5).

2. Align the control rack pin (2) with the notch (1) on the crankcase, and remove the injection pump (3).

3. Remove the injection pump shims.

4. In principle, the injection pump should not be disassembled.

(When reassembling)

• When installing the injection pump, insert the control rack pin (2) firmly into the groove (7) of the thrust lever of fork lever.

• Addition or reduction of shim (0.05 mm, 0.0020 in.) delays or advances the injection timing by approx. 0.0087 rad (0.5 °).

• In disassembling and replacing, be sure to use the same number or new gasket shims with the same thickness.

(1) Notch (2) Control Rack Pin (3) Injection Pump (4) Start Spring (5) Thrust Lever (6) Governor Spring (7) Groove

[A] Basic Model [B] BG Model

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IMPORTANTQ

KiSC issued 06, 2011 A

DIESEL ENGINE

Cam Gear, Idle Gear 1, 2 and Governor Gear

1. Remove the idle gear 2 (7) / idle gear 1 (4).

2. Remove the fuel camshaft stopper (8).

3. Draw out the fuel cam gear (1) with fuel camshaft (9).

4. Remove the camshaft stopper bolt.

5. Remove the cam gear (3) with camshaft.

6. Remove the external snap ring (11) from the governor shaft (12).

7. Remove the governor gear (6) with governor shaft (12).

• Three-lever type fork lever To remove the governor shaft, follow the procedures in 5, 6 above and never remove fork lever and the max torque limiter.

(When reassembling)

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

• Make sure to assemble the external snap ring of the governor shaft.

• Check the governor shaft for smooth rotation.

• There is a model of idle gear 1 (4) and idle gear 2 (7) by the difference of the method of transmission the power to the governor gear (6).

• When replacing the ball bearing of governor shaft, securely fit the ball bearing (10) to the crankcase, apply an adhesive (Three Bond 1324B or equivalent) to the set screw (13), and fasten the screw until its tapered part contacts the circumferential end of the ball bearing.

• When installing the idle gear, be sure to align the alignment marks on each gears.

(1) Fuel Cam Gear (2) Alignment Mark (3) Cam Gear (4) Idle Gear 1 (5) Crank Gear (6) Governor Gear (7) Idle Gear 2 (8) Fuel Camshaft Stopper

(9) Fuel Camshaft (10) Ball Bearing (11) External Snap Ring (12) Governor Shaft (13) Set Screw

[A] One Idle Gear Type [B] Two Idle Gear Type

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(5) Piston and Connecting Rod

DIESEL ENGINE

Oil Pan and Oil Strainer

1. Remove the oil pan mounting screws (5).

2. Remove the oil pan (4).

3. Remove the oil strainer (3).

(When reassembling)

• After cleaning the oil strainer, check to see that the filter mesh in clean, and install it.

• Visually check the O-ring (1), apply engine oil, and install it.

• Securely fit the O-ring to the oil strainer.

• To avoid uneven tightening, tighten oil pan mounting screws in diagonal order form the center.

• Scrape off the old adhesive completely. Wipe the sealing surface clean using waste cloth soaked with gasoline. Now apply new adhesive 3 to 5 mm (0.12 to 0.20 in.) thick all over the contact surface. Apply the adhesive also on the center of the flange as well as on the inner wall of each screw hole.

• Cut the nozzle of the “liquid gasket” container at its second notch. Apply “liquid gasket” about 5 mm (0.20 in.) thick. Within 20 minutes after the application of fluid sealant, reassemble the components. Wait then for about 30 minutes, and pour oil in the crankcase.

(1) O-ring (2) Screw (3) Oil Strainer

(4) Oil Pan (5) Oil Pan Mounting Screw

W10236610

Connecting Rod

1. Remove the connecting rod cap.

(When reassembling)

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

• Apply engine oil to the connecting rod screws and lightly screw it in by hand, then tighten it to the specified torque. If the connecting rod screw won’t be screwed in smoothly, clean the threads. If the connecting rod screw is still hard to screw in, replace it.

41.2 to 46.1 N·m

Tightening torque Connecting rod screw

4.2 to 4.7 kgf·m

30.4 to 34.0 ft-lbs

(a) Mark

W10242740

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KiSC issued 06, 2011 A

DIESEL ENGINE

Pistons

1. Turn the flywheel and bring the piston to top dead center.

2. Draw out the piston upward by lightly tapping it from the bottom of the crankcase with the grip of a hammer.

3. Draw out the other piston in the same method as above.

(When reassembling)

• Before inserting the piston into the cylinder, apply enough engine oil to the piston.

• When inserting the piston into the cylinder, face the mark on the connecting rod to the injection pump.

• Do not change the combination of cylinder and piston. Make sure of the position of each piston by marking. For example, mark “1” on the No.1 piston.

• When installing the piston into the cylinder, place the gaps of all the piston rings as shown in the figure.

• Carefully insert the pistons using a piston ring compressor (1). Otherwise, their chrome-plated section may be scratched, causing trouble inside the cylinder.

(1) Piston Ring Compressor

(A) Top Ring Gap (B) Second Ring Gap (C) Oil Ring Gap (D) Piston Pin Hole

(a) 0.785 rad (45 °) (b) 0.785 rad (45 °) (c) 1.57 rad (90 °)

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DIESEL ENGINE

Piston Ring and Connecting Rod

1. Remove the piston rings using a piston ring tool.

2. Remove the piston pin (7), and separate the connecting rod (6) from the piston (5).

(When reassembling)

• When installing the ring, assemble the rings so that the manufacturer’s mark (12) near the gap faces the top of the piston.

• When installing the oil ring onto the piston, place the expander joint (10) on the opposite side of the oil ring gap (11).

• Apply engine oil to the piston pin.

• When installing the connecting rod to the piston, immerse the piston in 80 °C (176 °F) oil for 10 to 15 minutes and insert the piston pin to the piston.

• When installing the connecting rod to the piston, align the mark (8) on the connecting rod to the fan-shaped concave (9).

• Mark the same number on the connecting rod and the piston so as not to change the combination.

(1) Top Ring (2) Second Ring (3) Oil Ring (4) Piston Pin Snap Ring (5) Piston (6) Connecting Rod

(7) Piston Pin (8) Mark

(9) Fan-shaped Concave (10) Expander Joint (11) Oil Ring Gap (12) Manufacturer’s Mark

W10281670

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(6) Flywheel and Crankshaft

DIESEL ENGINE

Flywheel

1. Secure the flywheel to keep it from turning, using a flywheel stopper.

2. Remove all flywheel screws (1) and then remove the flywheel (2).

(When reassembling)

• Align the “1TC” mark (a) on the outer surface of the flywheel horizontally with the alignment mark (b) on the rear end plate. Now fit the flywheel in position.

• Apply engine oil to the threads and the undercut surface of the flywheel screw and fit the screw.

53.9 to 58.8 N·m

Tightening torque Flywheel screw

5.5 to 6.0 kgf·m

39.8 to 43.4 ft-lbs

(1) Flywheel Screw (2) Flywheel

(a) 1TC Mark (b) Alignment Mark

W10290240

Bearing Case Cover

1. Remove the bearing case cover mounting screws.

2. Remove the bearing case cover (6).

(When reassembling)

• Fit the bearing case gasket (3) and the bearing case cover gasket (4) with correct directions.

• Install the bearing case cover (6) to position the casting mark “UP” on it upward.

• Apply engine oil to the oil seal (5) lip and take care that it is not rolled when installing.

• Tighten the bearing case cover mounting screws with even force on the diagonal line.

Tightening torque

(1) Bearing Case Cover Mounting Screw

(Inside)

(2) Bearing Case Cover Mounting Screw

(Outside) (3) Bearing Case Gasket (4) Bearing Case Cover Gasket

Bearing case cover mounting screw

(5) Oil Seal (6) Bearing Case Cover

(a) Top Mark “UP” (b) Upside

9.8 to 11.3 N·m

1.00 to 1.15 kgf·m

7.2 to 8.3 ft-lbs

W10292140

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KiSC issued 06, 2011 A

DIESEL ENGINE

Crankshaft Assembly

1. Remove the main bearing case screw 2 (1).

2. Pull out the crankshaft assembly.

• Take care to protect crankshaft bearing 1 from scratches, caused by the crank gear, etc.. (Wrap the gear in vinyl tape, etc.)

(When reassembling)

• Clean the oil passage of the crankshaft with compressed air.

• Apply oil to the main bearing case screw 2 (1).

• Install the crankshaft assembly, aligning the screw hole of main bearing case with the screw hole of crankcase.

• Clean the oil passage of the crankshaft with compressed air.

Tightening torque Main bearing case screw 2

(1) Main Bearing Case Screw 2

49.0 to 53.9 N·m

5.0 to 5.5 kgf·m

36.2 to 39.8 ft-lbs

W10295750

Main Bearing Case Assembly

1. Remove the two main bearing case screws 1 (2) of each main bearing cases.

2. Remove the main bearing case from crankshaft.

(When reassembling)

• Clean the oil passage in the main bearing cases.

• Apply clean engine oil on the bearings.

• Install the main bearing case assemblies in the original positions. Since diameters of main bearing cases vary, install them in order of makings (b) (A, B, C) from the gear case side.

• Match the alignment numbers (a) on the main bearing case assembly 1.

• When installing the main bearing case 1 and 2, face the mark “FLYWHEEL” to the flywheel.

• Install the thrust bearing (3) with its oil groove facing outward.

• Confirm that the main bearing case moves smoothly after tightening the main bearing case screw 1 to the specified torque.

Tightening torque Main bearing case screw 1

29.4 to 34.3 N·m

3.0 to 3.5 kgf·m

21.7 to 25.3 ft-lbs

(1) Main Bearing Case Assembly 1 (2) Main Bearing Case Screw 1 (3) Thrust Bearing

S-41

(a) Alignment Number (b) Marking (A, B, C)

W1037295

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(7) Starter

Q Electromagnetic Drive Type

DIESEL ENGINE

(1) Solenoid Switch Mounting Nut (2) Starter Drive Housing (3) Drive Lever (4) Gasket (5) Solenoid Switch (6) B Terminal Nut

(7) C Terminal Nut

(8) Snap RIng (9) Overrunning Clutch

(10) Armature

(11) Brush Spring (12) Connecting Lead (13) Rear End Frame (14) Gasket (15) Brake Spring (16) Brake Shoe (17) End Frame Cap (18) Screw (19) Yoke (20) Brush (21) Brush Holder (22) Through Bolt

W1037593

1. Unscrew the C terminal nut (7), and disconnect the connecting lead (12).

2. Unscrew the solenoid switch mounting nuts (1), and remove the solenoid switch (5).

3. Remove the end frame cap (17).

4. Remove the brake shoe (16), brake spring (15) and gasket (14).

5. Unscrew the through bolts (22), and remove the rear end frame (13).

6. Remove the brush from the brush holder while holding the spring up.

7. Remove the brush holder (21).

8. Draw out the yoke (19) from the starter drive housing (2).

9. Draw out the armature (10) with the drive lever (3).

• Do not damage to the brush and commutator.

(When reassembling)

• Apply grease (DENSO.CO.LTD. No. 50 or equivalent) to the parts indicated in the figure.

- Joint of solenoid switch (a)

- Bushing (b)

- Drive lever (c)

- Collar (d)

- Teeth of pinion gear (e)

- Armature shaft (f)

7.8 to 9.8 N·m

Tightening torque B terminal nut

0.8 to 1.0 kgf·m

5.8 to 7.2 ft-lbs

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Q Planetary Gear Reduction Type

DIESEL ENGINE

(1) Through Bolt (2) Brush (3) Yoke (4) Armature (5) Overrunning Clutch (6) Idle Gear (7) End Frame (8) Brush Holder (9) Magnet Switch Cover

(10) Plunger

(11) Housing

(12) C Ter m i n a l N u t (13) B Ter m i n a l N u t

W1222714

1. Unscrew the C terminal nut (12), and disconnect the connecting lead.

2. Remove the two through bolts (1).

3. Detach the motor.

4. Remove the end frame (7).

5. Remove the brush from the brush holder while holding the spring up.

6. Remove the brush holder (8).

7. Draw out the armature (4) from the yoke (3).

8. Remove the housing (11).

9. Remove the idle gear (6) and the overrunning clutch (5).

10.Remove the magnet switch cover (9).

11.Remove the plunger (10).

• Do not damage to the brush and commutator.

(When reassembling)

• Apply grease (DENSO No. 50 or equivalent) to the idle gear and overrunning clutch portions.

5.9 to 11.8 N·m

Tightening torque B terminal nut

0.6 to 1.2 kgf·m

4.3 to 8.7 ft-lbs

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(8) Alternator

DIESEL ENGINE

(1) Pulley (2) Drive End Frame (3) Stator (4) Bearing (5) Retainer Plate (6) Rotor (7) Bearing (8) Rear End Frame (9) Rectifier

(10) IC Regulator

(11) Brush Holder (12) Rear End Cover

W1224079

1. Remove the pulley (1).

2. Remove the rear end cover (12).

3. Remove the brush holder (11).

4. Remove the IC regulator (10).

5. Remove the four screws holding the stator lead wires.

6. Remove the rectifier (9).

7. Remove the rear end frame (8).

8. Press out the rotor (6) from drive end frame (2).

9. Remove the retainer plate (5).

10.Press out the bearing (4) from drive end frame (2) with a press and jig.

11.Lightly secure the rotor with a vise to prevent damage, and remove the bearing (7) with a puller.

(When reassembling)

58.3 to 78.9 N·m

Tightening torque Pulley nut

5.95 to 8.05 kgf·m

43.0 to 58.2 ft-lbs

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IMPORTANTQ

KiSC issued 06, 2011 A

[3] SERVICING

(1) Cylinder Head and Valves

DIESEL ENGINE

Top Clearance

1. Remove the cylinder head.

2. With the piston at TDC, use grease to affix three or four plastigauges of a diameter 1.5 mm (0.059 in.) x 5.0 to 7.0 mm (0.20 to 0.27 in.) long to the crown of the piston; keep the gauges away from the intake valve and combustion chamber fittings.

3. Take the piston to an intermediate position, install the cylinder head and tighten the head bolts to the specified torque.

4. Turn the crankshaft so the piston goes through TDC.

5. Remove the cylinder head and compare the width of the crushed plastigages with the scale.

6. If they are out of spec, check the oil clearance of the crank pin, journals and piston pin.

• Top clearance = Width of the crushed plastigauge.

Top clearance Factory spec.

Tightening torque Cylinder head screws

0.55 to 0.70 mm

0.0217 to 0.0276 in.

63.7 to 68.6 N·m

6.5 to 7.0 kgf·m

47.0 to 50.6 ft-lbs

(1) Plastigauge (2) Scale

W1020190

Cylinder Head Surface Flatness

1. Clean the cylinder head surface.

2. Place a straightedge on the cylinder head’s four sides and two diagonal as shown in the figure.

3. Measure the clearance with a thickness gauge.

4. If the measurement exceeds the allowable limit, correct it with a surface grinder.

• Do not place the straightedge on the combustion chamber.

• Be sure to check the valve recessing after correcting.

Cylinder head surface flatness

Allowable limit

0.05 mm

0.0020 in.

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DIESEL ENGINE

Cylinder Head Flaw

1. Prepare an air spray red check.

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

3. Spray the cylinder head surface with the red permeative liquid (1). Leave it five to ten minutes after spraying.

4. Wash away the read permeative liquid on the cylinder head surface with the detergent (2).

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

6. If flawed, it can be identified as red marks.

(1) Red Permeative Liquid (2) Detergent

(3) White Developer

W1076542

Valve Recessing

1. Clean the cylinder head surface, valve face and valve seat.

2. Insert the valve into the valve guide.

3. Measure the valve recessing with a depth gauge.

4. If the measurement exceeds the allowable limit, replace the valve.

5. If it still exceeds the allowable limit after replacing the valve, replace the cylinder head.

0.05 (protrusion) to

Factory spec.

Valve recessing

Allowable limit

0.25 (recessing) mm

0.0020 (protrusion) to

0.0098 (recessing) in.

0.40 (recessing) mm

0.0157 (recessing) in.

(1) Cylinder Head Surface (A) Recessing

(B) Protrusion

W10768800

Clearance between Valve Stem and Valve Guide

1. Remove carbon from the valve guide section.

2. Measure the valve stem O.D. with an outside micrometer.

3. Measure the valve guide I.D. with a small hole gauge, and calculate the clearance.

4. If the clearance exceeds the allowable limit, replace the valves. If it still exceeds the allowable limit, replace the valve guide.

Clearance between valve stem and valve guide

Valve stem O.D. Factory spec.

Valve guide I.D. Factory spec.

Factory spec.

Allowable limit

0.035 to 0.065 mm

0.0014 to 0.0025 in.

0.10 mm

0.0039 in.

6.960 to 6.975 mm

0.2741 to 0.2746 in.

7.010 to 7.025 mm

0.2760 to 0.2765 in.

W10774950

S-46

Kubota 05-E2B, 05-E2BG Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

TO THE READER

GENERAL

MECHANISM

SERVICING