Linhai LH1100U-D Service Manual
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Linhai LH1100U-D Service Manual

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SERVICE MANUAL
LH1100U-D
2019.0

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Summary of Contents for Linhai LH1100U-D

  • Page 1 SERVICE MANUAL LH1100U-D 2019.0...
  • Page 2 Foreword This manual is designed primarily for use by the UTV factory certified service technicians in a properly equipped shop. Persons using this manual should have a sound knowledge of mechanical theory, tool use, and shop procedures in order to perform the work safely and correctly.
  • Page 3 CONTENTS CHAPTER1 ………………………………………………General Information ↖ CHAPTER2 ………………………………………….……………Maintenance ↖ CHAPTER3…………………………………….………. ………………Chassis ↖ CHAPTER4…………………………………………..………………Final Drive ↖ CHAPTER5………………………………………………….……………Brakes ↖ CHAPTER6……………………………………………….………Transmission ↖ CHAPTER7…………………………………………Rear and Front Gearcase ↖ CHAPTER8………………………………………………….….………Electrical ↖ WARNING Never run an engine in an enclosed area. Carbon monoxide exhaust gas is poisonous and can cause severe injury or death. Always start engines outdoors. Gasoline is extremely flammable and explosive under certain conditions.
  • Page 4 CHAPTER 1 GENERALINFORMATION LH1100U-D SERVICE MANUAL 2019.0 CHAPTER 1 GENERAL INFORMATION The parts of different types/ variants/ versions maybe un-interchangeable, even some parts have almost same appearance. Always refer to Parts Manual of each UTV model for spare parts information and service.
  • Page 5 CHAPTER 1 GENERALINFORMATION LH1100U-D SERVICE MANUAL 2019.0 1.1 IMPORTANT INFORMATION PREPARATION FOR REMOVAL PROCEDURES 1. Remove all dirt, mud, dust and foreign material before removal and disassembly. 2. Use proper tools and cleaning equipment. 3. When disassembling the machine, always keep mated parts together. This includes gears, cylinders, pistons and other parts that have been ”mated ”through normal wear.
  • Page 6 CHAPTER 1 GENERALINFORMATION LH1100U-D SERVICE MANUAL 2019.0 Replace distorted circlips. When installing a circlip ① , make sure that the sharp-edged corner ② is positioned opposite the thrust ③ it receives. See sectional view. ④Shaft CHECKING OF CONNECTIONS Dealing with stains, rust, moisture, etc. on the connector.
  • Page 7 CHAPTER 1 GENERALINFORMATION LH1100U-D SERVICE MANUAL 2019.0 CONVERSION TABLE How to use the CONVERSION TABLE Use this table to convert METRIC unit data to IMPERIAL unit data. METRIC MULIPLIER **mm 0. 3937 **in **cm 0.03937 **in CONVERSION TABLE METRIC TO IMP...
  • Page 8 CHAPTER 1 GENERALINFORMATION LH1100U-D SERVICE MANUAL 2019.0 V.I.N AND ENGINE SERIAL NUMBER Record the frame VIN and the engine serial number from your UTV in the spaces provided. Frame VIN (found on the front right side of the frame tube) The vehicle frame is important for model identification when registering your vehicle, obtaining insurance or whenever replacement parts are required.
  • Page 9 CHAPTER 1 GENERALINFORMATION LH1100U-D SERVICE MANUAL 2019.0 VEHICLE DIMENSIONS CHAPTER 1 GENERAL PAGE. 1-6...
  • Page 10 CHAPTER 1 GENERALINFORMATION LH1100U-D SERVICE MANUAL 2019.0 NOTES CHAPTER 1 GENERAL PAGE. 1-7...
  • Page 11 CHAPTER 2 MAINTENANCE LH1100U-D SERVICE MANUAL 2019.0 CHAPTER 2 MAINTENANCE The parts of different types/ variants/ versions maybe un-interchangeable, even some parts have almost same appearance. Always refer to Parts Manual of each UTV model for spare parts information and service.
  • Page 12 CHAPTER 2 MAINTENANCE LH1100U-D SERVICE MANUAL 2019.0 2.1 PERIODIC MAINTENANCE GENARAL CAUTION Mark on the following chart D ： Dueto the nature of the adjustments marked withaD on the following chart, it is recommended thatservice be performed by an authorized dealer.
  • Page 13 CHAPTER 2 MAINTENANCE LH1100U-D SERVICE MANUAL 2019.0 Item Hours When Remarks Air Filter-Main Element Weekly Inspect ; Replace ifnecessary  Brake Pad Wear / Parking Inspect periodically 10 hrs Monthly Brake Pads 10 hrs Monthly Checkfor Axle boots, Front and rear axle boots...
  • Page 14 CHAPTER 2 MAINTENANCE LH1100U-D SERVICE MANUAL 2019.0 Item Hours When Remarks Transmission Oil Level 100hrs Monthly Check monthly and changeannually Spark Plug 100 hrs 12 months Inspect-replace ifnecessary Shock 100 hrs Inspect seals Brake Fluid 200 hrs 24 months Change every tow years...
  • Page 15 CHAPTER 2 MAINTENANCE LH1100U-D SERVICE MANUAL 2019.0 2.2 THROTTLEPEDAL INSPECTION THROTTLE FREEPLAY If the throttle pedal has excessive play due to cable stretch or cable misadjustment, it will cause a delay in throttle speed. Also, the throttle may not open fully.
  • Page 16 CHAPTER 2 MAINTENANCE LH1100U-D SERVICE MANUAL 2019.0 FUEL LINES 1. Check fuel lines for signsof wear, deterioration, damage or leakage. Replace if necessary. 2. Be sure fuel lines are routed properly and secured with cable ties. CAUTION: Make sure lines are not kinked orpinched.
  • Page 17 CHAPTER 2 MAINTENANCE LH1100U-D SERVICE MANUAL 2019.0 The following checks are recommended to keep the braking system in good operating condition. Service life of braking system componentsdepends on operating conditions. Inspect brakes in accordance with the maintenance schedule and before each ride ...
  • Page 18 CHAPTER 2 MAINTENANCE LH1100U-D SERVICE MANUAL 2019.0 Note: The adjusting on the caliper is for the wear out of the pads. 1. With the engine off, loosen the adjustor on the lever. 2. Loosen the jam nut of the adjuster on the caliper.
  • Page 19 CHAPTER 2 MAINTENANCE LH1100U-D SERVICE MANUAL 2019.0 Do not over tighten the wheel nuts. WHEEL REMOVAL 1. Stop the engine, place the transmission in gear and lock the parking brake. 2. Loosen the wheel nuts slightly. 3. Elevate the side of the vehicle by placing a suitable stand under the footrest frame.
  • Page 20 CHAPTER 2 MAINTENANCE LH1100U-D SERVICE MANUAL 2019.0  Maintain proper tire pressure. Refer to the warning tire pressure decal applied to the vehicle.  Improper tire inflation affect maneuverability. Tire Pressure Inspection  When replacing tire always original Front Rear equipment size and type and replace in pairs.
  • Page 21 CHAPTER 2 MAINTENANCE LH1100U-D SERVICE MANUAL 2019.0 NOTES CHAPTER 2 MAINTENANCE PAGE. 2- 11...
  • Page 22 CHAPTER 2 MAINTENANCE LH1100U-D SERVICE MANUAL 2019.0 CHAPTER 2 MAINTENANCE PAGE. 2- 12...

  • Page 23: Table Of Contents

    CHAPTER 3 CHASSIS LH1100U-D SERVICE MANUAL 2019.0 CHAPTER 3 CHASSIS WARNING The parts of different types/ variants/ versions maybe un-interchangeable, even some parts have almost same appearance. Always refer to Parts Manual of each UTV model for spare parts information and service.

  • Page 24: Front A-Arm Replacement

    CHAPTER 3 CHASSIS LH1100U-D SERVICE MANUAL 2019.0 3.1 FRONT A-ARM REPLACEMENT 1. Elevate and safely support the front of the vehicle and remove the front wheel. 2. Remove cotter pin from ball joint stud at wheel end of A- arm and loosen nut until it is flush with end of stud.

  • Page 25: Rear A-Arm Replacement

    CHAPTER 3 CHASSIS LH1100U-D SERVICE MANUAL 2019.0 5. Examine A-arm bushing. Replace if worn or tore. Discard hardware. 6. Install new A-arm assembly onto vehicle frame. Apply Loctite™ 263 to screw threads of the A arm bolts and torque new bolts to 37~44 ft. lbs (50~60 Nm ).
  • Page 26 CHAPTER 3 CHASSIS LH1100U-D SERVICE MANUAL 2019.0 4. Loosen bolts that secure the A-arm to frame. 5. Remove the nut from the upper portion of the stabilizer. 6. Examine the A-arm bushing and A-arm shaft. Replace if worn. Discard hardware.

  • Page 27: Rear Stabilizer Bar Removal/Installation

    CHAPTER 3 CHASSIS LH1100U-D SERVICE MANUAL 2019.0 Upon A-arm installation completion, test vehicle at low speeds before putting into regular service. 3.3 REAR STABILIZER BAR REMOVAL/INSTALLATION 1. Elevate and safely support vehicle with weight removed from the rear wheel(s). 2. Remove the rear wheel to gain access to the stabilizer bar, each side.

  • Page 28: Steering Assembly Removal/Installation

    CHAPTER 3 CHASSIS LH1100U-D SERVICE MANUAL 2019.0 hinge pin removed 6. With the hinge pins removed, remove the box from the frame. Two people maybe needed to remove the bed from the frame. CAUTION: Use caution when removing the box. It is recommended to have two people to carefully remove the box from the frame.
  • Page 29 CHAPTER 3 CHASSIS LH1100U-D SERVICE MANUAL 2019.0 3. Remove the steering column bolts. 4. Remove the upper of the steering column. 5. Remove the cotter pins and the tie rod end bolts (both sides). 6. With the cover bolts removed, remove the steering assy and the lower of the steering column.
  • Page 30 CHAPTER 3 CHASSIS LH1100U-D SERVICE MANUAL 2019.0 NOTES CHAPTER 3 CHASSIS PAGE. 3-...
  • Page 31 CHAPTER 4 FINAL DRIVE LH1100U-D SERVICE MANUAL 2019.0 CHAPTER 4 FINAL DRIVE WARNING The parts of different types/ variants/ versions maybe un-interchangeable, even some parts have almost same appearance. Always refer to Parts Manual of each UTV model for spare parts information and service.
  • Page 32 CHAPTER 4 FINAL DRIVE LH1100U-D SERVICE MANUAL 2019.0 4.1 WH E E L , H U B , AND SPINDLE TORQUE TABLE Item Specification heel Nuts 69 Ft.Lbs 95 Nm Front W heel Nuts 69 Ft.Lbs 95 Nm Rear W Front Hub Nut on Spindle/ outer CV joint 101 Ft.Lbs 137 Nm...
  • Page 33 CHAPTER 4 FINAL DRIVE LH1100U-D SERVICE MANUAL 2019.0 4.3 FRONT HUB AND KNUCKLE REMOVAL/INSPECTION 1. Elevate front end and safely support machine under footrest/frame area. CAUTION: Serious injury may result if machine tips or falls. Be sure machine is secure before beginning this service procedure.
  • Page 34 CHAPTER 4 FINAL DRIVE LH1100U-D SERVICE MANUAL 2019.0 4.4 FRONT HUB INSTALLATION 1. Inspect the hubstrut bearing surface for wear or 18ft.lbs(24NM) damage. 2. Apply grease to drive axle spindle. 3. Install spindle through the backside of the hubstrut. Install the hub onto the spindle.
  • Page 35 CHAPTER 4 FINAL DRIVE LH1100U-D SERVICE MANUAL 2019.0 NOTE: The outer CV joint cannot be disassembled or repaired, if damage or faulty the drive axle assembly must be replace. 1. Drive Axle/Outer CV Joint Assembly. 2. Boot Band “A”. 3. Outer Board Boot.
  • Page 36 CHAPTER 4 FINAL DRIVE LH1100U-D SERVICE MANUAL 2019.0 chapter. 2. Move each end of the drive shaft in a circular motion (and also a reciprocate for inner one) and check the drive shaft joints for excessive wear or play. 3. This inner CV joint (inboard pivot joint) can be serviced if there is wear or play.
  • Page 37 CHAPTER 4 FINAL DRIVE LH1100U-D SERVICE MANUAL 2019.0 4.7 FRONT DRIVE AXLE DISASSEMBLY/ INSPECTION INNER CV JOINT DISASSEMBLY NOTE: The outer CV joint cannot be disassembled or repaired, if damage or faulty the drive axle assembly must be replace. 1. Open the clamps on both boot band ”A” and ”B”...
  • Page 38 CHAPTER 4 FINAL DRIVE LH1100U-D SERVICE MANUAL 2019.0 replacement parts are available. 6. Clean the inner CV joint in solvent and thoroughly dry. 7. Inspect the interior of the inboard joint where the steel balls ride. Check for wear or damage and replace the joint if necessary.
  • Page 39 CHAPTER 4 FINAL DRIVE LH1100U-D SERVICE MANUAL 2019.0 4.8 REAR HUB EXPLODED VIEW 4.9 REAR HUB AND KNUCKLE REMOVAL/INSPECTION 1. Elevate rear end and safely support machine under main frame area. CAUTION: Serious injury may result if machine tips or falls. Be sure machine is secure before...
  • Page 40 CHAPTER 4 FINAL DRIVE LH1100U-D SERVICE MANUAL 2019.0 axle. 8. Inspect the rear hub and knuckle assembly by hand for smoothness and side to side movement, replace as needed. 4.10 REAR HUB AND KNUCKLE INSTALLATION 1. Start the rear hub and knuckle assembly onto the drive shaft.
  • Page 41 CHAPTER 4 FINAL DRIVE LH1100U-D SERVICE MANUAL 2019.0 4.12 REAR DRIVE SHAFT INSTALLATION 1. Install a new circlip onto the rear drive shaft. Apply Anti-Seize Compound onto the rear driveshaft splines (both ends). 2. Reinstall the rear driveshaft into the rear gearcase.
  • Page 42 CHAPTER 4 FINAL DRIVE LH1100U-D SERVICE MANUAL 2019.0 NOTES CHAPTER 4 FINAL DRIVE. 4- 12...
  • Page 43 CHAPTER 5 BRAKES LH1100U-D SERVICE MANUAL 2019.0 CHAPTER 5 BRAKES WARNING The parts of different types/ variants/ versions maybe un-interchangeable, even some parts have almost same appearance. Always refer to Parts Manual of each ATV model for spare parts information and service.
  • Page 44 CHAPTER 5 BRAKES LH1100U-D SERVICE MANUAL 2019.0 5.1 SPECIFICATIONS Front Brake Caliper Item Standard Service Limit Brake Pad Friction material 0.157"/ 4mm 0.04"/ 1mm Thickness B rake Disc Thickness 0.150- 0.164"/3.810- 4.166mm 0.140"/ 3.556mm Brake Disc Thickness Variance 0.002 "/ .051mm...
  • Page 45 CHAPTER 5 BRAKES LH1100U-D SERVICE MANUAL 2019.0  Test for brake drag after any brake system service and investigate cause if brake drag is evident.  Make sure caliper moves freely on guide pins (where applicable) .  Inspect caliper piston seals for foreign material that could prevent caliper pistons from returning freely.
  • Page 46 CHAPTER 5 BRAKES LH1100U-D SERVICE MANUAL 2019.0 3. If changing fluid, remove old fluid from reservoir with a brake fluid pump or similar tool. 4. Add brake fluid up to the indicated MAX level on the reservoir. DOT 3 Brake Fluid 5.
  • Page 47 CHAPTER 5 BRAKES LH1100U-D SERVICE MANUAL 2019.0 1. Inspect the spring on the parking brake lever assembly. 2. Inspect the parking brake cable at the parking brake lever assembly on the brake caliper. 3. Inspect the brake lines and brake line connections for possible leaks or loose lines.
  • Page 48 CHAPTER 5 BRAKES LH1100U-D SERVICE MANUAL 2019.0 Park Brake Caliper Disassembly / Pad Inspection NOTE: Do not get oil, grease, or fluid on the park brake pads. Damage to the pads may cause the pads to function improperly. 1. Loosen the two brake caliper bolts in equal increments.
  • Page 49 CHAPTER 5 BRAKES LH1100U-D SERVICE MANUAL 2019.0 1. Elevate and support front of UTV safely. CAUTION: Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur if machine tips or falls. 2. Remove the front wheel.
  • Page 50 CHAPTER 5 BRAKES LH1100U-D SERVICE MANUAL 2019.0 Front Caliper Mounting Bolts Torque 18 ft. lbs. (25 Nm ) 4. Slowly pump the brake lever until pressure has been built up. Maintain at least 1/2 ". (13 mm) of brake fluid in the reservoir to prevent air from entering the brake system.
  • Page 51 CHAPTER 5 BRAKES LH1100U-D SERVICE MANUAL 2019.0 2. Remove bolts and disc. 3. Clean mating surface of disc and hub. 4. Install new disc on hub and tighten to specified. CAUTION: Always use new brake disc mounting bolts. Front Brake Disc Mounting Bolt Torque : 18 ft.
  • Page 52 CHAPTER 5 BRAKES LH1100U-D SERVICE MANUAL 2019.0 5.12 REAR BRAKE PAD REMOVAL/ INSPECTION / INSTALLATION NOTE: The brake pads should be replaced as a set. REMOVAL 1. Elevate and support rear of UTV safely. CAUTION: Use care when supporting vehicle so that it does not tip or fall.
  • Page 53 CHAPTER 5 BRAKES LH1100U-D SERVICE MANUAL 2019.0 The caliper is a non-serviceable Component; it must be replaced as an assembly. NOTE: If any special service needed, contact the UTV manufacture via the agent for the parts and special instruction. CAUTION: Use care when supporting vehicle so that it does not tip or fall.
  • Page 54 CHAPTER 5 BRAKES LH1100U-D SERVICE MANUAL 2019.0 Brake Disc Thickness New 0.150-0.164" (3.810 - 4.166 mm) Service Limit 0.140" / 3.556 mm Brake Disc Thickness Variance Service Limit 0.002 " (0.051 mm) difference between measurements 3. Mount dial indicator as shown to measure disc runout on the dial indicator. Replace the disc if runout exceeds specifications.
  • Page 55 CHAPTER 5 BRAKES LH1100U-D SERVICE MANUAL 2019.0 CHAPTER 5 BRAKES PAGE. 5- 13...
  • Page 56 CHAPTER 6 TRANSMISSION LH1100U-D SERVICE MANUAL 2019.0 CHAPTER 6 TRANSMISSION 6.1 GEARBOX DISASSEMBLY TRANSMISSION EXPLODED VIEW CHAPTER 6 TRANSMISSION. 6-...
  • Page 57 CHAPTER 6 TRANSMISSION LH1100U-D SERVICE MANUAL 2019.0 NUT M8 SPRING WASHER WASHER 8 ENGAGEMENT A SHIFT BRACKET CIRCLIP 25 CIRCLIP 11 WASHER 25.5B GEAR SHIFT COMPONENT BEARING 25X29X13 BOLT M6X16 DRIVEN GEAR, REVERSE COVER WASHER 25.5A SPRING DRIVEN GEAR, LOW SPEED O-RING 13.2X1.8...
  • Page 58 CHAPTER 6 TRANSMISSION LH1100U-D SERVICE MANUAL 2019.0 O-Ring 18×2.65 Washer 40 Cover,Oil Important: Before staring any operation Fig 3 on the gearbox make sure electric sensor 3. Remove the gear consent sensor A. of the gear consent A is protected (if →Fig 4(page 1).
  • Page 59 CHAPTER 6 TRANSMISSION LH1100U-D SERVICE MANUAL 2019.0 Fig 10 10. Remove the oil drain plug A and let the oil drain from the gearbox. Important: Clean the plug carefully and Fig 7 Replace the sealing washer B before 7. Hit alternately, the shift drum.
  • Page 60 CHAPTER 6 TRANSMISSION LH1100U-D SERVICE MANUAL 2019.0 Fig 13 Fig 16 13. Remove the 4WD coupling running bushing 16. Remove the fork shaft B by a screws A B, then remove the electromagnet A. (M5), then remove the Selector fork C, SpringⅠD, SpringⅡE, Fork pole F.
  • Page 61 CHAPTER 6 TRANSMISSION LH1100U-D SERVICE MANUAL 2019.0 Fig 19 Fig 22 19. Remove the D20 lock snap ring, then 22. Remove the right semi-housing D. the 4WD fixed coupling bushing A. →Fig 23.(page 4). →Fig 20.(page 4). Fig 23 Fig 20 23.
  • Page 62 CHAPTER 6 TRANSMISSION LH1100U-D SERVICE MANUAL 2019.0 Table 1.Two Semi-Housing Components 25. Remove the safety ring F A Primary input drive shaft →Fig 27.(page 5). B Reverse gear shaft C Intermediate shaft D Shift fork E Shift fork rod F Shift drum G Output drive shaft →Fig 25.(page 5)
  • Page 63 CHAPTER 6 TRANSMISSION LH1100U-D SERVICE MANUAL 2019.0 28. Remove the safety ring X, the clearance 6.2 GEARBOX ASSEMBLY washer Y, and the gear Z. →Fig 30.(page 6). 1. Use a scraper to remove all the sealant residue from the coupling surfaces of the semi-housing.
  • Page 64 CHAPTER 6 TRANSMISSION LH1100U-D SERVICE MANUAL 2019.0 Important: clean the coupling surfaces Mount following components carefully with degreaser liquid. on the input drive shaft H: 2. Mount oil seals to its limit stop. a The bearing G. →Fig 33(page 7).
  • Page 65 CHAPTER 6 TRANSMISSION LH1100U-D SERVICE MANUAL 2019.0 Fig 37 Fig 39 h Mount the bearing I to its limit stop Note: During the assembly, it is not →Fig 38(page 8). necessary to adjust the components. All the swivel rings and the clearances have been calculated 4.
  • Page 66 CHAPTER 6 TRANSMISSION LH1100U-D SERVICE MANUAL 2019.0 f The engagementⅠG with the convexity g The waveform spring H h The engagementⅡO with the convexity i The Clearance washerⅡI j The Roller cageⅡJ slow gear running gear K, with the convexity for gear at the bottom.
  • Page 67 CHAPTER 6 TRANSMISSION LH1100U-D SERVICE MANUAL 2019.0 Fig 46 Fig 48 6. Put the output drive shaft F and the 8. Put shift drum B into their seats. then, cut intermediate shaft E as an assembly, as the apophysis E of selector fork G in the shown, then put them to their seats.
  • Page 68 CHAPTER 6 TRANSMISSION LH1100U-D SERVICE MANUAL 2019.0 Fig 51 Fig 54 11. Turn the shafts manually and make 15. Make sure that the two centring pins A are sure they run smoothly and are free in their correct position. from impediments.
  • Page 69 CHAPTER 6 TRANSMISSION LH1100U-D SERVICE MANUAL 2019.0 Spring Ⅱ 4WD coupling running bushing →Fig 60(page 8). Fig 57 18. Insert 4WD drive shaft B along with the two already mounted bearing. Note: The end with a hole inward. Fig 60 →Fig 58(page 12)
  • Page 70 CHAPTER 6 TRANSMISSION LH1100U-D SERVICE MANUAL 2019.0 Fig 63 Fig 66 The assembly is as shown in fig 64(page 13). 25. Mount the gasket X and the 4WD cover Y. →Fig 67(page 13). Fig 64 23. Use the Fork shaft B to drill through springⅠC，...
  • Page 71 CHAPTER 6 TRANSMISSION LH1100U-D SERVICE MANUAL 2019.0 Fig 69 Fig 72 28. Apply Loctite 510 sealant evenly on Table 4. Shift Housing Components A Shift housing cover the support surface of 4WD gearbox. →Fig 70(page 14). B Limit pole C O-ring...
  • Page 72 CHAPTER 6 TRANSMISSION LH1100U-D SERVICE MANUAL 2019.0 32. Mount the shift shaft D. →Fig 75(page 15). Fig 78 36. Apply Loctite 510 sealant evenly on Fig 75 the fringe of shift housing cover 33. Mount the shift cam E, then mount...
  • Page 73 CHAPTER 6 TRANSMISSION LH1100U-D SERVICE MANUAL 2019.0 Fig 80 Fig 83 38. Tighten the four screws M6（L16） 41. Mount the selector lever J. Then tighten the self-locking nut K to to a torque of 20Nm. Note: There is a screw fasten the a torque of 30Nm.
  • Page 74 CHAPTER 6 TRANSMISSION UTV SERVICE MANUAL 2010.0 PAGE. 6- 19 CHAPTER 6 TRANSMISSION...
  • Page 75 CHAPTER 7 Rear and Front Gearcase LH1100U-D SERVICE MANUAL 2019.0 CHAPTER 7 Rear and Front Gearcase 7.1 REAR GEAR CASE DISASSEMBLY REAR GEARCASE EXPLODED VIEW CHAPTER 7 Rear and Front Gearcase. 7-...
  • Page 76 CHAPTER 7 Rear and Front Gearcase LH1100U-D SERVICE MANUAL 2019.0 Hexagon Flange Bolt M8×25 Nut M20×1.5 Locating Pin Oil Seal 30X50X6.5 Washer Carrier Housing Half Fitting Holder-With Bearing Shift Return Spring O-Ring Hexagon Flange Bolt M8×1.25×35 Shift Yoke Fill Plug...
  • Page 77 CHAPTER 7 Rear and Front Gearcase LH1100U-D SERVICE MANUAL 2019.0 Fig 2 3. Remove the electromagnet A. →Fig 3.(page 17). Fig 5 6. Remove all two bolts A (M6 L15) then, remove the transition box cover B. Fig 3 →Fig 6.(page 18).
  • Page 78 CHAPTER 7 Rear and Front Gearcase LH1100U-D SERVICE MANUAL 2019.0 Fig 7 Fig 10 8. Remove the seven bolts H（M8 L30）from 11. Remove two selector housing plugs G the right backstop I. Then, remove the →Fig 11.(page 19). right backstop I.
  • Page 79 CHAPTER 7 Rear and Front Gearcase LH1100U-D SERVICE MANUAL 2019.0 Fig 13 Fig 15 14. Remove the four bolts M（M8 L30）from 16. Remove the 8 bolts K（M8`L25） the connecting plate N . Then, remove the from the rear gearcase cover J. Then, connecting plate N.
  • Page 80 CHAPTER 7 Rear and Front Gearcase LH1100U-D SERVICE MANUAL 2019.0 Fig 17 18. Remove the input shaft P with the bearing R. →Fig 18.(page 20). Fig 20 21. Remove the 8 bolts L （ M10`L25 ） ,8 washer M and 8 spring lock washer N.
  • Page 81 CHAPTER 7 Rear and Front Gearcase LH1100U-D SERVICE MANUAL 2019.0 Fig 22 Fig 25 23. Use a slender bar to remove the 26. Remove the bevel gear J and washer cylindrical pin X. K.→Fig 26.(page 22). →Fig 23.(page 21). Fig 26 Fig 23 24.
  • Page 82 CHAPTER 7 Rear and Front Gearcase LH1100U-D SERVICE MANUAL 2019.0 2. Put WasherⅡE close to the Bevel gearⅡ 7.2 REAR GEAR CASE ASSEMBLY F, then make the bevels gearⅠE and the Table 1. Differential housing Components Bevel gearⅠare in mesh, A Differential cover as shown.
  • Page 83 CHAPTER 7 Rear and Front Gearcase LH1100U-D SERVICE MANUAL 2019.0 Fig 4 Fig 7 3. Mount the washerⅠB on the bevel gear 6. Apply Loctite 263 evenly on the bolt ⅠC, then make the bevel gearⅠC mash thread.Tighten the eight bolts M10（L25）...
  • Page 84 CHAPTER 7 Rear and Front Gearcase LH1100U-D SERVICE MANUAL 2019.0 Fig 9 13. Tighten the eight screws C M8 10. Hammer at the differential assembly H to (L25) to a torque of 20~25Nm. mount it with the bearings on the rear →Fig 13(page 25).
  • Page 85 CHAPTER 7 Rear and Front Gearcase LH1100U-D SERVICE MANUAL 2019.0 then tighten the four bolts P M8(L30) to a torque of 20~25Nm. →Fig 18 (page 26). Fig 15 16. Mount the input shaft E in the input housing in rear gearcase box F →Fig 16(page 25).
  • Page 86 CHAPTER 7 Rear and Front Gearcase LH1100U-D SERVICE MANUAL 2019.0 Fig 19 Fig 22 20. Put SpringⅡC close to Fork pole D, then 23. Tighten two plug A to a torque of take the differential mandril H drill through 20~30Nm →Fig 66(page 13) them, as shown.
  • Page 87 CHAPTER 7 Rear and Front Gearcase LH1100U-D SERVICE MANUAL 2019.0 Bar sheath Electromagnet →Fig b (page 27). Fig 27 28. Mount the transition box D on the rear gearcase cover B, then apply some Fig b sealant on the bolt thread cannulation X 25.
  • Page 88 CHAPTER 7 Rear and Front Gearcase LH1100U-D SERVICE MANUAL 2019.0 surface of the seal. →Fig 33 (page 29). Fig 33 34. Mount the right backstop E, with the oil seal then tighten the seven bolts F M8(L30) to a torque of 20~25Nm.
  • Page 89 CHAPTER 7 Rear and Front Gearcase LH1100U-D SERVICE MANUAL 2019.0 Fig 37 Fig 36 37. Mount the Rubber protective sleeve A and Clip B.→Fig 37.(page 29). 7.3 FRONT GEAR CASE DISASSEMBLY CHAPTER 7 Rear and Front Gearcase. 7- 15...
  • Page 90 CHAPTER 7 Rear and Front Gearcase LH1100U-D SERVICE MANUAL 2019.0 FRONT GEARCASE EXPLODED VIEW Rear and Front Gearcase. 7- 16 CHAPTER 7...
  • Page 91 CHAPTER 7 Rear and Front Gearcase LH1100U-D SERVICE MANUAL 2019.0 Hexagon Flange Bolt M8×25 Case, Converter Bevel Gear -Driven Oil Seal 30X50X6.5 Nut M20×1.5 O-Ring 176X2.65-Housing Halves Fitting Holder-With Bearing Washer Locating Pin Hexagon Flange Bolt M8×1.25×35 Shift Return Spring...
  • Page 92 CHAPTER 7 Rear and Front Gearcase LH1100U-D SERVICE MANUAL 2019.0 7.4 FRONT GEARCASE DISASSEMBLY Fig 88 Important: Before staring any operation 3. Remove the bar sheath C from the bar D. On the gearbox make sure electric sensor →Fig 89.
  • Page 93 CHAPTER 7 Rear and Front Gearcase LH1100U-D SERVICE MANUAL 2019.0 Fig 91 6. Remove the pin B and the rocker C from Fig 94 9. Remove the six bolts （M8 L25） from the left the transition box D. →Fig 92.
  • Page 94 CHAPTER 7 Rear and Front Gearcase LH1100U-D SERVICE MANUAL 2019.0 front cover N . Then, remove the front cover N. →Fig 100. Fig 97 12. Remove the fork shaft F by a bolt E (M6). →Fig 98. Fig 100 15．Remove the front cover B with the oil seal C and the O-ring D.
  • Page 95 CHAPTER 7 Rear and Front Gearcase LH1100U-D SERVICE MANUAL 2019.0 Fig 104 19．Use the pliers to remove the safety snap ring A. →Fig 105. Fig 105 20. Use a bearing extractor to remove the bearing D. Fig 102 →Fig 106.
  • Page 96 CHAPTER 7 Rear and Front Gearcase LH1100U-D SERVICE MANUAL 2019.0 M and 8 spring lock washer N. then, remove the differential cover O with the bearing p. →Fig 107. Fig 109 24. Use a slender bar to remove the middle shaft Y.
  • Page 97 CHAPTER 7 Rear and Front Gearcase LH1100U-D SERVICE MANUAL 2019.0 A →Fig 114. Fig 112 Fig 114 2. Put WasherⅡE close to the Bevel gearⅡ F, 7.5 FRONT GEARCASE ASSEMBLY then make the bevels gearⅠE and the Bevel Table 1. Differential housing Components gearⅠare in mesh,...

  • Page 98: Mount The Washerⅰb On The Bevel Gear Ⅰc, Then Make The Bevel Gearⅰc Mash With Two Bevel Gears Ⅱf. →Fig

    CHAPTER 7 Rear and Front Gearcase LH1100U-D SERVICE MANUAL 2019.0 two bevel gears F, two washers E and differential cover A. →Fig 116. Fig 119 7.Mount the spring lock washer V and the washer W on the screw U（M10`L25）. Fig 116 →Fig 120.

  • Page 99: Mount The Clearance Washer C On The Rear Gearcase Cover D. →Fig

    CHAPTER 7 Rear and Front Gearcase LH1100U-D SERVICE MANUAL 2019.0 11. Make sure that the centring pins and the O-ring are in their correct position. →Fig 124. Fig 124 12. Assemble the two semi-housings with the help of a tool, as shown.
  • Page 100 CHAPTER 7 Rear and Front Gearcase LH1100U-D SERVICE MANUAL 2019.0 Fig 128 16. Mount the input shaft E in the input housing in rear gearcase box F →Fig 129 Fig 126 14. Mount the bearing I to its limit stop on the input shaft J.
  • Page 101 CHAPTER 7 Rear and Front Gearcase LH1100U-D SERVICE MANUAL 2019.0 tighten the four bolts M M8(L30) to a torque of 20~25Nm. →Fig 131. Fig 132 20. Put SpringⅡC close to Fork pole D, then take the differential mandril H drill through them, as shown.
  • Page 102 CHAPTER 7 Rear and Front Gearcase LH1100U-D SERVICE MANUAL 2019.0 Electromagnet →Fig 139. Fig 136 23. Tighten two plug A to a torque of Fig 139 20~30Nm →Fig 66(page 13) 25. Mount cylindrical pin B on the hole →Fig 137.
  • Page 103 CHAPTER 7 Rear and Front Gearcase LH1100U-D SERVICE MANUAL 2019.0 Fig 142 28. Mount the transition box D on the rear gearcase cover B, then apply some sealant on the screw thread cannulation X of transition box D. →Fig 143.
  • Page 104 CHAPTER 7 Rear and Front Gearcase LH1100U-D SERVICE MANUAL 2019.0 rotate speed sensor E to a torque of surface of the seal. →Fig 148. 15~18Nm. →Fig 151. Fig 148 34. Mount the right backstop E, with the oil Fig 151 seal then tighten the seven bolts F 37.
  • Page 105 CHAPTER 7 Rear and Front Gearcase LH1100U-D SERVICE MANUAL 2018.0 NOTES CHAPTER 7 Rear and Front Gearcase. 7- 31...
  • Page 106 CHAPTER 8 ELECTRICAL LH1100U-D SERVICE MANUAL 2019.0 CHAPTER 8 ELECTRICAL 8.1 . WIRING DIAGRAM 8. 2. STARTING SYSTEM [1]. Engine Starting Conditions 8. 3. CHARGING SYSTEM 8. 4. LIGHTING AND SIGNAL SYSTEM [1]. Head Light [2]. Tail Light [3]. Turn Signal Light [4].
  • Page 107 CHAPTER 8 ELECTRICAL LH1100U-D SERVICE MANUAL 2019.0 8.1. WIRING DIAGRAM CHAPTER 8 ELECTRICAL PAGE. 8-...
  • Page 108 CHAPTER 8 ELECTRICAL LH1100U-D SERVICE MANUAL 2019.0 8.2. STARTING SYSTEM When the main switch is turned to the “3” position, the terminal “30” is connected to the terminals “19” and “AC”. The glow plugs become red-hot, and at the same time, the glow plug indicator also lights on。...
  • Page 109 CHAPTER 8 ELECTRICAL LH1100U-D SERVICE MANUAL 2019.0 (1). Engine Starting Conditions When the following conditions become complete, electric current (12V) reaches starter S terminal through starter relay from main switch 50 terminal, and the engine can be started. (Neutral :...
  • Page 110 CHAPTER 8 ELECTRICAL LH1100U-D SERVICE MANUAL 2019.0 8.3. CHARGING SYSTEM The charge system supplies electric power for various electrical devices and also charges the battery while the engine runs. It consists of a AC dynamo . （1） When the engine working the Charging warning indicator will turn off.
  • Page 111 CHAPTER 8 ELECTRICAL LH1100U-D SERVICE MANUAL 2019.0 8.4. LIGHTING AND SIGNAL SYSTEM The lighting system consists of light switch, head lights etc.. LIGHTING SYSTEM Symptom Probable Cause Solution Head light Does Fuse blown (10A) Replace Bulb blown Replace Light Relay blown...
  • Page 112 CHAPTER 8 ELECTRICAL LH1100U-D SERVICE MANUAL 2019.0 8.5. THE LED METER 1. Coolant temperature meter 13. Neutral indicator light 2. Speedometer 14. L GEAR POSITION 3. Engine rpm meter 15. H GEAR POSITION 4. Engine working hour counter 16. Safety belt indicator light 5.
  • Page 113 CHAPTER 8 ELECTRICAL LH1100U-D SERVICE MANUAL 2019.0 8.6. TROUBLESHOOTING Symptom Probable Cause Solution All Electrical Battery Recharge or Replace Equipments Do discharged defective Operate Battery positive Repair or Replace cable disconnected or improperly connected Battery negative Repair or Replace cable...
  • Page 114 CHAPTER 8 ELECTRICAL LH1100U-D SERVICE MANUAL 2019.0 dynamo) Dynamo defective Repair or Replace Charging Lamp Wiring harness Repair or Replace Does disconnected or Not Go Off When improperly Engine Is connected (between main Running switch 30 terminal and regulator, between panel...
  • Page 115 CHAPTER 8 ELECTRICAL LH1100U-D SERVICE MANUAL 2019.0 Symptom Probable Cause Solution Fuel Gauge Fuel gauge defective Repair Does Not Fuel level sensor Replace Function defective Wiring harness Repair or disconnected or Replace improperly connected (between panel board and fuel level...
  • Page 116 CHAPTER 8 ELECTRICAL LH1100U-D SERVICE MANUAL 2019.0 8.7. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING (1) Battery Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing Antidote: External: Flush with water.
  • Page 117 CHAPTER 8 ELECTRICAL LH1100U-D SERVICE MANUAL 2019.0 Removing and Installing Battery Removing 1. Park the vehicle safely. 2. Raise passenger seat. 3. Disconnect all black negative cables (A) from battery first. 4. Slide back rubber protective cover （B）and disconnect all red positive cables.
  • Page 118 CHAPTER 8 ELECTRICAL LH1100U-D SERVICE MANUAL 2019.0 (2) Main Switch Main Switch 1. Remove the steering wheel and the meter panel. 2. Disconnect the 4P connector (1) and remove the main switch (2). 3. Perform the following checks. Connector Voltage 1.
  • Page 119 CHAPTER 8 ELECTRICAL LH1100U-D SERVICE MANUAL 2019.0 3) Main Switch Key at PREHEAT Position 1. Set and hold the main switch key at the PREHEAT position. 2. Measure the resistance with an ohmmeter across the 30 terminal and the 19 terminal, and measure the resistance across the 30 terminal and the AC terminal.
  • Page 120 CHAPTER 8 ELECTRICAL LH1100U-D SERVICE MANUAL 2019.0 Glow Plug Continuity Disconnect the lead from the glow plugs. Measure the resistance between the glow plug terminal and the chassis. If 0 ohm is indicated, the screw at the tip of the glow plug and the housing are short-circuited.
  • Page 121 CHAPTER 8 ELECTRICAL LH1100U-D SERVICE MANUAL 2019.0 （4）.ENGINE OIL PRESSURE LAMP When the engine oil pressure has dropped, the engine oil pressure switch is activated to let the current flow from the main switch and to light up the lamp.
  • Page 122 CHAPTER 8 ELECTRICAL LH1100U-D SERVICE MANUAL 2019.0 Indicate the temperature of the engine （6） “A” the coolant temperature 90±3℃ “B” the coolant temperature 100±2℃ 5. Thermo switch Remove the thermo switch from the radiator. Connect the pocket tester (ΩX1) to the thermo switch.
  • Page 123 CHAPTER 8 ELECTRICAL LH1100U-D SERVICE MANUAL 2019.0 (7) Engine meter System Speed Speed Sensor on the Transmission Out Put Shaft. Operation Instructions of LCD Meter and Speed Sensor Main Technical Parameter： Item Code Vol value Unit Operating voltage 5-20 Operating current ≤15...
  • Page 124 CHAPTER 8 ELECTRICAL LH1100U-D SERVICE MANUAL 2019.0 (8) GEAR POSITION INDICATOR SWITCH TEST Switch table CHAPTER 8 ELECTRICAL PAGE. 8- 19...
  • Page 125 CHAPTER 9 CVT Assy. LH1100U-D SERVICE MANUAL 2019.0 CHAPTER 9 CVT Assy. 9.1 CVT Assy. DISASSEMBLY CVT ASSY AND CVT Cover EXPLODED VIEW Bolt M10X166 Bolt M6X25 WASHER Clamp A Down Cover .CVT Intake Plastic Pipe Drive Pulley Bolt M6X110 Nut M12X1.25...
  • Page 126 CHAPTER 9 CVT Assy. LH800U-2D SERVICE MANUAL 2017.0 Disassembly: →Fig 1 1.Remove the rear cover, footrest 3. Remove Bolt M10X166 →Fig 2 →Fig 4 4. Put driving wheel puller into the bolts Bolt M10X166 hole ， Tighten the driving wheel puller clockwise，Then Following table parts is Disassembled...
  • Page 127 CHAPTER 9 CVT Assy. LH800U-2D SERVICE MANUAL 2017.0 Disassembly completed 5. remove Nut M12X1.25 , Take off Driven Pulley Comp. from the Transmission input shaft, Belt , djusting shim2 and remove Key, Installation B4.7X55。 Installation work is an opposite process →Fig 6 of Disassembly work, Pay attention to the installation torque of shaft and nut .
  • Page 128 WORKSHOP MANUAL DIESEL ENGINE 05-E4B SERIES, 05-E4BG SERIES KiSC issued 03, 2019 A...
  • Page 129 TO THE READER This Workshop Manual tells the servicing personnel about the mechanism, servicing and maintenance of the 05-E4B and 05-E4BG. It contains 4 parts: "Information", "General", "Mechanism" and "Servicing".  Information This section primarily contains information below. • Safety First •...
  • Page 130 Record of Revisions For pdf, use search function {Search word} to find all the revised locations. Last digit Month of Reference of the Main Revised Point and Corrective Measures {Search word} Revision Page Code No. 2014.04 • Add D1005-E4B 3000 rpm specifications type {2.
  • Page 131 INFORMATION KiSC issued 03, 2019 A...
  • Page 132 INFORMATION CONTENTS 1. SAFETY FIRST ..........................I-1 2. SPECIFICATIONS.......................... I-5 3. PERFORMANCE CURVES......................I-9 4. DIMENSIONS ..........................I-14 KiSC issued 03, 2019 A...

  • Page 133: Safety First

    INFORMATION 05-E4B, 05-E4BG SERIES, WSM 1. SAFETY FIRST 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. •...
  • Page 134 INFORMATION 05-E4B, 05-E4BG SERIES, WSM OPERATE SAFELY • Do not use the machine after you consume alcohol or medication or when you are tired. • Put on applicable clothing and safety equipment. • Use applicable tools only. Do not use alternative tools or parts.
  • Page 135 INFORMATION 05-E4B, 05-E4BG SERIES, WSM AVOID HOT EXHAUST • Servicing machine or attachments with engine operating can result in serious personal injury. Avoid exposure and skin contact with hot exhaust gases and components. • Exhaust parts and streams become very hot during operation.
  • Page 136 INFORMATION 05-E4B, 05-E4BG SERIES, WSM DISCARD FLUIDS CORRECTLY • Do not discard fluids on the ground, down the drain, into a stream, pond, or lake. Obey related environmental protection regulations when you discard oil, fuel, coolant, electrolyte and other dangerous waste. WSM000001INI0007US0 PREVENT ACID BURNS •...

  • Page 137: Specifications

    INFORMATION 05-E4B, 05-E4BG SERIES, WSM 2. SPECIFICATIONS Model D1005-E4B D1105-E4B Number of Cylinder Engine Type Vertical, water-cooled, 4-cycle diesel engine 76.0 × 73.6 mm 78.0 × 78.4 mm Bore × Stroke (2.99 × 2.90 in.) (3.07 × 3.09 in.) Total Displacement 1001 cm (61.08 cu.in.) 1123 cm...
  • Page 138 INFORMATION 05-E4B, 05-E4BG SERIES, WSM Model D1305-E4B V1505-E4B Number of Cylinder Engine Type Vertical, water-cooled, 4-cycle diesel engine 78.0 × 88.0 mm 78.0 × 78.4 mm Bore × Stroke (3.07 × 3.46 in.) (3.07 × 3.09 in.) Total Displacement 1261 cm (76.95 cu.in.) 1498 cm (91.41 cu.in.)
  • Page 139 INFORMATION 05-E4B, 05-E4BG SERIES, WSM D1005-E4BG D1105-E4BG Model Number of Cylinder Engine Type Vertical, Water-cooled, 4 cycle diesel engine 76.0 × 73.6 mm 78.0 × 78.4 mm Bore × Stroke (2.99 × 2.90 in.) (3.07 × 3.09 in.) 1001 cm 1123 cm Total Displacement (61.08 cu.in.)
  • Page 140 INFORMATION 05-E4B, 05-E4BG SERIES, WSM D1305-E4BG V1505-E4BG Model Number of Cylinder Engine Type Vertical, Water-cooled, 4 cycle diesel engine 78.0 × 88.0 mm 78.0 × 78.4 mm Bore × Stroke (3.07 × 3.46 in.) (3.07 × 3.09 in.) 1261 cm 1498 cm Total Displacement (76.95 cu.in.)

  • Page 141: Performance Curves

    INFORMATION 05-E4B, 05-E4BG SERIES, WSM 3. PERFORMANCE CURVES D1005-E4B (3000 rpm) (1) Brake Horsepower (2) Engine Speed (3) B.S.F.C. (Brake Specific Fuel (4) Torque Consumption) 9Y1210784INI0011US0 KiSC issued 03, 2019 A...
  • Page 142 INFORMATION 05-E4B, 05-E4BG SERIES, WSM D1005-E4B (3200 rpm) (1) Brake Horsepower (2) Engine Speed (3) B.S.F.C. (Brake Specific Fuel (4) Torque Consumption) 9Y1210784INI0003US0 I-10 KiSC issued 03, 2019 A...
  • Page 143 INFORMATION 05-E4B, 05-E4BG SERIES, WSM D1105-E4B (1) Brake Horsepower (2) Engine Speed (3) B.S.F.C. (Brake Specific Fuel (4) Torque Consumption) 9Y1210784INI0004US0 I-11 KiSC issued 03, 2019 A...
  • Page 144 INFORMATION 05-E4B, 05-E4BG SERIES, WSM D1305-E4B (1) Brake Horsepower (2) Engine Speed (3) B.S.F.C. (Brake Specific Fuel (4) Torque Consumption) 9Y1210784INI0005US0 I-12 KiSC issued 03, 2019 A...
  • Page 145 INFORMATION 05-E4B, 05-E4BG SERIES, WSM V1505-E4B (1) Brake Horsepower (2) Engine Speed (3) B.S.F.C. (Brake Specific Fuel (4) Torque Consumption) 9Y1210784INI0006US0 I-13 KiSC issued 03, 2019 A...

  • Page 146: Dimensions

    INFORMATION 05-E4B, 05-E4BG SERIES, WSM 4. DIMENSIONS D1005-E4B, D1105-E4B D1005-E4B D1105-E4B 497.8 mm (19.60 in.) 497.8 mm (19.60 in.) 230 mm (9.06 in.) 230 mm (9.06 in.) 330 mm dia. (13.0 in. dia.) 330 mm dia. (13.0 in. dia.) 396 mm (15.6 in.) 396 mm (15.6 in.) 194 mm (7.64 in.) 194 mm (7.64 in.)
  • Page 147 INFORMATION 05-E4B, 05-E4BG SERIES, WSM D1305-E4B D1305-E4B 497.6 mm (19.59 in.) 590.1 mm (23.23 in.) 396.0 mm (15.59 in.) 185.3 mm (7.295 in.) 125 mm dia. (4.92 in. dia.) 222.2 mm dia. (8.748 in. dia.) 9Y1210784INI0008US0 I-15 KiSC issued 03, 2019 A...
  • Page 148 INFORMATION 05-E4B, 05-E4BG SERIES, WSM V1505-E4B V1505-E4B 591.3 mm (23.28 in.) 230 mm (9.06 in.) 370 mm dia. (14.6 in. dia.) 396 mm (15.6 in.) 194 mm (7.64 in.) 607.0 mm (23.90 in.) 238.5 mm (9.390 in.) 200 mm (7.87 in.) 250.81 to 251.12 mm dia.
  • Page 149 INFORMATION 05-E4B, 05-E4BG SERIES, WSM D1005-E4BG, D1105-E4BG, V1505-E4BG D1005-E4BG D1105-E4BG V1505-E4BG 546.6 mm (21.52 in.) 546.6 mm (21.52 in.) 634.3 mm (24.97 in.) 4-3/8-16 UNC-2B 4-3/8-16 UNC-2B 4-3/8-16 UNC-2B Depth 16 mm (0.63 in.) Depth 16 mm (0.63 in.) Depth 16 mm (0.63 in.) 608.7 mm (23.96 in.) 608.7 mm (23.96 in.) 613.7 mm (24.16 in.)
  • Page 150 INFORMATION 05-E4B, 05-E4BG SERIES, WSM D1305-E4BG D1305-E4BG 551.3 mm (21.70 in.) 4-3/8-16 UNC-2B Depth 16 mm (0.63 in.) 590.1 mm (23.23 in.) 360 mm (14.2 in.) 333.38 mm dia. (13.125 in. dia.) 200.02 mm dia. (7.8748 in. dia.) 356 mm dia. (14.0 in. dia.) 296 mm dia.
  • Page 151 GENERAL KiSC issued 03, 2019 A...
  • Page 152 GENERAL CONTENTS 1. ENGINE IDENTIFICATION ......................G-1 [1] MODEL NAME AND ENGINE SERIAL NUMBER..............G-1 [2] E4B ENGINE .......................... G-3 [3] CYLINDER NUMBER ......................G-3 2. GENERAL PRECAUTIONS......................G-4 3. MAINTENANCE CHECK LIST ..................... G-5 4. CHECK AND MAINTENANCE ..................... G-7 [1] DAILY CHECK POINTS ......................

  • Page 153: Engine Identification

    GENERAL 05-E4B, 05-E4BG SERIES, WSM 1. ENGINE IDENTIFICATION [1] MODEL NAME AND ENGINE SERIAL NUMBER You must identify the engine model name and serial number before you start a job. When you get in touch with the manufacturer, always tell your engine model name and serial number. Engine Serial Number The engine serial number is an identified number for the engine.
  • Page 154 GENERAL 05-E4B, 05-E4BG SERIES, WSM (Continued) Month of manufacture Month Engine Lot Number January A0001 ~ A9999 B0001 ~ BZ999 February C0001 ~ C9999 D0001 ~ DZ999 March E0001 ~ E9999 F0001 ~ FZ999 April G0001 ~ G9999 H0001 ~ HZ999 J0001 ~ J9999 K0001 ~ KZ999 June...

  • Page 155: E4B Engine

    GENERAL 05-E4B, 05-E4BG SERIES, WSM [2] E4B ENGINE [Example: Engine Model Name D1105-E4B-XXXX] The emission controls previously implemented in various countries to prevent air pollution will be stepped up as Nonroad Emission Standards continue to change. The timing or applicable date of the specific Nonroad Emission regulations depends on the engine output classification.

  • Page 156: General Precautions

    GENERAL 05-E4B, 05-E4BG SERIES, WSM 2. GENERAL PRECAUTIONS • When you disassemble, carefully put the parts in a clean area to make it easy to find the parts. You must install the screws, bolts and nuts in their initial position to prevent the reassembly errors.

  • Page 157: Maintenance Check List

    GENERAL 05-E4B, 05-E4BG SERIES, WSM 3. MAINTENANCE CHECK LIST To make sure that the engine operates safely for a long time, refer to the table below to do regular inspections. Service Interval Every Item 1 or 2 1500 3000 months year years * Checking fuel hoses and clamp bands...
  • Page 158 GENERAL 05-E4B, 05-E4BG SERIES, WSM CAUTION • When changing or inspecting, be sure to level and stop the engine. 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).

  • Page 159: Check And Maintenance

    GENERAL 05-E4B, 05-E4BG SERIES, 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"...
  • Page 160 GENERAL 05-E4B, 05-E4BG SERIES, WSM Checking and Fill 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".

  • Page 161: Check Points Of Initial 50 Hours

    GENERAL 05-E4B, 05-E4BG SERIES, WSM [2] CHECK POINTS OF INITIAL 50 HOURS Changing Engine Oil 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.
  • Page 162 GENERAL 05-E4B, 05-E4BG SERIES, WSM Replacing Oil Filter Cartridge CAUTION • Be sure to stop the engine before changing filter cartridge. 1. Remove the oil filter cartridge with the filter wrench. 2. Apply a slight coat of oil onto the new cartridge gasket. 3.

  • Page 163: Check Point Of Every 50 Hours

    GENERAL 05-E4B, 05-E4BG SERIES, WSM [3] CHECK POINT 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.

  • Page 164: Check Points Of Every 100 Hours

    GENERAL 05-E4B, 05-E4BG SERIES, 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/cm , 30 psi).
  • Page 165 GENERAL 05-E4B, 05-E4BG SERIES, 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.

  • Page 166: Check Points Of Every 200 Hours

    GENERAL 05-E4B, 05-E4BG SERIES, WSM [5] CHECK POINTS OF EVERY 200 HOURS Changing Engine Oil 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.
  • Page 167 GENERAL 05-E4B, 05-E4BG SERIES, WSM Replacing Oil Filter Cartridge CAUTION • Be sure to stop the engine before changing filter cartridge. 1. Remove the oil filter cartridge with the filter wrench. 2. Apply a slight coat of oil onto the new cartridge gasket. 3.

  • Page 168: Check Points Of Every 400 Hours

    GENERAL 05-E4B, 05-E4BG SERIES, WSM [6] CHECK POINTS OF EVERY 400 HOURS Replacing Oil FIlter Cartridge (for BG Type) CAUTION • Be sure to stop the engine before changing filter cartridge. 1. Remove the oil filter cartridge with the filter wrench. 2.

  • Page 169: Check Points Of Every 500 Hours

    GENERAL 05-E4B, 05-E4BG SERIES, WSM [7] CHECK POINTS OF EVERY 500 HOURS Cleaning Water Jacket and Radiator Interior 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.
  • Page 170 GENERAL 05-E4B, 05-E4BG SERIES, WSM Anti-freeze • There are 2 types of anti-freeze available: use the permanent type (PT) for this engine. • When you add anti-freeze for the first time, flush the water jacket and radiator interior with clean, soft water several times. •...

  • Page 171: Check Points Of Every 1 Or 2 Months

    GENERAL 05-E4B, 05-E4BG SERIES, 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.

  • Page 172: Check Point Of Every Year

    GENERAL 05-E4B, 05-E4BG SERIES, WSM Battery Specific Gravity 1. Measure the specific gravity of the electrolyte in each cell with a battery and coolant tester. 2. If the electrolyte temperature is different from the one that the battery and coolant tester calibrated, correct the specific gravity measurement.

  • Page 173: Check Point Of Every 800 Hours

    GENERAL 05-E4B, 05-E4BG SERIES, WSM [10] CHECK POINT OF EVERY 800 HOURS Checking Valve Clearance 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.

  • Page 174: Check Points Of Every 1500 Hours

    GENERAL 05-E4B, 05-E4BG SERIES, WSM [11] CHECK POINTS OF EVERY 1500 HOURS CAUTION • Check the injection pressure and condition after you make sure 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 dest oyed and blood poisoning may be caused.

  • Page 175: Check Points Of Every 3000 Hours

    GENERAL 05-E4B, 05-E4BG SERIES, WSM [12] CHECK POINTS OF EVERY 3000 HOURS 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.
  • Page 176 GENERAL 05-E4B, 05-E4BG SERIES, WSM (Continued) NOTE • The liquid gasket is not required for assembling. • Shims are available in thickness of 0.20 mm (0.0079 in.), 0.25 mm (0.0098 in.), 0.30 mm (0.012 in.), 0.35 mm (0.014 in.) and 0.175 mm (0.00689 in.). Combine these shims for adjustments.
  • Page 177 GENERAL 05-E4B, 05-E4BG SERIES, 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).

  • Page 178: Check Points Of Every 2 Years

    GENERAL 05-E4B, 05-E4BG SERIES, 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.
  • Page 179 GENERAL 05-E4B, 05-E4BG SERIES, 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 trying the check and change prescribed above.
  • Page 180 GENERAL 05-E4B, 05-E4BG SERIES, WSM Changing Radiator Coolant (L.L.C.) 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.
  • Page 181 GENERAL 05-E4B, 05-E4BG SERIES, WSM (Continued)  Anti-freeze • There are 2 types of anti-freeze available: use the permanent type (PT) for this engine. • When you add anti-freeze for the first time, flush the water jacket and radiator interior with clean, soft water several times. •...

  • Page 182: Special Tools

    GENERAL 05-E4B, 05-E4BG SERIES, WSM 5. SPECIAL TOOLS Diesel Engine Compression Tester (for Nozzle Hole) Code No. • 07909-30208 (Assembly) • 07909-30934 (A to F) • 07909-31211 (E and F) • 07909-31231 (H) • 07909-31251 (G) • 07909-31271 (I) • 07909-31281 (J) Application •...
  • Page 183 GENERAL 05-E4B, 05-E4BG SERIES, WSM NOTE • The following special tools are not provided, so make them referring to the figure. 9Y1210784GEG0049US0 Injection Pump Pressure Tester Application • Use to check fuel tightness of injection pumps. Pressure gauge full scale: More than 29.4 MPa (300 kgf/cm , 4267 psi) PF 1/2...
  • Page 184 GENERAL 05-E4B, 05-E4BG SERIES, WSM Valve Guide Replacing Tool Application • Use to press out and press fit the valve guide. 225 mm (8.86 in.) 70 mm (2.8 in.) 45 mm (1.8 in.) 20 mm dia. (0.79 in. dia.) 11.7 to 11.9 mm dia. (0.461 to 0.468 in. dia.) 6.50 to 6.60 mm dia.
  • Page 185 GENERAL 05-E4B, 05-E4BG SERIES, WSM Flywheel Stopper Application • Use to loosen and tighten the flywheel screw. 140 mm (5.51 in.) 80 mm (3.1 in.) 49.3 mm (1.94 in.) 49.3 mm (1.94 in.) 23.8 mm (0.937 in.) 23.8 mm (0.937 in.) 11 mm dia.
  • Page 186 GENERAL 05-E4B, 05-E4BG SERIES, WSM Governor Gear Holder Bushing Replacing Tool Application • Use to press out and to press fit the governor gear holder bushing. C1: Chamfer 1.0 mm (0.039 in.) 73.90 to 74.00 mm dia. (2.910 to 2.913 in. dia.) 69.80 to 69.90 mm dia.
  • Page 187 GENERAL 05-E4B, 05-E4BG SERIES, WSM Crank Sleeve Setter Application • Use to fix the crankshaft sleeve. (1) Auxiliary Socket for Pushing 130 mm (5.12 in.) 112 mm (4.41 in.) 107 mm (4.21 in.) 82 mm (3.2 in.) 72 mm (2.8 in.) 67 mm (2.6 in.) 47 mm (1.8 in.) 36.00 to 36.20 mm (1.418 to 1.425 in.)
  • Page 188 ENGINE KiSC issued 03, 2019 A...
  • Page 189 MECHANISM CONTENTS 1. ENGINE BODY........................... 1-M1 [1] CLOSED BREATHER ......................1-M1 [2] HALF-FLOATING HEAD COVER (D1305-E4B/E4BG) ............1-M1 [3] GOVERNOR......................... 1-M2 [4] BOOST COMPENSATOR ....................1-M4 KiSC issued 03, 2019 A...

  • Page 190: Engine Body

    ENGINE 05-E4B, 05-E4BG SERIES, WSM 1. ENGINE BODY [1] CLOSED BREATHER 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 blow by gas in fed back to the intake manifold through breather valve (3) to be used for re-combustion.

  • Page 191: Governor

    ENGINE 05-E4B, 05-E4BG SERIES, WSM [3] GOVERNOR Three Lever Type Fork Lever (for standard type) 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. Because the feature of this mechanism takes out the engine speed directly as a centrifugal force of weight, the speed control that the change in the engine rotational...
  • Page 192 ENGINE 05-E4B, 05-E4BG SERIES, 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...

  • Page 193: Boost Compensator

    ENGINE 05-E4B, 05-E4BG SERIES, WSM [4] BOOST COMPENSATOR (1) Boost Compensator Assembly (2) Actuator (3) Plate (4) Injection Pump Assembly (5) Guide (6) Stop Solenoid Fulcrum 9Y1210784ENM0007US0 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".
  • Page 194 SERVICING CONTENTS 1. TROUBLESHOOTING.........................1-S1 2. SERVICING SPECIFICATIONS ....................1-S5 3. TIGHTENING TORQUES......................1-S12 [1] TIGHTENING TORQUES FOR GENERAL USE SCREWS, BOLTS AND NUTS....1-S12 [2] TIGHTENING TORQUES FOR SPECIAL USE SCREWS, BOLTS AND NUTS....1-S13 4. CHECKING, DISASSEMBLING AND SERVICING ..............1-S14 [1] CHECKING AND ADJUSTING....................1-S14 (1) Engine Body ........................1-S14 (2) Lubricating System ......................1-S16 (3) Cooling System ......................1-S17...

  • Page 195: Troubleshooting

    ENGINE 05-E4B, 05-E4BG SERIES, WSM 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Engine Does Not No fuel Fill fuel G-11 Start Air in the fuel system Vent air G-11 Water in the fuel system Change fuel and – repair or replace fuel system Fuel pipe clogged Clean or replace...
  • Page 196 ENGINE 05-E4B, 05-E4BG SERIES, WSM Reference Symptom Probable Cause Solution Page Engine Revolution Is Fuel filter clogged or dirty Replace G-16 Not Smooth Air cleaner clogged Clean or replace G-12, G-15, G-20 Fuel leak due to loose injection pipe retaining nut Tighten retaining nut –...
  • Page 197 ENGINE 05-E4B, 05-E4BG SERIES, WSM Reference Symptom Probable Cause Solution Page Excessive Lubricant Piston ring's gap facing the same direction Shift ring gap 1-S41 Oil Consumption direction Oil ring worn or stuck Replace 1-S41, 1-S42 Piston ring groove worn Replace piston 1-S40, 1-S41, 1-S42...
  • Page 198 ENGINE 05-E4B, 05-E4BG SERIES, WSM Reference Symptom Probable Cause Solution Page Engine Overheated Engine oil insufficient Fill Fan belt broken or elongated Replace or adjust G-12, G-13 Coolant insufficient Fill G-17 Radiator net and radiator fin clogged with dust Clean –...

  • Page 199: Servicing Specifications

    ENGINE 05-E4B, 05-E4BG SERIES, WSM 2. SERVICING SPECIFICATIONS ENGINE BODY Item Factory Specification Allowable Limit Valve Clearance (Cold) 0.145 to 0.185 mm – 0.00571 to 0.00728 in. Compression Pressure D1005-E4B/E4BG 3.73 to 4.11 MPa 2.26 MPa D1105-E4B/E4BG 38.0 to 42.0 kgf/cm 23.0 kgf/cm D1305-E4B/E4BG 541 to 597 psi...
  • Page 200 ENGINE 05-E4B, 05-E4BG SERIES, WSM Item Factory Specification Allowable Limit Rocker Arm Shaft to Rocker Arm Clearance 0.016 to 0.045 mm 0.10 mm 0.00063 to 0.0017 in. 0.0039 in. • Rocker Arm Shaft O.D. 11.973 to 11.984 mm – 0.47138 to 0.47181 in. •...
  • Page 201 ENGINE 05-E4B, 05-E4BG SERIES, WSM Item Factory Specification Allowable Limit Idle Gear • Idle Gear 1 Side Clearance 0.20 to 0.51 mm 0.80 mm 0.0079 to 0.020 in. 0.031 in. • Idle Gear 2 Side Clearance 0.20 to 0.51 mm 0.80 mm 0.0079 to 0.020 in.
  • Page 202 ENGINE 05-E4B, 05-E4BG SERIES, WSM Item Factory Specification Allowable Limit Connecting Rod Alignment – 0.05 mm 0.002 in. Crankshaft Alignment – 0.02 mm 0.0008 in. Crankshaft to Crankshaft Bearing 1 Oil Clearance 0.0340 to 0.114 mm 0.20 mm [D1005-E4B/E4BG] 0.00134 to 0.00448 in. 0.0079 in.
  • Page 203 ENGINE 05-E4B, 05-E4BG SERIES, WSM Item Factory Specification Allowable Limit Crankshaft Side Clearance 0.15 to 0.31 mm 0.50 mm 0.0059 to 0.012 in. 0.020 in. Cylinder Liner I.D. D1005-E4B/E4BG 76.000 to 76.019 mm 76.15 mm 2.9922 to 2.9928 in. 2.998 in. D1105-E4B/E4BG 78.000 to 78.019 mm 78.15 mm...
  • Page 204 ENGINE 05-E4B, 05-E4BG SERIES, WSM FUEL SYSTEM Item Factory Specification Allowable Limit Injection Pump [D1005-E4B] Injection Timing 0.3011 to 0.3272 rad – (3000 min (rpm)) (17.25 to 18.75°) before T.D.C. Injection Timing 0.3360 to 0.3621 rad – (3200 min (rpm)) (19.25 to 20.75°) before T.D.C.
  • Page 205 ENGINE 05-E4B, 05-E4BG SERIES, WSM ELECTRICAL SYSTEM Item Factory Specification Allowable Limit Glow Plug Resistance Approx. – 0.9 Ω Starter (Gear Reduction Type) • Commutator O.D. 30.0 mm 29.0 mm 1.18 in. 1.14 in. • Difference O.D. Less than 0.05 mm 0.02 mm 0.002 in.

  • Page 206: Tightening Torques

    ENGINE 05-E4B, 05-E4BG SERIES, WSM 3. TIGHTENING TORQUES Use a torque wrench to tighten the screws, bolts and nuts to the specified torque. Tighten the screws, bolts and nuts used, such as on the cylinder head in the correct sequence and torque. 9Y1210784ENS0003US0 [1] TIGHTENING TORQUES FOR GENERAL USE SCREWS, BOLTS AND NUTS...

  • Page 207: Tightening Torques For Special Use Screws, Bolts And Nuts

    ENGINE 05-E4B, 05-E4BG SERIES, WSM [2] TIGHTENING TORQUES FOR SPECIAL USE SCREWS, BOLTS AND NUTS NOTE • For the screws, bolts and nuts with the mark "*", apply engine oil to their threads and seats before you tighten. • The alphabet "M" in Dimension × Pitch shows that the screw, bolt or nut dimensions are in the metric system.

  • Page 208: Checking, Disassembling And Servicing

    ENGINE 05-E4B, 05-E4BG SERIES, WSM 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING (1) Engine Body Compression Pressure 1. Operate the engine until it is warmed up. 2. Stop the engine. 3. Remove the air cleaner, the muffler and all injection nozzles. 4.
  • Page 209 ENGINE 05-E4B, 05-E4BG SERIES, WSM Valve Clearance 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.

  • Page 210: Lubricating System

    ENGINE 05-E4B, 05-E4BG SERIES, WSM (2) Lubricating System Engine Oil Pressure 1. Remove the engine oil pressure switch, and set an oil pressure tester (Code No.: 07916-80380). (Adaptor screw: PT 1/8) 2. Start the engine. After warming up, measure the oil pressure of both idling and rated speeds.

  • Page 211: Cooling System

    ENGINE 05-E4B, 05-E4BG SERIES, WSM (3) Cooling System Fan Belt Tension 1. Measure the deflection (A), depressing the belt halfway between the fan drive pulley and alternator pulley at specified force 98 N (10 kgf, 22 lbf). 2. If the measurement is not within the factory specifications, loosen the alternator mounting screws and relocate the alternator to adjust.
  • Page 212 ENGINE 05-E4B, 05-E4BG SERIES, WSM Radiator Water Leakage 1. Pour a specified amount of water into the radiator. 2. Set a radiator tester (1) and an adaptor (2) and raise the water pressure to the specified pressure. 3. Check the radiator for water leaks. 4.

  • Page 213: Fuel System

    ENGINE 05-E4B, 05-E4BG SERIES, WSM (4) Fuel System 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.
  • Page 214 ENGINE 05-E4B, 05-E4BG SERIES, WSM (Continued) NOTE • The liquid gasket is not required for assembling. • Shims are available in thickness of 0.20 mm (0.0079 in.), 0.25 mm (0.0098 in.), 0.30 mm (0.012 in.), 0.35 mm (0.014 in.) and 0.175 mm (0.00689 in.). Combine these shims for adjustments.
  • Page 215 ENGINE 05-E4B, 05-E4BG SERIES, WSM Fuel Tightness of Delivery Valve 1. Remove the engine stop solenoid. 2. Remove the injection pipes and glow plugs. 3. Set a pressure tester to the fuel injection pump. 4. Install the injection nozzle (2) jetted with the proper injection pressure to the injection pump pressure tester (1).
  • Page 216 ENGINE 05-E4B, 05-E4BG SERIES, WSM Fuel Injection Pressure 1. Set the injection nozzle to a nozzle tester. 2. Slowly move the tester handle to measure the pressure at which fuel begins jetting out from the nozzle. 3. If the measurement is not within the factory specifications, replace the adjusting washer (1) in the nozzle holder to adjust it.
  • Page 217 ENGINE 05-E4B, 05-E4BG SERIES, WSM Nozzle Holder 1. Secure the nozzle retaining nut (7) with a vise. 2. Remove the nozzle holder (1) and internal parts. (When reassembling) • Assemble the nozzle in clean fuel oil. • Install the push rod (4), noting its direction. •...

  • Page 218: Electrical System

    ENGINE 05-E4B, 05-E4BG SERIES, WSM (5) Electrical System 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 operating. •...
  • Page 219 ENGINE 05-E4B, 05-E4BG SERIES, WSM Battery Specific Gravity 1. Measure the specific gravity of the electrolyte in each cell with a battery and coolant tester. 2. If the electrolyte temperature is different from the one that the battery and coolant tester calibrated, correct the specific gravity measurement.
  • Page 220 ENGINE 05-E4B, 05-E4BG SERIES, WSM Magnetic Switch Test 1. Disconnect the battery negative cable from the battery. 2. Disconnect the battery positive cable from the battery. 3. Disconnect the leads from the starter B terminal. 4. Remove the starter from the engine. 5.
  • Page 221 ENGINE 05-E4B, 05-E4BG SERIES, WSM Alternator on Unit Test (Before testing) • Before alternator on unit test, check the battery terminal connections, circuit connection, fan belt tension, charging indicator lamp, fuses on the circuit, and abnormal noise from the alternator. •...
  • Page 222 ENGINE 05-E4B, 05-E4BG SERIES, WSM Engine Stop Solenoid 1. Remove the engine stop solenoid from the engine. 2. Connect the jumper leads from the pulling coil P terminal to the switch (4), and from switch (4) to the battery positive terminal. 3.

  • Page 223: Disassembling And Assembling

    ENGINE 05-E4B, 05-E4BG SERIES, WSM [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.

  • Page 224: Cylinder Head And Valve

    ENGINE 05-E4B, 05-E4BG SERIES, WSM (3) Cylinder Head and Valve Cylinder Head Cover 1. Disconnect the breather hose (1). 2. Remove the cylinder head cover screw (2). 3. Remove the cylinder head cover (3). (When reassembling) • Check to see if the cylinder head cover gasket is not damaged. [D1005-E4B/E4BG, D1105-E4B/E4BG, V1505-E4B/E4BG] 7 to 8 N·m Tightening torque...
  • Page 225 ENGINE 05-E4B, 05-E4BG SERIES, WSM Nozzle Holder Assembly and Glow Plug 1. Remove the overflow pipe (1). 2. Remove the nozzle holder assemblies (4). 3. Remove the copper gasket (5) and heat seal (6). 4. Remove the lead (2) from the glow plugs (3). 5.
  • Page 226 ENGINE 05-E4B, 05-E4BG SERIES, WSM Rocker Arm and Push Rod 1. Remove the rocker arm bracket screws / nuts. 2. Remove the rocker arm assembly (1). 3. Remove the push rods (2). (When reassembling) • When putting the push rods (2) onto the tappets (3), check to see if their ends are properly engaged with the dimples.
  • Page 227 ENGINE 05-E4B, 05-E4BG SERIES, WSM Cylinder Head and Cylinder Head Gasket 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.
  • Page 228 ENGINE 05-E4B, 05-E4BG SERIES, WSM Valves 1. Remove the valve caps (2). 2. Remove the valve spring collet (3), pushing the valve spring retainer (4) by valve spring replacer (1). 3. Remove the valve spring retainer (4), valve spring (5) and valve stem seal (6).

  • Page 229: Gear Case And Timing Gears

    ENGINE 05-E4B, 05-E4BG SERIES, WSM (4) Gear Case and Timing Gears Oil Pan and Oil Strainer (for Extended Oil Pan) 1. Remove the oil pan mounting screws. 2. Remove the oil pan (2). 3. Remove the oil strainer (1). (When reassembling) •...
  • Page 230 ENGINE 05-E4B, 05-E4BG SERIES, WSM Gear Case 1. Remove the fuel feed pump. 2. Remove the gear case. (When reassembling) • Grease thinly to the oil seal, and install it, ensuring the lip does not come off. (1) Gear Case Bolt Length = 45 mm (1.8 in.) Bolt Length = 50 mm (2.0 in.) (A) Gear Case for Standard Oil Pan...
  • Page 231 ENGINE 05-E4B, 05-E4BG SERIES, WSM Boost Compensator (equipped with R24 Model) 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 remove the boost compensator.
  • Page 232 ENGINE 05-E4B, 05-E4BG SERIES, 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.
  • Page 233 ENGINE 05-E4B, 05-E4BG SERIES, 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.

  • Page 234: Piston And Connecting Rod

    ENGINE 05-E4B, 05-E4BG SERIES, WSM (5) Piston and Connecting Rod Oil Pan and Oil Strainer (for Standard Oil Pan) 1. Remove the oil pan mounting screws (5). 2. Remove the oil pan (4). 3. Remove the oil strainer (3). (When reassembling) •...
  • Page 235 ENGINE 05-E4B, 05-E4BG SERIES, 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.
  • Page 236 ENGINE 05-E4B, 05-E4BG SERIES, 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.

  • Page 237: Flywheel And Crankshaft

    ENGINE 05-E4B, 05-E4BG SERIES, 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.
  • Page 238 ENGINE 05-E4B, 05-E4BG SERIES, WSM Crankshaft Assembly (except D1305-E4B/E4BG) 1. Remove the main bearing case screw 2 (1). 2. Pull out the crankshaft assembly. IMPORTANT • Be careful to protect crankshaft bearing 1 from scratches, caused by the crank gear, etc.. (Wrap the gear in vinyl tape, etc.) (When reassembling) •...
  • Page 239 ENGINE 05-E4B, 05-E4BG SERIES, WSM Main Bearing Case Assembly 1. Remove the two main bearing case screws 1 (2) of each main bearing cases. 2. Remove the main bearing case from crankshaft. (When reassembling) • Clean the oil passage in the main bearing cases. •...

  • Page 240: Alternator

    ENGINE 05-E4B, 05-E4BG SERIES, WSM (7) Alternator (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 1.

  • Page 241: Starter

    ENGINE 05-E4B, 05-E4BG SERIES, WSM (8) Starter Electromagnetic Drive Type (1) Solenoid Switch Mounting (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...
  • Page 242 ENGINE 05-E4B, 05-E4BG SERIES, WSM Gear Reduction Type (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.

  • Page 243: Servicing

    ENGINE 05-E4B, 05-E4BG SERIES, 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 (1) of a diameter 1.5 mm (0.059 in.) × 5.0 to 7.0 mm (0.20 to 0.27 in.) long to the crown of the piston;...
  • Page 244 ENGINE 05-E4B, 05-E4BG SERIES, 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 5 to 10 minutes after spraying. 4.
  • Page 245 ENGINE 05-E4B, 05-E4BG SERIES, 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.
  • Page 246 ENGINE 05-E4B, 05-E4BG SERIES, WSM Correcting Valve and Valve Seat 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.
  • Page 247 ENGINE 05-E4B, 05-E4BG SERIES, 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.
  • Page 248 ENGINE 05-E4B, 05-E4BG SERIES, 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. 0.25 mm Push rod alignment Allowable limit 0.0098 in.

  • Page 249: Timing Gears, Camshaft And Governor Gear

    ENGINE 05-E4B, 05-E4BG SERIES, WSM (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.
  • Page 250 ENGINE 05-E4B, 05-E4BG SERIES, 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 0.070 to 0.22 mm Factory specification...
  • Page 251 ENGINE 05-E4B, 05-E4BG SERIES, WSM Oil Clearance between Idle Gear Shaft 1 and 2 and Idle Gear Bushing 1. Measure the idle gear shaft O.D. with an outside micrometer. 2. Measure the idle gear bushing I.D. with an inside micrometer, and calculate the oil clearance.

  • Page 252: Piston And Connecting Rod

    ENGINE 05-E4B, 05-E4BG SERIES, 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.
  • Page 253 ENGINE 05-E4B, 05-E4BG SERIES, WSM Connecting Rod Alignment 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.
  • Page 254 ENGINE 05-E4B, 05-E4BG SERIES, WSM Clearance between Piston ring and Piston Ring Groove 1. Clean the rings and the ring grooves, and install each ring in its groove. 2. Measure the clearance between the ring and the groove with a feeler gauge or depth gauge.

  • Page 255: Crankshaft

    ENGINE 05-E4B, 05-E4BG SERIES, WSM (4) Crankshaft Crankshaft Side Clearance 1. Set a dial indicator with its point on the end of the crankshaft. 2. Move the crankshaft to the front and rear to measure the side clearance. 3. If the measurement is more than the allowable limit, replace the thrust bearings.
  • Page 256 ENGINE 05-E4B, 05-E4BG SERIES, 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.
  • Page 257 ENGINE 05-E4B, 05-E4BG SERIES, 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.
  • Page 258 ENGINE 05-E4B, 05-E4BG SERIES, WSM Replacing Crankshaft Bearing 1 (When removing) 1. Press out the used crankshaft bearing 1 using a crankshaft bearing 1 replacing tool. (See page "SPECIAL TOOLS".) (When installing) 1. Clean a new crankshaft bearing 1 and crankshaft journal bore, and apply engine oil to them.
  • Page 259 ENGINE 05-E4B, 05-E4BG SERIES, 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.
  • Page 260 ENGINE 05-E4B, 05-E4BG SERIES, WSM (Continued) [D1305-E4B/E4BG] 0.0340 to 0.103 mm Factory specification Oil clearance between 0.00134 to 0.00405 in. crankshaft journal and 0.20 mm crankshaft bearing 2 Allowable limit 0.0079 in. Crankshaft journal O.D. 51.921 to 51.940 mm Factory specification (Intermediate) 2.0442 to 2.0448 in.

  • Page 261: Cylinder

    ENGINE 05-E4B, 05-E4BG SERIES, 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.
  • Page 262 ENGINE 05-E4B, 05-E4BG SERIES, WSM Correcting Cylinder 1. When the cylinder is worn beyond the allowable limit, bore and hone it to the specified dimension. D1005-E4B/ 76.500 to 76.519 mm E4BG 3.0119 to 3.0125 in. D1105-E4B/ Factory E4BG specifica- D1305-E4B/ 78.500 to 78.519 mm tion E4BG...

  • Page 263: Oil Pump

    ENGINE 05-E4B, 05-E4BG SERIES, WSM (6) Oil Pump Rotor Lobe Clearance 1. Measure the clearance between lobes of the inner rotor and the outer rotor with a feeler gauge. 2. If the clearance exceeds the factory specifications, replace the oil pump rotor assembly. 0.060 to 0.18 mm Rotor lobe clearance Factory specification...

  • Page 264: Starter

    ENGINE 05-E4B, 05-E4BG SERIES, WSM (7) Starter Overrunning Clutch 1. Check the pinion and if worn or damage, replace the clutch assembly. 2. Check that the pinion turns freely and smoothly in the overrunning direction and does not slip in the cranking direction. 3.
  • Page 265 ENGINE 05-E4B, 05-E4BG SERIES, 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.
  • Page 266 ENGINE 05-E4B, 05-E4BG SERIES, 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. 9Y1210784ENS0101US0 Armature Coil 1. Check the continuity across the commutator and armature coil core with resistance range of circuit tester.

  • Page 267: Alternator

    ENGINE 05-E4B, 05-E4BG SERIES, WSM (8) Alternator Bearing 1. Check the bearing for smooth rotation. 2. If it does not rotate smoothly, replace it. 9Y1210784ENS0104US0 Stator 1. Measure the resistance across each lead of the stator coil with resistance range of circuit tester. 2.
  • Page 268 ENGINE 05-E4B, 05-E4BG SERIES, 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. 9Y1210784ENS0109US0 IC Regulator 1.
  • Page 269 Editor : Engine Service Department Address 64, Ishizu-Kitamachi, Sakai-Ku, Sakai-City, Osaka, 590-0823, Japan Phone +81- 72-241-1531 +81- 72-245-2928 E-mail : kbt_g.estg-pub@kubota.com Printed in Japan 2019. 03, S, EI, EI, engusa Code No.9Y111-07843 2013. 02, S, EI, EI, engusa KUBOTA Corporation...

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