Kubota WSM 05-E4B Series - 3. MAINTENANCE

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3. MAINTENANCE

KiSC issued 03, 2023 A

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Table of Contents7
Safety13
Safety First15
Working Precautions15
Preparing for Emergencies15
Working Cautions16
Starting Machine Safely16
Preventing Fires17
Preventing Acid Burns17
Avoiding High Pressure Fluid17
Avoiding Hot Exhaust18
Cleaning Exhaust Filter18
General19
General Working Precautions21
Tightening Bolts and Nuts21
Applying Thread-Locking Fluid21
Installing Circlips22
Handling Liquid Gasket22
Replacing O-Rings22
Replacing Oil Seals23
Handling the Battery23
Handling Wire Harness24
Handling Fuses25
Handling Connectors25
Wiring Color26
Dispose Fluids Correctly26
Engine Identification29
Engine Model Name and Engine Serial Number29
E4B Engine30
Cylinder Number31
Information33
Specifications33
Specification for D1005-E4B, D1105-E4B33
Specification for D1305-E4B, V1505-E4B35
Specification for D1005-E4BG, D1105-E4BG36
Specification for D1305-E4BG, V1505-E4BG37
Performance Curves38
Performance Curve for D1005-E4B38
Performance Curve for D1105-E4B41
Performance Curve for D1305-E4B42
Performance Curve for V1505-E4B43
Dimensions44
Dimension for D1005-E4B, D1105-E4B44
Dimension for D1305-E4B45
Dimension for V1505-E4B46
Dimension for D1005-E4BG, D1105-E4BG, V1505-E4BG47
Dimension for D1305-E4BG49
Special Tools51
Diesel Engine Compression Tester (for Nozzle Hole)51
Injection Pump Pressure Tester51
Valve Guide Replacing Tool52
Bushing Replacing Tool52
Flywheel Stopper53
Governor Gear Holder Bushing Replacing Tool54
Crank Sleeve Setter54
Maintenance57
Maintenance Checklist59
Check and Maintenance63
Daily Check Points63
Checking Engine Oil Level63
Checking and Fill Coolant63
Check Points of Initial 50 Hours64
Changing Engine Oil64
Replacing Oil Filter Cartridge64
Check Point of Every 50 Hours65
Checking Fuel Hose65
Check Points of Every 100 Hours66
Cleaning Air Cleaner Element66
Cleaning Fuel Filter66
Checking Fan Belt Tension66
Checking Fan Belt Damage and Wear67
Checking Battery Electrolyte Level68
Changing Engine Oil68
Replacing Oil Filter Cartridge68
Checking Radiator Hoses and Clamp Bands69
Checking Intake Air Line69
Replacing Oil Filter Cartridge (for BG Type)69
Replacing Fuel Filter Cartridge69
Replacing Fuel Filter Element70
Cleaning Water Jacket and Radiator Interior70
Replacing Fan Belt71
Check Points of Every 1 or 2 Months72
Recharging Battery72
Checking Battery Specific Gravity73
Check Points of Every 1 Year73
Replacing Air Cleaner Element73
Checking Valve Clearance73
Check Points of Every 1500 Hours74
Checking Nozzle Spraying Condition74
Checking Fuel Injection Pressure74
Checking Valve Seat Tightness75
Check Points of Every 3000 Hours75
Checking Injection Timing75
Checking Injection Pump76
Check Points of Every 2 Years77
Replacing Intake Air Line77
Replacing Battery77
Replacing Radiator Hoses and Clamp Bands77
Replacing Fuel Hoses and Clamp Bands78
Changing Radiator Coolant (L.L.C.)79
Engine81
Mechanism83
Engine Body83
Closed Breather83
Function of Closed Breather83
Half-Floating Head Cover83
Outline of Half-Floating Head Cover (for D1305-E4B/E4BG)83
Governor83
Structure of Three Lever Type Fork Lever (for Standard Type)83
Structure of Two Lever Type Fork Lever (for BG Type)85
Boost Compensator86
Function of Boost Compensator86
Servicing87
Troubleshooting87
Troubleshooting for 05-E4, 05-E4BG87
Servicing Specifications91
Servicing Specification for Engine91
Tightening Torques98
Tightening Torques of Screws, Bolts and Nuts for General Use98
Tightening Torques of Screws, Bolts and Nuts for Special Use98
Checking and Adjusting99
Checking Compression Pressure of Cylinder99
Checking Valve Clearance100
Checking Engine Oil Pressure100
Checking Fan Belt Tension101
Checking Fan Belt Damage and Wear102
Checking Radiator Cap Air Leakage102
Checking Radiator Water Leakage102
Checking Opening Temperature of Thermostat Valve103
Checking Injection Timing103
Checking Fuel Tightness of Pump Element104
Checking Fuel Tightness of Delivery Valve105
Checking Injection Nozzle Spraying Condition105
Checking Fuel Injection Pressure106
Checking Nozzle Valve Seat Tightness106
Adjusting Injection Nozzle107
Checking Battery Voltage107
Checking Battery Specific Gravity108
Checking Starter Motor109
Checking Magnetic Switch of Starter110
Checking Magnetic Switch Continuity110
Checking Alternator on Unit111
Checking Voltage of Glow Lead Terminal111
Checking Glow Plug Continuity112
Checking Engine Stop Solenoid112
Disassembling and Assembling113
Draining Oil and Coolant113
Removing Air Cleaner and Muffler113
Removing Alternator and Fan Belt113
Removing Cylinder Head Cover113
Removing Injection Pipes114
Removing Nozzle Holder Assembly and Glow Plug114
Removing Nozzle Heat Seal114
Removing Rocker Arm and Push Rod115
Removing Cylinder Head and Cylinder Head Gasket116
Removing Tappets116
Removing Valves117
Removing Thermostat Assembly117
Removing Oil Pan and Oil Strainer (for Extended Oil Pan)117
Removing Fan Drive Pulley118
Removing Gear Case118
Removing Boost Compensator (Equipped with R24 Model)119
Removing Speed Control Plate120
Removing Injection Pump120
Removing Oil Pan and Oil Strainer (for Standard Oil Pan)122
Removing Connecting Rod123
Removing Pistons123
Removing Piston Ring and Connecting Rod124
Removing Flywheel125
Removing Bearing Case Cover125
Removing Crankshaft Assembly (Except D1305-E4B/E4BG)126
Removing Crankshaft Assembly (D1305-E4B/E4BG)126
Removing Main Bearing Case Assembly127
Removing Alternator127
Removing Starter (Electromagnetic Drive Type)128
Removing Starter (Gear Reduction Type)130
Servicing131
Checking Cylinder Head Top Clearance131
Checking Cylinder Head Surface Flatness132
Checking Cylinder Head Flaw133
Checking Valve Recessing133
Adjusting Valve Lapping134
Checking Clearance between Valve Stem and Valve Guide134
Replacing Valve Guide135
Adjusting Valve Angle136
Adjusting Valve Seat136
Checking Free Length of Valve Spring137
Checking Tilt of Valve Spring137
Checking Set Load of Valve Spring137
Checking Oil Clearance between Rocker Arm and Rocker Arm Shaft138
Checking Push Rod Alignment138
Checking Oil Clearance between Tappet and Tappet Guide Bore138
Checking Clearance between Outer Rotor and Pump Body139
Checking Side Clearance of Idle Gear 1, 2139
Checking Oil Clearance between Idle Gear Shaft and Idle Gear Bushing140
Replacing Idle Gear Bushing140
Checking Side Clearance of Camshaft141
Checking Camshaft Alignment141
Checking Cam Height141
Checking Oil Clearance between Camshaft Journal and Crankcase Bore142
Checking Piston Pin Bore I.D142
Checking Oil Clearance between Piston Pin and Small End Bushing143
Replacing Small End Bushing143
Checking Connecting Rod Alignment144
Checking Piston Ring Gap144
Checking Clearance between Piston Ring and Ring Groove146
Checking Side Clearance of Crankshaft146
Checking Crankshaft Alignment147
Checking Oil Clearance between Crankpin and Crankpin Bearing147
Checking Oil Clearance between Crankshaft Journal and Crankshaft Bearing 1148
Replacing Crankshaft Bearing 1150
Checking Oil Clearance between Crankshaft Journal and Crankshaft Bearing 2, 3150
Replacing Crankshaft Sleeve152
Checking Cylinder Wear152
Adjusting Cylinder Correction (over Size)153
Checking Clearance between Inner Rotor and Outer Rotor154
Checking Clearance between Outer Rotor and Pump Body154
Checking Clearance between Rotor and Cover155
Checking Overrunning Clutch of Starter155
Checking Commutator and Mica of Starter156
Checking Brush Wear of Starter157
Checking Brush Holder of Starter158
Checking Armature Coil of Starter158
Checking Field Coil of Starter158
Checking Bearing of Alternator159
Checking Stator of Alternator159
Checking Rotor of Alternator159
Checking Slip Ring of Alternator160
Checking Brush Wear of Alternator160
Checking Rectifier161
Checking IC Regulator161

Kubota WSM 05-E4B Series - 3. MAINTENANCE

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