Kubota Z402-EB-ONAN-1 Workshop Manual
WORKSHOP
MANUAL
DIESEL
ENG'INE
Z402-EB-ONAN-1
TO
THE
READER
This Workshop Manual has been prepared to provide servicing personnel with
information on the service and maintenance
of
KUBOTA Diesel Engine 2402-8.
Disassembling
and
Servicing
Under the heading ”General” section comes general precautions, troubleshooting,
lists
of servicing specifications and periodic inspection items. For each engine section, there
are “Checking and Adjustment”, “Disassembling and Assembling”, and “Servicing” which
cover procedures, precautions, factory specification and allowable limits.
AI1
information, illustrations and specifications contained in this manual are based
on
The right
is
resewed to make changes in all information at any time without notice.
the latest production information available at the time of publication.
September
2000
@
KUBOTA Corporation
2000
02090Z00010
SAFETY
INSTRUCTIONS
2402-8
WSM,
02090
A
DANGER :Indicates an imminently hazardous situation which,
if
not avoided, will result
in
death
or serious injury.
i
L
~/////////~////////////////////////~/////////////////~///////////////////////////////////~////~///////~/~/////////////////f///////~
g
f
f
A
SAFETY
FIRST
This symbol, the industry’s “Safety Alert Symbol”,
is
used throughout this manual and decals on
4
It
is essential that you read the instructions and safety regulations before you attempt to repair or
f
the engine itself to warn of the possibility of personal injury. Read these instructions carefully.
use this unit.
h
I
WARNING: Indicates a potentially hazardous situation which,
if
not avoided, could result
in
death
or serious injury.
c
I
CAUTION :Indicates a potentlally hazardous situation which, if not avoided, may result
in
minor
la
or moderate injury.
IMPORTANT :Indicates that equipment or property damage could result if instructions are not
followed.
:Gives helpful information.
I
OOOOOZOOOl
1
BEFORE SERVICING
AND
REPAIRING
(1)
Read all instructions and safety instructions
in
this
manual and on your engine safety decals.
(2)
Clean the work area and engine.
(3)
Place the engine on a firm and level ground.
(4)
allow the engine to cool before proceeding.
(5)
Stop the engine, and remove the key.
(6)
Disconnect the battery negative cable.
OOOOOFOOOlO
ooooozooo21
.
1
2402-8
WSM,
02090
SAFETY
JNSTRUCTIONS
00000F00021
00000F00030
00000F00040
A
)0000F00050
SAFETY STARTING
(1)
Do not
start
the engine by shorting across starter
terminals.
(2)
Unauthorized modifications to the engine may impair
the function and /or safety and affect engine life.
.
00000Z00031
SAFETY WORKING
(1)
Do
not work on the engine while under the influence
of alcohol, medication, or other substances or while
fatigued.
(2)
Wear close fitting clothing and safety equipment
appropriate to the job.
(3)
Use tools appropriate to the work. Makeshift tools,
parts, and procedures are not recommended.
(4)
When servicing is performed together by
two
or more
persons, take care to perform all work safely.
(5)
Do
not touch the rotating or hot parts while the engine
is running.
(6)
Never remove the radiator cap while the engine is
running, or immediately after stopping. Otherwise,
hot water
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.
(7)
Escaping fluid (fuel or hydraulic oil) under pressure
can penetrate the skin causing serious injury.
Relieve pressure before disconnecting hydraulic or
fuel lines. Tighten all connections before applying
pressure.
(8)
Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable
or uncomfortable loud noises.
I
0000020004
1
AVOID FIRES
(1)
Fuel is extremely flammable and explosive under
certain conditions.
Do
not smoke or allow flames or
sparks in your working area.
(2)
To
avoid sparks from an accidental short circuit,
always disconnect the battery negative cable first
and connect it last.
(3)
Battery gas can explode. Keep sparks and open
,
flame away from the top of battery, especially when
charging the battery.
(4)
Make sure that no fuel has been spilled
on
the
engine.
00000Z00050
2
SAFETY INSTRUCTIONS
Z402-B
WSM,
02090
VENTILATE
WORK
AREA
(1)
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.
00000Z00060
PREVENT ACID
BURNS
(1)
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.
00000Z00070
DISPOSE
OF
FLUIDS PROPERLY
(1)
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.
00000Z00080
PREPARE
FOR
EMERGENCIES
[I
(1)
Keep a first aid kit and fire extinguisher handy at all
._
-
times.
(2)
Keep emergency numbers for doctors, ambulance
service, hospital and fire department near your
telephone.
OOOOOFOOO9O
00000200090
3
ZW-B
LVS?J,
02090
SPEClFlCATl
ONS
~~~ ~
Number
of
cylinders
Tw
Bore
xstroke
SPECIFICATIONS
~ ~~~
2
Vertical,
Water-cooled, 4-cycle diesel engine
64
x
62.2
mm
(252 x 245
in.)
I
Model
I
2402
I
Total displacement
SAE net cont. H.P.
SAE net intermittent H.P.
n
2
SAE gross intermitlent H.P.
2
DIN6270-NA
DIN6270-NB
'
DIN70020
Maximum bare speed
Combustion Chamber
Fuel injection pump
Governor
Direction of rotation
Injection nozzle
Injection timing
Injection pressure
Compression ratio
Lubricating system
Oil pressure indicating
Lubricating filter
Cooling system
Starting system
Starting support device
Bettely
Fuel
Lubricating oil
Lubricating oil capacity
Weight
(Dry)
Dimension (L
x
W
x
H)
~~ ~
Injection order
400 CC (24.41 cu.in.)
5.5 kW/3000
rpm
(7.4 HPl3000
rpm)
6.3 kW/3000
rpm
(8.4 HP/3000
rpm)
6.5 kW/3000
rpm
(8.7 HP/3000
rpm)
5.5 kW13000
rpm
(7.5 PS/3000
rpm)
6.1 kW/3000
rpm
(8.3 PS/3000
rpm)
6.6 kW/3000
rpm
(9.0
PS/3000
rpm)
3200 to 3300
rpm
Spherical type
Bosch MD
type
mini pump
Centrifugal ball mechanical governor
Counter-clockwise (viewed from flywheel)
Bosch throttle type
0.31 to 0.35 rad. (18 to 20') before T.D.C.
1
-2
13.73 MPa (140 kgf/crn2, 1991 psi)
23:
1
Forced lubrication by pump
Electrical type switch
Full flow paper filter (cartridge
type)
Pressurized radiator, forced circulation with water pump
Electric starting with starter
12
V,
1.2 kW
By glow plug
in
combustion chamber
12
V,
CCA
600,
equivalent
Diesel fuel No. 2-D (ASTM D975)
API service CD or CE
1.9
L
(2.0 U.S.qts.,
1.7
Imp.qts.)
56 kg (123.5 Ibs)
314.5
x
380.4 x 449.1
mm
(12.38 x 14.98 x 17.68 in.)
~~
~ ~~
02090Z00020
4
CONTENTS
GENERAL
..........................................................................................................
S-I
[I]
ENGINE IDENTIFICATION
........................................................................
5-1
(1)
Model Name and Engine Serial Number
...............................................
5-1
(2) Cylinder Number
....................................................................................
5-1
(1)
Tightening Torques for Special Use Screws. Bolts and Nuts
................
5-3
[2] GENERAL PRECAUTION
..........................................................................
5-2
[3] TIGHTENING TORQUES
..........................................................................
5-3
(2) Tightening Torques for General Use Screws. Bolts and Nuts
...............
5-3
[4] TROUBLESHOOTING
................................................................................
5-4
[5] SERVICING SPECIFICATIONS
................................................................
5-7
(1)
Engine Body
..........................................................................................
5-7
(3)
Cooling System
...................................................................................
5-11
(4)
Fuel System
.........................................................................................
5-12
(1)
Daily Check Points
..............................................................................
5-14
(2)
Check Point of Every
50
Hours
...........................................................
5-15
(2)
Lubricating System
..............................................................................
5-11
[6]
MAINTENANCE CHECK LIST
................................................................
5-13
[71
CHECK AND MAINTENANCE
................................................................
5-14
(3) Check Points
of
Every
100
Hours
........................................................
5-16
(4) Check Points of Every 200 Hours
........................................................
5-18
(5)
Check Points
of
Every 800 Hours
........................................................
5-19
(6) Check Points of Every 1000 Hours
......................................................
5-20
[8] SPECIAL TOOLS
.....................................................................................
5-20
0
ENGINE BODY
...............................................................................................
5-26
CHECKING AND ADJUSTING
.....................................................................
5-26
DISASSEMBLING AND ASSEMBLING
........................................................
5-27
[I]
DRAINING WATER AND OIL
................................................................
5-27
[23
EXTERNAL COMPONENTS
...................................................................
5-27
[3] CYLINDER HEAD AND VALVES
..........................................................
5-28
[4]
TIMING GEAR AND CAMSHAFT
..........................................................
5-30
[5] PISTON AND CONNECTING ROD
.......................................................
5-32
[6] FLYWHEEL AND CRANKSHAFT
...........................................................
5-35
SERVICING
....................................................................................................
5-36
[I]
CYLINDER HEAD
....................................................................................
5-36
[2] TIMING GEAR AND CAMSHAFT
..........................................................
5-40
[3] PISTON AND CONNECTING ROD
.......................................................
5-42
[4] CRANKSHAFT
..........................................................................................
5-45
[5] CYLINDER
................................................................................................
5-49
IEl
LUBRICATING SYSTEM
................................................................................
5-50
CHECKING
.....................................................................................................
5-50
SERVICING
....................................................................................................
5-50
[I]
OIL PUMP
................................................................................................
5-50
IF1
COOLING SYSTEM
........................................................................................
5-52
CHECKING
.....................................................................................................
5-52
[I]
FAN BELT
................................................................................................
5-52
[2]
RADIATOR
...............................................................................................
5-52
DISASSEMBLING AND ASSEMBLING
........................................................
S-53
A
*
FUEL SYSTEM
................................................................................................
5-54
CHECKING AND ADJUSTING
......................................................................
5-54
[i]
INJECTION PUMP
...................................................................................
5-54
[2]
INJECTION NOZZLE
................................................................................
5-55
DISASSEMBLING AND ASSEMBLING
........................................................
5-56
[I]
INJECTION NOZZLE
................................................................................
5-56
DIESEL ENGINE
2402-B
WSM,
02090
GENERAL
[I]
ENGINE
IDENTIFICATION
(1)
Model
Name and Engine Serial Number
When contacting the manufacturer, always specify your engine
model name and serial number.
02090510010
(2)
Cylinder Number
The cylinder numbers of
2402
diesel engine are designated as
The sequence of cylinder numbers
is
given as No. 1 and
No.
2
shown
in
the figure.
starting from the gear case side.
c
t
(1)
No.
1
Cylinder
(2)
No.
2
Cylinder
(A)
Gear Case Side
01650510010
.
s-1
Z4M-B
VJSM.
02090
DIESEL
ENGINE
[Z]
GENERAL
PRECAUTION
11790F00051
0
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
make 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.
0
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.
A
CAUTION
Certain components used in this engine (cylinder headgasket, exhaust gasket, etc.) contain asbestos. Handle with
care according to safety regulation.
(1)
Grease
(2)
Force-
(3)
Place the Sharp Edge against the
Direction
of
Force
(A)
External Snap Ring
(B)
internal Snap Ring
01
64051
0030
s-2
DIESEL ENGINE
2402-6
WSM,
02090
[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 at the proper torque.
01640S10760
(1)
Tightening Torques for Special Use Screws, Bolts and Nuts
NOTE
For
“*”
marked screws, bolts and nuts on the table,
apply
engine oil to their threads and seats before
tightening.
t
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.
Standard Screw and Bolt
@
Item
Special Screw and Bolt
Q
*
Cylinder head cover cap nuts
*
Cylinder head screws
*
Main bearing case screws
1
*
Main bearing case screws
1
(Flywheel side)
*
Main bearing case screws
2
*
Flywheel screws
*
Connecting rod screws
*
Rocker arm bracket nuts
*
Idle gear shaft screws
*
Crankshaft end bolt
*
Bearing case cover screws
Glow plugs
Nozzle holder assembly
Oil switch taper screw
Injection pipe retaining nuts
Overflow pipe assembly retaining nuts
Starter’s terminal
B
mounting nut
N-m kgf.m ft-lbs
Diameter
M6
7.9
to
9.3 0.80
to
0.95 5.8
to
6.9
Size x Pitch
Nmm kgf.m ft-lbs
9.8
to
11.3
1-00
to
1.15
7.23
to
8.32
M6
x
1.0
M8 x 1.25
M6
x
1.0
M8 x 1.25
M7
x
1.0
MI0
x
1.25
M7
x
0.75
M6
x
1.0
M6 x 1.0
MI2
x
1.5
M6x
1.0
M8 x 1.0
M20 x 1.5
PT
118
MI2
x
1.5
MI2
x
1.5
M8
MI0
MI2
N.m
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
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
3.9
to
5.9
37.2
to
42.1
12.7
to
15.7
23.5
to
27.4
None or
4
7
26.5
to
30.4
53.9
to
58.8
26.5
to
30.4
9.8
to
11.3
9.8
to
11.3
117.6
to
127.4
9.8
to
11.3
7.8
to
14.7
49.0
to
68.6
14.7
to
19.6
24.5
to
34.3
19.6
to
24.5
8.8
to1
1.8
Standard screw and bolt
SS41
,
S20C
Special screw and bolt
S43C,
S48C
(Refined)
kgfam
0.4
to
0.6
3.8
to
4.3
1.3
to
1.6
2.4
to
2.8
2.7
to
3.1
5.5
to
6.0
2.7
to
3.1
1.00
to
1.15
1.00
to
1.15
12.0
to
13.0
1.00
to
1.15
0.8
to
1.5
5.0
to
7.0
1.5
to
2.0
2.5
to
3.5
2.0
to
2.5
0.9
to
1.2
ft-lbs
2.9
to
4.3
27.5
to
31
.I
9.4
to
11.6
17.4
to
20.3
19.5
to
22.4
39.8
to
43.4
19.5
to
22.4
7.2
to
8.3
7.2
to
8.3
86.4
to
93.6
7.2
to
8.3
5.8
to
10.8
36.2
to
50.6
10.8
to
14.5
18.1 to25.3
14.5
to
18.1
6.5
to
8.7
01650510020
(2)
Tightening Torques for General Use Screws, Bolts and Nuts
I I
I
I
I
I
M8
I
17.7
to
20.6 I 1.8
to
2.1
I
13.0
to
15.2 I 23.5 to27.5 I 2.4
to
2.8 I 17.4
to
20.3
I
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.
I
Punchednumber
I
Screw and bolt material grade
0164OS10040
5-3
zm-B
WSM.
02090
DIESEL
ENGINE
[4]
TROUBLESHOOTING
Symptom
Engine
Does
Not
Start
(Starter
Does
Not
Run)
~
Engine Revolution
Is
Not
Smooth
Either White
or
Blue
Exhaust
Gas
Is
0
bserved
Probable Cause
Nofuel
Air
in the fuel system
Water in the fuel system
Fuel pipe clogged
Fuel filter clogged
Excessively high viscosity of fuel or engine oil
at low temperature
Fuel with low cetane number
Fuel leak due to loose injection pipe retaining
Incorrect injection timing
Fuel camshaft worn
Injection nozzle clogged
Injection pump malfunctioning
nut
Seizure of crankshaft, camshaft, piston,
Compression leak from cylinder
cylinder or bearing
Improper valve timing
Piston ring and cylinder worn
0
Excessive valve clearance
Battery discharged
Starter malfunctioning
Key switch malfunctioning
Wiring disconnected
Fuel filter clogged or dirty
Air cleaner clogged
Fuel leak due to loose injection pipe retaining
Injection pump malfunctioning
nut
Incorrect nozzle opening pressure
Injection nozzle stuck or clogged
Governor malfunctioning
Excessive engine
oil
0
Piston ring and liner worn or stuck
0
Incorrect injection timing
0
Deficient compression
Solution
Replenish fuel
Vent air
Change fuel and
repair or replace fuel
system
Clean
Clean or change
Use specified fuel or
engine
oil
Use specified fuel
Tighten retaining nut
Adjust
Replace
Clean
Repair or replace
Repair or replace
Replace head
gasket, tighten
cylinder head screw,
glow plug and nozzle
holder
Correct or replace
timing gear
Replace
Adjust
Charge
Repair or replace
Repair or replace
Connect
Clean or change
Clean or change
Tighten retaining nut
Repair or replace
Adjust
Repair or replace
Repair
Reduce
to
specified
level
Repair or replace
Adjust
Adjust top clearance
Reference
Page
-
S-15
-
-
S-17
S-16
-
-
s-54
S-31
s-55
S-30,
54,
55
-
S-26,28
S-31
s-34, 35
s-19
-
-
-
-
S-17
S-17
-
S-30,54,
55
s-55
S-56
S-31
S-16
s-34,35
s-54
S-26
02090S70020
5-4
DIESEL ENGINE
2402-8
WSM,
02090
Either Black or Dark
Gray Exhaust Gas Is
Observed
Deficient Output
Excessive Lubricant
Oil
Consumption
Fuel Mixed into
Lubricant
Oil
Water Mixed into
Lubricant Oil
Low
Oil
Pressure
~~
High Oil Pressure
Probable Cause
Overload
0
Low grade fuel used
Fuel filter clogged
Air cleaner clogged
0
Deficient nozzle injection
0
Incorrect injection timing
0
Engine’s moving parts seem to be seizing
0
Uneven fuel injection
Deficient nozzle injection
Compression leak
0
Piston ring’s gap facing the same direction
Oil ring worn or stuck
Piston ring groove worn
0
Valve stem and valve guide worn
Carnkshaft bearing, and crank pin bearing
0
Oil leaking due to defective seals or packing
worn
Injection pump’s plunger worn
0
Deficient nozzle injection
0
Injection pump broken
Head gasket defective
0
Cylinder block or cylinder head flawed
__
~-~
0
Engine oil insufficient
0
Oil strainer clogged
0
Relief valve stuck with dirt
0
Relief valve spring weaken or broken
0
Excessive oil clearance of crankshaft bearing
0
Excessive oil clearance of crankpin bearing
0
Excessive oil clearance of rocker arm bearing
Oil passage clogged
Different type of oil
0
Oil pump defective
0
Different type of oil
0
Relief valve defective
Solution
Lessen load
Use specified fuel
Clean or change
Clean or change
Repair
or
replace
nozzle
Adjust
Repair or replace
Repair or replace
injection pump
Repair or replace
nozzle
Replace head
gasket, tighten
cylinder head screw,
glow plug and nozzle
holder
Shift ring gap
direction
Replace
Replace piston
Replace
Replace
Replace
Replace pump
element or injection
Pump
Repair
or
replace
nozzle
Replace
Replace
Replace
Replenish
Clean
Clean
Replace
Replace
Replace
Replace
Clean
Use specified type of
oil
Repair or replace
Use specified type of
oil
Replace
Reference
Page
8.-
-
S-17
S-17
5-55
5-54
5-30, 54,
55
5-56
S-26,28
-
5-33
s-33,
34
s-44
s-37
S-46
-
5-54,55
S-56
5-30
5-28
S-36’37
-
S-32
-
c
S-47,40
S-46
5-40
-
-
5-50
.
02090510030
5-5
DIESEL
ENGINE
2402-6
WSM.
02090
Symptom
Engine Overheated
Battery Quickly
Discharge
Probable Cause
0
Engine
oil
insufficient
0
Fan belt broken
or
elongated
0
Cooling water insufficient
0
Radiator net and radiator fin clogged with dust
0
Inside
of
radiator corroded
0
Cooling water flow
route
corroded
0
Radiator cap defective
Overload running
0
Head gasket defective
0
Incorrect injection timing
0
Unsuitable
fuel
used
Battery electrolyte insufficient
0
Fan belt slips
Wiring disconnected
Rectifier defective
0
Alternator defective
0
Battery defective
Solution
Replenish
Replace or adjust
Replenish
Clean
Clean or replace
Clean
or
replace
Replace
Loosen load
Replace
Adjust
Use
specified
fuel
Replenish distilled
water and charge
Adjust belt tension or
change
Correct
Replace
Replace
Change
Reference
Page
-
S-16
-
-
-
-
s-53
S-28
s-54
-
-
02090510040
S-6
DIESEL
ENGINE
2402-8
WSM,
02090
Variance Among Cylinders
-
I
[5]
SERVICING
SPECIFICATIONS
10
%or less
(1)
Engine Body
Cvlinder Head
0.1 45 to
0.1
85
mm
0.0057
to
0.0072 in.
0.785 rad.
45"
0.785 rad.
45'
Cylinder Head Surface Flatness
Top
Clearance
-
-
Factory Specification
-
Open
Close
0.50
to 0.70 mm
0.0197 to 0.0276 in.
0.35 rad.
(20")
-
before T.D.C.
0.79 rad. (45')
after B.D.C.
-
Allowable Limit
0.05
mm
0.0019 in.
Close
Compression Pressure
0.26 rad.
(15')
-
after T.D.C.
2.84 to 3.23 MPa
29.0
to
33.0 kgf/cm2
412 to 469 psi
2.25 MPa
23 kgflcm2
327 psi
Valves
I
Valve Clearance (Cold)
Valve Seat Angle
Valve Face Angle
I
Valve Recessing
Clearance between Valve Stem and Valve Guide
Valve Stem O.D.
Valve Guide I.D.
Valve Timing
-
Intake Valve
Exhaust Valve
-
0.10
to
0.10
mm
-
0.0039 to 0.0039 in.
0.030
to 0.057 mm
0.3 mm
0.01
18
in.
0.1
mm
+
0.001
18 to 0.00224
in.
0.0039 in.
5.968 to
5.980
mm
0.23496 to 0.23543 in.
6.010 to 6.025 mm
0.23661 to 0.23720 in.
Open
0.87 rad.
(50')
1
before B.D.C.
-
I
.
s-7
ZM2-B
LVSM,
02090
DIESEL
ENGINE
Factory
Specification
31.6
mm
1.244
in.
64.7
N
/
27
mm
6.6
kgf
/
27
mm
14.6
Ibs
/
1.063
in.
-
i.
Aliowable
Limit
28.4mm
1.118
in.
54.9 N /
27 mm
5.6
kgf
/
27 mm
12.3
Ibs
/
1.063
in.
1.2 mm
0.047
in.
Valve Spring
Clearance between Rocker Arm Shaft and Rocker Arm
0.016
to
0.045 mm
0.0006
to
0.0018
in.
Item
0.15 mm
0.0059
in.
Free Length
Set€ing Load
/
Setting Length
Rocker Arm
I.D.
10.500
to
10.51 8
mm
0.41339
to
0.4141
0
in.
Tilt
Clearance between Tappet and Guide
0.016
to
0.052
mm
0.00063
to
0.00205
in.
0.10
mm
0.0039
in.
Tappet Guide I.D.
Rocker Arm Shaft O.D.
18.000
to
18.01 8 mm
0.70866
to
0.70939
in.
-
10.473
to
10.484
mm
0.41232
to
0.41276
in.
Camshaft Side Clearance
0.15
to
0.31
mm
0.0059
to
0.01220
in.
Cam Height
27.00
mm
1.0630
in.
Oil Clearance of Camshaft
0.050
to
0.091
mm
0.0020
to
0.0036
in.
32.934
to
32.950
mm
1.2966
to
1.2972
mm
33.000
to
33.025
mm
1.2992
to
1.3002
in.
Camshaft Journal
O.D.
Camshaft Bearing
I.D.
0.5
mm
0.020
in.
26.97mm
1.061 8
in.
0.15 mm
0.0059
in.
-
-
Tappet O.D.
17.966
to
17.984
mm
0.70732
to
0.70803
in.
.
DIESEL
ENGINE
2402-B
WSM, 02090
Piston Pin Bore
Clearance between Compression Ring
2
and Ring Groove
Timing
Gear
20.000
to
20.01 3 mm
0.78740
to
0.78791
in.
0.085
to
0.1
12 mm
0.0033
to
0.0044
in.
20.05
mm
0.7894
in.
0.15
mm
0.0059 in.
item
Clearance between Oil Ring and Ring Groove
Ring Gap
Compression Ring
1,
Compression Ring
2
Timing Gear Backlash
Crank Gear-Idle Gear
Idle Gear-Cam Gear
Idle Gear-Injection Pump Gear
Crank Gear-Oil Pump Drive Gear
0.04
to 0.08 mm
0.0016
to
0.0031
in.
0.25
to
0.40
mm
0.0098 to
0.01
57 in.
Clearance between Idle Gear Shaft and Idle Gear Bushing
Idle Gear Bushing I.D.
Idle Gear Shaft
O.D.
Idle Gear Side Clearance
Piston Piston
Ring
Factory Specification
0.043 to 0.124
mm
0.001
69 to 0.00488
in.
0.047
to
0.123 mm
0.001
85 to 0.00484 in.
0.046 to 0.124 mm
0.00181
to
0.00488 in.
0.041 to 0.123
mm
0.001
61
to
0.00484 in.
0.020
to
0.084 mm
0.0008 to 0.00331 in.
20.000 to 20.051 mm
0.78740 to 0.78941 in.
19.967
to
19.980 mm
0.7861
0
to
0.78661
in.
0.20
to
0.51
mm
0.0079
to
0.0200
in.
Allowable Limit
0.15 mm
0.0059 in.
0.15 mm
0.0059 in.
0.15
mm
0.0059 in.
0.15 mm
0.0059 in.
0.10
mm
0.0039
in.
-
-
0.60 mm
0.0236
in.
Oil Ring
0.15
to 0.30 mm
0.0059 to
0.01
77
in.
I
0.15
mm
0.0059 in.
1.25mm
0.0492 in.
1.25 mm
0.0492 in.
Of650S10070
s-9
Z402-B
WSM,
02080
DIESEL ENGINE
8
Connecting
Rod
I
item
1
Factory
Specification
I
Allowable
Limit
-
I
I
Connecting Rod Alignment
0.05 mm
0.0020 in.
Clearance between Piston Pin and Small End Bushing
Piston Pin
O.D.
Small End Bushing
I.D.
0.014
to 0.038 mm
0.0006 to 0.0015
in.
20.002 to 20.01 1 mm
0.78748 to 0.78783
in.
20.025 to 20.040 mm
0.78839 to 0.78897
in.
0.10 mm
0.0039 in.
Crankshaft
Crankshaft Alignment
Oil Clearance between Crankshaft and Crankshaft Bearing
1
Crankshaft
O.D.
Crankshaft Bearing 1
I.D.
Oil Clearance between Crankshaft and Crankshaft Bearing 2
Crankshaft
O.D.
Crankshaft Bearing 2
I.D.
Oil Clearance between Crankshaft and Crankshaft Bearing 3
Crankshaft
O.D.
Crank bearing 3
I.D.
Oil Clearance between Crank Pin and Crank Pin Bearing
Crank Pin
O.D.
Crank Pin Bearing
I.D.
Crankshaft Side Clearance
0.034
to
0.1
06 mm
0.001 3 to 0.0042
in.
39.934 to 39.950 mm
1.57221 to 1.57281
in.
39.984 to 40.040 mm
1.57428 to 1.57648
in.
0.034 to 0.092 mm
0.001
3 to 0.0036
in.
43.934 to 43.950 mm
1.7297 to 1.7303 in.
43.984 to 44.026 mm
1.731
7 to 1.7333
in.
0.028 to 0.059 mm
0.001
1
to 0.0023
in.
39.934 to 39.950 mm
1.5722 to 1.5728 in.
39.978 to 39.993 mm
1.5739 to 1.5745 in.
0.02
to 0.051 mm
0.0008 to
0.0020
in.
33.959 to 33.975 mm
1.3370 to 1.3376 in.
33.995 to 34.010 mm
1.3384 to 1.3390
in.
0.15 to 0.25 mm
0.0059 to 0.0098
in.
0.02
mm
0.0008 in.
0.20
mm
0.0079 in.
0.20
mm
0.0079 in.
0.20
mm
0.0079 in.
-
-
0.15
mm
0.0059 in.
0.50 mm
0.01
97
in.
01
650s
10080
s-10
DIESEL
ENGINE
2402-9
WSM,
02090
Item Factory
Specification
64.000
to
64.01 9
mm
2.51 99
to
2.5204
in.
+
0.5
mm
+
0.01
97
in.
Cylinder Liner I.D.
Oversized Cylinder Liner
1.D.
Allowable Limit
64,169
mm
2.52634
in.
+
0.15
mm
0.0059
in.
(2)
Lubricating System
Oil Pump
At Idle Speed
At Rated Speed
98
kPa
1
.O
kgf/cm2,
14
psi
196.0
to
441
.O
kPa
2.0
to
4.5
kgf/cm2
28.0
to
64.0
psi
Clearance between Inner Rotor and Outer Rotor
-
98
kPa
1
.O
kgf/cm2
14
psi
Clearance between Outer Rotor and Pump Body
End Clearance between Inner Rotor and Cover
0.03
to
0.14
mm
0.0012
to
0.0055
in.
0.07
to
0,15
mm
0.0028
to
0.0059
in.
0.075
to
0.135
mm
0.0029
to
0.0053
in.
01650S10090
-
-
Thermostat's Valve Opening Temperature
Temperature at Which Thermostat Completely Opens
69.5
to
72.5
'C
-
85
'C
-
157.1
to
162.5
'F
01640S10511
Radiator Water Tightness
Radiator Cap Air Leakage
Fan Belt Tension
Water tightness at
-
specified pressure
I57
kPa
1.6
kgf/cm2,
23
psi
10
seconds or more
-
80 3 59
kPa
0.9 + 0.6
kgf/cm2
13 + 9
psi
10
to
12
mm
/
10
kgf
0.394
to
0.472
in.
/
10
kgf
(22.1
Ibs.)
I
I
185
'F
I
4-
s-11
Z402-B
WSM.
02090
DIESEL
ENGINE
~
Factory
specification
(4)
Fuel
System
Injection
Pump
1
item
13.73 to 14.71 MPa
140 to 150 kgf/cm2
1991 to 2133 psi
12.75 MPa
(1 30 kgf/cm2,
1
849 psi),
the valve seat must be
fuel tightness
When the pressure is
Injection Timing
I
-
-
Fuel Titghtness
of
Pump Element
Fuel Tightness of Delivery Valve
0.31 to 0.35 rad. (18
to
20') Before T.D.C.
Allowable
Limit
14.7 MPa
150 kgf/cm2
21 33 psi
5 seconds
14.7
+
13.7 MPa
150
41
40 kgf/cm2
2133
+
1990
psi
Injection
Nozzle
Fuel Injection Pressure
Fuel Titghtness
of
Nozzle Valve Seat
02090S10220
s-I2
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