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

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

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

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

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

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

DIESEL ENGINE

Z402-B

WSM,

02090

the table below.

Service Interval

50

hrs

100

hrs

200

hrs

400

hrs

800

hrs

1000

hrs one year

two

years

Item Every Every Every Every Every Every Every Every

Checking

fuel

pipes and clamps

*

Changing engine oil

T?

Cleaning air filter element

72

Cleaning

fuel

filter element

*

Checking fan belt tension and damage Checking water pipes and clamps

*

Changing oil filter element

Changing fuel filter cartridge

*

Checking valve clearance

a

Changing radiator coolant (L.L.C)

k

Changing air filter element

*

Checking nozzle injection pressure

*

Changing water pipes and clamps

Changing

fuel

pipes and clamps

-

*

a2

a

..

*

a

*

Change engine

oil

and oil cartridge after the first

50

hours

of

operation.

S-13

2402-B

WSM,

02090

DIESE

ENGINE

171

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, wipe

it

clean,

reinsert

it,

and draw

it

out again.

Check to see that the oil level lies between the

two

notches.

3.

If

the level

is

too low, add new oil to the specified level.

0

When using an oil of

different

maker or viscosity from the

previous one, drain old oil. Never mix

two

different types of

oil.

IMPORTANT

01640S10050

Checking and Replenish Cooling Water

1.

Remove the radiator cap and check

to

see that the cooling water

2.

If

low, add clean water and antifreeze.

A

CAUTION

Do

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

0

Be sure to close the radiator cap securely. If the cap is loose or improperly closed, water may leak out and

the

engine could overheat.

Do

not use an antifreeze and scale inhibitor at the same

time.

level is

just

bellow the port.

IMPORTANT

01

64051

0060

s-I

4

DIESEL ENGINE

24024

WSM,

02090

(2)

Check

Point

of

Every

50

Hours

I

01

640F10270

I

P

Checking Fuel Pipe

1.

If

the clamp

(1)

is loose, apply oil to the threads and securely

retighten it.

2.

The fuel pipe

(2)

is

made of rubber and ages regardless of the

period

of

service.

Change the fuel pipe together with the clamp every

two

years.

3.

However,

if

the fuel pipe and clamp are found to be damaged or

deteriorate earlier than two years, then change or remedy.

4.

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

A

CAUTION

Stop the engine when attempting the check and change

(1)

Clamp

(2)

Fuel Pipe

prescribed above.

01640S10070

(When bleeding fuel system)

4

'?.

1.

Fill the fuel tank with fuel, and open the fuel cock

(1).

2.

Loosen the air vent plug

(2)

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.

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

NOTE Always keep the air vent

plug

on the fuel injection pump

closed except when air is vented,

or

it may cause the engine

to

stop.

(1)

FuelCock

(2)

Air

Vent

Plug

0

1640s

IO080

S-15

Z402-8

WShl,

02090

DIESEL

ENGINE

(3)

Check

Points

of

Every

100

Hours

Model

2402-8

IOOOOF10621

Capacity

1.9

L

1.7

IrnD.ats.

2.0

u.s.qts.

lOOOOF10641

OOOOOF10631

Changing Engine OiI

1.

After warming up, stop €he engine.

2.

To

change the used

oil,

remove the drain plug at the bottom of

3.

Reinstall the drain plug.

4.

Fill the new oil up to the upper notch on the dipstick.

0

Engine

oil

should

be

MIL-L-46152 / MIL-L-2104C

or

have

0

Change the type of engine according to the ambient

the engine and drain

off

the oil completely.

IMPORTANT properties

of

API

classification

CD / CE

grades.

temperature.

.

0

'C

to

25

'C

(32

"F

to

77

OF)

......

SAE 20

or

1

OW-30

Below 0 'C

(32

'F).......................SAE

1OW or 1OW-30

Above

25

"C

(77

OF)

....................

SAE 30

or

1OW-30

02090510230

Checking Fan Belt Tension

1.

Press the fan belt between fan pulley and pulley at force of 98

N

(10

kgf, 22 Ibs).

Check

if

the fan belt deflection is

10

to 12 mm (0.394 to 0.472 in.).

2.

If

the deflection is not within the factory specifications, adjust

with the tension pulley adjusting bolts.

(A)

Good

(B)

Bad

01640510170

Fan Belt Damage and Wear

1.

Check the fan belt for damage.

2. Check

if

the fan belt is worn and sunk in the pulley groove.

3.

Replace the fan belt

if

the belt is damaged or nearly worn out

and deeply sunk in the pulley groove.

00000510462

S-1

6

DIESEL ENGINE

240243

WSM,

02090

131640F10280

Cleaning Fuel Filter

1.

Close the fuel filter cock

(3).

2.

Unscrew the retaining ring

(6)

and remove the 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.

IMPORTANT

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 periodically.

(1)

CockBody

(4)

Filter Element

(2)

Air

Vent

Plug

(3)

Filter

Cock

(6) Retaining Ring

(5)

Filter

Cup

01640S10120

Cleaning Air Cleaner

1.

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

2.

Remove and clean out the dust cup before it becomes half full with dust.

3.

When the air filter element

is

dusty,

clean it.

NOTE

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

Cleaning Air Filter Element

When dry

dust

adheres

02090S10050

Use clean dry compressed air on the inside of the element.

Air

pressure

at

the nozzle must

not

exceed

690

kPa

(7

kgf/cm2,

100

psi).

Maintain reasonable distance between the nozzle and the filter.

0209OS10060

f

S-17

.

2402-8

LVSM,

02090

DIESEL

ENGINE

(4)

Check

Points

of

Every

200

Hours

v

11 650F10080

Checking Radiator

Hoses

(Water Pipes)

1.

Check to see if the water pipes

are

properly fixed every

200

hours

of

operation or every six months.

2.

If

clamp bands are loose or water leaks, tighten bands securely. Replace hoses and tighten clamp bands securely, if radiator hoses are swollen, hardened or cracked.

3.

Replace hoses and clamp bands every 2 years or earlier

if

checked and found that hoses are swollen, hardened or cracked.

02090510070

Changing Engine Oil Filter Cartridge

1.

Remove the oil filter cartridge

(1)

with a filter wrench.

2.

Apply engine oil to the rubber gasket on the new cartridge.

3.

Screw the new cartridge in by hand.

H

NOTE Over-tightening may cause deformation of rubber gasket. After cartridge has been replaced, engine oil normally decreases

a

little.

Check the oil level and add new oil to the specified level.

(1)

Oil

Filter

Cartridge

01

650.51

0440

s-18

DIESEL

ENGINE

2402-B

WSM,

02090

0.145

to 0.185 mm

Valve clearance Factory spec.

0.0059

to 0.0073

in.

I

Number

of

cylinders Valve arrangement Adjustable cylinder

Location

of

piston

(1)

When

No.

1

piston Is at top

Ist

dead center compression 2nd

overlap position 2nd

(1)

When No. 1 piston is at

the

I

ISt

(1)

Punch Mark

(2)

TC

Mark Line

2

cylinder

IN.

Ex

*

(3)

Valve Clearance

01650S10290

S-19

2402-B

WSM.

02090

DIESEL

ENGINE

(6)

Check

Points

of

Every

1000

Hours

A

CAUTION

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.

01640S10160

Checking

Nozzle

Injection Pressure

[

OOOOOF10690

I

01 640F10500

I

[8]

SPECIAL

TOOLS

@e@

)OOOOFOO170

OOOOOFOO14O

1.

Set the injection nozzle to the nozzle tester (Code

No:

07909-

31

361).

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

(1)

until the proper injection pressure is obtained. (See page

S-

55.)

4.

If

the spraying condition is defective, replace the nozzle piece.

(Reference)

Pressure variation with

0.025

mm (0.001 in.) difference

of

adjusting washer thickness.

Approx. 59 kPa (6 kgf/cm2,

85

psi)

(1)

Adjusting

Washer

02090S10080

Flvwheel Puller

Code

No:

0791 6-3201

1

Application: Use to remove the flywheel.

01640S10180

Special-use Puller

Set

Code

No:

0791 6-09032

Application: Use for pulling out bearings, gears and other parts.

01640s70190

s-20

DIESEL

ENGINE

2402-8

WSM,

02090

00000F00240

Valve Seat Cutter Set

Code

No:

07909-331 02

Application: Use

for

correcting valve seats.

01640S10200

Diesel Engine Compression Tester

Code

No:

07909-30207

Application: Use for measureing diesel engine compression

pressure.

01640s10210

Oil

Pressure Teste;

Code

No:

0791 6-32031

Application: Use for measureing lubricating oil pressure.

)00000F00230

I

01640S10220

Connecting

Rod

Alignment

Tool

Code

No:

07909-31661

Application: Use for checking the connecting rod alignment. Applicable range: Connecting rod big end

I.D.

30

to

75

mrn

(1.18

to

2.95

in.dia.). Connecting rod length

65

to

330

mm

(2.56

to

12.99

in.).

00000F00250

01640510230

Press Gauge

Application: Use for checking the oil crearance between crankshaft

and bearing, etc.

Measureing: Green

----

0.025

to

0.076

rnm

range

(0.001

to

0.003

in.)

Red

---I---

0.051

to

0.152

mrn

(0.002

to

0.006

in.)

Blue--------

0.1

02

to

0.229

mm

(0.004

to

0.009

in.)

Code

NO:

07909-30241

01640S10240

s-21

.

H

I

J

2402-8

YJSM,

02090

DIESEL

ENGINE

5

rnrn

(0.197

in.)

6.0

to

6.1

rnrn

dia. (0.236

to

0.240

in.

dia.)

18

rnrn

dia. (0.71

in.

dia.1

~~

00000F10030

Red Check

(Crack

Check

Liquid)

Code

No:

07909-31371

Application:

Use

for

checking cracks

on

cylinder head, cylinder

block, etc.

NOTE

The following special tools are not provided,

so

make them referring to the figure.

D

I-

-.

“I

cI

)11790F00451

I

G

-

k

J

11790F00461

01640810250

01640510910

Valve Guide Replacing

Tool

Application:

Use

to press out and press fit

the valve guide.

I

A

I

20

rnrn

dia. (0.79

in.

dia.)

9.96

to

9.98

rnrn

dia.

lBl

0.3921

to

0.3929

in.

dia.

5.5

to

5.7

rnrn

dia.

IcI

0.21 65

to

0.2244

in.

dia.

41

15

rnrn

(0.59

in.)

I-

~

.-

K

I

10.6

to

10.7

mrn

dia.

(0.417

to

0.421

in.

dia.

L

I

7

rnrn

(0.276

in.)

C1

I

Chamfer 1

.O

rnrn

(0.039

in.)

I

C2

I

Chamfer 2.0

rnm

10.079

in.)

I

1

C0:3

I

Chamfer

0.3

mrn

(0.012

in.)

I1

790600623

S-22

DIESEL ENGINE

2402-6 WSM, 02090

M

N

P

I

8

mrn

(0.31 in.)

4

mm

(0.16 in.)

11.97 to 11.99

mm

dia.

Q

mfl

T

S

R

S

W

17

mm

(0.67

in.)

4

mm

(0.16 in.)

12.00 to 12.02

mm

dia.

1790F00500

I

U

V

Injection

Pump

Pressure Tester

Application: Use to check fuel tightness

of

injection

pumps.

I

A

I

29.4 MPa (300 knf/cm2, 4267 psi)

Pressure gauge

full

scale : More than

(0.4724 to 0.4732 in. dia.) 100

mm

(3.94

in.)

M12xP1.5

I

B

I

Comeraasket

I

C

D

I

Flange (Material : Steel)

I

Hex. nut 27

mm

(1.06 in.) across the plat

E

I

Injection pipe

F

I

PF 112

1

5

mm

(0.20 in.)

I

17

mm

dia.

(0.67

in. dia.)

8

mm

dia. (0.31 in.

dia.)

1

.O

mm

(0.039 in.)

17

mm

dia. 10.67 in. dia.)

6.1

0

to

6.20

mm

dia.

1

I

10.2402

to

0.2441

in. diaJ

I

(0.4713 to 0.4721 in.

dia.)

U

P

I

PFW2

I

Q

I

23mm

(0.91

in.)

I

a I Adhesive aoolication

I

b

I

Fillet welding on the enter circumference

1

1179060081

1

.

S-23

B

C

-

c

Z402-B

WSM,

02090

DIESEL

ENGINE

A

B

C

A

-

145

rnrn

(5.71 in.)

20

rnrn

(0.79 in.)

100

rnrn

(3.94 in.)

E

F

a

b

:I:

F

E

11790F00490

19.90

to

19.95

rnrn

(0.7835

to

0.7854 in.)

21 -90

to

21 -95

rnrn

(0.8622

to

0.8642 in.)

DIA.

25

rnrn

(0.98 in.)

6.3

prn

(250 pin.)

6.3

urn

1250 uin.)

A

B

C

150

rnrn

(5.91 in.)

20

rnrn

(0.79 in.)

100

rnrn

13.94 in.)

E

F

a

b

19.90

to

19.95

rnrn

(0.7835

to

0.7854 in.)

21.90

to

21.95

rnrn

(0.8622

to

0.8642 in.)

DIA.

25

rnrn

(0.98 in.)

6.3

prn

(250 pin.)

6.3

urn

(250 uin.1

11900G00442

Flywheel

Stopper

Application: Use

to

loosen and tighten the

flywheel screw.

A

B

C

200

rnrn

(7.87 in.)

30

rnrn

(1.18 in.)

20

rnrn

(0.79 in.)

I

D

I

15

rnrn

10.59 in.)

I

E F

G

15mrn (0.59 in.)

8

rnrn

(0.31 in.)

10

rnrn

DIA.

(0.39 in.

DIA.)

11

790G00801

S-24

DIESEL

ENGINE

2402-B

WSM,

02090

A

B

C

A

-,D

,_

E

130

mm

(5.12 in.)

72

rnrn

(2.83 in.)

1.57

rad.

(40')

Crankshaft Bearing 1 Replacing

Tool

Application:

Use to press

out

and

to

press

fit

the crankshaft bearing

1.

[Press

Out]

E

F

G

,

A

B

I

135

mrn

(5.31 in.)

I

72

mrn

(2.83 in.)

24

rnrn

(0.95 in.)

20

mm

dia.

(0.79

in.

dia.)

68

mrn

dia.

(2.68

in.

dia.)

39.90

to

39.95

mm

dia.

I

C

I

1.57

rad.

(40'1

I

1

i

1

10

mrn

(0.39

in.)

1

22

mrn

(0.87 in.)

20

rnrn

(0.79 in.)

48.90

to

48.95

rnm

dia.

(1.9251

to

1.9271

in.

dia.)

43.90

to

43.95

rnrn

dia.

I

11.7283

to

1.7303

in.

dia.)

I

[Press

Fit]

I

D

I

9

mm

10.35

in.)

I

c

I

(1 3709

to

1.5728

in.

dia.)

n

I

1

7900600452

S-25

2402-8

VWA,

02090

DIESEL

ENGINE

10

ENGINE

BODY

CHECKING

AND

ADJUSTING

Compression Pressure

1.

After warming up the engine, stop

it

and remove the air cleaner,

the muffler and all nozzle holders.

2.

Install a compression tester (Code

No:

07909-30204)

for diesel

engines to nozzle holder hole.

3.

After making sure that the speed control lever is set at the stop

position (Non-injection), run the engine at

200

to

300

rpm with

the starter.

4.

Read the maximum pressure. Measure the pressure more than

twice.

5.

If

the measurement is below the allowable limit, check the

cylinder, piston ring, top clearance, valve and cylinder head.

6.

If

the measurement is below the allowable limit, apply a small

amount

of

oil to the cylinder wall through the nozzle hole and

measure the compression pressure again.

7.

If

the compression pressure is still less than the allowable limit,

check the top clearance, valve and cylinder head.

8.

If

the compression pressure increases after applying oil, check

the cylinder wall and piston rings.

NOTE

clearance.

Check the compression pressure with the specified valve

Always use a fully charged battery for performing this test.

Variances in cylinder compression values should be under

10

Yo.

Factory spec.

29

to

33

kgf/cm2

2.26

MPa

327

psi

Compression pressure

Allowable limit

23

kgf/cm2

02090510090

S-26

DIESEL

ENGINE

2402-8

WSM,

02090

(3

@

=

OOOOOF10510

OOOOOF10520

Top Clearance

1.

Remove the cylinder head (remove the cylinder head gasket

completely).

2.

Bring the piston to its top dead center fasten

1.5

mm dia. 5 to

7

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

so

as to avoid the intake and exhaust valves and the combustion

chamber ports.

3.

Bring the piston to its middle position, install the cylinder head, and tighten the cylinder head bolts to specification. (Head gasket must be changed to new one.)

4.

Turn the crank shaft until the piston exceeds its top dead center.

5.

Remove the cylinder head, and measure squeezed fuse wires

for thickness.

6.

If

the measurement is not within the specified value, check the oil

clearance

of

the crankpin journal and the piston pin.

0.50

to

0.70

mm

0.0197

to

0.0276

in.

37.2

to

42.1

Nam

Factory spec.

Top

clearance

Cylinder head mounting

to

4.3

kgf.m

lightening torque

bolts

27.5

to

31.1

ft-lbs

(1)

Fuse

Draining Cooling Water and Engine

Oil

A

CAUTION

Never remove radiator cap until cooling water 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 cooling water.

2.

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

01640S10290

121

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.

Alternator and Fan Belt

1.

Remove the alternator.

2.

Remove the fan belt.

(When reassembling)

Check

to

see that there are no cracks on the belt surface.

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

02090s10100

01640S10300

S-27

24024

VJSM,

02090

DIESEL

ENGINE

[3I

CYLINDER HEAD AND VALVES

NonIe Holder Assembly

1

Loosen the screws on the pipe clamps.

2.

Remove the injection pipes.

3.

Remove the fuel overflow pipes.

4.

Loosen the lock nuts, and remove the nozzle holder assemblies.

5.

Remove the copper gaskets on the seats.

(1)

Nozzle Holder Assembly

01640510321

Cylinder Head Cover

1.

Remove the head cover cap nuts.

2.

Remove the cylinder head cover

(1).

(When reassembling)

0

Check to see

if

the cylinder head cover gasket is not defective.

(1)

Head Cover

01640S10331

Rocker Arm and Push Rod

1.

Remove the rocker arm bracket mounting nuts.

2.

Detach the rocker arm

as

a unit.

3.

Remove the push rods.

H

IMPORTANT

0

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

(When reassembling)

0

When putting the push rods onto the tappets, check to see

if

their ends are properly engaged with the grooves.

(1)

Rocker

Arm Assembly

(2)

PushRod

Cylinder Head

1.

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

2.

Remove the cylinder head screws in the order of

(IO)

to

(I),

and

3.

Remove the cylinder head gasket and O-ring.

(When reassembling)

Replace the head gasket with a new one.

0

Install the cylinder head, using care not to damage the O-ring.

0

Tighten the cylinder head screwsgradually in the order

of

(1)

to

(1

0)

after applying engine oil.

Retighten the cylinder head screws after running the engine for

30

minutes.

(A) Gear Case Side

11900810062

remove the cylinder head.

(B)

Flywheel Side

11900S10073

S-28

DIESEL ENGINE

2402-8

WSM,

02090

01650P10090

Tappets

1.

Remove the tappets

(1)

from the crankcase.

(When reassembling)

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

Mark the cylinder number to

the

tappets to prevent

(1)

Tappet

IMPORTANT

interchanging.

11900S10082

Valves

1.

Remove the valve cap

(1).

2.

Remove the valve spring collet

(2)

with a valve lifter.

3.

Remove the valve spring retainer

(3),

valve spring

(4)

and valve

(When reassembling)

Wash the valve stem and valve guide hole, and apply engine oil

After installing the valve spring collets, lightly tap the stem to

(1)

Valve Cap

(2)

Valve Spring Collet

(3)

Valve Spring Retainer

(5).

c

sufficiently assure proper fit

with

a

plastic hammer.

(4)

Valve Spring

(5)

Valve

11900510092

S-29

t

Tightening torque

2402-8

VJSi.n,

02080

DlESEL

ENGINE

9.81 to

11

-3 Nm

screw

Injection

and

pump

nut

retaining

.oo

to

.1

kgf.m

7.23 to 7.32

ft-lbS

141

TIMING GEAR AND CAMSHAFT

Tightening torque

01 650P10130

I

Ill

117.6 to 127.4 Nm

12.0

to

13.0 kgfm Crankshaft screw

86.4 to 93.6

ft-lbs

Injection Pump and Speed

Control

Plate

1.

Remove the socket head screws and nuts, and remove the

2.

Remove the screws and separate the speed control plate

(2),

3.

Disconnect the spring

(4)

and remove the speed control plate

(When reassembling)

0

Hook the spring

(4)

to the lever

(5)

first and install the speed

control plate

(2).

0

Be sure to place the copper washers underneath

two

screws

(1).

Position the slot

(9)

on the fork lever just under the slot

(8)

on the

crankcase.

0

Insert the injection pump

so

that the control rod

(7)

should be

pushed by the spring

(6)

at its end and the pin

(10)

on the rod

engages with the slot

(9)

on the fork lever.

injection pump

(3).

taking care not to damage the spring

(4).

(2)

-

W

NOTE

0

The sealant is applied to both sides

of

the

soft

metal gasket

shim. The liquid gasket is not required for assembling.

0

Addition or reduction

of

shim

(0.05

mm,

0.0020

in.) delays or

advances the injection timing by approx.

0.0087

rad

(0.5").

0

In

disassembling and replacing, be sure to use the same

020905101

10

5-30

DIESEL ENGINE

2402-8

WSM,

02090

--%mdr

15020F1

’f

01

650F10090

02090F10090

Gear Case

1.

Unscrew the screw

(2)

and disconnect the start spring

(1)

in the

2.

Remove the gear case.

(When reassembling)

Apply a liquid gasket (Three Bond

1215

or equivalent) to both

Grease thinly to the oil seal, and install it, ensuring the lip does

speed control plate mounting hole.

sides of the gear case gasket.

not

come off.

(1)

Start Spring

(2)

Screw

Idle Gear

01650510320

1.

Remove the external snap ring

(I),

the collar

(2)

and the idle

(When reassembling)

Install the idle gear, aligning the mark

on

the gears referring to

gear

(3).

the figure.

(1)

External Snap Ring

(2)

Idle Gear Collar

(3)

Idle Gear

01650510330

Fuel Camshaft

1.

Remove the screws and draw out the camshaft with the gear on

2.

Remove the retaining plate

(1).

3.

Remove the screws, then draw

out

the injection pump gear

(2)

(When reassembling)

Hook the spring to the fork lever

2

(4)

as shown in the figure

it.

and fuel camshaft

(3)

with the governor fork assembly.

before installing the fork lever assembly to the crankcase.

(1)

Retaining Plate

(2)

Injection Pump Gear

(3)

Fuel Camshaft

(4)

Fork Lever

2

(5)

Fork Lever

1

(6)

Governor Sleeve

02090510200

Oil

Pump and Crankshaft Gear

1.

Unscrew the flange nut

(7)

and remove the oil pump gear

(6).

2.

Unscrew the retaining screws and remove the oil pump

(5).

3.

Remove the collar

(I),

O-ring

(2)

and oil slinger

(3).

4.

Remove the crankshaft gear

(4)

with a puller.

(When reassembling)

0

Install the collar after aligning the marks on the gears. (See the

figure at “Idle Gear”.)

(1)

Crankshaft Collar

(2) O-ring

(3)

Crankshaft Oil Stinger

(4)

Crankshaft Gear

(5)

Oil Pump

(6)

Oil

Pump Gear

(7)

Flange

Nut

01650510350

+

S-31

t

Tightening toque

t

26.5

to

30.4

N.m

2.7

to

3.1

kgfm

Connecting rod screw

19.5

to 22.4

ft-lbs

2402-B

WSM,

02090

DIESEL

ENGINE

151

PISTON

AND

CONNECTlNG

ROD

11

650F10100

uzl

01

650F10110

01650F10120

Oil Pan and

Oil

Strainer

1.

Unscrewthe oil pan mounting screws

(5),

and remove the oil pan

2.

Unscrew the oil strainer mounting screw

(4),

and remove the oil

(3)-

strainer

(2).

(When reassembling)

Install the oil strainer, using care not

to

damage the O-ring

(1).

Using the hole

(6)

numbered

“2”,

install the oil strainer by mounting screw. Apply liquid gasket (Three Bond 1270D or 1270C) to the oil pan as shown in the figure.

IMPORTANT Scape

off

the oil adhesive completely. Wipe the’sealing surface clean using waste cloth soaked with gasoline. Now apply new adhesive

3

-

5

mm 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 bolt hole. Cut the nozzle of the “fluid sealang” container at its second notch. Apply “fluid sealant” about

5

mm 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)

Oil Strainer

(3)

Oil Pan

(4) Screw

(5)

Oil Pan Mounting Screws

(6)

Hole

11900510192

5-32

DIESEL ENGINE

2402-8

WSM,

02090

I

J1650F10130

Piston

1.

Turn the flywheel and bring the No. 1 piston to the top dead

2.

Pull

out the piston upward by lightly tapping it from the bottom

of

(When reassembling)

Before inserting the piston into the cylinder, apply enough engine oil to the cylinder. When inserting the piston into the cylinder, face the mark on the connecting rod to the injection pump.

center. the crankcase with the grip

of

a hammer.

IMPORTANT

Do

not change

the

combination of cylinder and piston.

Make sure of the position of each piston by marking. For

example, mark

“1”

on

the

No.1

piston.

e

When inserting

the

piston into the cylinder, place the gap of

the compression ring

1

on the opposite side of the combustion chamber and stagger the gaps of the compression ring

2

and oil

ring

making a right angle from

the

gap of the compression

ring

1.

Carefully insert the pistons using a piston ring compressor. Otherwise, their chrome-plated section may be scratched, causing trouble inside

the

liner.

!.*

(A)

Top

Ring

Gap

(B)

Second Ring

Gap

(C)

Oil Ring

Gap

(D)

Piston Pin Hole

11900510202

t

s-33

Z4.02-B

WSh4,02090

DIESEL

ENGINE

.

I1

900F10400

I

1900F10410

/"

P

/

11790F10500

I11790F10510

Piston Ring

and

Connecting

Rod

1.

Remove the piston rings using a piston

ring

tool.

2.

Put the casting mark

3.

Remove the piston pin

(l),

and separate the connecting rod

(7)

from the piston

(2).

(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

(IO)

on the opposite side

of

the oil ring gap

(1

1).

Apply engine oil

to

the piston pin.

When installing the piston pin, immerse the piston in

80

"C

(176

OF)

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

(9)

on the connecting rod to the casting mark

(8).

W

IMPORTANT Mark the same number on the connecting

rod

and the

(1) Piston Pin (2) Piston

(8)

Casting Mark

(3)

Piston Pin Snap Ring

(4)

Compression Ring

1

(5) Compression Ring 2

(6)

Oil Ring

(8)

on the piston as shown

in

figure.

piston

so

as

not to change the combination.

(7) Connecting Rod

(9)

Mark

(10)

Expander Joint

(1

1) Oil Ring Gap

(12) Manufacturer's Mark

11900S10211

s-34

DIESEL ENGINE

2402-8 WSM,

02090

[6]

FLYWHEEL

AND CRANKSHAFT

Starter

1.

Remove the starter.

02090S10240

Flywheel

1.

Lock the flywheel not to turn using the flywheel stopper.

2.

Remove the flywheel screws, except for two which must be

3. Set a flywheel puller (Code

No:

07916-32011), and remove the

(When reassembling)

Apply engine

oil

to the flywheel screws.

loosened and left as they are.

flywheel.

01640s10400

Bearing Case Cover and Crankshaft

NOTE Before disassembling, check the side clearance

of

crankshaft. Also check it during reassembly.

1.

Remove the bearing case cover mounting screws.

2.

Remove the bearing case cover.

3. Remove the bearing case screw

2

(5).

4.

Pull

out the crankshaft.

(When reassembling)

IMPORTANT

Install the crankshaft sub assembly, aligning the screw hole

of

main bearing case

2

(2)

with the screw hole of cylinder

block

(1).

Apply engine oil to

the

seat and thread of bearing case

screw

2

(5)

and tightening it.

Install the bearing case cover

(3)

to position the casting

mark

"T'

(4)

on

it

upward.

Tighten the bearing case cover mounting screws with even

force on the diagonal

line.

(I)

Cylinder Block

(2) Main Bearing Case

2

(5)

Bearing Case Screw 2

(3)

Bearing Case Cover

(4)

Top

Mark

'I?'

01650510370

,

s-35

Zm-8

WSM,

02090

DIESEL

ENGINE

~~

SERVICING

[I]

CYLINDER HEAD

01650F10150

I

OOOOOF1OOZO

Main Bearing Case Assembly

1.

Remove the

tv~o

main bearing case screws

I,

and remove

the

main bearing case assembly

1

(2),

being careful crankshaft

bearing

2.

Remove the main bearing case assemblies

(1).

(When reassembling)

Clean the oil passage

in

the main bearing case.

Apply clean engine oil on the crankshaft bearing 2 and main When installing the main bearing case assemblies

1,

face the

(1)

Main Bearing

Case

Assembly

bearing case assembly

1.

mark

“FLYWHEEL”

to

the flywheel.

(2)

Main Bearing Case

Assembly

1

01

650S10380

Cylinder Head Surface Flatness

1.

Thoroughly clean the cylinder head surface.

2.

Place a straightedge on the cylinder head’s four sides and two

diagonal as shown in the figure.

Measure the clearance with a feeler gauge.

surface grinder.

3.

If

the measurement exceeds the allowable limit, correct it with a

IMPORTANT Do

not place the straight edge on the combustion chamber.

Be sure to check the valve recessing after correcting.

OOOOOS

100

12

S-36

DIESEL

ENGINE

00000F10030

~00000F10050

I

2402-8

WSM,

02090

Cylinder Head Flaw

1.

Prepare an air spray red check (Code

No.

07909-31371).

2.

Clean the surface

of

the cylinder head

with

detergent

(2).

3.

Spray the cylinder head surface

with

the red permeative

liquid

4.

Wash away the red permeative

liquid

on the cylinder head

5.

Spray

the

cylinder head surface

with

white developer

(3).

6.

If

flawed,

it

can be identified as red marks.

(1)

Red Permeative Liquid

(3)

White Developer

(2)

Detergent

Valve Recessing

1.

Clean

the

cylinder head,

the

valve face and 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.

If

it

still

exceeds the allowable

limit

after replacing the valve,

correct

the

valve seat face of the cylinder head

with

a valve seat

cutter (Code

No.

07909-331

02)

or valve seat grinder.

Then, correct the cylinder head surface

with

a surface grinder,

or

replace the cylinder head.

(1).

Leave

it

five

to

ten

minutes

after spraying.

surface

with

the detergent

(2).

00000s10020

OOOOOS10032

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.

of

the

cylinder head at the most

wear pari as

shown

in

the

figure below

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.

00000510042

.

s-37

2402-B

k~~S~I,U2090

DIESEL ENGINE

Valve face angle

Valve Seating

I,

Coat the valve face lightly

with

Prussian blue and put the valve

on

its

seat to check the contact.

2.

If the valve does not seat all the way around the valve seat or the

valve contact is

less

than

70

%,

correct the valve seating as

follows.

3.

If

the valve contact does not comply with the reference value,

replace the valve or correct the contact

of

valve seating.

(1)

Correct

(3)

Incorrect

(2)

Incorrect

11

790F10450

0.79 rad.

45.0'

Factory spec.

0

11

790F10460

~00000F10090

I

7-

I

0.26

rad.

(1

5')

0.79

rad.

(45')

I

A

B

I

C

I

11790S10230

Correcting Valve and Valve Seat

NOTE

Before correcting the valve and seat, check the valve stem and the

I.D.

of the valve guide section, and repair them

if

necessary.

After correcting the valve seat,

be

sure to check the valve

recessing.

1)

Correcting Valve

1.

Correct the valve with a valve refacer.

I

0.79 rad.

I

Valveseatangle

I

Factoryspec.

I

(a)

Identical Dimensions

(b) Valve

Seat

Width

(A)

Check Contact

(B)

Correct Seat Width

(C)

Check Contact

0165OS10390

5-38

DIESEL ENGINE

Z402-B

WSM,

02090

Valve Lapping

1.

Apply compound evenly to the valve lapping surface.

2.

Insert the valve into the valve guide. Lap the valve onto its seat

3.

After lapping the valve, wash the compound away and apply oil,

4.

Apply Prussian blue to the contact surface to check the seated

I

IMPORTANT When valve lapping is performed, be sure to check the valve recessing and adjust the valve clearance after assembling

with a valve flapper or screwdriver. then repeat valve lapping with

oil.

rate,

If

it is less than

70

%,

repeat valve lapping again.

[00000F10120

L

OOOOOFl

01

30

the valve.

00000S70060

Replacing Valve Guide (When removing)

1.

Using a valve guide replacing tool (see page

5-22),

press out the

(When installing)

1.

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

2.

Using a valve guide replacing tool, press

in

a new valve guide

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

3.

Ream precisely the

I.D.

of the valve guide to the specified

dimension.

I

IMPORTANT

0

Do

not hit the valve guide with a hammer, etc. during

replacement.

(A)

When Removing

used valve guide.

(6)

When Installing

02090S70720

Free Length and Tilt

of

Valve Spring

1.

Measure the free length

(A)

with vernier calipers.

If

the

measurement is less than the allowable limit, replace

it.

2.

Put the spring on a surface plate, place a square

on

the side

of

the spring, and check to see

if

the entire side

is

in

contact with

the square. Rotate the spring and measure the maximum

(B).

If

the measurement exceeds the allowable limit, replace.

3.

Check the entire surface

of

the spring for scratches. Replac it,

if

any.

OOOOOS10082

Valve Spring Setting

Load

1.

Place the valve spring

on

a tester and compress it to the same

2.

Read the compression load on the gauge.

3.

If

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

length it is actually compressed

in

the engine.

00000S70092

.

s-39

2402-B

WSM.

02090

DIESEL

ENGINE

1dOOOOF10140

IOOOOOF10150

Oil

Clearance between Rocker

Arm

Shaft

and

Beraing

I.

Measure the rocker arm beating

I.D.

tyith

an

inside micrometer.

2.

Measure the rocker arm shaft

O.D.

with an outside micrometer,

and then calculate the

oil

Clearance.

3.

If

the clearance exceeds the allowable limit, replace the rocker

arm and measure the oil clearance again.

If

it still exceeds the

allowable limit, replace also the rocker arm shaft.

00000s10102

Push

Rod Alignment

1.

Check the both end

of

the push rod for cracks, damage and

2.

Measure the bending of the push rod with a dial indicator.

3.

If

the measurement exceeds the allowable limit, replace the push

unusual wear.

rod.

00000s10111

Oil

Clearance between Tappet and Tappet Guide Bore

1.

Measure the tappet

O.D.

with an outside micrometer

2.

Measure the

I.D.

of

the tappet guide bore with a cylinder gauge,

3.

If

the oil clearance exceeds the allowable limit

or

the tappet is

and calculate the oil clearance. damaged, replace the tappet.

[2]

TIMING GEAR AND CAMSHAFT

OOOOOS10123

Timing Gear Backlash

1.

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

2.

Move the gear to measure the backlash, holding its mating gear.

3.

If

the backlash exceeds the allowable limit, check the oil

4.

If

the oil clearance is proper, replace the gear.

clearance

of

the shafts and the gear.

02090S10130

5-40

DIESEL

ENGINE

2402-6

WSM.

02090

I " I

"Y".

a",

YY

OOOOOF10251

I02090F10030

I1

640F10531

OOOOOFI

01

90

Idle Gear

Side

Clearance

1.

Set a dial indicator with its tip on the idle gear.

2.

Measure the side clearance by moving the idle gear to the front

3.

If

the measurement exceeds the allowable limit, replace the idle

and rear. gear collar.

00000510143

Camshaft Side Clearance

1

Set a dial indicator with its tip on the camshaft.

2.

Measure the side clearance by moving the cam gear to the front

3.

If

the measurement exceeds the allowable limit, replace the

and rear. camshaft stopper.

f

OOOOOS10183

Cam Height

1.

Measure the height

of

the cam at its highest point with an outside

2.

If

the measurement

is

less

than the allowable limit, replace the

micrometer. camshaft.

OOOOOS10203

Oil Clearance

of

Camshaft Journal

1.

Measure the camshaft journal

O.D.

with an outside micrometer

2.

Measure the cylinder block bore

I.D.

for camshaft with an inside

3.

If

the clearance exceeds the allowable limit, replace the

micrometer. Calculate the oil clearance.

camshaft.

02090S10140

Oil Clearance between Idle Gear Shaft and Idle Gear Bushing

1.

Measure the idle gear shaft

O.D.

with an outside micrometer.

2.

Measure the idle gear bushings

1.D.

with an inside micrometer,

3,

If

the oil clearance exceeds the allowable limit, replace the

and calculate the oil clearance, bushing.

00000510152

S-41

*

DIESEL

ENGINE

2402-8

WSF.4.02090

1

Replacing Idle Gear Bushing

(A)

(When removing)

1.

Using

an

idle gear bushing replacing

tool

(see page

S-24),

press

out

the

used bushing.

(B) (When installing)

1.

Clean a new idle gear bushing and idle gear bore, and apply

engine oil

to

them.

2.

Using an idle gear bushing replacing tool, press

in

a new

bushing (service parts)

to

the specified dimension. (See figure.)

02090510150

[3]

PISTON

AND

CONNECTING

ROD

OOOOOF10260

000

Piston Pin Bore

I.D.

1.

Measure the piston pin bore

I.D.

in both the horizontal and

2.

If

the measurement exceeds the allowable limit, replace the

vertical directions with a cylinder gauge. piston.

00000510212

Oil Clearance between Piston Pin and

Small

End Bushing

1.

Measure the

O.D.

of the piston pin where it contacts the bushing

2.

Measure the I.D. of the piston pin bushing at the connecting rod

with an outside micrometer. small end with a cylilnder gauge.

Calculate the oil clearance.

If

it still exceeds the allowable limit, replace the piston pin.

3.

If

the clearance exceeds the allowable limit, replace the bushing.

00000510222

c

DIESEL ENGINE

2402-8

WSM,

02090

..

~0000Fl0280

IOOOOF10740

I

Replacing Small End Bushing (When removing)

1.

Press out the used bushing using a small end bushing replacing

(When installing)

1.

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

them.

2.

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

so

that the seam

(1)

of

bushing positions as shown in the figure,

until it is flash with the connecting rod.

3.

Drill a hole to the bushing with aligning the oil hole

(2)

of

connecting rod using

3.5

mm

dia.

(0.1

38

in.

dia.) drill.

4

NOTE Be sure

to

chamfer the

oil

hole circumference with an oil

stone.

(1)

Seam

(A)

When Removing

(2)

Oil

Hole

tool.

(B)

When Installing

00000S10232

Piston

Ring

Gap

1.

Insert the piston ring into the lower part of the liner (the least

2.

Measure the ring gap with a feeler gauge.

3.

If

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

worn

out part) with the piston.

02090S10160

s-43

DIESEL

ENGINE

2402-8

WSM,

02090

00000F10300

b

Clearance between Piston Ring

and

Groove

1.

Remove carbon

from

the ring grooves.

2.

Measure the clearance between

the

ring

and the groove

with

a

3.

If

the clearance exceeds allowable limit, replace the ring since

4.

If

the clearance still exceeds the allowable limit after replacing

feeler gauge or depth gauge. compression leak and oil shortage result. the ring, replace the piston.

1

Factory spec

:

A

I

More

than

0.079

Oa2

mm

in.

(A)

Top

Ring

(Key

Stone

Type)

(B)

2nd, Oil Ring

00000510252

Connecting Rod Alignment

NOTE

Since the

I.D.

of

the connecting rod small end bushing

is

the

basis

of

this check, check the bushing

for

wear beforehand.

1.

Remove the crankpin bearing, and install the connecting rod cap.

-

2.

Install the piston pin in the connecting rod.

3.

Install the connecting rod on the connecting rod alignment tool

(Code

No.

07909-31661).

4.

Put a gauge over the piston pin, and move it against the face

plate.

5.

If

the gauge does not fit squarely against the face plate, measure

the space between the pin

of

the gauge and the face plate.

6.

If

the measurement exceeds the allowable limit, replace the

connecting rod.

00000510261

.

DIESEL

ENGINE

[4]

CRANKSHAFT

Oversize

Oe2

mm

0.008

in.

0

2'-

Bearing Code Number Marking

Main bearing case assembly 02 15821-07201 020

OS

I

0.2 mm

Oversize

0.008

in.

2402-5 WSM, 02090

0.4

mm

0.01

6

in.

Crankshaft Side Clearance

1.

Set a dial indicator with its tip on the end of the crankshaft.

2.

Measure the side clearance by moving the crankshaft to the front and rear.

3.

If

the measurement exceeds the allowable limit, replace the main

bearing case assembly.

4.

If

the same size bearing is useless because

of

the crankshaft

journal wear, replace it with an oversize one referring to the table

and figure.

0.15 to

0.25

mm

0.0059 to

0.0098

in.

0.0197 in.

Factory spec.

Allowable limit

Crankshaft side clearance

(Reference)

0

Oversize main bearing case assembly

I

Mainbearingcaseassembly

041

15821-07211

I

0400s

I

-. . . - . .

.

1

I

Oversize dimensions of crankshaft journal

23.40 to 23.45

mm

23.80

to

23.85

mm

0.071

to

0.087 in. radius

I

The

crankshaft journal must be fine-finished

to

higher than

P8-V

VV

.

I

0

1650s

10400

Crankshaft Alignment

1.

Support the crankshaft with V blocks on the surface plate and set a dial indicator with its tip on the intermediate journal at right angle.

2.

Rotate the crankshaft on the V blocks and get the misalignment (half of the measurement).

3.

If

the misalignment exceeds the allowable limit, replace the

crankshaft.

000005

10282

5-45

2402-6

WSM,

02090

DlESEL

ENGINE

Crankpin bearing

I.D.

A

33.995

to

34.010

mm

1.33839

to

1.33898

in.

Factory spec.

Oil Clearance between Crankpin

and

Crankpin Bearing

1.

Clean

the

crankpin and crankpin bearing.

2.

Put

a strip

of

plastigage (Code

No.

07909-30241)

on the center

of the crankpin.

3.

Install the connecting

rod

cap and tighten the connecting rod

screws to the specified torque, and remove the cap again.

4.

Measure the amount of the flattening

MiN7

the scale, and get the

oil clearance.

5.

If the oil clearance exceeds the allowable limit, replace the

crankpin bearing.

6.

If

the same size bearing is useless because

of

the crankpin

wear, replace

it

with an undersize one referring to the table and

figure.

H

NOTE Never insert the plastigage into the crankpin

oil

hole.

Be

sure not to move the crankshaft while the connecting

rod screws are tightened.

2.3

to

2.7

mm

radius

0.091

to

0.106

in.

radius

A

0.019

to

0.081

mm

0.00075

to

0.00319

in.

Oil

clearance

between crankpin and crankpin bearing

Allowable limit

0.0059

in.

2.3

to

2.7

mm

radius

0.091

to

0.106

in. radius

I

Crankpin O.D.

4

mm

radius

0.1

6

in.

radius

33.759

to

33.775

mm

1.32910

to

1.32973

in.

B

C

I

33.959

to

33.975

mm

I

1.33679

to

1.33760

in.

Factory spec.

I

4

mm

radius

0.16

in.

radius

33.559

to

33.575

mm

1.32122

to

1.32185

in.

(Reference)

Undersize crankpin bearing

I

Undersize

I

Bearing

I

Code Number

I

Marking

I

0.2

mm

I

0.008

in.

1

Crankpin bearing

02

I

15861-22971

1,

020us

I

Undersize dimensions of crankpin

I

\Undersize

I

o.2

mm

I

Dimensd

I

O*Oo8

in'

0.4

mm

0.01

6

in.

I

c

I

0.8-S

I

The crankpin

must

be fine-finished

to

higher than

bVd.

00000510322

5-46

DIESEL

ENGINE

2402-B

WSM,

02090

crankshaft journal and crankshaft bearing

1

~00000Fl0~20

I

0.20

mm

0.0079

in.

Allowable limit

U

OOOOOF10430

Crankshaft journal

O.D.

Oil

Clearance between Crankshaft Journal and Crankshaft

Bearing

1

1.

Measure the

O.D.

of

the crankshaft front journal with an outside

micrometer.

2.

Measure the

I.D.

of

the crankshaft bearing

1

with

an inside

micrometer, and calculate the oil clearance.

3.

If

the oil clearance exceeds the allowable limit, replace the

crankshaft bearing

1,

4.

If

the same size bearing is useless because of the crankshaft

journal wear, replace

it

with an undersize one referring to the

table and figure.

39.934 to 39.950

mm

1.57221 to 1.57284 in.

Factory spec.

I

0.034 to 0.106

mm

I

0.0013 to 0.0042 in.

1

Oil clearance between 1 Factory

A

B

C

1.8 to 2.2

mm

radius

0.071 to

0.087

in.radius

5

mm dia.

0.20 in. dia.

39.734 to 39.750

mm

1.56433 to 1.56496 in.

1.8 to

2.2

mm

radius

0.071 to 0.087 in.radius

5

mm

dia.

0.20 in. dia.

39.534

to

39.550 mm

1.55646

to

1.55709

in.

I

39.984 to 40.040 mm

I

1.57148 to 1.57638 in.

I

Crankshaft bearing

1

I.D.

Factory spec.

I

(Reference)

Undersize crankshaft bearing

1

Undersize

I

Bearing CodeNumber

I

Marking

I

Crankshaft bearing 1

15861-23911

I

0.2

mm

I

1

040US

Crankshaft bearing

1

15861-23921

I

0.4

mm

I

0.016

in.

I

04

Undersize dimensions of crankshaft journal

\Undersize

I

o.2

mm

I

0.4mm

0.008

in. 0.016 in.

I

Dimension

(A)

0

to

0.3 mm

I

0

to

0,0118

in.

I

Factory spec.

1

I

(1)

Seam (3) Cyllnder Block

(2) Crankshaft Bearing

1

OOOOOS10341

$47

Z402-B

VJSM,

02090

DIESEL

ENGINE

p

Oil

Clearance between Crankshaft

Journal

and Crankshaft

Bearing

2

and Crankshaft Bearing

3

1.

Put a strip of plastigage (Code

No.

07909-30241) on the center

of the journal.

2.

Install the bearing case and tighten the bearing case screws

1

to

the specified torque, and remove the bearing case again.

3.

Measure the amount of the flattening with the scale, and get the oil clearance.

4.

If

the oil clearance exceeds the allowable limit, replace the

crankshaft bearing

2

or 3.

5.

If

the same size bearing is useless because of the crankshaft

journal wear, replace

it

with an undersize one referring to the

table and figure.

NOTE

0

Be sure not to move the crankshaft while the bearing case

screws

are

tightened.

Oil clearance between Factory spec. 0.0014

to

0.00232 in.

crankshaft journal and 0.20

mm

crankshaft bearing 3 Allowable limit 0.0079 in.

0.028 to 0.059

mm

I

JOOOOF10460

I

39.934

to

39.950

rnm

Crankshaft journal

O.D. Factory

spec.

1.57221 to 1.57284 in.

(Intermediate)

39.978 to 39.993

mm

Crankshaft bearing 3

I.D.

Factory spec. 1.57394 to 1.57453 in.

0.034 to 0.092

mrn

0.20

mrn

0.0079 in.

43.934 to 43.950

mm

1.72969

to

1.73032 in.

43.984 to 44.026

mm

1.731 66 to 1.73331 in.

Oil clearance between Factory spec. 0.00134 to 0.00362 in. crankshaft journal and

crankshaft bearing 2 Allowable limit

Crankshaft journal

O.D.

Factory

spec.

(Flywheel side)

Crankshaft bearing 2

I.D.

Factory spec.

Undersize Bearing Code Number

0.2

mrn

Crankshaft bearing 2 02 15694-23931

o.oo8

in-

Crankshaft bearing 3 02 15861-23861 Crankshaft bearing 2 04 15694-23941

0.4

mm

0.016

in.

Crankshaft bearing 3 04 15861-23871

0.4

mm

0.016 in.

Marking

020

us

020

us

040 US 040

US

1.8

to

2.2

rnm

radius

0.071 to 0.087 in. radius 3

mm

dia

0.12 in. dia

A

B

1.8 to 2.2

rnrn

radius

0.071 to 0.087 in. radius 3

rnm

dia

0.12 in. dia

*The crankpn

journal

must

be fine-finished to higher

than

WW

(0.8

S).

I

02090510250

C

D

S-48

39.534

to

39.550

mrn

1.55646 to 1.55709 in.

43.534 to

43.550

rnm

1.71394to 1.71457 in.

39.734 to 39.750

rnm

1.56433

to

1.56496

in.

43.734 to 43.750

mm

1.72181 to 1.72244 in.

DIESEL ENGINE

2402-8

WSM,

02090

Cyiihnder I.D. Factory spec.

[5]

CYLINDER

64.000

to

64.019

mm

2.51968 to 2.52043

in.

Cylinder Wear

1.

Measure the

I.D.

of the cylinder at the six positions (see figure)

with a cylinder gauge to find the maximum and minimum 1.D.k.

2.

Get the difference (Maximum wear) between the maximum and the minimum I.D.’s.

3.

If

the wear exceeds the allowable limit, bore and hone to the

oversize dimension. (Refer to

“Correcting Cylinder”.)

4.

Visually check the cylinder wall for scratches.

If

deep scratches

are found, the cylinder should be bored. (Refer

to

“Correcting

Cylinder”.)

Cylinder 1.D

64.500

to

64.519

mm

2.5394

to

2.5401

in.

Factory spec.

I

Maximum wear

0.15

mm

I

0.0059

in.

I

Allowable limit

0.15

mm

0.0059

in.

Allowable limit

(A)

TOP

(B)

Middle

(C)

Bottom

(Skirt)

Finishing

(a)

Right-angled to Piston Pin

(b)

Piston Pin Direction

I

Hone

to

1.2

to

2.0

rnR

max.

vvv

(0.000047

to

0.0079

in.R

ma.)

d“‘

Part Name Code Number

Piston

15821-2191

1

Piston

fins

assemblv

15821-21091

01650S10410

Marking

05

OS

05 OS

Correcting Cylinder

1.

When the cvlinder is worn beyond the allowable limit, bore and hone

it

to the specified dimension.

NOTE

When the oversize cylinder

is

worn beyond the allowable

limit, replace the cylinder block with a new one.

(1)

Cylinder

1.0.

(Before

Correction)

(2)

Oversize Cylinder

I.D.

01650510420

s-49

,

Z402-B

LISM,

02090

DIESEL

ENGINE

a

LUBRICATING

SYSTEM

CHECKING

Engine

Oil

Pressure

1.

Remove the

oil

switch and set a pressure tester (Code

No.

2.

Start the engine. Aiter warming up, measure the oil pressure of

3.

If

the oil pressure is less than the allowable limit, check the

0

Engine

oil

insufficient

Oil

pump defective

0

Oil strainer clogged

0

Oil filter cartridge Oil gallery clogged

0

Excessive oil clearance of bearing

0

Foreign matter in the relief valve

(When reassembling)

.

After checking the engine oil pressure, tighten the engine oil

0791

6-32031).

both idling and rated speeds. following.

pressure switch to the specified torque.

02090S10170

SERVICING

[I]

OIL

PUMP

OOOOOF10560

Rotor Lobe Clearance

1.

Measure the clearance between lobes of the inner rotor and the

2.

If

the clearance exceeds the factory specifications, replace the

outer rotor with a feeler gauge. oil pump rotor assembly.

OOOOOS10423

Clearance between Outer Rotor and Pump

Body

1.

Measure the clearance between the outer rotor and the pump

2.

If

the clearance exceeds the factory specifications, replace the

body with a feeler gauge. oil pump rotor assembly.

~OOOOOF10580

I

OOOOOSl0433

s-50

DIESEL

ENGINE

2402-8

WSM,

02090

Clearance between

Rotor

and

Cover

1.

Put a strip of plastigage (Code

No.

07909-30241)

onto the rotor

2.

Install the cover and tighten the screws.

3.

Remove the cover carefully, and measure the amount of the

4.

If

the clearance exceeds the factory specifications, replace

oil

face with grease.

flattening with the scale and get the clearance. pump rotor assembly.

OOOOOS10443

5-51

t

Factory spec.

Thermostat's valve

ooenino temoerature

Z4.02-B

Cn&M,

02090

DIESEL

ENGINE

COOLING

SYSTEM

CHECKING

111

FAN BELT

69.5 to

72.5

'C

157.1

to

162.5

'F

Fan Belt Tension

1.

Press the fan belt between fan pulley and pulley at force of

10

kgf

(98

N,

22

Ibs).

Check

if

the fan belt deflection

is

10

to 12 mm (0.394 to 0.472

in.)

2.

If

the deflection is not within the factory specifications, adjust

with the tension pulley adjusting nut.

OOOOOSl0451

A

CAUTION

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.

01

640S10430

Thermostat Valve Opening Temperature

1.

Push down the thermostat valve and insert a string between the

valve and the valve seat.

2.

Place the thermostat and a thermometer in a container with

water and gradually heat the water.

3.

Hold the string to suspend the thermostat

in

the water. When the water temperature rises, the thermostat valve will open, allowing it to fall down from the string.

Read the temperature at this moment on the thermometer.

valve has risen by about

6

mm (0.236 in.).

4. Continue heating the water and read the temperature when the

5.

If

the measurement is not acceptable, replace the thermostat.

185

'F

thermostat completely

Temperature at which opens

OOOOOS10492

Radiator Water Leakage

1.

Pour a specified amount of water into the radiator.

2.

Set a proper radiator tester and joints.

Increase water pressure to the specified pressure of

157

kPa

(1.6

kgf/cm2, 23 psi).

3.

Check the radiator for water leaks.

4.

When water leakage is excessive, replace the radistor.

If

water

leakage is caused by a small pinhole, correct the radiator with

radistor cement.

00000Sl0472

S-52

2402-8

WSM,

02090

DIESEL ENGINE

Radiator Cap Air Leakage

1. Set a proper radiator tester and an adapter on the radiator cap.

2. Apply the specified pressure of 88.2 kPa

(0.9

kgf/cm2, 12.8 psi),

3.

Check

if

the pressure drop to less than

59

kPa

(0.6

kgf/cm2,

9

4.

If the pressure is less than the factory specification, replace it.

psi) in 10 seconds.

DISASSEMBLING AND

ASSEMBLING

01650F10190

W

111900F10440

I

OOOOOSl0482

Thermostat Assembly

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

2.

Remove the thermostat assembly

(3).

(When reassembling)

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

c"

thermostat cover side of the gasket

(2).

(1)

Thermostat Cover

(3)

Thermostat Assembly

(2)

Thermostat Cover Gasket

1

190051

0271

Water Pump Assembly

1,

Loosen the alternator mounting bolts, and remove the fan belt.

2.

Remove the fan and fan pulley.

3.

Remove the water pump assembly from the gear case cover.

4.

Remove the water pump flange (1).

5.

Press

out

the water pump shaft (2) with the impeller

(5)

on it.

6.

Remove the impeller from the water pump shaft.

7.

Remove the mechanical seal

(4).

(When reassembling)

Apply a liquid gasket (Three Bond 1215 or equivalent)

to

the both sides of gasket. Replace the mechanical seal with new one.

(1)

Water Pump

Flange

(2)

Water Pump Shaft

(3)

Water Pump Body

(4)

Mechanical Seal

(5)

Impeller

5-53

Z4M-B

VfShl,

02090

DIESEL

ENGINE

I

FUEL

SYSTEM

CHECKING AND ADJUSTING

[I1

INJECTION

PUMP

d209OF10100

11790F10470

1

Injection Timing

IMPORTANT

When

inspecting the fuel injection timing, the timing control actuates during starting and the correct fuel injection timing cannot be measured.

1.

Remove the injection pipes.

2.

Set the speed control lever to the maximum fuel discharge

3.

Turn the flywheel until the fuel fills up to the hole of the delivery

4.

Turn the flywheel further to check the injection timing, and stop

5.

Check to see if the mark or punch mark

(2)

on the flywheel is

6.

If

the timing is out of adjustment, readjust the timing with shims.

NOTE

The sealant is applied to both sides of the

soft

metal gasket shim. 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').

0

In

disassembling and replacing, be sure to use the same

number of new gasket shims with the same thickness.

(1)

Delivery Valve Holder

(2)

Punch Mark

(5)

One-hole

:

0.25

mm

(0.0098

in.)

(3)

Timing Mark

position.

valve holder

(1).

turning when the fuel begins to flow over again. aligned with the timing mark

(3).

.

(4)

Two-holes

:

0.20

mrn

(0.0079

in.)

(6)

Without

hole

:

0.30

rnrn

(0.01 18

in.)

02090s10210

Fuel Tightness

of

Pump Element

1.

Remove the injection pipes and glow plugs.

2.

Install the injection pump pressure tester to the injection pump.

3.

Set the speed control lever to the maximum speed position.

4.

Turn the flywheel ten times or more to increase the pressure.

5.

If

the pressure can not reach the allowable limit, replace the

pump element or injection pump assembly.

02090s

101

80

5-54

2402-8

WSM,

02090

DIESEL ENGINE

Fuel Tightness

of

Delivery Valve

1.

Remove the injection pipes and glow plugs.

2.

Set a pressure tester

to

the fuel injection pump.

3. Turn the flywheel and raise the pressure to approx. 14.7 MPa

(150

kgf/cm2, 2133 psi).

4.

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 14.7 to 13.7 MPa (from

150

to 140 kgf/cm2, from 2133 to

1990

psi).

5.

Measure the time needed to decrease the pressure from 14.7 to

13.7 MPa (from 150 to

140

kgf/cm2, from

21

33 to 1990 psi).

6.

If

the measurement

is

less than allowable limit, replace the

delivery valve.

02090510190

pi

INJECTION

NOZZLE

A

CAUTION

0

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.

f

“I

1

I790S10690

Nozzle Injection Pressure

1.

Set the injection nozzle

to

the 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,

disassemble the injecetion nozzle, and change adjusting washer

(1)

until the proper injection pressure is obtained.

...

(Reference)

Pressure variation with

0.025

mm

(0.001

in.)

difference of adjusting washer thickness. Approx. 59 kPa

(6

kgf/cm2,

85

psi)

OOOOOF10690

.....

10000F10680

(1)

Adjusting

Washer

00000510512

Nozzle Spraying Condition

1.

Set the injection nozzle to a nozzle tester (Code

No.

07909-

2.

If

the spraying condition is defective, replace the nozzle piece.

31 361), and check the nozzle spraying condition.

(a)

Good

(b)

Bad

00000S10500

s-55

2402-8

'WSM,

02090

DIESEL

ENGINE

,

,~IOOO0F00270

Valve

Seat

Tightness

1.

Set the injection nouie

to

a

nonIe tester (Code

No.

07909-

2.

Raise the fuel pressure, and keep

at

12.75 MPa (130 kgf/cm2,

3. If any fuel leak

is

found, replace the nozzle piece.

31361). 1849 psi) for 10 seconds.

00000S70521

DISASSEMBLING AND ASSEMBLING

[I]

INJECTION

NOZZLE

I

\

00000F10700

Nozzle Holder

1.

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

2.

Remove the nozzle holder

(I),

and take

out

parts inside.

(When

reassembling)

Assemble the nozzle

in

clean fuel oil.

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

0

After assembling the nozzle, be sure to adjust the fuel injection

pressure.

(1)

Nozzle Holder

(2)

Adjusting Washer

(3)

Nozzle Spring

(4)

Push

Rod

(5)

Distance Piece

(6)

Nozzle Piece

(7) Nozzle Retaining

Nut

OOOOOS10531

S-56

I

EDITOR:

KUBOTA

FARM

&

INDUSTRIAL MACHINERY SERVICE, LTD.

64, ISHIZU-KITAMACHI, SAKAI-CITY,

OSAKA,

JAPAN

PHONE

:

(81)722-41-1129

FAX

:

(81)722-45-2484

E-mail

:

ksos-pub6oa.kubota.co.jp

I

KUBOTA Corporation

Printed

in

Japan

2000.10,

S,

El,

El, e Code

No.97897-02090

2000.09,

S,

El,

EL

e

991

-

49593

Kubota Z402-EB-ONAN-1 Workshop Manual

Specifications and Main Features

Frequently Asked Questions

User Manual