Ea330 PDF

WORKSHOP MANUAL
DIESEL ENGINE
EA330-E4 SERIES
KiSC issued 05, 2015 A

TO THE READER
This Workshop Manual tells the servicing personnel about the mechanism, servicing and
maintenance of the EA330-E4. It contains 4 parts: "Information", "General", "Mechanism" and
"Servicing".
 Information
This section primarily contains information below.
• Safety First
• Specification
• Performance Curve
• Dimension
 General
• Engine Identification
• General Precautions
• Maintenance Check List
• Check and Maintenance
• Special Tools
 Mechanism
This section contains information on the structure and the function of the unit. Before you continue
with the subsequent sections, make sure that you read this section.
Refer to the latest version of Workshop Manual (Code No. 9Y021-01870) for the diesel engine
mechanism that this workshop manual does not include.
 Servicing
• Troubleshooting
• Servicing Specifications
• Tightening Torques
• Checking, Disassembling and Servicing
All illustrations, photographs and specifications contained in this manual are of the newest
information available at the time of publication.
KUBOTA reserves the right to change all information at any time without notice.
Since this manual includes many models, information or illustrations and photographs can show
more than one model.
December, 2013
© KUBOTA Corporation 2013

Record of Revisions
For pdf, use search function {Search word} to find all the revised locations.
Last digit
Issue Reference
of the Main Revised Point and Corrective Measures {Search word}
month Page
Code No.
1 2015.05 Change the Adjusting Injection Timing to Replacing Injection pump. 1-S19

I INFORMATION

INFORMATION
CONTENTS
1. SAFETY FIRST .............................................................................................................................. I-1

2. SPECIFICATIONS.......................................................................................................................... I-4
3. PERFORMANCE CURVES............................................................................................................ I-5
4. DIMENSIONS ................................................................................................................................. I-6

EA330-E4, WSM INFORMATION
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.
• It is essential that you read the instructions and safety regulations before you try to repair or use this
unit.
DANGER
• Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
WARNING
• Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
• Indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate
injury.
IMPORTANT
• Indicates that equipment or property damage could result if instructions are not followed.
NOTE
• Gives helpful information.
WSM000001INI0001US1
BEFORE YOU START SERVICE
• Read all instructions and safety instructions in this
manual and on your engine safety decals.
• Clean the work area and engine.
• Park the machine on a stable and level ground.
• Let the temperature of the engine decrease before
you start a job.
• Stop the engine, then remove the key.
• Disconnect the battery negative cable.
• Hang a "DO NOT OPERATE" tag in the operator
station.
WSM000001INI0002US0
START SAFELY
• Do not do the procedures below when you start the
engine.
– short across starter terminals
– bypass the safety start switch
• Do not make unauthorized modifications to the
engine. This can cause damage and decrease the
engine life.
WSM000001INI0003US0
I-1
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.
• When 2 or more persons do servicing, make sure
that you do it safely.
• Do not touch the hot parts or parts that turn when the
engine operates.
• Do not remove the radiator cap when the engine
operates, or immediately after it stops. If not, hot
water can spout out from the radiator. Only remove
the radiator cap when it is at a sufficiently low
temperature to touch with bare hands. Slowly loosen
the cap to release the pressure before you remove it
fully.
• Released fluid (fuel or hydraulic oil) under pressure
can cause damage to the skin and cause serious
injury. Release the pressure before you disconnect
hydraulic or fuel lines. Tighten all connections before
you apply the pressure.
• Do not open a fuel system under high pressure.
The fluid under high pressure that stays in fuel lines
can cause serious injury. Do not disconnect or repair
the fuel lines, sensors, or any other components
between the fuel pump and injectors on engines with
a common rail fuel system under high pressure.
• Put on an applicable ear protective device (earmuffs
or earplugs) to prevent injury against loud noises.
• Be careful about electric shock. The engine
generates a high voltage of more than DC100 V in
the ECU and is applied to the injector.
WSM000001INI0004US0
PREVENT A FIRE
• Fuel is very flammable and explosive under some
conditions. Do not smoke or let flames or sparks in
your work area.
• To prevent sparks from an accidental short circuit,
always disconnect the battery negative cable first
and connect it last.
• The battery gas can cause an explosion. Keep the
sparks and open flame away from the top of battery,
especially when you charge the battery.
• Make sure that you do not spill fuel on the engine.
WSM000001INI0005US0
I-2
KEEP A GOOD AIRFLOW IN THE WORK AREA
• If the engine is in operation, make sure that the area
has good airflow. Do not operate the engine in a
closed area. The exhaust gas contains poisonous
carbon monoxide.
WSM000001INI0006US0
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

• Keep electrolyte away from your eyes, hands and
clothing. Sulfuric acid in battery electrolyte is
poisonous and it can burn your skin and clothing and
cause blindness. If you spill electrolyte on yourself,
clean yourself with water, and get medical aid
immediately.
WSM000001INI0008US0
PREPARE FOR EMERGENCIES

• Keep a first aid kit and fire extinguisher ready at all
times.
• Keep the emergency contact telephone numbers
near your telephone at all times.
WSM000001INI0009US0
I-3
2. SPECIFICATIONS
Model EA330-E4-NB1 EA330-E4-NB1-APU-1 EA330-E4-NB1-SCS-1
Number of Cylinder 1
Engine Type Horizontal, water-cooled, 4-cycle diesel engine
Bore × Stroke 77.0 mm × 70.0 mm (3.03 in × 2.76 in.)
Displacement 325 cc (19.8 cu.in.)
5.76 kW (7.72 HP) /
SAE Intermittent 5.15 kW (6.91 HP) / 3000 min-1 (rpm)
3000 min-1 (rpm)
Brake Horsepower
4.8 kW (6.4 HP) /
SAE Continuous 4.4 kW (5.9 HP) / 3000 min-1 (rpm)
3000 min-1 (rpm)
Maximum Bare Speed 3220 min-1 (rpm)
Minimum Bare Idling Speed 1300 min-1 (rpm)
Combustion Chamber Spherical type (TVCS)
Fuel Injection Pump Bosch K type mini pump
Governor Mechanical all speed governor
Direction of Rotation Counter-clockwise (Viewed from flywheel side)
Injection Nozzle DN-PD Mini Nozzle
Injection Timing 0.445 rad (25.5 °) Before T.D.C.
Injection Pressure 13.73 MPa (140.0 kgf/cm2, 1991 psi)
Compression Ratio 24
Lubricating System Forced Lubrication by Trochoid Pump
Cooling System Radiator –
Starting System Electric Starting with Starter
Starting Motor 12 V, 0.8 kW
Starting Support Device By glow plug in combustion chamber
EGR None
Battery 12V, 28 AH equivalent
Charging Alternator 12V, 60W
Fuel No. 2-D S500 or S15, See page G-6
Class CF lubricating oil as per API classification is recommended.
Lubricating Oil
For details on recommended lubricating oils. (see page G-6)
Lubricating Oil Capacity 1.3 L (0.34 U.S.gals)
Coolant Capacity 1.2 L (0.32 U.S.gals) –
Fuel Tank Capacity 4.8 L (1.3 U.S.gals) –
Weight (Dry) 54.0 kg (119 lbs) 43.0 kg (94.8 lbs) 39.0 kg (86.0 lbs)
*Conversion Formula: HP=0.746 kW, PS=0.7355 kW
9Y1211018INI0001US0
I-4
3. PERFORMANCE CURVES
(1) Intermittent Torque (2) Brake Horse Power (3) Fuel Consumption (4) Brake Horse Power
(Intermittent) (Continuous)
NOTE
• Each performance curves obtained in accordance with SAE J816b are corrected to 760 mm Hg
(29.9 in.Hg), 20 °C (68 °F) 60 % humidity.
9Y1211018INI0002US0
I-5
4. DIMENSIONS
EA330-E4-NB1
A 311.5 mm (12.26 in.)

B 138 mm (5.43 in.)
C 173.5 mm (6.831 in.)
D 326 mm dia. (12.8 in. dia.)
E 64 mm (2.5 in.)
F 46 mm (1.8 in.)
G 567.7 mm (22.35 in.)
H 335 mm (13.2 in.)
I 232.7 mm (9.161 in.)
J 457 mm (18.0 in.)
K 326 mm (12.8 in.)
L 125 mm (4.92 in.)
M 451 mm (17.8 in.)
N 160 mm (6.30 in.)
O 125 mm (4.92 in.)
P 317 mm (12.5 in.)
Q 163 mm (6.42 in.)
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I-6
EA330-E4-NB1-APU-1
A 303.5 mm (11.95 in.)

B 130 mm (5.12 in.)
C 173.5 mm (6.831 in.)
D 64 mm (2.5 in.)
E 46 mm (1.8 in.)
F 485 mm (19.1 in.)
G 317 mm (12.5 in.)
H 168 mm (6.61 in.)
I 400 mm (15.7 in.)
J 304 mm (12.0 in.)
K 125 mm (4.92 in.)
L 429 mm (16.9 in.)
M 160 mm (6.30 in.)
N 125 mm (4.92 in.)
9Y1211018INI0004US0
I-7
EA330-E4-NB1-SCS-1
A 303.5 mm (11.95 in.)

B 130 mm (5.12 in.)
C 173.5 mm (6.831 in.)
D 64 mm (2.5 in.)
E 46 mm (1.8 in.)
F 485 mm (19.1 in.)
G 317 mm (12.5 in.)
H 168 mm (6.61 in.)
I 221 mm (8.70 in.)
J 216.8 mm (8.535 in.)
K 125 mm (4.92 in.)
L 341.8 mm (13.46 in.)
M 160 mm (6.30 in.)
N 125 mm (4.92 in.)
9Y1211018INI0005US0
I-8
Pulley Shaft (EA330-E4-NB1, EA330-E4-NB1-APU-1, EA330-E4-NB1-SCS-1)
No. 19501-8451-0
A 9.525 to 9.575 mm (0.3750 to 0.3769 in.)
36.487 to 36.512 mm dia.
B
(1.4365 to 1.4374 in. dia.)
C 88.9 mm (3.50 in.)
D 66.60 to 66.90 mm (2.622 to 2.633 in.)
E 3 Through holes-9.0 mm dia. (0.35 in. dia.)
F 128.9 mm (5.075 in.)
G 116 mm dia. (4.57 in. dia.)
H 138 mm dia. (5.43 in. dia.)
(1) Key
9Y1211018INI0006US0
V-Pulley
No. 19704-8401-0
A 130 mm dia. (5.12 in. dia.)
B 53 mm (2.1 in.)
C 44 mm (1.7 in.)
D 10 mm (0.39 in.)
9Y1211018INI0007US0
Flywheel
A 3 Screw holes - Screw dia. size 8.0 mm (0.31 in.)

B 116 mm dia. (4.57 in. dia.)
97.000 to 97.035 mm dia.
C
(3.8189 to 3.8202 in. dia.)
D 16.8 to 17.2 mm (0.662 to 0.677 in.)
9Y1211018INI0008US0
I-9
G GENERAL

GENERAL
CONTENTS
1. ENGINE IDENTIFICATION .......................................................................................................... G-1

[1] MODEL NAME AND ENGINE SERIAL NUMBER.................................................................. G-1
[2] E4 ENGINE ............................................................................................................................ G-3
2. GENERAL PRECAUTIONS.......................................................................................................... G-4
3. MAINTENANCE CHECK LIST ..................................................................................................... G-5
4. CHECK AND MAINTENANCE ..................................................................................................... G-7
[1] DAILY CHECK LIST ............................................................................................................... G-7
[2] CHECK POINT OF EVERY 50 HOURS ................................................................................. G-8
[3] CHECK POINT OF EVERY 100 HOURS ............................................................................... G-8
5. SPECIAL TOOLS ....................................................................................................................... G-10

EA330-E4, WSM GENERAL
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.
 Engine Serial Number
The engine serial number is an identified number for the engine.
It is marked after the engine model name.
It indicates month and year of manufacture as follows.
Engine Series
Number or Number or
Series Series
Alphabet Alphabet
1 05 (include: WG) 7 03
2 V3 8 07
3 08 A EA, RK
03 (KET
4 SM (include: WG) B
Production)
Air Cooled V3, 07 (KEW
5 C
Gasoline Production)
GZ, OC, AC, EA,
6
E
Production Year
Alphabet or Alphabet or
Year Year
Number Number
1 2001 F 2015
2 2002 G 2016
3 2003 H 2017
4 2004 J 2018
5 2005 K 2019
6 2006 L 2020
7 2007 M 2021
8 2008 N 2022
9 2009 P 2023
A 2010 R 2024
B 2011 S 2025
C 2012 T 2026
D 2013 V 2027
E 2014
(1) Engine Model (3) Emission Label

(2) Serial Number (4) Engine Label
(To be continued)
G-1
(Continued)
Production Month and Lot Number
Month Engine Lot Number
January A0001 ~ A9999 B0001 ~
February C0001 ~ C9999 D0001 ~
March E0001 ~ E9999 F0001 ~
April G0001 ~ G9999 H0001 ~
May J0001 ~ J9999 K0001 ~
June L0001 ~ L9999 M0001 ~
July N0001 ~ N9999 P0001 ~
August Q0001 ~ Q9999 R0001 ~
September S0001 ~ S9999 T0001 ~
October U0001 ~ U9999 V0001 ~
November W0001 ~ W9999 X0001 ~
December Y0001 ~ Y9999 Z0001 ~
* Alphabetical letters "I" and "O" are not used.

(a) (b) (c) (d) (e)
e.g. EA330 - 6 D B A001
(a) EA330: Engine Model Name
(b) 6: Engine Series (EA series)
(c) D: Production Year (2013)
(d) B: Production Month (January)
(e) A001: Lot Number: (0001 ~ 9999 or A001 ~ Z999)
9Y1211018GEG0001US0
G-2
[2] E4 ENGINE
[Example: Engine Model Name EA330-E4-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.
Over the past several years, KUBOTA has been supplying diesel engines that comply with regulations in the
respective countries affected by Nonroad Emission regulations. For KUBOTA Engines, E4 will be the designation that
identifies engine models affected by the next emission phase (See the table below).
When servicing or repairing ###-E4 series engines, use only replacement parts for that specific E4 engine,
designated by the appropriate E4 KUBOTA Parts List and perform all maintenance services listed in the appropriate
KUBOTA Operator's Manual or in the appropriate E4 KUBOTA Workshop Manual. Use of incorrect replacement parts
or replacement parts from other emission level engines (for example: E3 engines), may result in emission levels out
of compliance with the original E4 design and EPA or other applicable regulations. Please refer to the emission label
located on the engine head cover to identify Output classification and Emission Control Information. E4 engines are
identified with "EF" at the end of the Model designation, on the US EPA label. Please note: E4 is not marked on the
engine.
Category (1) Engine output classification EU regulation
K From 19 to less than 37 kW STAGE IIIA
P From 37 to less than 56 kW STAGE IIIB
N From 56 to less than 75 kW STAGE IIIB
M From 75 to less than 130 kW STAGE IIIB
Category (2) Engine output classification EPA regulation

Less than 19kW Tier 4
From 19 to less than 56 kW Interim Tier 4
EF
(1) EU regulation engine output classification category

(2) "E4" engines are identified with "EF" at the end of the Model designation, on
the US EPA label.
"E4" designates some Interim Tier 4 / Tier 4 models, depending on engine
output classification.
9Y1211018GEG0002US0
G-3
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.
• When it is necessary to use special tools, use KUBOTA special
tools. Refer to the drawings when you make special tools that
you do not use frequently.
• Before you disassemble or repair machine, make sure that you
always disconnect the ground cable from the battery first.
• Remove oil and dirt from parts before you measure.
• Use only KUBOTA genuine parts for replacement to keep the
machine performance and to make sure of safety.
• You must replace the gaskets and O-rings when you assemble
again. Apply grease (1) to new O-rings or oil seals before you
assemble.
• When you assemble the external or internal snap rings, make
sure that the sharp edge (3) faces against the direction from
which force (2) is applied.
• Make sure that you try to operate the engine after you repair or
assemble it. Do not try to give a heavy load immediately, if not,
you can cause serious damage to the engine.
(1) Grease (A) External Snap Ring
(2) Force (B) Internal Snap Ring
(3) Sharp Edge
WSM000001GEG0091US0
G-4
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 Every
Item Initial Every Every Every Every Every Every 1 Every 2
Daily 1500 3000
50 hrs 50 hrs 100 hrs 300 hrs 500 hrs 800 hrs year years
hrs hrs
Check 
Radiator coolant
Change 
Check 
Crankcase oil
Change  
Check 
Fuel feed piping
Change 
Check  @
Air cleaner element Clean 
Change 
Clean 
Fuel filter
Change 
Check 
Fuel tank
Clean 
Valve clearance Check 
Nozzle Check  @
Injection pump Check  @
Fan belt Change 
Battery Check 
• When the battery is used for less than 100 hours in a year, check its electrolyte yearly. (for refillable battery's only.)
• The items listed above (@ marked) are registered as emission related critical parts by KUBOTA in the U.S.EPA
nonroad emission regulation. As the engine owner, you are responsible for the performance of the required
maintenance on the engine according to the above instruction. Please see the Warranty Statement in detail.
9Y1211018GEG0003US0
G-5
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).
Engine oil classification (API classification)
Fuel Type Engines with non-EGR
Engines with external EGR
Engines with internal EGR
CF
High Sulfur Fuel
(If the "CF-4, CG-4, CH-4, or CI-4" engine
[0.05 % (500 ppm) ≤
oil is used with a high-sulfur fuel, change –
Sulfur Content <
the engine oil at shorter intervals.
0.50 % (5000 ppm)]
(approximately half))
Low Sulfur Fuel
[Sulfur Content <
CF or CI-4
0.05 % (500 ppm)] or
CF, CF-4, CG-4, CH-4 or CI-4 (Class CF-4, CG-4 and CH-4 engine oils
Ultra Low Sulfur Fuel
cannot be used on EGR type engines.)
[Sulfur Content <
0.0015 % (15 ppm)]
EGR: Exhaust Gas Re-circulation
• CJ4 classification oil is intended for use in engines equipped with DPF (Diesel Particulate Filter) and is
Not Recommended for use in KUBOTA E3 specification engines.
• Oil used in the engine should have API classification and Proper SAE Engine Oil Viscosity according to
the ambient temperatures where the engine is operated.
• With strict emission control regulations now in effect, the CF-4 and CG-4 engine oils have been developed
for use with low sulfur fuels, for On-Highway vehicle engines. When a Non-Road engine runs on high
sulfur fuel, it is advisable to use a "CF or better" classification engine oil with a high Total Base Number
(a minimum TBN of 10 is recommended).
Fuel:
• Cetane Rating: The minimum recommended Fuel Cetane Rating is 45. A cetane rating greater than 50 is
preferred, especially for ambient temperatures below −20 °C (−4 °F) or elevations above 1500 m (4921 ft).
• Diesel Fuel Specification Type and Sulfur Content % (ppm) used, must be compliant with all applicable
emission regulations for the area in which the engine is operated.
• Use of diesel fuel with sulfur content less than 0.10 % (1000 ppm) is strongly recommended.
• If high-sulfur fuel (sulfur content 0.50 % (5000 ppm) to 1.0 % (10000 ppm)) is used as a diesel fuel, change
the engine oil and oil filter at shorter intervals. (approximately half)
• DO NOT USE Fuels that have sulfur content greater than 1.0 % (10000 ppm).
• Diesel fuels specified to EN 590 or ASTM D975 are recommended.
• No.2-D is a distillate fuel of lower volatility for engines in industrial and heavy mobile service. (SAE J313
JUN87)
• Since KUBOTA diesel engines of less than 56 kW (75 hp) utilize EPA Tier 4 and Interim Tier 4 standards,
the use of low sulfur fuel or ultra low sulfur fuel is mandatory for these engines, when operated in US EPA
regulated areas. Therefore, please use No.2-D S500 or S15 diesel fuel as an alternative to No.2-D, and use
No.1-D S500 or S15 diesel fuel as an alternative to No.1-D for ambient temperatures below −10 °C (14 °F).
1) SAE: Society of Automotive Engineers
2) EN: European Norm
3) ASTM: American Society of Testing and Materials
4) US EPA: United States Environmental Protection Agency
5) No.1-D or No.2-D, S500: Low Sulfur Diesel (LSD) less than 500 ppm or 0.05 wt.%
No.1-D or No.2-D, S15: Ultra Low Sulfur Diesel (ULSD) 15 ppm or 0.0015 wt.%
9Y1211018GEG0004US0
G-6
4. CHECK AND MAINTENANCE

[1] DAILY CHECK LIST
Checking Coolant Level (Daily)
CAUTION
• During operation or immediately after operation, coolant in
the radiator is extremely hot.
If the radiator cap is removed, hot water may gush out,
causing scalding. Open the radiator cap after the engine
has cooled.
1. Fill the radiator with tap or fresh water.
NOTE
• Dirt or dust in the water will hinder water flow, impairing
cooling efficiency.
2. When draining coolant, open both the drain valve (2) and the
radiator cap (1). Water will drain even more completely if the
engine is shaken several times.
3. When there is a chance of freezing and no antifreeze is added
to coolant, drain it after every use.
4. Periodically remove the radiator net (3) and check to see if the
radiator fin may greatly lower cooling or pressurized water, do
not use anything hard like a screwdriver or a spatula which may
scratch the fin.
(1) Radiator Cap A: OPEN
(2) Drain Valve B: CLOSE
(3) Radiator Net
9Y1211018GEG0005US0
Checking Engine Oil Level (Daily)

NOTE
• Engine should be on a level surface when oil level is
checked.
1. Pull out dipstick (1) and check oil level.
2. If necessary, add engine oil to bring oil level between the oil
level mark (2) on dipstick.
(1) Dipstick (3) Oil Inlet
(2) Oil Level Mark
9Y1211018GEG0006US0
G-7
[2] CHECK POINT OF EVERY 50 HOURS

Checking Air Cleaner Element
IMPORTANT
• When used in a dustily place, check the cleaner every day,
and clean.
1. Ensure that the element (1) or the dust cup (2) is not clogged by
dirt or dust.
2. If necessary, clean them according to the procedure in the
following section "Cleaning Air Cleaner Element".
NOTE
• Do not let dust build up to move than half way up the dust
cap.
(1) Air Cleaner Element (2) Dust Cap
9Y1211018GEG0007US0
[3] CHECK POINT OF EVERY 100 HOURS

Changing Engine Oil and Cleaning Oil Strainer (First 50 Hours
and Every 100 Hours)
1. After warming up the engine, remove the drain plug (1) and
drain the oil completely.
2. Clean the inside of the oil strainer and the cylinder block withe
gas oil.
3. Supply the specified quantity of the specified oil through the oil
inlet.
1.3 L
Engine oil quantity
0.34 U.S.gals
IMPORTANT
• Engine oil should have properties of API classification CF.
• Change the type of engine oil according to the ambient
temperature.
Above 20 °C (68 °F) SAE30
5 to 20 °C (41 to 68 °F) SAE20
Below 5 °C (41 °F) SAE10W or SAE10W-30
(1) Drain Plug (Oil Strainer)

9Y1211018GEG0008US0
Cleaning of Air Cleaner Element
1. Remove the air cleaner element.
2. Use clean dry compressed air on the inner side of the element.
The pressure of compressed air must be less than 205 kPa
(2.1 kgf/cm2, 30 psi).
Keep an appropriate distance between the nozzle and the filter.
NOTE
• The air cleaner uses a dry element. Do not apply oil to it.
• Do not operate the engine without the filter element.
• Replace the element once a year or every sixth cleaning.
9Y1211018GEG0009US0
G-8
Cleaning Fuel Element
CAUTION
• If the element is damaged, replace it. Otherwise, dust may
enter the injection pump and the nozzle, shortening their
service life.
1. Close the fuel valve.
2. Loosen the retainer ring (2) on the cap (3) and the bolt mounting
element holder, take out the cap, and clean out any dust or
water collected in the bottom of it.
3. The element (1) can be detached by pulling downward gently.
Immerse it in new fuel and swish gently to wash.
4. Apply a thin film of fuel to the O-ring and then fully tighten it by
hand.
IMPORTANT
• The retainer ring must be tightened by hand at all times.
(1) Filter Element (3) Filter Cap
(2) Retainer Ring
9Y1211018GEG0010US0
G-9
5. SPECIAL TOOLS
Special Use Puller Set
Code No.
• 07916-09032
Application
• Use exclusively to pull out bearing, gears and other parts with
ease.
WSM000001GEG0011US0
Wet Liner Puller

Code No.
• 07916-30012
Application
• A puller for pulling out the wet liner. It combines with a presser
for pushing in the wet liner.
9Y1211018GEG0011US0
Flywheel Puller
Code No.
• (1) 07916-04052
• (2) 07916-32491
Application
• Use to remove the flywheel.
9Y1211018GEG0012US0
Diesel Engine Compression Tester (for Injection Nozzle)

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
• Use to measure diesel engine compression and diagnostics of
need for major overhaul.
(1) Gauge (7) Adaptor F
(2) L Joint (8) Adaptor G
(3) Adaptor A (9) Adaptor H
(4) Adaptor B (10) Adaptor I
(5) Adaptor C (11) Adaptor J
(6) Adaptor E
WSM000001GEG0014US0
G-10
Oil Pressure Tester
Code No.
• 07916-32032
Application
• Use to measure lubricating oil pressure.
(1) Gauge (5) Adaptor 2
(2) Cable (6) Adaptor 3
(3) Threaded Joint (7) Adaptor 4
(4) Adaptor 1 (8) Adaptor 5
WSM000001GEG0015US0
G-11
NOTE
• The following special tools are not provided, so make them referring to the figure.
9Y1211018GEG0013US0
Valve Guide Replacing Tool
Application
• Use to press out and press in the valve guide.
A 225 mm (8.86 in.)
B 70 mm (2.8 in.)
C 45 mm (1.8 in.)
D 20 mm dia. (0.79 in. dia.)
E 11.7 to 11.9 mm dia. (0.461 to 0.468 in. dia.)
F 6.50 to 6.60 mm dia. (0.256 to 0.259 in. dia.)
G 25 mm dia. (0.98 in. dia.)
H 6.70 to 7.00 mm dia. (0.264 to 0.275 in. dia.)
I 5.0 mm (0.20 in.)
J 20 mm dia. (0.79 in. dia.)
K 12.5 to 12.8 mm dia. (0.493 to 0.503 in. dia.)
L 8.90 to 9.10 mm (0.351 to 358 in.)
C1 Chamfer 1.0 mm (0.039 in.)
C0.3 Chamfer 0.30 mm (0.012 in.)
9Y1211018GEG0014US0
Idle Gear Bushing Replacing Tool
Application
• Use to press out and to press fit the idle gear bushing.
Material
• S43C
Heat Treatment
• Hardening, Anneal.
A 19.90 to 19.95 mm dia. (0.7835 to 0.7854 in. dia.)
B 17.90 to 17.95 mm dia. (0.7048 to 0.7066 in. dia.)
C 15 mm dia. (0.59 in. dia.)
D 8 mm (0.3 in.)
E 25 mm (0.98 in.)
F 100 mm (3.94 in.)
C0.3 Chamfer 0.3 mm (0.012 in.)
9Y1211018GEG0015US0
G-12
Piston Pin Bushing Replacing Tool
Application
• Use to press out and to press fit the piston pin bushing.
Material
• S43C
Heat Treatment
• Hardening, Anneal.
A 22.90 to 22.95 mm dia. (0.9016 to 0.9035 in. dia.)
B 19.90 to 19.95 mm dia. (0.7835 to 0.7854 in. dia.)
C 15 mm dia. (0.59 in. dia.)
D 8 mm (0.3 in.)
E 25 mm (0.98 in.)
F 100 mm (3.94 in.)
C0.3 Chamfer 0.3 mm (0.012 in.)
9Y1211018GEG0016US0
Flywheel Stopper
Application
• Use to loosen and tighten the flywheel nut.
Material
• SS41.
A 235 mm dia. (9.25 in. dia.)
B 30 mm (1.2 in.)
C 20 mm (0.79 in.)
D 30 mm (1.2 in.)
E 26 mm (1.0 in.)
F 8 mm (0.3 in.)
G 10 mm dia. (0.39 in. dia.)
9Y1211018GEG0017US0
G-13
Crank Gear Puller
Application
• Use exclusively to pull out easily the crank gear.
Material
• (1) Hexagonal Bar Steel
• (2) SS41
A 125 mm (4.92 in.)
B 95 mm (3.7 in.)
C 5 mm (0.2 in.)
D 20 mm (0.79 in.)
E 10 mm (0.39 in.)
F 19 mm (0.75 in.)
G 10 mm dia. (0.39 in. dia.)
H M16 × P1.5
I 0.87 rad (50 °)
J 30 mm (1.2 in.)
K 11.5 mm (0.453 in.)
L 7 mm (0.3 in.)
M 13.5 mm (0.531 in.)
N M16 × P1.5
O 60 mm (2.4 in.)
P 18 mm (0.71 in.)
Q 12 mm (0.47 in.)
C2 Chamfer 2 mm (0.08 in.)
R0.5 R0.5 mm (0.02 in.)
R4.5 R4.5 mm (0.18 in.)
R14 R14 mm (0.55 in.)
9Y1211018GEG0018US0
G-14
Injection Pump Pressure Tester
Application
• Use to check fuel tightness of injection pumps.
Pressure gauge full scale:
A
More than 29.4 MPa (300 kgf/cm2, 4270 psi)
B PF 1/2
C Copper gasket
D Flange (Material Steel)
E Hex. nut 27 mm (1.1 in.) across the plat
F Adhesive application
G Fillet welding on the enter circumference
H Retaining nut
I 17 mm dia. (0.67 in. dia.)
J 8.0 mm dia. (0.3 in. dia.)
K 1.0 mm (0.039 in.)
L 17 mm dia. (0.67 in. dia.)
M 6.10 to 6.20 mm dia. (0.241 to 0.244 in. dia.)
N 8.0 mm (0.31 in.)
O 4.0 mm (0.16 in.)
P 11.97 to 11.99 mm dia. (0.4713 to 0.4720 in. dia.)
Q PF 1/2
R 23 mm (0.91 in.)
S 17 mm (0.67 in.)
T 4.0 mm (0.16 in.)
U 12.00 to 12.02 mm dia. (0.4725 to 0.4732 in. dia.)
V 100 mm (3.94 in.)
W M12 × P1.5
X 5 mm (0.2 in.)
9Y1211018GEG0019US0
G-15
1 ENGINE

MECHANISM
CONTENTS
1. FEATURE ................................................................................................................................... 1-M1

2. ENGINE BODY........................................................................................................................... 1-M2
[1] CYLINDER HEAD ................................................................................................................ 1-M2
[2] VALVE MECHANISM ........................................................................................................... 1-M4
[3] CYLINDER BLOCK AND CYLINDER LINER ....................................................................... 1-M6
[4] CRANKSHAFT AND CRANKSHAFT JOURNAL BEARING ................................................ 1-M6
[5] PISTON AND PISTON RING ............................................................................................... 1-M7
[6] CONNECTING ROD AND CONNECTING ROD BEARING................................................. 1-M7
[7] TIMING GEAR...................................................................................................................... 1-M8
[8] CAMSHAFT.......................................................................................................................... 1-M8
[9] FLYWHEEL .......................................................................................................................... 1-M8
[10]DYNAMIC BALANCER......................................................................................................... 1-M9
3. LUBRICATING SYSTEM.......................................................................................................... 1-M10
[1] GENERAL .......................................................................................................................... 1-M10
[2] OIL PUMP .......................................................................................................................... 1-M11
[3] OIL STRAINER................................................................................................................... 1-M11
[4] RELIEF VALVE .................................................................................................................. 1-M11
[5] OIL SIGNAL........................................................................................................................ 1-M12
[6] OIL PRESSURE SWITCH .................................................................................................. 1-M12
4. COOLING SYSTEM ................................................................................................................. 1-M13
[1] GENERAL .......................................................................................................................... 1-M13
[2] RADIATOR ......................................................................................................................... 1-M13
[3] RADIATOR CAP................................................................................................................. 1-M14
5. INTAKE / EXHAUST SYSTEM ................................................................................................. 1-M15
[1] GENERAL .......................................................................................................................... 1-M15
[2] AIR CLEANER.................................................................................................................... 1-M15
[3] MUFFLER........................................................................................................................... 1-M15
6. FUEL SYSTEM......................................................................................................................... 1-M16
[1] GENERAL .......................................................................................................................... 1-M16
[2] INJECTION PUMP ............................................................................................................. 1-M17
[3] INJECTION NOZZLE ......................................................................................................... 1-M20
[4] GOVERNOR MECHANISM................................................................................................ 1-M21
[5] FUEL FILTER ..................................................................................................................... 1-M23
7. ELECTRICAL SYSTEM............................................................................................................ 1-M24
[1] GENERAL .......................................................................................................................... 1-M24
[2] FAN DYNAMO.................................................................................................................... 1-M25
[3] STARTER........................................................................................................................... 1-M26
[4] GLOW PLUG ...................................................................................................................... 1-M31

EA330-E4, WSM ENGINE
1. FEATURE
NOTE
• Figure shows EA330 engine
The EA330-E4 series engines are horizontal,
water-cooled 4-cycle diesel engine.
They are incorporated KUBOTA's foremost
technologies.
With KUBOTA's exclusive E-TVCS (Three Vortex
Combustion System) combustion chamber and 2-shaft
dynamic balances, well-known Bosch M type injection
pump, they give greater power, low fuel consumption,
little vibration and quiet operation.
9Y1211018ENM0001US0
1-M1
2. ENGINE BODY
[1] CYLINDER HEAD
As the cylinder head is subjected to high
temperature and high pressure, it is made of special
alloy iron.
The cylinder head is installed on top of the cylinder
block, it houses the intake and exhaust valves (4), rocker
arm (1), injection nozzle (3), and others.
It is also equipped with a decompressor to reduce
compression in the cylinder so the crankshaft rotates
with less force for staring.
The area of the cylinder head that faces the piston
head and forms the combustion chamber has the intake
and exhaust holes and nozzle hole. In the other area, a
lubricating oil gallery, coolant gallery, screw hole, and
others are machined symmetrically with the cylinder
block.
The EA330-E4 engine is equipped with the glow plug
for easy starting even in cold weather.
(1) Rocker Arm (3) Injection Nozzle
(2) Decompression Shaft (4) Valve
9Y1211018ENM0002US0
The intake port (1) and exhaust port (2) are cross
flow type which open respectively at both sides of the
cylinder head. In this cylinder head, less exhaust heat is
hardly conducted to the intake port, so that high density
air is always inhaled into the cylinder for stable
combustion.
(1) Intake Port (2) Exhaust Port
9Y1211018ENM0003US0
1-M2
This engine employs KUBOTA's exclusive (Three
Vortex Combustion System) system. This system
provides three swirls inside a spherical vortex chamber
during the combustion stroke for effective combustion.
Specific fuel consumption is improved by approx. 10 %
over our conventional engines. This combustion system
also features good starting performance and reduced
noise.
(1) Combustion Chamber (5) Injection Nozzle
(2) Intake Air Port (6) Cylinder Head
(3) Atomized Fuel (7) Cylinder Liner
(During Compression) (8) Piston
(4) Atomized Fuel
(During Explosion)
9Y1211018ENM0004US0
1-M3
[2] VALVE MECHANISM

This engine adopts the overhead valve (OHV)
mechanism. The intake and exhaust valves (7), (1) open
and close as follows:
1. The crankshaft rotation is transmitted to the
camshaft via the timing gears (crank gear (12), cam
gear (10) and idle gear (11)).
2. The cam actuated by the rotation of the camshaft
push up the tappet (8) and push rad (6), and the
rocker arm (3) rocks with the rocker arm shaft as an
axis like a seesaw and overcomes the tension or the
valve spring (5), allowing the valve to open.
3. When the convex portion of the cam passes its top,
the valve closes by the spring tension.
Since the intake / exhaust valves expand due to heat

during engine running, a small clearance (valve
clearance) is provided between the end of rocker arm (3)
and the valve cap (2) in cold condition to prevent
compression leak caused by the valve pushing-up. This
clearance is adjusted with an adjusting screw (4)
mounted on the rocker arm.
The intake / exhaust valves are made of heat
resisting steel, and induction hardened at the valve stem
ends for improved wear resistance. The valve cap is
forged and carburized, and induction hardened at the
contact section with the valve cap of the rocker arm for
improved wear resistance. The valve springs (5) are
made of piano wires and its surfaces is performed
shot-peening for greater fatigue strength.
(1) Exhaust Valve (7) Intake Valve
(2) Valve Caps (8) Tappet
(3) Rocker Arms (9) Camshaft
(4) Adjusting Screw (10) Cam Gear
(5) Valve Spring (11) Idle Gear
(6) Push Rod (12) Crank Gear
9Y1211018ENM0005US0
1) Valve Guide
The valve guides are cast iron and reamer-finished
after being pressed into the cylinder head. The lower
area of the exhaust valve guide has a carbon cutter
which prevents carbon adhesion to the valve.
(1) Exhaust Valve Guide (3) Intake Valve Guide
(2) Carbon Cutter
9Y1211018ENM0006US0
1-M4
2) Valve Timing
The valve opening and closing timing is extremely
important for effectively taking air into the cylinder and
sufficiently discharging unnecessary exhaust gas.
An appropriate timing can be obtained by aligning
the alignment line on the crank gear, idle gear and cam
gear.
0.35 rad before T.D.C.
Intake valve open (I.D.)
(20° before T.D.C.)
0.79 rad after B.D.C.
Intake valve close (I.C.)
(45° after B.D.C.)
0.87 rad before B.D.C.
Exhaust valve open (E.O.)
(50° before B.D.C.)
0.26 rad after T.D.C.
Exhaust valve close (E.C.)
(15° after T.D.C.)
0.4320 to 0.4581 rad (24.75 to

Fuel Injection Timing
26.25°) before T.D.C.
(1) Intake (a) 0.35 rad before T.D.C.

(2) Compression (20° before T.D.C.)
(3) Combustion (Power) (b) 0.79 rad after B.D.C.
(4) Exhaust (45° after B.D.C.)
(c) 0.87 rad before B.D.C.
FI: Fuel Injection (50° before B.D.C.)
T.D.C.:Top Dead Center (d) 0.26 rad after T.D.C.
B.D.C.:Bottom Dead Center (15° after T.D.C.)
9Y1211018ENM0007US0
1-M5
[3] CYLINDER BLOCK AND CYLINDER LINER

The cylinder block is made of aluminium die-cast.
The cylinder block is provided with oil galleries to
lubricate the crankshaft, main bearing case and rocker
arm bracket. The cylinder liner (1) made of special cast
iron having excellent wear resistance, is press fitted into
the cylinder block.
These engines adopt a wet type cylinder liner which
periphery comes into direct contact with coolant. To
prevent water leakage, O-rings (2) are installed at the
lower part of cylinder liner periphery. To prevent gas
leakage, the upper part of the liner slightly protrudes
from the cylinder block. This is because the gasket at this
part is tightened strongly between the cylinder head and
the liner.
NOTE
• Similarly as the aluminum alloy gear case, etc.
cylinder blocks that are made of aluminum alloy
are prone to scratches and greater thermal
expansion. Therefore, following advises need to
be followed during repair.
• Parts must be tightened when they are cold.
• Follow specified tightening torques accurately.
• Protect processed surfaces, especially, from
scratches.
(1) Cylinder Liner (3) Cylinder Block
(2) O-ring
9Y1211018ENM0008US0
[4] CRANKSHAFT AND CRANKSHAFT JOURNAL BEARING

The crankshaft (1) is made of tough special alloy
steel, and the pin and oil seal slinging portions are
induction hardened to increase the hardness for higher
wear resistance.
The journal portions are supported by main bearing
1 (7) and 2 (5).
The crankshaft is provided with an oil gallery which
feeds engine oil to the pin portion and lubricate it.
The oil fed from the oil pump travels along the groove
on the oil filler rings (3), passes through the oil gallery in
the crankshaft and lubricates the crank pin part. The filler
ring is made of aluminum alloy casting.
The oil seal (2) is provided to prevent oil leakage.
(1) Crankshaft (5) Main Bearing 2
(2) Oil Seal (6) Crank Pin Bearing
(3) Oil Filler Ring (7) Main Bearing 1
(4) Main Bearing Case
9Y1211018ENM0009US0
1-M6
[5] PISTON AND PISTON RING

Since the piston is always subjected to high
temperature and high pressure and reciprocates within
the cylinder, it must be lightweight, tough, heat resistant,
wear resistant, and of little thermal expansion. For this
reason, the piston is made of High-silicone (aluminium
alloy).
The piston crown is flat-formed. Grooves are formed
around the piston crown and these aid heat dissipation
and prevent scuffing of the piston and cylinder liner.
The piston has three piston rings.
The top ring (1) is of a Keystone type to prevent gas
leakage, and it designed for a better initial fit and to
prevent abnormal wear and seizure. The ring surface is
hard-chromium plated for improved wear resistance.
The second ring (2) is an under-cut type which
effectively prevents the rise of oil.
The oil ring (3) has chamfered contact faces and an
expander ring, which increase the pressure of the oil ring
against the cylinder wall.
A portion of the scraped oil is forced inside the piston
as it passes through escape holes in rings and piston.
These oil rings are plated with hard chrome to give
increased wear resistance.
(1) Top Ring (3) Oil Ring
(2) Second Ring
9Y1211018ENM0010US0
[6] CONNECTING ROD AND CONNECTING ROD BEARING

The connecting rod (2) is made of I-shape forging of
carbon steel so that it can withstand large repetitive
impacts.
The big end of the connecting rod is of a horizontal
split type and tightened with special screws. Since the
connecting rod body (2) and cap (4) are I.D. machined
after matching, matching must not be changed.
The crank pin bearing (3) is a split type, and made of
copper-lead alloy (called Kelmet) (with a mild steel back
metal). The surface is tin plated to obtain a better initial
fit.
The piston pin bushing (1) is made of lead bronze
(with a mild steel back metal) which has the most
excellent shock resistance, load resistance and heat
resistance. The surface is tin plated.
(1) Piston Pin Bushing (3) Crank Pin Bearing
(2) Connecting Rod (4) Connecting Rod Cap
9Y1211018ENM0011US0
1-M7
[7] TIMING GEAR

The timing gears consisting of the crank gear (2),
cam gear (1), idle gear (6), (7) and balancer gears (4),
(5) serve to correctly control the intake and exhaust
valves opening, closing timing, fuel injection timing and
balance movement, etc.
Respective gears are marked with alignment marks
to assure correct relative positioning of gears when
assembling. For these timing gears, helical gears are
used. They smoothly convey rotations with less noise.
(1) Cam Gear (5) Balancer Gear 1
(2) Crank Gear (6) Idle Gear (45T)
(3) Balancer Gear 2 (7) Idle Gear (21T)
(4) Balancer Gear 3
9Y1211018ENM0012US0
[8] CAMSHAFT
The camshaft is made of carbon steel forging and its
cam and journal faces are induction hardened.
The oval-shaped cam improves intake efficiency and
at the same time reduces noise.
On the camshaft, the cam gear (3) is installed.
The camshaft is provided with an intake and exhaust
cam to actuate the intake and exhaust valves. In
addition, a groove is machined at the tip of the camshaft
to drive the trochoid pump for lubrication.
(1) Camshaft (3) Cam Gear
(2) Camshaft Stopper
9Y1211018ENM0013US0
[9] FLYWHEEL
The flywheel stores the rotating force in the
combustion stroke as inertial energy, reduces crankshaft
rotating speed fluctuation and maintains the smooth
rotating conditions.
On the circumference of the flywheel are stamped
the top dead center "T" mark and four lines indicating
every 0.03 rad (2 °) of crank angle from 0.35 rad (20 °) to
0.49 rad (28 °) before mark "T".
On the NB type, ring gears are press-fitted into the
periphery inside the flywheel to allow the engine to be
started withe a starter.
(1) Fuel Injection Timing Line (3) T.D.C. Mark "T"
(2) Fan Cover Mark
9Y1211018ENM0014US0
1-M8
[10] DYNAMIC BALANCER

The engine has a dynamic balancer (biaxial
balancer) to offset primary force caused by the
reciprocating motion of the piston. This significantly
reduces engine vibration and resultant vibrating noises.
9Y1211018ENM0015US0
1-M9
3. LUBRICATING SYSTEM
[1] GENERAL
(1) Rocker Arm (4) Crank Pin Portion (6) Relief Valve (8) Oil Strainer
(2) Rocker Arm Bracket (5) Oil Signal (7) Trochoid Pump (9) Piston Pin Bushing
(3) Oil Filler Ring
Lubrication is forced on with a trochoid pump.

Lubrication oil is sucked in by the trochoid pump (7) via an oil strainer (8) mounted on the side of the gear case.
The pressure of lubricating oil discharged from the trochoid pump is regulated by a relief valve (6) to 200 to 390 kPa
(2.0 to 4.0 kgf/cm2, 29 to 56 psi) (at the rated revolution speed of the engine), and the pressure-regulated oil is then
fed to various portions through the oil gallery in the cylinder block.
Lubricating oil sent to the oil gallery in the crankshaft lubricates the crank pin portion (4).
Oil sent to the cylinder head via the oil gallery in the cylinder block lubricates rocker arms (1) via a rocker arm
bracket (2).
Other items such as the piston, piston pin bushing (9), cam shaft journal portion, tappet, timing gear and bearings
are lubricated by splash of the crankshaft, etc.
An oil signal (5) is provided to enable the judgement whether the oil pressure is 50 kPa (0.5 kgf/cm2, 7 psi) or
more.
9Y1211018ENM0016US0
1-M10
[2] OIL PUMP

The oil pump is of trochoid pump type, whose rotors
have trochoid lobes. The inner rotor (3) has 4 lobes and
the outer rotor (4) has 5 lobes, and they are eccentrically
engaged with each other. The inner rotor, which is driven
by the crankshaft through the gears, rotates the outer
rotor in the same direction, varying the spaces between
the lobes.
While the rotors rotate from (A) to (B), the space
leading to the inlet port increases, which causes the oil
to flow through the inlet port.
When the rotors rotate to (C), the port to which the
space leads is changed from inlet to outlet.
At (D), the space decreases and sucked oil is
discharged from the outlet port.
(1) Inlet (3) Inner Rotor
(2) Outlet (4) Outer Rotor
9Y1211018ENM0017US0
[3] OIL STRAINER

Entry of foreign material such as iron chips, dirt, etc.
into the lubricating system may damage the lubricated
parts. To prevent this, an oil strainer is equipped prior to
the oil pump. This strainer has a double wound stainless
steel net (50 meshes) at the outside, and four magnets
(2) are mounted inside.
This stainless steel net (screen (4)) removes small
dirt in the lubricating oil. Further, fine iron chips passing
through this net are attracted by these magnets to
prevent them from entering the lubricating system.
(1) Plug (4) Stainless Steel Net
(2) Magnet (5) Spring
(3) Spacer (6) End Plate
9Y1211018ENM0018US0
[4] RELIEF VALVE

The relief valve consists of ball (4), spring (3), and
plug (1), which holds them, and is built into the lower part
of the gear case.
The relief valve (5) is used to adjust the lubricating oil
pressure to a proper level (200 to 390 kPa, 2.0 to
4.0 kgf/cm2, 29 to 56 psi).
The oil which has passed through the relief valve
falls to the cylinder block.
If this regulated pressure is too low, the delivery of
lubricating oil to various portions will become deficient
and may cause seizure. Too high oil pressure may cause
oil leakage.
(1) Plug (5) Relief Valve
(2) Gasket (6) Trochoid Pump
(3) Spring (7) Oil Strainer
(4) Ball
9Y1211018ENM0019US0
1-M11
[5] OIL SIGNAL

The oil signal is mounted to the cylinder block to
warn the operator that the lubricating oil pressure is poor.
At engine stop and at unusually low pressure (Less
than 50 kPa, 0.5 kgf/cm2, 7 psi), the red indication (2) is
displayed.
When the oil pressure is normal (50 kPa,
0.5 kgf/cm2, 7 psi or more), the blue signal (1) is pushed
out by means of the oil pressure.
(1) Blue Signal (A) At Proper Oil Pressure
(2) Red Indication (B) At Low Oil Pressure
9Y1211018ENM0020US0
[6] OIL PRESSURE SWITCH

While oil pressure is high and the force applied to the
diaphragm (2) is larger than the spring tension, the
terminal contact (3) is separated from the body contact
(4).
If the pressure drops below 50 kPa (0.5 kgf/cm2,
7 psi), the contact closes.
(1) Spring (A) At Proper Oil Pressure
(2) Diaphragm (B) At Low Oil Pressure
(3) Terminal Contact
(4) Body Contact
9Y1211018ENM0021US0
1-M12
4. COOLING SYSTEM
[1] GENERAL
This engine employ a pressurized radiator natural
convection cooling system.
Cooling by the radiator (1) and radiator fan (2)
increases in specific gravity. And it absorbs combustion
heat of the cylinder liner (5) and cylinder head (3) and
friction heat generated from moving parts to cool them.
Then, coolant moves upward, as the water absorbs
heat and decreases in specific gravity.
The heated water is cooled again by the radiator.
Thus, the coolant circulates naturally to cool the engine.
(1) Radiator (4) Cylinder Block
(2) Radiator Fan (5) Cylinder Liner
(3) Cylinder Head
9Y1211018ENM0022US0
[2] RADIATOR
The radiator adopted is of a plate fin type which is
durable and resistant to pressure, and has good heat
transfer proper ties. As it passes through the radiator
core, coolant is cooled by air from outside, and is again
circulated to the engine body.
The radiator core is composed of a tube (1), through
which water flow, and cooling fins (2). Both of the
components are formed of thin copper plate, etc. which
gives good heat transfer. Cooling air passing between
the fins helps coolant in the tube to give off heat.
(1) Tube (2) Cooling Fin
(Waved Plate Fin)
9Y1211018ENM0023US0
1-M13
[3] RADIATOR CAP

Radiator Cap Function
 When Radiator Pressure is High
When temperature increases inside the radiator,
there is expansion of water followed by conversion of
water to steam as the temperature continues to
increase.
The pressure valve is designed to prevent internal
pressure rising above specified opening pressure
(110 kPa, 1.1 kgf/cm2, 16 psi) in order to protect the
radiator, therefore, the pressure valve opens allowing
steam to escape, as shown in the figure.
An additional function of the radiator cap is to
prevent foam forming inside the engine and to restrict the
loss of coolant resulting from temperature increase.
 When Radiator Pressure is Negative
When the temperature of the coolant decreases,
internal pressure becomes negative as a result of water
contraction. In this situation, the vacuum valve opens
allowing the entry of air and a return to atmospheric
pressure, thereby preventing distortion of the radiator.
(1) Pressure Valve [A] At High Pressure
(2) Vacuum Valve [B] At Negative Pressure
9Y1211018ENM0024US0
1-M14
5. INTAKE / EXHAUST SYSTEM

[1] GENERAL
The intake / exhaust system consists of an intake
system to supply clean air into the cylinder and an
exhaust system to reduce exhaust noise.
The intake system consists of an air cleaner (3) and
an inlet pipe (5). The air cleaner prevents dust and dirt in
the air (4), or raindrops from entering into the cylinder
and the inlet pipe directs clean, filtered air into the
cylinder. The exhaust system consists of a muffler flange
(6) that directs exhaust gas (1) from the cylinder
collectively into the muffler (2), and muffler to reduce
exhaust noise.
(1) Exhaust Gas (4) Intake Air
(2) Muffler (5) Inlet Pipe
(3) Air Cleaner (6) Muffler Flange
9Y1211018ENM0025US0
[2] AIR CLEANER

The air cleaner is a dry type. The air enters it from the
periphery of the element (1), and the air is turned into a
cyclone swirl by the impeller (2) to separate coarse dust
particles centrifugally from the air. As the air passes the
element, remaining dust is removed from the air, and the
clean air is sucked into the cylinder from the center.
(1) Element (3) Dust Guide
(2) Impeller
9Y1211018ENM0026US0
[3] MUFFLER
The muffler consists of the perforated inner tube (2)
and outer tube (3), glass wool (1), main body (4), etc.
The inner and outer tube baffle plates (5) effectively
dampen exhaust noises. The glass wool placed between
the outer tube and main body, absorb higher frequency
of exhaust noises.
(1) Glass Wool (4) Main Body
(2) Inner Tube (5) Baffle Plate
(3) Outer Tube
9Y1211018ENM0027US0
1-M15
6. FUEL SYSTEM
[1] GENERAL
(1) Fuel Overflow Pipe (4) Injection Pump (7) Fuel Pipe 2 (9) Fuel Pipe 1
(2) Injection Nozzle (5) Air Vent Pipe 1 (8) Fuel Filter (10) Fuel Tank
(3) Injection Pipe (6) Air Vent Pipe 2
Fuel from the fuel tank (10) passes through the fuel filter (8), and then enters the injection pump (4) after impurities
such as dirt, water, etc. are removed.
The fuel pressurized by the injection pump to the opening pressure (13.73 to 14.70 MPa, 140.0 to 150.0 kgf/cm2,
1992 to 2133 psi), of the injection nozzle (2) is injected into the combustion chamber.
Part of the fuel fed to the injection nozzle (2) lubricates the moving parts of the plunger inside the nozzle, then
returns to the fuel tank through the fuel overflow pipe (1) from the upper part of the nozzle holder.
9Y1211018ENM0028US0
1-M16
[2] INJECTION PUMP

A Bosch M type mini pump is used for the injection
pump. It is small, lightweight and easy to handle.
The plunger (4) with a left-hand lead reciprocates via
the tappet roller (3) by means of the camshaft fuel cam,
causing the fuel to be delivered into the injection nozzle.
The fuel in the fuel chamber is drawn into the
delivery chamber when the plunger lowers. When the
plunger rises, delivery valve (5) is pushed open to force
into the injection nozzle.
The control rack (2) is actuated by the governor, and
the control rack movement is transmitted to the control
sleeve (1). As a result, the plunger rotates to vary the
amount of fuel fed into the injection nozzle.
When the speed control lever is set to the stop
position, the fuel is not pressurized, and is not injected
since the feed hole meets with the control groove.
(1) Control Sleeve (5) Delivery Valve
(2) Control Rack (6) Delivery Valve Holder
(3) Tappet Roller (7) Dumping Valve
(4) Plunger
9Y1211018ENM0029US0
Fuel Pressure-feed Stroke to Injection Nozzle
1. Fuel Suction
The fuel fed into fuel chamber (2) by the action of the
fuel feed pump when plunger (1) is down is drawn into
delivery chamber (4) after passing through feed hole (3).
2. Fuel Pressure-feeding Commencement
When plunger (1) rises, the surface of the plunger
head blocks feed hole (3) and the pressure inside
delivery chamber (4) increases thereby raising delivery
valve (5) and fuel commences to be pressure-feed into
the nozzle.
3. During Fuel Pressure-feeding
The plunger continues to rise and pressure-feeding
of fuel continues.
4. Conclusion of Fuel Pressure-feeding
The plunger continues to rise even further and
control groove (6) on the outer periphery of the plunger
reaches the feed hole, fuel then passes from delivery
chamber (4) through the control groove and returns to
fuel chamber (2) after passing once again through feed
hole (3).
(1) Plunger (4) Delivery Chamber
(2) Fuel Chamber (5) Delivery Valve
(3) Feed Hole (6) Control Groove
9Y1211018ENM0030US0
1-M17
Regulating Fuel Injection
1. No Fuel Delivery....Engine Stopped
When the control rack (5) is set at the engine stop
position, the plunger (2) is rotated to a position where the
vertical slot (6) in the plunger (2 aligns with the feed hole
(4). Since the vertical slot prevents the feed hole from
being covered, pressure in the delivery chamber (7)
cannot build up. Therefore, no fuel can be forced to the
injection nozzle.
2. Fuel Injection....Small to Medium
When the plunger rotates in the direction of the arrow
by the action of the control rack (as shown in the figure)
and after the head-section of plunger (2) closes off feed
hole (4), the quantity of fuel in the effective stroke "A"
(the section of strode up until control groove (3) reaches
the feed hole) is fed to the nozzle and injected.
3. Fuel Injection....Maximum
When the control rack has moved maximum
distance in the direction of the arrow, effective stroke "B"
of the plunger is at its maximum, consequently, fuel
injection is also at maximum.
(1) Control Sleeve (6) Vertical Rack
(2) Plunger (7) Delivery Chamber
(3) Control Groove
(4) Feed Hole A: Effective Stroke (Small)
(5) Control Rack B: Effective Stroke (Large)
9Y1211018ENM0031US0
1) Pump Element
The pump element (1) consists of the plunger (3) and
the cylinder (2). Their sliding surfaces are
super-precision finished to maintain a sufficient injection
pressure at low speeds.
The driving face (8) goes inside the control sleeve,
and moves the control rack. As a result, the plunger (3)
is turned and increases or decreases the fuel injection
rate accordingly.
As explained earlier, the plunger is provided with a
control groove (7), a notch (5) for stopping and a speed
advance lead (6). The control groove is a left-hand lead.
(1) Pump Element (5) Notch for Stopping
(2) Cylinder (6) Speed Advance Lead
(3) Plunger (7) Control Groove
(4) Feed Hole (8) Driving Face
9Y1211018ENM0032US0
1-M18
2) Delivery Valve
The delivery valve consists of the relief valve (1) and
delivery valve seat (2).
(1) Relief Valve (2) Delivery Valve Seat
9Y1211018ENM0033US0
Delivery Valve Operation

Non-return Function
Time delay from the beginning of pressure-feeding of
the pump element to the beginning of nozzle
feed-injection becomes large when the delivery chamber
of the pump and the injection nozzle are in alignment and
the cut-off of fuel is also delayed. Then, simultaneously
with the completion of the pressure-feeding of fuel, the
delivery valve descends as a result of the action of the
delivery valve spring thereby forming a cut-off between
the delivery chamber and the injection pipe preventing
any reverse flow of fuel.
Reverse Suction Function (Dripping Prevention)
1. When the pressure-feeding of fuel ends, the delivery
valve lowers and relief valve (1) section comes into
contact with the valve seat.
2. Furthermore, the valve descends until seat surface
(2) is in contact with delivery valve seat (3) but as the
amount of fuel during interval "A" is sucked back
from inside the injection pipe, pressure within the
pipe is reduced giving improved cut-off of fuel
injection by the nozzle, thereby preventing
subsequent dripping of the injectors.
(1) Relief Valve (a) Non-return Function
(2) Seat Surface (b) Reverse Section Function
(3) Delivery Valve Seat (Dripping Prevention)
9Y1211018ENM0034US0
Dumping Valve
At Fuel Injection
Since dumping valve is pushed up to press the
spring, fuel is pressure-fed to injection nozzle the same
as without dumping valve.
At Suck-Back
At suck-back by delivery valve after fuel injection,
fuel returns through dumping valve orifice. Generally
second injection is apt to occur by reflex pressure due to
reaction of sudden pressure drop when changing into
suck-back by delivery valve from high injection pressure.
As a result of preventing this second injection perfectly
by dumping valve and dissolving nozzle clogging,
durability of injection nozzle is improved.
(1) Dumping Valve (a) At Fuel Injection
(2) Delivery Valve (b) At Suck-Back
(3) Orifice A: Suck-back Stroke
9Y1211018ENM0035US0
1-M19
[3] INJECTION NOZZLE

Since the nozzle is a throttle type, only a small
amount of fuel is injected at the initial stage of injection,
and the amount increases gradually until a full amount is
injected. As a result, combustion starts up more
smoothly with less noise. Fuel pressurized by the
injection pump pushes up needle valve (7), and as a
result, fuel is injected into the combustion chamber.
The injection pressure is adjusted to opening
pressure values in the table below.
If the pressure drops and adjustment is necessary, a
shim must be inserted between nozzle holder body (1)
and adjustment washer (2). Increases of approximately
980 kPa (10 kgf/cm2, 140 psi) will occur with shim
thicknesses of 0.1 mm (0.004 in.).
As these components are precision-machined like
the nozzle and pump, adequate care must be taken to
prevent entry of water or foreign matter.
(1) Nozzle Holder Body (6) Nozzle Body
(2) Adjustment Washer (7) Needle Valve
(3) Nozzle Spring (8) Combustion Chamber
(4) Push Rod (9) Eye-tube Joint
(5) Retaining Nut (10) Overflow Pipe
9Y1211018ENM0036US0
1-M20
[4] GOVERNOR MECHANISM

(1) Governor Spring
(2) Stop Spring
(3) Crank Gear
(4) Governor Weight
(5) Governor Shaft
(6) Governor Lever
(7) Speed Control Lever
(8) Fuel Limiter
(9) Idling Spring
(10) Control Rack
The governor maintains the constant engine speed and at the same time controls the output. The centrifugal
mechanical governor used in this engine is an all-speed type which controls engine speed at any point between idling
and maximum speed positions.
 At Starting
When the speed control lever (7) is moved in the direction "A", the governor lever (6) is pulled in the direction "C"
by the force the governor spring (1). At this time, the governor weight (4) has no active centrifugal force, since the
engine is not rotating. Thus, the control rack (10) moves to the maximum fuel injection position to facilitate starting of
the engine.
 At Idling
When the speed control lever (7) is set in the idling position, the governor spring (1) is almost relaxed and the
idling spring (9) of small tension alone is at work. This idling spring works in the direction "C" (to increase fuel supply).
To the contrary, the governor weight (4) extends by the centrifugal force in the direction of "E" to push the governor
shaft (5) and in turn move the governor lever (6) in the direction of "D" (to decrease the fuel supply). The engine will
idle in a condition in which the two forces are balanced with each other.
9Y1211018ENM0037US0
1-M21
(1) Governor Spring

(2) Stop Spring
(3) Crank Gear
(4) Governor Weight
(5) Governor Shaft
(6) Governor Lever
(8) Fuel Limiter
(9) Idling Spring
(10) Control Rack
 At Idling to Maximum Speeds

When the engine rotates at idling to maximum speeds, engine rotates at a constant speed at the point where the
governor spring tension and the governor weight's centrifugal force are well balanced. If the load is increased, the
engine speeds down and the centrifugal force of the governor weight (4) becomes smaller, so that the control rack
(10) is moved in the direction C in which fuel is increased to restore the original speed. In this way, the engine speed
is automatically controlled for a constant revolution.
 At Maximum Engine Speed
When the speed control lever (7) is moved in the direction "A", the governor weight (4) is at the maximum
centrifugal force, with the governor lever (6) contacting the fuel limiter (8). As the load becomes large, the speed is
reduced, decreasing the governor lever pushes the fuel limiter (the limiter contains a spring) and moves in the
direction "C". Thus, the control rack (10) is placed at the maximum fuel injection position, producing the maximum
engine output power.
 At Engine Stop
When the speed control lever (7) is moved fully in the direction "B" to the stop position, arm pushes the governor
lever pin to move the governor lever (6) in direction "D", thus the control rack (10) is set to the stop position (No fuel
injection) and the engine stops.
9Y1211018ENM0038US0
Fuel Limiter Apparatus Construction
At starting and maximum power point, the governor
lever (2) of the fuel limiter pushes the pin (3), which
touches the lock screw (4) and stops. As a result, the
control rack (1) moves to the position at which point the
largest amount of fuel is injected.
(1) Control Rack (3) Pin
(2) Governor Lever (4) Lock Screw
9Y1211018ENM0039US0
1-M22
[5] FUEL FILTER

Each moving part of the injection pump and nozzle is
extremely precision machined, and clearances of their
sliding parts are extremely small. Fuel itself serves as
lubricating oil. For this reason, it is extremely important
to completely remove water and dirt contained in fuel.
This fuel filter, which uses very fine filter paper,
serves to separate and filter dirt in fuel and water
accumulated in the tank.
After passing through the filter element (6) from
outside to the center of the filter, the fuel flows to the
injection pump from the fuel outlet port (1).
When the filter element (6) is replaced, or the pipe is
removed, or air enters together with fuel, air is
automatically bled from the air vent port (2), (3).
(1) Fuel Outlet Port (4) Fuel Inlet
(2) Air Vent Port (5) Fuel Valve
(3) Air Vent Port (6) Fuel Element
9Y1211018ENM0040US0
1-M23
7. ELECTRICAL SYSTEM
[1] GENERAL
EA330-E4-NB1
(1) Battery (option) (5) Fan Dynamo (8) Oil Lamp (11) Glow Lamp Timer
(2) Starter (6) Switch Box (9) Glow Lamp (12) Fuse
(3) Oil Switch (option) (7) Starter Switch (10) Regulator
(4) Glow Plug
Color of Wiring
Bl...................................Black Ye ................................ Yellow Re ................................Red
Blu.................................Blue Bl / Wh ......................... Black / White Bl / Re ..........................Black / Red
Re / Wh ........................Red / White Gr ................................ Green
9Y1211018ENM0041US0
1-M24
The electrical system of this engine comes equipped
with the starter, glow plug, fan dynamo and switch box as
standard.
The fan dynamo is a single-phase alternating current
generator built in the radiator fan. The rectifier rectifies
the single-phase alternating current. When the rectified
current voltage is higher than the battery voltage, the
battery is charged. When the battery is charged and its
voltage exceeds approximately 14 V, the zener diode of
the current limiter conduct, causing the thyristor to
conduct. Thus, current generated at the dynamo is
grounded directly through the thyristor, preventing
overcharge.
Recommendation battery changing
28 to 32 Ah
capability
NOTE
• The thick line indicates a circuit normally live
with 12 V.
9Y1211018ENM0042US0
[2] FAN DYNAMO

The fan dynamo generates a single-phase
alternating current as the permanent magnet (2) which is
an integral part of the fan (1) rotates outside the dynamo
coil (3) which is fixed.
Power Generating Performance
EA330-E4-NB1 13V 1.6 to 2.6 A
EA330-E4-NB1-APU-1 (Fan speed: 6950 min-1 (rpm))
(1) Fan (3) Fan Dynamo

(2) Permanent Magnet
9Y1211018ENM0043US0
1-M25
[3] STARTER
(1) Drive End Frame (6) Bushing (11) Brush Spring (16) End Frame Cap
(2) Drive Lever (7) Collar (12) Bushing (17) Yoke
(3) Cover (8) Snap Pin (13) Gasket (18) Brush Holder
(4) Magnet Switch (9) Overrunning Clutch (14) Brake Spring (19) End Frame
(5) Plug (10) Armature (15) Brake Shoe
9Y1211018ENM0044US0
1-M26
1) Starting Motor
The starting motor converts the electrical energy into
rotary mechanical energy to crank the engine, and is
composed of an armature, commutator, field coil,
brushes and others.
(1) Armature Shaft [A] Armature Construction
(2) Stopper [B] Field Coil and Brush
(3) Coil Constructions
(4) Slot Insulator [C] Motor Circuit
(5) Armature Core
(6) Hemp String
(7) Commutator
(8) Rubber Bushing
(9) Cotton Tape
(10) Flat Wire
(11) Yoke
(12) Brush
(13) Pole Core
(14) Armature
9Y1211018ENM0045US0
1-M27
2) Overrunning Clutch
The overrunning clutch prevents the armature from
being driven by the rotational force of the engine when
the pinion and the engine flywheel ring gear are in mesh.
1. When power is transmitted, the rotational force of the
outer clutch gear (1) drives the pinion gear (6)
through the roller (2).
2. Even when the pinion gear is driven by the engine
flywheel ring gear and its speed exceeds that of the
outer clutch gear, the rotation force of the ring gear
is not transmitted to the outer clutch gear.
(1) Outer Clutch Gear [A] Overrunning Clutch
(2) Roller Operation
(3) Roller Spring [B] Overrunning Clutch
(4) Inner Spline Tube Construction
(5) Pinion Shaft, Solid with (a) When Power is
Pinion Gear Transmitted
(6) Pinion Gear (b) Idling Rotation with Shaft
(7) Locked Position Speed Exceeding That of
(8) Clutch Cover Outer Clutch
9Y1211018ENM0046US0
3) Armature Brake
The armature brake stops armature rotation
immediately after the starter switch is turned off.
(1) Overrunning Clutch (7) Brush
(2) Brake Spring (8) Washer
(3) Armature (9) Brake Spring
(4) Yoke (10) End Frame
(5) Brush Spring (11) Field Coil
(6) Brush Holder
9Y1211018ENM0047US0
1-M28
4) Magnet Switch
The magnet switch serves as a relay to drive the
armature. It consists of a pull-in coil, a holding coil and a
plunger. It works as follows.
1. When the starter switch is set to START position, the
armature is rotated at a small amperage as the
pull-in coil (9) and the holding coil (7) attract the
plunger (6) to the left.
2. When the main circuit from the contact plate (11) to
armature is closed by the plunger (6), the armature
starts rotating at a strong torque.
At the same time, a current stops flowing into the
pull-in coil and the plunger is kept attracted by the
holding coil alone.
3. When the starter switch is released after starting the
engine, the flow of a current to the holding coil also
stops. Thus, the armature stops rotating.
(1) Joint [A] Magnet Switch
(2) Switch Housing Construction
(3) Return Spring [B] Pull-in and Holding Coil
(4) Magnetic Cover
(5) Switch Cover
(6) Plunger
(7) Holding Coil
(8) Plunger Shaft
(9) Pull-in Coil
(10) Spring
(11) Contact Plate
9Y1211018ENM0048US0
1-M29
5) Operation of Starter
 When Starter Switch is Turned to START
Position
Current from the battery flows through the pull-in coil
and holding coil, producing the magnetism in the
windings to pull the plunger in.
At this time, the drive lever moves the pinion to
engage with the ring gear.
(1) Drive Lever A: Operated by Lever
(2) Contact Plate PC: Pull-in Coil
(3) Commutator HC: Holding Coil
(4) Screw S: Switch
(5) Armature
(6) Pole Core
(7) Return Spring
(8) Battery
(9) Ground
(10) Pinion
(11) Ring Gear
(12) Spline Tube
 When Contact Plate is Closed

Large current flows through the motor section to
operate the motor.
At this time, the pinion is moved forward by the screw
for more contact.
Since the pull-in coil ends are short-circuit by the
contact plate, the plunger is held only by the magnetism
of the holding coil.
 When Starter Switch is Released

Current flows instantaneously through the pull-in coil
the opposite direction as shown in figure. Therefore, the
magnetic field is collapsed immediately.
As a result, the plunger is returned by the return
spring. Simultaneously, the pinion is disengaged from
the ring gear, the contact plate is disconnected, and the
starter is immediately stopped by the armature brake.
9Y1211018ENM0049US0
1-M30
[4] GLOW PLUG

The glow plug is used for pre-combustion chamber
of the cylinder head to make starting easier. The glow
plug is quick-heating type, which makes starting easier
with short pre-hearing time
9Y1211018ENM0050US0
1-M31
SERVICING
CONTENTS
1. TROUBLESHOOTING.................................................................................................................1-S1
2. SERVICING SPECIFICATIONS ..................................................................................................1-S5
3. TIGHTENING TORQUES..........................................................................................................1-S11
[1] TIGHTENING TORQUES FOR SPECIAL USE SCREWS, BOLTS AND NUTS.................1-S11
[2] TIGHTENING TORQUES FOR GENERAL USE SCREWS, BOLTS AND NUTS...............1-S12
4. CHECKING, DISASSEMBLING AND SERVICING ...................................................................1-S13
[1] CHECKING AND ADJUSTING............................................................................................1-S13
(1) Engine Body ..................................................................................................................1-S13
(2) Lubricating System ........................................................................................................1-S16
(3) Cooling System .............................................................................................................1-S17
(4) Fuel System...................................................................................................................1-S19
(5) Electrical System ...........................................................................................................1-S22
[2] DISASSEMBLING AND ASSEMBLING ..............................................................................1-S23
(1) Draining Coolant and Oil ...............................................................................................1-S23
(2) External Components ....................................................................................................1-S23
(3) Cylinder Head................................................................................................................1-S26
(4) Gear Case .....................................................................................................................1-S30
(5) Piston and Connecting Rod...........................................................................................1-S35
(6) Flywheel and Crankshaft ...............................................................................................1-S38
(7) Starter............................................................................................................................1-S42
[3] SERVICING .........................................................................................................................1-S44
(1) Cylinder Head and Valves .............................................................................................1-S44
(2) Piston and Connecting Rod...........................................................................................1-S50
(3) Crankshaft .....................................................................................................................1-S53
(4) Timing Gear and Camshaft ...........................................................................................1-S55
(5) Cylinder Liner ................................................................................................................1-S59
(6) Oil Pump........................................................................................................................1-S60
(7) Starter............................................................................................................................1-S61

1. TROUBLESHOOTING
Reference
Symptom Probable Cause Solution
Page
Engine Does Not No fuel Replenish fuel –
Start Air in the fuel system Vent air –
Water in the fuel system Replace fuel and G-9, 1-M16
repair or replace fuel
system
Fuel hose clogged Clean –
Fuel filter clogged Clean G-9
Excessively high viscosity of fuel or engine oil at Use specified fuel or I-4, G-6
low temperature engine oil
Fuel with low cetane number Use the specified fuel I-4, G-6
Fuel leak due to loose injection pipe retaining nut Tighten nut 1-S26
Incorrect injection timing Adjust 1-S19
Fuel camshaft worn Replace 1-S32
Injection nozzle clogged Clean 1-S21,
1-S27
Injection pump malfunctioning Replace 1-S19,
1-S20,
1-S31
Seizure of crankshaft, camshaft, piston, cylinder Repair or replace –
liner or bearing
Compression leak Replace head gasket, 1-S13,
tighten cylinder head 1-S27,
screw, glow plug, 1-S28,
nozzle holder and 1-S29,
correct valve seat 1-S46
Deficient compression Check top clearance, 1-S13,
correct valve 1-S15,
recessing, piston ring 1-S45,
and cylinder 1-S46,
1-S52,
1-S59
Improper valve seat alignment, valve spring Repair or replace 1-S29,
broken, valve seized 1-S45,
1-S46
Improper valve timing Correct or replace 1-M5,
timing gear 1-S33
Piston ring and cylinder worn Replace 1-S52,
1-S59
Excessive valve clearance Adjust 1-S14
1-S1
Reference
Page
Starter Does Not Run Battery discharged Charge –
Starter malfunctioning Repair or replace 1-S22,
1-S42,
1-S61,
1-S62,
1-S63,
1-S64
Starter switches malfunctioning Replace –
Wiring disconnected Connect 1-M24
Engine Revolution Is Fuel filter clogged or dirt Clean or replace G-9
Not Smooth Air cleaner clogged Clean or replace G-8
Fuel leak due to loose injection pipe retaining nut Tighten nut 1-S26
Injection pump malfunctioning Replace 1-S19,
1-S31
Incorrect nozzle opening pressure Adjust 1-S21,
1-S27
Injection nozzle stuck or clogged Repair or replace 1-S21,
1-S27
Fuel over flow hose clogged Clean –
Governor malfunctioning Repair 1-S33
Either White or Blue Excessive engine oil Reduce to the G-7
Exhaust Gas Is specified level
Observed Piston ring and liner worn or stuck Repair or replace 1-S52,
1-S59
Deficient compression Check top clearance, 1-S13,
correct valve 1-S15,
recessing, piston ring 1-S45,
and cylinder 1-S46,
1-S52,
1-S59
Either Black or Dark Overload Lessen the load –
Gray Exhaust Gas Is Low grade fuel used Use the specified fuel I-4, G-6
Observed
Fuel filter clogged Replace G-9
Air cleaner clogged Clean or replace G-8
Deficient Output Incorrect injection timing Adjust 1-S19
Engine's moving parts seem to be seizing Repair or replace –
Deficient nozzle injection Repair or replace the 1-S21,
nozzle 1-S27
Compression leak Replace head gasket, 1-S13,
tighten cylinder head 1-S27,
screw, glow plug, 1-S28,
nozzle holder and 1-S29,
correct valve seat 1-S46
1-S2
Reference
Page
Excessive Lubricant Piston ring's gap facing the same direction Shift ring gap 1-S36
Oil Consumption direction
Oil ring worn or stuck Replace 1-S37,
1-S52
Piston ring groove worn Replace the piston 1-S52
Valve stem and valve guide worn Replace 1-S46,
1-S47
Crank pin bearing worn Replace 1-S35,
1-S53
Oil leak Repair –
Fuel Mixed into Injection pump's plunger worn Replace injection 1-S19,
Lubricant Oil pump assembly 1-S31
Injection pump broken Replace 1-S19,
1-S31
Water Mixed into Head gasket defective Replace 1-S28
Lubricant Oil Cylinder block or cylinder head flawed Replace 1-S44
Low Oil Pressure Engine oil insufficient Replenish G-7
(Engine oil pressure) Oil strainer clogged Clean G-8
Relief valve stuck with dirt Clean 1-M10,
1-M11
Relief valve spring weaken or broken Replace 1-M10,
1-M11
Excessive oil clearance of oil filler ring Replace 1-S38,
1-S54
Excessive oil clearance of crank pin bearing Replace 1-S35,
1-S53
Excessive oil clearance of rocker arm bushing Replace 1-S28,
1-S48
Oil passage clogged Clean 1-M10
Different type of oil Use the specified type I-4, G-6
of oil
Oil pump defective Repair or replace 1-S31,
1-S60
High Oil Pressure Different types of oil Use specified type of I-4, G-6
(Engine oil pressure) oil
Relief valve defective Replace 1-M10,
1-M11
1-S3
Reference
Page
Engine Overheated Engine oil insufficient Replenish G-7
Fan belt broken or tensioned improperly Replace or adjust 1-S17
Coolant insufficient Replenish G-7
Radiator net and radiator fin clogged with dust Clean G-7
Inside of radiator corroded Clean or replace 1-S25
Coolant flow route corroded Clean or replace 1-M13
Radiator cap defective Replace 1-S18
Overload running Loosen the load –
Head gasket defective Replace 1-S28
Unsuitable fuel used Use specified fuel I-4, G-6
Battery Quickly Battery fluid insufficient Replenish distilled –
Discharge (NB type) water and charge
Fan belt slips Adjust belt tension or 1-S17
replace
Wiring defective Correct 1-M24
Fan dynamo defective Replace 1-M25,
1-S22,
1-S24
Battery defective Replace –
Glow Plug Indicator Glow plug defective Replace 1-M24,
Heats too Slowly or 1-S22,
Does Not Heat 1-S24
(EA330-NB1) Wiring improper Check and correctly 1-M24
connect
Glow plug indicator defective Replace –
Battery discharged or defective Charge or replace –
Glow Plug Indicator Glow plug or glow plug indicator short-circuited Repair or replace 1-M24
Heats too Quickly or wiring between them short-circuit
9Y1211018ENS0001US0
1-S4
2. SERVICING SPECIFICATIONS
ENGINE BODY
Item Factory Specification Allowable Limit
Cylinder head surface Flatness – 0.05 mm / 100 mm
0.002 in. / 3.94 in.
Top Clearance 0.60 to 0.80 mm –
0.024 to 0.031 in.
Compression Pressure 3.48 MPa 2.60 MPa
35.5 kgf/cm2 26.5 kgf/cm2
505 psi 377 psi
Decompression Device 0.940 to 1.31 mm –
0.0370 to 0.0515 in.
Valve Clearance (Cold) 0.16 to 0.20 mm –
0.0063 to 0.0078 in.
Valve Face Angle 0.786 to 0.794 rad –
45.0 to 45.5 °
Valve Seat Angle 0.785 rad –
45.0 °
Valve Seat Width 2.1 mm –
0.083 in.
Valve Recessing 0.80 to 0.90 mm 1.5 mm
0.032 to 0.035 in. 0.059 in.
Valve Stem and Valve Guide Oil Clearance 0.035 to 0.065 mm 0.1 mm
0.0014 to 0.0025 in. 0.004 in.
• Valve Stem O.D. 6.960 to 6.975 mm –

0.2741 to 0.2746 in.
• Valve Guide Bore I.D. 7.010 to 7.025 mm –

0.2760 to 0.2765 in.
Intake Valve Open 0.35 rad –
20 ° before T.D.C.
Close 0.79 rad –

45 ° after B.D.C.
Exhaust Valve Open 0.87 rad –
50 ° before B.D.C.
Close 0.26 rad –

15 ° after T.D.C.
Valve Spring Free Length 34.5 mm 33.8 mm
1.36 in. 1.33 in.
Valve Spring Setting Load / Setting Length 59 N / 31 mm 49 N / 31 mm
6.0 kgf / 31 mm 5.0 kgf / 31 mm
13 lbf / 1.2 in. 11 lbf / 1.2 in.
Valve Spring Tilt – 1.2 mm
0.047 in.
1-S5

Rocker Arm shaft and Rocker Arm I.D. Oil Clearance 0.016 to 0.045 mm 0.15 mm
0.00063 to 0.0017 0.0059 in.
• Rocker Arm Shaft O.D. 10.973 to 10.984 mm

0.43201 to 0.43244 in. –
• Rocker Arm I.D. 11.000 to 11.018 mm

0.43307 to 0.43377 in. –
Tappet and Guide Oil Clearance 0.020 to 0.062 mm 0.15 mm

0.00079 to 0.0024 in. 0.0059 in.
• Tappet O.D. 19.959 to 19.980 mm –

0.78579 to 0.78661 in.
• Tappet Guide Bore I.D. 20.000 to 20.021 mm –

0.78741 to 0.78822 in.
Push Rod Alignment – 0.125 mm
0.00492 in.
Piston Skirt O.D. 76.925 to 76.945 mm Liner I.D.
3.0286 to 3.0293 in. 0.25 mm
0.0098 in.
Piston Pin Bore I.D. 20.000 to 20.013 mm 20.04 mm
0.78741 to 0.78791 in. 0.7890 in.
Clearance between Ring Groove and Ring Top Ring – –
Second Ring 0.0850 to 0.112 mm 0.2 mm

0.00335 to 0.00440 in. 0.008 in.
Oil Ring 0.020 to 0.055 mm 0.15 mm

0.00079 to 0.0021 in. 0.0059 in.
Ring Gap Top Ring 0.30 to 0.45 mm 1.2 mm
0.012 to 0.017 in. 0.047 in.
Second Ring 0.30 to 0.45 mm 1.2 mm

0.012 to 0.017 in. 0.047 in.
Oil Ring 0.25 to 0.40 mm 1.2 mm

0.0099 to 0.015 in. 0.047 in.
Connecting Rod Alignment – 0.05 mm / 100 mm
0.002 in. / 3.94 in.
Piston Pin and Bushing Oil Clearance 0.014 to 0.038 mm 0.15 mm
0.00056 to 0.0014 in. 0.0059 in.
• Piston Pin O.D. 20.002 to 20.011 mm –

0.78748 to 0.78783 in.
• Piston Pin Bushing I.D. 20.025 to 20.040 mm –

0.78839 to 0.78897 in.
Crankshaft Alignment – 0.04 mm
0.002 in.
1-S6

Crankshaft and Oil Filler Ring Oil Clearance 0.025 to 0.066 mm 0.2 mm
0.00099 to 0.0025 in. 0.008 in.
• Crankshaft O.D. 34.959 to 34.975 mm –

1.3764 to 1.3769 in.
• Oil Filler Ring I.D. 35.000 to 35.025 mm –

1.3780 to 1.3789 in.
Crank Pin and Bearing Oil Clearance 0.019 to 0.077 mm 0.2 mm
0.00075 to 0.0030 in. 0.008 in.
• Crank Pin O.D. 36.959 to 36.975 mm –

1.4551 to 1.4557 in.
• Crank Pin Bearing I.D. 36.994 to 37.036 mm –

1.4565 to 1.4581 in.
Crankshaft Side Clearance 0.050 to 0.46 mm 0.56 mm
0.0020 to 0.018 in. 0.022 in.
Timing Gear Backlash Barancer Gear 1 × 0.0490 to 0.135 mm 0.3 mm
Barancer Gear 2 0.00193 to 0.00531 in. 0.01 in.
0.0430 to 0.130 mm –
Other Gears 0.00170 to 0.00511 in.
Idle Gear Side Clearance 0.20 to 0.51 mm 0.9 mm
0.0079 to 0.020 in. 0.04 in.
Idle Gear Shaft and Idle Gear Bushing Oil Clearance 0.016 to 0.045 mm 0.1 mm
0.00063 to 0.0017 in. 0.004 in.
• Idle Gear Shaft O.D. 17.973 to 17.984 mm –

0.70760 to 0.70803 in.
• Idle Gear Bushing I.D. 18.000 to 18.018 mm –

0.70867 to 0.70937 in.
Camshaft Alignment – 0.08 mm
0.003 in.
Cam Height (IN, EX) 27.0 mm 26.5 mm
1.06 in. 1.04 in.
Camshaft (Flywheel Side) Oil Clearance 0.020 to 0.054 mm 0.25 mm
0.00079 to 0.0021 in. 0.0098 in.
• Camshaft Journal O.D. 21.967 to 21.980 mm –

0.86485 to 0.86535 in.
• Camshaft Bore I.D. 22.000 to 22.021 mm –

0.86615 to 0.86696 in.
Camshaft (Gear Side) Oil Clearance 0.025 to 0.066 mm 0.1 mm

0.00099 to 0.0025 in. 0.004 in.
• Camshaft Journal O.D. 32.959 to 32.975 mm –

1.2976 to 1.2982 in.
• Camshaft Bore I.D. 33.000 to 33.025 mm –

1.2993 to 1.3001 in.
1-S7

Cam Gear Side Clearance 0.0700 to 0.220 mm 0.3 mm
0.00276 to 0.00866 in. 0.01 in.
Cylinder Liner I.D. 75.000 to 75.019 mm +0.25 mm
2.9528 to 2.9535 in. +0.0098 in.
Projection of Cylinder Liner 0.030 to 0.13 mm –
0.0012 to 0.0051 in.
1-S8
LUBRICATING SYSTEM
Engine Oil Pressure At Idle Speed 50 kPa –
0.5 kgf/cm2
7 psi or more
At Rated Speed 250 kPa 200 kPa
(Engine Speed) 2.5 kgf/cm2 2.0 kgf/cm2
36 psi or more 28 psi
(3000 rpm) (3000 rpm)
Inner Rotor to Outer Rotor Clearance 0.15 mm or less 0.20 mm
0.0059 in. or less 0.0079 in.
Outer Rotor to Pump Body Clearance 0.0900 to 0.171 mm 0.24 mm
0.00355 to 0.00673 in. 0.0094 in.
Inner Rotor to Cover Clearance 0.02 to 0.06 mm 0.25 mm
0.0008 to 0.002 in. 0.0098 in.
Relief Pressure 200 to 390 kPa –
2.0 to 4.0 kgf/cm2
29 to 56 psi
COOLING SYSTEM
Fan Belt Tension 5.0 to 10 mm / 98 N –
0.20 to 0.39 in.
(10 kgf, 22 Ibs)
Radiator Water Tightness No leak at –
190 kPa
1.9 kgf/cm2
27 psi
Radiator Cap Air Leakage 10 seconds or more –
110 → 80 kPa
1.1 → 0.8 kgf/cm2
16 → 10 psi
FUEL SYSTEM
Injection Timing (Static) 0.4320 to 0.4581 rad –
(24.75 to 26.25 °)
before T.D.C.
Fuel Tightness of Pump Element – 13.73 MPa
140.0 kgf/cm2
1991 psi
Fuel Tightness of Delivery Valve 10 seconds 5 seconds
13.73 → 12.75 MPa 13.73 → 12.75 MPa
140.0 → 130.0 kgf/cm2 140.0 →
1991 → 1849 psi 130.0 kgf/cm2
1991 → 1849 psi
Fuel Injection Pressure 13.73 to 14.70 MPa –
140.0 to 150.0 kgf/cm2
1992 to 2133 psi
Fuel Tightness of Nozzle Valve Seat 12.75 to 13.72 MPa –
130.0 to 140.0 kgf/cm2
1849 to 1991 psi
1-S9
ELECTRICAL SYSTEM
-1
Power Generation Performance Fan Speed 6900 min (rpm) –
[Fan Dynamo:
(EA330-E4-NB1, EA330-E4-NB1-APU-1)] Voltage Approx. 13 V –
Current 1.6 to 2.6 A –

Glow Plug Resistance Approx. 0.9 V –
(at cold occasion)
Starter Commutator O.D. 28.0 mm 27.0 mm
1.10 in. 1.06 in.
Starter Mica Undercut 0.5 to 0.8 mm 0.2 mm
0.02 to 0.03 in. 0.008 in.
Starter Brush Length 16.0 mm 10.5 mm
0.630 in. 0.413 in.
9Y1211018ENS0002US0
1-S10
3. TIGHTENING TORQUES
[1] TIGHTENING TORQUES FOR SPECIAL USE SCREWS, BOLTS
AND NUTS
Screw, bolts and nuts must be tightened to the specified torque using a torque wrench.
Several bolts and nuts such as ones used on the cylinder head must be tightened in proper sequence and to the
proper torque.
Item Size × Pitch N·m kgf·m lbf·ft
Cylinder head (Stud) M9 × 1.25 25 to 29 2.5 to 3.0 18 to 21
**Cylinder head (Nut) M9 × 1.25 57 to 61 5.8 to 6.3 42 to 45
**Connecting rod screw M7 × 0.75 27 to 30 2.7 to 3.1 20 to 22
**Flywheel nut M20 × 1.5 197 to 215 20.0 to 22.0 145 to 159
Main bearing case mounting screw /
M6 × 1.0 9.81 to 11.2 1.00 to 1.15 7.24 to 8.31
nut
Crankcase cover mounting screw M6 × 1.0 7.9 to 9.3 0.80 to 0.95 5.8 to 6.8
Gear case mounting screw M6 × 1.0 9.81 to 11.2 1.00 to 1.15 7.24 to 8.31
Idle gear shaft screw M6 × 1.0 9.81 to 11.2 1.00 to 1.15 7.24 to 8.31
Head cover mounting nut M7 × 1.0 9.8 to 10 1.0 to 1.1 7.3 to 7.9
**Rocker arm bracket mounting nut M7 × 1.0 17 to 20 1.7 to 2.1 13 to 15
Oil signal holder PT 1/8 15 to 19 1.5 to 2.0 11 to 14
Oil signal / Oil Switch PT 1/8 6.9 to 9.8 0.70 to 1.0 5.1 to 7.2
Oil strainer M20 ×x 1.5 25 to 34 2.5 to 3.5 18 to 25
Injection pump mounting screw M6 × 1.0 9.81 to 11.2 1.00 to 1.15 7.24 to 8.31
Nozzle holder Assembly M20 × 1.5 49 to 68 5.0 to 7.0 37 to 50
Nozzle holder – 35 to 39 3.5 to 4.0 26 to 28
Over flow eye joint pipe mounting nut M12 × 1.5 20 to 24 2.0 to 2.5 15 to 18
Muffler mounting nut M8 × 1.25 24 to 27 2.4 to 2.8 18 to 20
Tension pulley pivot screw M8 × 1.25 20 to 23 2.0 to 2.4 15 to 17
Injection pipe retaining nut M12 × 1.5 25 to 34 2.5 to 3.5 18 to 25
Injection pump eye joint bolt M12 × 1.5 25 to 29 2.5 to 3.0 18 to 21
Glow plug M8 × 1.0 7.9 to 14 0.80 to 1.5 5.8 to 10
Glow plug terminal nut M4 × 0.7 0.98 to 1.7 0.10 to 0.18 0.73 to 1.3
Radiator mounting screw / nut M6 × 1.0 5.9 to 7.8 0.60 to 0.80 4.4 to 5.7
NOTE
• For "**" marked screws and nuts on the table, apply engine oil to their threads and seats before
tightening.
9Y1211018ENS0003US0
1-S11
[2] TIGHTENING TORQUES FOR GENERAL USE SCREWS, BOLTS

AND NUTS
If the tightening torque is not specified, refer to the table below for the none specified torques values.
Indication on
top of bolt No-grade or 4T 7T
Indication on
top of nut No-grade or 4T
Unit N·m kgf·m lbf·ft N·m kgf·m lbf·ft

M6 7.9 to 9.3 0.80 to 0.95 5.8 to 6.8 9.81 to 11.2 1.00 to 1.15 7.24 to 8.31
M8 18 to 20 1.8 to 2.1 13 to 15 24 to 27 2.4 to 2.8 18 to 20
M10 40 to 45 4.0 to 4.6 29 to 33 49 to 55 5.0 to 5.7 37 to 41
M12 63 to 72 6.4 to 7.4 47 to 53 78 to 90 7.9 to 9.2 58 to 66
9Y1211018ENS0004US0
1-S12
4. CHECKING, DISASSEMBLING AND SERVICING

[1] CHECKING AND ADJUSTING
(1) Engine Body
Compression Pressure
1. Run the engine until warm up.
2. Stop the engine and remove the air cleaner and nozzle holder.
3. Attach a compression tester (Code No. 07909-30204) to the
adapter B or H.
4. After making sure that the speed control lever (1) is set at the
stop position (Non-injection), run the flywheel at 320 to
440 min-1 (rpm) with starter and read constant maximum on the
tester. Execute the test at least twice. (Run the engine the for 5
to 10 seconds for each test.)
NOTE
• Measure specific gravity of the battery electrolyte and
ensure that the battery is fully charged.
• Compression occurs every second approximately when
the engine speed is 320 to 440 min-1 (rpm). Try to learn this
"feeling" and ensure that the engine is running at this
speed range when measuring compression.
5. If the pressure does not reach the allowable limit, apply a small
amount of oil to the cylinder wall through the nozzle holder hole
and measure the pressure again.
6. If the pressure raises after applying oil, check the cylinder wall
and piston rings.
7. If the pressure is still low, check the top clearance, valve
clearance, cylinder head and piston rings.
3.48 MPa
Factory specification 35.5 kgf/cm2
505 psi
Compression Pressure
2.60 MPa
Allowable limit 26.5 kgf/cm2
377 psi

9Y1211018ENS0005US0
Decompression Device
1. Align the T mark on the flywheel to the mark on the fan cover at
the top dead center in the compression stroke.
2. Remove the decompression cover from the cylinder head cover.
3. Pull the decompression lever (1) to the operating position.
4. Loosen the lock nut (3) and screw (2) until it contacts the rocker
arm (4).
5. From the position where the adjusting screw contacts the rocker
arm, further screw in the adjusting screw by one and a half turns
(9.42 ± 1.56 rad, 540 ± 90 °).
6. Tighten the lock nut.
7. After adjustment, make sure that the piston does not push up
the valve when slightly turning the flywheel with the
decompression lever.
0.940 to 1.31 mm
Decompression device Factory specification
0.0370 to 0.0515 in.
(Adjusting screw pitch: 0.75 mm (0.030 in.))
(1) Decompression Lever (3) Lock Nut

(2) Decompression Adjusting Screw (4) Rocker Arm
9Y1211018ENS0006US0
1-S13
Valve Clearance
IMPORTANT
• The valve clearance must be inspected and adjusted as
needed when the engine is cold (equal to the atmospheric
air temperature).
1. Remove the cylinder head cover.
2. Align the T mark (1) on the flywheel with the fan cover mark (2)
at the top dead center in the compression stroke.
3. Measure the valve clearance using a thickness gauge.
4. If the clearance is not within the factory specifications, adjust
with the adjusting screw.
5. After tightening the lock nut and turning the flywheel twice or
three times counterclockwise, recheck the valve clearance.
0.16 to 0.20 mm
Valve clearance (Cold) Factory specification
0.0063 to 0.0078 in.
(1) T Mark (3) Valve Clearance

(2) Fan Cover Mark
9Y1211018ENS0007US0
1-S14
Top Clearance
1. Tighten the cylinder head to the specified torque (57 to 61 N·m,
5.8 to 6.3 kgf·m, 42 to 45 lbf·ft).
2. Remove the nozzle holder.
3. Set the piston to the bottom dead center and insert a
high-quality fuse through the nozzle holder hole. (Use care so
that the fuse does not contact the valve head.).
4. Turn the piston slowly with the flywheel until it passes the top
dead center.
5. Pull out the fuse slowly without letting it drop.
6. Measure the top clearance three times, each with a new fuse
positioned in different directions.
7. Measure the thickness of the crushed fuse with a vernier
caliper.
(Reference)
• The top clearance (A) can be determined also from the amount
of projection (C) above the liner.
[Top clearance (A) = (B) - (C)]
Head gasket thickness 0.950 to 1.05 mm
Tightened
(B) 0.0374 to 0.0413 in.
8. If the clearance is not within the factory specifications, check
and correct the oil clearance at the crank pin, oil filler ring and
piston pin.
0.60 to 0.80 mm
Top clearance Factory specification
0.024 to 0.031 in.
(1) Cylinder Head (A) Top Clearance

(2) Head Gasket (B) Head Gasket Thickness
(3) Cylinder Block (C) Amount of Projection
(4) Piston
(5) Cylinder Liner
9Y1211018ENS0008US0
1-S15
(2) Lubricating System

Engine Oil Pressure
1. Remove the oil signal (or oil switch) and install an oil pressure
tester (Code No. 07916-32031) (Adaptor screw size: PT 1/8).
2. Start the engine. After warming up, measure the oil pressure of
both idling and rated speeds.
3. If the oil pressure is less than the allowable limit, check the
following.
• Engine oil insufficient
• Oil pump defective
• Oil strainer clogged
• Excessive oil clearance of bearing
• Foreign matter in the relief valve
• Oil gallery clogged
More than
50 kPa
At idle speed
0.5 kgf/cm2
Engine oil pressure 7 psi
250 kPa
At rated speed
2.5 kgf/cm2
(3000 min-1 (rpm))
36 psi
* When engine oil is 100 to 120 °C (212 to 248 °F)
(When installing)
6.9 to 9.8 N·m
Oil signal /Oil Switch 0.70 to 1.0 kgf·m
5.1 to 7.2 lbf·ft
Tightening torque
15 to 19 N·m
Oil signal holder 1.5 to 2.0 kgf·m
11 to 14 lbf·ft
NOTE
• Check for oil leakage after installing the oil signal (or oil
switch).
9Y1211018ENS0009US0
1-S16
(3) Cooling System

Fan Belt Tension
1. Check to see the belt tension allows a depression of the
specified amount when the belt is pressed down by a finger
midway between the cooling fan pulley (2) and tension pulley
(5).
2. Adjust the tension by the tension bolt (6).
5.0 to 10 mm
Fan belt tension Factory specification
0.20 to 0.39 in.
Size of fan belt FM 32.5
* The FM type refers to a low edge plain type, which is a van

rope for general fans having a upper canvas width of 11.0 mm
(0.433 in.) and a height of 8.0 mm (0.31 in.).
NOTE
• Whenever a new fan belt is installed, provide a tension
somewhat higher than specified, and adjust it as specified
after running the fan for some time.
(1) Fan Drive Pulley (4) Force of 98 N (10 kgf, 22 lbf)
(2) Fan Pulley (5) Tension Pulley
(3) Tension (6) Tension Bolt
9Y1211018ENS0010US0
Fan Belt Damage and Wear
1. Check the fan belt for wear.
2. Check if the fan belt is worn and sunk in the pulley groove.
3. Replace the fan belt if the belt is nearly worn out or deeply sunk
in the pulley groove.
(1) Defective Belt
9Y1211018ENS0011US0
Radiator Water Tightness

1. Fill the radiator with water to the specified amount and warm up
the engine.
2. Set a radiator tester and raise the water pressure to the
specified pressure.
3. Check the radiator for water leaks.
4. For water leak from the pin hole, repair with the radiator cement,
and for other leaks, replace the radiator.
CAUTION
has cooled.
No leak at
190 kPa
Radiator water tightness Factory specification
1.9 kgf/cm2
27 psi
9Y1211018ENS0012US0
1-S17
Radiator Cap Air Leakage
1. Set a radiator tester on the radiator cap.
2. Apply specified pressure and measure the time for the pressure
to fall.
3. If the measurement is less than the factory specification,
replace the radiator cap.
10 seconds or more
110 kPa (1.1 kgf/cm2,
Radiator cap air leakage Factory specification
16 psi) → 80 kPa
(0.8 kgf/cm2, 10 psi)
9Y1211018ENS0013US0
1-S18
(4) Fuel System

Replacing Injection Pump
1. Remove the injection pump.
2. Remove the tamper proof cap and then remove the fuel limiter.
3. Mount a new injection pump and adjust the injection timing and
the fuel limit position.
A: <How to Adjust the Injection Timing>
1. Mount the injection pump as indicated in the picture.
2. Set the speed adjustment lever to the max revolutions position.
3. Turn the crankshaft using a start handle and make sure fuel is
discharged from the tip of the injection pipe.
4. Turn the flywheel in the counter clockwise direction until the line
mark (timing angle lines (1)) on the outer circumference of the
flywheel nears the fan cover mark (2).
5. From this position, slowly continue to rotate the flywheel in the
counter clockwise direction and stop rotation of the flywheel
when the fuel level at the tip of the injection pipe starts to rise
and check the angle indicated by the fan cover mark (2) at this
point.
6. If injection timing is off, adjust using shims (3) on the mounting
surface of the injection pump.
B: <How to Adjust the Fuel Limit Position>
1. After adjusting injection timing, remove the new injection pump.
2. Reset the fuel limiter using a prescribed jig (Pitak-Q). Refer to
Pitak-Q Workshop Manual (Code No. 9Y120-00110). (Match
the number of shims (3) for after adjusting the injection timing
when mounting the jig.)
3. Mount the new injection pump.
NOTE
• Even if not replacing the injection pump, when checking
the injection timing, first release the fuel limiter and then
readjust the fuel limiter using the procedure indicated in B
above <How to Adjust the Fuel Limit Position>.
0.4320 to 0.4581 rad
Injection timing (static) Factory specification (24.75 to 26.25 °) before
T.D.C.
(Reference)
• If injection timing is advanced → increase the number of shims.
• If injection timing is retarded → decrease the number of shims.
NOTE
• The crank angle changes approximately 1.5 ° for one
0.15 mm shim.
(1) Timing Angle lines (3) Shim
(2) Fan Cover Mark
9Y1211018ENS0014US0
Pump Element Fuel Tightness
1. Remove the injection pipe.
2. Install an injection pump pressure tester to the injection pump.
3. Set the speed control lever to the maximum speed position.
4. Turn the flywheel counterclockwise ten times or more.
5. If the pressure can not reach the allowable limit, replace the
injection pump assembly.
13.73 MPa
Pump element fuel
Allowable limit 140.0 kgf/cm2
tightness
1991 psi
9Y1211018ENS0015US0
1-S19
Delivery Valve Fuel Tightness
1. Remove the injection pipe.
2. Set an injection pump pressure tester to the injection pump.
3. In the same way as to check the pump element fuel tightness,
turn the flywheel counterclockwise ten times or more so that the
pressure is increased to specified pressure (Refer to the table).
4. Set the plunger at the bottom dead center to reduce the delivery
chamber pressure to zero.
5. Measure the fall time for the pressure to drop to the reference
pressure from the specified initial pressure.
6. If the measurement is less than the allowable limit, replace the
injection pump assembly.
(Reference)
• How to set the plunger to the bottom dead center.
Turn the flywheel to clockwise 1.6 rad (90 °) from the injection
timing position. (Align the injection timing line (2) on the flywheel
with the fan cover mark (1).)
10 seconds or more
13.73 → 12.75 MPa
Factory specification
140.0 → 130.0 kgf/cm2
Delivery valve fuel 1991 → 1849 psi
tightness 5 seconds
13.73 → 12.75 MPa
Allowable limit
140.0 → 130.0 kgf/cm2
1991 → 1849 psi
(1) Fan Cover Mark (a) 1.6 rad (90 °)

(2) Timing Line
9Y1211018ENS0016US0
1-S20
CAUTION
• Be careful not to come into direct contact with the injected spray destroys any cells it touches. It may also
cause blood poisoning, etc, Check the injection nozzle after confirming that nobody is standing in the
direction of the spray.
9Y1211018ENS0017US0
Fuel Injection Pressure
1. Set the injection nozzle to a nozzle tester.
2. Measure the injection pressure.
3. If the measurement is not within the factory specifications,
adjust with the adjusting washer inside the nozzle holder.
13.73 to 14.70 MPa
Fuel injection pressure Factory specification 140.0 to 150.0 kgf/cm2
1992 to 2133 psi
(Reference)
• Pressure change per 0.1 mm (0.004 in.) adjusting washer:
Approx. 980 kPa (10 kgf/cm2, 140 psi)
9Y1211018ENS0018US0
Fuel Tightness of Nozzle Valve Seat
1. Apply a pressure 980 kPa (10 kgf/cm2, 140 psi) lower than the
fuel injection pressure.
2. After keeping the nozzle under this pressure for 10 seconds,
check to see if fuel leaks from the nozzle.
3. If fuel should leak, replace the nozzle piece.
12.75 to 13.72 MPa
Fuel tightness of nozzle
Factory specification 130.0 to 140.0 kgf/cm2
valve seat
1849 to 1991 psi
9Y1211018ENS0019US0
Nozzle Spraying Condition

1. Set the nozzle to a nozzle tester and check the nozzle spraying
condition.
2. If the spraying condition is defective, replace the nozzle piece.
(a) Good (b) Bad
9Y1211018ENS0020US0
1-S21
(5) Electrical System

Fan Dynamo
1. Check the continuity among the leads following the table
(1) (2) (3)
(1) Continuity Continuity
2. Check the continuity among the leads following the table
(1) Lead (Red) (3) Lead (Yellow)
(2) Lead (Yellow)
9Y1211018ENS0021US0
Starter
Motor Test
1. Disconnect the ground cable clamp from the battery negative
terminal post.
2. Disconnect the battery positive cable and leads from the starter.
3. Remove the starter from the engine.
4. Disconnect the connecting lead from the starter C terminal.
CAUTION
• Secure the starter in a vise to prevent it from jumping up
and down while testing the motor.
5. Connect a jumper lead from the connecting lead to the battery
positive terminal post.
6. Connect a jumper lead momentarily between the starter
housing and battery negative terminal post.
7. If the motor does not run, check the motor.
(1) Body Earth (2) Connecting Lead
9Y1211018ENS0022US0
Glow Plug
Glow Plug Disconnection / Short-circuit Test
1. Remove the glow plug cord.
2. Measure the resistance between the thread (1) at the glow plug
end and engine body or the resistance between the thread and
housing (2) with an ohmmeter.
3. If the resistance is 0 ohm or infinity, replace the glow plug.
0.9 Ω
Glow plug resistance Factory specification
(Normal temperature)
(1) Thread (2) Housing

9Y1211018ENS0023US0
1-S22
[2] DISASSEMBLING AND ASSEMBLING

(1) Draining Coolant and Oil
Draining Coolant and Engine Oil
CAUTION
has cooled.
1. Open the drain valve (1) to drain coolant.
2. Remove the oil strainer (2) (drain plug) to drain engine oil.
1.2 L
Coolant
0.32 U.S.gals
Specified quantity
1.3 L
Engine oil
0.34 U.S.gals
25 to 34 N·m
Tightening torque Oil strainer (Drain plug) 2.5 to 3.5 kgf·m
18 to 25 lbf·ft
(1) Drain Valve (2) Oil Strainer

9Y1211018ENS0024US0
(2) External Components

Air Cleaner and Muffler
1. Loosen the band to remove the air cleaner (1).
2. Remove the muffler flange cover (3).
3. Remove the muffler (2).
(When reassembling)
• When installing the muffler gasket, face the steel to the muffler
flange.
• When installing the air cleaner, face an air inlet as shown in the
figure.
24 to 27 N·m
Tightening torque Muffler mounting nut 2.4 to 2.8 kgf·m
18 to 20 lbf·ft
(1) Air Cleaner (3) Muffler Flange Cover

(2) Muffler
9Y1211018ENS0025US0
1-S23
Fuel Tank and Filter
1. Close the fuel valve (7) as shown in the photograph.
2. Remove the engine hook (1) and radiator cover (2).
3. Disconnect the overflow hose (3).
4. Remove the eye joint bolt of the injection pump to detach the
fuel hose 2 (4).
5. Remove the fuel filter mounting screw (8).
6. Remove the fuel tank (5), fuel filter and hose as an unit.
7. Remove the radiator net (6).
(When reassembling)
• Lap the overflow hose (3) below the radiator cover (2) as shown
in the photograph.
• Set the hose clamps securely.
25 to 29 N·m
Injection pump eye joint
Tightening torque 2.5 to 3.0 kgf·m
bolt
18 to 21 lbf·ft
(1) Engine Hook (5) Fuel Tank

(2) Radiator Cover (6) Radiator Net
(3) Overflow Hose (7) Fuel Valve
(4) Fuel Hose 2 (8) Fuel Filter Mounting Screw
9Y1211018ENS0026US0
Wire Harness
1. Disconnect the fan leads (1).
(When reassembling)
• The lead wire must be grounded at particular locations as
illustrated.
0.98 to 1.7 N·m
Tightening torque Glow plug terminal nut 0.10 to 0.18 kgf·m
0.73 to 1.3 lbf·ft
(1) Fan Lead

9Y1211018ENS0027US0
Fan Cover and Starter
1. Disconnect the glow plug cord (4).
2. Remove the flywheel cover (2).
3. Remove the fan cover (3).
4. Remove the starter (1), wire harness and battery cable as an
unit.
(1) Starter (3) Fan Cover
(2) Flywheel Cover (4) Glow Plug Cord
9Y1211018ENS0028US0
Cooling Fan
1. Remove the tension pulley (2).
2. Remove the cooling fan assembly (1).
(When reassembling)
• Adjust the fan belt tension to the factory specifications.
(1) Cooling Fan Assembly (2) Tension Pulley
9Y1211018ENS0029US0
1-S24
Radiator
(When reassembling)
• Apply liquid gasket (Three Bond 1102 or equivalent) to the both
sides of radiator gasket (2).
5.9 to 7.8 N·m
Radiator mounting screw /
nut
4.4 to 5.7 lbf·ft
(1) Radiator Assembly (2) Radiator Gasket

9Y1211018ENS0030US0
1-S25
(3) Cylinder Head

(1) Nozzle Holder
(2) Injection Pipe
(3) Decompress Hole Cover
(4) Cylinder Head Cover
(5) Rocker Arm Bushing
(6) Rocker Arm
(7) Rocker Arm Bracket
(8) Valve Cap
(9) Valve Spring Collet
(10) Valve Spring Retainer
(11) Valve Spring
(12) Exhaust Valve Guide
(13) Exhaust Valve
(14) Decompress Shaft
(15) Intake Valve Guide
(16) Cylinder Head
(17) Cylinder Head Gasket
(18) Intake Valve
(19) Drain Valve
(20) Glow Plug
(21) Heat Seal
9Y1211018ENS0031US0
Injection Pipe and Nozzle Holder

1. Remove the injection pipe (3).
2. Remove the nozzle holder assembly (1) with a socket wrench
and remove heat seal and the copper gasket.
3. Remove the glow plug (2).
(When reassembling)
• When reassembling the nozzle holder, take care that no carbon
or dirt gets in.
• Replace the copper gasket and heat seal with a new one.
49 to 68 N·m
Nozzle holder assembly 5.0 to 7.0 kgf·m
37 to 50 lbf·ft
25 to 34 N·m
Tightening torque Injection pipe retaining nut 2.5 to 3.5 kgf·m
18 to 25 lbf·ft
7.9 to 14 N·m
Glow plug 0.80 to 1.5 kgf·m
5.8 to 10 lbf·ft
(1) Nozzle Holder Assembly (3) Injection Pipe

(2) Glow Plug (4) Pipe Clamp Mounting Screw
9Y1211018ENS0032US0
1-S26
Nozzle Heat Seal Service Removal Procedure
IMPORTANT
• Use a plus (phillips head) screw driver that has a Dia. which
is bigger than the heat seal hole (Approx. 6 mm (1/4 in.).
1. Drive screw driver lightly into the heat seal hole.
2. Turn screw driver three or four times each way.
3. While turning the screw driver, slowly pull the heat seal out
together with the injection nozzle gasket.
If the heat seal drops, repeat the above procedure. Heat seal
and injection nozzle gasket must be changed when the injection
nozzle is removed for cleaning or for service.
(1) Plus Screw Driver (3) Injection Nozzle Gasket
(2) Injection Nozzle (4) Heat Seal
9Y1211018ENS0033US0
Nozzle Holder
1. Secure the nozzle retaining nut (7) with a vise.
2. Remove the nozzle holder (1), and take out parts inside.
(When reassembling)
• Assemble the nozzle in clean fuel oil.
• Install the push rod (4), noting its direction.
• After assembling the nozzle, be sure to adjust the fuel injection
pressure.
35 to 39 N·m
Nozzle holder 3.5 to 4.0 kgf·m
26 to 28 lbf·ft
Tightening torque
49 to 68 N·m
Nozzle holder assembly 5.0 to 7.0 kgf·m
37 to 50 lbf·ft
(1) Nozzle Holder (5) Distance Piece

(2) Adjusting Washer (6) Nozzle Piece
(3) Nozzle Spring (7) Nozzle Retaining Nut
(4) Push Rod
9Y1211018ENS0034US0
Cylinder Head Cover
1. Remove the cylinder head cover (1).
(When reassembling)
• After reassembling the head cover, adjust decompression
device.
9.8 to 10 N·m
Tightening torque Head cover mounting nut 1.0 to 1.1 kgf·m
7.3 to 7.9 lbf·ft
(1) Cylinder Head Cover

9Y1211018ENS0035US0
1-S27
Rocker Arm Bracket and Push Rod
1. Remove the rocker arm bracket (1) and rocker arms together.
2. Pull out the push rods (2).
(When reassembling)
• Apply engine oil to the rocker arm bushing bore and nut thread.
• Insert the push rod into groove of tappet securely as shown in
the figure.
• After tightening bracket mounting nut to the specified torque,
check that the rocker arm smoothly.
NOTE
• Do not keep the push rods apart from the rocker arms while
tightening the nut.
IMPORTANT
• The valve clearance must be adjusted after the rocker arm
is installed.
17 to 20 N·m
Rocker arm bracket
mounting nut
13 to 15 lbf·ft
(1) Rocker Arm Bracket (3) Tappet

(2) Push Rod
9Y1211018ENS0036US0
Cylinder Head
1. Remove the screws of tension bolt guide (1).
2. Remove the air cleaner flange (2).
3. Remove the cylinder head.
(When reassembling)
• Replace on the O-ring (3) between cylinder block and cylinder
head with a new one.
• Replace the head gasket with a new one.
• When installing the new head gasket, be careful of the
installation direction.
IMPORTANT
• Gradually tighten the nuts in three passes in the order of (a)
to (f) as shown in the figure. After tuning the engine for
more than 30 minutes, be sure to retighten the head nut.
• The valve clearance must be adjusted after the cylinder
head is installed.
57 to 61 N·m
Tightening torque Cylinder head mounting nut 5.8 to 6.3 kgf·m
42 to 45 lbf·ft
(1) Tension Bolt Guide (3) O-ring

(2) Air Cleaner Flange
9Y1211018ENS0037US0
1-S28
Valve
1. Remove the valve caps (5).
2. Remove the valve spring collets (4) with a valve lifter (6).
3. Remove the valve spring retainers (3), valve springs (2) and
valves (1).
(When reassembling)
• Wash the valve stem and valve guide hole, and apply engine oil
sufficiently.
• After installing the valve spring collets, lightly tap the stem to
assure proper fit with a plastic hammer.
(1) Valve (4) Valve Spring Collet
(2) Valve Spring (5) Valve Cap
(3) Valve Spring Retainer (6) Valve Lifter
9Y1211018ENS0038US0
1-S29
(4) Gear Case
(1) Balancer (6) Idle Gear Shaft (10) Camshaft Stopper (14) Injection Pump Assembly
(2) Balancer Gear 2 (7) Idle Gear (11) Breather Assembly (15) Pump Adjusting Shim
(3) Balancer Gear 1 (8) Camshaft (12) Breather Oil Guard (16) Gear Case
(4) Balancer Gear 3 (9) Camshaft Gear (13) Governor (17) Oil Pump Rotor Assembly
(5) Balancer Bearing Retainer
9Y1211018ENS0039US0
1-S30
Injection Pump
1. Remove the injection pump mounting screws.
2. Move the speed control lever (3) and align the control rack pin
(1) and notch (2) on the gear case to remove the injection pump.
NOTE
• Record the number of injection timing adjusting shims
used to adjust the injection timing.
(When reassembling)
• Apply a thin coat of liquid gasket (Three bond 1215 or
equivalent) to the shim.
IMPORTANT
• Insert the same number of shims as used before, install the
pump and then check the injection timing.
• Correctly fit the control rack pin (1) into the groove of the
governor lever (4).
9.81 to 11.2 N·m
Injection pump mounting
screw
7.24 to 8.31 lbf·ft
(1) Control Rack Pin (3) Speed Control Lever

(2) Notch (4) Governor Lever
9Y1211018ENS0040US0
Oil Pump Cover and Oil Pump (If necessary)
1. Remove the oil pump cover.
2. Remove the gear case.
3. Push out the inner rotor shaft from inside of the gear case.
(When reassembling)
• Apply engine oil in each section (gear case oil pump body, inner
rotor shaft, inner rotor, outer rotor.).
NOTE
• After installing the gear case to the cylinder block, be sure
to fit the inner rotor shaft into the camshaft end groove.
9Y1211018ENS0041US0
Gear Case
1. Remove the gear case.
(When reassembling)
• Dismount the inner rotor shaft of oil pump beforehand.
• Replace the O-ring (1) of the oil gallery connection with a new
one.
• Coat the gear case gasket with grease, and take case to avoid
any misalignment of the new O-ring or screw holes.
9.81 to 11.2 N·m
Tightening torque Gear case mounting screw 1.00 to 1.15 kgf·m
7.24 to 8.31 lbf·ft
(1) O-ring
9Y1211018ENS0042US0
1-S31
Cam Gear and Camshaft

NOTE
• Before disassembling, check the backlash of each gears.
Also check them during reassembly.
1. Remove the lock plate mounting screw (2).
2. Remove the cam gear (1) and camshaft together.
(When reassembling)
IMPORTANT
• Align the alignment marks of each gears.
(1) Cam Gear (2) Lock Plate Mounting Screw
9Y1211018ENS0043US0
Idle Gear
1. Draw out the external snap ring (3) on the idle gear shaft (6) and
take out the idle gear (2).
2. Alternatively, remove the idle gear shaft screw, and the take out
the idle gear and gear shaft together.
3. Remove the balancer bearing retainer (5).
(When reassembling)
NOTE
• Align the alignment marks of the idle gear, balancer gear (4)
and crank gear (1).
9.81 to 11.2 N·m
Tightening torque Idle gear shaft screw 1.00 to 1.15 kgf·m
7.24 to 8.31 lbf·ft
(1) Crank Gear (4) Balancer Gear

(2) Idle Gear (5) Balancer Bearing Retainer
(3) External Snap Ring (6) Idle Gear Shaft
9Y1211018ENS0044US0
Crankcase Cover
1. Remove the crankcase cover (1).
(When reassembling)
• Tighten the crankcase cover mounting screws gradually in the
order of (a) to (h) as shown in the figure.
7.9 to 9.3 N·m
Crankcase cover mounting
screw
5.8 to 6.8 lbf·ft
(1) Crankcase Cover

9Y1211018ENS0045US0
1-S32
Balancer Gear and Balancer
NOTE
• Before disassembling, check the backlash of the balancer
gears 1 (2) and 2 (1). Also check it during reassembly.
1. From the inside of the cylinder block place a brass rod against
the end of the balancer and tap it off to the gear case side with
a hammer.
(When reassembling)
• If the piston and the connecting rod have been removed, it is
easier to reassemble the connecting rod cap first, and then
proceed to the balancer gear reassembly.
IMPORTANT
• Align the alignment marks of the balancer gears 1 (2) and 2
(1).
(1) Balancer Gear 2 (2) Balancer Gear 1
9Y1211018ENS0046US0
Reassembling Procedure of Gears
1. Set the crankshaft so the crank pin comes directly to the left side
as viewed from the gear.
2. Align the alignment marks of balancer gear 2 (3) and balancer
gear 1 (5).
3. Turn the balancer gear by 3.14 rad (180 °) to the position as
shown in the figure.
4. Align the alignment marks of the crank gear (2), cam gear (1)
and balancer gear 3 (4), and reassemble the idle gear (6), (7).
(1) Cam Gear (5) Balancer Gear 1
(2) Crank Gear (6) Idle Gear (45T)
(3) Balancer Gear 2 (7) Idle Gear (21T)
(4) Balancer Gear 3
9Y1211018ENS0047US0
Governor Lever
1. Detach the governor spring (3) and spring (4) from the governor
lever (1).
2. Remove the screw (2) and pull out the governor lever shaft
toward the breather side.
3. Remove the governor lever.
NOTE
• Do not lose the ball onto the governor shaft in the process.
(1) Governor Lever (3) Governor Spring
(2) Screw (4) Idling Spring
9Y1211018ENS0048US0
Breather
1. Remove the breather mounting screw (1) to remove the
breather assembly.
(When reassembling)
• Install the breather assembly with the valve hole (3) in the
opposite side of the oil escape groove (2).
(1) Mounting Screw (3) Valve Hole
(2) Oil Escape Groove
9Y1211018ENS0049US0
1-S33
Governor Weight
1. Remove the governor weight (1) and governor weight holder (2)
together.
9.81 to 11.2 N·m
Governor weight holder
mounting screw
7.24 to 8.31 lbf·ft
(1) Governor Weight (2) Governor Weight Holder

9Y1211018ENS0050US0
1-S34
(5) Piston and Connecting Rod

(1) Piston
(2) Connecting Rod
(3) Crank PIn Bearing
(4) Connecting Rod Cap
(5) Connecting Rod Screw
(6) Crankcase Cover
(7) Piston RIng Assembly
(8) PIston Pin
(9) Piston Pin Bushing
9Y1211018ENS0051US0
Connecting Rod Cap

1. Set the piston in the bottom dead center.
2. Remove the connecting rod screws (2) to remove the
connecting rod cap (1).
NOTE
• Untighten rod screws slowly and equally.
(When reassembling)
• Apply engine oil to the crank pin bearings and connecting rod
screws.
• The connecting rod cap must be installed with the stamped
mark facing the radiator so the mark (3) of the connecting rod
and that of the connecting rod cap are aligned.
IMPORTANT
• Screw the rod screws light by hand and fully insert it. If it
cannot be screwed in lightly by hand, clean the thread. If it
is still hard to screw, replace the screw.
27 to 30 N·m
Tightening torque Connecting rod screw 2.7 to 3.1 kgf·m
20 to 22 lbf·ft
(1) Connecting Rod Cap (3) Mark

(2) Connecting Rod Screw
9Y1211018ENS0052US0
1-S35
Piston and Connecting Rod
1. Turn the flywheel and bring the piston to the top dead center.
2. Pull out the piston upward by tapping it from the bottom of the
cylinder block with the grip of a hammer.
(When reassembling)
• Before installing the piston into the cylinder, apply enough
engine oil to the cylinder liner wall.
• When inserting the piston into the cylinder, face the mark on the
connecting rod to the radiator side.
• When inserting the piston into the cylinder, place the top ring
gap (b) on the opposite side of the combustion chamber (a), and
stagger the second ring gap (c) and oil ring gap (d) marking a
right angle from the top ring gap.
(1) Piston Ring Compressor A: 1.6 rad (90 °)
B: 1.6 rad (90 °)
(a) Combustion Chamber C: 0.31 rad (18 °)
(b) Top Ring Gap
(c) Second Ring Gap
(d) Oil Ring Gap
9Y1211018ENS0053US0
1-S36
Piston Ring and Connecting Rod
1. Remove the piston rings with a piston ring tool.
2. Put the parting mark (8) on the piston head as shown in the
photograph.
3. Remove the piston pin (7), and separate the connecting rod (6)
from the piston (1).
(When reassembling)
• Clean all the parts before assembling.
• When installing the ring, assemble the rings so that the
manufacturer's mark R near the gap faces the top of piston.
• When installing the oil ring onto the piston, place the expander
joint (10) on the opposite side of the oil ring gap (11).
• Apply engine oil to the piston pin, and insert it to the piston.
• When installing the connecting rod to the piston, align the
stamped mark (9) on the connecting rod to the parting mark (8).
(1) Piston (8) Parting Mark
(2) Top Ring (9) Mark
(3) Second Ring (10) Expander Joint
(4) Oil Ring (11) Oil Ring Gap
(5) Piston Pin Snap Ring (12) Manufacturer's Mark
(6) Connecting Rod
(7) Piston Pin (a) 3.14 rad (180 °)
9Y1211018ENS0054US0
1-S37
(6) Flywheel and Crankshaft

(1) Pulley Shaft
(2) Flywheel Nut
(3) Flywheel
(4) Oil Seal
(5) O-ring
(6) Oil Filler Ring
(7) Internal Snap Ring
(9) O-ring
(10) Main Bearing Retainer
(11) Main Bearing 2
(12) Crankshaft
(13) Main Bearing 1
(14) Crankshaft Gear
(15) Ring Gear
9Y1211018ENS0055US0
Pulley Shaft
1. Place a wood block, etc. to prevent the crankshaft from turning,
and remove the pulley shaft (or the pulley).
9Y1211018ENS0056US0
Flywheel Nut
1. Stretch the lock washer.
2. Lock the flywheel nut to turn with a flywheel stopper.
3. Remove the flywheel nut with a socket wrench 36 mm.
(When reassembling)
• Apply molybdenum disulfide oil to the flywheel nut seat and
thread, and tighten the flywheel nut to the specified torque.
• Be sure to bend up the lock washer (1) to prevent loosening as
197 to 215 N·m
Tightening torque Flywheel nut 20.0 to 22.0 kgf·m
145 to 159 lbf·ft
(1) Lock Washer

9Y1211018ENS0057US0
1-S38
Flywheel
1. Set a flywheel puller (Code No. 17916-04052) and remove it
with the flywheel.
IMPORTANT
• Clean the flywheel and crankshaft tapered section to be
free from any dirt or chips. Also take care so that oil does
not stick to the crankshaft tapered section.
9Y1211018ENS0058US0
Crankshaft and Main Bearing Case

1. Remove the flywheel key.
2. Remove the bolts of main bearing case.
3. Insert the tip of a screwdriver in the gap "A" between the
bearing case and the cylinder block (as shown with in the
photo). Then, by prying the screwdriver to left and right evenly,
pull out the bearing and the crank shaft together.
(When reassembling)
• Check that the O-ring is not damaged and apply a light coating
of oil to the ring.
• Tighten the main bearing case retaining bolts gradually in the
order of (a) to (i) as shown in the figure.
9.81 to 11.2 N·m
Main bearing case
mounting screw / nut
7.24 to 8.31 lbf·ft
A: Gap
9Y1211018ENS0059US0
1-S39
Main Bearing Case and Crankshaft
1. Remove the bolts retaining (1) and the bearing retainer.
2. Remove the flywheel key (2) from the crankshaft.
3. Tap the main bearing case (3) with a plastic hammer to
separate it from crankshaft.
(When reassembling)
• Fit the outer lace notch (5) of the bearing into the "A" position
• Press the oil seal (4) until outside surface of the oil seal
becomes lush with boss of the main bearing case.
(1) Retaining Bolt (4) Oil Seal
(2) Flywheel Key (5) Notch
9Y1211018ENS0060US0
Main Bearing Case and Crankshaft

1. Pull the main bearing off using press.
(When reassembling)
• The crank shaft, the main bearing and fitting part of the bearing
must be thoroughly cleaned before oiling and pressing in.
• Place the notch (1) in the inner ring to the orientation of flywheel
key of the crank shaft, and then press in the bearing so that the
gap between the inner ring and the crank shaft is eliminated.
(1) Notch
9Y1211018ENS0061US0
1-S40
Crank Gear and Main Bearing 1
1. Secure the crankshaft with a vise and installing a crank gear
puller.
2. Pull out the crank gear.
(When reassembling)
• Tap the outer ring (5) of the main bearing 1 (roller bearing near
the gear case) into the cylinder block (3) until the end surface of
the outer ring (5) is flush with that of the cylinder block (3).
IMPORTANT
• Tap the outer ring of the bearing carefully without
damaging the roller raceway surface (4).
• Confirm that main bearing is press-fitted so that the gap
between the crankshaft end surface and main bearing side
surface is 0 mm (0 in.).
• Press-fit the crank gear (6) so that the gap between the
bearing side and bearing inner side is 0 mm (0 in.).
(1) Gear Case Surface (5) Roller Bearing Outer Ring
(2) Inserting Tool (6) Crank Gear
(3) Cylinder Block
(4) Roller Raceway Surface A: 0 mm (0 in.)
9Y1211018ENS0062US0
Tappet
1. Pull out the tappet (1).
(When reassembling)
• Before installing the tappet, apply engine oil around it.
(1) Tappet
9Y1211018ENS0063US0
1-S41
(7) Starter
Magnet Switch
1. Disconnect the connecting lead.
2. Remove the mounting nut.
3. Remove the magnet switch (1) by sliding it up so that it is
disconnected from the drive lever.
(1) Magnet Switch
9Y1211018ENS0064US0
Armature Brake
1. Remove the end frame cap (1).
2. Remove the brake shoe (2).
3. Remove the brake spring (3).
4. Remove the gasket (4).
(When reassembling)
• After reassembling the brake shoe (2), adjust the shaft thrust
gap.
(1) End Frame Cap (3) Brake Spring
(2) Brake Shoe (4) Gasket
9Y1211018ENS0065US0
End Frame
1. Remove the two through bolts.
2. Remove the end frame (1).
(1) End Frame
9Y1211018ENS0066US0
Brush Holder
1. Draw out the brush from the holder while holding the spring up.
2. Remove the brush holder (1).
(When reassembling)
• When replacing the spring, install it by referring to the figure.
• Do not contact the brush's positive lead with the body.
(1) Brush Holder (3) Attach the brush spring in this
(2) Spring Hanger method
(4) Brush
9Y1211018ENS0067US0
1-S42
Yoke
1. Draw out the yoke (1) from the drive end frame.
(When reassembling)
• Install the yoke, nothing the location of dowel pin.
(1) Yoke
9Y1211018ENS0068US0
Armature
1. Draw out the armature (2) with the drive lever (1).
(When reassembling)
• Install the drive lever, nothing its direction.
(1) Drive Lever (3) Drive End Frame
(2) Armature
9Y1211018ENS0069US0
1-S43
[3] SERVICING
(1) Cylinder Head and Valves
Cylinder Head Surface Flatness
1. Clean the surface of the cylinder head.
2. Place a straight edge on each of the cylinder head's four sides
and two diagonal as shown at the right to check the straightness
of the surface.
3. Insert a feeler gauge between the straight edge and the cylinder
head surface.
4. The maximum thickness that can be inserted is the amount of
distortion.
NOTE
• Do not place the straight edge on the combustion chamber
(1).
5. If the measurement exceeds the allowable limit, correct it with a
surface grinder. Inspect the amount of the valve recession after
correction.
0.05 mm / 100 mm
Cylinder head surface 0.002 in. / 3.94 in.
Allowable limit
flatness of cylinder head surface
length
Finishing 8 μRmax
(1) Combustion Chamber (3) Exhaust Valve

(2) Intake Valve
9Y1211018ENS0070US0
Cylinder Head Flaw
1. Prepare an air spray red check.
2. Clean the surface of the cylinder head with the detergent (2).
3. Spray the cylinder head surface with the red permeative liquid
(1). Leave it five to ten minutes after spraying.
4. Wash away the red permeative liquid on the cylinder head
surface with the detergent (2).
5. Spray the cylinder head surface with the white developer (3).
6. If flawed, it can be identified as red marks.
(1) Red Permeative Liquid (3) White Developer
(2) Detergent
9Y1211018ENS0071US0
1-S44
Valve Recessing
1. Clean the cylinder head, the valve face and seat.
2. Insert the valve into the guide.
3. Measure the valve recessing "A" with a depth gauge.
4. If the recession exceeds the allowable limit, replace the valve.
In addition, repair the cylinder head seat surface with a valve
seat cutter or valve seat grinder, and then repair the head
surface with a surface grinder. Or, replace the cylinder head.
0.80 to 0.90 mm
Valve recessing 0.032 to 0.035 in.
(IN and EX) 1.5 mm
Allowable limit
0.059 in.
A: Valve recessing
9Y1211018ENS0072US0
Width of Contact between Valve and Valve Seat

1. Check the contact between the valve face and valve seat.
2. When parts are not contacting evenly, or the contact width "A"
(See figure) is extremely wide, repair or replace the valve and
cylinder head seat, rub and refit parts to each other applying an
appropriate amount of compound.
2.1 mm
Valve seat width Factory specification
0.083 in.
A: Contact Width
9Y1211018ENS0073US0
Correcting Valve Face Angle
1. Correct the valve seat to the factory specification with a valve
seat cutter or a valve seat grinder.
2. Correct the valve using a valve refacer.
0.785 rad
Valve seat angle
45.0 °
0.786 to 0.794 rad
Valve face angle
45.0 to 45.5 °
(1) Valve (a) 0.26 rad (15 °)

(2) Corrected Valve Seat (b) 0.79 rad (45 °)
(3) Valve Refacer
9Y1211018ENS0074US0
1-S45
Correcting Procedure for Valve Seat
NOTE
• Always try to minimize the valve seat recession.
1. Correct the valve seat surface with a 0.79 rad (45 °) valve seat
cutter.
2. Place the valve and visually check the contact position between
the valve face and valve seat with red lead.
(If the valve has been used for a long period of time, the seat
tends to come into contact with the upper side of the valve
face.).
3. Cut the seat with a 0.26 rad (15 °) valve seat cutter so that the
valve seat width makes contact in the same dimensions to the
valve face width.
4. Cut the seat with a 0.79 rad (45 °) valve seat cutter again, and
visually recheck the contact between the valve and seat.
5. Repeat steps "B" and "C" until the correct contact is achieved.
6. Continue lapping until the seated rate is more than 70% of the
total contact area.
(1) Valve Seat Cutter A: 0.79 rad (45 °) Cutter
(2) Identical Dimensions B: Contact Check
(3) Seat Surface Width C: 0.26 rad (15 °) Cutter
D: 0.79 rad (45 °) Cutter
(a) 0.26 rad (15 °) E: Contact Check
(b) 0.79 rad (45 °)
(c) 0.79 rad (45 °)
(d) 0.26 rad (15 °)
(e) 0.79 rad (45 °)
9Y1211018ENS0075US0
Correcting Valve Seating (Valve Lapping)
1. Apply compound evenly to the valve lapping surface.
2. Insert the valve into the valve guide. Lap the valve onto its seat
with a valve flapper.
3. After lapping the valve, wash the compound away and apply oil,
then repeat valve lapping with oil.
4. Apply prussian blue to the contact surface to check the seated
rate. If it is less than 70 %, repeat valve lapping again.
IMPORTANT
• When valve lapping is performed, be sure to check the
valve recessing and adjust the valve clearance after
assembling the valve.
9Y1211018ENS0076US0
Oil Clearance between Valve Stem and Valve Guide
1. Remove carbon from the valve guide bore.
2. Measure the valve stem O.D. with an outside micrometer.
3. Measure I.D. of the cylinder head valve guide at the most worn
part with a small hole gauge, and find the oil clearance.
(Normally, a greater wear results in parallel to the rocker arm.).
4. If the clearance exceeds the allowable limit, replace the valve
guide and valve.
0.035 to 0.065 mm
Oil clearance between Factory specification
0.0014 to 0.0025 in.
valve stem and valve
guide 0.1 mm
Allowable limit
0.004 in.
6.960 to 6.975 mm
Valve stem O.D. Factory specification
0.2741 to 0.2746 in.
7.010 to 7.025 mm
Valve guide bore I.D. Factory specification
0.2760 to 0.2765 in.
9Y1211018ENS0077US0
1-S46
Replacing Valve Guide
(When removing)
1. Press out valve guide with a valve guide replacing tool.
(When installing)
1. Clean the valve guide bore, and apply engine oil to it.
2. Press in the valve guide until its flange contacts the cylinder
head.
3. Provide an oil return hole in the exhaust valve with a drill.
4. Ream precisely the bore of the valve guide to the specified
dimension in the table below.
IMPORTANT
• Do not hit the valve guide with a hammer during
replacement.
7.010 to 7.025 mm
Valve guide bore I.D. Factory specification
0.2760 to 0.2765 in.
Finishing 6.3 S
9Y1211018ENS0078US0
Valve Spring Free Length and Tension

1. Measure the free length of the spring with vernier calipers.
2. Place the spring on a spring compression tester and compress
to the specified length, and get the tension.
valve spring.
34.5 mm
1.36 in.
Free length
33.8 mm
Allowable limit
1.33 in.
59 N / 31 mm
Factory specification 6.0 kgf / 31 mm
Setting load / Setting 13 lbf / 1.2 in.
length 49 N / 31 mm
Allowable limit 5.0 kgf / 31 mm
11 lbf / 1.2 in.
9Y1211018ENS0079US0
1-S47
Valve Spring Tilt
1. Place the spring on the surface plate and a square at its side.
2. Measure the free length "A" (See figure) by rotating spring.
3. If the measurement exceeds the allowable limit, replace the
valve spring.
1.2 mm
Tilt B Allowable limit
0.047 in.
A: Free Length B: Tilt

9Y1211018ENS0080US0
Oil Clearance between Rocker Arm Shaft and Rocker Arm

1. Measure the rocker arm shaft O.D. with an outside micrometer.
2. Measure the rocker arm I.D. with an inside micrometer, and
calculate the oil clearance.
3. If the clearance exceeds the allowable limit, replace the rocker
arm.
0.016 to 0.045 mm
Oil clearance between 0.00063 to 0.0017 in.
rocker arm and shaft 0.15 mm
Allowable limit
0.0059 in.
10.973 to 10.984 mm
Rocker arm shaft Factory specification
0.43201 to 0.43244 in.
11.000 to 11.018 mm
Rocker arm I.D. Allowable limit
0.43307 to 0.43377 in.
9Y1211018ENS0081US0
Oil Clearance between Tappet and Guide
1. Measure the tappet O.D. with a outside micrometer.
2. Measure the tappet guide bore I.D. of the cylinder block with an
inside micrometer, and calculate the oil clearance.
3. If the oil clearance exceeds the allowable limit or the sliding
surface is scored, replace the tappet.
0.020 to 0.062 mm
tappet and guide 0.15 mm
Allowable limit
0.0059 in.
19.959 to 19.980 mm
Tappet O.D. Factory specification
0.78579 to 0.78661 in.
20.000 to 20.021 mm
Guide bore I.D. Factory specification
0.78741 to 0.78822 in.
9Y1211018ENS0082US0
1-S48
Push Rod Alignment
1. Check the both end of the push rod for cracks, damage and
unusual wear.
2. Measure the bending of the push rod with a dial indicator.
push rod.
0.125 mm
Bending Allowable limit
0.00492 in.
9Y1211018ENS0083US0
1-S49
(2) Piston and Connecting Rod

Piston Skirt O.D.
1. Measure the piston skirt O.D. with an outside micrometer.
(Measuring points are shown in the figure.)
piston.
76.925 to 76.945 mm
3.0286 to 3.0293 in.
Piston skirt O.D. Cylinder liner I.D.
Allowable limit −0.25 mm
−0.0098 in.
9Y1211018ENS0084US0
Piston Pin Bore
1. Measure the piston pin bore I.D. (lengthwise and widthwise of
the piston) with a cylinder gauge.
piston.
20.000 to 20.013 mm
0.78741 to 0.78791 in.
Piston pin bore I.D.
20.04 mm
Allowable limit
0.7890 in.
9Y1211018ENS0085US0
Oil Clearance between Piston Pin and Bushing
1. Measure the piston pin O.D. with an outside micrometer.
2. Measure the piston pin bushing I.D. with an inside micrometer,
and calculate the oil clearance.
3. If the clearance exceeds the allowable limit, replace the
bushing.
4. If the clearance still exceeds the allowable limit with new
bushing, replace the piston pin.
0.014 to 0.038 mm
piston pin and bushing 0.15 mm
Allowable limit
0.0059 in.
20.002 to 20.011 mm
Piston pin O.D. Factory specification
0.78748 to 0.78783 in.
20.025 to 20.040 mm
Small end bushing I.D. Factory specification
0.78839 to 0.78897 in.
9Y1211018ENS0086US0
1-S50
Replacing Piston Pin Bushing
(When removing)
1. Press out piston pin bushing with a piston pin bushing replacing
tool.
(When installing)
1. Clean the new bushing and bore, and apply engine oil to them.
2. Insert a new bushing onto the tool and press-fit it with the press
so that the oil holes (2) are aligned as shown in the figure, until
it is flush with the connecting rod.
3. Drill a hole to the bushing with aligning the oil hole (2) of
connecting rod using 4.0 mm dia. (0.16 in. dia.) drill.
NOTE
• Be sure to chamfer the oil hole circumference with an oil
stone.
• Check that the seam (1) of the bushing positions as shown
in the figure.
(Reference)
• Service parts dimension:
0.015 to 0.075 mm
piston pin and bushing 0.15 mm
Allowable limit
0.0059 in.
20.002 to 20.011 mm
Piston pin O.D.
0.78748 to 0.78783 in.
20.026 to 20.077 mm
Piston pin bushing I.D.
0.78843 to 0.79043 in.
(1) Seam (A) When Removing

(2) Oil Hole (B) When Installing
(a) 0.79 rad (45 °)
9Y1211018ENS0087US0
Connecting Rod Alignment
NOTE
• Since the piston pin bushing I.D. is the basis of this check,
check bushing for wear beforehand.
1. Remove the connecting rod bearing and install the bearing cap.
2. Install the piston pin into the connecting rod.
3. Install the connecting rod on the connecting rod alignment tool.
4. Put a gauge over the piston pin and move it against the face
plate.
5. If the gauge does not fit squarely against the face plate,
measure the space between the pin of the gauge and the face
plate.
connecting rod.
0.05 mm / 100 mm
Bent "A"
0.002 in. / 3.94 in.
Allowable limit
0.05 mm /100 mm
Twist "B"
0.002 in. / 3.94 in.
9Y1211018ENS0088US0
1-S51
Piston Ring Gap
1. Insert the piston ring into the lower part of the liner (Measuring
points are shown in the figure) with a piston ring compressor
and the piston.
2. Measure the ring gap with a feeler gauge.
3. If the gap exceeds the allowable limit, replace the piston ring.
Top ring
0.30 to 0.45 mm
Factory Second
0.012 to 0.017 in.
specifica- ring
Ring gap tion 0.25 to 0.40 mm
Oil ring
0.0099 to 0.015 in.
1.2 mm
Allowable limit
0.047 in.
(a) Approx. 90 mm (3.5 in.)

9Y1211018ENS0089US0
Clearance between Piston Ring and Ring Groove

1. Clean the rings and the ring grooves, and install each ring into
its groove.
2. Measure the clearance between the ring and the groove with a
feeler gauge.
3. If the clearance exceeds the allowable limit, replace the piston
ring.
4. If the clearance still exceeds the allowable limit with new ring,
replace the piston.
Top ring Keystone ring
Factory Second 0.0850 to 0.112 mm
specifica- ring 0.00335 to 0.00440 in.
tion
Clearance between 0.020 to 0.055 mm
Oil ring
piston ring and ring 0.00079 to 0.0021 in.
groove
Second 0.2 mm
Allowable ring 0.008 in.
limit 0.15 mm
Oil ring
0.0059 in.
NOTE
• As the top ring is a Keystone type, it cannot be measured
by this method.
9Y1211018ENS0090US0
1-S52
(3) Crankshaft
Oil Clearance between Crank Pin and Bearing
1. Put a strip of press gauge lengthwise on the center of the crank
pin in each direction as shown in the figure.
2. Install the connecting rod cap and tighten the screws to the
specified torque (27 to 30 N·m, 2.7 to 3.1 kgf·m, 20 to 22 lbf·ft)
once, and remove the cap again.
3. Measure the amount of the flattening with the scale and get the
oil clearance.
4. If the clearance exceeds the allowable limit, replace the bearing.
NOTE
• Do not insert the press gauge into the crank pin oil hole.
• Fasten the crankshaft so that it does not turn.
(Reference)
• When the crank pin wears further over a long period of use and
oil clearance exceeds the allowable limit after replacing the
standard bearing, use a undersize bearing. Machine the crank
pin according to the following precautions.
0.019 to 0.077 mm
crank pin and bearing 0.2 mm
Allowable limit
0.008 in.
36.959 to 36.975 mm
Crank pin O.D.
1.4551 to 1.4557 in.
Crank pin bearing I.D. 36.994 to 37.036 mm
(When tightening) 1.4565 to 1.4581 in.
(a) 0.52 rad (30 °) (b) 0.52 rad (30 °)

9Y1211018ENS0091US0
Use of Under size Bearing and Crank Pin Correction
1. Be sure to correctly grind the corner radius of the crank pin.
2. Be sure to chamfer the entire circumference of each oil hole,
using an oil stone.
3. Be sure to precision finish the crank pin section to higher than
0.4S.
0.2 mm (0.008 in.) 0.4 mm (0.02 in.)
Bearing Code No. 15531-2297-1 15531-2298-1
Bearing Name Crank pin bearing (0.2) Crank pin bearing (0.4)
Bearing Mark 0.2 US 0.4 US
Crankshaft machined
36.759 to 36.775 mm 36.559 to 36.575 mm
Dimension D
1.4472 to 1.4478 in. 1.4394 to 1.4399 in.
(See figure)
(1) Corner Radius 2.8 to 3.2 mm R (3) Maker Mark

(0.11 to 0.12 in. R) (4) Manufacture's No.
(2) The End of the Oil Hole Should be (5) Size
Chamfered to 1.0 to 1.5mm R
(0.040 to 0.059 in. R) [A] Marking and Numbering on
Under size Bearing
9Y1211018ENS0092US0
1-S53
Crankshaft Side Clearance
1. Move the crankshaft to the flywheel side.
2. Attach a dial gauge to the crankshaft (3).
3. Measure the end play by pushing the crankshaft toward the
crank gear (5).
main bearing retainer (1).
5. If the new end play still exceeds the allowable limit, check main
bearings 2 (2) and 1 (4). If worn abnormally, replace main
bearings.
NOTE
• When the end play is below the factory specifications, it
may be heavy turning or difficult starting, and when it is
over, it may be vibration of the flywheel or knocking.
0.050 to 0.46 mm
Crankshaft side 0.0020 to 0.018 in.
clearance 0.56 mm
Allowable limit
0.022 in.
Thickness of main 1.9 to 2.0 mm

bearing retainer 0.075 to 0.078 in.
(1) Main Bearing Retainer (4) Main Bearing 1

(2) Main Bearing 2 (5) Crank Gear
(3) Crankshaft
9Y1211018ENS0093US0
Oil Clearance between Crankshaft and Oil Filler Ring
1. Measure the crankshaft O.D. with an outside micrometer.
2. Measure the oil filler ring I.D. with an inside micrometer, and
3. If the clearance exceeds the allowable limit, replace the oil filler
ring.
0.025 to 0.066 mm
0.00099 to 0.0025 in.
crankshaft and oil filler
ring 0.2 mm
Allowable limit
0.008 in.
34.959 to 34.975 mm
Crankshaft O.D.
1.3764 to 1.3769 in.
35.000 to 35.025 mm
Oil filler ring I.D.
1.3780 to 1.3789 in.
9Y1211018ENS0094US0
Crankshaft Alignment
1. Support the crankshaft with V block on the surface plate and set
a dial indicator with its tip on the intermediate journal at right
angle.
2. Rotate the crankshaft on the V block and get the misalignment
(half of the measurement).
3. If the misalignment exceeds the allowable limit, replace the
crankshaft.
0.04 mm
Crankshaft alignment Allowable limit
0.002 in.
9Y1211018ENS0095US0
1-S54
(4) Timing Gear and Camshaft

Timing Gear Backlash
1. Set a dial indicator (lever type) with its tip on the gear tooth.
2. Move the gear to measure the backlash, holding its mating gear.
3. If the backlash exceeds the allowable limit, check the oil
clearance of the shafts and gear.
4. If the oil clearance is proper, replace the gear.
Barancer
0.0490 to 0.135 mm
Factory gear 1 ×
0.00193 to 0.00531 in.
specifica- gear 2
Backlash tion Other 0.0430 to 0.130 mm
gears 0.00170 to 0.00511 in.
Allowable 0.3 mm
All gears
limit 0.01 in.
9Y1211018ENS0096US0
Side Clearance of Idle Gear
1. Pull the idle gear collar 2 (1) and push the idle gear (2) to each
end.
2. Measure the clearance "A" between the idle gear and idle gear
collar 2 with a feeler gauge.
3. If the clearance exceeds the allowable limit, replace the idle
gear collar 1 (3).
0.20 to 0.51 mm
0.0079 to 0.020 in.
Idle gear side clearance
0.9 mm
Allowable limit
0.04 in.
Thickness of idle gear 2.45 to 2.50 mm

collar 1 0.0965 to 0.0984 in.
(1) Idle Gear Collar 2 A: Clearance

(2) Idle Gear
(2) Idle Gear Collar 1
9Y1211018ENS0097US0
Side Clearance of Cam Gear
1. Pull the cam gear (2) with the camshaft (1) to its end.
2. Measure the clearance "A" between the cam gear (2) and
camshaft stopper (3).
camshaft stopper.
0.0700 to 0.220 mm
0.00276 to 0.00866 in.
Cam gear side clearance
0.3 mm
Allowable limit
0.001 in.
Thickness of camshaft 3.780 to 3.855 mm

stopper 0.1489 to 0.1517 in.
(1) Camshaft A: Clearance

(2) Cam Gear
(2) Stopper
9Y1211018ENS0098US0
1-S55
Oil Clearance between Idle Gear Shaft and Bushing
1. Measure the idle gear shaft O.D. with an outside micrometer.
2. Measure the idle gear bushings I.D. with an inside micrometer,
and calculate the oil clearance.
bushing.
bushing, replace the idle gear shaft.
0.016 to 0.045 mm
0.00063 to 0.0017 in.
idle gear shaft and
bushing 0.1 mm
Allowable limit
0.004 in.
17.973 to 17.984 mm
Idle gear shaft O.D.
0.70760 to 0.70803 in.
18.000 to 18.018 mm
Idle gear bushing I.D.
0.70867 to 0.70937 in.
9Y1211018ENS0099US0
Replacing Idle Gear Bushing
(When removing)
1. Press out the bushings with an idle gear bushing replacing tool.
(When installing)
1. Clean the new bushings and bore, and apply engine oil to them.
2. Press in the bushing with an idle gear bushing replacing tool.
(Reference)
• Service parts dimension:
0.016 to 0.078 mm
0.00063 to 0.0030 in.
idle gear shaft and
bushing 0.1 mm
Allowable limit
0.004 in.
17.973 to 17.984 mm
Idle gear shaft O.D.
0.70760 to 0.70803 in.
18.000 to 18.048 mm
Idle gear bushing I.D.
0.70867 to 0.71055 in.
(A) When removing (B) When installing

9Y1211018ENS0100US0
1-S56
Oil Clearance of Camshaft
1. Measure the camshaft journal O.D. with an outside micrometer.
2. Measure the camshaft bore I.D. withe an inside micrometer and
camshaft.
camshaft, replace the cylinder block.
0.020 to 0.054 mm
Oil clearance of Factory specification
0.00079 to 0.0021 in.
camshaft
[Flywheel side] 0.25 mm
Allowable limit
0.0098 in.
21.967 to 21.980 mm
Camshaft journal O.D.
0.86485 to 0.86535 in.
22.000 to 22.021 mm
Camshaft bore I.D.
0.86615 to 0.86696 in.
0.025 to 0.066 mm
Oil clearance of Factory specification
0.00099 to 0.0025 in.
camshaft
[Gear side] 0.1 mm
Allowable limit
0.004 in.
32.959 to 32.975 mm
Camshaft journal O.D.
1.2976 to 1.2982 in.
33.000 to 33.025 mm
Camshaft bore I.D.
1.2993 to 1.3001 in.
9Y1211018ENS0101US0
Intake and Exhaust Cam Height
1. Measure the height of the camshaft lobes at their largest O.D.
with an outside micrometer.
camshaft and tappet.
27.0 mm
1.06 in.
Cam height (IN, EX)
26.5 mm
Allowable limit
1.04 in.
(1) Cam Height

9Y1211018ENS0102US0
1-S57
Camshaft Alignment
1. Support the camshaft with V block on the surface plate and set
a dial indicator with its tip on the intermediate journal at right
angle.
2. Rotate the camshaft on the V block and get the misalignment
(half of the measurement).
3. If the misalignment exceeds the allowable limit, replace the
camshaft.
0.08 mm
Camshaft alignment Allowable limit
0.003 in.
9Y1211018ENS0103US0
1-S58
(5) Cylinder Liner

Cylinder Liner I.D.
1. Visually check the cylinder liner I.D. for vertical scratches.
2. Measure the six points as shown in the figure with a cylinder
gauge to find out the maximum wear. Generally, position (1) in
the (a) direction (at approx. 10 mm (0.39 in.) from the top) shows
the maximum wear. Since position (3) at the lower part of the
liner shown the minimum wear, find this difference.
cylinder liner.
75.000 to 75.019 mm
2.9528 to 2.9535 in.
Cylinder liner I.D.
+0.25 mm
Allowable limit
+0.0098 in.
(1) Top (a) Right-angle to the Piston Pin

(2) Middle (b) Parallel to the Piston Pin
(3) Bottom (Skirt)
9Y1211018ENS0104US0
Replacing Cylinder Liner

(When removing)
1. Pull out the liner with a wet liner puller (Code No. 07916-30012).
(When installing)
2. Clean the fitting surface of liner and cylinder block and apply
engine oil to the wall of cylinder liner bore, and apply grease to
the O-ring.
3. Press-fit the cylinder liner into the cylinder block.
4. After press-fitting the liner, check the projection of cylinder liner.
9Y1211018ENS0105US0
Projection of Cylinder Liner

1. Apply straight edge to the flange portion of cylinder liner, and
measure the gap "A" between the cylinder block and the
straight edge with a feeler gauge.
2. If the measurement is not within the factory specifications,
check the press-fit condition.
Projection of cylinder 0.030 to 0.13 mm
liner 0.0012 to 0.0051 in.
(1) Cylinder Block A: Gap

(2) Cylinder Liner
9Y1211018ENS0106US0
1-S59
(6) Oil Pump

Clearance between Inner Rotor and Outer Rotor
1. Measure the clearance between a high point on the inner rotor
and high point on the outer rotor with a feeler gauge.
2. If the clearance exceeds the allowable limit, replace the oil
pump rotor assembly.
0.15 mm or less
Clearance between inner 0.0059 in. or less
rotor and outer rotor 0.20 mm
Allowable limit
0.0079 in.
9Y1211018ENS0107US0
Clearance between Outer Rotor and Pump Body
1. Measure the clearance between the outer rotor and the pump
body with a feeler gauge.
0.0900 to 0.171 mm
Clearance between outer 0.00355 to 0.00673 in.
rotor and pump body 0.24 mm
Allowable limit
0.0094 in.
9Y1211018ENS0108US0
Clearance between Rotor and Cover
1. Put a strip of press gauge onto the rotor face with grease.
2. Install the cover and tighten the screws.
3. Remove the cover carefully, and measure the depression of
press gauge with a sheet of gauge.
0.02 to 0.06 mm
Clearance between rotor 0.0008 to 0.002 in.
and cover 0.25 mm
Allowable limit
0.0098 in.
9Y1211018ENS0109US0
1-S60
(7) Starter
Magnet Switch
NOTE
• Each test should be carried out for a short time (3 to 5
seconds), and at half of the rated voltage (6V).
1) Pull - in Coil (Attraction Test)
1. Connect jumper lead from the battery negative terminal post to
the C terminal.
2. The plunger should be attracted strongly when a jumper lead is
connected from the battery positive terminal to the S terminal.
2) Holding Coil (Retention Test)
1. Connect jumper leads from the battery negative terminal post to
the body and the battery positive terminal post to the S terminal.
2. Push the plunger in by hand and release it.
Then, the plunger should remain being attracted.
9Y1211018ENS0110US0
Continuity Across Terminal

1. Check the resistance with an ohmmeter across the C terminal
and the B terminal, pushing in the plunger.
2. If 0 ohm is not indicated, replace the magnet switch.
(1) C Terminal (2) B Terminal
9Y1211018ENS0111US0
Shaft Thrust Gap

1. Measure the thrust gap of armature shaft with a feeler gauge.
2. If the gap is not within factory specifications, adjust by the brake
shoe.
0.050 to 1.0 mm
Shaft thrust gap Factory specification
0.0020 to 0.039 in.
9Y1211018ENS0112US0
1-S61
Commutator and Mica
1. Check the contact face of the commutator for wear, and grind
the commutator with sand paper if it is slightly worn.
2. Measure the commutator O.D. at several points.
3. If the difference of the O.D.'s exceeds the allowable limit, correct
the commutator on a lathe to the factory specification.
4. If the minimum O.D. is less than the allowable limit, replace the
armature.
5. Measure the mica undercut.
6. If the undercut is less than the allowable limit, correct with a saw
blade and chamfer the segment edges.
28.0 mm
1.10 in.
Commutator O.D.
27.0 mm
Allowable limit
1.06 in.
Less than
Factory specification 0.1 mm
Difference of O.D.'s 0.004 in.
0.4 mm
Allowable limit
0.02 in.
0.5 to 0.8 mm
0.02 to 0.03 in.
Mica undercut
0.2 mm
Allowable limit
0.008 in.
(1) Segment (a) Correct

(2) Undercut (b) Incorrect
(3) Mica
9Y1211018ENS0113US0
Clearance between Shaft and Bushing

1. Measure the bushing I.D. on the drive side and commutator
side.
2. Measure the shaft O.D. on the drive side and commutator side.
bushing.
Commutator 0.030 to 0.10 mm
Factory side 0.0012 to 0.0039 in.
specifica-
Clearance between tion 0.050 to 0.10 mm
Drive side
shaft and bushing 0.0020 to 0.0039 in.
Allowable Allowable 0.20 mm
limit limit 0.0079 in.
12.50 mm
Shaft O.D.
0.4921 in.
12.53 to 12.60 mm
Commutator bushing I.D. Factory specification
0.4933 to 0.4960 in.
12.55 to 12.60 mm
Drive bushing I.D.
0.4941 to 0.4960 in.
9Y1211018ENS0114US0
1-S62
Armature Coil
1. Check the continuity across the commutator and armature shaft
with an ohmmeter.
2. If it conducts, replace the armature.
9Y1211018ENS0115US0
Brush Wear
1. Measure the brush length (A).
2. If the length is less than the allowable limit, replace the brush
holder.
16.0 mm
0.630 in.
Brush length (A)
10.5 mm
Allowable limit
0.413 in.
9Y1211018ENS0116US0
Brush Holder
1. Check the continuity across the brush holder and the holder
support with an ohmmeter.
2. If it conducts, replace the brush holder.
Brush holder – Holder
Resistance Infinity
support
9Y1211018ENS0117US0
Field Coil
1. Check the continuity across the lead (1) and brush (2) with an
ohmmeter.
2. If it does not conduct, replace the yoke assembly.
3. Check the continuity across the brush (2) and yoke (3) with an
ohmmeter.
4. If it conducts, replace the yoke assembly.
(1) Lead (3) Yoke
(2) Brush
9Y1211018ENS0118US0
1-S63
Bearing and Clutch
1. Check the bearing and clutch for smooth rotation.
2. The clutch should engage and rotate with the pinion shaft in
driving direction and disengage in reverse.
(a) Free (b) Lock
9Y1211018ENS0119US0
1-S64
Editor : Farm and Industrial Machinery International Service Department
Address : 64, Ishizu-Kitamachi, Sakai-Ku, Sakai-City, Osaka, 590-0823, Japan
Phone : +81-72-241-1129
Fax : +81-72-245-2484
E-mail : [email protected]
Printed in Japan 2015. 05, S, EI, EI, engusa Code No.9Y111-10181

KUBOTA Corporation 2013. 12, S, EI, EI, engusa

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WORKSHOP MANUAL

KiSC issued 05, 2015 A

KiSC issued 05, 2015 A

KiSC issued 05, 2015 A

KiSC issued 05, 2015 A

1. SAFETY FIRST .............................................................................................................................. I-1

KiSC issued 05, 2015 A

DISCARD FLUIDS CORRECTLY

PREVENT ACID BURNS

PREPARE FOR EMERGENCIES

A 311.5 mm (12.26 in.)

A 303.5 mm (11.95 in.)

A 303.5 mm (11.95 in.)

A 3 Screw holes - Screw dia. size 8.0 mm (0.31 in.)

KiSC issued 05, 2015 A

1. ENGINE IDENTIFICATION .......................................................................................................... G-1

KiSC issued 05, 2015 A

(1) Engine Model (3) Emission Label

* Alphabetical letters "I" and "O" are not used.

Category (2) Engine output classification EPA regulation

(1) EU regulation engine output classification category

3. MAINTENANCE CHECK LIST

4. CHECK AND MAINTENANCE

Checking Engine Oil Level (Daily)

[2] CHECK POINT OF EVERY 50 HOURS

[3] CHECK POINT OF EVERY 100 HOURS

(1) Drain Plug (Oil Strainer)

Wet Liner Puller

Diesel Engine Compression Tester (for Injection Nozzle)

KiSC issued 05, 2015 A

1. FEATURE ................................................................................................................................... 1-M1

KiSC issued 05, 2015 A

[2] VALVE MECHANISM

Since the intake / exhaust valves expand due to heat

0.4320 to 0.4581 rad (24.75 to

(1) Intake (a) 0.35 rad before T.D.C.

[3] CYLINDER BLOCK AND CYLINDER LINER

[4] CRANKSHAFT AND CRANKSHAFT JOURNAL BEARING

[5] PISTON AND PISTON RING

[6] CONNECTING ROD AND CONNECTING ROD BEARING

[7] TIMING GEAR

[10] DYNAMIC BALANCER

Lubrication is forced on with a trochoid pump.

[2] OIL PUMP

[3] OIL STRAINER

[4] RELIEF VALVE

[5] OIL SIGNAL

[6] OIL PRESSURE SWITCH

[3] RADIATOR CAP

5. INTAKE / EXHAUST SYSTEM

[2] AIR CLEANER

[2] INJECTION PUMP

Delivery Valve Operation

[3] INJECTION NOZZLE

[4] GOVERNOR MECHANISM

(1) Governor Spring

 At Idling to Maximum Speeds

[5] FUEL FILTER

[2] FAN DYNAMO