wsm 05-E2B SERIES Workshop Manual
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wsm 05-E2B SERIES Workshop Manual

wsm 05-E2B SERIES Workshop Manual

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WORKSHOP MANUAL
DIESEL ENGINE
05-E2B SERIES,
05-E2BG SERIES
KiSC issued 06, 2011 A

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  • Page 1 WORKSHOP MANUAL DIESEL ENGINE 05-E2B SERIES, 05-E2BG SERIES KiSC issued 06, 2011 A...
  • Page 2 TO THE READER This Workshop Manual has been prepared to provide servicing personnel with information on the mechanism, service and maintenance of 05-E2B and 05-E2BG series. It is divided into three parts, “General”, “Mechanism” and “Servicing”. General Information on the engine identification, the general precautions, maintenance check list, check and maintenance and special tools are described.
  • Page 3 SAFETY INSTRUCTIONS 05-E2B, 05-E2BG, WSM SAFETY INSTRUCTIONS SAFETY FIRST This symbol, the industry’s “Safety Alert Symbol”, is used throughout this manual and on labels on the machine itself to warn of the possibility of personal injury. Read these instructions carefully.
  • Page 4 SAFETY INSTRUCTIONS 05-E2B, 05-E2BG, WSM SAFETY STARTING • Do not start the engine by shorting across starter terminals or bypassing the safety start switch. • Unauthorized modifications to the engine may impair the function and / or safety and affect engine life.
  • Page 5 SAFETY INSTRUCTIONS 05-E2B, 05-E2BG, WSM VENTILATE WORK AREA • If the engine must be running to do some work, make sure the area is well ventilated. Never run the engine in a closed area. The exhaust gas contains poisonous carbon monoxide.

  • Page 6: Specifications

    SPECIFICATIONS 05-E2B, 05-E2BG, WSM SPECIFICATIONS Model D905-E2B D1005-E2B V1305-E2B Number of Cylinders Type Vertical, Water-cooled, 4 cycle diesel engine Bore × Stroke 72 × 73.6 (2.83 × 2.90) 76 × 73.6 (2.99 × 2.90) mm (in.) (cu.in.) 898 (54.80) 1001 (61.08) 1335 (81.46)
  • Page 7 SPECIFICATIONS 05-E2B, 05-E2BG, WSM Model D1105-E2B V1505-E2B D1105-T-E2B V1505-T-E2B Number of Cylinders Type Vertical, Water-cooled, 4 cycle diesel engine Bore × Stroke 78 × 78.4 (3.07 × 3.09) mm (in.) Total Displacement (cu.in.) 1123 (68.53) 1498 (91.41) 1123 (68.53) 1498 (91.41)
  • Page 8 SPECIFICATIONS 05-E2B, 05-E2BG, WSM D905-E2BG D1005-E2BG V1305-E2BG Model Number of Cylinders Type Vertical, Water-cooled, 4 cycle diesel engine Bore × Stroke 72 × 73.6 (2.83 × 2.90) 76 × 73.6 (2.99 × 2.90) mm (in.) Total Displacement (cu.in.) 898 (54.86) 1001 (61.08)
  • Page 9 SPECIFICATIONS 05-E2B, 05-E2BG, WSM D1105-E2BG V1505-E2BG Model Number of Cylinders Type Vertical, Water-cooled, 4 cycle diesel engine Bore × Stroke 78 × 78.4 (3.07 × 3.09) mm (in.) Total Displacement (cu.in.) 1123 (68.53) 1498 (91.41) ISO 3046 kW/min (rpm) 11.5 / 1800 15.1 / 1800...

  • Page 10: Performance Curves

    PERFORMANCE CURVES 05-E2B, 05-E2BG, WSM PERFORMANCE CURVES (1) Gross Int. (4) Brake Horsepower (7) Torque (9) Overload (2) Net Int. (5) Engine Speed (8) Gross (10) Continuous (3) Net Cont. (6) Specified Fuel KiSC issued 06, 2011 A...
  • Page 11 PERFORMANCE CURVES 05-E2B, 05-E2BG, WSM (1) Gross Int. (4) Brake Horsepower (7) Torque (9) Overload (2) Net Int. (5) Engine Speed (8) Gross (10) Continuous (3) Net Cont. (6) Specified Fuel KiSC issued 06, 2011 A...
  • Page 12 PERFORMANCE CURVES 05-E2B, 05-E2BG, WSM (1) Gross Int. (4) Brake Horsepower (7) Torque (9) Overload (2) Net Int. (5) Engine Speed (8) Gross (10) Continuous (3) Net Cont. (6) Specified Fuel KiSC issued 06, 2011 A...
  • Page 13 DIMENSIONS 05-E2B, 05-E2BG, WSM DIMENSIONS Unit : mm (in.) D905-E2B D1005-E2B D1105-E2B D1105-T-E2B 497.8 (19.60) 497.8 (19.60) 497.8 (19.60) 497.8 (19.60) 230 (9.06) 230 (9.06) 230 (9.06) 230 (9.06) 320 dia. (12.6 dia.) 330 dia. (12.99 dia.) 330 dia. (12.99 dia.) 330 dia.
  • Page 14 DIMENSIONS 05-E2B, 05-E2BG, WSM Unit : mm (in.) V1305-E2B V1505-E2B V1505-T-E2B 583.8 (22.98) 591.3 (23.28) 591.3 (23.28) 230 (9.06) 230 (9.06) 230 (9.06) 350 dia. (13.78 dia.) 370 dia. (14.57 dia.) 370 dia. (14.57 dia.) 396 (15.59) 396 (15.59) 396 (15.59) 194 (7.64)
  • Page 15 DIMENSIONS 05-E2B, 05-E2BG, WSM Unit : mm (in.) D1005-E2BG D1105-E2BG V1305-E2BG V1505-E2BG D905-E2BG 546.6 (21.52) 546.6 (21.52) 546.6 (21.52) 634.3 (24.97) 634.3 (24.97) 4-3/8-16 UNC-2B 4-3/8-16 UNC-2B 4-3/8-16 UNC-2B 4-3/8-16 UNC-2B 4-3/8-16 UNC-2B Depth 16 (0.63) Depth 16 (0.63) Depth 16 (0.63) Depth 16 (0.63)

  • Page 16: Table Of Contents

    GENERAL CONTENTS 1. ENGINE IDENTIFICATION ................G-1 [1] MODEL NAME AND ENGINE SERIAL NUMBER ........ G-1 [2] E2B ENGINE..................... G-2 [3] CYLINDER NUMBER ................G-2 2. GENERAL PRECAUTIONS ................G-3 3. MAINTENANCE CHECK LIST ............... G-4 4. CHECK AND MAINTENANCE ............... G-6 [1] DAILY CHECK POINTS................

  • Page 17: Engine Identification

    G GENERAL 05-E2B, 05-E2BG, WSM 1. ENGINE IDENTIFICATION [1] MODEL NAME AND ENGINE SERIAL NUMBER When contacting the manufacture, always specify your engine model name and serial number. The engine model and its serial number need to be identified before the engine can be serviced or parts replaced.

  • Page 18: E2B Engine

    G GENERAL 05-E2B, 05-E2BG, WSM • Month of manufacture Engine Serial Number Month 0001 ~ 9999 10000 ~ January A0001 ~ A9999 B0001 ~ February C0001 ~ C9999 D0001 ~ March E0001 ~ E9999 F0001 ~ April G0001 ~ G9999...

  • Page 19: General Precautions

    G GENERAL 05-E2B, 05-E2BG, WSM 2. GENERAL PRECAUTIONS • During disassembly, carefully arrange removed parts in a clean area to prevent confusion later. Screws, bolts and nuts should be replaced in their original position to prevent reassembly errors. • When special tools are required, use KUBOTA genuine special tools.

  • Page 20: Maintenance Check List

    G GENERAL 05-E2B, 05-E2BG, WSM 3. MAINTENANCE CHECK LIST To maintain long-lasting and safe engine performance, make it a rule to carry out regular inspections by following the table below. Service Interval Every Item 1 or 2 1500 3000 months 1 year...
  • Page 21 G GENERAL 05-E2B, 05-E2BG, WSM CAUTION • When changing or inspecting, be sure to level and stop the engine. NOTE Lubricating Oil With the emission control now in effect, the CF-4 and CG-4 lubricating oils have been developed for use of a low- sulfur fuel on-road vehicle engines.

  • Page 22: Check And Maintenance

    G GENERAL 05-E2B, 05-E2BG, WSM 4. CHECK AND MAINTENANCE [1] DAILY CHECK POINTS Checking Engine Oil Level 1. Level the engine. 2. To check the oil level, draw out the dipstick (1), wipe it clean, reinsert it, and draw it out again.
  • Page 23 G GENERAL 05-E2B, 05-E2BG, WSM Checking and Replenish Coolant 1. Without recovery tank : Remove the radiator cap (1) and check to see that the coolant level is just below the port. With recovery tank (2) : Check to see that the coolant level lies between FULL (A) and LOW (B).

  • Page 24: Check Points Of Initial 50 Hours

    G GENERAL 05-E2B, 05-E2BG, 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.
  • Page 25 G GENERAL 05-E2B, 05-E2BG, 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.

  • Page 26: Check Points Of Every 50 Hours

    G GENERAL 05-E2B, 05-E2BG, WSM [3] CHECK POINTS OF EVERY 50 HOURS Checking Fuel Hose 1. If the clamp (2) is loose, apply oil to the threads and securely retighten it. 2. The fuel hose (1) is made of rubber and ages regardless of the period service.

  • Page 27: Check Points Of Every 100 Hours

    G GENERAL 05-E2B, 05-E2BG, WSM [4] CHECK POINTS OF EVERY 100 HOURS Cleaning Air Cleaner Element 1. Remove the air cleaner element. 2. Use clean dry compressed air on the inside of the element. Pressure of compressed air must be under 205 kPa (2.1 kgf/cm 30 psi).
  • Page 28 G GENERAL 05-E2B, 05-E2BG, WSM Fan Belt Damage and Wear 1. Check the fan belt for damage. 2. If the fan belt is damaged, replace it. 3. Check if the fan belt is worn and sunk in the pulley groove.

  • Page 29: Check Points Of Every 200 Hours

    G GENERAL 05-E2B, 05-E2BG, 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.

  • Page 30: Check Points Of Every 400 Hours

    G GENERAL 05-E2B, 05-E2BG, 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.

  • Page 31: Check Points Of Every 500 Hours

    G GENERAL 05-E2B, 05-E2BG, WSM Replacing Fuel Filter Element (Element Type) 1. Close the fuel cock (3). 2. Unscrew the retaining ring (6) and remove the filter cup (5), and rinse the inside with kerosene. 3. Replace the filter element (4).
  • Page 32 G GENERAL 05-E2B, 05-E2BG, WSM Anti-Freeze • There are two types of anti-freeze available: use the permanent type (PT) for this engine. • Before adding anti-freeze for the first time, clean the radiator interior by pouring fresh, soft water and draining it a few times.

  • Page 33: Check Points Of Every 1 Or 2 Months

    G GENERAL 05-E2B, 05-E2BG, WSM [8] CHECK POINTS OF EVERY 1 OR 2 MONTHS Recharging CAUTION • When the battery is being activated, hydrogen and oxygen gases in the battery are extremely explosive. Keep open sparks and flames away from the battery at all times, especially when charging the battery.

  • Page 34: Check Points Of Every Year

    G GENERAL 05-E2B, 05-E2BG, WSM Battery Specific Gravity 1. Check the specific gravity of the electrolyte in each cell with a hydrometer. 2. When the electrolyte temperature differs from that at which the hydrometer was calibrated, correct the specific gravity reading following the formula mentioned in (Reference).

  • Page 35: Check Points Of Every 800 Hours

    G GENERAL 05-E2B, 05-E2BG, WSM [10] CHECK POINTS 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 36: Check Points Of Every 1500 Hours

    G GENERAL 05-E2B, 05-E2BG, WSM [11] CHECK POINTS OF EVERY 1500 HOURS CAUTION • Check the injection pressure and condition after confirming that there is nobody standing in the direction the fume goes. If the fume from the nozzle directly contacts the human body, cells may be destroyed and blood poisoning may be caused.

  • Page 37: Check Points Of Every 3000 Hours

    G GENERAL 05-E2B, 05-E2BG, WSM [12] CHECK POINTS OF EVERY 3000 HOURS Checking Turbocharger (Turbine Side) 1. Check the exhaust port (3) and inlet port (5) side of turbine housing (1) to see if there is no exhaust gas leak.
  • Page 38 G GENERAL 05-E2B, 05-E2BG, WSM Injection Timing 1. Remove the injection pipes. 2. Remove the engine stop solenoid. 3. Turn the flywheel counterclockwise (viewed from flywheel side) until the fuel fills up to the hole of the delivery valve holder (3) for No.
  • Page 39 G GENERAL 05-E2B, 05-E2BG, WSM Checking Injection Pump (Fuel Tightness of Pump Element) 1. Remove the engine stop solenoid. 2. Remove the injection pipes and glow plugs. 3. Install the injection pump pressure tester to the injection pump. 4. Install the injection nozzle (2) jetted with the proper injection pressure to the injection pump pressure tester (1).

  • Page 40: Check Points Of Every 2 Years

    G GENERAL 05-E2B, 05-E2BG, WSM [13] CHECK POINTS OF EVERY 2 YEARS Replacing Intake Air Line 1. Loosen the clamp (2). 2. Remove the intake air hose (1) and clamp (2). 3. Replace new intake air hose (1) and new clamp (2).
  • Page 41 G GENERAL 05-E2B, 05-E2BG, WSM Replacing Fuel Hoses and Clamp Bands 1. Loosen the clamp (2) and remove the fuel hose (1). 2. Replace new fuel hose (1) and new clamp (2). 3. Tighten the clamp (2). CAUTION • Stop the engine when attempting the check and change prescribed above.
  • Page 42 G GENERAL 05-E2B, 05-E2BG, 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.
  • Page 43 G GENERAL 05-E2B, 05-E2BG, WSM Changing Radiator Coolant (L.L.C.) (Continued) (Anti-freeze) • There are two types of anti-freeze available: use the permanent type (PT) for this engine. • Before adding anti-freeze for the first time, clean the radiator interior by pouring fresh, soft water and draining it a few times.

  • Page 44: Special Tools

    07909-31211 (E and F) 07909-31281 (J) 07909-31231 (H) Application: Use to measure diesel engine compression and diagnosis of need for major overhaul. Adaptor : H for 05-E2B series. (1) Gauge (7) Adaptor F (2) L Joint (8) Adaptor G (3) Adaptor A...
  • Page 45 G GENERAL 05-E2B, 05-E2BG, WSM NOTE • The following special tools are not provided, so make them referring to the figure. Injection Pump Pressure Tester Application: Use to check fuel tightness of injection pumps. Pressure gauge full scale : More than 29.4 MPa (300 kgf/cm...
  • Page 46 G GENERAL 05-E2B, 05-E2BG, WSM Bushing Replacing Tool Application: Use to press out and press fit the bushing. 1. For small end bushing 157 mm (6.1811 in.) 24 mm (0.9449 in.) 120 mm (4.7244 in.) 21.8 to 21.9 mm dia. (0.8583 to 0.8622 in. dia.) 24.8 to 24.9 mm dia.
  • Page 47 G GENERAL 05-E2B, 05-E2BG, WSM Crankshaft Bearing 1 Replacing Tool Application: Use to press out and press fit the crankshaft bearing 1. [Press Out] 135 mm (5.31 in.) 72 mm (2.83 in.) 40 mm radius (1.57 in. radius) 10 mm (0.39 in.) 24 mm (0.95 in.)
  • Page 48 G GENERAL 05-E2B, 05-E2BG, 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 (3.23 in.) 72 mm (2.83 in.) 67 mm (2.64 in.)
  • Page 49 MECHANISM CONTENTS 1. ENGINE BODY ....................M-1 [1] CLOSED BREATHER (NATURAL ASPIRATION TYPE ONLY)... M-1 [2] GOVERNOR ....................M-2 [3] BOOST COMPENSATOR ................ M-4 KiSC issued 06, 2011 A...

  • Page 50: Engine Body

    DIESEL ENGINE 05-E2B, 05-E2BG, WSM 1. ENGINE BODY [1] CLOSED BREATHER (NATURAL ASPIRATION TYPE ONLY) Closed breather system has been adopted to prevent the release of blow-by gas into the atmosphere. After its oil content is filtered by oil shield (4), the blow- by gas in fed back to the intake manifold through breather valve (3) to be used for re-combustion.

  • Page 51: Governor

    DIESEL ENGINE 05-E2B, 05-E2BG, WSM [2] GOVERNOR Three Lever Type Fork Lever (for General) The governor system is a mechanical governor that used the flyweight (5). The flyweight (5) is mounted on the governor shaft that rotates at the same speed as the crankshaft.
  • Page 52 DIESEL ENGINE 05-E2B, 05-E2BG, WSM (Overloaded Operation) The amount of the movement of the fork lever assembly is limited with the fuel limitation bolt (10) and can not be moved in the direction of the fuel increase. As overload reduces the centrifugal force of the...

  • Page 53: Boost Compensator

    DIESEL ENGINE 05-E2B, 05-E2BG, WSM [3] BOOST COMPENSATOR (1) Boost Compensator Assembly (2) Actuator (3) Plate (4) Injection Pump Assembly (5) Guide (6) Stop Solenoid A : Fulcrum W1013537 Boost compensator is the device that reduces black smoke during the engine startup and acceleration.
  • Page 54 SERVICING CONTENTS 1. TROUBLESHOOTING ..................S-1 2. SERVICING SPECIFICATIONS ..............S-5 3. TIGHTENING TORQUES ................S-13 [1] TIGHTENING TORQUES FOR GENERAL USE SCREWS, BOLTS AND NUTS....................S-13 [2] TIGHTENING TORQUES FOR SPECIAL USE SCREWS, BOLTS AND NUTS....................S-14 4. CHECKING, DISASSEMBLING AND SERVICING........S-15 [1] CHECKING AND ADJUSTING ...............S-15 (1) Engine Body..................S-15 (2) Lubricating System ................S-17 (3) Cooling System ...................S-17...

  • Page 55: Troubleshooting

    DIESEL ENGINE 05-E2B, 05-E2BG, WSM 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Engine Does Not No fuel Replenish fuel G-10 Start Air in the fuel system Vent air G-10 Water in the fuel system Change fuel and – repair or replace fuel...
  • Page 56 DIESEL ENGINE 05-E2B, 05-E2BG, WSM Reference Symptom Probable Cause Solution Page Engine Revolution Is Fuel filter clogged or dirty Replace G-14, 15 Not Smooth Air cleaner clogged Clean or replace G-11, 14, Fuel leak due to loose injection pipe retaining nut Tighten retaining nut –...
  • Page 57 DIESEL ENGINE 05-E2B, 05-E2BG, WSM Reference Symptom Probable Cause Solution Page Deficient Output Incorrect injection timing Adjust S-19 Engine’s moving parts seem to be seizing Repair or replace – Injection pump malfunctioning Repair or replace S-20, 35 Deficient nozzle injection...
  • Page 58 DIESEL ENGINE 05-E2B, 05-E2BG, WSM Reference Symptom Probable Cause Solution Page High Oil Pressure Different type of oil Use specified type of Relief valve defective Replace – Engine Overheated Engine oil insufficient Replenish Fan belt broken or elongated Replace or adjust...

  • Page 59: Servicing Specifications

    DIESEL ENGINE 05-E2B, 05-E2BG, 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 D905-E2B / E2BG 3.72 to 4.12 MPa 2.25 MPa D1005-E2B / E2BG 38 to 42 kgf/cm 23.0 kgf/cm...
  • Page 60 DIESEL ENGINE 05-E2B, 05-E2BG, WSM ENGINE BODY (Continued) Item Factory Specification Allowable Limit Rocker Arm Shaft to Rocker Arm Clearance 0.016 to 0.045 mm 0.10 mm 0.00063 to 0.00177 in. 0.0039 in. Rocker Arm Shaft O.D. 11.973 to 11.984 mm –...
  • Page 61 DIESEL ENGINE 05-E2B, 05-E2BG, WSM ENGINE BODY (Continued) Item Factory Specification Allowable Limit Idle Gear Shaft to Gear Bushing Idle Gear 1 Clearance 0.020 to 0.054 mm 0.10 mm 0.0008 to 0.0021 in. 0.0039 in. Idle Gear Bushing I.D. 26.000 to 26.021 mm –...
  • Page 62 DIESEL ENGINE 05-E2B, 05-E2BG, WSM ENGINE BODY (Continued) Item Factory Specification Allowable Limit Piston Ring Gap Top Ring 0.25 to 0.40 mm 1.25 mm [D905-E2B] 0.0098 to 0.0157 in. 0.0492 in. Second Ring 0.25 to 0.40 mm 1.25 mm 0.0098 to 0.0157 in.
  • Page 63 DIESEL ENGINE 05-E2B, 05-E2BG, WSM ENGINE BODY (Continued) Item Factory Specification Allowable Limit Crankshaft to Crankshaft Bearing 2 Oil Clearance 0.034 to 0.095 mm 0.20 mm 0.0013 to 0.0037 in. 0.0079 in. Crankshaft Journal O.D. 47.934 to 47.950 mm –...
  • Page 64 DIESEL ENGINE 05-E2B, 05-E2BG, WSM LUBRICATING SYSTEM Item Factory Specification Allowable Limit Engine Oil Pressure At Idle Speed More than 49 kPa – 0.5 kgf/cm 7 psi At Rated Speed 196 to 441 kPa 147 kPa 2.0 to 4.5 kgf/cm 1.5 kgf/cm...
  • Page 65 DIESEL ENGINE 05-E2B, 05-E2BG, WSM FUEL SYSTEM Item Factory Specification Allowable Limit Injection Pump Injection Timing 0.30 to 0.33 rad – (3000 min (rpm)) (17 to 19°) before T.D.C. Injection Timing 0.35 to 0.39 rad – (3600 min (rpm)) (20 to 22°) before T.D.C.
  • Page 66 DIESEL ENGINE 05-E2B, 05-E2BG, WSM ELECTRICAL SYSTEM Item Factory Specification Allowable Limit Approx. 0.9 Ω Glow Plug Resistance – Starter (Planetary Gear Reduction Type) Commutator O.D. 30.0 mm 29.0 mm 1.181 in. 1.142 in. Difference O.D. Less than 0.02 mm 0.05 mm...

  • Page 67: Tightening Torques

    DIESEL ENGINE 05-E2B, 05-E2BG, WSM 3. TIGHTENING TORQUES Screws, bolts and nuts must be tightened to the specified torque using a torque wrench, several screws, bolts and nuts such as those used on the cylinder head must be tightened in proper sequence and the proper torque.

  • Page 68: Tightening Torques For Special Use Screws, Bolts And Nuts

    DIESEL ENGINE 05-E2B, 05-E2BG, WSM [2] TIGHTENING TORQUES FOR SPECIAL USE SCREWS, BOLTS AND NUTS NOTE • For “*” marked screws, bolts and nuts on the table, apply engine oil to their threads and seats before tightening. • 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.

  • Page 69: Checking, Disassembling And Servicing

    DIESEL ENGINE 05-E2B, 05-E2BG, WSM 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING (1) Engine Body Compression Pressure 1. Run the engine until it is warmed up. 2. Stop the engine. 3. Remove the air cleaner, the muffler and all glow plugs (or nozzles).
  • Page 70 DIESEL ENGINE 05-E2B, 05-E2BG, 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 71: Lubricating System

    DIESEL ENGINE 05-E2B, 05-E2BG, WSM (2) Lubricating System Engine Oil Pressure 1. Remove the engine oil pressure switch, and set an oil pressure tester. 2. Start the engine. After warming up, measure the oil pressure of both idling and rated speeds.
  • Page 72 DIESEL ENGINE 05-E2B, 05-E2BG, WSM Fan Belt Damage and Wear 1. Check the fan belt for damage. 2. If the fan belt is damaged, replace it. 3. Check if the fan belt is worn and sunk in the pulley groove.

  • Page 73: Fuel System

    DIESEL ENGINE 05-E2B, 05-E2BG, WSM Thermostat Valve Opening Temperature 1. Suspend the thermostat in the water by a string with its end inserted between the valve and seat. 2. Heating the water gradually, read the temperature when the valve opens and leaves the string.
  • Page 74 DIESEL ENGINE 05-E2B, 05-E2BG, WSM Fuel Tightness of Pump Element 1. Remove the engine stop solenoid. 2. Remove the injection pipes and glow plugs. 3. Install the injection pump pressure tester to the injection pump. 4. Install the injection nozzle (2) jetted with the proper injection pressure to the injection pump pressure tester (1).
  • Page 75 DIESEL ENGINE 05-E2B, 05-E2BG, WSM CAUTION • Check the nozzle injection pressure and condition after confirming that there is nobody standing in the direction the fume goes. If the fume from the nozzle directly contacts the human body, cells may be destroyed and blood poisoning may be caused.

  • Page 76: Electrical System

    DIESEL ENGINE 05-E2B, 05-E2BG, WSM Nozzle Holder 1. Secure the nozzle retaining nut (7) with a vise. 2. Remove the nozzle holder (1), and take out parts inside. (When reassembling) • Assemble the nozzle in clean fuel oil. • Install the push rod (4), noting its direction.
  • Page 77 DIESEL ENGINE 05-E2B, 05-E2BG, WSM Battery Specific Gravity 1. Check the specific gravity of the electrolyte in each cell with a hydrometer. 2. When the electrolyte temperature differs from that at which the hydrometer was calibrated, correct the specific gravity reading following the formula mentioned in (Reference).
  • Page 78 DIESEL ENGINE 05-E2B, 05-E2BG, WSM Motor Test CAUTION • Secure the starter to prevent it from jumping up and down while testing the motor. 1. Disconnect the battery negative cable from the battery. 2. Disconnect the battery positive cable from the battery.
  • Page 79 DIESEL ENGINE 05-E2B, 05-E2BG, WSM Magnet Switch Continuity Test 1. Check the continuity across the C terminal (1) and the B terminal (2) with a circuit tester, pushing in the plunger. 2. If not continuous or if a certain value is indicated, replace the magnet switch.

  • Page 80: Turbocharger

    DIESEL ENGINE 05-E2B, 05-E2BG, WSM Glow Plug Continuity 1. Remove the glow plug. 2. Measure the resistance with a circuit tester between the glow plug terminal and the glow plug housing. 3. If the factory specification is not indicated, glow plug is faulty.

  • Page 81: Disassembling And Assembling

    DIESEL ENGINE 05-E2B, 05-E2BG, WSM Radial Clearance 1. If the wheel contact to the housing, replace the turbocharger assembly with new one. W1077353 [2] DISASSEMBLING AND ASSEMBLING (1) Draining Oil and Coolant Draining Oil and Coolant CAUTION • Never remove radiator cap until coolant temperature is below its boiling point.

  • Page 82: Cylinder Head And Valve

    DIESEL ENGINE 05-E2B, 05-E2BG, WSM Turbocharger (equipped with Turbocharger Model) CAUTION • While the engine is running and or just after it stops, the turbocharger is hot, be careful not to touch the turbocharger. NOTE • When detaching and attaching the turbocharger assembly, be very careful not to allow dust, dirt and other foreign matters in the oil pipes.
  • Page 83 DIESEL ENGINE 05-E2B, 05-E2BG, WSM Nozzle Heat Seal Service Removal Procedure 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.
  • Page 84 DIESEL ENGINE 05-E2B, 05-E2BG, WSM Cylinder Head and Cylinder Head Gasket (To be continued) 1. Loosen the pipe clamps (1), and remove the water return pipe (2). 2. Remove the cylinder head screw in the order of (n or r) to (a) and remove the cylinder head.
  • Page 85 DIESEL ENGINE 05-E2B, 05-E2BG, WSM Cylinder Head and Cylinder Head Gasket (Continued) (When reassembling the carbon gasket type) • Replace the cylinder head gasket with new one. • Securely fit the O-ring (1) to the pin pipe (2). • When mounting the gasket, set it to the pin pipe holes. Take care not to mount it reversely.

  • Page 86: Gear Case And Timing Gears

    DIESEL ENGINE 05-E2B, 05-E2BG, WSM Thermostat Assembly 1. Remove the thermostat cover mounting screws (1), and remove the thermostat cover (2). 2. Remove the thermostat assembly (4). (When reassembling) • Apply a liquid gasket (Three Bond 1215 or equivalent) only at the thermostat cover side of the gasket (3).
  • Page 87 DIESEL ENGINE 05-E2B, 05-E2BG, WSM Gear Case 1. Remove the gear case. (When reassembling) • Grease thinly to the oil seal, and install it, ensuring the lip does not come off. • Measure (L) when the gear case mounting bolt is inserted in the...
  • Page 88 DIESEL ENGINE 05-E2B, 05-E2BG, WSM Boost Compensator (equipped with Turbocharger 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 detach the boost compensator.
  • Page 89 DIESEL ENGINE 05-E2B, 05-E2BG, WSM Injection Pump 1. Disconnect the start spring (4) on the thrust lever side (5). 2. Align the control rack pin (2) with the notch (1) on the crankcase, and remove the injection pump (3). 3. Remove the injection pump shims.
  • Page 90 DIESEL ENGINE 05-E2B, 05-E2BG, WSM Cam Gear, Idle Gear 1, 2 and Governor Gear 1. Remove the idle gear 2 (7) / idle gear 1 (4). 2. Remove the fuel camshaft stopper (8). 3. Draw out the fuel cam gear (1) with fuel camshaft (9).

  • Page 91: Piston And Connecting Rod

    DIESEL ENGINE 05-E2B, 05-E2BG, WSM (5) Piston and Connecting Rod Oil Pan and Oil Strainer 1. Remove the oil pan mounting screws (5). 2. Remove the oil pan (4). 3. Remove the oil strainer (3). (When reassembling) • After cleaning the oil strainer, check to see that the filter mesh in clean, and install it.
  • Page 92 DIESEL ENGINE 05-E2B, 05-E2BG, WSM Pistons 1. Turn the flywheel and bring the piston to top dead center. 2. Draw out the piston upward by lightly tapping it from the bottom of the crankcase with the grip of a hammer.
  • Page 93 DIESEL ENGINE 05-E2B, 05-E2BG, WSM Piston Ring and Connecting Rod 1. Remove the piston rings using a piston ring tool. 2. Remove the piston pin (7), and separate the connecting rod (6) from the piston (5). (When reassembling) • When installing the ring, assemble the rings so that the manufacturer’s mark (12) near the gap faces the top of the piston.

  • Page 94: Flywheel And Crankshaft

    DIESEL ENGINE 05-E2B, 05-E2BG, WSM (6) Flywheel and Crankshaft Flywheel 1. Secure the flywheel to keep it from turning, using a flywheel stopper. 2. Remove all flywheel screws (1) and then remove the flywheel (2). (When reassembling) • Align the “1TC” mark (a) on the outer surface of the flywheel horizontally with the alignment mark (b) on the rear end plate.
  • Page 95 DIESEL ENGINE 05-E2B, 05-E2BG, WSM Crankshaft Assembly 1. Remove the main bearing case screw 2 (1). 2. Pull out the crankshaft assembly. IMPORTANT • Take care to protect crankshaft bearing 1 from scratches, caused by the crank gear, etc.. (Wrap the gear in vinyl tape, etc.)

  • Page 96: Starter

    DIESEL ENGINE 05-E2B, 05-E2BG, WSM (7) Starter Electromagnetic Drive Type (1) Solenoid Switch Mounting Nut (2) Starter Drive Housing (3) Drive Lever (4) Gasket (5) Solenoid Switch (6) B Terminal Nut (7) C Terminal Nut (8) Snap RIng (9) Overrunning Clutch...
  • Page 97 DIESEL ENGINE 05-E2B, 05-E2BG, WSM Planetary Gear Reduction Type (1) Through Bolt (2) Brush (3) Yoke (4) Armature (5) Overrunning Clutch (6) Idle Gear (7) End Frame (8) Brush Holder (9) Magnet Switch Cover (10) Plunger (11) Housing (12) C Terminal Nut...

  • Page 98: Alternator

    DIESEL ENGINE 05-E2B, 05-E2BG, WSM (8) 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 W1224079 1.

  • Page 99: Servicing

    DIESEL ENGINE 05-E2B, 05-E2BG, WSM [3] SERVICING (1) Cylinder Head and Valves Top Clearance 1. Remove the cylinder head. 2. With the piston at TDC, use grease to affix three or four plastigauges of a diameter 1.5 mm (0.059 in.) x 5.0 to 7.0 mm (0.20 to 0.27 in.) long to the crown of the piston;...
  • Page 100 DIESEL ENGINE 05-E2B, 05-E2BG, WSM Cylinder Head Flaw 1. Prepare an air spray red check. 2. Clean the surface of the cylinder head with detergent (2). 3. Spray the cylinder head surface with the red permeative liquid (1). Leave it five to ten minutes after spraying.
  • Page 101 DIESEL ENGINE 05-E2B, 05-E2BG, WSM Replacing Valve Guide (When removing) 1. Press out the used valve guide using a valve guide replacing tool. (See page “SPECIAL TOOLS”.) (When installing) 1. Clean a new valve guide and valve guide bore, and apply engine oil to them.
  • Page 102 DIESEL ENGINE 05-E2B, 05-E2BG, 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 103 DIESEL ENGINE 05-E2B, 05-E2BG, WSM Free Length and Tilt of Valve Spring 1. Measure the free length (B) of valve spring with vernier calipers. If the measurement is less than the allowable limit, replace it. 2. Put the valve spring on a surface plate, place a square on the side of the valve spring.
  • Page 104 DIESEL ENGINE 05-E2B, 05-E2BG, WSM Push Rod Alignment 1. Place the push rod on V blocks. 2. Measure the push rod alignment. 3. If the measurement exceeds the allowable limit, replace the push rod. 0.25 mm Push rod alignment Allowable limit 0.0098 in.

  • Page 105: Timing Gears, Camshaft And Governor Gear

    DIESEL ENGINE 05-E2B, 05-E2BG, WSM W10293660 (2) Timing Gears, Camshaft and Governor Gear Timing Gear Backlash 1. Set a dial indicator (lever type) with its tip on the gear tooth. 2. Move the gear to measure the backlash, holding its mating gear.
  • Page 106 DIESEL ENGINE 05-E2B, 05-E2BG, WSM Camshaft Side Clearance 1. Set a dial indicator with its tip on the camshaft. 2. measure the side clearance by moving the cam gear to the front to rear. 3. If the measurement exceeds the allowable limit, replace the camshaft stopper.
  • Page 107 DIESEL ENGINE 05-E2B, 05-E2BG, WSM Oil Clearance of Camshaft Journal 1. Measure the camshaft journal O.D. with an outside micrometer. 2. Measure the cylinder block bore I.D. for camshaft with a cylinder gauge, and calculate the oil clearance. 3. If the oil clearance exceeds the allowable limit, replace the camshaft.

  • Page 108: Piston And Connecting Rod

    DIESEL ENGINE 05-E2B, 05-E2BG, WSM (3) Piston and Connecting Rod Piston Pin Bore I.D. 1. Measure the piston pin bore I.D. in both the horizontal and vertical directions with a cylinder gauge. 2. If the measurement exceeds the allowable limit, replace the piston.
  • Page 109 DIESEL ENGINE 05-E2B, 05-E2BG, 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.
  • Page 110 DIESEL ENGINE 05-E2B, 05-E2BG, WSM Piston Ring Gap (To be continued) 1. Insert the piston ring into the lower part of the cylinder (the least worn out part) with a piston. 2. Measure the ring gap with a thickness gauge.
  • Page 111 DIESEL ENGINE 05-E2B, 05-E2BG, WSM Piston Ring Gap (Continued) Factory 0.25 to 0.40 mm spec. 0.0098 to 0.0157 in. Top ring Allowable 1.25 mm limit 0.0492 in. Factory 0.25 to 0.40 mm Piston ring gap spec. 0.0098 to 0.0157 in.

  • Page 112: Crankshaft

    DIESEL ENGINE 05-E2B, 05-E2BG, WSM (4) Crankshaft Crankshaft Side Clearance 1. Set a dial indicator with its tip on the end of the crankshaft. 2. Measure the side clearance by moving the crankshaft to the front and rear. 3. If the measurement exceeds the allowable limit, replace the thrust bearings.
  • Page 113 DIESEL ENGINE 05-E2B, 05-E2BG, WSM Oil Clearance between Crankpin and Crankpin Bearing 1. Clean the crankpin and crankpin bearing. 2. Put a strip of plastigage on the center of the crankpin. 3. Install the connecting rod cap and tighten the connecting rod screws to the specified torque, and remove the cap again.
  • Page 114 DIESEL ENGINE 05-E2B, 05-E2BG, WSM Oil Clearance between Crankshaft Journal and Crankshaft Bearing 1 1. Measure the O.D. of the crankshaft front journal with an outside micrometer. 2. Measure the I.D. of the crankshaft bearing 1 with an inside micrometer, and calculate the oil clearance.
  • Page 115 DIESEL ENGINE 05-E2B, 05-E2BG, WSM Oil Clearance between Crankshaft Journal and Crankshaft Bearing 2 (Crankshaft Bearing 3) 1. Put a strip of plastigage on the center of the journal. 2. Install the bearing case and tighten the baring case screws 1 to the specified torque, and remove the bearing case again.
  • Page 116 DIESEL ENGINE 05-E2B, 05-E2BG, WSM Replacing Crankshaft Sleeve 1. Remove the used crankshaft sleeve. 2. Set the sleeve guide (2) to the crankshaft. 3. Heat a new sleeve to a temperature between 150 and 200 °C (302 and 392 °F), and fix the sleeve to the crankshaft as shown in figure.

  • Page 117: Cylinder

    DIESEL ENGINE 05-E2B, 05-E2BG, WSM (5) Cylinder Cylinder Wear 1. Measure the I.D. of the cylinder at the six positions (see figure) with a cylinder gauge to find the maximum and minimum I.D.’s. 2. Get the difference (Maximum wear) between the maximum and the minimum I.D.’s.

  • Page 118: Oil Pump

    DIESEL ENGINE 05-E2B, 05-E2BG, WSM Correcting Cylinder 1. When the cylinder is worn beyond the allowable limit, bore and hone it to the specified dimension. D905-E2B / 72.500 to 72.519 mm E2BG 2.85433 to 2.85507 in. D1005-E2B / E2BG 76.500 to 76.519 mm V1305-E2B / 3.0118 to 3.0126 in.

  • Page 119: Starter

    DIESEL ENGINE 05-E2B, 05-E2BG, WSM Clearance between Outer Rotor and Pump Body 1. Measure the clearance between the outer rotor and the pump body with a feeler gauge. 2. If the clearance exceeds the factory specifications, replace the oil pump rotor assembly.
  • Page 120 DIESEL ENGINE 05-E2B, 05-E2BG, WSM Commutator and Mica 1. Check the contact of the commutator for wear, and grind the commutator with emery paper if it is slightly worn. 2. Measure the commutator O.D. with an outside micrometer at several points.
  • Page 121 DIESEL ENGINE 05-E2B, 05-E2BG, WSM Brush Holder 1. Check the continuity across the brush holder and the holder support with a circuit tester. 2. If it conducts, replace the brush holder. W1156895 Armature Coil 1. Check the continuity across the commutator and armature coil core with resistance range of circuit tester.

  • Page 122: Alternator

    DIESEL ENGINE 05-E2B, 05-E2BG, WSM (8) Alternator Bearing 1. Check the bearing for smooth rotation. 2. If it does not rotate smoothly, replace it. W1019790 Stator 1. Measure the resistance across each lead of the stator coil with resistance range of circuit tester.
  • Page 123 DIESEL ENGINE 05-E2B, 05-E2BG, WSM Rectifier 1. Check the continuity across each diode of rectifier with resistance range of circuit tester. 2. The rectifier is normal if the diode in the rectifier conducts in one direction and does not conduct in the reverse direction.
  • Page 124 EDITOR : KUBOTA FARM & INDUSTRIAL MACHINERY SERVICE, LTD. 64, ISHIZU-KITAMACHI, SAKAI-KU, SAKAI-CITY, OSAKA, 590-0823, JAPAN PHONE : ( 81 ) 72-241-1129 : ( 81 ) 72-245-2484 E-mail : ksos-pub@kubota.co.jp Printed in Japan 2011. 06, S, EI, EI, e Code No.9Y011-02754 KUBOTA Corporation 2004.

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