Kubota WSM OC60-E2, WSM OC95-E2 Workshop Manual
WORKSHOP MANUAL
DIESEL ENGINE
OC60-E2,OC95-E2
TO THE READER
This Workshop Manual has been prepared to provide servicing personnel with information on the mechanism,
service and maintenance of OC60-E2, OC95-E2. It is divided into three parts, "General", "Mechanism" and
"Servicing".
B
General
Information on the engine identification, the general precautions, maintenance check list, check and maintenance
and special tools are described.
B
Mechanism
Information on the construction and function are included. This part should be understood before proceed ing with
troubleshooting, disassembli ng and servicing.
Refer to Diesel Engine Mechanism Workshop Manual (Code No. 97897-01873) for the one which has not been
described to this workshop manual.
B
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 thi s 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.
Due to covering many models of this manual, information or picture being used have not been specified as one
model.
February 2005
KUBOTA Corporation 2005
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OC60-E2, OC95-E2, WSM 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.
A
Indicates an imminently hazardous situation which, if not avoi ded, will result in death or serious injury.
A
Indicates a potentially hazardous si tuatio n which, if not avoide d, could resul t in death or serious injury.
A
Indicates a potentiall y hazardous sit uation which, if not avoided, may result in minor or moder ate injury.
A
Indicates that equipment or property damage could result if i nstructions are not followed.
A
Gives helpful information.
BEFORE SERVICING AND REPAIRING
A
Read all instructions and safety instructions in this
manual and on your engine safety decals.
A
Clean the work area and engine.
A
Park the machine on a firm and level ground.
A
Allow the engine to cool before proceeding.
A
Stop the engine, and remove the key
A
Disconnect the battery negative cable
SAFETY STARTING
A
Do not start the engine by shorting across starter
terminals or bypassing the safety start switch.
A
Unauthorized modificat ions to the engine may impair
the function and / or safety and affect engine life.
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1
OC60-E2, OC95-E2, WSM SAFETY INSTRUCTIONS
SAFETY WORKING
A
Do not work on the machine while under the
influence of alcohol , medication, or other substance s
or while fatigued.
A
Wear close fitting clothing and safety equipment
appropriate to the job.
A
Use tools appropriate to the work. Makeshift tools,
parts, and procedures are not recommended.
A
When servicing is performed together by two or
more persons, take care to perform all work safely.
A
Do not touch the rotating or hot parts while the
engine is running.
A
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.
A
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.
A
Wear a suitable hearing protective device such as
earmuffs or earplugs t o protect agai nst objectionabl e
or uncomfortable loud noises.
0000001389E
AVOID FIRES
A
Fuel is extremely flammable and explosive under
certain conditions. Do not smoke or allow flames or
sparks in your working area.
A
To avoid sparks from an accidental short circuit,
always disconnect the battery negative cable first
and connect it last.
A
Battery gas can explode. Keep sparks and open
flame away from the top of battery, especially when
charging the battery.
A
Make sure that no fuel has been spilled on the
engine.
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2
OC60-E2, OC95-E2, WSM SAFETY INSTRUCTIONS
VENTILATE WORK AREA
A
If the engine must be running to do some work, make
sure the area is well ventilat ed. Never r un the engi ne
in a closed area. The exhaust gas contains
poisonous carbon monoxide.
0000001391E
DISPOSE OF FLUIDS PROPERLY
A
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.
0000001393E
PREVENT ACID BURNS
A
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.
0000001392E
PREPARE FOR EMERGENCIES
A
Keep a first aid kit and fire extinguisher handy at all
times.
A
Keep emergency numbers for doctors, ambulance
service, hospital and fire department near your
telephone.
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3
OC60-E2, OC95-E2, WSM SPECIFICATIONS
SPECIFICATIONS
Model OC60-E2(-X) OC60-E2(-X)-L OC95-E2(-X) OC95-E2(-X)-L
Number of Cylinders 1
Type Oil-cooled 4-cycle diesel engine
Bore x Stroke mm (in.) 72 x 68 (2.83 x 2.68) 83 x 77 (3.27 x 3.03)
Total Displ acement (cu.in.) 276 (16.8) 276 (16.8) 416 (25.4) 416 (25.4)
ISO Net Continuous kW / (rpm)
(HP / (rpm))
ISO / SAE Net Intermittent kW / (rpm)
(HP / (rpm))
Maximum Bare Sp eed (rpm) 3800
Minimum Bare I dling S peed (rpm) 1300
Combustion System TVCS (Three-vortex combustion system)
Fuel Injection Pump ND type (DENSO)
Governor Centrifugal mechanical governor
Direction of Rotation Clockwise (View from flywheel side)
Injection Nozzle DN4PD82 (DENSO)
Injection Timi ng (Static)
Injection Pressure 13.7 MPa (140 , 1987 psi)
Compression Ra tio 24.5 : 1 24.0 : 1
Lubricating System Forced lubrica tion with trochoid pump
Lubricatin g F i lter Oil strainer
Cooling System Oil cooling + Air cool ing
Starting Sys tem Electric starting with starter
Starting Mot or 12 V 1.0 kW 12 V 1.2 kW
Charging Alt ernator 12 V, 48 W 12 V, 150 W 12 V, 48 W 12 V, 150 W
Fuel Diesel fuel No.2-D (ASTM D975)
Fuel Tank Capaci ty 3.6 L (0.95 U.S. gal s, 0.79 Imp.gals ) 5.5 L (1.45 U.S.gals, 1.2 Imp.gals)
Lubricating Oi l Quality better than API service CC cla ss (SAE 10W-30)
Lubricating Oil Capacity 1.3 L (1.37 U.S.qts, 1.14 Imp.qts) 1.7 L (1.80 U.S.qts, 1.49 Imp.qts)
Weight (Dry) kg (lbs) 38(83.8) 55 (121.3)
0.26 to 0.30 rad (15 to 17 )
4.2 / 3600
(5.6 / 3600)
4.5 / 3600
(6.1 / 3600)
before top dead center
6.3 / 3600
(8.5 / 3600)
7.0 / 3600
(9.5 / 3600)
0.23 to 0.26 rad (13 to 15 )
before top dead ce nter
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4
OC60-E2, OC95-E2, WSM PERFORMACE CURVES
PERFORMACE CURVES
(1) Brake Horsepower (3) Fuel Consumption (5) Net Intermittent Torque (7) Net Continuous B.H.P.
(2) Engine Speed (4) Torque (6) Net Intermittent B.H.P. (8) Net Intermittent B.S.F.C
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5
OC60-E2, OC95-E2, WSM DIMENSIONS
DIMENSIONS
B
STANDARD TYPE [OC60-E2]
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6
OC60-E2, OC95-E2, WSM DIMENSIONS
B
X TYPE (WITH STOP SOLENOID) [OC60-E2]
STANDARD TYPE X TYPE
A 461 mm (18.15 in.) 461 mm (18.15 in.)
B 457.5 mm (18.02 in.) 457.5 mm (18.02 in.)
C 403 mm (15.87 in.) 403 mm (15.87 in.)
D 133.5 mm (5.26 in.) 133.5 mm (5.26 in.)
E 121 mm (4.77 in.) 121 mm (4.77 in.)
F 164 mm (6.46 in.) 164 mm (6.46 in.)
G 3 mm (0.12 in.) 3 mm (0.12 in.)
H 47 mm (1.85 in.) 47 mm (1.85 in.)
I 40 mm (1.57 in.) 40 mm (1.57 in.)
J 138 mm (5.43 in.) 138 mm (5.43 in.)
K 95 mm (3.47 in.) 95 mm (3.47 in.)
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7
OC60-E2, OC95-E2, WSM DIMENSIONS
B
STANDARD TYPE [OC95-E2]
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8
OC60-E2, OC95-E2, WSM DIMENSIONS
B
X TYPE (WITH STOP SOLENOID) [OC95-E2]
STANDARD TYPE X TYPE
A 503 mm (19.81 in.) 503 mm (19.81 in.)
B 501 mm (19.73 in.) 501 mm (19.73 in.)
C 452 mm (17.80 in.) 452 mm (17.80 in.)
D 145 mm (5.71 in.) 145 mm (5.71 in.)
E 135 mm (5.32 in.) 135 mm (5.32 in.)
F 170 mm (6.69 in.) 170 mm (6.69 in.)
G 3 mm (0.12 in.) 3 mm (0.12 in.)
H 57 mm (2.24 in.) 57 mm (2.24 in.)
I 43 mm (1.69 in.) 43 mm (1.69 in.)
J 145 mm (5.71 in.) 145 mm (5.71 in.)
K 110 mm (4.33 in.) 110 mm (4.33 in.)
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9
OC60-E2, OC95-E2, WSM PTO SHAFT DIMENSIONS
PTO SHAFT DIMENSIONS
B
[OC60-E2]
A 30 mm dia. (1.18 in. dia.)
B 2.9 mm (0.12 in.)
C 60 mm (2.36 in.)
D 24.979 to 25 .000 mm dia. (0.9835 to 0.9842 in. dia.)
E 7.000 to 7.022 mm (0.27 56 to 0.2764 in.)
F 38 mm (1.50 in.)
G M 8 x 1.25 mm (M 0.31 x 0.05 in.)
H 22 mm (0.87 in.)
I 20.800 to 21.000 mm (0.8189 to 0.8267 in.)
0000009667E
A 30 mm dia. (1.18 in. dia.)
B 15.7 mm (0.62 in.)
C 72.2 mm (2.84 in. )
D 25.379 to 25.400 mm dia. (0.9992 to 1.000 in. dia.)
E 6.312 to 6.342 mm (0.24 86 to 0.2496 in.)
F 56 mm (2.20 in.)
G 7 / 16 - 20 UNF
H 28 mm (1.10 in.)
I 21.619 to 21.819 mm (0.8512 to 0.8590 in.)
0000009668E
A 30 mm dia. (1.18 in. dia.)
B 16.4 mm (0.65 in.)
C 72.2 mm (2.84 in. )
D 25.379 to 25.400 mm dia. (0.9992 to 1.000 in.dia.)
G1 - 14 UNS
H 25 mm (0.98 in.)
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10
OC60-E2, OC95-E2, WSM PTO SHAFT DIMENSIONS
A 30 mm dia. (1.18 in. dia.)
B 30.4 mm (1.20 in.)
C 75.5 mm (2.97 in. )
D 22.14 to 22.16 mm dia. (0.8717 to 0.8724 in. dia.)
E Taper 2 - 1 / 4 per foot
F 46.5 mm (1.83 in.)
G 5 / 16 - 24 UNF
H 18 mm (0.71 in.)
0000009670E
B
[OC95-E2]
A 35 mm dia. (1.38 in. dia.)
B 2.9 mm (0.12 in.)
C 60 mm (2.36 in.)
D 24.979 to 25 .000 mm (0.9835 to 0.9842 in.)
E 7.000 to 7.022 mm (0.27 56 to 0.2764 in.)
F 38 mm (1.50 in.)
G M 8 x 1.25 mm (M 0.31 x 0.05 in.)
H 22 mm (0.87 in.)
I 20.800 to 21.000 mm (0.8189 to 0.8267 in.)
0000009671E
A 35 mm dia. (1.38 in. dia.)
B 16.7 mm (0.66 in.)
C 72.2 mm (2.84 in. )
D 25.379 to 25 .400 mm dia. (0.9992 to 1.0000 in. dia.)
E 6.312 to 6.342 mm (0.24 86 to 0.2496 in.)
F 56 mm (2.20 in.)
G 7 / 16 - 20 UNF
H 28 mm (1.10 in.)
I 21.619 to 21.819 mm (0.8512 to 0.8590 in.)
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11
OC60-E2, OC95-E2, WSM PTO SHAFT DIMENSIONS
A 35 mm dia. (1.38 in. dia.)
B 16.4 mm (0.65 in.)
C 72.2 mm (2.84 in. )
D 25.379 to 25 .400 mm dia. (0.9992 to 1.0000 in. dia.)
G1 - 14 UNS
H 25 mm (0.98 in.)
0000009673E
A 35 mm dia. (1.38 in. dia.)
B 30.4 mm (1.20 in.)
C 75.5 mm (2.97 in. )
D 22.14 to 22.16 mm dia. (0.8717 to 0.8724 in. dia.)
E Taper 2 - 1 / 4 per foot
F 46.5 mm (1.83 in.)
G 5 / 16 - 24 UNF
H 18 mm (0.71 in.)
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12
CONTENTS
1. ENGINE IDENTIFICATION ......... .................. ........... ................... .......... .............................G-1
[1] MODEL NAME AND ENGINE SERIAL NUMBER.. ........... ..................................... ......G-1
2. GENERAL PRECAUTIONS......... .......... ................... .......... ................... ........... ..................G-2
3. E2 ENGINE................... ...................................... ..................................... ..................... ...... G-3
4. LUBRICANTS, AND FUEL......................... ........... ...................................... .......... ............G-4
5. MAINTENANCE CHECK LIST ............. ........... .................. ........... ................... ..................G-5
6. CHECK AND MAINTENANCE ..........................................................................................G-6
[1] DAILY CHECK..................................................................................................................G-6
[2] CHECK POINT OF INITIAL 25 HOURS....................................................................... G-7
[3] CHECK POINTS OF EVERY 100 HOURS...................................... ............... .... ..........G-7
[4] CHECK POINT OF EVERY 500 HOURS .....................................................................G -8
[5] CHECK POINT OF EVERY 800 HOURS .....................................................................G -9
[6] CHECK POINTS OF EVERY 1500 HOURS...................................... ............... .... ........G-9
[7] CHECK POINT OF EVERY 1 YEAR .......................................................................... G-10
[8] CHECK POINT OF EVERY 2 YEARS........................................................................G-10
7. SPECIAL TOOLS ............. ................... ................... .......... ................... ................... ..........G-11
OC60-E2, OC95-E2, WSM GENERAL
1. ENGINE IDENTIFICATION
[1] MODEL NAME AND ENGINE SERIAL NUMBER
When contacting the manufacture, always specify your engine
model name and serial number.
(1) Model Name (3) Serial Number
(2) Emission Label
0000009322E
G-1
OC60-E2, OC95-E2, WSM GENERAL
2. GENERAL PRECAUTIONS
A
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.
A
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.
A
Before disassembling or servicing live wires, make sure to
always disconnect the grounding cable from the battery first.
A
Remove oil and dirt from parts before measuri ng.
A
Use only KUBOTA genuine parts for parts replacement to
maintain engine performance and to ensur e safety.
A
Gaskets and O-rings must be replaced during reassembly.
Apply grease to new O-rings or oil seals before assembling.
A
When reassembling external or internal snap rings, position
them so that the sharp edge faces against the direction from
which force is applied.
A
Be sure to perform run-i n the service d or reassembled engi ne.
Do not attempt to give heavy load at once, or serious damage
may result to the engine.
(1) Grease (A) External Snap Ring
(2) Force (B) Internal Snap Ring
(3) Place the Shar p Edge against
the Direction of F orc e
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G-2
OC60-E2, OC95-E2, WSM GENERAL
3. E2 ENGINE
The emission controls that have been put int o effec t in vari ous countri es to preven t air pol lution wi ll be st epped 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 regulati on.
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 E2 as a new model name for the engines conforming Tier 2 / Phase 2
regulations.
In the after-sale s ervices for E2 engine s, only use t he dedicated p arts for E2 models and ca rry out the maintenance
services accordingly .
0000009326E
G-3
OC60-E2, OC95-E2, WSM GENERAL
4. LUBRICANTS, AND FUEL
No. Place
1 Engine oil
2Fuel
*KUBOTA original transmission hydraulic fluid.
OC60-E2 OC95-E2
1.3 L
1.4 U.S.qts
1.1 lmp.qts
3.6 L
0.95 U.S.gals
0.79 lmp.gals
Capacity
1.7 L
1.8 U.S.qts
1.5 lmp.qts
5.5 L
1.45 U.S.gals
1.21 lmp.gals
Lubricants, fuel and coolant
Higher than CC class (API)
Above 25 (77 ) : SAE10W-30
SAE10W-40
SAE30
0 to 25 (32 to 77 ) :
SAE10W-30
SAE10W-40
SAE20
Below 0 (32 ) : SAE10W-30
SAE10W-40
SAE10
Diesel fuel No. 2-D
(No. 1-D deisel fuel, if temperature
is below -10 (14 ).)
0000009327E
G-4
OC60-E2, OC95-E2, WSM GENERAL
5. MAINTENANCE CHECK LIST
Service interval
No Item
1 Engine oil
2 Oil strainer Cleaning G-7
Rubber hoses and clamp
3
bands
4 Air cleaner
5 Fuel fi lter
6 Valv e clearance Checking G-9
Nozzle injection pressure
7
and spraying co ndition
Checking G-6
Changing G-7
Checking G-6
Changing G-10
Cleaning G-8
Changi ng Once ye ar or after 6 clea n i ng s G-10
Cleaning G-8
Changing G-8
Checking G-9, 10
Cleaning G-9, 10
Daily
Initial
25h
Every
100h
Every
500h
Every
800h
Every
1500h
Every
1 year
Every
2 year
Refere-
page
0000009332E
nce
G-5
OC60-E2, OC95-E2, WSM GENERAL
6. CHECK AND MAINTENANCE
[1] DAILY CHECK
Checking Engine Oil Level
1. Put the engine on a flat surface, and check the amount and
condition of the oil with an oil plug (1).
2. If the oil level is below the lower limit (2), add new oil up to the
upper limit (3).
3. When using an oil of different maker or viscosity from the
previous one, r emove all old o il . Nev er mix two di fferen t type s
of oil.
A
Use the proper engine oil viscosity (SAE) according to the
ambient temperature.
(1) Oil Plug (3) Upper Limit
(2) Lower Limit
0000009337E
Checking Fuel Hose and Clamp Bands
1. If the clamps (1) are loose, replace with new ones.
2. The fuel and lubricating hoses are made of rubber and ages
regardless of period of service. Change the fuel pipes
together with the clamps every two year.
3. However, if the fuel and lubricating hose and clamp are found
to be damaged or deteriorated earlier than two year s, replace
with new ones.
(1) Clamp
0000009344E
G-6
OC60-E2, OC95-E2, WSM GENERAL
[2] CHECK POINT OF INITIAL 25 HO URS
Changing Engine Oil and Cleaning Oil Strainer
1. After warming up the engine, remove the drain plug (1) and
drain the oil completely.
2. Put the drain plug and supply the specified quantity of the
specified oil through the oil inl et.
A
Clean the oil strainer (2) each time oil is changed.
(When cleaning oil strainer)
1. Clean the oil strainer with fuel oil.
2. If the oil strainer is deformed or broken, replace it.
(1) Drain Plug (2) Oil Strainer
0000009339E
[3] CHECK POINTS OF EVERY 100 HOURS
Changing Engine Oil and Cleaning Oil Strainer
1. After warming up the engine, remove the drain plug (1) and
drain the oil completely.
2. Put the drain plug and supply the specified quantity of the
specified oil through the oil inl et.
A
Clean the oil strainer (2) each time oil is changed.
(When cleaning oil strainer)
1. Clean the oil strainer with fuel oil.
2. If the oil strainer is deformed or broken, replace it.
(1) Drain Plug (2) Oil Strainer
0000009339E
G-7
OC60-E2, OC95-E2, WSM GENERAL
Cleaning and Changing Air Cleaner Element
A
Change air cleaner element (1) once a year or six times of
cleaning.
(Cleaning Air Filter Element)
A
When dry dust adheres
1. To clean the element, use clean dry compressed air on the
inside of the element.
Air pressure at the nozzle must not exceed 205 kPa (2.1
, 30 psi).
Maintain reasonable distance between the nozzle and the
filter.
(1) Element
0000009368E
Cleaning Fuel Filter
1. Empty the fuel tank and disconnect the fuel pipe.
2. Loosen the ring nut and take out the filter (1).
3. Wash the filter clean off impurities with fresh fuel.
4. Take much care when handling t he element because it is ver y
fragile.
A
If the element should have holes, replace it with a new
one. A damaged element will shorten the service life of
the nozzle and injection pump.
(1) Filter
[4] CHECK POINT OF EVERY 500 HOURS
Changing Fuel Filter
1. Empty the fuel tank and disconnect the fuel pipe.
2. Loosen the ring nut and take out the filter (1).
3. Replace the filter (1).
4. Take much care when handling t he element because it is ver y
fragile.
A
A damaged element will shorten the service life of the
nozzle and injection pump.
(1) Filter
0000009677E
0000009370E
G-8
OC60-E2, OC95-E2, WSM GENERAL
[5] CHECK POINT OF EVERY 800 HOURS
Checking Valve Clearance
A
Valve clearance must be checked and adjusted when
engine is cold.
1. Remove the cylinder head cover.
2. Align the "T" mark line (1) on the fl ywheel and the mark (2) on
the fin at the T.D.C. in the compression stroke.
3. Check the intake and exhaust valve clear ance with a thicknes s
gauge.
4. If the clearance is not within the factory specifications, adjust
with the adjusting screw.
5. After adjusting the valve clearance, firmly tighten the lock nut
on the adjusting screw.
A
After rotating the flywhee l clockwise twi ce or three times,
check the valve clearance again.
Valve clearance Factory spec.
0.14 to 0.18 mm
0.0055 to 0.0071 in.
(1) T Mark Line (2) Mark
0000009371E
[6] CHECK POINTS OF EVERY 1500 HOURS
A
Check the nozzle inj ection pressure and condition after confirming that there is nobody standing in t he
direction the fume goes.
A
If the fume from the nozzle penetrate the human body, cell s may be destroyed and blood poisoning may
be caused.
0000009373E
Checking Nozzle Injection Pressure
1. Set the injection nozzle to the nozzl e 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,
disassemble the injection nozzle, and change adjusting
washer until the proper injec ti on pressure is obtained.
Nozzle injection
pressure
Factory spec.
13.9 to 14.7 MPa
142 to 150
2019 to 2133 psi
(Reference)
A
Pressure variation with 0.15 mm (0.0059 in.) difference of
adjusting washer thickness 981 kPa (10 , 142 psi).
0000009374E
G-9
OC60-E2, OC95-E2, WSM GENERAL
Nozzle Spraying Condition
1. Check the nozzle spray condition.
2. If the spray pattern and spraying direction are faulty, replace
the nozzle piece.
(a) Good (b) Bad
0000009212E
[7] CHECK POINT OF EVERY 1 YEAR
Cleaning and Changing Air Cleaner Element
A
Change air cleaner element (1) once a year or six times of
cleaning.
(Cleaning Air Filter Element)
A
When dry dust adheres
1. To clean the element, use clean dry compressed air on the
inside of the element.
Air pressure at the nozzle must not exceed 205 kPa (2.1
Maintain reasonable distance between the nozzle and the
filter.
(1) Element
[8] CHECK POINT OF EVERY 2 YEARS
Checking Fuel Hose and Clamp Bands
1. If the clamps (1) are loose, replace with new ones.
2. The fuel and lubricating hoses are made of rubber and ages
regardless of period of service. Change the fuel pipes
together with the clamps every two year.
3. However, if the fuel and lubricating hose and clamp are found
to be damaged or deteriorated earlier than two year s, replace
with new ones.
, 30 psi).
0000009368E
(1) Clamp
0000009344E
G-10
OC60-E2, OC95-E2, WSM GENERAL
7. SPECIAL TOOLS
Special Use Puller Set
Code No : 07916-09032
Application : Use exclusively for pulling out bearing, gears and
other parts with ease.
0000000677E
Piston Ring Compressor
Code No : 07909-32111
Application : Use exclusively for pushing i n the pis ton with
piston rings into the cylinder.
0000000678E
Connecting Rod Alignment Tool
Code No : 07909-31661
Application : Use to check the connecting rod alignment .
Applicable : Connecting rod big end I.D.
range 30 to 75 mm (1.18 to 2.95 in.) dia.
Connecting rod length
65 to 330 mm (2.56 to 12. 99 in .)
0000009381E
Nozzle T e ster
Code No : 07909-31361
Application : Use to check the fuel injection pressure and
spraying condition of nozzle.
Measuring : 0 to 50 MPa
range (0 to 500 , 0 to 7000 psi)
0000009382E
G-11
OC60-E2, OC95-E2, WSM GENERAL
Press Gauge
Code No : 07909-30241
Application : Use to check the oil clearance between
crankshaft and bearing, etc..
Measuring : Green.....0.025 to 0.076 mm (0.01 to 0.03 in.)
range Red.........0.051 to 0.152 mm (0.02 to 0.06 in. )
Blue.........0.102 to 0.229 mm (0.04 to 0.09 in.)
0000009383E
Diesel Engine Compression Tester
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
diagnostics of need for major overhaul.
(1) Gauge (7) Adaptor F
(2) L Joint (8) Adaptor G
(3) Adaptor A (9) Adaptor H
(4) Adaptor B (10) Adaptor I
(5) Adaptor C (11) Adaptor J
(6) Adaptor E
0000000680E
Valve Seat Cutter
Code No : 07909-33102
Application : Use to reseat valves.
Angle : 0.785 rad (45 )
0.262 rad (15 )
Diameter : 28.6 mm (1.126 in.) 38.0 mm (1.496 in.)
31.6 mm (1.244 in.) 41.3 mm (1.626 in.)
35.0 mm (1.378 in.) 50.8 mm (2.000 in.)
0000000682E
Oil Pressure Tester
Code No : 07916-32032
Application : Use to measure lubricating oil pressure.
(1) Gauge (5) Adaptor 2
(2) Cable (6) Adaptor 3
(3) Threaded Joint (7) Adaptor 4
(4) Adaptor 1 (8) Adaptor 5
0000000681E
G-12
OC60-E2, OC95-E2, WSM GENERAL
Flywheel Puller
Code No : 07916-30161
Application : Use for removing the flywheel from crankshaft.
0000009387E
A
The following special tools are not provided, so make them referring to the figures.
0000009388E
Side Cover Oil Seal Guide (OC60-E2)
Application : The oil sealing guide is helpful in fitt ing the side
cover in position.
Material : S43C
Q Type G Type
26.9 to 27.1 mm dia.
A
(1.060 to 1.066 in. dia.)
B 0.2618 rad (15 ) 0.2618 rad (15 )
29.75 to 29.85 mm dia.
C
(1.172 to 1.175 in. dia.)
25.500 to 25.533 mm dia.
D
(1.004 to 1.005 in. dia.)
E 70 mm (2.755 in.) 70 mm (2.755 in.)
F R 0.5 mm (R 0.020 in.) R 0.5 mm (R 0.020 in.)
G R 2 mm (R 0.079 in.) R 2 mm (R 0.079 in.)
C0.1 Chamfer 0.1 mm (0.012 in.) Chamfer 0.1 mm (0.012 in.)
C0.2 Chamfer 0.2 mm (0.0039 in.) Chamfer 0.2 mm (0.0039 in.)
C0.3 Chamfer 0.3 mm (0.0079 in.) Chamfer 0.3 mm (0.0079 in.)
26.9 to 27.1 mm dia.
(1.060 to 1.066 in. dia.)
29.75 to 29.85 mm dia.
(1.172 to 1.175 in. dia.)
22.300 to 22.333 mm dia.
(0.878 to 0.879 in. dia.)
0000009530E
G-13
OC60-E2, OC95-E2, WSM GENERAL
Side Cover Oil Seal Installing Tool
Application : Use to install the oil seal.
Material : S43C
OC60-E2 OC95-E2
A 40 mm dia. (1.575 in. dia.) 46 mm dia. (1.811 in. dia.)
B 31 mm dia. (1.220 in. dia.) 36 mm dia. (1.417 in. dia.)
44.0 to 44.3 mm dia.
C
(1.733 to 1.744 in. dia.)
D 52 mm dia. (2.047 in. dia.) 58 mm dia. (2.283 in. dia.)
E 7 mm (0.276 in.) 7 mm (0.276 in.)
F 10 mm (0.394 in.) 10 mm (0.394 i n.)
G 100 mm (3.937 in.) 100 mm (3.937 in.)
H 127 mm (5.000 in.) 127 mm (5.000 in.)
I R20 mm (R0.79 in.) R20 mm (R0.79 in.)
C1 Chamfer 1 mm (0. 039 in.) Chamfer 1 mm (0.039 in.)
49.0 to 49.3 mm dia.
(1.930 to 1.940 in. dia.)
0000009531E
Crank Case Oil Seal Installing Tool
Application : Use to install the crank case oilseal.
Material : S43C
OC60-E2 OC95-E2
A 40 mm dia. (1.575 in. dia.) 46 mm dia. (1.811 in. dia.)
B 31 mm dia. (1.220 in. dia.) 36 mm dia. (1.417 in. dia.)
C 52 mm dia. (2.047 in. dia.) 58 mm dia. (2.283 in. dia.)
D 10 mm (0.394 in.) 10 mm (0.394 in.)
E 100 mm (3.937 in.) 100 mm (3.937 in.)
F 120 mm (4.724 in.) 120 mm (34.724 in.)
G R20 mm (R0.79 in.) R20 mm (R0.79 in.)
C1 Chamfer 1 mm (0. 039 in.) Chamfer 1 mm (0.039 in.)
C5 Chamfer 5 mm (0. 20 i n.) Chamfer 5 mm (0.20 i n.)
Balancer Bearing Installing Tool
Application : Use to install the balancer bearing.
Material : S43C
OC60-E2 OC95-E2
13.8 to 13.9 mm dia.
A
(0.544 to 0.547 in. dia.)
19.8 to 19.9 mm dia.
B
(0.780 to 0.783 in. dia.)
C 112.5 mm (4.429 in.) 112.5 mm (4.429 in.)
D 100 mm (3.937 in.) 100 mm (3.937 in.)
0.4 to 0.6 mm
E
(0.0158 to 0.0236 in.)
F 12 mm (0.472 in.) 12 mm (0.472 i n.)
G 30 mm dia. (1.181 in. dia .) 30 mm dia. (1.181 in. dia.)
C1 Chamfer 1 mm (0.039 i n.) Chamfer 1 mm (0.039 in.)
G-14
15.8 to 15.9 mm dia.
(0.623 to 0.625 in. dia.)
21.8 to 21.9 mm dia.
(0.859 to 0.862 in. dia.)
0.4 to 0.6 mm
(0.0158 to 0.0236 in.)
0000009532E
0000009533E
OC60-E2, OC95-E2, WSM GENERAL
Camshaft Bearing Installing Tool (Crank Case)
Application : Use to install the camshaft bearin g.
Material : S43C
OC60-E2 OC95-E2
16.8 to 16.9 mm dia.
A
(0.544 to 0.547 in. dia.)
22.8 to 22.9 mm dia.
B
(0.898 to 0.901 in. dia.)
C 122 mm (4.803 in.) 122 mm (4.803 in.)
D 100 mm (3.937 in.) 100 mm (3.937 in.)
E 10 mm (0.394 in.) 10 mm (0.394 in.)
F 12 mm (0.472 in.) 12 mm (0.472 i n.)
G 30 mm dia. (1.181 in. dia .) 30 mm dia. (1.181 in. dia.)
H R2 mm (R0.08 in.) R2 mm (R0.08 in.)
C1 Chamfer 1 mm (0. 039 in.) Chamfer 1 mm (0.039 in.)
19.8 to 19.9 mm dia.
(0.780 to 0.783 in. dia.)
25.8 to 25.9 mm dia.
(1.016 to 1.019 in. dia.)
0000009534E
Crankshaft Bearing 1 Replacing Tool (For Extracting)
Application : Use to press out and press fit th e crankshaft
bearing.
Material : S43C
OC60-E2 OC95-E2
43.7 to 44.3 mm dia.
A
(1.721 to 1.744 in. dia.)
B 95 mm (3.740 in.) 96 mm (3.780 in.)
C 15 mm (0.590 in.) 16 mm (0.630in.)
34.6 to 34.9 mm dia.
D
(1.363 to 1.374 in. dia.)
38.7 to 38.9 mm dia.
E
(1.524 to 1.531 in. dia.)
F 30 mm (1.181 in.) 30 mm (1.181 i n.)
G 50 mm (1.969 in.) 50 mm (1.969 in.)
C0.3 Chamfer 0.3 mm (0.012 in.) Chamfer 0.3 mm (0.012 in.)
C1 Chamfer 1 mm (0. 039 in.) Chamfer 1 mm (0.039 in.)
C5 Chamfer 5 mm (0. 20 i n.) Chamfer 5 mm (0.20 i n.)
48.7 to 49.3 mm dia.
(1.918 to 1.940 in. dia.)
39.6 to 39.9 mm dia.
(1.560 to 1.570 in. dia.)
43.7 to 43.9 mm dia.
(1.721 to 1.728 in. dia.)
0000009535E
G-15
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