Service Manual: Diesel Engine
Service Manual: Diesel Engine
Service Manual: Diesel Engine
Dec.2008
Service Manual
V2403 Diesel Engine
Forklifts
Important Safety Information
Most accidents involving product operation, maintenance and repair are caused by failure to observe basic
safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations
before an accident occurs. A person must be alert to potential hazards. This person should also have the
necessary training, skills and tools to perform these functions properly.
Read and understand all safety precautions and warnings before operating or performing lubrication,
maintenance and repair on this product.
Basic safety precautions are listed in the “Safety” section of the Service or Technical Manual. Additional safety
precautions are listed in the “Safety” section of the owner/operation/maintenance publication. Specific safety
warnings for all these publications are provided in the description of operations where hazards exist.
WARNING labels have also been put on the product to provide instructions and to identify specific hazards. If
these hazard warnings are not heeded, bodily injury or death could occur to you or other persons. Warnings in
this publication and on the product labels are identified by the following symbol.
WARNING
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could
result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read
and understood the operation, lubrication, maintenance and repair information.
Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.
DOOSAN cannot anticipate every possible circumstance that might involve a potential hazard. The warnings
in this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or
operating technique not specifically recommended by DOOSAN is used, you must satisfy yourself that it is
safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the
operation, lubrication, maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis of information available at
the time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and
other items can change at any time. These changes can affect the service given to the product. Obtain the
complete and most current information before starting any job. DOOSAN dealers have the most current
information available.
1
Index
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.
WARNING
Indicates a potentially hazardous situation which, if not avoided, could result in death or serious
injury.
CAUTION
Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate
injury.
IMPORTANT
Indicates that equipment or property damage could result if instructions are not followed.
Safety Working
• Do not work on the machine while under the
influence of alcohol, medication, or other
substances or while fatigued.
1.1. Specifications
Model V2403-M
Number of Cylinders 4
Type Vertical, Water-cooled, 4 cycle diesel engine
Bore × Stroke 87.0 X 102.4 mm (3.43 X 4.031 in.)
Total Displacement 2434 cm3 (148.5 cu.in.)
SAE Gross Intermittent 34.1 kW @ 2400 rpm
(46.4 ps @ 2400 rpm)
High Idle Speed @ Dynamo 2670 ±50 rpm
Low Idle Speed @ Dynamo 775 ~ 825rpm (for D18G)
875 ~ 925rpm (for D18S)
Combustion Chamber Spherical Type (E-TVCS)
Fuel Injection Pump PFR 4M Type Mini Pump (DENSO)
Governor Mechanical all speed governor
Direction of Rotation Counter-clockwise (viewd from flywheel side)
Injection Nozzle OPD Mini Nozzle (DENSO)
Injection Timing 15.25 Before T.D.C
Firing Order 1-3-4-2
Injection Pressure 13.73 MPa (140.0 kgf/cm2, 1991 psi)
Compression Ratio 23.8 : 1
Lubricating System Forced Lubrication by Trochoid Pump
Oil Pressure Indicating Electrical type switch
Lubricating Filter Full flow paper filter (cartridge type)
Cooling System Pressurized radiator, forced circulation with water pump
Starting System Electric Starting with Starter
Starting Motor 12 V, 2.0 kW
Starting Support Device By glow plug in combustion chamber
EGR NONE
Recommended Battery 12 V, 92 AH equivalent
Charging Alternator 12V, 40A
Recommended Fuel Diesel Fuel No.2-D (ASTM D975)
Lubricating Oil Class CF lubricating oil as per API classification is recommended.
Lubricating Oil Capacity For details on recommended lubricating oils, see page G-7, 10
9.5 L (2.5 U.S.gals)
Weight (Dry) 184 kg (406 lbf)
• Year of manufacture
Alphabet or Alphabet or
Year Year
Number Number
1 2001 F 2015
2 2002 G 2016
3 2003 H 2017
4 2004 J 2018
5 2005 K 2019
6 2006 L 2020
7 2007 M 2021
8 2008 N 2022
9 2009 P 2023
A 2010 R 2024
B 2011 S 2025
C 2012 T 2026
D 2013 V 2027
E 2014
(1) Engine Model Name and Serial Number
The emission controls previously implemented in various countries to prevent air pollution will be stepped up
as Non-Road Emission Standards continue to change. The timing or applicable date of the specific Non-Road
Emission regulations depends on the engine output classification.
Over the past several years, Kubota has been supplying diesel engines that comply with regulations in the
respective countries affected by Non-Road Emission regulations. For Kubota Engines, E3B will be the
designation that identifies engine models affected by the next emission phase (See the table below).
When servicing or repairing ###-E3B series engines, use only replacement parts for that specific E3B engine,
designated by the appropriate E3B Kubota Parts List and perform all maintenance services listed in the
appropriate Kubota Operator's Manual or in the appropriate E3B Kubota Workshop Manual. Use of incorrect
replacement parts or replacement parts from other emission level engines (for example: E2B engines), may
result in emission levels out of compliance with the original E3B design and EPA or other applicable
regulations.Please refer to the emission label located on the engine head cover to identify Output
classification and Emission Control Information. E3B engines are identified with "ET" at the end of the Model
designation, on the US EPA label. Please note : E3B is not marked on the engine.
Categ EU
Engine output classification
ory (1) regulation
K From 19 to less than 37 kW STAGE ΙΙΙA
J From 37 to less than 75 kW STAGE ΙΙΙA
I From 75 to less than 130 kW STAGE ΙΙΙA
Categ EPA
Engine output classification
ory (2) regulation
Less than 19kW Tier 4
From 19 to less than 56 kW Interim Tier 4
ET
From 56 to less than 75 kW Tier 3
From 75 to less than 130 kW Tier 3
(1) EU regulation engine output classification category
(2) “E3B” engines are identified with “ET” at the end of
the Model designation, on the US EPA label.
“E3B” designates Tier 3 and some Interim Tier 4 /
Tier 4 models, depending on engine output
classification.
To maintain long-lasting and safe engine performance, make it a rule to carry out regular inspections by
following the table below.
Service Interval
Item Every
50 100 150 200 400 500 1 or 2 1 800 1500 3000 2
hrs hrs hrs hrs hrs hrs months year hrs hrs hrs years
* Checking fuel hoses and clamp
☆
bands
Changing (1) Oil pan depth
★ ☆
engine oil (90 mm, 3.5 in.)
(depending
(2) Oil pan depth
on the oil ★ ☆
(124 mm, 4.88 in.)
pan)
*Cleaning air cleaner element
(replace the element after 6-times ☆
cleanings)
*Cleaning fuel filter (Element type) ☆
Checking battery electrolyte level ☆
Checking fan belt tension and
☆
damage
(1) Oil pan depth
Replacing oil ★ ☆
(90 mm, 3.5 in.)
filter
cartridge (2) Oil pan depth
★ ☆
(124 mm, 4.88 in.)
Checking radiator hoses and clamp
☆
bands
* Checking intake air line ☆
Replacing fuel filter cartridge ☆
Cleaning water jacket and radiator
☆
interior
Replacing fan belt ☆
Recharging battery ☆
* Replacing air cleaner element ☆
Checking valve clearance ☆
* Checking injection nozzle
☆
condition
* Checking turbocharger ☆
* Checking injection pump ☆
* Replacing intake air line ☆
Replacing battery ☆
Replacing radiator hoses and
☆
clamp bands
* Replacing fuel hoses and clamps ☆
Changing radiator coolant (L.L.C.) ☆
★ Change engine oil and replace oil filter cartridge after the first 50 hours of operation.
* The items listed above (* marked) are registered as emission related critical parts by KUBOTA in the U.S. EPA nonroad emission
regulation. As the engine owner, you are responsible for the performance of the required maintenance on the engine according to the
above instruction.
NOTE
Engine Oil :
Refer to the following table for the suitable American Petroleum Institute (API) classification of engine
oil according to the engine type (with internal EGR, external EGR or non-EGR) and the Fuel Type
Used : (Low Sulfur, Ultra Low Sulfur or High Sulfur Fuels).
CF
High Sulfur Fuel
(If the "CF-4, CG-4, CH-4, or CI-4" engine
[0.05 % (500 ppm) ≤
oil is used with a high-sulfur fuel, change -
Sulfur Content <
the engine oil at shorter intervals.
0.50 % (5000 ppm)]
(approximately half))
• CJ-4 classification oil is intended for use in engines equipped with DPF (Diesel Particulate Filter) and
is Not Recommended for use in Kubota E3 specification engines.
• Oil used in the engine should have API classification and Proper SAE Engine Oil Viscosity according
to the ambient temperatures where the engine is operated.
• With strict emission control regulations now in effect, the CF-4 and CG-4 engine oils have been
developed for use with low sulfur fuels, for On-Highway vehicle engines. When a Non-Road engine
runs on high sulfur fuel, it is advisable to use a "CF or better" classification engine oil with a high
Total Base Number (a minimum TBN of 10 is recommended).
Fuel :
• Cetane Rating : The minimum recommended Fuel Cetane Rating is 45. A cetane rating greater than
50 is preferred, especially for ambient temperatures below .20 °C (.4 °F) or elevations above 1500 m
(5000 ft).
• Diesel Fuel Specification Type and Sulfur Content % (ppm) used, must be compliant with all
applicable emission regulations for the area in which the engine is operated.
• Use of diesel fuel with sulfur content less than 0.10 % (1000 ppm) is strongly recommended.
• If high-sulfur fuel (sulfur content 0.50 % (5000 ppm) to 1.0 % (10000 ppm)) is used as a diesel fuel,
change the engine oil and oil filter at shorter intervals. (approximately half)
• No.2-D is a distillate fuel of lower volatility for engines in industrial and heavy mobile service. (SAE
J313 JUN87)
• Since KUBOTA diesel engines of less than 56 kW (75 hp) utilize EPA Tier 4 and Interim Tier 4
standards, the use of low sulfur fuel or ultra low sulfur fuel is mandatory for these engines, when
operated in US EPA regulated areas. Therefore, please use No.2-D S500 or S15 diesel fuel as an
alternative to No.2-D, and use No.1-D S500 or S15 diesel fuel as an alternative to No.1-D for ambient
temperatures below .10 °C (14 °F).
2) EN : European Norm
5) No.1-D or No.2-D, S500 : Low Sulfur Diesel (LSD) less than 500 ppm or 0.05 wt.%
No.1-D or No.2-D, S15 : Ultra Low Sulfur Diesel (ULSD) 15 ppm or 0.0015 wt.%
2.4.1. Check Point When Required Draining the Water from the Fuel Filter
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 between the two
notches.
IMPORTANT
When using an oil of different maker or viscosity
from the previous, drain old oil. Never mix two
different types of oil.
NOTE
• Be sure to inspect the engine, locating it on a
horizontal place. If placed on gradients, accurately,
oil quantity may not be measured.
CAUTION
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.
IMPORTANT
• During filling the coolant, air must be vented from
the engine coolant passages. The air vents by
jiggling the radiator upper and lower hoses.
• 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.
• Do not use an antifreeze and scale inhibitor at the
same time.
• Never mix the different type or brand of L.L.C..
CAUTION
• Be sure 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.
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.
• Never mix two different types of oil.
• Engine oil should have properties of API
classification CF (See page G-7).
• Use the proper SAE Engine Oil according to
ambient temperature.
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.
IMPORTANT
To prevent serious damage to the engine,
replacement element must be highly efficient. Use
only a KUBOTA genuine filter or its equivalent.
CAUTION
Stop the engine when attempting the check and
change prescribed above.
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.
IMPORTANT
If dust and dirt enter the fuel, the fuel injection
pump and injection nozzle will wear quickly. To
prevent this, be sure to clean the fuel filter cup (5)
periodically.
2. If the level is below than lower level line (2), and the
distilled water to pour level of each cell.
7.0 to 9.0 mm
Deflection (A) Factory spec.
0.28 to 0.35 in.
(A) Deflection
CAUTION
• Be sure 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.
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.
• Never mix two different types of oil.
• Engine oil should have properties of API
classification CF (See page G-7).
• Use the proper SAE Engine Oil according to
ambient temperature.
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.
IMPORTANT
To prevent serious damage to the engine,
replacement element must be highly efficient. Use
only a KUBOTA genuine filter or its equivalent.
IMPORTANT
To prevent serious damage to the engine, keep out
any dust inside the intake air line.
WARNING
Fuel leaked or spilled onto hot surfaces or
electrical components can cause a fire.
Turn the disconnect switch OFF if fitted or
disconnect the battery when changing fuel filters.
NOTICE
Do not fill fuel filters with fuel before installing them.
Contaminated fuel will cause accelerated wear to
fuel system parts.
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.
1. Stop the engine and let cool down.
2. 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).
3. After all coolant is drained, close the drain plug.
4. Fill with clean water and cooling system cleaner.
5. Follow directions of the cleaner instruction.
6. After flushing, fill with clean water and anti-
freeze until the coolant level is just below the port.
Install the radiator cap (1) securely.
7. Fill with coolant up to “FULL” (A) mark on the
recovery tank (4).
8. Start and operate the engine for few minutes.
9. Stop the engine and let cool. Check coolant level
of radiator and recovery tank (4) and add coolant
if necessary.
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 antifreeze 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.
• Mix the anti-freeze with fresh, soft water, and then fill
into the radiator.
IMPORTANT
When the anti-freeze is mixed with fresh, soft water,
the antifreeze mixing ratio must be less than 50 %.
NOTE
• The above data represents industrial standards
that necessitate a minimum glycol content in the
concentrated anti-freeze.
• 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.
• Do 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.)
7.0 to 9.0 mm / 98 N
Deflection (A) Factory spec. 0.28 to 0.35 in. / 98 N
(10 kgf, 22 lbf)
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. When
connecting the cable to the battery, start with the positive terminal first.
• Never check battery charge by placing a metal object across the posts.
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 °C (104 °F) during charging. If it exceed 40 °C (104 °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
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.
NOTE
• Hold the hydrometer tube vertical without
removing it from the electrolyte.
• Do not suck too much electrolyte into the tube.
• Allow the float to move freely and hold the
hydrometer at eye level.
• The hydrometer reading must be taken at the
highest electrolyte level.
(Reference)
NOTE
• The air cleaner uses a dry element. Never apply
oil to it.
• Do not run the engine with filter element
removed.
Valve Clearance
IMPORTANT
Valve clearance must be checked and adjusted
when engine is cold.
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.
(Reference)
No fuel leak at
Valve seat 12.75 MPa
Factory spec. 2
tightness 130.0 kgf/cm
1849 psi
Nozzle Holder
(When reassembling)
35 to 39 N·m
Nozzle holder 3.5 to 4.0 kgf·m
26 to 28 lbf·ft
20 to 24 N·m
Tightening Overflow pipe
2.0 to 2.5 kgf·m
torque retaining nut
15 to 18 lbf·ft
49 to 68 N·m
Nozzle holder
5.0 to 7.0 kgf·m
assembly
37 to 50 lbf·ft
13.73 MPa
2
Fuel tightness of pump element Allowable limit 140.0 kgf/cm
1991 psi
10 seconds
13.73 → 12.75 MPa
Factory spec. 2
140.0 → 130.0 kgf/cm
1991 → 1849 psi
Fuel tightness of delivery valve
5 seconds
13.73 → 12.75 MPa
Allowable limit 2
140.0 → 130.0 kgf/cm
1991 → 1849 psi
NOTE : Never try to disassemble the injection pump assembly. For repairs, you are strongly requested to
contact a Kubotaauthorized pump service shop.
(1) Injection Pump Pressure Tester (3) Protection Cover for Jetted Fuel
(2) Injection Nozzle
3. Replace new intake air hose (1) and new clamp (2).
Replacing Battery
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. When
connecting the cable to the battery, start with the
positive terminal first.
• Never check battery charge by placing a metal
object across the posts.
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.
1. Loosen the clamp (2) and remove the fuel hose (1).
CAUTION
Stop the engine when attempting the check and
[B] change prescribed above.
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.
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 antifreeze 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.
(Anti-freeze)
IMPORTANT
When the anti-freeze is mixed with fresh, soft water,
the antifreeze mixing ratio must be less than 50 %.
NOTE
• The above data represents industrial standards
that necessitate a minimum glycol content in the
concentrated anti-freeze.
• 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.
• Do 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.)
1. Extracting tool
2. Inserting tool
A 24 mm (0.94 in.)
B 10 mm dia. (0.39 in. dia.)
C 0.5 mm radius (0.02 in. radius)
D M20 x Pitch 2.0
E 10 mm (0.39 in.)
F 20 mm (0.79 in.)
G 5 mm (0.2 in.)
H 95 mm (3.7 in.)
I 125 mm (4.92 in.)
J 0.87 rad (50 °)
K 5 mm (0.2 in.)
L 60 mm radius (2.4 in. radius)
M M20 x Pitch 2.0
N 30 mm (1.2 in.)
O 10 mm (0.39 in.)
P 10 mm (0.39 in.)
Q 10 mm (0.39 in.)
R 35.5 mm (1.40 in.)
S 4.5 mm radius (0.18 in. radius)
T 40 mm (1.6 in.)
U 40 mm (1.6 in.)
V 12 mm (0.47 in.)
W 120 mm (4.72 in.)
C2 Chamfer 2.0 mm (0.079 in.)
3.1.1. Piston
3.3.1. Governor
4.1. Troubleshooting
Engine Body
Item Factory Specification Allowable Limit
0.18 to 0.22 mm
Valve Clearance (When Cold)
0.0071 to 0.0086 in.
3.24 to 3.72 MPa / 290 2.55 MPa / 290
min-1 (rpm) -1
min (rpm)
2 2
Compression Pressure 33.0 to 38.0 kgf/cm / 290 26.0 kgf/cm / 290
-1 -1
(When Cranking with Starting Motor) min (rpm) min (rpm)
-1 -1
470 to 540 psi / 290 min 370 psi / 290 min
(rpm) (rpm)
0.575 to 0.675 mm
Top Clearance -
0.0227 to 0.0265 in.
0.05 mm / 500 mm
Cylinder Head Surface Flatness
0.002 in. / 19.7 in.
0.05 mm
Protrusion
0.002 in.
Valve Recessing
(Protrusion to Recessing) Recessing
0.15 mm 0.40 mm
0.0059 in. 0.016 in.
Valve Recessing Recessing 0.65 to 0.85 mm -
[D1803-M-DI], [V2403-M-DI] 0.026 to 0.033 in.
[V2403-M-DI-T]
Tilt - 1.0 mm
0.039 in.
Rocker Arm Shaft to Rocker Arm Oil Clearance 0.016 to 0.045 mm 0.10 mm
0.00063 to 0.0017 in. 0.0039 in.
0.25 mm
Push Rod Alignment -
0.0098 in.
Piston Pin to Small End Bushing Oil Clearance 0.014 to 0.036 mm 0.15 mm
0.00056 to 0.0014 in. 0.0059 in.
Lubricating System
Item Factory Specification Allowable Limit
Engine Oil Pressure At Idle Speed More than 98 kPa 50 kPa
2 2
1.0 kgf/cm 0.5 kgf/cm
14 psi 7 psi
Cooling System
Item Factory Specification Allowable Limit
Fan Belt Tension 7.0 to 9.0 mm (0.28 to -
0.35 in.) deflection at 98
N (10 kgf, 22 lbf) of force
Thermostat Valve Opening 69.5 to 72.5 °C -
Temperature (At 157.1 to 162.5 °F
Beginning)
Valve Opening 85 °C -
Temperature 185 °F
(Opened
Completely)
Radiator Water Tightness No leak at specified -
pressure
Radiator Cap Pressure Falling More than 10 seconds -
Time for pressure fall from 90
to 60 kPa from 0.9 to 0.6
2
kgf/cm from 10 to 9 psi
Electrical System
Item Factory Specification Allowable Limit
Starter
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.
4.3.1. 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.
Unit
Screw and bolt material grades are shown by numbers punched on the screw and bolt heads. Prior to
tightening, be sure to check out the numbers as shown below.
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.
Engine Body
Compression Pressure
5. After making sure that the stop lever is set at the stop position (non-injection).
6. While cranking the engine with the starter, measure the compression pressure.
8. If the measurement is below the allowable limit, apply a small amount of oil to the cylinder wall through the
nozzle hole and measure the compression pressure again.
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 oil, check the cylinder wall and piston rings.
NOTE
• Check the compression pressure with the specified valve clearance.
IMPORTANT
Valve clearance must be checked and adjusted
when engine is cold.
NOTE
• The “1TC” mark 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 counterclockwise 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 “1TC” mark line 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.
(When reassembling)
• After checking the engine oil pressure, tighten the engine oil pressure switch to the specified torque.
15 to 19 N·m
Tightening torque Oil pressure switch 1.5 to 2.0 kgf·m
11 to 14 lbf·ft
7.0 to 9.0 mm
Deflection (A) Factory spec.
0.28 to 0.35 in.
(A) Deflection
(A) Good
(B) Bad
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.
Injection Timing
(Reference)
13.73 MPa
Fuel tightness of 2
Allowable limit 140.0 kgf/cm
pump element
1991 psi
6. Stop the starter when the fuel jets from the injection
nozzle. After that, turn the flywheel by the hand and
raise the pressure to approx. 13.73 MPa (140.0
2
kgf/cm , 1991 psi).
7. Now turn the flywheel back about half a turn (to keep
the plunger free). Maintain the flywheel at this
position and clock the time taken for the pressure to
drop from 13.73 to 12.75 MPa (140.0 to 130.0
2
kgf/cm , 1991 to 1849 psi).
10 seconds
Factory 13.73 → 12.75 MPa
2
spec. 140.0 → 130.0 kgf/cm
Fuel tightness 1991 → 1849 psi
of delivery
valve 5 seconds
Allowable 13.73 → 12.75 MPa
2
limit 140.0 → 130.0 kgf/cm
1991 → 1849 psi
(Reference)
No fuel leak at
12.75 MPa
Valve seat tightness Factory spec. 2
130.0 kgf/cm
1849 psi
Nozzle Holder
(When reassembling)
35 to 39 N·m
Nozzle holder 3.5 to 4.0 kgf•m
26 to 28 lbf•ft
20 to 24 N·m
Tightening Overflow pipe
2.0 to 2.5 kgf•m
torque retaining nut
15 to 18 lbf•ft
49 to 68 N•m
Nozzle holder
5.0 to 7.0 kgf•m
assembly
37 to 50 lbf•ft
CAUTION
• To avoid accidental short circuit, be sure to attach the positive cable to the positive terminal before
the negative cable is attached to the negative terminal.
• Never remove the battery cap while the engine is running.
• Keep electrolyte away from eyes, hands and clothes. If you are spattered with it, wash it away
completely with water immediately.
• Keep open sparks and flames away from the battery at all times. Hydrogen gas mixed with oxygen
becomes very explosive.
IMPORTANT
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.
Battery Voltage
NOTE
• Hold the hydrometer tube vertical without
removing it from the electrolyte.
• Do not suck too much electrolyte into the tube.
• Allow the float to move freely and hold the
hydrometer at eye level.
• The hydrometer reading must be taken at the
highest electrolyte level.
(Reference)
• 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).
CAUTION
Secure the starter to prevent it from jumping up
and down while testing the motor.
NOTE
• B terminal : It is the terminal which connects the
cable from the battery to the starter.
• C terminal : It is the terminal which connects the
cable from the motor to the magnet switch.
NOTE
• B terminal : It is the terminal which connects the
cable from the battery to the starter.
• S terminal : It is the terminal which connects the
cable from the starter switch to the magnet switch.
(Before testing)
5. When switch (4) is turn on, the plunger pull into the
solenoid body and then turn off the switch (4), the
plunger comes out.
6. Turn on the switch (3) then turn on the switch (4), the
plunger pull into the solenoid body and it keep in
holding position after turn off the switch (4).
IMPORTANT
Never apply the current for pulling coil more than
two seconds when inspecting.
(Reference)
• The procedure of confirming the solenoid’s movement
Alternator
(1) Alternator
(2) Terminal L (Harness Side)
ON 0Ω
Resistance
OFF Infinity
ON 0Ω
Resistance
OFF Infinity
ON 0Ω
Resistance
OFF Infinity
Battery
(1) Battery
(When refilling)
IMPORTANT
• Never mix two different types of oil.
• Use the proper SAE Engine Oil according to
ambient temperature.
Draining Coolant
CAUTION
Never remove radiator cap 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.
2. Remove the fan (1), fan belt (4), alternator (2) and
starter (3).
(When reassembling)
IMPORTANT
• After reassembling the fan belt, be sure to adjust
the fan belt tension.
• Do not confuse the direction of the fan.
(1) Fan
(3) Starter
(2) Alternator
(4) Fan Belt
(When reassembling)
Injection Pipes
(When reassembling)
25 to 34 N·m
Tightening Injection pipe
2.5 to 3.5 kgf·m
torque retaining nut
18 to 25 lbf·ft
(When reassembling)
49 to 68 N·m
Nozzle holder assembly 5.0 to 7.0 kgf·m
37 to 50 lbf·ft
20 to 24 N·m
Tightening torque Overflow pipe assembly retai ning nut 2.0 to 2.5 kgf·m
15 to 18 lbf·ft
20 to 24 N·m
Glow plug 2.0 to 2.5 kgf·m
15 to 18 lbf·ft
(1) Lead (2) Glow Plug (3) Overflow Pipe Assembly (4) Nozzle Holder Assembly (5) Heat Seal
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.
(When reassembling)
• Heat seal and injection nozzle gasket must be
changed when the injection nozzle is removed for
cleaning or for service.
(When reassembling)
• When putting the push rods (2) onto the tappets (3),
check to see if their ends are properly engaged with
the grooves.
IMPORTANT
After installing the rocker arm, be sure to adjust the
valve clearance.
24 to 27 N•m
Tightening Rocker arm bracket
2.4 to 2.8 kgf•m
torque screw
18 to 20 lbf•ft
(When reassembling)
IMPORTANT
To replace the cylinder head gasket (4), in advance
make sure the marking (5) of cylinder head gasket
in the original engine, and replace the same
marking as the original cylinder head gasket.
IMPORTANT
When replacing piston, piston pin, small end
bushing, connecting rod, or crankpin bearings,
measure piston head’s protrusion or recessing
from the level of crankcase cylinder face (average
of all pistons) after installing the pistons, and
select the cylinder head gasket following the below
table.
0.500 to 0.540 mm
15
0.0197 to 0.0212 in.
0.550 to 0.590 mm
20
0.0217 to 0.0232 in.
0.600 to 0.640 mm
25
0.0237 to 0.0251 in.
0.650 to 0.690 mm
30
0.0256 to 0.0271 in.
0.700 to 0.740 mm
35
0.0276 to 0.0291 in.
(When reassembling)
IMPORTANT
Do not change the combination of tappet and
tappet guide.
(1) Tappet
Valves
(When reassembling)
• Wash the valve stem and valve guide hole, and apply
engine oil sufficiently.
IMPORTANT
Do not change the combination of valve and valve
guide.
(When reassembling)
(When reassembling)
IMPORTANT
Before removing the injection pump assembly (2),
be sure to remove the solenoid (4), hi-idling body
(1), engine stop lever (3) and solenoid guide (6).
(When reassembling)
• Before fitting the stop lever (3) to the gear case, install
the solenoid guide (6) first into position. Then attach
the stop lever and use it to see if it functions well.
45 to 49 N·m
Tightening Hi-idling body 4.5 to 5.0 kgf·m
torque
33 to 36 lbf·ft
IMPORTANT
Before removing the injection pump assembly (1),
be sure to remove the boost compensator
assembly (2), hi-idling body (4), solenoid (3) and
solenoid guide (5).
(When reassembling)
IMPORTANT
If you replace new boost compensator, it is
necessary to adjust it.
Get the adjustment procedure from KUBOTA.
45 to 49 N·m
Tightening
Hi-idling body 4.5 to 5.0 kgf·m
torque
33 to 36 lbf·ft
NOTE
Specific tool (1) :
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 springs.
6. Take out the speed control plate (6) with care not to
let the large (3) and small (4) governor springs come
off this plate and fall in to the gear case.
(When reassembling)
• Hook the small spring (4) first and then the large
governor spring (3) on the speed control plate (6).
• Put the specific tool (1) from the injection pump side to
catch the large governor spring (3). Keep this spring
slightly extended and place the speed control plate (6)
in its specified position.
NOTE
• Be careful not to stretch the small governor
spring (4) too long because otherwise it may get
deformed permanently.
• Using the specific tool (1), hook the large
governor spring (3) onto the fork lever (2).
• Make sure both the governor springs (3), (4) are
tight on the fork lever (2).
• Apply and tighten up the two bolts and two nuts
on the speed control plate (6).
• Check that the speed control lever (5) positions
low idle, after assembling governor springs.
• 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.
• Finally attach the injection pump cover in position.
3. Remove the fan drive pulley (2) with gear puller (4).
(When reassembling)
(When reassembling)
24 to 27 N·m
Idle gear 2 shaft
2.4 to 2.8 kgf·m
set screw
Tightening 18 to 20 lbf·ft
torque Idle gear 2 49 to 55 N·m
stopper set 5.0 to 5.7 kgf·m
screw 37 to 41 lbf·ft
(When reassembling)
• Apply a thin film of engine oil to the oil seal, and install
it, noting the lip come off.
Gear Case
(When reassembling)
• Apply a thin film of engine oil to the oil seal (3), and
install it, noting the lip come off.
(When reassembling)
Idle Gear
(When reassembling)
Camshaft
(When reassembling)
24 to 27 N·m
Tightening Camshaft set
2.4 to 2.8 kgf·m
torque screw
18 to 20 lbf·ft
4. Draw out the fuel camshaft assembly (5), (6) and fork
lever assembly (3), (4), (7) at the same time.
(When reassembling)
Oil Pump
2. Draw out the oil pump drive gear (2) with gear puller
(1).
Crank Gear
(When reassembling)
• After cleaning the oil strainer (1), check to see that the
filter mesh in clean, and install it.
Pistons
(When reassembling)
IMPORTANT
• Do not change the combination of cylinder and
piston. Make sure of the position of each piston
by marking. For example, mark “1” on the No. 1
piston.
• Place the piston rings with their gaps at 0.79 rad
(45 °) from the piston pin’s direction as shown in
the figure.
• Carefully 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.
45 to 49 N·m
Tightening Connecting rod
4.5 to 5.0 kgf·m
torque screw
33 to 36 lbf·ft
(When reassembling)
• When installing the oil ring (3) onto the piston (6),
place the expander joint (10) on the opposite side of
the oil ring gap (11).
Flywheel
(When reassembling)
IMPORTANT
The length of inside screws (5) and outside screws
(3) are different. Do not take a mistake using inside
screws and outside screws.
(When reassembling)
• Fit the bearing case gasket (1) and the bearing case
cover gasket (2) with correct directions.
Crankshaft
(When reassembling)
IMPORTANT
• Install the crankshaft sub assembly, aligning the
screw hole of main bearing case 2 (2) with the
screw hole of cylinder block.
• When tightening the main bearing case screw 2
(1), apply 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.
69 to 73 N·m
Tightening Main bearing
2 7.0 to 7.5 kgf·m
torque case screw
51 to 54 lbf·ft
(When reassembling)
• Install the thrust bearing with its oil groove (8) facing
outward.
46 to 50 N·m
Tightening Main bearing
1 4.7 to 5.2 kgf·m
torque case screw
34 to 37 lbf·ft
(1) Through Bolt (2) Brush (3) C Terminal Nut (4) Yoke
(5) Armature (6) Overrunning Clutch (7) Idle Gear (8) End Frame
(9) Brush Holder (10) Magnet Switch Cover (11) Plunger (12) B Terminal Nut
(13) Housing
1. Unscrew the C terminal nut (3), and disconnect the connecting lead.
2. Remove the two through bolts (1).
3. Detach the motor.
4. Remove the end frame (8).
5. Remove the brush from the brush holder while holding the spring up.
6. Remove the brush holder (9).
7. Draw out the armature (5) from the yoke (4).
8. Remove the housing (13).
9. Remove the idle gear (7) and the overrunning clutch (6).
10. Remove the magnet switch cover (10).
11. Remove the plunger (11).
(When reassembling)
• Apply grease (DENSO No. 50 or equivalent) to the idle gear and overrunning clutch portions.
5.9 to 11 N·m
Tightening torque B terminal nut 0.60 to 1.2 kgf·m
4.4 to 8.6 lbf·ft
(1) Pulley (2) Drive End Frame (3) Stator (4) Bearing
(5) Retainer Plate (6) Rotor (7) Bearing (8) Rear End Frame
(9) Rectifier (10) IC Regulator (11) Brush Holder (12) Rear End Cover
(When reassembling)
Top Clearance
0.575 to 0.675 mm
Top clearance Factory spec.
0.0227 to 0.0265 in.
(1) Piston
(2) Fuse
IMPORTANT
• Do not place the straightedge on the combustion
chamber.
• Be sure to check the valve recessing after
correcting.
0.05 (protrusion) to
0.15 (recessing) mm
Factory spec.
0.002 (protrusion) to
Valve recessing 0.0059 (recessing) in.
0.40 (recessing) mm
Allowable limit
0.016 (recessing) in.
(When removing)
(When installing)
IMPORTANT
Do not hit the valve guide with a hammer during
replacement.
1. Coat the valve face lightly with prussian blue and put
the valve on its seat to check the contact.
2. If the valve does not seat all the way around the
valve seat or the valve contact is less than 70 %,
correct the valve seating as follows.
2.12 mm
Valve seat width Factory spec.
0.0835 in.
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
1.0 rad
IN.
Valve face Factory 60 °
angle spec. 0.79 rad
EX.
45 °
Valve Lapping
2. Insert the valve into the valve guide. Lap the valve
onto its seat with a valve flapper or screwdriver.
IMPORTANT
When valve lapping is performed, be sure to check
the valve recessing and adjust the valve clearance
after assembling the valve.
1.0 mm
Tilt (A) Allowable limit
0.039 in.
41.7 to 42.2 mm
Factory spec.
1.65 to 1.66 in.
Free length (B)
41.2 mm
Allowable limit
1.62 in.
118 N / 35.0 mm
Factory spec. 12.0 kgf / 35.0 mm
Setting load / 26.5 lbf / 1.38 in.
Setting length 100 N / 35.0 mm
Allowable
10.2 kgf / 35.0 mm
limit
22.5 lbf / 1.38 in.
1. Set a dial indicator (lever type) with its tip on the gear
tooth.
0.04150 to 0.1122 mm
Factory spec.
Backlash between idle gear and 0.001634 to 0.004417 in.
crank gear 0.15 mm
Allowable limit
0.0059 in.
0.04150 to 0.1154 mm
Factory spec.
Backlash between idle gear and 0.001634 to 0.004543 in.
cam gear 0.15 mm
Allowable limit
0.0059 in.
0.04150 to 0.1154 mm
Factory spec.
Backlash between idle gear and 0.001634 to 0.004543 in.
injection pump gear 0.15 mm
Allowable limit
0.0059 in.
0.04150 to 0.1090 mm
Factory spec.
Backlash between crank gear and 0.001634 to 0.004291 in.
oil pump gear 0.15 mm
Allowable limit
0.0059 in.
0.04150 to 0.1154 mm
Factory spec.
Backlash between crank gear and 0.001634 to 0.004543 in.
idle gear 2 0.15 mm
Allowable limit
0.0059 in.
0.03080 to 0.1062 mm
Factory spec.
Backlash between idle gear 2 and 0.001213 to 0.004181 in.
hydraulic pump drive gear 0.15 mm
Allowable limit
0.0059 in.
Camshaft Alignment
33.90 mm
Factory spec.
Cam height of 1.335 in.
intake 33.85 mm
Allowable limit
1.333 in.
33.90 mm
Factory spec.
Cam height of 1.335 in.
exhaust 33.85 mm
Allowable limit
1.333 in.
(When removing)
(When installing)
(When removing)
(When installing)
1. Insert the piston ring into the lower part of the liner
(the least worn out part) with the piston.
0.25 to 0.40 mm
Factory spec.
0.0099 to 0.015 in.
Top ring
1.25 mm
Allowable limit
0.0492 in.
0.30 to 0.45 mm
Factory spec.
0.012 to 0.017 in.
Second ring
1.25 mm
Allowable limit
0.0492 in.
0.25 to 0.45 mm
Factory spec.
0.0099 to 0.017 in.
Oil ring
1.25 mm
Allowable limit
0.0492 in.
1. Clean the rings and the ring grooves, and install each
ring in its groove.
0.20 mm
Top Ring Allowable limit
0.0079 in.
0.0930 to 0.128 mm
Factory spec.
0.00367 to 0.00503 in.
Second ring
0.20 mm
Allowable limit
0.0079 in.
0.020 to 0.060 mm
Factory spec.
0.00079 to 0.0023 in.
Oil ring
0.15 mm
Allowable limit
0.0059 in.
(Reference)
0.2 mm 0.4 mm
Oversize
0.008 in. 0.02 in.
54.50 to 54.70 mm 54.60 to 54.80 mm
Dimension A
2.146 to 2.153 in. 2.150 to 2.157 in.
26.20 to 26.25 mm 26.40 to 26.45 mm
Dimension B
1.032 to 1.033 in. 1.040 to 1.041 in.
2.8 to 3.2 mm radius 2.8 to 3.2 mm radius
Dimension C
0.11 to 0.12 in. radius 0.11 to 0.12 in. radius
(0.4S)
The crankshaft journal must be fine-finished to higher than ∇∇∇∇
Crankshaft Alignment
Crankshaft 0.02 mm
Allowable limit
alignment 0.0008 in.
NOTE
• Never insert the plastigage into the crankpin oil
hole.
• Be sure not to move the crankshaft while the
connecting rod screws are tightened.
(Reference)
0.2 mm 0.4 mm
Undersize
0.008 in. 0.02 in.
3.3 to 3.7 mm radius 3.3 to 3.7 mm radius
Dimension A
0.13 to 0.14 in. radius 0.13 to 0.14 in. radius
1.0 to 1.5 mm relief 1.0 to 1.5 mm relief
*Dimension B
0.040 to 0.059 in. relief 0.040 to 0.059 in. relief
46.759 to 46.775 mm dia. 46.559 to 46.575 mm dia.
Dimension C
1.8409 to 1.8415 in. dia. 1.8331 to 1.8336 in. dia.
(0.4S)
The crankpin must be fine-finished to higher than ∇∇∇∇
*Holes to be de-burred and edges rounded with 1.0 to 1.5 mm
(0.040 to 0.059 in.) relief.
(Reference)
0.2 mm 0.4 mm
Undersize
0.008 in. 0.02 in.
2.8 to 3.2 mm radius 2.8 to 3.2 mm radius
Dimension A
0.11 to 0.12 in. radius 0.11 to 0.12 in. radius
1.0 to 1.5 mm relief 1.0 to 1.5 mm relief
*Dimension B
0.040 to 0.059 in. relief 0.040 to 0.059 in. relief
59.721 to 59.740 mm dia. 59.521 to 59.540 mm dia.
Dimension C
2.3513 to 2.3519 in. dia. 2.3434 to 2.3440 in. dia.
(0.4S)
The crankshaft journal must be fine-finished to higher than ∇∇∇∇
*Holes to be de-burred and edges rounded with 1.0 to 1.5 mm
(0.040 to 0.059 in.) relief.
(When removing)
(When installing)
4.20 to 4.50 mm
Dimension (A) Factory spec.
0.166 to 0.177 in.
0.0400 to 0.104 mm
Factory spec.
Oil clearance between crankshaft 0.00158 to 0.00409 in.
and crankshaft bearing 2 0.20 mm
Allowable limit
0.0079 in.
59.921 to 59.940 mm
Crankshaft journal O.D. Factory spec.
2.3591 to 2.3598 in.
59.980 to 60.025 mm
Crankshaft bearing 2 I.D. Factory spec.
2.3615 to 2.3631 in.
(Reference)
0.2 mm 0.4 mm
Undersize
0.008 in. 0.02 in.
2.8 to 3.2 mm radius 2.8 to 3.2 mm radius
Dimension A
0.11 to 0.12 in. radius 0.11 to 0.12 in. radius
1.0 to 1.5 mm relief 1.0 to 1.5 mm relief
*Dimension B
0.040 to 0.059 in. relief 0.040 to 0.059 in. relief
59.721 to 59.740 mm dia. 59.521 to 59.540 mm dia.
Dimension C, D
2.3513 to 2.3519 in. dia. 2.3434 to 2.3440 in. dia.
(0.4S)
The crankshaft journal must be fine-finished to higher than ∇∇∇∇
*Holes to be de-burred and edges rounded with 1.0 to 1.5 mm
(0.040 to 0.059 in.) relief.
NOTE
• Mount the sleeve with its largely chamfered
surface facing outward.
• Should heating is not enough, a sleeve might stop
halfway, so careful.
Cylinder Wear
87.000 to
87.022 mm
Factory spec.
3.4252 to
Cylinder I.D. 3.4260 in.
87.170 mm
Allowable limit
3.4319 in.
83.250 to 83.272 mm
3.2776 to 3.2784 in.
Factory spec.
Oversize 87.250 to 87.272 mm
cylinder 3.4351 to 3.4359 in.
V2403-M- 83.420 mm
BG I.D. 3.2843 in.
Allowable limit
87.420 mm
3.4417 in.
Hone to 2.2 to 3.0 μmRz
Finishing (0.000087 to 0.000118 in.Rz)
∇∇∇.
Overrunning Clutch
35.0 mm
Factory spec.
Commutator 1.38 in.
O.D. Allowable 34.0 mm
limit 1.34 in.
0.45 to 0.75 mm
0.018 to 0.029 in.
Factory spec.
Mica under 0.55 to 0.85 mm
cut 0.022 to 0.033 in.
0.20 mm
Allowable limit
0.0079 in.
15.0 mm
Factory spec.
0.591 in.
Brush length (A)
9.0 mm
Allowable limit
0.35 in.
Brush Holder
Field Coil
Bearing
Stator
Rotor
14.4 mm
Factory spec.
0.567 in.
Slip ring O.D.
14.0 mm
Allowable limit
0.551 in.
Brush Wear
10.5 mm
Factory spec.
0.413 in.
Brush length
8.4 mm
Allowable limit
0.33 in.
IC Regulator
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