Specifications

ManualsBrandswsm ManualsAutomotive05-E2BG SERIES

05-E2B SERIES,

05-E2BG SERIES

WORKSHOP MANUAL

DIESEL ENGINE

KiSC issued 06, 2011 A

Summary of content (124 pages)

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WORKSHOP MANUAL DIESEL ENGINE 05-E2B SERIES, 05-E2BG SERIES KiSC issued 06, 2011 A
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TO THE READER This Workshop Manual has been prepared to provide servicing personnel with information on the mechanism, service and maintenance of 05-E2B and 05-E2BG series. It is divided into three parts, “General”, “Mechanism” and “Servicing”. Q General Information on the engine identification, the general precautions, maintenance check list, check and maintenance and special tools are described. Q Mechanism Information on the construction and function are included.
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SAFETY INSTRUCTIONS 05-E2B, 05-E2BG, 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. It is essential that you read the instructions and safety regulations before you attempt to repair or use this unit. DANGER : Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
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SAFETY INSTRUCTIONS 05-E2B, 05-E2BG, WSM SAFETY STARTING • Do not start the engine by shorting across starter terminals or bypassing the safety start switch. • Unauthorized modifications to the engine may impair the function and / or safety and affect engine life. SAFETY WORKING • Do not work on the machine while under the influence of alcohol, medication, or other substances or while fatigued. • Wear close fitting clothing and safety equipment appropriate to the job.
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SAFETY INSTRUCTIONS 05-E2B, 05-E2BG, WSM VENTILATE WORK AREA • If the engine must be running to do some work, make sure the area is well ventilated. Never run the engine in a closed area. The exhaust gas contains poisonous carbon monoxide. DISPOSE OF FLUIDS PROPERLY • Do not pour fluids into the ground, down a drain, or into a stream, pond, or lake. Observe relevant environmental protection regulations when disposing of oil, fuel, coolant, electrolyte and other harmful waste.
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SPECIFICATIONS 05-E2B, 05-E2BG, WSM SPECIFICATIONS Model D905-E2B D1005-E2B Number of Cylinders V1305-E2B 3 Type 4 Vertical, Water-cooled, 4 cycle diesel engine Bore × Stroke mm (in.) 72 × 73.6 (2.83 × 2.90) 3 cm (cu.in.) Total Displacement -1 76 × 73.6 (2.99 × 2.90) 898 (54.80) 1001 (61.08) 1335 (81.46) kW/min (rpm) (HP/min-1 (rpm)) 13.0 / 3000 (17.4 / 3000) 15.2 / 3600 (20.4 / 3600) 14.5 / 3000 (19.5 / 3000) 16.8 / 3600 (22.5 / 3600) 19.0 / 3000 (26.0 / 3000) 22.4 / 3600 (30.
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SPECIFICATIONS 05-E2B, 05-E2BG, WSM Model D1105-E2B Number of Cylinders V1505-E2B D1105-T-E2B V1505-T-E2B 4 3 4 3 Type Vertical, Water-cooled, 4 cycle diesel engine Bore × Stroke 78 × 78.4 (3.07 × 3.09) mm (in.) 3 cm (cu.in.) 1123 (68.53) 1498 (91.41) 1123 (68.53) 1498 (91.41) kW/min-1 (rpm) (HP/min-1 (rpm)) 16.2 / 3000 (21.7 / 3000) 21.7 / 3000 (29.1 / 3000) 20.4 / 3000 (27.4 / 3000) 27.2 / 3000 (36.4 / 3000) ISO/SAE Net Intermittent kW/min-1 (rpm) (HP/min-1 (rpm)) 18.
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SPECIFICATIONS 05-E2B, 05-E2BG, WSM D905-E2BG Model BG1 BG1 3 Type 4 Vertical, Water-cooled, 4 cycle diesel engine Bore × Stroke Total Displacement NET CONT. V1305-E2BG BG1 Number of Cylinders STANDBY D1005-E2BG ISO 3046 SAE J-1349 ISO 3046 SAE J-1349 mm (in.) cm3 (cu.in.) kW/min-1 72 × 73.6 (2.83 × 2.90) 76 × 73.6 (2.99 × 2.90) 898 (54.86) 1001 (61.08) 1335 (81.46) (rpm) 8.9 / 1800 9.8 / 1800 13.1 / 1800 (HP/min-1 (rpm)) 11.9 / 1800 13.7 / 1800 17.5 / 1800 7.8 / 1800 8.
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SPECIFICATIONS 05-E2B, 05-E2BG, WSM Model Number of Cylinders D1105-E2BG V1505-E2BG BG1 BG1 3 4 Type Vertical, Water-cooled, 4 cycle diesel engine Bore × Stroke Total Displacement STANDBY NET CONT. ISO 3046 SAE J-1349 ISO 3046 SAE J-1349 78 × 78.4 (3.07 × 3.09) mm (in.) cm3 (cu.in.) 1123 (68.53) 1498 (91.41) (rpm) 11.5 / 1800 15.1 / 1800 (HP/min-1 (rpm)) 15.4 / 1800 20.2 / 1800 10.1 / 1800 13.4 / 1800 kW/min-1 -1 kW/min (rpm) (HP/min-1 (rpm)) 13.6 / 1800 17.
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PERFORMANCE CURVES 05-E2B, 05-E2BG, WSM PERFORMANCE CURVES (1) Gross Int. (2) Net Int. (3) Net Cont.
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PERFORMANCE CURVES 05-E2B, 05-E2BG, WSM (1) Gross Int. (2) Net Int. (3) Net Cont.
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PERFORMANCE CURVES 05-E2B, 05-E2BG, WSM (1) Gross Int. (2) Net Int. (3) Net Cont.
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DIMENSIONS 05-E2B, 05-E2BG, WSM DIMENSIONS Unit : mm (in.) A D905-E2B D1005-E2B D1105-E2B D1105-T-E2B 497.8 (19.60) 497.8 (19.60) 497.8 (19.60) 497.8 (19.60) B 230 (9.06) 230 (9.06) 230 (9.06) 230 (9.06) C 320 dia. (12.6 dia.) 330 dia. (12.99 dia.) 330 dia. (12.99 dia.) 330 dia. (12.99 dia.) D 396 (15.59) 396 (15.59) 396 (15.59) 396 (15.59) E 194 (7.64) 194 (7.64) 194 (7.64) 194 (7.64) F 608.7 (23.96) 608.7 (23.96) 608.7 (23.96) 608.7 (23.96) G 233.5 (9.19) 233.5 (9.
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DIMENSIONS 05-E2B, 05-E2BG, WSM Unit : mm (in.) V1305-E2B V1505-E2B V1505-T-E2B A 583.8 (22.98) 591.3 (23.28) 591.3 (23.28) B 230 (9.06) 230 (9.06) 230 (9.06) C 350 dia. (13.78 dia.) 370 dia. (14.57 dia.) 370 dia. (14.57 dia.) D 396 (15.59) 396 (15.59) 396 (15.59) E 194 (7.64) 194 (7.64) 194 (7.64) F 613.7 (24.16) 613.7 (24.16) 629.3 (24.16) G 238.5 (9.39) 238.5 (9.39) 238.5 (9.39) H 200 (7.87) 200 (7.87) 200 (7.87) I 250.81 to 251.12 dia. (9.874 to 9.887 dia.) 250.
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DIMENSIONS 05-E2B, 05-E2BG, WSM Unit : mm (in.) D905-E2BG D1005-E2BG D1105-E2BG V1305-E2BG V1505-E2BG A 546.6 (21.52) 546.6 (21.52) 546.6 (21.52) 634.3 (24.97) 634.3 (24.97) B 4-3/8-16 UNC-2B Depth 16 (0.63) 4-3/8-16 UNC-2B Depth 16 (0.63) 4-3/8-16 UNC-2B Depth 16 (0.63) 4-3/8-16 UNC-2B Depth 16 (0.63) 4-3/8-16 UNC-2B Depth 16 (0.63) C 608.7 (23.96) 608.7 (23.96) 608.7 (23.96) 613.7 (24.16) 613.7 (24.16) D 360 (14.17) 360 (14.17) 360 (14.17) 360 (14.17) 360 (14.17) E 333.
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GENERAL CONTENTS 1. ENGINE IDENTIFICATION ............................................................................. G-1 [1] MODEL NAME AND ENGINE SERIAL NUMBER ................................ G-1 [2] E2B ENGINE............................................................................................. G-2 [3] CYLINDER NUMBER ............................................................................... G-2 2. GENERAL PRECAUTIONS ........................................................................
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G GENERAL 05-E2B, 05-E2BG, WSM 1. ENGINE IDENTIFICATION [1] MODEL NAME AND ENGINE SERIAL NUMBER When contacting the manufacture, always specify your engine model name and serial number. The engine model and its serial number need to be identified before the engine can be serviced or parts replaced. Q Engine Serial Number The engine serial number is an identified number for the engine. It is marked after the engine model number. It indicates month and year of manufacture as follows.
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G GENERAL 05-E2B, 05-E2BG, WSM • Month of manufacture Month Engine Serial Number 0001 ~ 9999 10000 ~ January A0001 ~ A9999 B0001 ~ February C0001 ~ C9999 D0001 ~ March E0001 ~ E9999 F0001 ~ April G0001 ~ G9999 H0001 ~ May J0001 ~ J9999 K0001 ~ June L0001 ~ L9999 M0001 ~ July N0001 ~ N9999 P0001 ~ August Q0001 ~ Q9999 R0001 ~ September S0001 ~ S9999 T0001 ~ October U0001 ~ U9999 V0001 ~ November W0001 ~ W9999 X0001 ~ December Y0001 ~ Y9999 Z0001 ~ e.g.
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G GENERAL 05-E2B, 05-E2BG, WSM 2. GENERAL PRECAUTIONS • During disassembly, carefully arrange removed parts in a clean area to prevent confusion later. Screws, bolts and nuts should be replaced in their original position to prevent reassembly errors. • When special tools are required, use KUBOTA genuine special tools. Special tools which are not frequently used should be made according to the drawings provided.
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G GENERAL 05-E2B, 05-E2BG, WSM 3. MAINTENANCE CHECK LIST To maintain long-lasting and safe engine performance, make it a rule to carry out regular inspections by following the table below. Item * Checking fuel hoses and clamp bands * Changing engine oil (Oil pan depth : 125 mm (4.92 in.), 130 mm (5.12 in.
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G GENERAL 05-E2B, 05-E2BG, WSM CAUTION • When changing or inspecting, be sure to level and stop the engine. Q NOTE Lubricating Oil With the emission control now in effect, the CF-4 and CG-4 lubricating oils have been developed for use of a lowsulfur fuel on-road vehicle engines. When an off-road vehicle engine runs on a high-sulfur fuel, it is advisable to employ the CF, CD or CE lubricating oil with a high total base number.
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G GENERAL 05-E2B, 05-E2BG, WSM 4. CHECK AND MAINTENANCE [1] DAILY CHECK POINTS Checking Engine Oil Level 1. Level the engine. 2. To check the oil level, draw out the dipstick (1), wipe it clean, reinsert it, and draw it out again. Check to see that the oil level lies (A) between the two notches. 3. If the level is too low, add new oil to the specified level. Q IMPORTANT • When using an oil of different maker or viscosity from the previous, drain old oil. Never mix two different types of oil.
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G GENERAL 05-E2B, 05-E2BG, WSM Checking and Replenish Coolant 1. Without recovery tank : Remove the radiator cap (1) and check to see that the coolant level is just below the port. With recovery tank (2) : Check to see that the coolant level lies between FULL (A) and LOW (B). 2. If coolant level is too low, check the reason for decreasing coolant. (Case 1) If coolant is decreasing by evaporation, replenish only fresh, soft water.
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G GENERAL 05-E2B, 05-E2BG, WSM [2] CHECK POINTS OF INITIAL 50 HOURS Changing Engine Oil • 1. 2. 3. 4. 5. Q • • • • • CAUTION Be sure to stop engine before changing engine oil. Start and warm up the engine for approx. 5 minutes. Place an oil pan underneath the engine. To drain the used oil, remove the drain plug (1) at the bottom of the engine and drain the oil completely. Screw the drain plug (1). Fill new oil up to upper line on the dipstick.
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G GENERAL 05-E2B, 05-E2BG, WSM Replacing Oil Filter Cartridge • 1. 2. 3. 4. Q • CAUTION Be sure to stop the engine before changing filter cartridge. Remove the oil filter cartridge with the filter wrench. Apply a slight coat of oil onto the new cartridge gasket. To install the new cartridge, screw it in by hand. Over tightening may cause deformation of rubber gasket. After the new cartridge has been replaced, the engine oil normally decrease a little.
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G GENERAL 05-E2B, 05-E2BG, WSM [3] CHECK POINTS OF EVERY 50 HOURS Checking Fuel Hose 1. If the clamp (2) is loose, apply oil to the threads and securely retighten it. 2. The fuel hose (1) is made of rubber and ages regardless of the period service. Change the fuel hose together with the clamp every two years. 3. However, if the fuel hose and clamp are found to be damaged or deteriorate earlier than two years, then change or remedy. 4.
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G GENERAL 05-E2B, 05-E2BG, WSM [4] CHECK POINTS OF EVERY 100 HOURS Cleaning Air Cleaner Element 1. Remove the air cleaner element. 2. Use clean dry compressed air on the inside of the element. Pressure of compressed air must be under 205 kPa (2.1 kgf/cm2, 30 psi). Maintain reasonable distance between the nozzle and the filter. Q NOTE • The air cleaner uses a dry element. Never apply oil to it. • Do not run the engine with filter element removed. • Change the element once a year or every 6th cleaning.
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G GENERAL 05-E2B, 05-E2BG, WSM Fan Belt Damage and Wear 1. Check the fan belt for damage. 2. If the fan belt is damaged, replace it. 3. Check if the fan belt is worn and sunk in the pulley groove. 4. If the fan belt is nearly worn out and deeply sunk in the pulley groove, replace it. (A) Good (B) Bad W1209480 Checking Battery Electrolyte Level 1. Check the battery electrolyte level. 2. If the level is below than lower level line (2), and the distilled water to pour level of each cell.
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G GENERAL 05-E2B, 05-E2BG, WSM [5] CHECK POINTS OF EVERY 200 HOURS Changing Engine Oil • 1. 2. 3. 4. 5. Q • • • • • CAUTION Be sure to stop engine before changing engine oil. Start and warm up the engine for approx. 5 minutes. Place an oil pan underneath the engine. To drain the used oil, remove the drain plug (1) at the bottom of the engine and drain the oil completely. Screw the drain plug (1). Fill new oil up to upper line on the dipstick.
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G GENERAL 05-E2B, 05-E2BG, WSM Replacing Oil Filter Cartridge • 1. 2. 3. 4. Q • CAUTION Be sure to stop the engine before changing filter cartridge. Remove the oil filter cartridge with the filter wrench. Apply a slight coat of oil onto the new cartridge gasket. To install the new cartridge, screw it in by hand. Over tightening may cause deformation of rubber gasket. After the new cartridge has been replaced, the engine oil normally decrease a little.
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G GENERAL 05-E2B, 05-E2BG, WSM Replacing Fuel Filter Element (Element Type) 1. Close the fuel cock (3). 2. Unscrew the retaining ring (6) and remove the filter cup (5), and rinse the inside with kerosene. 3. Replace the filter element (4). 4. Reassemble the fuel filter, keeping out dust and dirt. 5. Bleed the fuel system.
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G GENERAL 05-E2B, 05-E2BG, WSM Anti-Freeze • There are two types of anti-freeze available: use the permanent type (PT) for this engine. • Before adding anti-freeze for the first time, clean the radiator interior by pouring fresh, soft water and draining it a few times. • The procedure for mixing water and anti-freeze differs according to the make of the anti-freeze and the ambient temperature. Basically, it should be referred to SAE J1034 standard, more specifically also to SAE J814c.
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G GENERAL 05-E2B, 05-E2BG, WSM [8] CHECK POINTS OF EVERY 1 OR 2 MONTHS Recharging CAUTION • When the battery is being activated, hydrogen and oxygen gases in the battery are extremely explosive. Keep open sparks and flames away from the battery at all times, especially when charging the battery. • When charging battery, remove battery vent plugs. • When disconnecting the cable from the battery, start with the negative terminal first.
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G GENERAL 05-E2B, 05-E2BG, WSM Battery Specific Gravity 1. Check the specific gravity of the electrolyte in each cell with a hydrometer. 2. When the electrolyte temperature differs from that at which the hydrometer was calibrated, correct the specific gravity reading following the formula mentioned in (Reference). 3. If the specific gravity is less than 1.215 (after it is corrected for temperature), charge or replace the battery. 4. If the specific gravity differs between any two cells by more than 0.
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G GENERAL 05-E2B, 05-E2BG, WSM [10] CHECK POINTS OF EVERY 800 HOURS Checking Valve Clearance Q IMPORTANT • Valve clearance must be checked and adjusted when engine is cold. 1. Remove the cylinder head cover and the glow plugs. 2. Align the “1TC” mark (1) on the flywheel and alignment mark (2) on the rear end plate so that the No. 1 piston comes to the compression top dead center. 3. Check the following valve clearance marked with “,” using a thickness gauge. 4.
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G GENERAL 05-E2B, 05-E2BG, WSM [11] CHECK POINTS OF EVERY 1500 HOURS 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. Nozzle Spraying Condition 1. Set the injection nozzle to a nozzle tester, and check the nozzle spraying condition. 2. If the spraying condition is defective, replace the nozzle piece.
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G GENERAL 05-E2B, 05-E2BG, WSM [12] CHECK POINTS OF EVERY 3000 HOURS Checking Turbocharger (Turbine Side) 1. Check the exhaust port (3) and inlet port (5) side of turbine housing (1) to see if there is no exhaust gas leak. 2. If any gas leak is found, retighten the bolts and nuts or replace the gasket (2) / (4) / (6) with new one. (Compressor Side) 1. Check the inlet hose (9) of the compressor cover (10) to see if there is no air leak. 2.
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G GENERAL 05-E2B, 05-E2BG, WSM Injection Timing 1. Remove the injection pipes. 2. Remove the engine stop solenoid. 3. Turn the flywheel counterclockwise (viewed from flywheel side) until the fuel fills up to the hole of the delivery valve holder (3) for No. 1 cylinder. 4. After the fuel fills up to the hole of the delivery valve holder for No. 1 cylinder, turn back (clockwise) the flywheel around 1.57 rad (90 °). 5. Turn the flywheel counterclockwise to set at around 0.44 rad (25 °) before T.D.C.. 6.
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G GENERAL 05-E2B, 05-E2BG, WSM Checking Injection Pump (Fuel Tightness of Pump Element) 1. Remove the engine stop solenoid. 2. Remove the injection pipes and glow plugs. 3. Install the injection pump pressure tester to the injection pump. 4. Install the injection nozzle (2) jetted with the proper injection pressure to the injection pump pressure tester (1). (Refer to the photo.) 5. Set the speed control lever to the maximum speed position. 6. Run the starter to increase the pressure. 7.
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G GENERAL 05-E2B, 05-E2BG, WSM [13] CHECK POINTS OF EVERY 2 YEARS Replacing Intake Air Line 1. Loosen the clamp (2). 2. Remove the intake air hose (1) and clamp (2). 3. Replace new intake air hose (1) and new clamp (2). 4. Tighten the clamp (2). Q NOTE • To prevent serious damage to the engine, keep out any dust inside the intake air line.
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G GENERAL 05-E2B, 05-E2BG, WSM Replacing Fuel Hoses and Clamp Bands 1. Loosen the clamp (2) and remove the fuel hose (1). 2. Replace new fuel hose (1) and new clamp (2). 3. Tighten the clamp (2). CAUTION • Stop the engine when attempting the check and change prescribed above. (When bleeding fuel system) 1. Fill the tank with fuel and open the cock (4). 2. Loosen the air vent plug (3) of the fuel filter a few turns. 3. Screw back the plug when bubbles do not come up any more. 4.
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G GENERAL 05-E2B, 05-E2BG, WSM Changing Radiator Coolant (L.L.C.) • 1. 2. 3. 4. 5. 6. 7. 8. 9. Q • • • • CAUTION Do not remove the radiator cap when the engine is hot. Then loosen cap slightly to the stop to relieve any excess pressure before removing cap completely. 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 of engine body.
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G GENERAL 05-E2B, 05-E2BG, WSM Changing Radiator Coolant (L.L.C.) (Continued) (Anti-freeze) • There are two types of anti-freeze available: use the permanent type (PT) for this engine. • Before adding anti-freeze for the first time, clean the radiator interior by pouring fresh, soft water and draining it a few times. • The procedure for mixing water and anti-freeze differs according to the make of the anti-freeze and the ambient temperature.
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G GENERAL 05-E2B, 05-E2BG, WSM 5. SPECIAL TOOLS Diesel Engine Compression Tester (for Nozzle Hole) Code No: 07909-30208 (Assembly) 07909-31251 (G) 07909-30934 (A to F) 07909-31271 (I) 07909-31211 (E and F) 07909-31281 (J) 07909-31231 (H) Application: Use to measure diesel engine compression and diagnosis of need for major overhaul. Adaptor : H for 05-E2B series.
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G GENERAL 05-E2B, 05-E2BG, WSM Q NOTE • The following special tools are not provided, so make them referring to the figure. Injection Pump Pressure Tester Application: Use to check fuel tightness of injection pumps. A Pressure gauge full scale : More than 29.4 MPa (300 kgf/cm2, 4267 psi) B PF 1/2 C Copper gasket D Flange (Material : Steel) E Hex. nut 27 mm (1.06 in.) across the plat F Adhesive application G Fillet welding on the enter circumference H Retaining nut I 17 mm dia. (0.67 in.
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G GENERAL 05-E2B, 05-E2BG, WSM Bushing Replacing Tool Application: Use to press out and press fit the bushing. 1. For small end bushing A 157 mm (6.1811 in.) B 24 mm (0.9449 in.) C 120 mm (4.7244 in.) D 21.8 to 21.9 mm dia. (0.8583 to 0.8622 in. dia.) E 24.8 to 24.9 mm dia. (0.9764 to 0.9803 in. dia.) F 20 mm dia. (0.7874 in. dia.) a 6.3 μm (250 μin.) b 6.3 μm (250 μin.) 2. For idle gear bushing A 196 mm (7.7165 in.) B 26 mm (1.0236 in.) C 150 mm (5.9055 in.) D 25.8 to 25.9 mm dia.
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G GENERAL 05-E2B, 05-E2BG, WSM Crankshaft Bearing 1 Replacing Tool Application: Use to press out and press fit the crankshaft bearing 1. [Press Out] A 135 mm (5.31 in.) B 72 mm (2.83 in.) C 40 mm radius (1.57 in. radius) D 10 mm (0.39 in.) E 24 mm (0.95 in.) F 20 mm dia. (0.79 in. dia.) G 51.2 to 51.4 mm dia. (2.0157 to 2.0236 in. dia.) H 47.3 to 47.5 mm dia. (1.862 to 1.870 in. dia.) C1 Chamfer 1.0 mm (0.039 in.) C2 Chamfer 2.0 mm (0.079 in.) C0.3 Chamfer 0.3 mm (0.012 in.
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G GENERAL 05-E2B, 05-E2BG, WSM Crank Sleeve Setter Application: Use to fix the crankshaft sleeve. (1) Auxiliary Socket for Pushing A 130 mm (5.12 in.) B 112 mm (4.41 in.) C 107 mm (4.21 in.) D 82 mm (3.23 in.) E 72 mm (2.83 in.) F 67 mm (2.64 in.) G 47 mm (1.85 in.) H 36.0 to 36.2 mm (1.417 to 1.425 in.) I 17 mm (0.67 in.) J 5 mm dia. (0.20 in. dia.) K 52 mm dia. (2.05 in. dia.) L 40 mm dia. (1.57 in. dia.) M 10 mm (0.39 in.) N 33 mm (1.30 in.) O 20 mm dia. (0.79 in. dia.
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MECHANISM CONTENTS 1. ENGINE BODY ............................................................................................... M-1 [1] CLOSED BREATHER (NATURAL ASPIRATION TYPE ONLY)........... M-1 [2] GOVERNOR .............................................................................................. M-2 [3] BOOST COMPENSATOR ........................................................................
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM 1. ENGINE BODY [1] CLOSED BREATHER (NATURAL ASPIRATION TYPE ONLY) Closed breather system has been adopted to prevent the release of blow-by gas into the atmosphere. After its oil content is filtered by oil shield (4), the blowby gas in fed back to the intake manifold through breather valve (3) to be used for re-combustion.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM [2] GOVERNOR Q Three Lever Type Fork Lever (for General) The governor system is a mechanical governor that used the flyweight (5). The flyweight (5) is mounted on the governor shaft that rotates at the same speed as the crankshaft.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM (Overloaded Operation) The amount of the movement of the fork lever assembly is limited with the fuel limitation bolt (10) and can not be moved in the direction of the fuel increase. As overload reduces the centrifugal force of the governor weight, which is pressing the torque pin (8) into the floating lever (7), the floating lever pushes the fork lever 1 (6) in the way to increase the fuel supply with the help of the torque spring tension.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM [3] BOOST COMPENSATOR (1) Boost Compensator Assembly (2) Actuator (3) Plate (4) Injection Pump Assembly (5) Guide (6) Stop Solenoid A : Fulcrum W1013537 Boost compensator is the device that reduces black smoke during the engine startup and acceleration. The rod of actuator (2) is pushed out by the rise of boost pressure, and the plate (3) moves in the direction of the fuel increase around the fulcrum (A).
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SERVICING CONTENTS 1. TROUBLESHOOTING ......................................................................................S-1 2. SERVICING SPECIFICATIONS ......................................................................S-5 3. TIGHTENING TORQUES ..............................................................................S-13 [1] TIGHTENING TORQUES FOR GENERAL USE SCREWS, BOLTS AND NUTS...............................................................................................
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM 1.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM Symptom Engine Revolution Is Not Smooth Probable Cause Solution Reference Page Fuel filter clogged or dirty Replace G-14, 15 Air cleaner clogged Clean or replace G-11, 14, 18 Fuel leak due to loose injection pipe retaining nut Tighten retaining nut Injection pump malfunctioning Repair or replace Incorrect nozzle opening pressure Adjust Injection nozzle stuck or clogged Repair or replace S-21, 22 Governor malfunctioning Repair S-35, 36 Turbocharger b
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM Symptom Deficient Output Excessive Lubricant Oil Consumption Fuel Mixed into Lubricant Oil Probable Cause Reference Page Solution Incorrect injection timing Adjust S-19 Engine’s moving parts seem to be seizing Repair or replace – Injection pump malfunctioning Repair or replace S-20, 35 Deficient nozzle injection Repair or replace nozzle S-21, 22 Compression leak Check the compression pressure and repair Gas leak from exhaust system Repair or replace
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM Symptom High Oil Pressure Engine Overheated Battery Quickly Discharged Probable Cause Solution Reference Page Different type of oil Use specified type of oil G-8 Relief valve defective Replace Engine oil insufficient Replenish Fan belt broken or elongated Replace or adjust G-11, 12 Coolant insufficient Replenish G-15, 16 Radiator net and radiator fin clogged with dust Clean Inside of radiator corroded Clean or replace G-15 Coolant flow route corro
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM 2. SERVICING SPECIFICATIONS ENGINE BODY Item Factory Specification Allowable Limit 0.145 to 0.185 mm 0.00571 to 0.00728 in. – D905-E2B / E2BG D1005-E2B / E2BG D1105-E2B / E2BG V1305-E2B / E2BG V1505-E2B / E2BG 3.72 to 4.12 MPa 38 to 42 kgf/cm2 539 to 596 psi 2.25 MPa 23.0 kgf/cm2 327 psi D1105-T-E2B V1505-T-E2B 3.14 to 3.53 MPa 32 to 36 kgf/cm2 454 to 511 psi 2.25 MPa 23.0 kgf/cm2 327 psi – 10 % or less 0.55 to 0.70 mm 0.0217 to 0.0276 in. – – 0.05 mm 0.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM ENGINE BODY (Continued) Item Rocker Arm Shaft to Rocker Arm Clearance Factory Specification Allowable Limit 0.016 to 0.045 mm 0.00063 to 0.00177 in. 0.10 mm 0.0039 in. Rocker Arm Shaft O.D. 11.973 to 11.984 mm 0.4714 to 0.4718 in. – Rocker Arm I.D. 12.000 to 12.018 mm 0.4724 to 0.4731 in. – Push Rod Alignment – 0.25 mm 0.0098 in. Tappet to Tappet Guide Clearance 0.020 to 0.062 mm 0.0008 to 0.0024 in. 0.07 mm 0.0028 in. Tappet O.D. 19.959 to 19.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM ENGINE BODY (Continued) Item Idle Gear Shaft to Gear Bushing Idle Gear 1 Clearance Factory Specification Allowable Limit 0.020 to 0.054 mm 0.0008 to 0.0021 in. 0.10 mm 0.0039 in. Idle Gear Bushing I.D. 26.000 to 26.021 mm 1.0236 to 1.0244 in. – Idle Gear Shaft 1 O.D. 25.967 to 25.980 mm 1.0223 to 1.0228 in. – Idle Gear 2 Clearance 0.020 to 0.054 mm 0.0008 to 0.0021 in. 0.10 mm 0.0039 in. Idle Gear Bushing I.D. 26.000 to 26.021 mm 1.0236 to 1.0244 in.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM ENGINE BODY (Continued) Item Factory Specification Allowable Limit Top Ring 0.25 to 0.40 mm 0.0098 to 0.0157 in. 1.25 mm 0.0492 in. Second Ring 0.25 to 0.40 mm 0.0098 to 0.0157 in. 1.25 mm 0.0492 in. Oil Ring 0.25 to 0.40 mm 0.0098 to 0.0157 in. 1.25 mm 0.0492 in. Piston Ring Gap [D1005-E2B] [V1305-E2B] [D1105-E2B] [V1505-E2B] Top Ring 0.30 to 0.45 mm 0.0118 to 0.0177 in. 1.25 mm 0.0492 in. Second Ring 0.30 to 0.45 mm 0.0118 to 0.0177 in. 1.25 mm 0.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM ENGINE BODY (Continued) Item Crankshaft to Crankshaft Bearing 2 Oil Clearance Factory Specification Allowable Limit 0.034 to 0.095 mm 0.0013 to 0.0037 in. 0.20 mm 0.0079 in. Crankshaft Journal O.D. 47.934 to 47.950 mm 1.8872 to 1.8878 in. – Crankshaft Bearing 2 I.D. 47.984 to 48.029 mm 1.8891 to 1.8909 in. – 0.034 to 0.098 mm 0.0013 to 0.0039 in. 0.20 mm 0.0079 in. Crankshaft to Crankshaft Bearing 3 Oil Clearance Crankshaft Journal O.D. 51.921 to 51.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM LUBRICATING SYSTEM Item Engine Oil Pressure Factory Specification Allowable Limit At Idle Speed More than 49 kPa 0.5 kgf/cm2 7 psi – At Rated Speed 196 to 441 kPa 2.0 to 4.5 kgf/cm2 28 to 64 psi 147 kPa 1.5 kgf/cm2 21 psi Inner Rotor to Outer Rotor Clearance 0.06 to 0.18 mm 0.0024 to 0.0071 in. – Outer Rotor to Pump Body Clearance 0.100 to 0.180 mm 0.0039 to 0.0071 in. – Inner Rotor to Cover Clearance 0.025 to 0.075 mm 0.0010 to 0.0030 in.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM FUEL SYSTEM Item Factory Specification Allowable Limit Injection Timing (3000 min-1 (rpm)) 0.30 to 0.33 rad (17 to 19°) before T.D.C. – Injection Timing (3600 min-1 (rpm)) 0.35 to 0.39 rad (20 to 22°) before T.D.C. – Injection Pump (BG Type) Injection Timing (60 Hz / 1800 min-1 (rpm)) 0.27 to 0.31 rad (15.5 to 17.5 °) before T.D.C. – Pump Element Fuel Tightness – 13.73 MPa 140 kgf/cm2 1991 psi Delivery Valve Fuel Tightness 10 seconds 13.73 → 12.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM ELECTRICAL SYSTEM Item Factory Specification Allowable Limit Approx. 0.9 Ω – Glow Plug Resistance Starter (Planetary Gear Reduction Type) Commutator O.D. 30.0 mm 1.181 in. 29.0 mm 1.142 in. Difference O.D. Less than 0.02 mm 0.0008 in. 0.05 mm 0.0020 in. Mica Undercut 0.50 to 0.80 mm 0.0197 to 0.0315 in. 0.20 mm 0.0079 in. Brush Length 16.0 mm 0.630 in. 10.5 mm 0.413 in. O.D. 28.0 mm 1.102 in. 27.0 mm 1.063 in. Difference O.D. Less than 0.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM 3. TIGHTENING TORQUES Screws, bolts and nuts must be tightened to the specified torque using a torque wrench, several screws, bolts and nuts such as those used on the cylinder head must be tightened in proper sequence and the proper torque. [1] TIGHTENING TORQUES FOR GENERAL USE SCREWS, BOLTS AND NUTS When the tightening torques are not specified, tighten the screws, bolts and nuts according to the table below.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM [2] TIGHTENING TORQUES FOR SPECIAL USE SCREWS, BOLTS AND NUTS Q NOTE • For “*” marked screws, bolts and nuts on the table, apply engine oil to their threads and seats before tightening. • The letter “M” in Size x Pitch means that the screw, bolt or nut dimension stands for metric. The size is the nominal outside diameter in mm of the threads. The pitch is the nominal distance in mm between two threads. Item Size x Pitch N·m kgf·m ft-lbs M7 x 1.0 6.9 to 8.8 0.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING (1) Engine Body Compression Pressure 1. Run the engine until it is warmed up. 2. Stop the engine. 3. Remove the air cleaner, the muffler and all glow plugs (or nozzles). 4. Set a compression tester with the adaptor to the glow plug hole (or nozzle hole). Nozzle hole : Adaptor H (07909-31231) Glow plug hole : Adaptor L (07909-31301) 5.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM Valve Clearance Q IMPORTANT • Valve clearance must be checked and adjusted when engine is cold. 1. Remove the cylinder head cover and the glow plugs. 2. Align the “1TC” mark (1) on the flywheel and alignment mark (2) on the rear end plate so that the No. 1 piston comes to the compression top dead center. 3. Check the following valve clearance marked with “,” using a thickness gauge. 4.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM (2) Lubricating System Engine Oil Pressure 1. Remove the engine oil pressure switch, and set an oil pressure tester. 2. Start the engine. After warming up, measure the oil pressure of both idling and rated speeds. 3. If the oil pressure is less than the allowable limit, check the following.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM Fan Belt Damage and Wear 1. Check the fan belt for damage. 2. If the fan belt is damaged, replace it. 3. Check if the fan belt is worn and sunk in the pulley groove. 4. If the fan belt is nearly worn out and deeply sunk in the pulley groove, replace it. (A) Good (B) Bad W1016443 CAUTION • When removing the radiator cap, wait at least ten minutes after the engine has stopped and cooled down. Otherwise, hot water may gush out, scalding nearby people.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM Thermostat Valve Opening Temperature 1. Suspend the thermostat in the water by a string with its end inserted between the valve and seat. 2. Heating the water gradually, read the temperature when the valve opens and leaves the string. 3. Continue heating and read the temperature when the valve opens approx. 8 mm (0.315 in.). 4. If the measurement is not within the factory specifications, replace the thermostat. Thermostat’s valve opening temperature Factory spec. 69.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM Fuel Tightness of Pump Element 1. Remove the engine stop solenoid. 2. Remove the injection pipes and glow plugs. 3. Install the injection pump pressure tester to the injection pump. 4. Install the injection nozzle (2) jetted with the proper injection pressure to the injection pump pressure tester (1). (Refer to the photo.) 5. Set the speed control lever to the maximum speed position. 6. Run the starter to increase the pressure. 7.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM CAUTION • Check the nozzle injection pressure and condition after confirming that there is nobody standing in the direction the fume goes. If the fume from the nozzle directly contacts the human body, cells may be destroyed and blood poisoning may be caused. Nozzle Spraying Condition 1. Set the injection nozzle to a nozzle tester, and check the nozzle spraying condition. 2. If the spraying condition is defective, replace the nozzle piece.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM Nozzle Holder 1. Secure the nozzle retaining nut (7) with a vise. 2. Remove the nozzle holder (1), and take out parts inside. (When reassembling) • Assemble the nozzle in clean fuel oil. • Install the push rod (4), noting its direction. • After assembling the nozzle, be sure to adjust the fuel injection pressure. Tightening torque (1) (2) (3) (4) Nozzle Holder Adjusting Washer Nozzle Spring Push Rod Nozzle holder 34.3 to 39.2 N·m 3.5 to 4.0 kgf·m 25.3 to 28.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM Battery Specific Gravity 1. Check the specific gravity of the electrolyte in each cell with a hydrometer. 2. When the electrolyte temperature differs from that at which the hydrometer was calibrated, correct the specific gravity reading following the formula mentioned in (Reference). 3. If the specific gravity is less than 1.215 (after it is corrected for temperature), charge or replace the battery. 4. If the specific gravity differs between any two cells by more than 0.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM Motor Test • 1. 2. 3. 4. 5. 6. 7. Q • • CAUTION Secure the starter to prevent it from jumping up and down while testing the motor. Disconnect the battery negative cable from the battery. Disconnect the battery positive cable from the battery. Disconnect the leads from the starter B terminal. Remove the starter from the engine. Connect a jumper lead from the starter C terminal (1) to the battery positive terminal (2).
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM Magnet Switch Continuity Test 1. Check the continuity across the C terminal (1) and the B terminal (2) with a circuit tester, pushing in the plunger. 2. If not continuous or if a certain value is indicated, replace the magnet switch.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM Glow Plug Continuity 1. Remove the glow plug. 2. Measure the resistance with a circuit tester between the glow plug terminal and the glow plug housing. 3. If the factory specification is not indicated, glow plug is faulty. Resistance Factory spec. Approx. 0.9 Ω 0000010726E Engine Stop Solenoid 1. Remove the engine stop solenoid from the engine. 2.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM Radial Clearance 1. If the wheel contact to the housing, replace the turbocharger assembly with new one. W1077353 [2] DISASSEMBLING AND ASSEMBLING (1) Draining Oil and Coolant Draining Oil and Coolant CAUTION • Never remove radiator cap until coolant temperature is below its boiling point. Then loosen cap slightly to the stop to relieve any excess pressure before removing cap completely. 1. Prepare a bucket. Open the drain cock to drain coolant. 2. Prepare an oil pan.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM Turbocharger (equipped with Turbocharger Model) • Q • • • 1. 2. 3. 4. CAUTION While the engine is running and or just after it stops, the turbocharger is hot, be careful not to touch the turbocharger. NOTE When detaching and attaching the turbocharger assembly, be very careful not to allow dust, dirt and other foreign matters in the oil pipes. When the turbocharger assembly has been replaced, pour fresh engine oil through the oil filter port of the turbocharger.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM Nozzle Heat Seal Service Removal Procedure Q IMPORTANT • Use a plus (phillips head) screw driver (1) that has a diameter which is bigger than the heat seal hole (Approx. 6 mm (1/4 in.)). 1. Drive screw driver (1) lightly into the heat seal hole. 2. Turn screw driver three or four times each way. 3. While turning the screw driver, slowly pull the heat seal (4) out together with the injection nozzle gasket (3). 4. If the heat seal drops, repeat the above procedure.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM Cylinder Head and Cylinder Head Gasket (To be continued) 1. Loosen the pipe clamps (1), and remove the water return pipe (2). 2. Remove the cylinder head screw in the order of (n or r) to (a) and remove the cylinder head. 3. Remove the cylinder head gasket. 4. Remove the O-ring. (Carbon gasket type only.) Q NOTE • Material of cylinder head gasket has been changed from carbon to metal.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM Cylinder Head and Cylinder Head Gasket (Continued) (When reassembling the carbon gasket type) • Replace the cylinder head gasket with new one. • Securely fit the O-ring (1) to the pin pipe (2). • When mounting the gasket, set it to the pin pipe holes. Take care not to mount it reversely. • The cylinder head should be free of scratches and dust. • Install the cylinder head, using care not to damage the gasket.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM Thermostat Assembly 1. Remove the thermostat cover mounting screws (1), and remove the thermostat cover (2). 2. Remove the thermostat assembly (4). (When reassembling) • Apply a liquid gasket (Three Bond 1215 or equivalent) only at the thermostat cover side of the gasket (3). (1) Thermostat Cover Mounting Screw (2) Thermostat Cover (3) Thermostat Cover Gasket (4) Thermostat Assembly W10363950 (4) Gear Case and Timing Gears Fan Drive Pulley 1.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM Gear Case 1. Remove the gear case. (When reassembling) • Grease thinly to the oil seal, and install it, ensuring the lip does not come off. • Measure (L) when the gear case mounting bolt is inserted in the gear case bolt hole and judge the installation position of the mounting bolt when you do not understand the installation position of the mounting bolt. A : L = 18 mm (0.71 in.) (Pipe Pin Position) B : L = 13 mm (0.51 in.) (Water Pipe Mounting) C : L = 10 mm (0.39 in.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM Boost Compensator (equipped with Turbocharger Model) Q IMPORTANT • Use the stop solenoid mounting bolt (3) for the dropout prevention of boost compensator (2) and the damage prevention of the guide (6) when detach the boost compensator. • The guide (6) of boost compensator and the control rack (7) should be made the level when you install boost compensator assembly. 1. Disconnect the hose (4). 2. Remove the stop solenoid mounting bolt (M6 × 87 mm) (3). 3.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM Injection Pump 1. Disconnect the start spring (4) on the thrust lever side (5). 2. Align the control rack pin (2) with the notch (1) on the crankcase, and remove the injection pump (3). 3. Remove the injection pump shims. 4. In principle, the injection pump should not be disassembled. (When reassembling) • When installing the injection pump, insert the control rack pin (2) firmly into the groove (7) of the thrust lever of fork lever.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM Cam Gear, Idle Gear 1, 2 and Governor Gear 1. Remove the idle gear 2 (7) / idle gear 1 (4). 2. Remove the fuel camshaft stopper (8). 3. Draw out the fuel cam gear (1) with fuel camshaft (9). 4. Remove the camshaft stopper bolt. 5. Remove the cam gear (3) with camshaft. 6. Remove the external snap ring (11) from the governor shaft (12). 7. Remove the governor gear (6) with governor shaft (12).
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM (5) Piston and Connecting Rod Oil Pan and Oil Strainer 1. Remove the oil pan mounting screws (5). 2. Remove the oil pan (4). 3. Remove the oil strainer (3). (When reassembling) • After cleaning the oil strainer, check to see that the filter mesh in clean, and install it. • Visually check the O-ring (1), apply engine oil, and install it. • Securely fit the O-ring to the oil strainer.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM Pistons 1. Turn the flywheel and bring the piston to top dead center. 2. Draw out the piston upward by lightly tapping it from the bottom of the crankcase with the grip of a hammer. 3. Draw out the other piston in the same method as above. (When reassembling) • Before inserting the piston into the cylinder, apply enough engine oil to the piston. • When inserting the piston into the cylinder, face the mark on the connecting rod to the injection pump.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM Piston Ring and Connecting Rod 1. Remove the piston rings using a piston ring tool. 2. Remove the piston pin (7), and separate the connecting rod (6) from the piston (5). (When reassembling) • When installing the ring, assemble the rings so that the manufacturer’s mark (12) near the gap faces the top of the piston. • When installing the oil ring onto the piston, place the expander joint (10) on the opposite side of the oil ring gap (11).
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM (6) Flywheel and Crankshaft Flywheel 1. Secure the flywheel to keep it from turning, using a flywheel stopper. 2. Remove all flywheel screws (1) and then remove the flywheel (2). (When reassembling) • Align the “1TC” mark (a) on the outer surface of the flywheel horizontally with the alignment mark (b) on the rear end plate. Now fit the flywheel in position. • Apply engine oil to the threads and the undercut surface of the flywheel screw and fit the screw.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM Crankshaft Assembly 1. Remove the main bearing case screw 2 (1). 2. Pull out the crankshaft assembly. Q IMPORTANT • Take care to protect crankshaft bearing 1 from scratches, caused by the crank gear, etc.. (Wrap the gear in vinyl tape, etc.) (When reassembling) • Clean the oil passage of the crankshaft with compressed air. • Apply oil to the main bearing case screw 2 (1).
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM (7) Starter Q Electromagnetic Drive Type (1) Solenoid Switch Mounting Nut (2) Starter Drive Housing (3) Drive Lever (4) Gasket (5) Solenoid Switch (6) B Terminal Nut (7) C Terminal Nut (8) Snap RIng (9) Overrunning Clutch (10) Armature (11) Brush Spring (12) Connecting Lead (13) Rear End Frame (14) Gasket (15) Brake Spring (16) Brake Shoe (17) End Frame Cap (18) Screw (19) Yoke (20) Brush (21) Brush Holder (22) Through Bolt W1037593 1.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM Q Planetary Gear Reduction Type (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) Through Bolt Brush Yoke Armature Overrunning Clutch Idle Gear End Frame Brush Holder Magnet Switch Cover Plunger Housing C Terminal Nut B Terminal Nut W1222714 1. Unscrew the C terminal nut (12), and disconnect the connecting lead. 2. Remove the two through bolts (1). 3. Detach the motor. 4. Remove the end frame (7). 5.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM (8) Alternator (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) Pulley Drive End Frame Stator Bearing Retainer Plate Rotor Bearing Rear End Frame Rectifier IC Regulator Brush Holder Rear End Cover W1224079 1. Remove the pulley (1). 2. Remove the rear end cover (12). 3. Remove the brush holder (11). 4. Remove the IC regulator (10). 5. Remove the four screws holding the stator lead wires. 6. Remove the rectifier (9). 7. Remove the rear end frame (8). 8.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM [3] SERVICING (1) Cylinder Head and Valves Top Clearance 1. Remove the cylinder head. 2. With the piston at TDC, use grease to affix three or four plastigauges of a diameter 1.5 mm (0.059 in.) x 5.0 to 7.0 mm (0.20 to 0.27 in.) long to the crown of the piston; keep the gauges away from the intake valve and combustion chamber fittings. 3. Take the piston to an intermediate position, install the cylinder head and tighten the head bolts to the specified torque. 4.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM Cylinder Head Flaw 1. Prepare an air spray red check. 2. Clean the surface of the cylinder head with detergent (2). 3. Spray the cylinder head surface with the red permeative liquid (1). Leave it five to ten minutes after spraying. 4. Wash away the read permeative liquid on the cylinder head surface with the detergent (2). 5. Spray the cylinder head surface with white developer (3). 6. If flawed, it can be identified as red marks.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM Replacing Valve Guide (When removing) 1. Press out the used valve guide using a valve guide replacing tool. (See page “SPECIAL TOOLS”.) (When installing) 1. Clean a new valve guide and valve guide bore, and apply engine oil to them. 2. Press in a new valve guide using a valve guide replacing tool. 3. Ream precisely the I.D. of the valve guide to the specified dimension. Valve guide I.D. (Intake and exhaust) Factory spec. 7.010 to 7.025 mm 0.2760 to 0.2765 in.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM Correcting Valve and Valve Seat Q NOTE • Before correcting the valve and seat, check the valve stem and the I.D. of valve guide section, and repair them if necessary. • After correcting the valve seat, be sure to check the valve recessing. 1) Correcting Valve 1. Correct the valve with a valve refacer. Valve face angle Factory spec. IN. 1.047 rad 60 ° EX. 0.785 rad 45 ° 2) Correcting Valve Seat 1. Slightly correct the seat surface with a 1.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM Free Length and Tilt of Valve Spring 1. Measure the free length (B) of valve spring with vernier calipers. If the measurement is less than the allowable limit, replace it. 2. Put the valve spring on a surface plate, place a square on the side of the valve spring. 3. Check to see if the entire side is in contact with the square. Rotate the valve spring and measure the maximum tilt (A). If the measurement exceeds the allowable limit, replace it. 4.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM Push Rod Alignment 1. Place the push rod on V blocks. 2. Measure the push rod alignment. 3. If the measurement exceeds the allowable limit, replace the push rod. Push rod alignment Allowable limit 0.25 mm 0.0098 in. W10292900 Oil Clearance between Tappet and Tappet Guide Bore 1. Measure the tappet O.D. with an outside micrometer. 2. Measure the I.D. of the tappet guide bore with a cylinder gauge, and calculate the oil clearance. 3.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM W10293660 (2) Timing Gears, Camshaft and Governor Gear Timing Gear Backlash 1. Set a dial indicator (lever type) with its tip on the gear tooth. 2. Move the gear to measure the backlash, holding its mating gear. 3. If the backlash exceeds the allowable limit, check the oil clearance of the shafts and the gear. 4. If the oil clearance is proper, replace the gear. Factory spec. 0.032 to 0.115 mm 0.0013 to 0.0045 in. Allowable limit 0.15 mm 0.0059 in. Factory spec. 0.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM Camshaft Side Clearance 1. Set a dial indicator with its tip on the camshaft. 2. measure the side clearance by moving the cam gear to the front to rear. 3. If the measurement exceeds the allowable limit, replace the camshaft stopper. Camshaft side clearance Factory spec. 0.07 to 0.22 mm 0.0028 to 0.0087 in. Allowable limit 0.30 mm 0.0118 in. W10295630 Camshaft Alignment 1. Support the camshaft with V blocks on the surface plate at both end journals. 2.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM Oil Clearance of Camshaft Journal 1. Measure the camshaft journal O.D. with an outside micrometer. 2. Measure the cylinder block bore I.D. for camshaft with a cylinder gauge, and calculate the oil clearance. 3. If the oil clearance exceeds the allowable limit, replace the camshaft. Factory spec. 0.050 to 0.091 mm 0.00197 to 0.00358 in. Allowable limit 0.15 mm 0.0059 in. Camshaft journal O.D. Factory spec. 35.934 to 35.950 mm 1.4147 to 1.4153 in.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM (3) Piston and Connecting Rod Piston Pin Bore I.D. 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. Factory spec. 22.000 to 22.013 mm 0.8661 to 0.8667 in. Allowable limit 22.03 mm 0.8673 in. Piston pin bore I.D. W10304770 Oil Clearance between Piston Pin and Small End Bushing 1. Measure the piston pin O.D.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM Connecting Rod Alignment Q NOTE • 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. 2. Install the connecting rod on the connecting rod alignment tool. 3. Put a 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.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM Piston Ring Gap (To be continued) 1. Insert the piston ring into the lower part of the cylinder (the least worn out part) with a piston. 2. Measure the ring gap with a thickness gauge. 3. If the measurement exceeds the allowable limit, replace the piston ring.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM Piston Ring Gap (Continued) Top ring Piston ring gap [D905-E2BG] [D1005-E2BG] [V1305-E2BG] Second ring Oil ring Top ring Piston ring gap [D1105-E2BG] [V1505-E2BG] Second ring Oil ring Factory spec. 0.25 to 0.40 mm 0.0098 to 0.0157 in. Allowable limit 1.25 mm 0.0492 in. Factory spec. 0.25 to 0.40 mm 0.0098 to 0.0157 in. Allowable limit 1.25 mm 0.0492 in. Factory spec. 0.25 to 0.40 mm 0.0098 to 0.0157 in. Allowable limit 1.25 mm 0.0492 in.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM (4) Crankshaft Crankshaft Side Clearance 1. Set a dial indicator with its tip on the end of the crankshaft. 2. Measure the side clearance by moving the crankshaft to the front and rear. 3. If the measurement exceeds the allowable limit, replace the thrust bearings. 4. If the same size bearing is useless because of the crankshaft journal wear, replace it with an oversize one referring to the table and figure. Crankshaft side clearance Factory spec. 0.15 to 0.31 mm 0.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM Oil Clearance between Crankpin and Crankpin Bearing 1. Clean the crankpin and crankpin bearing. 2. Put a strip of plastigage on the center of the crankpin. 3. Install the connecting rod cap and tighten the connecting rod screws to the specified torque, and remove the cap again. 4. Measure the amount of the flattening with the scale, and get the oil clearance. 5. If the oil clearance exceeds the allowable limit, replace the crankpin bearing. 6.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM Oil Clearance between Crankshaft Journal and Crankshaft Bearing 1 1. Measure the O.D. of the crankshaft front journal with an outside micrometer. 2. Measure the I.D. of the crankshaft bearing 1 with an inside micrometer, and calculate the oil clearance. 3. If the clearance exceeds the allowable limit, replace the crankshaft bearing 1. 4.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM Oil Clearance between Crankshaft Journal and Crankshaft Bearing 2 (Crankshaft Bearing 3) 1. Put a strip of plastigage on the center of the journal. 2. Install the bearing case and tighten the baring case screws 1 to the specified torque, and remove the bearing case again. 3. Measure the amount of the flattening with the scale and get the oil clearance. 4. If the clearance exceeds the allowable limit, replace the crankshaft bearing 2 (1) and crankshaft bearing (3). 5.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM Replacing Crankshaft Sleeve 1. Remove the used crankshaft sleeve. 2. Set the sleeve guide (2) to the crankshaft. 3. Heat a new sleeve to a temperature between 150 and 200 °C (302 and 392 °F), and fix the sleeve to the crankshaft as shown in figure. 4. Press fit the sleeve using the auxiliary socket for pushing (3). Q NOTE • Mount the sleeve with its largely chamfered surface facing outward. • Should heating is not enough, a sleeve might stop halfway, so careful.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM (5) Cylinder Cylinder Wear 1. Measure the I.D. of the cylinder at the six positions (see figure) with a cylinder gauge to find the maximum and minimum I.D.’s. 2. Get the difference (Maximum wear) between the maximum and the minimum I.D.’s. 3. If the wear exceeds the allowable limit, bore and hone to the oversize dimension. (Refer to “Correcting Cylinder”.) 4. Visually check the cylinder wall for scratches. If deep scratches are found, the cylinder should be bored.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM Correcting Cylinder 1. When the cylinder is worn beyond the allowable limit, bore and hone it to the specified dimension. Factory spec. Oversized cylinder liner I.D. Allowable limit Finishing D905-E2B / E2BG 72.500 to 72.519 mm 2.85433 to 2.85507 in. D1005-E2B / E2BG V1305-E2B / E2BG 76.500 to 76.519 mm 3.0118 to 3.0126 in. D1105-E2B / E2BG D1105-T-E2B V1505-E2B / E2BG V1505-T-E2B 78.500 to 78.519 mm 3.0906 to 3.0913 in. D905-E2B / E2BG 72.65 mm 2.8602 in.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM Clearance between Outer Rotor and Pump Body 1. Measure the clearance between the outer rotor and the pump body with a feeler gauge. 2. If the clearance exceeds the factory specifications, replace the oil pump rotor assembly. Clearance between outer rotor and pump body Factory spec. 0.100 to 0.180 mm 0.0039 to 0.0071 in. W10356560 Clearance between Rotor and Cover 1. Put a strip of plastigage onto the rotor face with grease. 2. Install the cover and tighten the screws.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM Commutator and Mica 1. Check the contact of the commutator for wear, and grind the commutator with emery paper if it is slightly worn. 2. Measure the commutator O.D. with an outside micrometer at several points. 3. If the minimum O.D. is less than the allowable limit, replace the armature. 4. If the difference of the O.D.'s exceeds the allowable limit, correct the commutator on a lathe to the factory specification. 5. Measure the mica undercut. 6.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM Brush Holder 1. Check the continuity across the brush holder and the holder support with a circuit tester. 2. If it conducts, replace the brush holder. W1156895 Armature Coil 1. Check the continuity across the commutator and armature coil core with resistance range of circuit tester. 2. If it conducts, replace the armature. 3. Check the continuity across the segments of the commutator with resistance range of circuit tester. 4.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM (8) Alternator Bearing 1. Check the bearing for smooth rotation. 2. If it does not rotate smoothly, replace it. W1019790 Stator 1. Measure the resistance across each lead of the stator coil with resistance range of circuit tester. 2. If the measurement is not within factory specification, replace it. 3. Check the continuity across each stator coil lead and core with resistance range of circuit tester. 4. If infinity is not indicated, replace it.
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DIESEL ENGINE 05-E2B, 05-E2BG, WSM Rectifier 1. Check the continuity across each diode of rectifier with resistance range of circuit tester. 2. The rectifier is normal if the diode in the rectifier conducts in one direction and does not conduct in the reverse direction. W1020452 IC Regulator 1. Check the continuity across the B terminal (2) and the F terminal (1) of IC regulator with resistance range of circuit tester. 2.
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EDITOR: KUBOTA FARM & INDUSTRIAL MACHINERY SERVICE, LTD. 64, ISHIZU-KITAMACHI, SAKAI-KU, SAKAI-CITY, OSAKA, 590-0823, JAPAN PHONE : (81)72-241-1129 FAX : (81)72-245-2484 E-mail : ksos-pub@kubota.co.jp KUBOTA Corporation Printed in Japan 2011. 06, S, EI, EI, e Code No.9Y011-02754 2004.