KUBOTA-03-M-E2B KUBOTA-03-M

о ENGINE BASE
ERVICE MAN Us и
KUBOTA a
— 03-M- E2B
REFERENCE ONLY
- FORK LIFT(HDF15-18, -5 SERIES)
TO THE READER
This Workshop Manual has been prepared t to provide servicing personnel with information on the mechanism,
service and maintenance of 03- M- E2B series. ltis divided into three parts, “General”, "Mechanism" and "Servicing".
HB General
Information on the engine identification, the general precautions, maintenance check list, check and maintenance
and special tools are described.
| Mechanism
Information on the construction and function are included. This part should be understood before proceeding with
troubleshooting, disassembling and servicing.
Refer to Diesel Engine Mechanism Workshop Manual (Code No. 97897-01872) for the one which has not been
described to this workshop manual. |
Ш Servicing
Information on the troubleshooting, servicing specification lists, tightening torque, checking and adjusting,
disassembling and assembling, and servicing which cover procedures, precautions, factory specifications and
allowable limits.
All information illustrations and specifications contained in this manual are based on the latest product information
available at the time of publication.
The right is reserved to make changes in all information at any time without notice.
Due to covering many models of this manual, information or picture being used have not been specified as one
model.
February 2004
© KUBOTA Corporation 2004
0000006469E
© instructions and safety regulations before you attempt to repair or use this unit.
03-M-E2B,WSM "SAFETY INSTRUCTIONS —
— SAFETY FIRST
| This symbol, the industry's "Safety Alert Symbol" is used throughout this manual and on labels on the machine. |
‘itself to warn of the possibility of personal injury. Read these instructions carefully. Mi 15 essential that you read the a
A: DANGER
® Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
A WARNING
|e Indicates a potentially hazardous situation which, if not avoided, could result i in 1 death or serious injury.
: A CAUTION
e Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
— [NIMPORTANT |
| ® Indicates that equipment or property damage could result if instructions are > not followed.
и МОТЕ
e Gives helpful information.
a ~~ 0000001386Е
BEFORE SERVICING AND REPAIRING
e Read all instructions and safety instructions in this
manual and on your engine safety decals.
Clean the work area and engine. |
Park the machine on a firm and level ground.
“Allow the engine to cool before proceeding.
‘Stop the engine, and remove the key
Disconnect the battery negative cable
0000001387E
SAFETY STARTING
e Do not start the engine by shorting across starter
terminals or bypassing the safety start switch.
e Unauthorized modifications to the engine may impair
the function and / or safety and affect engine life.
0000001388E
03-M-E2B, WSM
SAFETY INSTRUCTIONS
SAFETY WORKING
e Do not work on the machine while under the
influence of alcohol, medication, or other substances
or while fatigued. -
® Wear close fitting clothing and safety equipment
- appropriate to the job.
® Use tools appropriate to the work. Makeshift tools,
parts, and procedures are not recommended.
® When servicing is performed together by two or
more persons, take care to perform all work safely.
® Do not touch the rotating or hot parts while the
engine is running.
e Never remove the radiator cap while the engine is
running, or immediately after stopping. Otherwise,
~~ hot water will spout out from radiator. Only remove
radiator cap when cool enough to touch with bare
hands. Slowly loosen the cap to first stop to relieve
pressure before removing completely.
® Escaping fluid (fuel or hydraulic oil) under pressure
can penetrate the skin causing serious injury.
Relieve pressure before disconnecting hydraulic or
fuel lines. Tighten all connections before applying
pressure.
® Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable
or uncomfortable loud noises.
0000001389E
AVOID FIRES
e Fuel is extremely flammable and explosive under
certain conditions. Do not smoke or allow flames or
sparks in your working area.
e To avoid sparks from an accidental short circuit,
always disconnect the battery negative cable first
and connect it last.
e Battery gas can explode. Keep sparks and open
flame away from the top of battery, especially when
charging the battery.
® Make sure that no fuel has been spilled on the
engine.
0000001390E
03-M-E2B, WSM
SAFETY INSTRUCTIONS
‚ МЕМТИАТЕ WORK AREA |
e lf the engine must be running to do some work, r make
sure the area is well ventilated. Never run the engine
in a closed area. The exhaust gas contains
poisonous carbon monoxide.
- 0000001391E
DISPOSE OF FLUIDS PROPERLY
e 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. o
0000001393E
PREVENT ACID BURNS
® Sulfuric acid in battery electrolyte is poisonous. It is
strong enough to burn skin, clothing and cause
blindness if splashed into eyes. Keep electrolyte
away from eyes, hands and clothing. if you spill
electrolyte on yourself, flush with water, and get
- medical attention immediately.
0000001392E
PREPARE FOR EMERGENCIES
e Keep a first aid kit and fire extinguisher handy at all
times.
e Keep emergency numbers for doctors, ambulance
service, hospital and fire department near your
telephone.
0000001394E
SPECIFICATIONS |
03- M- E2B, WSM
SPECIFICATIONS
Model — Disoa-m D1703-M D1803-M
Number of Cylinders 3
[Type
Vertical, water- cooled; 4- -cycle IDI diesel € engine
Bore x Stroke
83 х 92.4 mm (3.26 x 3.64 In)
87 x 92.4 mm (3.43 x 3.64 in.)
87 x 102.4 mm (3.43 x 4.04 in.)
| Total Displacement
1499 cm? (91.47 cu.in.)
1647 cm? (100.51 cu.in.) -
1826 cm? (111 43 Cu. in.)
SAE Net Continuous
19.8 kW / 2800 min”? (rpm).
22.4 kW / 2800 min” (rpm)
(30. О НР / 2800 min” (rpm )
23.3 KW / 2600 min 1 (грип) _
(31.2 HP / 2600 пп"?! (rpm))
rpm)
(26.5 HP / 2800 min™* (rpm))
)
)
22.8 kW / 2800 min! (rpm 25.7 kW / 2800 min”! (rpm) 26.9 kW / 2600 min”! (rpm)
SAE Net Intermittent (80.5 HP / 2800 min" (pm) | (34.5 HP /2800 mint (pm) | (36.1 HP / 2600 min“ (rpm)
24.9 kW / 2800 min! (rpm) 27.4 kW / 2800 min” (rom) 28.4 kW / 2600 min” (rpm)
| SAE Gross intermittent (33.4 HP / 2800 min* (rpm). (36.7 HP / 2800 min* (rpm)) | (38.1 HP / 2600 min! (rpm}))
Maximum Bare Speed 3000 min* (rpm) | 2800 min” (pm)
Minimum Idling Speed
750 to 850 min” (rpm)
Combustion Chamber —
Spherical Type (E-TVCS)
Fuel Injection Pump
Bosch Type Mini Pump
(Governor -
"Centrifugal Ball Type, All Speed Mechanical Governor Е
Direction of Rotation
Counter-clockwise (viewed from flywheel side)
| Injection Nozzle
Bosch Throttle Type Mini Nozzle (OPD)
| Injection Timing
0.314 rad (18 °) before T.D.C.
Firing Order
1-2-3
{ Injection Pressure
“13.73 MPa (140 kgf/em?, 1991 psi)
J
| Compression Ratio 23 22.6 23.8
Lubricating System Forced Lubrication by Trochoid Pump
Cooling System Pressurized radiation, forced circulation with water pump
{ Starting System Co | Electric Starting with Starter ) o
o 12 V,1.4 kW | 12V,20KW |
Starting Support Device Pre- -heating by Glow Plug in Combustion Chamber
Battery 12 V, 70 to 80 АН | 12V.100t0120AH
Charging Alternator 12 V, 480 W |
Fuel Diesel Fuel No.2-D or No.2-DLS
Lubricating Oil Better than CD class (API)
| Oil Pan Depth 90 mm 5.6 L (1.48 U.S.gal, 1.23 Imp.gal)
Lubricating Oil (3.54 in.) |
Capacity agony 124 mm 7.0 L (1.85 U.S.gal, 1.54 Imp.gal)
Weight (Dry) BB spec. 148 kg (326.3 Ibs) 151 kg (333 Ibs)
0000006470E
03-M-E2B, WSM
SPECIFICATIONS
V2403-M
Model V2003-M “ V2203-M V2003-M-T
Number of Cylinders 4
Type Vertical, water-cooled, 4-cycle IDI diesel engine
| Bore x Stroke a 5 x 6) 3.49 x se. in) (3.26 x 0 ni а 4.04 in)
Total Displacement (1 21.99 ing (1 3407 ny (1 > 99 ing (1 pe cuna
26.4 kW / 29.8 kW / 35.8 kW / 31.1 kW/
SAE Not Cots mom | ac (re) | omen | 2000 mer (om
2800 min (rpm)) 2800 min (rpm)) 2800 min (rpm) 2600 min! (rpm))
30.4 KW / 34.3 KW / 41.0 KW/ 35.8 KW/
| SAE Net Intermitent age | aeons | Zesower | moMPr
2800 min” (rpm)) 2800 min” (rpm)) 2800 min” (rpm)) 2600 min”! (rpm))
33.2 КМУ / 36.4 kW / 44.0 kW / 38.0 KW /
SAE Gross Intermitent ano | ener | ouer | OMR
| 2800 min“ (rpm)) 2800 min (rpm)) 2800 min (rpm)) 2600 min* (rpm))
Maximum Bare Speed 3000 min” (rpm) | 2800 min (rpm)
Minimum Idling Speed 750 to 850 min (rpm) | 850 to 950 min” (rpm) 750 to 850 min (rpm) -
Combustion Chamber Spherical Type (E-TVCS) |
| Fuel Injection Pump Bosch Type Mini Pump
Governor Centrifugal Ball Type, All Speed Mechanical Governor
[ Direction of Rotation Counter-clockwise (viewed from flywheel side)
Injection Nozzle Bosch Throttle Type Mini Nozzle (OPD)
Injection Timing 0.314 rad (18 °) before T.D.C.
Firing Order 1-3-2-4
Injection Pressure 13.73 MPa (140 kgffcm?, 1991 psi)
Compression Ratio 23 | 22.6 22.0 23.8
Lubricating System
Forced Lubrication by Trochoid Pump
Cooiing Sysiem
Pressurized radiation, forced circulation with water pum
y
Electric Starting with Starter
Starting System
| 12 V, 1.4 KW 12 V, 2.0 kW
Starting Support Device Pre-heating by Glow Plug in Combustion Chamber
Battery 12 V, 100 to 120 AH
Charging Alternator
12 V, 480 W
Fuel Diesel Fuel No.2-D or No.2-DLS
Lubricating Oil Better than CD class (API)
a Ed Depth 90 mm 7.6 L (2.01 U.S.gal, 1.67 Imp.gal)
Lubricating Oil | (3-54 in.)
Capacity Oil Pan Depth 124 mm
(4.88 in.) 9.5 L (2.51 U.S.gal, 2.09 Imp.gal)
Weight (Dry) BB spec. 180 kg (397 Ibs) 186 kg (410 Ibs) 184 kg (406 Ibs)
0000006471E
03ME2B.WSM В ~~ DIMENSIONS
DIMENSIONS
3EEADACFPOC1A
— D1503-M D1703-M | D1803-M
А | 572.1 mm(22.5in.) | 572.1 тт (22.5 п.) | 575.9 тт (22.7 in.)
| 507.1 тт (20.0 п.) | 507.1 mm (20.0in) | 499.0 mm (19.6 in.)
с | 6433mm(253in) | 643.3 mm (25.3 in.) | 685.0 mm (27.0 in.)
©
0000006472E
03-M-E2B, WSM
DIMENSIONS
А
=
2 |
О
д
00)
О
:
E
3EEADACFPOO2A
V2003-M
” V2203-M
V2003-M-T
V2403-M |
667.1 mm (26.3 in.)
667.1 mm (26.3 in.)
667.1 mm (26.3 in.)
670.9 mm (26.4 in.)
wo
507.1 mm (20.0 in.)
507.1 mm (20.0 in.)
507.1 mm (20.0 in.)
© 499.0 mm (19.6 in.)
635.0 тт (25.0 т.) |
635.0 mm (25.0 in.)
698.3 mm (27.5 in.) |
‚ 684.5 mm (26.9 in.) |
0000006473E
“CONTENTS _
1. ENGINE IDENTIFICATION . O HERE MG
[1] MODEL NAME AND ENGINE SERIAL NUMBER......... e e
[2] E2B ENGINE ................. ee HC
[3] CYLINDER NUMBER east ee e
2. GENERAL PRECAUTION ................eeeceemeeeenenenn e enanas. GB
3. MAINTENANCE CHECK LIST ............—..—.e..ereei enarenerenDe GA
4. CHECK AND MAINTENANCE .……….….……….……ercrccreacerenrernenceneencereenes ee anne …G6
[1] DAILY CHECK POINTS.….……..….….….……cirreerseeneenees eee eee GB
[2] CHECK POINTS OF EVERY 50 HOURS TT ee Bee EEE G8
[3] CHECK POINTS OF EVERY 100 HOURS ee ..... G-9
[4] CHECK POINTS OF EVERY 150 HOURS..…………………….…icrenenmensenennennnnnns G-11
[5] CHECK POINTS OF EVERY 200 HOURS ….……….…….……seecereerennnsenmennnsnn …G-12
[6] CHECK POINTS OF EVERY 300 HOURS ……………………….….…...…-.riscccsrerescennnensennennenn …G-13
7] CHECK POINTS OF EVERY 400 HOURS ars GT
[8] CHECK POINTS OF EVERY 500 HOURS……….……………………ceeieerrenceenenennennnentennenn G-15
[9] CHECK POINTS OF EVERY 1 OR 2 MONTHS.........….isssssseeeenenniencennennennencen G-17
[10] CHECK POINTS OF EVERY YEAR........... ee 6-19 |
[11] CHECK POINTS OF EVERY 800 HOURS................... AA tener bere G-20
[12] CHECK POINTS OF EVERY 1500 HOURS.………….….……srrrsremenrenmencnnennenmnnenennG=21
[13] CHECK POINTS OF EVERY 2 YEARS...………….….…ceererenmennnnnenmnnnnnnnnnnnnG-tr -
5, SPECIAL TOOLS …….…..…......……rirsscrsrensrasenserarencenmecenneense eeriaveareecerioonnenecas ID €
—osMEZO, SM GENERAL
A. ENGINE IDENTIFICATION
[11 MODEL NAME AND ENGINE SERIAL NUMBER
When contacting the manufacture, always ресйу у your engine Ш
model name and serial number, |
The engine model and its serial number need to be. o identified
before the engine can be serviced or parts replaced. a
Mm Engine Serial Number
The engine serial number is an identified number for the
engine. It is marked after the engine model number. |
It indicates month and year of manufacture as follows.
e Year of manufacture |
3EEADAAT РООЗА a Alphabetor | уваг Alphabet or Year
Number | ~~. Number | |
7 20 TF | 2015
2 2002 a 2016
3 2003 H 2017
4 2004 J 2018
5 | 2005 K 2019
6 2006 L 2020
7 2007 M 2021
e 2008 N 2022
9 2009 ОР 2023
“A a 2010 R 2024
B 2011 Ts 2025
С 2012 T 2026
D. “2013 v "2027
(1) Engine Model Name and
Serial Number
0000004814E
G-1
- GENERAL
03-M-E2B, WSM
e Month of manufacture о
В Engine Serial Number
Month — —
| 0001 ~ 9999 10000 ~
January A0001 - A9999 B10000 ~
February C0001 ~ C9999 D10000 -
March E0001 - E9999 F10000 ~
April G0001 - G9999 H10000 ~
| "May J0001 ~ J9999 K10000 ~
June L0001 - L9999 M10000 ~
“July N0001 - N9999 P10000 -
August Q0001 - Q9999 R10000 ~
September S0001 ~ 89999 710000 ~
October U0001 ~ U9999 V10000 -
November W0001 ~ W9999 X10000 ~
— December — Yo001 - Y9999 710000 -
e.g. D1803-3A0001
"3" indicates 2003 and "A" indicates January.
So, 3A indicates that the engine v was manufactured on January,
2003.
0000006218E
[2] E28 ENGINE
[ex.: Model Name D1803-M-E2B-XXXX]
The emission controls that have been put into effect in various countries to prevent air pollution will be stepped up.
The time to enforce the regulations differs depending on the engine output classifications. —
‘Kubota has been supplying the diesel engines conforming to the emission regulations in respective
countries.Exhaust emissions regulations shift to the second stage. Kubota executed the improvement of the engine
according to this regulation. |
In order to discriminate the engines conforming to Tier 1 / Phase 1 requirements and those conforming to Tier 2 /
Phase 2 requirements, we have adopted E2B as a new model name for the engines conforming Tier 2 / Phase 2
reguiations.
In the after-sale services for 03-M-E2B series engines, only use the dedicated parts for E2B models and carry out
the maintenance services accordingly.
00000064 74E
[3] CYLINDER NUMBER
The cylinder numbers of KUBOTA diesel engine are designated
as shown in the figure.
The sequence of cylinder numbers is given as No.1, No.2, No.3
and No.4 starting from the gear case side.
0000004816E
3EEABABIPOTÍA
G-2
| 03-M-E28, WSM ‘ В a Ш о о В a GENERAL
2. (GENERAL PRECAUTION
—e 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.
e When special tools are required, use KUBOTA genuine
special tools. Special tools which are not frequently used
should be made according to the drawings provided.
e 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.
(2) ——
Apply grease to new O-rings or oil seals before assembling.
e When reassembling external or internal Snap rings, position
them so that the sharp edge faces against the direction from |
which force is applied. |
| e Be sure to perform run-in the serviced or reassembled engine.
3EEABAB1PO12A ~~ ~~ = ~~ Do not attempt to give heavy load at once, or serious damage
| —. may result to the engine.
oy
(1) Grease (A) External Snap Ring
(2) Force | (B) Internal Snap Ring
(3) Place the Sharp Edge against
‘the Direction of Force
0000001277E
G-3
‘ e Gaskets and O-rings must be replaced during reassembly.
03-M- E28, WSM
GENERAL —
3. MAINTENANCE CHECK LIST
To maintain long- lasting and safe > engine performance, make it a rule to carry out regular inspections by following a
the table below.
‘The lubricating oil change i intervals listed | in the table below are for Classes CF, CE and CD lubricating oils of API
classification with a low-sulfur fuel in use. If the CF-4 or CG-4 lubricating oil is used with a high-sulfur fuel, change
the lubricating oil at shorter intervals than recommended i in the table below depending on the operating condition. |
— Service interval -
G-4
tem 50 [100 [150 | 200 | 300 | 400 | 500 | 1or2 [ 1 [8001500 [ 2
hrs | hrs hrs hrs | hrs | hrs | hrs months | year | hrs | hrs | years
Checking fuel pipes nd clamp bands Yo |
| (1) Oil pan depth | +
| *Changing engine oil (90 mm, 3.54 in.) |
| (depending on the oil pan) (2) Oil pan depth |
(124. mm, 4.88 in.) o
| Cleaning air cleaner element У
Cleaning fuel filter (Normal type) 1 3%
| Checking battery electrolyte level À
Check fan belt tension and damage tx | E
‘Checking radiator hoses and clamp bands —— o À |
| Ш In ) Oil pan depth x
*Replacing oil filter | (90 mm, 3.54 in.)
cartridge (2) oil pan depth x |
(124 mm, 4.88 in.)
| Checking intake air line a +
Replacing fuel filter cartridge Xx
Cleaning fuel tank inside x
Cleaning water jacket and radiator interior | Xx
Replacing fan belt Tw |
| Recharging battery À |
Replacing air cleaner element | | * |
Check ing valve clearance * |
**Checking injection nozzle pressure À
Replacing intake air line Ù
Replacing battery *
Replacing radiator hoses and clamp bands À
| Replacing fuel pipes and clamp bands À
Changing radiator coolant (L.L.C.) À
* Change engine oil and oil filter cartridge after the first 50 hours of operation.
** Maintenance interval as per EPA instructions.
0000006231E
— 03-M-E2B, WSM |
А: CAUTION
® When changing or inspecting, be sure to level and stop the engine.
E NOTE
e Lubricating oi
GENERAL
With the emission control now in effect, the CF-4 and CG-4 lubricating oils have been developed for use of a low-
sulfur fuel on-road vehicle engines. When an off-road vehicle engine runs on a high-sulfur fuel, it is advisable to
employ the CF, CD or CE lubricating oil with a high total base number. If the CF-4 or CG-4 lubricating oil is used
with a high- -sulfur fuel, change the lubricating oil at shorter intervals.
e Lubricating oil recommended when a low-sulfur or high-sulfur fuel is employed.
Fuel
‚| Lubricating. > 05%) | High sulfur Remarks
oil class
CF o O TBN > 10
CF-4 O X
CG-4 О X
O: Recommendable X :
Not recommendable
G-5
0000001294E
| A. CHECK AND MAINTENANCE
[1] DAILY CHECK POINTS
Checking Engine Oil Level
| 1. Level the engine. | o
2. Tochecktheoil level, draw out the dipstick (1), wipe clean,
reinsert it, and draw it out again. | E
Check to see that the oil level lies between the t two notches. |
3. Tf the level is too low, add new oil to the specified level.
| IMPORTANT
e When using an oil of different maker or viscosity from the
previous, drain old oil. Never mix two different types of
Oi 1 |
. INNOTE
SEEADAA1P004D
e Be sure to inspect the engine, locating iton a horizontal o
place. If placed on gradients, accurately, oil quantity may
not be measured.
e Be sure to keep the oil level between upper and lower
limits of the dipstick. Too much oil may cause a drop in
output or excessive blow-by gas. On the closed breather
“type engine in which mist is sucked through port, too --
much oil may caused oil hammer. While too little oil, may
seize the engine's rotating and sliding parts.
(1) Dipstick | (a) Maximum
(b) Minimum
`0000004818Е
G-6
03-M-E2B, WSM
GENERAL
B
3EEABAB1POISD
Checking. and Replenish Coolant
1. Without recovery tank ;
Remove the radiator cap (1) and check to see that the coolant
level is just below the port. |
With recovery tank (2);
— Check to see that the coolant level lies between FULL (A) ano
LOW (B). |
2. If coolant level is too low, check the reason for decreasing
coolant. |
(Case 1)
If coolant is decreasing by evaporation replenish only fresh,
soft water.
(Case 2) -
If coolant is decreasing by leak, replenish coolant of the same
manufacture and type in the specified mixture ratio (fresh, soft —
water and L.L.C.). If the coolant brand cannot be identified,
drain out all of the remaining coolant and refill with a totally
new brand of coolant mix. |
А CAUTION
e Do not remove the radiator cap until coolant temperature
is below its boiling point. Then loosen the cap slightly to
relieve any excess pressure before removing the cap
completely.
H IMPORTANT |
e During filling the coolant, air must be vented from the
engine coolant passages. The air vents by jiggling the
radiator upper and lower hoses.
e Be sure to close the radiator cap securely. If the cap is
loose or improperly closed, coolant may leak out and the
engine could overheat.
e Do not use an antifreeze and scale inhibitor at the same
time. |
e Never mix the different type or brand of L. L. C..
(1) Radiator Cap (A) FULL
(2) Recovery Tank (B) LOW
0000001296Е
G-7
03-M- E2B, WsM В GENERAL
[2] CHECK POINTS OF EVERY 50 HOURS
Checking Fuel Pipe
[A] 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 regardiess of the
period 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.
3EFACAA1P057A
[B] A CAUTION
e Stop the engine when attempting the check and change
prescribed above.
(1) Clamp [A] Cartridge Type
— (2) Fuel Pipe [B] Normal Type
0000006239E
3EEACAA1PO58A
G-8
03-M-E2B, WSM
GENERAL
(When bleeding fuel system) |
SEEACAA1P059D 6.
Hehe
5,
Fill the tank with fuel and open the fuel cock (2). ([B] only)
‘Loosen the air vent plug (1) of the fuel filter a few turns.
Screw back the plug when bubbles do not come up any more.
Tf equipped electrical fuel feed pump, turn the key to AC
_ position and pump the fuel up for 10 to 15 seconds.
If equipped mechanical fuel feed pump, set the stop lever on т
stop position and crank the engine for 10 to 15 seconds.
Open the air vent cock (3) on top of the fuel injection pump.
Close securely the air vent cock after air bleeding.
E NOTE
[B] - a | e Always keep the air vent cock on the fuel injection pump
SEEADAA1 PO0SG
[3] CHECK POINTS OF EVERY 100 HOURS
closed except when air is vented, or it may cause the
-_ engine to stop. |
(1) AirventPluy [A] Cartridge Type
(2) Fuel Cock | [B] Normal Type
(3) Air VentCock .
`0000006240Е
Cleaning Air Cleaner Element
À
2.
Remove the air cleaner element.
Use clean dry compressed air on the inside of the element.
Pressure of compressed air must be under 205 kPa
(2.1 kgf/em”, 30 psi).
Maintain reasonable distance between the nozzle and the
filter.
BH NOTE
e The air cleaner uses a dry element. Never apply oil to it.
e Do not run the engine with filter element removed.
SEEABAB1P020A ® Change the element once a year or every 6th cleaning.
0000001301E
© 03-M-E2B, WSM
GENERAL
SEEABAB1PO23A
A TH...
~~ (2)
SEEABAB1P024A
3EEABAB1P017B
Е Checking Battery Electrolyte
- Cleaning Fuel Filter (Norma Type only)
1. Close the fuel 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 itin the kerosene to rinse.
| 4. After cleaning, reassemble the fuel filter, keeping out dust and В
dit.
5. Bleed the fuel system.
HM IMPORTANT
e If dust and dirt enter the fuel, the fuel injection pump and
injection nozzle will wear quickly. To prevent this, be sure
to clean the fuel filter cup (5) periodically. |
(1) CockBody — (4) Filter Element
(2) Air Vent Plug о (5) Filter Cup
(8) Fuel Cock (6) Retaining Ring
0000006225E
1. Check the battery electrolyte level. | - |
2. If the level is below than lower level line (2), and the distilled
‘water to pour level of each cell. В
(1) Upper Level Line | | (2) Lower Level Line
0000004824E
a Belt Tension | SEN |
. Measure the deflection (A), depressing the belt halfway
between the fan drive pulley and alternator pulley at specified
force (98 N, 10 kgf, 22 Ibs).
2. If the measurement is not within the factory specifications,
loosen the alternator mounting screws and relocate the
alternator to adjust.
17109 mm
Deflection (A) 1 + | Factoryspec. 1 0.28 10 0.35 in.
(A) Deflection
0000004277E
03-M-E2B,WSM | ВЕ - a _ a _ ; GENERAL
— Fan Belt Damage and Wear +
‘ 1. Check the fan belt for damage.
2. Ifthe fan belt is damaged, replace it.
3. Check if the fan belt is worn and sunk in the pulley groove.
| 4. If the fan belt is nearly worn out and deeply sunk | in the pulley |
- groove, replace it. |
(A) Good | ®) Bad
| 0000000920E
3EEABAB1PO1 9A
we
| 3EEABAB1 PO18A
[4] CHECK POINTS OF EVERY 150 HOURS
Changing En ine Oil
1. For 90 mm (3.54 in.) depth oil pan only.
See the "CHECK POINTS OF EVERY 200 HOURS".
0000006244E
“ 03-M-E2B, WSM ) CTT В “GENERAL |
[5] CHECK POINTS OF EVERY 200 HOURS
EE BER “Changing Engine Oil В
A CAUTION
e Besure to stop engine before changing engine oil.
1. Start and warm up the engine for approx. 5 minutes.
2. Place an oil pan underneath the engine. — :
3. To drain the used oil, remove the drain plug (1) at the bottom
‚| of the engine and drain the oil completely. a
4. Screw the drain plug (1). |
5. Fill new oil up to upper line on the dipstick (2).
IMPORTANT |
® When using an oil of different maker or viscosity from the
previous one, remove all of the old oil. |
e Engine oil should have properties of API classification
4 HER ! | a CD/CE/CF/CF-4/CG-4.
Bilge a —— —e Use the proper SAE Engine Oil according to ambient
LR ENS temperature.
| | ` e. o | SAE30 or SAE10W-30
DD Фу | | Авоме 25 с (7% | " SAE1OWAD
3EEADAA1P004B | o e mie. une — | SAE20 or SAE10W-30
0 °C to 25 © (32 F1077 F) SAE1OW-40
o ес SAE10W or SAE10W-30
Below 0 C (32 F) | SAE10W-40
Oil pan depth ВЕ
Models —
: 124 mm (4.88 in.) * 90 mm (3.54 in.)
D1503-M 7.0L | 5.6L
D1703-M | 1.85 U.S.gals 1.48 U.S.gals
D1803-M 1.54 Imp.gals 1.23 Imp.gals
Vom 9.5L 76L
| ал. - 2.51 U.S.gals . | 2.01 U.S.gals
| V2003-M-T 2.09 Imp.gals 1.672 Imp.gals
| V2403-M 57 MP9 DISPO
*90 mm (3.54 in.) oil pan depth is optional.
(1) Drain Plug | a (2) Dipstick
0000006247E
Checking Radiator Hoses and Clamp Bands
1. Check to see if the radiator hoses are properly fixed every 250
hours of operation or every six months, whichever comes first.
2. If the clamp is loose, apply oil to the threads and retighten it
securely.
3. The water hose is made of rubber and tends to age. It must
be replaced every two years. Also replace the clamp and
tighten it securely.
(1) Upper Hose | (2) Lower Hose
SEEABAB1P022A 0000004822E
G-12
03-M-E2B, WSM
GENERAL
3EEABAB1P025A
[6] CHECK POINTS OF EVERY
[7] CHECK POINTS OF EVERY
3EEADAA1P005C
= BE
(1)
SEEACAA1P0578
Checking Intake Air Line
1. Check to see if the intake air hose(s) are properly fixed every
200 hours of operation.
2. If the clamp is loose, apply oil to the threads and retighten it
securely.
3. The intake air hose(s) is made of rubber and tends to age. It
must be change every two years. Also change the clamp and
tighten it securely.
ll IMPORTANT
e To prevent serious damage to the engine, keep out any
dust inside the intake air line.
(1) Intake Air Hose (2) Clamp
ВЕ 0000001304E
300 HOURS. —.—.
Replacing Oil Filter Cartridge (For 90 mm (3.54 in.) Depth Oil Pan)
1. See the "CHECK POINTS OF EVERY 400 HOURS".
0000006254
400 HOURS
Rep lacing Oil Filter Cartridge
à CAUTION
® Be sure to stop the engine before replacing filter
cartridge.
“1. Remove the oil filter cartridge (1) with the filter wrench.
2. Apply a slight coat of oil onto the new cartridge gasket.
3. To install the new cartridge, screw it in by hand. Over
tightening may cause deformation of rubber gasket.
4. After the new cartridge has been replaced, the engine oil
normally decrease a little. Thus see that the engine oil does
not leak through the seal and be sure to read the oil level on
the dipstick. Then, replenish the engine oil up to the specified
level.
IN IMPORTANT
e To prevent serious damage to the engine, replacement
element must be highly efficient. Use only a KUBOTA
genuine filter or its equivalent.
(1) Engine Oil Filter Cartridge
0000001305E
Replacing Fuel Filter Cartridge (Cartridge Type)
Water and dust in fuel are collected in the filter cartridge. So,
change the filter cartridge every 400 hours service.
1. Remove the used filter cartridge with filter wrench.
2. Apply a thin film of fuel to the surface of new filter cartridge
gasket before screwing on.
3. Then tighten enough by hand.
A. Loosen the air vent plug to let the air out.
5. Start engine and check for fuel leakage.
(1) Fuel Filter Cartridge
0000001306E
© 03-M-E2B, WSM GENERAL
1. Close the fuel cock (3). — : |
2. Unscrew the retaining ring (6) and remove the filter cup (5 ),
and rinse the inside with kerosene.
3. Replace the filter element (4).
— 4. Reassemble the fuel filter, keeping out dust and dirt.
—D. Bleed the fuel system.
— > (1) CockBody (4) Filter Element
ES -(6) 1 ° (2) ArrVentPlug 8 (5) Filter Cup
SEEABAB1PO23A о — (3) FuelCock ВЕ — (6) Retaining Ring
0000006258E
03-M-E2B, WSM
GENERAL
[8] CHECK POINTS OF EVERY 500 HOURS
SEEABABIPOI4A UN
SEEADAA1PO05H
(4)
B
SEEABAB1P015C
С
С
leanin: Water Jacket and Radiator Interior
leaning Fuel Tank Inside
0000006260E
A CAUTION |
e Do not remove the radiator cap when the engine is hot.
D wk
о с К ©
‘Then loosen cap slightly to the stop to relieve any excess
pressure before removing cap completely.
. Stop the engine and let cool down.
. To drain the coolant, open the radiator drain plug (2) and
remove the radiator cap (1). Then radiator cap (1) must be
removed to completely drain the coolant. And open the drain
cock (3). ©
After all coolant is drained, close the drain plug.
Fill with clean water and cooling system cleaner.
Follow directions of the cleaner instruction.
After flushing, fill with clean water and anti-freeze until the
_ coolant level is just below the port. Install the radiator cap (1)
8.
9.
securely.
Fill with coolant up to "FULL" (A) mark on the recovery tank
(4).
Start and operate the engine for few minutes.
Stop the engine and let cool. Check coolant level of radiator
and recovery tank (4) and add coolant if necessary.
HW IMPORTANT
Do not start engine without coolant.
Use clean, fresh, soft water and anti-freeze to fill the
radiator and recovery tank.
When the anti-freeze is mixed with fresh, soft water, the
anti-freeze mixing ratio must be less than 50 %.
Securely tighten radiator cap. If the cap is loose or
improperly fitted, water may leak out and the engine could
overheat.
(1) Radiator Cap A: Ful
(2) Drain Plug B: Low
(3) Drain Cock
(4) Recovery Tank
0000001309E
03-M-E2B, WSM
GENERAL
ЗЕЕАВАВ1РОЗЗА
PT
ЗЕЕАВАВ1РО17С
(А)
Anti-Freeze
® There are two types of anti-freeze available: use the
permanent type (PT) for this engine.
® Before adding anti-freeze for the first time, clean the radiator
interior by pouring fresh, soft water and draining it a few times.
e The procedure for mixing water and anti-freeze differs
according to the make of the anti-freeze and the ambient
temperature. Basically, it should be referred to SAE J1034
standard, more specifically also to SAE J814c.
® Mix the anti-freeze with fresh, soft water, and then fill into the
radiator.
E IMPORTANT
e When the anti-freeze is mixed with fresh, soft water, the
anti-freeze mixing ratio must be less than 50 %.
“Vol% Anti: | FreezePoint “| —— Boiling Point” -
freeze °C °F °С | SE
40 -24 12 | 106 222
50 -37 -34 | 108 226
*At 1.013 x 1000000 Pa (760 mmHg) pressure (atmospheric).
A higher boiling point is obtained by using a radiator pressure cap
which permits the development of pressure within the cooling
system.
BM NOTE
e The above data represents industrial standards that
necessitate a minimum glycol content in the concentrated
anti-freeze.
e When the coolant level drops due to evaporation, add
fresh, soft water only to keep the anti-freeze mixing ratio
less than 50 %. In case of leakage, add anti-freeze and
fresh, soft water in the specified mixing ratio.
® Anti-freeze absorbs moisture. Keep unused anti-freeze in
a tightly sealed container. |
o not use radiator cleaning agents when anti-freeze has
been added to the coolant.
(Anti-freeze contains an anti-corrosive agent, which will
react with the radiator cleaning agent forming sludge
which will affect the engine parts.)
0000004828E
Replacing Fan Belt
1. Remove the alternator.
2. Remove the fan belt (1).
3. Replace new fan belt.
4. install the alternator.
5. Check the fan belt tension.
7.0 to 9.0 mm
Deflection (A) Factory spec. AA к!
/ 98 N or 22 lbs
(1) Fan Belt (A) Deflection
0000001310E
G-16
—03- M-E2B, WSM
GENERAL
Lo CHECK POINTS OF EVERY 1 OR 2 MONTHS |
Recharging
A CAUTION
e When the battery is being activated, hydrogen and -
oxygen gases in the battery are extremely explosive.
Keep open sparks and flames away from the battery at all
- times, especially when charging the battery.
e When charging battery, remove battery vent plugs.
® When disconnecting the cable from the battery, start with
the negative terminal first. When connecting the cable to
— the battery, start with the positive terminal first.
e Never check battery charge by placing a metal object
-across the posts. | Co
e Use a voltmeter or hydrometer.
1) Slow Charging
— 1. Add distilled water if the electrolyte level is low. When
charging, the amount of electrolyte should be slightly lower
than the specified level to prevent overflow.
2 Connect the battery to the charging unit, following the
manufacture's instructions. | |
3. As the electrolyte generates gas while charging, remove all
port caps.
4. The electrolyte temperature must not exceed 40 °С (105 °F)
during charging. |
If it exceed 40 °C (1 05 °F) decrease the charging amperage
or stop charging for a while. |
5. When charging several batteries in series, charge at the rate
of the smallest battery in the line.
_—2) Quick Charging a. .
1 Determine the proper charging current and charging time with
the tester attached to the quick charger.
2. Determine the proper charging current as 1/1 of the battery
capacity. If the battery capacity exceeds 50 Ah, consider 50 A
as the maximum.
MM Precaution for Operating a Quick Charger
® Operation with a quick charger differs according to the type.
Consult the instruction manual and use accordingly.
0000004829E
G-17
03-M-E2B, WSM
GENERAL -
3EFABAB1PO35A
Battery Specific Gravity |
1. Check the specific gravity of the electrolyte in each cell with a
hydrometer.
2. When the electrolyte temperature differs from that at which the
hydrometer was calibrated, correct the specific gravity reading
following the formula mentioned | in (Reference). |
3. Ifthe specific gravity is less than 1.215 (after it is corrected for
temperature), charge or replace the battery.
4. If the specific gravity differs between any two cells by more
than 0.05, replace the battery.
EN NOTE
e Hold the hydrometer tube vertical without removing it
from the electrolyte.
e Do not suck too much electrolyte into the tube.
e Allow the float to move freely and hold the hydrometer at
eye level.
® The hydrometer reading must be taken at the highest
I electrolyte level. |
(Reference)
—e Specific gravity slightly varies with temperature. To be exact,
the specific gravity decreases by 0.0007 with an increase of
1 °C (0.0004 with an increase of 1 °F) in temperature, and
increases by 0.0007 with a decreases of 1 °C (0.0004 with a
decrease of 1 °F).
Therefore, using 20 °C (68 °F) as a reference, the specific
gravity reading must be corrected by the following formula :
-Specific gravity а! 20 °С = Measured value + 0.0007 x
(electrolyte temperature - 20 °C)
~ -Specific gravity at 68 °F = Measured value + 0.0004 x
(electrolyte temperature - 68 °F).
Specitic Gravity State of Charge
| 1.260 Sp. Gr. 100 % Charged
1.230 Sp. Gr. 75 % Charged
1.200 Sp. Gr. 50 % Charged
1.170 Sp. Gr. | 25% Charged
1.140 Sp. Gr. Very Little Useful Capacity
1.110 Sp. Gr. - | Discharged
At an electrolyte temperature of 20 °C (68 °F)
0000001142E
GENERAL
-— 03-M-E28,WSM
Directions for Storage
1. When shutting down the tractor for long periods of time,
remove the battery from the tractor, adjust the electrolyte to
the proper level, and after fully charging, store the battery in a
well ventilated placed where it is not exposed to direct
sunlight.
2. Since the battery self- -discharges by approx. 0. 5% per day
even in storage, it must be once > every two months in cold
season.
3. When storaging the battery mounted on the tractor, disconnect
the ground cable from the battery’ 5 negative terminal post.
(Reference)
e Self- -discharge Rate
Temperature |
Self- discharge rate
30 °C (86 °F)
Approx. 1.0 % per day
20 °C (68 °F)
Approx. 0.5 % per day
10°C (50 °F)
| Approx. 025 %perday —__
NOJERECK POINTS OF EVERY YEAR
Replacing Air Cleaner Element
0000001728E
1. See the "CHECK POINTS OF EVERY 100 HOURS".
G-19
0000006262E
03-M-E2B, WSM
GENERAL
[11]CHECK POINTS OF EVERY 800 HOURS
3TMABABOP046C
SEEADAA1P007A
Valve Clearance
M IMPORTANT
e Valve clearance must be checked and adjusted when
engine is coid.
. Remove the head cover. ВЕ
2. Align the "1TC" mark line (3) on the flywheel and projection (2)
on the housing so that the No.1 piston comes to the
compression or overlap top dead center.
. Check the following valve clearance (1) marked with ">" using
a feeler gauge.
. If the clearance is not within the factory specifications, adjust
with the adjusting screw.
‚ | Маме сеагапсе | Factory spec.
0.18 10 0.22 mm
H NOTE
e The "TC" marking line on the flywheel is just for No. 1
cylinder. There is no "TC" marking for the other
cylinders.
No. 1 piston comes to the top dead center position when
the "TC" marking is aligned with the projection (2) in the
window on flywheel-housing. Turn the flywheel 0.26 rad
(15 °) clockwise and counterciockwise to see if the piston
is at the compression top dead center or the overlap
position. Now referring to the table below, readjust the
valve clearance (1). (The piston is at the top dead center
when both the IN. and EX. valves do not move; it is at the
overlap position when both the valves move.)
Finally turn the flywheel 6.28 rad (360 °) and align the "TC"
marking and the projection (2) perfectly. Adjust all the
other valve clearance as required.
After turning the flywheel counterclockwise twice or three
times, recheck the valve clearance (1).
After adjusting the valve clearance (1), firmly tighten the
lock nut of the adjusting screw.
Valve | D1503-M pases mt
arrangement D1703-M 3-
Adjustable D1803-M V2003-M-T
cylinder V2405-M
location of piston IN. EX. IN. EX.
When No. 1 piston i No. 1 À À À À
en No. 1 piston is
compression top dead No.2 x X
No. 4 — —
№. 1
When No. 1 piston is No. 2 À w
overlap position No. 3 + +
No. 4 — — À À
(1) Valve Clearance (3) TC Mark Line
(2) Projection
0000006265E
G-20
03-M-E28, WSM ВЕ GENERAL
[12]CHECK POINTS OF EVERY 1500 HOURS
A CAUTION
® 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.
0000000932E
Fuel Injection Pressure
1. Set the injection nozzle to a nozzle tester.
2. Slowly move the tester handle to measure the pressure at
which fuel begins jetting out from the nozzle.
replace the adjusting washer (1) in the nozzle holder to adjust
See the "Disassembling and Assembling” for nozzle holder.
13.73 to 14.71 MPa
Fuel injection pressure | Factory spec. | 140 t0 150 kgf/em*
| 1991 to 2134 psi
(Reference)
e Pressure variation with 0.01 mm (0. 0004 in.) difference of
adjusting washer thickness.
Approx. 235 kPa (2.4 kgf/cm?, 34 psi)
(1) Adjusting Washer
0000004830E
SEEABAB1P171B
Nozzle Spraying Condition
(a) (b) 1. Set the injection nozzle to a nozzle tester, and check the
nozzle spraying condition.
2. If the spraying condition is defective, replace the nozzle piece.
See the "Disassembling and Assembling" for nozzle holder.
(a) Good (b) Bad
0000004831E
3EEABAB1P037A
G-21
3. If the measurement is not within the factory specifications,
03-M-E2B, WSM a A DIESEL ENGINE
Valve Seat Tightness
~~ a | 1. Set the injection nozzle to a nozzle tester.
О | a 2. Raise the fuel pressure, and keep at 12.75 MPa (130 kaffem®,
qd 849 psi) for 10 seconds.
3.1 any fuel leak is found, replace the nozzle piece.
See the "Disassembling and Assembling" for nozzle holder.
| No fuel leak at
12.75 MPa
130 kgf/cm? |
1849 psi
Valve seat tightness Factory spec.
STLABAB1PO41A
[13]CHECK POINTS OF EVERY 2 YEARS
0000004832E
Replacing Intake Air Line
1. See the "CHECK POINTS OF EVERY 200 HOURS".
0000006271E
Replacing Battery |
| 0000006272Е
Replacing Radiator Hoses and Clamp Bands
1. See the "CHECK POINTS OF EVERY 200 HOURS".
0000006273E
PO Fuel Pipes and Clamp Bands
. See the "CHECK POINTS OF EVERY 50 HOUR <".
0000006275Е
Replacing Radiator Coolant (L.L.C.)
1. See the "CHECK POINTS OF EVERY 500 HOURS".
0000006276E
G-22
03-M-E2B, WSM
— GENERAL
5, SPECIAL TOOLS
(10) (11)
a —e Г |
(3) © © (©) 7 (8) ©)
CHE
3TMABABOPO52A
©
(©)
hr „ | - 3 era
MES | wem (May
——] N— ]— N— A
REAA| (REE | | REZ
el) (ВЫ) |)
3TMABABOPQO59A |
Diesel Engine Compression Tester
Code No :
Application :
(1)
(2)
(3)
(4)
(5)
(6)
Gauge
L Joint
Adaptor À
Adaptor B
Adaptor C
AdaptorE
07909-30208 (Assembly)
07909-30934 (A to F)
07909-31211 (E and F)
07909-31231 (H)
Use to measure diesel engine compression and
diagnostics of need for major overhaul.
07909-31251 (G)
‚07909-31271 (1
07909-31281 (J)
(7 y Adaptor F
(8) Adaptor G
(9) Adaptor H
(10)
(11)
Adaptor |
Adaptor J
0000000680E
Oil Pressure Tester
07916-32032
Code No: |
Application : Use to measure lubricating oil pressure.
(1) Gauge (5) Adaptor2
(2) Cable (6) Adaptor 3
(3) Threaded Joint (7) Adaptor 4
(4) Adaptor 1 (8) Adaptor 5
0000000681 E
Plastigage
Code No: 07909-30241
Application : Use to check the oil clearance between
о ~~ crankshaft and bearing, efc..
Measuring : Green.....0.025 to 0.076 mm (0.001 to 0.003 in. п.)
range Red......... 0.051 to 0.152 mm (0.002 to 0.006 in.)
Blue.........0.102 to 0.229 mm (0.004 to 0.009 in.)
0000000686E
Red Check
Code No: 07909-31371
Application : Use to check cracks on cylinder head, cylinder
G-23
block, etc..
0000000687E
GENERAL
03-M-E2B, WSM
STAAAABOPO29A
NOTE
Connecting Rod Alignment Too!
Code No: 07909-31661
Application : Use to check the connecting rod alignment.
Applicable : Connecting rod big end |.D.
range ~~ 30to 75 mm (1.18 to 2.95 in.) dia.
© Connecting rod length =
65 to 300 mm (2.56 to 11.81 in.)
0000000684
Radiator Tester
Code No: 07909-31551
Application : Use to check of radiator cap pressure, and leaks
from cooling system.
Remarks : Adaptor (1) BANZAI Code No. RCT-2A-30S. |
000000081 5E
e The following special tools are not provided, so make them referring to the figure.
A
3TMABABOPO63A
ны G > = J >
| K
чер — >
NN
NN
И ИИ АН
3TMABABOPO64A
0000002319E
Valve Guide Replacing Tool
Application : Use to press out and press fit the valve guide.
A 20 mm dia. (0.79 in. dia.)
11.7 to 11.9 mm dia. (0.460 to 0.468 in.dia.)
|6-510 6.6 mm día. (0.256 to 0.259 india)
225 mm (8.86 in.)
70 mm (2.76 in.)
45 mm (1.77 in.)
25 mm (0.98 in.)
|| IM O|O| ®
5 mm (0.197 in.) -
6.7 to 7.0 mm dia. (0.263 to 0.275 in.dia.)
20 mm dia. (0.787 in.dia.)
12.5 to 12.8 mm dia. (0.492 to 0.504 in.dia.)
r|x|ie
8.9 to 9.1 mm (0.350 to 0.358 in.)
C1 Chamfer 1.0 mm (0.039 in.)
C2 | Chamfer 2.0 mm (0.079 in.)
C0.3 Chamfer 0.3 mm (0.012 in.)
0000005170E
G-24
03-M-E2B, WSM
GENERAL
‘Bushing Replacing Tools
Application Use to press out and press it the bushing.
For small end bushing
162 mm (6.38 in.)
35 mm (1 -38 in.)
- 27 mm (1.06in.)
| 35 mm dia. (1 381 in. dia)
27. 90 to 27. 951 mm dia. aa 098 to 1.100 in. dia.)
mio Lo
25.00 to 25. 01 mm n dia. (0. 984 to 0. 985 i in. . dia. )
2. _For dle gear bushing
175 mm (6. 89 in.)
40 mm (1.57 in.)
38 mm (1.49 in.)
45 mm dia. (1.77 in. dia.)
| 41 90 to 41.95 mm dia. (1. 650 to 1 652 | in. da)
37.95 to 37.97 mm dia. (1.494 to 1.495 in. dia.)
Flywheel Stopper
0000005172E
Application : Use to loosen and tighten the flywheel screw.
200 mm (7.87 in.)
STMABABOPOS6A
A
я
С
—D
E |
F
BL
cl A
Y AN
20 mm (0.79 in.)
Y |
‘130 mm (1.18 in:
8 mm (0.31 in.)
тп | UI OIM
DÍ | А
STMABABOP0678
G-25
10 mm dia. (0.39 in. dia.)
| 0000000818Е
03-M-E2B, WSM
GENERAL
ul >
Ш:
2 A
‚3TMABABOP068A
Crankshaft Bearing 1 Replacing Tool
Application : Use to press out and press fit the crankshaft |
bearing 1. PR + | |
1. Extracting tool
A
135mm (5.311in)
72 mm (2.83 in.)
B40 mm (R1.57 in.) |
| 10 mm (0.39 in.)
| 20 mm (0.79 in) -—
| 20 mm dia. (0.79 in. dia.)
64.8 to 64.9 mm dia. (2.551 to 2.555 in. dia.)
TI| | mio Of m|
59.8 to 59.9 mm dia. (2.354 to 2.358 in. dia.)
2. Inserting tool —
A
130 mm (5.12 in.)
| 72 mm (2.83 in.) -
R40 mm (R1.57 in) —
9mm (0.35in.)
4 mm (0.16 in.)
| 20 mm (0.79 in)
20 mm dia. (0.79 in. dia.)
т | © | n| m| 0| о| с
68 mm dia. (2.68 in. dia.)
59.8 to 59.9 mm dia. (2.354 to 2.358 in. dia.)
64.8 to 64.9 mm dia. (2.551 to 2.555 in. dia.)
G-26
0000006284E
“ 03-M-E2B, WSM
© GENERAL —
~~ Balancer Metal Replacing Tool (for Removing)
Application:Use to remove the metal bearing.
. 6
LH
| py | A 1
i Nu
== A E F
I Y
TN В 1
I! Y
- 1 | CB
с B с C С
\, — le \, В В
de 4 | | 5 1
А J > K L XX ml |N D
Y | | | | A!
y N Y Ÿ - Y | O
R Ql _P_ .
+ о
S3TMABABOPOGSA
“A | 25mm (0.98 in. dia.) L | 41.934 to 41.950 mm dia. (1.6509 to 1.6516 in. dia.)
B {10mm (0.39 in.) M | 24.959 to 24.980 mm dia. (0.9826 to 0.9835 in. dia.)
C Chamter 0.3 mm (0.01 in.) N 21.947 to 21.960 mm dia. (0.8641 to 0.8646 in. dia.)
D’ |o52rad(30% — “O |28mm(1.10in)
E 46.950 to 46.975 mm dia. (1.8484 to 1.8494 in. dia.) P 29 mm (1.14 in.)
F 43.934 to 43.950 mm dia. (1.7297 to 1.7303 in. dia.) Q 5 mm (0.20 in.)
G |41mm(1.61 in.) | R 136mm (1.42 in.)
H | 32.5 mm (1.28 in.) 5 195.25 to 195.75 mm (7.687 to 7.707 in.)
| 148.5 mm (5.85 in.) T 145 mm (5.71 in.)
J 46.50 to 46.75 mm dia. (1.831 to 1.841 in. dia.) - U 384.75 to 385.25 mm (15.148 to 15.167 in.)
K 44.950 to 44.975 mm dia. (1.7697 to 1.7707 in. dia.)
0000006285E
03-M-E2B, WSM
21.947 to 21.960 mm dia. (0.8641 to 0.8646 in. dia.)
41.934 to 41.950 mm dia. (1.6509 to 1.6516 in. dia.)
24.959 to 24.980 mm dia. {0.9826 to 0.9835 in. dia.)
145 mm (5.71 in.)
8.8 to 9.2 mm (0.346 to 0.362 in.)
195.25 to 195.75 mm (7.687 to 7.707 in.)
25 mm dia. (0.98 in. dia.) _
29 mm (1.14 in.)
GENERAL
Balancer Metal Replacing Tool (for Fitting)
Application:Use to press fit the metal bearing.
Y
Y an Y
Ne
С С VA
k
| 4 ‘ A
maine A SA A 7 | > ZA
L T U L V | W
Y Y .
` LI у y
B B
OL ll T°
a
= X тт Y Ei 2 =
3TMABABOPQ70A
A 0.52 rad (30 °) O 5 mm (0.20 in.)
B 10 mm (0.39 in.) P 3.3 to 3.7 mm (0.130 to 0.146 in.)
С Chamfer 0.3 mm (0.01 in.) Q 43.934 to 43.950 mm dia. (1.7297 to 1.7303 in. dia.)
D 182 mm (7.16 in.) R 140 mm (5.51 in.)
E 140 mm (5.51in.) S 36 mm (1.42 in.)
F 35 mm dia. (1.38 in dia.) T 60 mm dia. (2.36 in. dia.)
G 60 mm dia. (2.36 in dia.) U 46.950 to 46.975 mm dia. (1.8484 to 1.8494 in. dia.)
H | 37 mm (1.46 in.) V 44.950 to 44.975 mm dia. (1.7697 to 1.7707 in. dia.)
i W
X
Y
Z
a
60 mm dia. (2.36 in. dia.)
36 mm (1.42 in.)
Z<|— | |
46.950 to 46.975 mm dia. (1.8484 to 1.8494 in. dia.)
G-28
0000006288E
—
CONTENTS
1. ENGINE BODY ................eeeccovrececenecoeeneeenenenceneascenanrenccean acera rene cenecocaneree cerro ereneenrnenenecennenn. M-1
[1] PISTON ........….………ccrrcesrecrerrerereseeeesrenenen er raensensenener mena sn eee eee resesenene ces ccece nsc MA
[2] BUILT-IN DYNAMIC ‘BALANCER (BALANCER MODEL ONLY)....................... меннее M-1
[3] HALF-FLOATING HEAD COVER ........ccrcrcrccsssensenceenensanneerencasennreanee nes encens peueenonenen …M-2
2. COOLING SYSTEM ........ eee eeeeeeeteeaeeetseeeestesosecessessisesaseessassescueeeecraeiiteeciisieeiaeerntnrarereens M-3
[1] BOTTOM BYPASS SYSTEM perinereovecaenerenmecon. carccc seen esse caraaceess rere rere eee ce... M-3
3. РЫЕ!М_ ЗУЗТЕМ.........ннненннннееееюененеыеееыенееныененыннненннннынннннненннненнннннннннннннннннннннннннннннннсске: М-4
[1] GOVERNOR...............eemeeceneneen een ne eran ereceerenererrencecanereneecnnncecenecaracenacanerner ene neeene M-4
4. ELECTRICAL SYSTEM.............——.cm... Nrnorcceneenenereaneceneenenccanecanare tene aassrece near enean ane n cena M-5
[1] STARTER AUTO REDUCTION UNIT Leen M-5
(1) Сепега!...........еееенннененнененнннненннеенннееененнннннненннннненнннечсеннн оне ченеменееннеНннннНенннкне: M-5
5. TURBOCHARGER SYSTEM ...............eeerececrrenecoreccrevneacecaavanereerenenarenrennrenenaneen nesses M-6
[1] BOOST COMPENSATOR …………….cceeorrecessennesseensersecenescenrensnnenmennnnenmannenennnnececencsnnenenns M-6
03- -M- E2B, WSM
1. ENGINE BODY
[1] PISTON
SEEADAAT Poot A
DIESEL ENGINE
Piston's skirt is coated with molybdenum disulfied*,
which reduces the piston slap noise and thus the entire
operating noise. о -
* Molybdenum disulfide (MoS:) . |
The molybdenum disulfide (1) serves as a solid
lubricant, like a Graphite or Teflon. This material helps
resist metal wears even with little lube oil.
(1) Molybdenum Disulfide
0000006291E
[2] BUILT-IN DYNAMIC BALANCER (BALANCER MODEL ONLY)
(1)-
SEEADAA1P002A
(1)
Engine are sure to vibrate by piston' s reciprocation.
Theoretically, three-cylinder engines are much less
prone to cause vibration than four-cylinder ones
(second inertia, etc.). However, any engine has many
moving parts in addition to its pistons and cannot be
M-1
completely free from vibration. |
The four cylinders engine can be fitted with balance
weight on crankcase to absorb the second inertia
mentioned above and reduce vibration.
This engine is internally provide with two balancers
(1), one at the suction side and the other at the exhaust
side.
‚ (1) Balancer
0000006292Е
03-M-E2B, WSM DIESEL ENGINE
[3] HALF-FLOATING HEAD COVER
В | В The rubber packing is fitting in to maintain the head
cover 0.5 mm or so off the cylinder head. This
arrangement helps reduce noise coming from the
cylinder head.
(1) Cylinder Head Cover (2) Rubber Packing
0000004839E
3EEABAB1PO04A (2)
M-2
ВЕ 03- M- E2B, WSM
_ DIESEL ENGINE
: 2. “COOLING SYSTEM
[1] BOTTOM BYPASS SYSTEM
œ
— OSEEMAMIPIOA
® ow
3EEAAAA1P111A
the thermostat is held closed and the coolant is allowed
| Bottom bypass system is introduced in 03-M Series
fori improving the cooling performance of the radiator.
While the temperature of coolant in the engine is low,
to flow through the bypass pipe and to circulate in the
~ engine.
- When the temperature exceeds the thermostat valve
opening level, the thermostat fully opens itself to
prevent the hot coolant from flowing through 1 the bypass
into the engine. |
“In this way, the radiator can increase its cooling
| performance.
M-3
(1) Thermostat (A) Thermostat Closed
| | (B) Thermostat Open
0000006293E
| os M- E2B, WSM |
DIESEL ENGINE —
3. FUEL SYSTEM
[1] GOVERNOR
ITGAAAB1POO1A
— The governor serves to keep engine speed constant
by automatically adjusting the amount of fuel supplied to
the engine according to changes in the load. This
engine employs an all-speed governor which controls
the centrifugal force of the steel ball (1) weight,
M-4
balanced.
(1)
(2)
(3)
Cw
(5)
(6)
Steel Ball
Governor Sleeve
Stee! Ball —
Governor Ball Case
Fuel Camshaft
Governor Lever
(7)
(8)
(9)
do
(11)
(12)
produced by rotation of the fuel camshaft (5), and the
tension of the governor spring 1 (7) and 2 (8) are
Governor Spring 1
Governor Spring 2
Fork Lever2
Fork Lever1 ——
Fork Lever Shaft
Fork Lever Holder
0000006294
03-M-E2B, WSM —— | | | DIESEL ENGINE
4. ELECTRICAL SYSTEM
[11 STARTER AUTO REDUCTION UNIT
(1) General
The starter auto reduction unit (7) is designed to start the machine equipped with engine more reliably. This unit
has the following function by integrating an alternator (1) that puts out rpm- proportional pulses.
1. Fail-Safe Functions |
a) Preventing the starter pinion from getting in mesh while the engine is runnning.
With the engine running, pulses from the alternator terminal P are constantly detected. Even if key switch (2) is
wrongly operated or the wiring gets short-circuited, the starter (5) can stay off, the starter (5) and flywheel fing gear
are effectively protected.
b) Starter auto reduction at a start of the engine.
When the engine has got started and the alternator (1) has reached the specified rpm, the electical current to the
starter (5) is automatically cut off, even if the key switch (2) is is at the > START position.
c) Safety mechanism in case of engine stall. a
if the engine stalls with the key switch (2) at AC or START position, the key must t be set once to OFF position for
added safety. The starter (5) is thus kept from turning on unexpectedly.
2. Other Features and Functions
a) Simplified wiring with built-in power relay.
The unit is internally provided with a power relay to get simpler wiring than ever before. If the key switch terminal AC,
ground cable or any other parts is wrongly connected, the starter (5) stays off. This helps identify wrong wiring more
easily.
b) With the output terminal for confirming engine start (Relay drive possible).
The unit has an external output terminal in order to confirm an engine start. An external relay (6) may also be
connected to this terminal. (Output current : below 200 mA)
0000006299E
M-5
03- M- E2B, WSM
DIESEL ENGINE
5. TURBOCHARGER SYSTEM
[1] BOOST COMPENSATOR
(2)
— TT
SEEADAB1PO28A
—
3SEEADAB1P0O29A
pr
> =
3EEADAB1P0O30A
©)
m
Injection Pump Assembly
Hi- Idling Body
Stop Solenoid Guide
Plunger |
Boost Compensator
Assembly
‘Actuator
Stop Solenoid
0000006751E
The higher the boost pressure rises, the more fuel is
fed. In this way, the turbocharger proves itself for high-
power performance.
0000006752E
‘When the boost pressure drops, excess fuel is cut
down, allowing much less black emission.
The system is tremendously efficient in cutting down
on the emission; under low boost pressures at quick
speed-up or start-up, in particular.
M-6
0000006753E
- — CONTENTS _"”. —
4. TROUBLESHOOTING rene SA
2. SERVICING SPECIFICATIONS Ne e... S-5
3. TIGHTENING TORQUES o.oo. ss
[1] TIGHTENING TORQUES FOR GENERAL USE SCREWS, BOLT AND NUTS. e... 5-13
[2] TIGHTENING TORQUES FOR SPECIAL USE SCREWS, BOLT AND NUTS. rene S-14
4. CHECKING, DISASSEMBLING AND SERVICING... e... Grésranensenerene OT 1D
[1] CHECKING AND ADJUSTING -.............—-...0e.eenmeenen. ene. O CD 1
(1) Engine BOTY oceans ees errr S-15
(2) Lubricating System .................c......e.e=meeemmerieccee enn een eran eer 5-17
(3) Cooling SyStEM cuits eerste sees errr. S-17
(4) Fuel System....................e2du0reeneneeDe DA neneronneneneniencen. eee ———— S-20
(5) Electrical System .........................2.em ener enn eee eee S-22
(6) Turbocharger.......................eeeeeeiererene en ee RI Re Gebe S-27
[2] DISASSEMBLING AND ASSEMBLING. crt неее. 5-28.
“ (1) Draining Coolant and Oil ..........c......... Lena caraneera rene eeceansasanasnes nee eee 3°28
(2) External Components.......................... eenilaacarenacon e raaaearare Arana anar eean eee renaenaracanrenaneeae 5-28
(3) Cylinder Head and Valves............:........e-.ece=ereneecerre anrsanesareasrrenaseanencarancenanne D2
(4) Timing Gears, Camshaft and Fuel Camshaft . een sessaraaacacennanners casneensastennen cena nanas .5-34
(5) Piston and Connecting Rod nerereneenneneenen ne Ra rereeaeee pecicereneenecener ee nenranenecen. eerecanenneneeen. S-43
— (6) Crankshatft.....................—..—.... Lenstaralensa see necnne nee ne naasasasnnan encens A S-46
(7) Thermostat and Water PUMP eee e... envenarnanonaines EERRRRKKRRERERRERKRRERKEREEREERKERRKLEREEEEEG 5-49
CS JES) 2-1 (= GOP cerscnee sance a rcnsaceenneraneenen nana en cena nee S-50
(9) XL T=] T= Lo] (FO UOT retrace Eee S-51
(10) Turbocharger............ Lerane ane unra near eone ee nana pans ne aan ren ane ne naen ee ane e ae ace nec een ce Scene casncnenes S-53
[3] SERVICING ...............e.ememmesennneco a annioaoueneicaneoicandaceninarere Nenininaiacen eee ceecenncenanecacen nene. 5-55.
(1) Cylinder Head and Valves N ERREREEARRARRAERERRREUDKRRERERERKERSEBURERREBULEEDKRDGÄRRURKAURERUUEELULEKENG 5-55
(2) Timing Gears, Camshaft and Fuel Camshaft Gnrrare crane nan aaaarenaa scan anna an nan casse mener can S-61
(3) Piston and Connecting ROd..........…........………rcecssrsnserseenenceneeue DO S-65
(4) Crankshaft. нненееееееененнненнннененненнееннннкнннннннноные еее. macieannanénensanirenaeresenen cena since S-68
(SR C300 [=] SR SS FUER ERCP TORI ces O13
(5) IO LLIN 20151] o JS EOP PPPOPPPPPP TPIS S-74
(7) Starter. EEE eneuerccenenenaeoeeannes acaseranencenenaananarnancecenneranan canne 5-75
( ) Alternator .............-e-..e=.——neonrocccaceococoneonace neon eereoananenearereorececeace enc aeuuenoaucancananan S-78
(9) Wiring Diagram peneeooeneanene. Deneneranivenearearmadenrenaneecenanvenenevarace enema nenenoaceceneavereenveneennee. 5-80
03-M-E2B, WSM
1. TROUBLESHOOTING
DIESEL ENGINE
Symptom Probable Cause Solution Relerence
age
Engine Does Not Start | e No fuel - Replenish fuel -
© Air in the fuel system Ventair G-9
® Water in the fuel system Change fuel and G-9, 10, 13,
| В repair or replace fuel | 14
system
® Fuel pipe clogged | Clean G-8
e Fuel filter clogged - Replace 1G-10, 13, 14
® Excessively high viscosity of fuel or engine oil | Use specified fuel |4,5
at low temperature or engine oil |
e Fuel with low cetane number | Use specified 4,5
a. fuel |
e Fuel ieak due to loose injection pipe retaining | Tighten retaining nut | S-29
nut | Do
e Incorrect injection timing Adjust 18-20
® Fuel camshaft worn Replace | S-40
e Injection nozzle clogged Clean or replace S-21
e Injection pump malfunctioning Repair or replace 18-34, 35
® Seizure of crankshaft, camshaft, piston, | Repair or replace —
cylinder or bearing
e Compression leak from cylinder Replace head gasket, | S-30, 32
| tighten cylinder head
‘screw, glow plug and
| nozzle holder
® Improper valve timing Correct or replace S-40
timing gear
e Piston ring and cylinder worn | Replace S-15, 44, 45,
: 166, 67, 73
® Excessive valve clearance Adjust G-20
| ® Stop solenoid mulfunctioning Replace S-26
| (Starter Does Not ® Battery discharged Charge G-17
Run) ® Starter malfunctioning Repair or replace S-23, 50, 75
e Key switch malfunctioning ‘Replace | —
® Starter auto reduction unit defective Replace S-27, 80
® Wiring disconnected Connect S-80
S-1
03-M-E2B, WSM
DIESEL ENGINE
Reference
nozzle
Symptom Probable Cause Solution Page
Engine Revolution Is | ® Fuel filter clogged or dirty Replace G-10, 13, 14
| Not Smooth ® Air cleaner clogged | Clean or replace G-9
| e Fuel leak due to loose injection pipe retaining | Tighten retaining nut S-29
e Injection pump malfunctioning Repair or replace 5-34, 35
e Incorrect nozzle opening pressure Adjust S-21
e Injection nozzle stuck or clogged Repair or replace S-21
® Governor malfunctioning Repair S-37, 42
e Bearingwornout | Replace the — S-54
o turbocharger ВЕ
assembly
| ® Turbocharger shaft bent Replace the S-54
a | turbocharger
assembly
® Turbocharger fin or other part damaged due to | Replace the | S-54
foreign matters | turbocharger
| assembly
Either White or Blue | ® Excessive engine oll Reduce to specified | G-6
Exhaust Gas Is level
| Observed ® Piston ring and cylinder worn or stuck | Repair or replace S-15, 44, 45,
66, 67, 73
® Incorrect injection timing | Adjust S-20
® Deficient compression Adjust top clearance |S-15
Oil Leak into Exhaust | ® Waste oil pipe clogged or deformed Repair or replace S-54
Pipe or Suction Pipe ® Piston ring seal faulty Replace the S-54
turbocharger
assembly
Either Black or Dark | ® Overload Lessen the load —
| Gray Exhaust Gas Is —
Observed @ Low grade fuel used — Use specified fuel | 4,5 |
® Fuel filter clogged Replace G-10, 13, 14
e Air cleaner clogged Clean or replace G-9
® Deficient nozzle injection Repair or replace S-21
5-2
03-M-E2B, WSM
DIESEL ENGINE
Reference
Symptom В Probable Cause Solution Page
Deficient Output © Incorrect injection timing Adjust | S-2 20
e Engine's moving parts seem to be seizing — Repair or replace —
e Injection pump malfunctioning Repair or replace S-34, 35
e Deficient nozzle injection : Repair or replace S21
EE | | nozzle
e Compression leak | Check the 5-15
compression
pressure and repair
e Gas leak from exhaust system Repair or replace S-27
e Air leak from compressor discharge side Repair or replace S-27
“e Air cleaner dirty or clogged | Clean or replace | G9
e Compressor wheel turning heavily Replace the S-54
TE eT | turbocharger
| | assembly
Excessive Lubricant | ® Piston ring's gap facing the same direction | Shift ring gap S-44
Oil Consumption | | | direction
® Oil ring worn or stuck Replace S-44, 66, 67
e Piston ring groove worn | Replace piston S-44, 66, 67
e Valve stem and valve guide worn Replace S-33, 56, 57
e Crankshaft bearing, and crank pin bearing | Replace | 5-69, 70, 74
worn
e Oil leaking due to defective seals or packing | Replace —
Fuel Mixed into e injection pump's plunger worn Replace injection 5-34, 35
Lubricant Oil В | pump. o
e Deficient nozzle injection Repair or replace 5-21
ВЕ nozzle
e Injection pump broken Replace S-34, 35
Water Mixed into e Head gasket defective Replace S-32
Lubricant Oil ["® Cylinder block or cylinder head flawed Replace S32, 55
| Low Oil Pressure ® Engine oil insufficient Replenish G-6
® Oil strainer clogged Clean S-43
© Relief valve stuck with dirt Clean —
e Relief valve spring weaken or broken Replace — |
'® Excessive oil clearance of crankshaft bearing | Replace S-48, 70, 71
® Excessive oil clearance of crankpin bearing Replace S-44, 69
® Excessive oil clearance of rocker arm | Replace S-33, 59
e Oil passage clogged Clean —
e Different type of oil specified type of | 4, 5, G-12
oi
e Oil pump defective Repair or replace S-17, 42, 74
S-3
03-M-E2B, WSM
DIESEL ENGINE
5-4
| Symptom Probable Cause Solution | age
High Oil Pressure |e Different type of oil 80 specified type of |4, 5, 6-12.
| | | | oil | |
e Relief valve defective | Replace —
[Engine Overheated | ® Engine oil insufficient _ Replenish [ae
| ® Fan belt broken or elongated Replace or adjust G-11, 16
| ® Coolant insufficient Replenish [a7
e Radiator net and radiator fin clogged with dust | Clean — —
e Inside of radiator corroded | Clean or replace G-15
e Coolant flow route corroded . Clean or replace —
je Radiator cap defective — — Replace. = 1848
e Overload running Reduce the load —
e Head gasket defective — Replace | S-32
e incorrect injection timing Adjust 5-20
® Unsuitable fuel used [Use specified fuel | 4, 5
Battery Quickly e Battery electrolyte insufficient | Replenish distilled G-10, 17
Discharged | ‘water and charge |
® Fan belt slips Adjust belt tension or | G-10, 16
replace
e. Wiring disconnected Connect | 5-80
e Rectifier defective | Replace S-52, 79
e Alternator defective Replace | S-51, 78
e Battery defective Replace —
0000006305E
— 03-M-E2B, WSM
‘2. SERVICING SPECIFICATIONS
ENGINE BODY
DIESEL ENGINE
T Factory Specification
“Allowable Limit |
Cylinder Head Surface |
Flatiess
1 0.05mm/500mm |
‘| 0.0020 тп. / 19.69 in.
| Compression Pressure
(When Cranking with Starting Motor)
3.53 to 4.02 MPa /
290 min” (pm) -
- 36to 41 kaf/em2/
290 min! (rpm)
512 to 583 psi /
- 290 min” (rpm)
- 290 min” (rom)
~~ 255MPa/
© 290 min” (rpm)
26 kgf/em? /
290 min” (rpm)
370 psi /
Difference among oe
Cylinders
do - “10% or less — _.
a | Top Clearance
0.55 to 0.70 mm
1 a. — 0.0217 t00.0276in. | a
Valve Clearance (When Cold) © 0.1810 0.22mm _
© © 0.0071 to 0.0087 in.
Valve Seat Width (Intake) 2.12 mm __
0.0835 in.
Width (Exhaust) 2.12 mm a
Ш 0.0835 in.
| Valve Seat | Angle (Intake) 1.047 rad a
60°
“| Angle (Exhaust) 0.785 rad —
| 45°
| Valve Face Angle (Intake) 1.047 rad —
Angle (Exhaust) 0.785 rad _
45° |
Valve Stem to Valve Guide
Clearance
0.040 to 0.070 mm
0.00157 t0 0.00276 in.
0.1 mm
0.0039 in.
| valve Stem ————
7.960 to 7.975 mm
(O.D.) 0.31339 to 0.31398 in. нЕ
Valve Guide 8.015 to 8.030 mm _
(1.D.) 0.31555 to 0.31614 in.
Valve Recessing Protrusion 0.05 mm —
0.0020 in.
Recessing
0.15 mm
0.0059 in.
0.4 mm
0.0157 in.
S-5 .
— 03-ME2B,WSM
DIESEL ENGINE
Item
T Factory Specification
- Allowable Limit _
[Valve Timing (Intake Valve)
| D1 503-M (Open)
0.14 rad (8 °)
) before T.D.C. a
| D1503-M (Close) 0.35 rad (20%) _
р after B.D.C.
—|D1703-M (Open) e.
D1803-M | 0.21 rad (12°) |
V2003-M before T.D.C п
Iy2203M efore T.D.C.
| V2403-M
D1703-M (Close)
| D1803-M ‚0.63 rad (36°) —. | |
—|v2203-M. | EEE 0
V2403-M
V2003-M-T (Open) 0.35 rad (20 °) a
+f | before T.D.C.
| V2003-M-T (Close) 0.79 rad (45°) _
bo | after B.D.C.
| Valve Timing (Exhaust Valve) | D1503-M (Open) 1.05 rad (60 ”) N
о В before B.D.C.
| D1503-M (Close) 0.21 rad (12°) _
a after T.D.C.
| D1 703-M (Open) | ВЕ
D1803-M 1.05 rad (60 °)
v2003-M before B.D.C _
V2203-M | RE
| V2403-M
|D1703-M (Close) |
D1803-M 0.24 rad (12°)
V2003-M after T.D.C a
| V2203-M SEE
| V2403-M
V2003-M-T (Open) 0.96 rad (55 °) a
ro before B.D.C. N
V2003-M-T (Close) 0.24 rad (14 °) __
after T.D.C.
Valve Spring Free Length 41.7 to 42.2 mm 41.2 mm
1.6417 to 1.6614 in. 1.6220 in.
Setting Load / 117.6 N/ 35.0 mm 100.0 N / 35.0 mm
| Setting Length 12.0 kgf / 35.0 mm 10.2 kgf / 35.0 mm
26.4 Ibs / 1.3780 in. 22.5 los / 1.3780 in.
Tilt __ 1.0 mm
0.039 in.
S-6
03-M-E2B, WSM
DIESEL ENGINE
Allowable Limit _
Item Factory Specification
| Rocker Arm Shaft to Rocker Arm Clearance 0.016 to 0.045 mm 0.1mm -
0.00063 to 0.00177 in. 0.0039 in.
Rocker Arm Shaft | 13.973 to 13.984 mm _
(O.D.) 0.55012 to 0.55055 in.
Rocker Arm — 14.000 to 14.018 mm _
(1.D.) 0.55118 to 0.55189 in.
Push Rod Alignment om 0.25 mm
| 0.0098 in.
Tappet to Tappet Guide Clearance 0.020 to 0.062 mm 0.07 mm
| 0.00079 to 0.00244 in. 0.0028 in.
| Tappet (0.D.) 23.959 to 23.980 mm _
| 0.94327 to 0.94410 in.
| Tappet Guide (1.D) 24.000 to 24.021 mm —
| © 0.94488 to 0.94571 in.
Timing Gear | Crank Gear to Idle | 0.0415 to 0.1122 mm 0.15 mm
Gear (Backlash) 0.00163 to 0.00442 in. 0.0059 in.
| Idle Gear to Cam 0.0415 to 0.1154 mm 0.15 mm
‘Gear (Backlash) 0.00163 to 0.00454 in. 0.0059 in.
Injection Pump 0.0415 10 0.1154 mm 0.15 mm
Gear (Backlash) 0.00163 to 0.00454 in. 0.0059 in.
Crank tear to ÓN | 0.041510 0.1090 mm 0.15 mm
р зе 0.00163 to 0.00429 in. 0.0059 in.
(Backlash) |
idle Gear to
any 0.0350 to 0.1160 mm 0.15 mm
(Ba lancer Model 0.00138 10 0.00457 in. 0.0059 in.
Only)
Idle Gear Side Clearance 0.12 to 0.48 mm 0.9 mm
0.0047 to 0.0189 in. 0.0354 in.
Idle Gear Shaft to Idle Gear Bushing Clearance 0.025 to 0.066 mm 0.1 mm
| | a = | 0.00098 to 0.00260 in. 0.0039 in.
| Idle Gear Shaft 37.959 to 37.975 mm _—
(0.D.) 1.49445 to 1.49508 in.
Idle Gear Bushing 38.000 to 38.025 mm _—
(1.D.) 1.49606 to 1.49704 in.
Camshaft Side Clearance 0.07 to 0.22 mm 0.3 mm
0.0028 to 0.0087 in. 0.0118 in.
Camshaft Alignment — 0.01 mm
0.0004 in.
Cam Height 33.90 mm 33.85 mm
(Intake / Exhaust) 1.3346 in. 1.3327 in.
03-M-E2B, WSM
— DIESEL ENGINE
a Item a — Factory Specification | Allowable Limit
Camshaft Journal to Cylinder Block Bore | Clearance — - 0.050 to 0.091 mm 0.15 mm _
о | | 5 | a 0.00197 to 0.00358 in. 0.0059 in.
| Camshaft Journal | 39.934 to 39.950 mm | B
| (0.D.) 1.57221 to 1.57284 in. -
‘Cylinder Block Bore | 40.000 to 40.025 mm | _
(1.D.) 1.57480 to 1.57579 in.
Balancer Shaft ~~ Side Clearance 0.07 to 0.22mm - 03mm.
(Balancer Model Only) 0.0028 to 0.0087 in. 0.0118 in.
Balancer Shaft Journal 1 to Balancer Shaft | Clearance 0.030to 0.111 mm 0.2 mm
Bearing 1 (Balancer Model Only) 0.00118 to 0.00437 in. 0.0079 in.
o В ВЕ [Balancer Shaft | 43-93410 43.950 тт — —
Journal 1 (0.D.) . | 1.72968 to 1.73031 in.
| Balancer Shaft 43.980 to 44.045 mm _
| Journal 1 (1D) 1.73149 to 1.73405 in.
‘Balancer Shaft Journal 2 to Balancer Shaft | Clearance | 0.030to 0.111mm | 0.2mm
Bearing 2 (Balancer Model Only) Po | 0.00118 to 0.00437 in. 0.0079 in.
| Balancer Shaft 41.934 to 41 950 mm —
| Journal 2 (O.D.) 1.65094 to 1.65157 in.
| Balancer Shaft 41.980 to 42.045 mm _
Journal 2 (1.D.) 1.65275 to 1.65531 in.
Balancer Shaft Journal 3 to Balancer Shaft | Clearance 0.020 to 0.094 mm 0.2mm |
| Bearing 3 (Balancer Model Only) 1 Е 0.00079 to 0.00370 in. 0.0079 in.
Balancer Shaft — 21.947 to 21.960 mm — т
Journal 3 (O.D.) 0.86405 to 0.86456 in.
Balancer Shaft 21.980 to 22.041 mm _
a | Journal 3 (1.D.) 0.86535 to 0.86775 in.
Piston Pin Bore D. “25.000 to 25.013mm | 25.05 mm
0.98425 to 0.98476 in. 0.9862 in.
Second Ring to Ring Groove | Clearance 0.093 to 0.128 mm 0.2 mm
0.0037 to 0.0050 in, 0.0079 in.
| Oil Ring to Ring Groove | Clearance 0.020 to 0.060 mm 0.15 mm
LS AEE 0.0008 to 0.0021 in. 0.0059 in.
Top Ring D1503-M
V2003-M 0.20 to 0.35 mm 1.25 mm
V2003-M-T 0.0079 to 0.0138 in. 0.0492 in.
(Ring Gap)
D1703-M
| 0.25 to 0.40 mm 1.25 mm
V2403-M 0.0098 to 0.0157 in. 0.0492 in.
(Ring Gap)
5-8
— 03-M-E28, WSM
— DIESEL ENGINE
| - tem o | Factory Specification F Allowable Limit +
| Second Ring D1503-M Ea a.
— 1D1703-M- В
|D1803-M 0.30 to 0.45 mm 1.25 mm
|V2203-M 0.0118 to 0.0177 in. 0.0492 in.
| V2403-M — a / a EE
| (Ring Gap)
IMA 0.40 to 0.55 mm | 1.25 mm
PEO ov 0.0157 to 0.0217 in. 0.0492 in.
| (Ring Gap) : a |
Oil Ring Ring Gap 0.25 to 0.45 mm 1.25 mm
0.0098 to 0.0177 in. 0.0492 in.
Connecting Rod | Alignment o ‘ 0.05 mm |
o o 0077 | 00020in. |
Piston Pin to Small End Bushing Clearance 0.014 to 0.038 mm 0.15 mm
| | 0.00055 to 0.00150 in. 0.0059 in.
[Piston Pin (O.D.) | 25.002t025.011 mm | _
|| 0.98433 0.98468 ._
Small End Bushing | 25.025 to 25.040 mm _
(1.D.) 0.98523 to 0.98582 in. a.
Crankshaft | Alignment = _ 0.02 mm
| 0.00079 in.
Crankshaft Journal to Crankshaft Bearing 1 | Oil Clearance 0.040 to 0.118 mm 0.2 mm
a ВЕ 0.00157 to 0.00465 in. © 0.0079 in.
Crankshaft Journal | 59.921 to 59.940 mm _
(O.D.) 2.35909 to 2.35984 in.
Crankshatt Bearing | 59.980 to 60.039 mm _
diay... | 2.36142102.36374in. |
(1D)
Crankshaft Journal to Crankshaft Bearing 2 | Oil Clearance 0.040 to 0.104 mm 0.2 mm
| | | —0.00157 to 0.00409 in. 0.0079 in.
| Crankshaft Journal | 59.921 to 59.940 mm _
| (O.D.) 2.35909 to 2.35984 in.
Crankshaft Bearing | 59 98040 60.025 mm | _
2.36142 to 2.36374 in.
(1.D.)
Crankpin to Crankpin Bearing | Oil Clearance 0.025 to 0.087 mm 0.2 mm
0.00098 to 0.00343 in. 0.0079 in.
| Crankpin 46.959 to 46.975 mm a
1(0.D.) 1.84878 to 1.84941 in. |
Crankpin Bearing 47.000 to 47.046 mm _
(1.D.) 1.85039 to 1.85220 in.
Crankshaft Side Clearance 0.15 to 0.31 mm 0.5 mm
0.0059 to 0.0122 in. 0.0197 in.
Crankshaft Sleeve Wear a 0.1 mm
0.0039 in.
S-9
03-M-E2B, WSM
DIESEL ENGINE
S-10
o oem "Factory Specification | Allowable Limit |
| Cylinder Bore — | D1503-M EE
[Standard] | V2003-M | 83.000 to 83.022 mm + 0.15 mm
. V2003-M-T +. | 3.26772 to 3.26858 in. ‚+ 0.0059 тп.
0D). o | o
|D1703-M В
vea 87.000 to 87.022 mm + 0.15 mm
V2403-M -3.42519 to 3.42606 in. + 0.0059 in.
a (1.D.)
‘Cylinder Bore D1503-M
[Oversize] | V2003-M 83.250 to 83.272 mm + 0.15 mm
o | V2003-M-T 3.27756 to 3.27843 in. | + 0.0059 in.
(1.D.) | | a
D1703-M
aot | 87.250 t0 87.272 mm + 0.15 mm
V2403-M 3.43503 to 3.43590 in. + 0.0059 in.
(1.D.) |
0000006306E
LUBRICATING SYSTEM
) Item a Factory Specification | Allowable Limit
Engine Oil Pressure At Idle Speed ‘98 kPa or more — 49 kPa
1.0 kgf/cm? or more 0.5 kgf/cm?
14 psi or more 7 psi
| At Rated Speed 294 to 441 kPa 245 kPa,
3.0 to 4.5 kgf/cm? 2.5 kgf/cm?
© 43tobdpsi © 36psi
Engine Oil Pressure Switch - Working Pressure | 49 kPa
| o | 0.5 kgf/cm? —
7 psi
Inner Rotor to Outer Rotor | Clearance 0.03 to 0.14 mm | 0.2 mm
A 0.0012 to 0.0055 in. | 0.0079 мп.
Outer Rotor to Pump Body Clearance 0.11 to 0.19 mm 0.25 mm
0.0043 to 0.0075 in. 0.0098 in.
Inner Rotor to Cover Clearance 0.105 to 0.150 mm 0.2 mm
0.00413 to 0.00591 in. 0.0079 in.
0000005274E
— 03-M-E2B,WSM
DIESEL ENGINE |
COOLING SYSTEM
‚Нет
Factory Specification
Allowable Limit |
| Fan Belt ;
Tension
7.0 to 9.0 mm /(0.28to |
0.35 in.) deflection
at 98 N (10 kgf, 22 Ibs) |
of force
Thermostat
Ш Valve Opening
Temperature
(At Beginning)
157.1 10 162.5 °Е
Valve Opening
85 °C
| Temperature
(Opened Completely) - - 185 F |
No leaks at
137 kPa
1.4 kgf/cm?
20psi
10 seconds or more for |
pressure falling В
— Тот 88 10 59 КРа —
from 0.9 to 0.6 kgf/cm? |
— from 13 to 9 psi
[ Radiator Water Tightness a
Radiator Cap a Pressure Falling Time
0000005275E
FUEL SYSTEM
Item Factory Specification | Allowable Limit
| Injection Pump | Injection Timing | 0.297 to 0.331 rad
before T.D.C.
Cl (1710 19°) be a a = Cb
13.73t0 1471 MPa |
140 to 150 kgf/cm? —
— 1991 to 2133 psi
| Injection Nozzle | Injection Pressure |
When the pressure is
12.75 MPa
(130 kgf/em?, 1849 psi), —
the valve seat must be
fuel tightness.
— | Valve Seat . -— |
Tightness
Injection Nozzle Valve Seat.
0000005276E
— 03-M-E28B, WSM
— ELECTRICAL SYSTEM
— DIESEL ENGINE —
| ltem | Factory Specification Allowable Limit
| Starter В Commutator o
|D1503-M он! В
Di703-M 300mm 29.0 mm
V2003-M 1.181 in 1.142 in
V2003-M-T -— o o
V2203-M о
1(0.D.) :
Commutator
| D1803-M ~~ 35.0 mm 34.0 mm
| V2403-M jp 1378in. — 1.339 in.
Mica | 0.45 to 0.75 mm 0.20 mm
(Under Cut) 0.0177to 0.0295in. 0.0079 in.
|Brush — a Е
|D1S03-M
|P1703-M 15.0 mm 11.0 mm
| V2003-M 0.591 in 0.433 in
V2003-M-T or
V2203-M
| (Length)
| Brush |
D1803-M 15.0 mm | 9.0 mm
V2403-M 0.591 in. 0.354 in.
(Length)
¡| Brush Holder and
Holder Support Infinity —
.| (Resistance) e
Alternator No-load voltage More than 13.5 V —
Stator oscila En
(Resistance) Less than 1.0 Q —
Rotor
| (Resistance) 298 Во
Slip Ring 14.4 mm 14.0 mm
(O.D.) 0.567 in. 0.551 in.
Brush 10.5 mm 8.4 mm
(Length) 0.413 in. 0.331 in.
Glow Plug Resistance Approx. 0.9 Q —
Stop Solenoid | Pulling Coit Arma NAYEÁ —
(Resistance) Approx. 0.375 Q
Holding Coil
(Resistance) Approx. 15.6 Q —
0000006307E
—03- M-E2B, WM DIESEL ENGINE |
3. TIGHTENING TORQUES
Screws, bolts and nuts must be tightened to the specified torque using a torque wrench, several: screws, bolts and
nuts such as those used on the cylinder head must be tightened i in proper sequence and the proper torque.
0000001 286E
FUI TIGHTENING TORQUES FOR GENERAL USE SCREWS, BOLT AND
NUTS
When the tightening torques are not specified, tighten the screws, bolts and nuts according to the table below.
Grade Standard Screw and Bolt Special Screw and Bolt
Nominal — |
Diameter Unit N-m kgf-m ft-lbs N-m kgf-m ft-lbs
| — M6 — 791093 | 0.8010 0.95 5.810 6.9 9.81t011.3 |- 1.00t01.15 | 7.2310 8.32.
“me | 17710206 | 18w21 | 1300152 — 23510275 | 241028 | 17410203 |
M10 39.2 to 45.1 4.0 to 4.6 28.9 to 33.3 48.1 to 55.9 4.9 to 5.7 35.4 to 41.2
M12 62.8 to 726 | 641074 46.3 to 53.5 77.5 10 90.2 7910 9.2 57.1 to 66.5
Screw and bolt material grades are shown by numbers punched on the screw y and bolt heads. Prior to tightening,
be sure to check out the numbers as shown below. |
‘Screw and bolt material grade |
None or 4 Standard screw and bolt SS41, s20C
| 7 Special screw and bolt S43C, S48C (Refined)
‘Punched number
0000001288E
03-M-E2B, WSM
DIESEL ENGINE
© TIGHTENING TORQUES FOR SPECIAL USE SCREWS, BOLT AND
NUTS
HE NOTE
e For '™*" ‘marked screws, bolts and nuts ¢ on the table, apply engine ой to their threads and seats before
“tightening.
e 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 15 the nominal distance i in mm between
two threads.
N-m
kgf-m
S-14
item Size x Pitch ft-lbs
Cylinder head cover screw "M6x10 | 6.910113 | 07t01.15 | 51to83 |
| *Cylinder head screw M11x1.25 | 93.110 98. 0 9.510 10.0 | 68710723
| *Main bearing case screw 1 “ M9x125 | 46110509 | 471052 | 34010376
| *Main bearing case screw 2 a M10x1.25 | 68.6 to 73.5 | 70 to 75 | 50.6to54.2
*Flywheel screw Mi2x1.25 | 98.0t0107.8 | 10.0t011.0 | 72.310 79.5
| *Connecting rod screw _ M8x10 | 44.1 to 49.0 4.5 to 5.0 “| 325t036.2
*Rocker arm bracket screw M8 x 1.25 23.5t027.5 2.4 to 2.8 17.4 10 20.3
*Idle gear shaft screw M8x 1.25 | 23.510 27.5 2.4 to 2.8 17.4 to 20.3
| Fan drive pulley mounting nut = 137.3 to 156.9 | 14.0t016.0 | 101.3 to 115.7
“Bearing case cover screw M8 x 1.25 23.5 to 275 2.410 2.8 | 17.410 20.3
Glow plugs M10 x 1.25 19.6 to 24.5 | 2.0t025 14.5 to 18.1
Nozzle holder assembly M20x1.5 | 49.0to 686 5.0t07.0 | 36.210 50.6
Oil pressure switch R 1/8 14.710 19.6 1.510 2.0 | 10.8 to 14.5
Injection pipe retaining nut M12 x 1.5 24.5 to 34.3 25t03.5 | 18.1t025.3
[Overflow pipe assembly retaining nut CE 19.6 to 24.5 2.0t025 14.5 to 18.1
| Camshaft set screw M8x1.25 | 23510275 | 241028 | 17.410208
Hi-idling body — 44.11049.0 | 45t05.0 32.5 to 36.2
Balancer shaft set bolt M8 x 1.25 23.5 to 27.5 2.4 to 2.8 17.4 to 20.3
Alternator pulley nut CC — - 58.3 to 78.9 5.95t08.05 | 43.0t058.2
0000006316E
03- M- E2B, WSM
DIESEL ENGINE о
4. “CHECKING, DISASSEMBLING AND SERVICING
[1] CHECKING AND ADJUSTING
(1) Engine Body
— STLABABIPOOIA .
—2.
| — Compression Pressure ‘ |
‘Run the engine until it is warmed up.
Stop the engine and disconnect the 2P ‹ connector from the
stop solenoid in order to inject fuel.
. Remove the air cleaner, the muffler and all injection nozzles.
Set a compression tester (Code No. 07909- -30208) with the
adaptor to the nozzle hole.
Keep the engine stop lever at "Stop Position". |
While cranking the engine with the starter, measure the. В
compression pressure.
. Repeat steps 4 through 6 for each eylinder.
If the measurement is below the allowable limit, apply a a small
amount of oil to the cylinder wall through the nozzle hole and
~~ measure the compression pressure again.
9.
If the compression pressure is still less than the allowable limit,
~ check the top clearance, valve and cylinder head.
10. If the compression pressure increases after applying oll, check
the cylinder wall and piston rings.
ENOTE
® Check the compression pressure with the specified valve
clearance.
e Always use a fully charged battery for performing this
test.
® Variances in cylinder compression values should De
under 10 %.
3.53 to 4.02 MPa
| Factory spec.. ... .. |. 36041 kgffem? . . |
512 to 583 psi
Compression pressure | |
| 2.55 MPa
| Allowable limit | 26kgf/cm?
370 psi
0000005278E
5-15
_ 03-M-E2B, WSM
DIESEL ENGINE
ЗТМАВАВ1РО2ЗА
3EEABAB1P057A
1.
nN
Lae
3.
Top Clearance |
- Remove the cylnclr head. a Е
Move the piston and stick a strip of fuse on the piston head at
- three positions with grease. — LS
Lower the piston and install the cylinder head. “(Use a new
cylinder head gasket and tighten y with a ‘specified tightening ;
torque.) - o
Turn the flywheel until the piston passes s through the T.D. С.
. Remove the cylinder head and measure the thickness of the
fuses.
. If the measurement is not within the factory specifications,
check the oil clearance between the crankpin and bearing and
between the piston pin and bushing.
"ENOTE o
—e After checking the top clearance, be sure to assemble the. =.
cylinder head with a new cylinder head gasket.
| Top clearance — Factory spec | | 6-55 № 0-70 тт |
p clearance y sp © 0.021710 0.0276 in.
НО ~~ |93.1t0980Nm
Tightening torque { Cylinder head screws — | 9.5 to 10.0 kgf.m
ВЕ | 68.7 to 72.3 ft-lbs
(1) Piston (2) Fuse
0000005280E
S-16
03-M-E2B, WSM
DIESEL ENGINE
(2) Lubricating System
AY ZAS
3EEADAATPO21A
(3) Cooling System
(A)
SEEABAB1P017B
Engine Oil Pressure
©
1. Remove the engine oil pressure switch, and set an oil
pressure tester (Code No. 07916- 32032). (Adaptor screw size
: PT 1/8) |
2. Startthe engine. After warming up, measure > the oil pressure |
of both idling and rated speeds. |
If the oil pressure is less than the allowable limit, check the
following. |
e Engine oil insufficient.
e Oil pump defective
e Oil strainer clogged
© Oil filter cartridge clogged
e Oil gallery ciogged
e Excessive oil clearance
e Foreign matter in the relief valve
inn, | More than 98 kPa
Factory 1.0 kgffcm?
spec. >
Atidle 14 psi
speed | | |
Allowable 49 kPa
timi "1 0.5 kgf/cm?
Imit 7
| 7 psi
Engine oil pressure —1 1
| 294 to 441 kPa
Factory | 8.0 to 4.5 kgflem?
Atrated | °°° | 42,7 to 64.0 psi
speed 5 kF
| Allowable | 245 KPa
limit 2.5 kgffem
35.6 psi
(When reassembling)
After checking the engine oil pressure, tighten the engine oil
pressure switch to the specified torque.
Tightening torque Oil pressure switch 1.5 to 2.0 kgf/em?
14.7 to 19.6 Nem
10.8to 14.5 ft-Ibs
0000005283E
Fan Belt Tension
1. Measure the deflection (A), depressing the belt halfway
between the fan drive pulley and alternator pulley at specified
— force (95 N, 10 kgf, 22 165).
2. If the measurement is not within the factory specifications,
loosen the alternator mounting screws and relocate the
alternator to adjust.
; 7t09 mm
Deflection (A) Factory spec. 0.28 to 0.35 in.
(A) Deflection
0000004277E
S-17
03-M-E2B, WSM |
DIESEL ENGINE
3EEABAB1PO1SA
3EEABAB1P018B
SEEABAB1P162A
>on =
Fan Belt Damage and Wear ~~
. Check the fan belt for damage.
if the fan belt is damaged, repiace it. |
Check if the fan belt is worn and sunk in the pulley groove.
If the fan belt is nearly worn out and deeply sunk in the pulley
groove, replace it. - a
0000002122E
Radiator Cap Air Leakage
A CAUTION
® When removing the radiator cap, wait at least ten minutes
after the engine has stopped and cooled down.
Otherwise, hot water way gush out, scalding nearby
people.
1. Set a radiator tester (Code No. 07909-31551) on the radiator
cap.
2. Apply the specified pressure (88 kPa, 0.9 kgf/em”, 13 psi), and
measure the time for the pressure to fall to 59 kPa (0.6
kgf/em?, 9 psi).
3. If the measurement is less than the factory specification,
replace the radiator cap.
| More than 10 seconds for
| pressure fall from
Pressure falling time Factory spec. | 88 to 59 kPa
(from 0.9 to 0.6 kgf/cm?
from 13 to 9 psi)
0000005286E
5-18
© 03-M-E2B, WSM
DIESEL ENGINE
Radiator Water. Leakage a
1. Роига specified amount of water into the radiator. |
2. Setaradiator tester (Code No. 07909-31551) with an adaptor
— (BANZAI Code No. RCT-2A-30S) and raise the water
— pressure to the specified pressure. LS a
3. Check the radiator for water leaks. |
4. For water leak from the pinhole, replace the radiator or repair
‘with the radiator cement. When water leak is excessive,
replace the radiator. Co
| | | o | 137 kP
SEEABABIPIGIA | | Es prou O | Factory spec. | 14 irs
= 0000005287E -
Thermostat Valve Opening Temperature
‘Suspend the thermostat in the water by a string v with its end
3EEABAB1P160A
| opening temperature
1.
inserted between the valve and seat.
2. Heating the water gradually, read the temperature when the
“valve opens and leaves the string. |
3. Continue heating and read the temperature when the valve
~ opens approx. 6 mm (0.236 in.). a
4. If the measurement is not within the factory specifications,
replace the thermostat.
Thermostat's valve 69.5 to 72.5 °C
Factory Spec. 157.110 162.5 °F
Temperature at which |
thermostat completely Factory spec.
opens
85°C
185 °F
0000005285E
5-19
03-M-E2B, WSM
DIESEL ENGINE
(4) Fuel System
3EEABAB1P167D _
(2)
3TMABAB1P091B
(2)
Injection Timing ~~
1. Remove the stop solenoid.
2. Remove the injection pipes and nozzle.
3. Set the speed control lever to maximum fuel discharge
position.
(Reference)
e Turnthe flywheel with screwdriver, |
4. Turn the flywheel counterclockwise (facing the flywheel) until |
the fuel fills up to the hole of the delivery valve holder for 1st
cylinder.
5. Turn the flywheel further and stop turning when the fuel begins
“to flow over, to get the present injection timing. _
6. (The flywheel has mark 1TC and four lines indicating every
0.087 rad (5 °) of crank angle from 0.175 rad (10 °) to 0.436
rad (25 °) before mark 1TC) Calculate the angle which the
center of the window points out. If the calculation differs from
specified injection timing, add or remove the shim to adjust.
(Injection Timing)
0.297 to 0.331 ad
17 * to 19 “B.T.D.C.
Injection timing Factory spec.
M NOTE
e The sealant is applied to both sides of the soft metal
gasket shim. The liquid gasket is not required for
assembling.
e Shims are available in thickness of 0.20 mm, 0. 25mm and
9.30 mm. Combine these shims for adiustment.
e Addition or reduction of shim (0.05mm, 0.0020 in.) delays
or advances the injection timing by approx. 0.0087 rad
(05°).
e In disassembling and replacing, be sure to use the same
number of new gasket shims with the same thickness.
(1) Delivery Valve Holder (4) 1-Hole : 0.25 mm (Shim)
(2) Timing Mark (5) Without Hole : 0.30 mm (Shim)
(3) 2-Holes : 0.20 mm (Shim)
0000006423E
S-20
-03-M-E2B, WSM | В o DIESEL ENGINE
А: CAUTION
e 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.
a — 0000000932E
Nozzle Spraying Condition o
. Set the injection nozzle to a nozzle tester, and check the
nozzle spraying condition.
2. Ifthe spraying condition is s defective, replace the nozzle piece.
a Good e Bad 02022
0000004880E
SEEABAB1PO37A
Fuel Injection Pressure
1. Set the injection nozzle to a nozzle tester.
2. Slowly move the tester handle to measure the pressure at
which fuel begins jetting out from the nozzle.
3. If the measurement is not within the factory specifications,
replace the adjusting washer (1) in the nozzle holder to adjust
it.
13.73 to 14.71 MPa
Fuel injection pressure | Factory spec. | 140 to 150 kgf/cm?
| 1991 to 2134 psi
(Reference) —
e Pressure variation with 0.01 mm (0.0004 in) difference of
adjusting washer thickness.
Approx. 235 kPa (2.4 kgf/cm?, 34 psi)
(1) Adjusting Washer
0000004881E
3EEABAB1P171B
S-21
‘03-M-E2B, WSM EE В ~~ DIESEL ENGINE
Valve Seat Tightness | |
A. Set the injection nozzle to 2 nozzle tester.
2. Raise the fuel pressure, and keep at 12. 75 MPa а (130 kaf/em?,
1849 psi) for 10 seconds.
- 3. Ifany fuel leak i is found, replace the nozzle piece.
No fuel leak at
12.75 MPa
130 Каст
1849 psi
| Injection pressure | Расюгу врес.
STLABAB1PO41A — | | | | 0000004882Е
(5) ectrcal System a
А. CAUTION
e To avoid accidental short circuit, be sure to attach the positive cable to the positive t terminal before the
negative cable is attached to the negative terminal. | | | |
e Never remove the battery cap while the engine is running. | - |
e Keep electrolyte away from eyes, hands and clothes. If you are spatiered with it, wash it away
completely with water immediately. a
® Keep open sparks and flames away from the battery at all times. Hydrogen gas mixed with oxygen
becomes very explosive.
H IMPORTANT -
e If the machine is to be operated for a short time without battery (using a slave battery for starting), use
‘additional current (lights) while engine is running and insulate terminal of battery. If this advice is
disregarded, damage to alternator and regulator may result.
® insuiate terminal of battery. if this advice is disregarded, damage to aiternator and reguiator may resuii.
0000001726E
— Battery Voltage
1. Stop the engine and t tum nther main y switch off.
2. Connect the COM (-) lead of the voltmeter to the battery's
— negative terminal post and the (+) lead to the positive terminal
post, and measure the battery voltage.
3. If the battery voltage is less than the factory specification,
“check the battery specific gravity and recharge the battery.
Battery voltage Factory spec. | | More than 12 V
0000001140E
Battery Terminal Connection
1. Turn the main switch on, and turn on the head light or all
accessories. |
2. Measure the voltage with a voltmeter across the battery's
positive termina! post and the cable terminal, and the voltage
across the battery's negative terminal post and the chassis.
3. If the measurement exceeds the factory specification, clean
the battery terminal posts and cable clamps, and tighten them
TNT RRR firmly.
3TMABAB9P001A Potential difference Factory spec. Less than 0.1 V
0000004883E
5-22
03-M-E2B, WSM
— DIESEL ENGINE
SEJABAA1P044B
- SEJABAA1P045B
Motor Test Test
A CAUTION
e Secure the starter to prevent it from j jumping up and down |
while testing the motor.
: ‘Disconnect the battery negative cable from the battery.
. Disconnect the battery positive cable and the leads from the
starter C terminal (1).
Remove the starter from the engine. |
. Disconnect the connecting lead (2) from the starter с terminal
(1).
Connect a jumper lead from the connecting lead (2 to the
battery positive terminal post.
. Connect a jumper lead momentarily between the starter motor a
ee ‘housing and the battery negative terminal post.
7. |
If the motor does not run, check the motor.
(1) C Terminal oo (2) Connecting Lead
‚ 0000001 749E
Magnet Switch Test
Disconnect the battery negative cable from the battery.
1.
2. Disconnect the battery positive cable and the leads from the
starter M terminal.
3. Remove the starter from the engine.
4. Disconnect the connecting lead (1) from the starter C terminal .
(2).
5. Connect a jumper lead from the starter 5 terminal (3) to the
battery positive terminal post.
6. Connect a jumper lead momentarily between the starter C
terminal (2) and the battery negative terminal post.
7. Ifthe pinion gear does not pop out, check the magnetic switch. _
NOTE
e This test should be carried out for a short time, about 3 to
5 seconds. |
(1) Connecting Lead (3) S Terminal
(2) C Terminal
“ 0000006756E
S-23
03-M-E28, WSM )
— DIESEL ENGINE
(Precaution when checking)
° If disconnect the B terminal or coupler, engine will stop by emergency device. Ce
© Do not directory connect the L terminal with the B terminal. Otherwise the three exciting diodes may be
damaged. When connecting the L terminal, insert a 3. 4 W lamp between the L and B terminals. |
e Always use a full charged battery.
e Be careful to observe the proper polarity of the battery. Never instal the battery i in the wrong direction.
e Never disconnect the battery while the alternator i is operating.
MNOTE
e Check the alternator with alternator test bench.
3EJABAA1P046A
3EJABAA1P046A
SEJABAA1P046A
0000006424E
Regulating Voltage
. Make the connections as shown in the figure, and turn on
switch SW1. a |
. Increase the alternator speed to 5000 min“ (rom).
Turn on switch SW2. Adjust load resistance R so that the
ammeter shows 10 A.
. Check that the voltage reading on the voltmeter | is ; within the
factory specifications. - o
| Regulating voltage | Factory spec. az to 148 v a |
0000006425E
No-load Characteristics
. Make the connection as shown in the figure, and turn on switch
SW1.
. Increase the alternator speed so that the pointer of the
ammeter swings to the plus side.
Turn on switch SW1 to decrease the speed, and read the
speed at witch the voltage is equal to the factory
specifications.
The speed must be below the factory specifications.
“| No-load characteristics Factory spec.
1150 min’! (rpm) or less at
1135V
0000006426E
Output Characteristics
4
2.
Make the connection as shown in the figure, and turn on switch
SW1 and SW2.
Increase the alternator speed while adjusting the load
resistance so that the voltage complies with the factory
specifications.
Read the speed at which the current is equal to the factory
Specifications.
The speed must be below the factory specifications.
Decrease the speed so that the current approaches zero, the
turn off switches SW1 and SW2.
Qutput characteristics Factory spec.
40 A or more at 13.5 V,
5000 min” (rpm)
0000006427E
5-24
03-M-E2B, WSM |
(2)
3TMABABIPO11A =
3TMABABSPO12A
3TGAAABIPO21A
DIESEL ENGINE
Glow Plug Lead Terminal Voltage
1.
Disconnect the wiring lead (1) from the glow plug (2) after
turning the main switch off.
Turn the main switch key to the "PREHEAT" position, and
‘measure the voltage between the lead terminal and the
chassis. —
Turn the main switch key to the "START" position, ‘and
measure the voltage between the lead terminal and the
chassis.
If the voltage at either position differs from the battery voltage,
the wiring harness or main switch is faulty. -
Voltage |"PREHEAT" |
(Lead terminal - — —
| Chassis) | Main switch key at
Main switch key at Approx. battery voltage
| "START"
Glow Plug Continuity —
(1) Wiring Lead (Positive) (2) Glow Plug
0000005102E
1. Disconnect the lead from the glow plugs.
2. Measure the resistance between the glow plug terminal and
the chassis.
3. If 0 ohm is indicated, the screw at the tip of the glow plug and
the housing are short-circuited.
4. If the factory specification is not indicated, the glow plug is
faulty.
| Glow plug resistance Factory spec. Approx. 0.9 Q
0000005103E
Connector Voltage
1. Disconnect the 2P connector from engine stop solenoid.
2. Turn the main switch key to the "ON" position.
3. Measure the voltage between the terminal 1, terminal 2 and
body.
4. If the voltage differs from the battery voltage, the wiring
harness or main switch is faulty.
Terminal 1 - Body
Voltage Approx. battery voltage
Terminal 2 - Body
(1) Terminal 1 (2) Terminal 2
0000005122E
S-25
| Approx. battery voltage o
© 03-M-E2B, WSM o В — DIESEL ENGINE
Sto Solenoid Coi |
1. Disconnect the 2P connector from engine stop solenoid.
2. Measure the resistance between the terminal 1, terminal 2 and
body. В
3. If resistance differs from the factory specification, the coil is
_ faulty. |
Terminal 1- Body | Approx 0375, Q
Resistance
Terminal 2 - Body Approx. 15.60.
STGAAAB9P021B (1) Terminal 1 (Pulling Coil) (1) Terminal 2 (Holding Coil)
0000006757E
Glow Lamp and Glow Lamp Relay |
1. Check the glow lamp indicator lights up then lights off after
- about 5 seconds when main switch (2) is- turned- to glow
position (1).
2. If the glow lamp indicator does not lights up, the fuse, glow
lamp, glow lamp relay or wiring harness is faulty. |
(1) Glow Position | (2) Main Switch
0000006428E
Glow Lamp Relay
1. Remove the glow lamp relay (1).
(Ei | | | 2. Connect the jumper leads as shown in the figure left.
Oe . OUT 3. If the bulb (2) lights up when connecting a jumper lead to
© (2) 16) battery (3) and go off about 5 seconds late, the glow lamp relay
J I (1) is proper.
) (1) Glow Lamp Relay (3) Battery (12 Vv)
| © Bib A
(1) 0000006429E
ЗТСАААВЭРО2ЗА - a | |
S-26
03-M-E2B, WSM
DIESEL ENGINE
3EEADAATPO26A
(6) Turbocharger
Continuity — a a
1. Disconnect the 6P connector from the starter auto reduction
2. Remove the starter auto reduction unit from the machine.
3. Measure the resistance according to below the matrix chart by
circuit tester.
Negative Terminal
1 2 | 3 | 4 | 5 6
2 co 00 155 | 100 7
Positive |
, 3 00 co со со со
Terminal
4 со со wo | | © | =»
5 со co co co 00
6 | œ 55 | © | 90 | 60
(1) Input Terminal from Key Switch (4) Input Terminal from Alternator
50 Terminal ~~ В P Terminal
(2) Output Terminal for an External (5) Input Terminal from Key Switch
Relay AC Terminal
(3) Output Terminal for Starter (6) Output Terminal for Ground
ST Terminal
0000006430E
Turbine Side
1. Check the exhaust port (3) and inlet port (2) side of turbine
housing (1) to see if there is no exhaust gas leak.
2. If any gas leak is found, retighten the bolts and nuts or replace
the gasket with new one.
(1) Turbine Housing (3) Exhaust Port
(2) Inlet Port
0000006758E
Compressor Side
1. Check the inlet pipe 1 (1) of the compressor cover (2) to see if
there is no air leak.
2. Check for loose connections or cracks in the suction side of
the intake pipe.
3. If any air leak is found, change the clamp (3) and or inlet pipes.
(1) InletPipet | (8) Clamp
(2) Compressor Cover
0000002135E
S-27
03M-E2B,WSM | a A _ " DIESEL ENGINE
2] DISASSEMBLING AND ASSEMBLING
(1) Draining Coolant and Oil
Draining Coolant |
a A CAUTION
N e Never remove radiator cap p while operating or immediately
- after stopping. Otherwise, hot water will spout out from
‘the radiator. Wait for more than ten minutes to cool the
radiator, before opening the cap. |
4. Prepare a bucket. Open the coolant drain cock.
(1) Coolant Drain Cock
SEEADAA1POOSI Е — 0000001290E
N Drala En ine Oil
1. Start and warm up the engine for approx. 5 minutes.
> Place an oil pan underneath the engine.
3. Remove the drain plug (1) to drain oil.
4. After draining, screw in the drain plug.
— (When refilling) |
© Fill the engine oil up to the upper line on the dipstick (2)
E IMPORTANT
e Never mix two different type of oil.
e Use the proper SAE Engine Oil according to ambient
temperature.
(1) Drain Plug — _ (2) Dipstick
0000004893E
o, NED
3EEADAA1PO04B Фу
(2) External Components o
Air Cleaner, Muffler and Others
(3) 1. Remove the air cleaner and muffler.
2. Remove the fan (1), fan belt (2), alternator (3) and starter (4).
(When reassembling)
e Check to see that there are no cracks on the belt surface.
TY a
< (4) E IMPORTANT
LA e After reassembling the fan belt, be sure to adjust the fan
| belt tension.
(2) e Do not confuse the direction of the fan. Attach the fan
with its "1C010" marking facing frontward (toward the
SEEADAA1PO006B radiator).
(1) Fan (3) Alternator
(2) Fan Belt (4) Starter
0000006431E
5-28
03-M-E2B, WSM
(3) Cylinder Head and Valves
|
2 . Cylinder Head Cover a Ш ©
(4) - 1. Remove the lead (1).
à | Le o
UP a 2. Remove the breather hose (2).
"— Vb 70 — 3 Removethe head cover screws (3).
| a. 4. Remove the cylinder head cover (4).
AA — (When reassembling) Е | o |
— SAN ® Check to see if the cylinder head cover gasket is not defective.
B|. W- | В | | Air et save 6.910 11.3Nm
= Tightening torque concer head cover 0.7 to 1.15 kgf.m
T o | 5110882 ftbs
(1) Lead (5) Cylinder Head Cover Gasket
(3) Head CoverScrew =... (7) Plate Le
à (4) Cylinder Head Cover
i - Y Eo E
e ай ; 0000006432E
VO UT. He E
Injection Pipes В |
1. Loosen the screws on the pipe clamps (1).
2. Detach the injection pipes (2).
~ (When reassembling)
e Blow out dust inside the pipes.
Injection pipe retaining | 245 10 343 Nm
Tightening torque n ut РР 9 | 2.510 3.5 kgf-m
18.1 to 25.3 ft-lbs
(1) Pipe Clamp (2) Injection Pipe
0000006433E
5-29
— DIESEL ENGINE
03-M-E2B, WSM
DIESEL ENGINE |
| PTE
STMABAB1P027A (>
ON
3EEABAB1PO61A
Nozzle Holder Assembly and Glow Plug
4. Remove the overflow pipe assembly (5). | |
2. Remove the nozzle holder assemblies (2) usinga 21 mm deep .
socket wrench.
3. Remove the copper gasket and heat seal (3).
4. Remove the glow plugs (1 )- a.
(When reassembling)
e > Replace the copper gasket € and heat seal with new one.
| 49.0 to 68.6 Nm
| Nozzle holder assembly 5.0t0 7.0 kgfm
| 36.2 to 50.6 ft-lbs
19.6 to 24.5 N-m
2.0 to 2.5 kgf-m
-14.5 to 18.1 ft-Ibs -
1 (19.6t0245NmM |
Glow plug — : 120t0o25kgfm ——
| | 14.5 to 18.1 ft-lbs
Overflow pipe assembly
Tightening torque | retaining nut
— (1) GlowPlug | (4) Lead |
(2) Nozzle Holder Assembly ©’ Overflow Pipe Assembly
(3) Heat Seal | |
° 0000005335Е
Nozzle Heat Seal Service Removal Procedure
IMPORTANT
e Use a plus (phillips head) screw driver (1) that has a Dia.
Which is bigger than the heat seal hole (Approx. 6 mm)
1/4 in.
1. Drove screw driver (1) ightly into the heat seal hole.
2. Turn screw driver three or four times each way.
3. While turning the screw driver, slowly pull the heat seal (4) out
together with the copper gasket (3).
4. Ifthe heat seal drops, repeat the above procedure.
(When reassembling)
® Heat seal and copper gasket must be changed when the
injection nozzle is removed for cleaning or for service.
(1) Plus Screw Driver (8) Copper Gasket
— (2) NozzleHolder (4) HeatSeal |
0000005338E
5-30
“ 03-M-E2B, WSM _
DIESEL ENGINE
Rocker Arm and Push Rod
1. Remove the rocker arm bracket mounting bolts.
2. Detach the rocker arm assembly (1).
3. Remove the push rods (2)
(When reassembling) -
* When putting the push rods (2) onto the tappets (3), check to о
see if their ends are properly engaged with the grooves.
H IMPORTANT
e After installing the rocker arm, be sure to > adjust U the valve |
о clearance. EE
3EEABAB1P062A
| Rocker arm bracket T23.510275 Nm
Tightening torque | rocker am bracket 2.4 to 2.8 kgf.m
17.4 t0 20.3 ft-lbs
(1) Rocker Arm Assembly a. (a) Tappet В o
— (2) Push Rod o
0000006434E
5-31
03-M-E2B, WSM
DIESEL ENGINE
NE |
EN ZN
LEAN
a 1)
У
—'
Оп Of 66 Ok
Or Oj Ob Og O
OO OO OO OO (B)
o "EZ © ) h о
био Do Oa o Op
(A)
3GFABAB1P017B
3EEADAATPO12A +X LEO
Cylinder Head о | ВЕ
1. Loosen the pipe clamp (1), and remove the water return pipe
(2). o ©
2. Remove the cylinder head screw in the order of (r or n) to (a).
3. Lift up the cylinder head (3) to detach. ———
4. Remove the cylinder head gasket (4). _
- (When reassembling) E |
® Replace the cylinder head gasket (4) with a new one.
® Tighten the cylinder head screws after applying sufficient oil.
® Tighten the cylinder head screws in diagonal sequence
starting from the center in the order of (a) to (n or r).
® Tighten them uniformly, or the head may deform in the long
run. |
| 93.1 t098.0N.m
Tightening torque | Cylinder head screw © | 9.5t0 10.0 kgfm
| | 68.7 to 72.3 ft-lbs
(1) Pipe Clamp (ror n) to (a) : To Loosen
(2) Return Pipe (a) to (n or r) : To Tighten
(3) Cylinder Head (A) Gear Case Side
(4) Cylinder Head Gasket (B) Flywheel Side
0000006435E
Tappets —
1. Remove the tappets (1) from the crankcase.
(When reassembling)
© Visually check the contact between tappets and cams for
proper rotation. If defect is found, replace tappets.
® Before installing the tappets, apply engine oil thinly around
them.
H IMPORTANT
® Do not change the combination of tappet and tappet
guide.
(1) Tappet
0000000854E
5-32
— 03-M-E2B, WSM
DIESEL ENGINE
— Valves
1. Remove the valve caps (2).
2. Remove the valve spring collet (3), pushing the valve spring
retainer (4) by valve spring replacer (1). | |
I 3. Remove the valve spring retainer (4), valve spring (5) and
valve stem seal (6).
4. Remove the valve (7).
(When reassembling)
e Wash the valve stem seal and valve guide hole, and apply
engine oil sufficiently. o
e After installing the valve spring collets, lightly tap the stem to
assure proper fit with a plastic hammer.
MIMPORTANT ~~ ~~ a
e Do not change the combination of valve and valve guide.
(1) Valve Spring Replacer (5) ValveSpring
(2) Valve Cap | | (6) Valve Stem Seal
(3) Valve Spring Collet — (7) Valve
(4) Valve Spring Retainer
0000000855E
S-33
03-M-E2B, WSM В a A DIESEL ENGINE
| В Injection Pump (for Non Turbocharger Model)
@ « | 1. Remove the stop solenoid (1) and hi-idling body (2).
2. Remove the engine stop lever (3) and stop solenoid guide (35).
TX Aedo 3. Remove the fuel injection pump assembly (4).
ne ES HIMPORTANT 110
_ e Before removing the injection pump assembly (4), be sure
ЕЛ to remove the stop solenoid (1), hi-idling body (2), engine
Ù J |= stop lever (3) and stop solenoid guide (5).
OAT | eN (When reassembling) |
fn © Before attaching the stop solenoid (1), hi-idling body (2) and
solenoid guide (5), install the injection pump first into position.
‚ ® Replace the hi-idling body gasket (6) with a new one.
e Before fitting the stop lever (3) to the gear case, install the
solenoid guide (5) first into position. Then attach the stop lever
and use it to see if it functions well.
~ ® Before fitting the idling limiter in place, attach the solenoid
‘guide (5) and the engine stop lever (3) in their respective
positions. o
® When installing the stop solenoid (1), be careful to keep the O-
ring in place. -
e Be sure to insert the push rod of the stop solenoid into the hole
at the center of the solenoid guide (5).
| — | 44.1 to 49.0 Nm
Tightening torque Hi-idling body 4.5 to 5.0 kgf-m
: | | 32.6 to 36.2 ft-lbs
(4) Timing Gears, Camshaft and Fuel Camshaft ~~
MA
AER
2 = . 3
` <
7
ED
E
- Yo
3TLABAB1P006A
. L OST 7
e Ue
OD >
(1) Stop Solenoid (4) Injection Pump Assembly
(2) Hi-idling Body (5) Stop Solenoid Guide
(3) Stop Lever (6) Hi-idling Body Gasket
0000006436E
S-34
03-M-E2B, WSM
DIESEL ENGINE
ния
В THT n La = : T A AC
, CO LT)
(4) E E
Ea Ab
O e DD
‚ [J iJ
| :
a ADA e
A 7
E we A ——
TN
3EEADAB1PO33A
3EEADAB1P0O35A
Injection Pump (for Turbocharger Model)
1.
n
Las
Remove the stop solenoid (3).
Remove the high-idling body (4).
IN NOTE
Do not remove the boost compensator assembly (2) from
gear case. | |
. Check to see if the stop solenoid guide (6) touches boost lever
(5). If not, push the control rack from the mounting hole of
- high-idling body to make the solenoid guide (6) touched boost
4.
Hi
e
lever (5). (See figure.)
Remove the injection pump assembly (1).
MPORTANT
Before removing the injection pump assembly (1), be sure
to remove the stop solenoid (3) and hi-idling body (4).
And check to see if the stop solenoid guide (6) touches
boost lever (5). |
(1) Injection Pump Assembly — (4) Hi-idling Body
(2) Boost Compensator Assembly (5) Boost Lever
(3) Stop Solenoid (6) Stop Solenoid Guide
0000007351E
S-35
03-M-E2B, WSM
| | DIESEL ENGINE
[A]
lo 6)
3EEADAB1PO36A
Jd
Injection Pump. (for Turbocharger Model) (Continued)
(When reassembling) CR -
Check to see if the stop solenoid ¢ guide 6) touches boost lever
(5). If not, push the solenoid guide (6) to make the solenoid
guide (6) touched boost lever (5). (See figure [A]) —
Install the injection pump assembly into position. |
Tighten the injection pump assembly mounting bolts and nuts
with specified torque.
. Install the high-idling body and new gasket, and sighten them
with specified torque.
. Install the stop solenoid and tighten it with specified torque.
Tightening torque | Hi-idling body | 4.5 to 5.0 kgfm
44.1 to 49.0 N.m
| 32610363 ftbs —
(5) BoostLever [A] Correct
(6) Stop Solenoid Guide | [В] Incorrect
0000007352
5-36
© 03-M-E2B, WSM
(1)
SEEADAA1PO14A I
3TLABAB1PO11B
O
OT
|e— E
a \ 7 Ne
7 — O |
3EEADAA1POT5A
0
К
ЧЩ
SEEADAA1P017A
—e Specific tool (1):
“DIESEL ENGINE |
1.2 mm diameter hard wire with its end hooked, overall
— length 200 mm (7.87 in.).
~The tip of wire is bent like the hook to hang governor
-—
SEEADAA1PO18A
- (1) Specific Tool
(2) Large Governor Spring
(8) ForkLever .. —...
Remove the injection pump cover. В
. Remove the speed control plate (6) mounting nuts and bolts.
Using the specific tool (1), undo the large governor spring (2)
“from the fork lever (3).
Using the specific tool (1), undo the small governor spring (4)
from the fork lever (3). | -
. Set the speed control lever (5) as the figure. _
. Take out the speed control plate (6) with care not to let the a
— large (2) and small (4) governor springs come off this plate and
fall into the gear case. o |
(4) Small Governor Spring -
(5) Speed Control Lever
.... . (6). Speed Control Plate... = =.
0000006437E
@
S-37
03-M-E2B, WSM
DIESEL ENGINE
mT
LIT]
SEEADAAT В 5
(522
3EFADAA1POISA
Governor Springs and Speed Control Plate ( Continued) |
(When reassembling)
e Hook the small spring (4) first and then the large governor
spring (2) on the speed control plate (6). |
e Putthe specific too! (1) from the injection pump side to catch
the large governor spring (2 >), Keep this spring slightly
“extended and place the speed control plate (6) in its specified
position.
© Using the specific tool (1 ), hook the small governor spring (4)
onto the fork lever (3).
M NOTE | |
e Be careful not to stretch the small governor spring (4) too
long because otherwise it may get deformed permanently.
e Using the specific tool (1 ih hook the large governor spring
- (2) onto the fork lever (3). - В
® Make sure both the governor springs (2), (4) аге tight c on
the fork lever (3).
e Apply and tighten up the two bolts and two nuts on the
speed control plate (6). |
e Check that the speed control lever (5) positions low idle,
- after assembling governor springs.
e Check that the speed control lever (5) returns to the high
idle position rather than the low idle position, after
moving the lever to the maximum speed position.
e Finally attach the injection pump cover in position.
_ (4)
Te
SEEADAA1P019A
(1) Specific Tool (4) Small Governor Spring —
(2) Large Governor Spring (5) Speed Control Lever
(3) Fork Lever (6) Speed Control Plate
0000006438E
5-38
03-M-E2B, WSM
— DIESEL ENGINE =
Camshaft
1.. Remove the camshaft set bolts e): and draw out the camshaft
(1).
(When reassembling) |
o ‘When installing the idle gear, be sure to 0 align the alignment
| ‘marks on gears.
_ 285 0275 N-m
Tightening torque Camshaft set bolt 2.4 to 2.8 kgf-m
o | 17.4 to 20.3 ft-Ibs -
(1) Camshaft (2) Camshaft Set Bolt
0000005385E
‘Camshaft and Balancer Shaft (For Balancer Model) |
1. Remove the camshaft set bolts and draw out the camshaft (1).
2. Remove the balancer shaft 1 (2) set bolts and draw out the
balancer shaft 1 (2).
3. Remove the balancer shaft 2 (3) set bolts and draw out the
balancer shaft 2 (3).
(When reassembling)
® Wheninstall the balancer shaft 1 (2) and 2 (3 3), be sure to place
— the 1st and 4th cylinders piston at the top dead center in
compression then, align all mating marks on each gear to
assemble the timing gears, set the idle gear last.
— |235t0275N.m
Camshaft set bolt 2.4 to 2.8 kgf-m
| | 17.4 t020.3 ft-lbs
23.5 to 27.5 N-m
Balancer shaft set bolt | 2.4 to 2,8 kgf-m
Tightening torque |
17.4 to 20.3 ft-Ibs
STMABABIPO41A
(1) Camshatt (3) Balancer Shaft 2
(2) Balancer Shaft 1 | a o
0000006443E
S-41
03-M-E2B, WSM
— DIESEL ENGINE
3TLABAB1PO19A
| >. N 5
Fuel Camshaft and Fork Lever Assembly к
Remove the fuel feed pump. a DET
Detach the fuel camshaft t stopper (1) |
Remove the three fork lever holder mounting screws (2).
Draw out the fuel camshaft assembly (5), (6 ) and fork lever
| assembly (3), (4), (7) at the same time. |
(When reassembling) | ВЕ
e After installation, check to see that the fork lever 1 (3) and (4 )
— arefixed to the fork lever shaft, and that they can turn smoothly a
in the holder (7 (7).
(1) Fuel Camshaft Stopper — (4) Fork Lever 2
(2) Fork Lever Holder Mounting (5) Injection Pump Gear
a Screw В a Do (6) Fuel Camshaft В
(8) ForkLevert (7) ForkLeverHolder —
© 0000006444E
— Oil Pump
1. Remove the nut.
2. Draw out the oil pump drive gear (1) with gear puller (2).
3. Remove the four oil pump mounting * screws. Detach the oil
pump (3). |
(1) Oil Pump Drive Gear (3) Oil Pump
(2) Gear Puller |
0000005390E
Crank Gear
1. Draw out the crank gear (1) with a puller (2).
2. Remove the feather key.
(1) Crank Gear (2) GearPuller - —
0000005391E
S-42
03-M-E2B, WSM
DIESEL ENGINE
Fan Drive Pulley a
1. Lock the flywheel not to turn using the flywheel stopper.
2. Remove the fan drive pulley mounting nut (1). —
3. Remove the fan drive pulley (2) with gear puller (3).
4. Remove the feather key. a.
(When reassembling) -
e Apply grease to the splines of coupling.
, | 137.3 to 156.9 N-m
Tightening torque Fan deve pulley 14.0 to 16.0 kgf-m
mounting | 101.3 to 115.7 ft-lbs
(1) Nut | (3) Gear Puller
(2) Fan Drive Pulley
0000006439E
Gear Case
1. Remove the hour meter gear case (if equipped).
2. Remove the gear case (1). a
3. Remove the O-rings (2).
(When reassembling)
e Apply liquid gasket (Three Bond 1215 or equivalent) to both
sides of hour meter gear case gasket.
® Check to see if there are four O-rings (2) inside the gear case
(1).
® Apply a thin film of engine oil to the oil seal (3), and install it,
noting the lip come off.
® Before installing the gear case gasket, apply a non-drying
adhesive. |
(1) Gear Case (3) Oil Seal
(2) O-ring
0000006440E
5-39
03-M-E2B, WSM
00
3TMABAB1 ST
о foe
(1)
(7)
ЗТМАВАВ1РОЗ8В
DIESEL ENGINE
| Crankshaft Qil Slinger
1. Remove the crankshaft collar (3).
2
2. Remove t ne O-ring (2).
| 3. Detach the crankshaft oil | slinger (1 1)
(When reassembling) |
® Insert the crankshaft collar (3 ) after install the gear case to
cylinder body. | - В | a
(1) Crankshaft Oil Slinger ~ (3) Crankshaft Collar
(2) O- -ring |
| 0000006441E
Idle Gear
1. Remove the external snap ring. —
2. Detach the idle gear collar. '
3. Detach the idle gear (2). —
(When reassembling) -
o Check to see each gear is aligned with its aligning mark.
- Idle gear (2) and crank gear (4)
- idle gear (2 2) and camshaft gear (3)
- Idle gear (2) and injection pump gear (1)
(1) Injection Pump Gear (4) Crank Gear
(2) Idle Gear (5) Oil Pump Drive Gear
(3) Cam Gear
0000005383E
Idle Gear (For Balancer Model)
1. Remove the external snap ring.
2. Detach the idle gear collar
3. Detach the idle gear (2).
(When reassembling)
® Check to see each gear is aligned with its aligning mark:
e Idle gear (2) and crank gear (5), cam gear (3) and balancer
gear (4) |
e Cam gear (3) and idle gear (2)
e Idle gear (2) and injection pump gear (1)
e Idle gear (2) and balancer gear (7)
(1) Injection Pump Gear (5) Crank Gear
(2) Idle Gear (6) Oil Pump Drive Gear
(3) Cam Gear (7) Balancer Gear
(4) Balancer Gear
0000006442Е
5-40
03- M-E2B, WSM
(5) Piston and Connecting Rod
STLABAB1PO21A
— DIESEL ENGINE
Oil Pan and Oil Strainer
1. Remove the oil pan mounting screws.
2. Remove the oil pan (1) by ightly tapping the rim of the pan with
— awooden hammer.
3. Remove the oil pan gasket (2).
4, Remove the oil strainer (3) and O-ring (4 ).
(When reassembling)
© After cleaning the oil strainer (3), check to see that the filter
mesh in clean, and install it.
e Visually check the O-ring (4), apply engine oil, and install it.
e Securely fit the O-ring (4) to the oil strainer (3).
e Apply a liquid gasket (Three Bond 1215 or equivalent) to the
oil pan side of the oil pan gasket (2).
® To avoid uneven tightening, tighten oil pan mounting screws in
diagonal order from the center.
0) OlFan °° (8) Oil Strainer
(2) Oil Pan Gasket (4) O-rin g
0000006445E
S-43
03-M-E2B, WSM
DIESEL ENGINE
3TLABAB1P024A
Mur
blo
STLABAB1PO25A
(B)
7
7
|
3TMABAB1P0O46A
(C)
Pistons
ooze
5
Completely clean carbon (1) in the cylinders.
Remove the connecting rod cap (3).
Turn the flywheel and bring the piston to top dead center.
Draw out the piston upward by lightly tapping it from the
bottom of the crankcase with the grip of a hammer.
Draw out the other piston in the same method as above.
(When reassembling)
® Before inserting piston into the cylinder, apply enough engine
oil to the piston.
e When inserting the piston into the cylinder, face the mark on
the connecting rod to the injection pump.
IMPORTANT
e Do not change the combination of cylinder and piston.
Carefully
‘Make sure of the position of each piston by marking. For
example, mark "1" on the No. 1 piston.
Place the piston rings with their gaps at 0.79 rad (45 °)
from the piston pin's direction as shown i in the figure.
insert the pistons using a piston ring
compressor (6). | -
When inserting the piston in place, be careful not to get
the molybdenum disulfide coating torn off its skirt. This
coating is useful in minimizing the clearance with the
cylinder liner. Just after the piston pin has been press-
fitted, in particular, the piston is still hot and the coating
is easy to peel off. Wait until the piston cools down.
(6)
STLABAB1PO26A
44.1 to 49.0 N-m
Tightening torque Connecting rod screw 4.5 to 5.0 kgf-m
32.5 to 36.2 ft-lbs
(1) Carbon (A) Top Ring Gap
(2) Connecting Rod Screw (B) Second Ring Gap
(3) Connecting Rod Cap (C) Oil Rig Gap
(4) Connecting Rod (D) Piston Pin Hole
(5)
(6)
Molybdenum Disulfide Coating
in Piston Skirt
Piston Ring Compressor
S-44
(a)
0.79 rad (45 °)
0000006446E
03-M-E2B, WSM
DIESEL ENGINE
3TMABAB1P047D
STAAAAB1PO58A
(11)
/
SEEABAB1P100A
3EEABAB1P101A
Piston Ring and Connecting Rod
1. Remove the piston rings (4), (5), (6) using a piston ring tool
(Code No. 07909-32121). a.
2. Remove the piston pin (1), and separate the connecting rod
(7) from the piston (2).
(When reassembling)
© When installing the rings, assemble the rings so that the
manufacturer's mark (12) near the gap faces the top of the
piston (2). a | o
e When installing the oil ring (6) onto the piston (2), place the
expander joint (10) on the opposite side of the oil ring gap (11).
e Apply engine oil to the piston pin.
e When installing the piston pin (1), immerse the piston (2) in 80
°C (176 °F) oil for 10 to 15 minutes and insert the piston pin (1)
e When installing the connecting rod (7) to the piston (2), align
‘the mark (8) on the connecting rod (7) to the fan-shaped
concave (9).
HE NOTE |
e Mark the same number on the connecting rod (7) and the
piston (2) so as not to change the combination. |
(1) Piston Pin (7) Connecting Rod
(2) Piston (8) Mark
(3) Piston Pin Snap Ring (9) Fan-Shaped Concave
(4) Top Ring (10) Expander Joint
(5) Second Ring (11) Oil Ring Gap
(6) Oil Ring (12) Manufacturer's Mark
0000006447E
S-45
03-M-E2B,WSM
— (© Crankshaft |
ITLABAB1PO29A
RUN
ВЕ (When reassembling) o
—fiywheelboltandfitthebolt. o
| | EE SE | 98.0 to 107.8 N-m
~~ DIESEL ENGINE ‘
Fit the stopper to the flywheel (1).
At first, remove two pieces of the flywheel screws (2).
. Insert two pieces of the flywheel guide screws (3) in the holes.
- Remove the all flywheel screws (2).
Remove the flywheel (1) slowly along the flywheel guide
screws (3). o
e Insert two pieces of the flywheel guide screws.
e Check to see that there are no metal particles left on the
flywheel mounting surfaces. |
e. Apply engine oil to the threads and the undercut surface of the :
Tightening torque | Flywheel screws | 10.0 10 11.0 Кат
| | o - | 72.3 to 79.5 ft-Ibs
(1) Flywheel (3) Flywheel Guide Screw
| (2) Flywheel Screw. PE
| | | 0000006448E
Bearing Case Cover 22282
1. Remove the bearing case cover mounting screws. First,
remove inside screws (6) and then outside screws (3).
2. Screw two removed screws into the screw hole of bearing
- case cover (5) to remove it.
BM IMPORTANT a | |
® The iength of inside screws (6) and outside screws (3) are
different. Do not take a mistake using inside screws and
outside screws. | a
(When reassembling) ~~...
® Fit the bearing case gasket (1) and the bearing case cover
gasket (2) with correct directions. —
“© Install the bearing case cover (5) to position the casting mark
"UP" on it upward.
e Apply engine oil to the oil seal lip and take care that it is not
rolled when installing.
® Tighten the bearing case cover mounting screws with even
force on the diagonal line. |
23.5 to 27.5 №т
2.4 to 2.8 kgfm
17.4 to 203 fi-lbs
Bearing case cover
Tightening torque | mounting screw
-{1) Bearñng Case Gasket -- (5) Bearing Case Cover -
(2) Bearing Case Cover Gasket (6) Bearing Case Cover Mounting
(3) Bearing Case Cover Mounting Screw
Screw
(4) Oil Seal (a) Upside
0000006449E
S-46
03-M-E2B, WSM
Æ
OO
3TLABAB1PO31A
3TLABAB1POSSA
1. Remove the main bearing case screw 2 (1).
e zx A lA \
ol SER ls
— DIESEL ENGINE
Crankshaft —
MNOTE QU 1
~® Before disassembling, check the side clearance of
crankshaft. Also check it during reassembling.
"For D1503-M, D1703-M, V2003-M, V2003-M-T and V2203-M
2. Pull out the crankshaft assembly, taking care not to damage
the crankshaft bearing 1 (3).
For D1803-M o E.
1. Remove the main bearing case screw 2 (1).
2. Turn the crankshaft to set the crank pin of the third cylinder to _
the bottom dead center. Then draw out the crankshaft until the
crank pin of the second cylinder comes to the center of the
third cylinder.
the crank pin of the second cylinder to the bottom dead center.
Draw out the crankshaft until the crank pin of the first cylinder
— comes to the center of the third cylinder.
4. Repeat the above steps to draw out all the crankshaft.
Рог М2403-М = | 5
1. Remove the main bearing case screw 2 (1).
2. Turn the crankshaft to set the crank pin of the 4th cylinder to
- the horizontal directions (Right or Left). Then draw out all the
crankshaft, holding the crank pins to the horizontal directions
(Right or Left).
(When reassembling)
HM IMPORTANT — o a.
e Install the crankshaft sub assembly, aligning the screw
hole of main bearing case 2 (2) with the screw hole of
cylinder block.
‘® When tightening the main bearing case screw 2 (1), apply
© 3. Turnthe crankshaft by 2.09 rad (120 °) counterclockwise to set
oil to the screw and screw by hand before tightening the ~~
specific torque.
If not smooth to screw by hand, align the screw holes
between the cylinder block and the main bearing case.
[ | Main bearing case 68.6 to 73.5 Nm
Tightening torque | screwsz (70% /5kgfm
50.6 to 54.2 ft-lbs
(1) Main Bearing Case Screw 2 (a) Cut place for removing and
(2) Main Bearing Case 2 installing the crankshaft
(3) Crankshaft bearing 1 [A] D1803-M
0000006450
S-47
03-M-E2B, WSM
DIESEL ENGINE
3TMABABi
PO55B
3TLABAB1P035B
Main Bearing Case Assembly _
1.
Remove the two main bearing case screws 1 (8), and remove
1 Aba ar
“the main bearing case assembly being careful with thrust
bearing and crankshaft bearing.
2. Remove the main bearing case 1, 2 as above.
(When reassembling)
e Ciean the oil passage in the main bearing case.
Apply clean engine oil on the bearings.
Install the main bearing case assemblies in the original
positions. Since diameters of main bearing cases vary, install
them in order of makings (A, В for 3 cylinders and A, B, C for
4 cylinders) from the gear case side.
Match the alignment numbers (1) and mark (2) on the main
bearing case.
When installing the main bearing case 1 and 2, face the mark
"FLYWHEEL" to the flywheel.
Install the thrust bearing with its oil groove facing (6) outward.
Confirm that the main bearing case moves smoothly after
tightening the main bearing case screw 1 (8) to the specified
torque.
Main bearing case 46.1 to 50.9 Nm
Tightening torque Crew 3 4.7 to 5.2 kgfm
34.0 to 37.6 ft-lbs
(1) Alignment Number (5) C
(2) Alignment Mark (6) No Mark
(3) A (7) Oil Groove
(4) B (8) Main Bearing Case Screw 1
0000006451E
5-48
03MEB,WSM DIESEL ENGINE
= emana det Pp
A. CAUTION
e When removing the radiator cap, wait at least ten minutes after the engine has stopped. and cooled 5
‚down. Otherwise, hot water way gush out, , scalding nearby people. a
| | 0000006452Е
Thermostat. Assembly |
1. Remove the thermostat cover mounting screws, and move
the thermostat cover (1).
2. Remove the thermostat assembly (3).
(When reassembling)
| o Apply a liquid gasket (Three Bond 1: 1215 or r equivalent) only at
“the thermostat cover side of the thermostat cover gasket (2). —
(1) Thermostat Cover — (3) Thermostat Assembly
(2) Thermostat Cover Gasket :
0000006453E
Water Pump. Assembly |
Loosen the alternator mounting bolts, and remove the fan belt.
Remove the fan and fan pulley.
Remove the water pump assembly from the gear case cover.
Remove the water pump flange (1).
Press out the water pump shaft (2) with the impeller (5) on it.
Remove the impeller from the water pump shaft (2).
. Remove the mechanical seal (4).
IN (When reassembling)
SEEADAA1PO23A A e Apply a liquid gasket (Three Bond 1215 or y equivalen to the
В | a both sides of gasket.
e Replace the mechanical seal with new one.
Neer
(1) Water Pump Flange (4) Mechanical Seal
“ (2) Water Pump Shaft ~~ (5) Impeller —
(3) Water Pump Body
0000006454E
5-49
— 03-M-E2B, WSM
DIESEL ENGINE
(8) Starter
ЗТМАВАВЭРО1ЗА
Pr ©
ss
SITMABAB9PO15A
Disassembling Motor
1. Disconnect the connecting lead (9) from the magnet switch
® o
2. Remove the screws (6), and then separate the end frame (4),
yoke (2) and armature (1).
3. Remove the two screws (5), and then take out the brush holder |
(3) from the end frame (4).
(When reassembling)
e Apply grease to the spline teeth A of the armature (1).
(1) Armature (7) Nut
(2) Yoke | (8) Magnet Switch
(3) Brush Holder Ш (9) Connecting Lead
(4) EndFrame | :
(5) Screw | "A: Spline Teeth
(6) Screw
| ВЕ 0000002955Е
Disassembling Magnet Switch
1. Remove the drive end frame (1) mounting screws.
2. Take out the overrunning clutch (2), ball (3), spring (4), gears
(5), rollers (6) and retainer (7).
(When reassembling)
® Apply grease to the gear teeth of the gears (5) and
overrunning clutch (2), and ball (3).
(1) Drive End Frame (5) Gear
(2) Overrunning Clutch (6) Roller
(3) Ball (7) Retainer
(4) Spring
a 0000002956E
Plunger |
1. Remove the end cover (1).
2. Take out the plunger (2).
(1) End Cover (2) Plunger
0000002957E
S-50
03-M-E2B, WSM —
DIESEL ENGINE
© Aerator
3TMABAB9PO22A
—_ (When reassembiing)
Pulley
1. Secure the hexagonal end of the pulley shaft with a double-
ended ratchet wrench as shown in the figure, loosen the pulley
о | 58.310 789 Nm —
Tightening torque | Pulley nut 5.95 to 8.05 kgf.m
| | о ВЕ 43.0 to 58.2 ft-lbs
“ 0000002964E
Rear End Cover. 2
‚1. Unscerew the three rear end cover screws and the B terminal
"nut, and remove the rear end cover. —
0000002965E
Brush Holder
1. ‘Unscrew the two SCrews holding the brush holder, and remove
the brush holder (1). as В
(1) Brush Holder
0000002966E
IC Regulator
1. Unscrew the three screws holding the IC regulator, and
remove the IC regulator (1).
(1) 1C Regulator
0000002967E
S-51
03-M-E2B, WSM DIESEL ENGINE
Rectifier
1. Remove the four
lead wires.
2. Remove the rectifier (1).
screws holding the rectifier and the stator
(1) ‘Rectifier
LS 0000002968E
Rear End Frame
1. Unscrew the two nuts and two screws ho
frame and the rear end frame.
— 2. Remove the rear end frame (1). |
ding the drive end
(1) Rear End Frame
a ВЕ 0000002969E
Rotor |
1. Press out the rotor (1) from drive end frame (3).
IMPORTANT a
e Take special care not to drop the rotor and damage the
(8) — slip ring or fan, etc..
(1) Rotor (3) Drive End Frame
(2) Block |
- 0000002970E
Retainer Plate
1. Unscrew the four screws holding the retainer plate, and
_ remove the retainer plate (1).
(1) Retainer Plate
0000002971E
3TMABAB9PO26A
S-52
08-M-E2B, WSM “DIESEL ENGINE |
BearngonDriveEndSide <<.
1. Press out the bearing from drive end frame (3) with a press
and fig (4). ve | | |
(1) Jig : (8) Drive End Frame
(2) Block.
“ 0000002972E
Bearing at Slip Ring Side |
1. Lightly secure the rotor (1) with a vise to prevent damage, and
р) removethebearing (2) withapuller (3).
AS a | (1) Rotor | | (3) Puller
Ne ACIS к | (2) Bearing
>) Le) A
“y LE Bra ol В" o | В 11 … |
DL [EET \ OST | ‘ ‚0000001767 Е
777 / : N
(3)
STMABAB9PO28A
(10) Turbocharger
A caymon is running and or just after it stops, the turbocharger is hot, be careful not to touch the
turbocharger. | a
NOTE | | | |
‘® ‘When detaching and attaching the turbocharger assembly, be very careful not to allow dust, dirt and
other foreign matters in the oil pipes. |
e When the turbocharger assembly has been replaced, pour fresh engine oil through the oil filler port of
the turbocharger. o
e Before starting the engine, make sure that the air cleaner is in position.
| о ~~ 0000006759E —
Air Cleaner and Muffler
а) 1. Remove the intake pipe (1).
| 2. Remove the inlet pipe 1 (2).
3. Remove the muffler (3).
(When reassembling)
e Replace the gasket with new one.
(1) (1) Intake Pipe (3) Muffler
(2) Inlet Pipe 1
0000006760E
5-53
03-M-E2B, WSM DIESEL ENGINE |
OilPipe о
Remove the joint bolt (1), (2) and take off the oil pipe 1 (3).
Remove the bolts (4) and release the clamp (5).
a
. Disconnect the oil pipe 2 (6) and pipe 4 (7).
1.
2. e
3
(When reassembling) ‘ | - о
e Pour fresh engine oil through the oil filler port of the
wocharger,
® Replace the gaskets with new one. |
e Be careful not to allow dust, dirt and other foreign matters in
the oil pipes. | | | aH as
MNOTE — as
e Tape or plug all opening to prevent foreign matters from
damaging the oil cavities in the turbocharger.
(1) Joint Bolt В (5) Clamp |
(e) JointBot (6 OiPpez —
(3) Oil Pipe 1 (7) Oil Pipe 4
(4) Bolt a
0000006761E
Turbocharger
1. Remove the bolt (1). |
2. Take off the turbocharger assembly (2).
(When reassembling)
e Replace the gasket with new one.
(1) Bolt ВЕ SE (2) Turbocharger Assembly
0000006762E
SEEADAB1P025A (1)
5-54
03-M-E2B, WSM !
DIESEL ENGINE
[3] SERVICING
(1) Cylinder Head and Valves
LRT
Sa >=
KO Se
2,
STMABAB1POS6A
—
с D
B
SEEABAB1P112A
Aa @ =
A 4d } > - A
| DED | wem]
04h aye.
(==) | [az]
— ZZ
3TMABABOP059B
3.
Cylinder Head Surface Flatness
7
Clean. the cylinder head surface.
Place a straightedge onthe cylinder head's four sides (A ), (B),
(©). and (D) and two diagonal (E) and | (F) as shown in the
figure.
Measure the clearance with a feeler gauge.
If the measurement exceeds the allowable limit, correct it with
a surface grinder.
IMPORTANT o
e Do not place the straightedge on the combustion
chamber.
4 o Be sure to check the valve recessing after correcting.
Cylinder head surface
flatness
0.05 mm
10.0020 in.
Allowable mit.
0000002081E
Cvlinder Head Flaw
(1) Red Permetive Liquid - @
(2) Detergent
. Prepare an air spray red check (Code No. 07909-31371).
. Clean the surface of the cylinder head with the detergent (2).
. Spray the cylinder head surface with the red permeative liquid
(1). Leave it five to ten minutes after spraying.
Wash away the red permeative liquid on the cylinder head
surface with the detergent (2).
Spray the cylinder head surface with the white developer (3).
If flawed, it can be identified as red marks.
White Developer
0000000875E
S-55
© 03-M-E2B,WSM |
© DIESEL ENGINE
STMABABI POS7A
(1) 0
3TMABAB1P058A
3EEABAB1P116A
Valve. ; Recessing В o
. Clean the cylinder head surface, valve face and valve seat.
Insert the valve into the valve guide.
Measure the valve recessing with a depth gauge.
. If the measurement exceeds the allowable limit, » replace the
valve. Aa В
If it still exceeds the allowable limit after replacing the valve, TE
| replace Y the cylinder | head.
‘Valve recessing — | В a 0.0059 (recessing) in. |
. 0. 05 (protrusion) to.
0.15 (recessing) m
F actory Spec. 0.0020 (protrusion) to
| Allowable limit 0.40 (recessing) mm
tle)
| 0.0157 (recessing) in. ~~
(B) Protrusion
° 0000006455Е.
Clearance between Valve Stem and Valve Guide
. Remove carbon from the valve guide section.
2. Measure the valve stem O.D. with an outside micrometer.
. Measure the valve guide LD. 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. |
ВЕ ТЕ | | 0.040 to 0.070 mm
Clearance-between Loue „Factory spec A 0.00157 10:0.00276 in.
valve stem and valve — —t —
{guide Y Alinuabla lima. | O-10MM—
oo Allowable limit — | 0.0039 in.
= J ans | 7:960 to 7.975 mm
Valve stem O.D. | Factory spec. | 0.31339 10 0.31398 in.
A 8.030 mm 4
Valve guide 1.D. Factory spec. 0.31555 10 0.31614 in.
0000005441 E
S-56
03-M-E2B, WSM
“DIESEL ENGINE
3EEABAB1P117A
3TMABAB1P0O59A
œ
3TMABAB1P0O60A
e
@
Replacing Valve Guide
(When removing)
1. Press out the used valve guide using a valve guide replacing
tool. |
(When installing)
1. Clean a new valve guide and valve guide bore, and apply
engine oil to them. o |
2. Press in a new valve guide ı using a valve guide replacing tool.
3. Ream precisely the 1.D. of the valve guide to the specified
dimension. == | - Y Baad
Valve guide 1.D. (Intake | -. | | 8.01510 8.030 mm
and exhaust) Factory spec. 0.31555 to 0.31614 in.
IMPORTANT
e Do not hit the valve guide with a hammer. during
replacement.
(A) When Removing (B) When Installing
a 0000005442E
ake Seating a
. Coatthe 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 valve,
replace the valve or correct the contact of valve seating
(1) Correct (3) Incorrect
(2) Incorrect
0000004342E
S-57
03-M-E2B, WSM
DIESEL ENGINE
3EEABAB1P118A
=
3TMABAB1P061A —
Correcing Valve and Valve Seat
MNOTE o
“stem and the 1.0. ‘of valve guide section, and repair them
~ if necessary. EEE
e After correcting the valve seat, be: sure to check the valve
— recessing. © | -
‚ Correcting Valve
. Correct the valve with a valve refacer.
Ca) Correcting Valve Seat ——
1. Slightly correct the seat surface with a 1.047 rad (60 °) (intake
valve) or 0.785 rad (45 ) (exhaust valve) seat cutter (Code No.
07909-33102). |
2. Resurface the seat surface with a 0. 523 rad 30 °) valve seat —
cutter to intake valve seat and with a-0.262 rad (15 °) valve
seat cutter to exhaust valve seat so that the width is close to
specified valve seat width (2.12 mm, 0. 0835 in.).
3. After resurfacing the seat, inspect for even valve seating,
apply a thin film of compound between the valve face and
valve seat, and fit them with valve lapping tool.
4. Check the valve seating with prussian blue. The valve seating
surface should show good contact all the way around.
(a) Identical Dimensions A: Check Contact
(b) Valve Seat Width B: Correct Seat Width
(с) 0.523 rad (30 °) or 0.262 rad C: Check Contact
(15°) о
(d) 0.262 rad (15 °) or 0.523 rad
(30°)
(e) 0.785 rad (45 °) or 1.047 rad
(60°)
| “0000005444E
Valve Lappi ng
1. Apply compound evenly to the valve lapping surface.
2. Insert the valve into the valve guide. Lap the valve onto its
seat with a valve flapper or screwdriver.
3. After lapping the valve, wash the compound away and apply
oil, then repeat valve lapping with oil.
4. Apply prussian blue to the contact surface to check the seated
rate. If it is less than 70 %, repeat valve lapping again.
H IMPORTANT
e When valve lapping is performed, be sure to check the
valve recessing and adjust the valve clearance after
assembling the valve.
0000004345E
S-58
03-M-E2B, WSM
3EEABAB1P121B
3EEABAB1P122A
SEEABAB1P123A
I
LL ——
К
Cy ————
Ш
{
MIC
|
Ш
Ц
a
|
|
a]
u
DIESEL ENGINE
Free Length and Tilt of Valve Spring
1.
Measure the free length o of valve > spring with vernier
calipers. If the measurement is less th n the allowable limit,
replace it. |
Putthe valve spring on a surface plate, place a square on the
side of the valve spring.
Check to see if the entire side is in contact with the square.
Rotate the valve spring and measure the maximum tilt (B).
If the measurement exceeds the allowable limit, replace it.
Check the entire surface of the valve spring for scratches.
If there is any defect, replace it.
Free length (A)
41.7 to 42.2 mm
Factory spec. | 1.6417 10 1.6614 in.
| e 41.2 mm
| TIR(B) Allowable limit - | 1-0 MM
0.039 in.
(A) Free Length (B) Tilt
0000005474E
Valve Spring Setting Load
1. Place the valve spring on a tester and compress it to the same
length it is actually compressed in the engine.
2. Read the compression load on the gauge.
3. Ifthe measurement is less than the allowable limit, replace it.
117.6 N/ 35.0 mm
Factory spec. 12.0 kgf / 35.0 mm
Setting load / Setting 26.4 Ibs / 1.3780 in.
length | 100 N / 35.0 mm
10.2 kgf / 35.0 mm
Allowable limit
DE 22.5 Ibs/ 1.3780 in.
0000005475E
Oil Clearance between Rocker Arm and Rocker Arm Shaft
1.
2.
3.
Measure the rocker arm shaft O.D. with an outside
micrometer.
Measure the rocker arm 1.D. with an inside micrometer, and
then calculate the oil clearance.
If the oil 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.
Fact 0.016 to 0.045 mm
Oil clearance between actlory spec. 0.00063 t0 0.00177 in.
rocker arm and rocker E.
arm shaft . 0.10 mm
Allowable limit 0.0039 in.
Rocker arm shaft O.D. | Factory spec.
13.973 to 13.984 mm
0.55012 to 0.55055 in.
Rocker arm 1-0.
14.000 to 14.018 mm
Factory spec. 0.55118 to 0.55189 in.
0000005476E
5-59
- Push Rod Alignment
1. Place the push rod on Vv blocks.
2. Measure the push rod alignment. o
— 3. |f the measurement exceeds the allowable limit, replace the
Push rod. | WO DS
| E E 0.25 mm -
Push rod alignment ВЕ Allowable limit “| 0.0098 in.
E
3TMABAB1PO62A
Oil Clearance between Tappet and Tappet Guide Bore
A. Measure the tappet O.D. with.an outside micrometer.
gauge, ‘and calculate the oil clearance.
3. If the oil clearance exceeds the allowable limit or the tappet is
: damaged, replace the tappet.
“10.020 to 0.062 mm
Factory s spec. 0.00079 0 0.11244 in.
| oil clearance between
| tappet and tappet guide —
bore | Allowable timit | 90207
SEEABAB1P124A
| E 123.959 to 23.980 mm
Tappet O.D. Factory spec. | 0.94327 10 0.94410 in.
à | 24.000 to 24.021 mm
| Tappet guide bore 1.D. Factory Spec. | 0.94488 to 0.94571 in.
0000005477E
S-60
0000000885E
- | 2. Measure the 1.D. of the tappet guide bore with a ‘cylinder N |
03-M-E2B, WSM
DIESEL ENGINE
(2) Timing Gears, Camshaft and Fuel Camshaft
>=.
STGAAABIPO48A
3TMABAB1P064A
- Timing Gear Backlash
1. Setadial 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
clearance of the shafts and the gear.
4. If the oil clearance is not proper, replace the gear.
Backlash between idle
gear and crank gear
Factory spec.
0.0415 10.0.1122 mm
0.00163 to 0.00442 in.
., 10.15 mm
Allowable limit 0.0059 in.
| an 0.0415 to 0.1154 mm
| | Factory spec. — "
Backlash between idle | = 0.00163 10 0.00454 in. |
gear and cam gear ВЕ 0.15 mm
| Allowable limit 0.0059 in.
Backlash between idle
gear and injection pump
Factory spec.
0. 0415 to 0.1154 mm
0. 00163 to 0.00454 in.
о и 0.15 mm
gear |
Allowable limit 0.0059 in.
a Factory spec 0.0415 to 0.1090 mm
Backlash between y Spec. 0.00163 to 0.00429 in.
crank gear oil pump
| gear / es 0.15 mm
| Allowable limit 0.0059 in.
For Balancer Model Only
Backlash between idle
gear and balancer gear
Factory spec.
0.0350 to 0.1160 mm
0.00138 to 0.00457 in.
Allowable limit
0.0059 in.
0.15 mm
Idle Gear Side Clearance
0000006456E
1. Set a dial indicator with its tip on the idle gear.
front and rear.
idle gear collar.
2. Measure the side clearance by moving the idle gear to the
If the measurement exceeds the allowable limit, replace the
Idle gear side clearance
Factory spec.
| 0.12 to 0.48 mm
0.0047 to 0.0189 in.
Allowable limit
10.0354 in.
0.90 mm
S-61
0000005479E
PE e Ta O | Camshaft Side Clearance В
В FE Ce | A A. Set a dial indicator with its tip on the c cam gear. A ‘
I Co 2. Measure the side clearance бу moving the cam gear to the
| front and rear. | |
—3. If the measurement exceeds the allowable mit, replace the В
a E camshaft stopper. Ш
a | Factory spec. 0.07 10022 mm. |
Camshaft side ysSpec. 10.0028 to 0.0087 in.
| a a ~~ | clearance - E
_ 7 | о. a CS Less 0.0118 in.
STMABAB1POSSA APTO —
0000005480E
a Balancer! Shaft Side Clearance (For Balancer Model Only)
‚1. Seta dial indicator with tip on the balancer shaft.
the front and rear.
3. If the measurement exceeds the allowable init, replace tt the
: _balancer < shaft.
В Factory spec. — To.o7 0 022mm' ;
Side clearance of | | 0:0028 t00.0087 in.
| DDN - |balancershat +. [| о Toa mm
и NL 0 |Plewadlelmt | 9.0148 in.
STMABABI POSSA |
© 0000006457E
S-62
— 2. Measure the side clearance by- moving the balancer shaft to = -
© 03-M-E2B, WSM DIESEL ENGINE
Oil Clearance of. Balancer Shaft Journal (For Balancer Model -
1. Measure the balancer shat journal : ob. with an outside
micrometer.
2. ‘Measure the cylinder block bore I.D. for balancer s shaft with € an
inside micrometer or cylinder gauge. |
“3. If the clearance exceeds the allowable limit, replace the
balancer shaft.
‘Factory spec. —
0.030 to 0.111 mm
| OD.
Factory spec.
Oil clearance of 0.00118 to 0.00437 in.
balancer shaft journal | 1. [02mm
Allowable limit 0.0079 in.
| Balancer shaft journal 1 43.934 to 43.950 mm ”
‘| 1-72968 to 1.73031 in.
Balancer shaft bearing 1
| Factory spec.
43.980 to 44.045 mm
| 1D. 1.73149 to 1.73405 in.
NET 0.030 0 0.111 mm —_
A Oil clearance of | oo Spee 0.00118 0 0.00437 in.
OST balancer shaft journal 2 | So |
ЗТМАВАВ1РОВВА o Allowable limit 0.2 mm
1 0.0079 in.
Balancer shaft journal 2
0.D. |
Factory spec.
| 41.934 to 41.950 mm
1.65094 to 1.65157 in.
Balancer shaft bearing 2
LD.
Factory spec.
41.980 to 42.045 mm
1.65275 to 1.65531 in.
Factory spec.
0.020 to 0.094 mm
| Oil clearance of 1 0.00079 to 0.00370 in.
balancer shaft journal 3 Alowabl mi 02mm
ance SOUT [raro ono | 219471021 500mm
| O.D. | 1 0.86405 to 0.86456 in.
SE
(1) Balancer Shaft Journal 1
(2) Balancer Shaft Journal 2 —
(3) Balancer Shaft Journal 3
0000006458E
S-63
—03-M-E2B, WSM
DIESEL ENGINE
STMABAB1POG9A
SEEABAB1P129A
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 bushing 1.D. with an inside micrometer,
and calculate the oil clearance. |
3. If the oil clearance exceeds the allowable limit, replace the
~ bushing. | |
4. fit still exceeds the allowable limit, replace the idle gear r shaft.
о | 0.025 to 0.066 mm
Oil clearance between 0.00098 to 0.00260 in.
| Factory spec.
idie gear shaft and idie” | —— :
gear bushing | Ale Fre 0.10 mm
- | Aliowable limit | 0.0039 in.
37.959 to 37.975 mm
Idle gear shaft O.D. Factory Spec. 1.49445 10 1.49508 in.
| 88.000 to 38.025 mm
| 1.496086 to 1.49704 in.
Idle gear bushing LD. | Factory spec.
a В 0000005483E
Replacing Idle Gear Bushing
(When removing)
1. Press out the used idle gear bushing. using an idle gear
bushing replacing tool.
(When installing)
1. Clean a new idle gear bushing and idle gear bore, and apply
engine oil to them.
2. Press in a new bushing using an idle gear bushing replacing
tool, until it is flush with the end of the idle gear.
(A) When removing (B) When installing
0000000895E
1. Support the camshaft with V blocks on the surface plate at
both end journals.
2. Set a dial indicator with its tip on the intermediate journal.
3. Measure the camshaft alignment.
4. If the measurement exceeds the allowable limit, replace the
camshaft.
o 0.01 mm
Camshaft alignment Allowable limit 0.0004 in.
0000000891E
Cam Height
1. Measure the height of the cam at its highest point with an
outside micrometer.
2. lf the measurement is less than the allowable limit, replace the
camshaft.
33.90 mm
Cam height of intake 1.3346 in.
and exhaust o 33.85 mm
Allowable limit 1.3327 in.
Factory spec.
0000005481E
5-64
03-M-E2B, WSM
DIESEL ENGINE
3TMACAA1PO52A |
3TMABAB1P071A
(3) Piston and Connecting Rod
ЗЕБАВАВ1Р1ЗВА
ЗЕЕАВАВ1Р139А N \
Qi Clearance of Camshaft Journal
“Messe the camshaft journal OD. with an outside | nn
| Camshaft journal O.D. | Factory spec.
nicrometer.
Measure the cylinder block bore LD. for camshaft with a
~ cylinder gauge, and calculate the oil clearance. Ta
. If the oil clearance exceeds. the allowable limit, replace t the >
| camshaft. 5 В
| ‘ | a 0.050 to 0.091 mm
Oil clearance of l'actory SPEC | 0.00197 10 0.00358 1.
| camshaft journal О [РОБ ти
| Allowable mi lo. 0059 in.
39.934 to 39.950 mm
1.57221 10 1.57284 in.
1.57480 to 1.57579 in.
‚ 0000005482Е
Piston Pin Bore |. D.
2.
3.
1. Measure the piston pin bore I.D. in both the horizontal and
~ vertical directions with a cylinder gauge.
2. If the measurement exceeds the allowable limit, replace the |
piston. o |
| Ш 25.000 to 25.013 mm
Factory spec. 0.98425 to 0.98477 in.
Piston pin bore 1.D.
PL la mis 25.05 mm |
— 0000005486E
Oil Clearance b n Piston Pin and Small End Bushin
1.
Measure the piston pin O.D. where it contacts the bushing with
“an outside micrometer.
Measure the small end bushing |. р. with a an inside micrometer,
and calculate the oil clearance.
If the oil clearance exceeds the allowable limit, replace the
bushing. If it still exceeds the allowable limit, replace the
piston pin.
F 0.014 to 0.038 mm
| Oil clearance between... | Factory spec. 1 0.00055 10.0.00150 in.
piston pin and small end
bushing в 0.15 mm
Allowable limit 0.0059 in.
. , 25.002 to 25.011 mm
Piston pin O.D. Factory spec. 0.98433 to 0.98468 in.
Small end bushing 1.D. | Factory spec. ro omg
0000005488E
S-65
03-M-E2B, WSM
— DIESEL ENGINE
3EEABAB1P144A
Replacing Connecting Rod Small End Bushing
(When removing) |
1. Press out the small end bushing with a connecting rod small
end bushing replacing tool. |
Suman installing)
Clean a new small end bushing and bore, and apply engine oil
tothtem :
2. Press fit a new bushing, taking due care to see that the
“connecting rod hole matches the busing hole.
(A) When removing (B) When installing
0000005490E
Piston Ring Gap
1. Insert the piston ring into the lower part of the liner (the least
worn out part) with the piston.
2. Measure the ring gap with a feeler gauge.
3. Ifthe gap exceeds the allowable limit, replace the ring.
DISO3-M | 0.20to 0.35 mm
V2003-M — | 0.0079 to 0.0138 in
V2003-M-T - ; -
Factory
spec. D1703-M |
Top ring D1803-M 0.25 to 0.40 mm
V2203-M 0.0098 to 0.0157 in.
V2403-M
o | 1.25 mm
Allowabie limit 0.0492 in.
D1503-M
D1703-M 0.30 to 0.45 mm
D1803-M | 0.0118 to 0.0179 in
Factory | V2203-M
N Е Ш spec. . |1v2403-M . .
Second ring
V2003-M 0.40 to 0.55 mm
V2003-M-T ° 0. 01 57 to 0. 021 7 in.
но 1 25 mm
Allowable limit 0.0492 in.
‘Factor spec. | 0.25 to 0.45 mm_
y SPEC. 0.0098 to 0.0177 in.
Oil ring
2, 1.25 mm
Allowable limit 0.0492 in.
0000006763E
S-66
— 03-M-E28, WSM
DIESEL ENGINE |
3TMABAB1P072A
3TMABABOPO56A
| e —
A.
2
fF
8.
Clearance between Piston Ring and Groove
Remove carbon from the ring grooves.
Measure the clearance between the ring and the groove e with |
a feeler gauge or depth gauge. |
If the clearance exceeds the allowable limit, replace the ring |
— since compression leak and oil shortage result.
À.
if the clearance still exceeds the allowable limit after replacing |
the ring, replace the piston.
-| Second ring
| 0.093 to 0.128 mm
| Factory spec. | 0.0037 to 0.0050 in.
Allowable imi 0.0079 in.
| Factory spec.
| 0.15 mm
Allowable limit 0.0059 in.
Connecting Rod Aïgnment
NOTE |
0000006459E
e Since the I. D. of the connecting rod small end bushing is
the basis of this check, check bushing for wear
beforehand.
1. Install the piston pin into the connecting rod.
Install the connecting | rod on the connecting rod alignment
tool. | a | - - |
3. Puta gauge over the piston pin, and move it against the face
plate.
4. If the gauge does not fit squarely against the face plate,
measure the space between the pin of the gauge and the face
plate. | |
5. If the measurement exceeds the allowable limit replace 1 the
_ connecting rod.
TRE FE
0000005493E
S-67
|0.020t00.060mm |
0.0008 to 0.0021 in. |
— 03-M-E2B, WSM
DIESEL ENGINE
(4) —_—
AL a
>— 0 CA
3TLABADI PO36A *
Side Clearance of Crankshaft
1.
2.
3.
Move the crankshaft to the fiywheel side.
Set a dial indicator to the crankshaft. |
Measure the end play by pulling the crankshaft toward the
crank gear.
If the measurement exceeds the allowable limit, replace the
thrust bearing 1 and 2.
Ns
STMABAB1P074A
SEEABAB1P147A
Crankshaft side | 0.0059 to 0.0122 in.
clearance oo 0.5 mm
Allowable limit 0.0197 in.
(Reference)
e Oversize dimensions of crankshaft journal -
Oversize 0.2 mm 0.4 mm
0.008 in. | 0.016 in.
“Dimension À 26.20 to 26.25 mm | 26.401026.45mm
1.0315 to 1.0335 in. —. 1.0394 to 1.0413 in.
Dimension B 54.5 to 54.7 mm 54.6 to 54.8 mm
or 2.1456 to 2.1535 in. — 2.1496 10 2.1574 in.
Dimension C 2.8 to 3.2 mm radius 2.8 to 3.2 mm radius
0.1102 to 0.1260 in. radius | 0.1102 to 0.1260 in. radius
(0.8-S)
The crankshaft journal must be fine-finished to higher than vwvv
0000006460E
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.
Rotate the crankshaft on the V blocks and get the
misalignment (half of the measurement).
If the misalignment exceeds the allowable limit, replace the
crankshaft.
, . | 0.02 mm
Crankshaft alignment Allowable limit В | 0.00079 in.
0000005496Е
S-68
03-M-E2B, WSM
DIESEL - ENGINE
STMABAB1P075A
ne
Oil Clearance between Crankpin and Crankpin Bearing |
1.
>
быт №
3.
Clean the crankpin and crankpin bearing.
Put a strip of plastigage (Code No. 07909- -30241) on the
center of the crankpin each direction as shown in the figure.
Install the connecting rod cap and tighten the connecting rod
screws to the specified torque, and remove the cap again.
Measure the amount of the flattening with the scale, and get
the oil clearance.
. If the oil clearance exceeds the allowable limit, replace the
crankpin bearing.
If the same size bearing is useless because of the crankpin
wear, replace it with an undersize one referring to the table
and figure.
NOTE
e Never insert the plastigage into the crankpin oil hole. |
® Be sure not to move the crankshaft while the connecting
rod screws are tightened.
3TMABAB1P0748
Oil clearance between | Factory spec.
crankpin and crankpin
| 0.025 to 0.087 mn
0. 00098 to 0. 00343 in.
bearing | la limit |0.2mm
Allowable limit | 0.0079 in.
Crankpin O.D. ‚| | Factory spec. | 46.959 to 46.975 mm
1.84878 to 1.84941 in.
Crankpin bearing I.D. | Factory spec.
| 47.000 to 47.046 mm
1.85039 to 1.85220 in.
(Reference)
e Undersize dimensions of crankpin
Undersize 0.2 mm | 0.4 mm
a 0.008 in. 0.016 in.
Dimension A 3.3 to 3.7 mm radius — 33t03.7 mmradius
0.1299 to 0.1457 in. radius 0.1299 to 0.1457 in. radius
Dimension B 1.0 to 1.5 mm radius 1.0 10 1.5 mm radius
0.0394 to 0.0591 in. radius | 0.0394 to 0.0591 in. radius
Dimension € 46.759 to 46.775 mm dia. 46.559 to 46.575 mm dia.
1.84091 to 1.84154 in. dia. 1.83303 to 1.83366 in. dia.
- (0.8-S)
The crankpin must be fine-finished to higher than vv vv
5-69
0000006461Е
03-M-E2B, WSM ER ae DIESEL ENGINE |
oi. Clearance between Crankshaft Journal and Crankshaft
Bearing 1 EE ©
1. Measure the 0D of the crankshaft journal ith an outside ‘
micrometer.
2. Measure the .D. of the crankshaft bearing 1 with : an | inside
micrometer, and calculate ой clearance. — o
3. If the 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. |
0.040 to 0.118 mm
Oil clearance between | 0.00157 10 0.00465 in.
| crankshaft journal and An ——
‘Factory spec.
Crankshaft journal O.D. | Factory spec. 199.921 10 59.940 mm
| 2.35909 to 2.35984 in. —
‘ Grankshat beating 1 lu | 59.980 10 60.039 тит:
10 to. Allowable limit | 2.36142 10 2.36374 .
3TMABAB1P078A | | |
(Reference)
e Undersize dimensions of crankshaft journal |
| | Oversize | ©. 2 mm 0.4mm
— Е “0.008 in. 0.016 in.
| | Dimension A 28to3.2mmradius | 2.8t03.2mm radius
—_— TTT | 0.1102 Ю 0.1260 1. radius | 0.1102 10 0.1260 in. radius
Dimension B 1.0 to 1.5 mm radius “1.0 to 1.5 mm radius
- 0.0394 to 0.0591 in. radius | 0.0394 to 0.0591 in. radius
Dimension € 59.721 10 59.740 mm | 59.521 to 59.540 mm
3TMABAB1P079A 2.35122 to 2.35197in. | 2.34335 t0 2.34409 In.
The crankshaft journal must be fine-finished to higher than vvvv
0000006462E
Replacing Crankshaft Bearing 1
(When removing)
1. Press out the used crankshaft bearing 1 using a crankshaft
bearing 1 replacing tool.
(When installing)
1. Clean a new crankshaft bearing 1 and crankshaft journal bore,
and apply engine oil to them.
(AN
EN
ber | 2. Using a crankshaft bearing 1 replacing tool, press in a new
fe bearing 1 (2) so that its | seam (1) directs toward the exhaust
3TMABAB1P080A manifold side.
. . 2 to 4.
Dimension (A) Factory spec. N 4 don 01772 in.
(1) Seam (3) Cylinder Block
(2) Crankshaft Bearing 1
0000005509E
S-70
~ 10.0079 in. LL o
03-M-E2B, WSM
DIESEL ENGINE
3TMABAB1PO8iA
‘
SEEABAB1 P152B
STMABAB1POS2A
Oil Clearance between Crankshaft Journal and Crankshaft
Bearing 2 | o -
1. Puta strip of plastigage c on the centre 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 e flattening with the scale and dgett the Е
— oilclearance. 5
4. If the clearance exceeds the allowable mit, , replace the
crankshaft bearing 2. -_ N
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.
BM NOTE
e Be sure not to move > the crankshaft while the bearing case a
screws are tightened.
‘Oil clearance between
crankshaft and =
crankshaft bearing 2
| 0.040 to 0.104 mm
Factory Spec. 0.00157 to 0.00409 in.
oe | 020mm
| Allowable limit [0.0079in.
‘Crankshaft OD.
59.921 to 59.940 mm
Factory spec. 2.35909 10 2.35984 in.
| Crankshaft bearing 2 N | “ | 59.980 to 60.025 mm
11D. | Factory spec. | 2.86142 to 2.368318 in.
® Undersize dimensions of crankshaft journal
Undersize 0.2 mm 0.4 mm
| | 0.008 in. 0.016 in.
A 2.8 to 3.2 mm radius 2.8 10 3.2 mm radius
0.1102 to 0.1260 in. radius | 0.1102 to 0.1260 in. radius
B 1.0 to 1.5 mm radius 1.0 to 1.5 mm radius
Ви | 0.039410 0.0591 in. radius | 0.03940 0.0591 in. radius |
со © 59.721 to 59.740 mm 59.521 to 59.540 mm
Cn 2.35122 to 2.35197 in. 2.34335 to 2.34409 in.
— (0.8-8) —
The crankshaft journal must be fine-finished to higher than Yv vY
Crankshaft Sleeve Wear
‚ 0000006463Е
; Check the wear on the crankshaft sleeve (1).
. Ifthe wear exceeds the allowable limit or when the engine oil
leaks, replace the crankshaft sleeve. |
Wear of sleeve
Allowable limit
0.1 mm
0.0039 in.
(1) Crankshaft Sleeve
s-71
0000005512E
a -
03-M-E2B, WSM | | a В DIESEL ENGINE
Replacing Crankshaft Sleeve
1. Remove the used crankshaft sleeve using a special- use puller
‘set (Code No. 07916-32091).
2. Set the sleeve guide (2) to the crankshaft.
Set the stopper (1) to the crankshaft as shown in figure.
4. Неа! a new sleeve toa temperature between 150 to 200 °C
(302 to 392 °F), and fix the sieeve to the crankshaft as shown
in figure.
5. Press fit the sleeve using the auxiliary socket for pushing (4).
Ш МОТЕ
e Mount the sleeve with its largely chamfered surface
‘facing outward.
со
(1) Stopper | (4) Auxiliary Socket for Pushing
(2) Sleeve Guide (5) Crankshatft
(3) Crankshaft Sleeve | NT TT
| 0000005520E
(1) 8
STMABAD1POS4A
S-72
03- M-E2B, WsM_
DIESEL ENGINE
(5) Cylinder
| |
. 8B
| < с >
SEEABAB1P155A
Cylinder Wear
1. Measure the LD. of the cylinder at the six positions (see figure)
with a cylinder gauge to find the maximum and minimum 1.D.'s.
2. Get the difference (Maximum wear) between the maximum
and the minimum 1.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".)
2008 MM | 88.000 to 83.022 mm
co “| v2003-M-T 3.2677210 3.26858 in.
| Factory — | |
Cylinder 1.D. . . [spec. |Di70M | 30
D1803-M 87.000 to 87.022 mm
V2203-M | 3.42519 t0 3.42606 in.
V2403-M |
D1503-M nde
угосаы | холл,
a 5 | veoo3-mT | >
A | Allowable }—
Maximum wear limit D1703-M |
D1803-M +0.15 mm
V2203-M +0.0059 in.
V2403-M |
А: Тор (а) Right-angled to Piston Pin
B: Middle
C: Bottom (Skirt)
5-73
(6) Piston Pin Direction
0000006464E
DIESEL ENGINE
(6) Oil Pump
3TMABAB1P086A
3TMABAB1POS7A
‚ 03- M- E2B, WSM
Correcting Cylinder (Oversize +0. 25mm) oo
1. When the cylinder i isworn beyond the allowable mit bore and
: hone it to the specified dimension.
1 5 @
A ft 1 _ .
n |: ‘ 01508 M | 83.250 to 83.272 mm
Ea) | | V2008:M-T о | 3.27756 10 3.27843 In.
ho dl Oversize cylinder 1.D. : coe D1703- M. Y
В (2) : | | D1803-M | 87.250 to 87.272 mm
— V2203-M | 3.43503 to 3.43590 in.
|, | V2403-M a
t 1 -
' D1503- M | |
ol V2003-M oa
' | V2003-M-T A
| "UU Maxi Allowable
| y ' | В aximum wear limit D1703-M |
A v2403-M- | ————
Horn to 2:2 to 3.0 ¿m Rmax.
{ Finishing | vvv
a a. (0.00087 to 0.0018 In. Ama)
2. Replace the piston and piston rings v with oversize (+0.25 mm)
ones.
HNOTE |
e When the oversize cylinder i is worn beyond the allowable
limit, replace the cylinder block with a new one.
(1) Cylinder |.D. (2) Oversize Cylinder ID.
(Before Correction)
0000006466E
Rotor Lobe Clearance
1. Measure the clearance between lobes of the inner rotor and
the outer rotor with a feeler gauge.
‚2. Measure the clearance between the outer rotor and the pump
body with a feeler gauge.
If the clearance exceeds the factory specifications, replace the
‘oil pump rotor assembly.
0.03 to 0.14 mm
Factory spec. 0.0012 to 0.0055 in.
Clearance between
inner rotor and outer
rotor imi 0.0078
Allowable limit 0.0079 in.
0.11 to 0.19 mm
Clearance between 0.0043 to 0.0075 in.
outer rotor and pump - - —
body о 0.25 mm
Allowable limit 0.0098 in.
Factory spec.
0000005528E
S-74
03-M-E2B, WSM
DIESEL ENGINE
UT CU
T EXCLAE T SHAN Y Evexer
i PERFECT CIRCLE PLASTIGA С
3TMABAB1P088A
(7) Starter
3EEABAB1P188A
N Clearance between Rotor and Cover
. Put a strip of plastigage (Code No. 07909-30241) onto the
— rotor face wi th gr ease.
Install the cover and tighten the screws.
Remove the cover carefully, and measure the width of the
press gauge with a sheet of gauge.
. If the clearance exceeds the factory specifications, replace the
oil pump rotor assembly.
End clearance between | 0.00413 to 0.00591 in.
inner rotor and cover
| Factory spec. 0.105 to 0.150 mm
0.2 mm
0.0079 in.
Allowable limit
0000005529E
Overrunning Clutch
1.
2.
3.
Inspect the pinion for wear or damage.
If there is any defect, replace the overrunning clutch assembly.
Check that the pinion turns freely and smoothly in the
overrunning direction and does not slip in the cranking
direction. | |
If the pinion slips or does not rotate in the both directions,
replace the overrunning clutch assembly.
0000001168E
S-75
03-M-E2B, WSM
DIESEL ENGINE
3EEABAB1P184A
Commutator and Mica
1.
2.
Check the contact face of the commutator for wear, and grind
the commutator with emery paper if it is slightly worn.
Measure the commutator O.D. with an outside micrometer at
“several points. — ‘ a. о |
Ifthe minimum O.D. is less than the allowable limit, replace the
armature. |
If the difference of the O.D.'s exceeds the allowable limit,
‘correct the commutator on a lathe to the factory specification.
. Measure the mica undercut. | -
if the undercut is less than the allowable limit, correct it with a
6.
saw blade and chamfer the segment edges.
| | D1593-M.. |
|D1703-M |. |
|. |v2003-M Se _
Factory | v2003-M-T o
spec. v223M |
| DI803-M— . |35.0mm
В V2403-M | 1.378 in.
Commutator O.D. - — —
a D1503-M a
| D1703-M >
~~ lveoosm [230M
Allowable | V2003-M-T +142.
| limit V2203-M
D1803-M | 34.0 mm
V2403-M 1.339 in.
o Less than 0.02 mm
| Factory spec.
0.0008 in.
Difference of O.D.'s о
| a 0.05 mm
| Allowable limit | 0.0020 in.
| Factory spec 0.45 to 0.75 mm
| Faclory spec. | "10.0177 10 0.0295 in.
Mica undercut
. 10.20 mm
Allowable limit 1 0.0079 in.
(1) Segment (a) Correct
(2) Undercut (b) incorrect
(8) Mica
0000007114E
S-76
03-M-E2B, WSM
“DIESEL ENGINE
SEEABAB1P185A
SEEABABIPIS9A |
3EEABAB1P186A
— Brush Wear
1. Ifthe contact face of the brush | is dirty or dusty, clean it with
emery paper.
2. Measure the brush length A) with vernier calipers. |
3. If the length is less than the allowable limit | replace Ÿ the > yoke |
assembly and brush holder.
Brush length (A)
D1503-M
D1703-M |
| | v2003-M > e В
Factory | v2003-M T |
spec. | v2203-M
D1803-M | 15.0 mm
V2403-M 0.591 in.
D1503-M |
D1703-M |...
| {veoozm |10MM
| Allowable | v2003-M-7 — | 90-433 in.
limit V2203-M
“ |D1803-M |9.0mm
| v2403M |0.345in.
Pue Holder
0000007115E |
. Check the continuity across the brush holder and the holder
support with an ohmmeter. ©
2. If it conducts, replace the brush holder.
Resistance
Brush holder - Holder
support‘ |
| Infinity
©
Armature Coil
41. Check the continuity across the commutator and armature coll
core with an ohmmeter.
N
with an ohmmeter.
4. Ifit does not conduct, replace the armature.
S-77
If it conducts, replace the armature.
. Check the continuity across the segments of the commutator
0000005175E
0000001172E
03-M-E2B, WSM | a | — DIESEL ENGINE
Field Coil |
(1) — (2) | 1. Check the continuity across the lead (1) and brush (2) with an
[= Г oh Да о шо
onmmeter. | |
2. If it does not conduct, replace the yoke assembly.
3. Check the continuity across the brush (2) and yoke (3) with an
~ ohmmeter.
4. If it conducts, replace the yoke assembly.
(1) Lead (3) Yoke
(2) Brush
3EEABAB1P190A 0000001173E
3EEABAB1P191A
(8) Alternator
Bearing
1. Check the bearing for smooth rotation.
2. If it does not rotate smoothly, replace it.
0000001178E
SEEABAB1P192A
Stator
1. Measure the resistance across each lead of the stator coil with
anohmmeter. ss o
2. Ifthe measurement is not within factory specification, replace
it.
3. Check the continuity across each stator coil lead and core with
an ohmmeter.
4. If infinity is not indicated, replace it.
| Resistance Factory spec. Less than 1.0 О |
i
SEEABAB1P193A
0000001768E
5-78
03-M-E2B, WSM
DIESEL ENGINE
SEEABABIP194A
SEEABABiP195A
3EEABAB1P197A
> ENE
Rectifier |
1. Check the continuity across each diode of rectifier with an
‘Rotor -
— -
. Measure the resistance across the slip. rings with an
- ohmmeter. | |
2. If the resistance is not tthe factory specification, replace it.
3. Check the continuity 2 across the > sip fing and « core with - an
— ohmmeter. ВЕ ВО
4. If infinity is not indicated, replace it.
| Resistance . — | Factory spec. 2.9 о
‘ 0000002973E
Slip Ring
Check the slip ring for score.
df scored, correct with an emery paper or on a lathe.
. Measure the O.D. of slip ring with vernier: calipers. |
If the measurement is less than the allowable limit, replace it.
a | | [144mm
Lo Factory spes. lose7in. —
Slip ring O.D. SANT - Co
a . 4 0 mm
Allowable limit 0.551 in.
a 0000002974E
Brush Wear |
1. Measure the brush length with vernier calipers.
2. If the measurement is less than allowable limit, replace it.
3. Make sure that the brush moves smoothly. |
4. If the brush | IS defective, replace it.
Factory spec | 10.5 mm
| clory spec. 0.413 in.
Brush length
| | da fimis | 84mm
| Allowable limit . — |oggin —
0000002975E
analog ohmmeter. Conduct the test in the (R x 1) setting.
2. The rectifier is normal if the diode in the rectifier conducts in
one direction and does not conduct in the reverse direction.
EN IMPORTANT
e Do not use a 500 V megger for measuring because it will
destroy the rectifier.
Ш МОТЕ
e Do not use an auto digital multimeter. Because it's very
hard to check the continuity of rectifier by using it.
0000005178E
S-79
03-M-E2B, WSM
DIESEL ENGINE
STMABAB9PO29A
(9)
o wm am em em ww Ee x aE
EEE EE ER ER EW SS WE — Ma a Sr ER EN EM a de Ч GR US Ma am EW
e > Reguiator
|
t
+
+
в
t
E
t
-
Tes MAS EER A Ae
. Check the continuity across the B terminal and the F terminal
of IC regulator with an analog chmmeter. Conduct the test in
the (R x 1) setting. | |
2. The IC regulator is normal if the IC regulator conducts i in one
direction and does not conduct | in the r reverse direction.
и IMPORTANT
e Do not use a 500 V megger for measuring because it will
“destroy the Ic regulator.
HEH NOTE
e Do not use an auto digital multimeter. Because itis very
hard to check the continuity of IC regulator by using it.
0000002978E
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SEEADAATPO27A
(1)
(2)
(3)
(4)
(5)
tarter Auto Reduction Unit (6)
External Relay
(less than 200 mA) (7)
Alternator (8)
Starter (9)
Battery (12 V)
Fuse (3 су! : 50 А,
4 су! : 65 А)
Key Switch
Glow Plug
Fuse Box
(10) Water Temperature Lamp (15) Water Temperature Switch
(11) Oil Pressure Lamp (16) Oil Switch
(12) Charge Lamp (17) Fuel Feed Pump
(13) Glow Lamp (18) Stop Solenoid
(14) Pilot Lamps (12 V, 3.4W) (19) Timer (Giow Lamp)
0000006467E
5-80