05-E2B SERIES,05-E2BG SERIESWORKSHOP MANUALDIESEL ENGINEKiSC issued 06, 2011 A

805-E2B, 05-E2BG, WSMPERFORMANCE CURVESPERFORMANCE CURVES(1) Gross Int.(2) Net Int.(3) Net Cont.(4) Brake Horsepower(5) Engine Speed(6) Specified Fue

S-4605-E2B, 05-E2BG, WSMDIESEL ENGINECylinder Head Flaw1. Prepare an air spray red check.2. Clean the surface of the cylinder head with detergent (2)

S-4705-E2B, 05-E2BG, WSMDIESEL ENGINEReplacing Valve Guide(When removing)1. Press out the used valve guide using a valve guide replacing tool.(See pa

S-4805-E2B, 05-E2BG, WSMDIESEL ENGINECorrecting Valve and Valve SeatNOTEQ• Before correcting the valve and seat, check the valve stemand the I.D. of

S-4905-E2B, 05-E2BG, WSMDIESEL ENGINEFree Length and Tilt of Valve Spring1. Measure the free length (B) of valve spring with vernier calipers.If the

S-5005-E2B, 05-E2BG, WSMDIESEL ENGINEPush Rod Alignment1. Place the push rod on V blocks.2. Measure the push rod alignment.3. If the measurement exce

S-5105-E2B, 05-E2BG, WSMDIESEL ENGINEW10293660(2) Timing Gears, Camshaft and Governor GearTiming Gear Backlash1. Set a dial indicator (lever type) wi

S-5205-E2B, 05-E2BG, WSMDIESEL ENGINECamshaft Side Clearance1. Set a dial indicator with its tip on the camshaft.2. measure the side clearance by mov

S-5305-E2B, 05-E2BG, WSMDIESEL ENGINEOil Clearance of Camshaft Journal1. Measure the camshaft journal O.D. with an outside micrometer.2. Measure the

S-5405-E2B, 05-E2BG, WSMDIESEL ENGINE(3) Piston and Connecting RodPiston Pin Bore I.D.1. Measure the piston pin bore I.D. in both the horizontal andv

S-5505-E2B, 05-E2BG, WSMDIESEL ENGINEConnecting Rod AlignmentNOTEQ• Since the I.D. of the connecting rod small end bushing is thebasis of this check,

905-E2B, 05-E2BG, WSMPERFORMANCE CURVES(1) Gross Int.(2) Net Int.(3) Net Cont.(4) Brake Horsepower(5) Engine Speed(6) Specified Fuel(7) Torque(8) Gros

S-5605-E2B, 05-E2BG, WSMDIESEL ENGINEPiston Ring Gap (To be continued)1. Insert the piston ring into the lower part of the cylinder (the leastworn ou

S-5705-E2B, 05-E2BG, WSMDIESEL ENGINEPiston Ring Gap (Continued)W1043413Clearance between Piston ring and Piston Ring Groove1. Clean the rings and th

S-5805-E2B, 05-E2BG, WSMDIESEL ENGINE(4) CrankshaftCrankshaft Side Clearance1. Set a dial indicator with its tip on the end of the crankshaft.2. Meas

S-5905-E2B, 05-E2BG, WSMDIESEL ENGINEOil Clearance between Crankpin and Crankpin Bearing1. Clean the crankpin and crankpin bearing.2. Put a strip of

S-6005-E2B, 05-E2BG, WSMDIESEL ENGINEOil Clearance between Crankshaft Journal and CrankshaftBearing 11. Measure the O.D. of the crankshaft front jour

S-6105-E2B, 05-E2BG, WSMDIESEL ENGINEOil Clearance between Crankshaft Journal and CrankshaftBearing 2 (Crankshaft Bearing 3)1. Put a strip of plastig

S-6205-E2B, 05-E2BG, WSMDIESEL ENGINEReplacing Crankshaft Sleeve1. Remove the used crankshaft sleeve.2. Set the sleeve guide (2) to the crankshaft.3.

S-6305-E2B, 05-E2BG, WSMDIESEL ENGINE(5) CylinderCylinder Wear1. Measure the I.D. of the cylinder at the six positions (see figure)with a cylinder ga

S-6405-E2B, 05-E2BG, WSMDIESEL ENGINECorrecting Cylinder1. When the cylinder is worn beyond the allowable limit, bore andhone it to the specified dim

S-6505-E2B, 05-E2BG, WSMDIESEL ENGINEClearance between Outer Rotor and Pump Body1. Measure the clearance between the outer rotor and the pumpbody wit

1005-E2B, 05-E2BG, WSMPERFORMANCE CURVES(1) Gross Int.(2) Net Int.(3) Net Cont.(4) Brake Horsepower(5) Engine Speed(6) Specified Fuel(7) Torque(8) Gro

S-6605-E2B, 05-E2BG, WSMDIESEL ENGINECommutator and Mica1. Check the contact of the commutator for wear, and grind thecommutator with emery paper if

S-6705-E2B, 05-E2BG, WSMDIESEL ENGINEBrush Holder1. Check the continuity across the brush holder and the holdersupport with a circuit tester.2. If it

S-6805-E2B, 05-E2BG, WSMDIESEL ENGINE(8) AlternatorBearing1. Check the bearing for smooth rotation.2. If it does not rotate smoothly, replace it.W101

S-6905-E2B, 05-E2BG, WSMDIESEL ENGINERectifier1. Check the continuity across each diode of rectifier with resistancerange of circuit tester.2. The re

EDITOR:KUBOTA FARM & INDUSTRIAL MACHINERY SERVICE, LTD.64, ISHIZU-KITAMACHI, SAKAI-KU, SAKAI-CITY, OSAKA, 590-0823, JAPANPHONE : (81)72-241-1129FA

1105-E2B, 05-E2BG, WSMDIMENSIONSDIMENSIONSUnit : mm (in.)W1038971D905-E2B D1005-E2B D1105-E2B D1105-T-E2BA 497.8 (19.60) 497.8 (19.60) 497.8 (19.60) 4

1205-E2B, 05-E2BG, WSMDIMENSIONSUnit : mm (in.)W1039589V1305-E2B V1505-E2B V1505-T-E2BA 583.8 (22.98) 591.3 (23.28) 591.3 (23.28)B 230 (9.06) 230 (9.0

1305-E2B, 05-E2BG, WSMDIMENSIONSUnit : mm (in.)W1040012D905-E2BGD1005-E2BG D1105-E2BG V1305-E2BG V1505-E2BGA 546.6 (21.52) 546.6 (21.52) 546.6 (21.52)

CONTENTSGENERAL1. ENGINE IDENTIFICATION ... G-1[1] MODEL NAME AND ENGINE

G-105-E2B, 05-E2BG, WSMG GENERAL1. ENGINE IDENTIFICATION[1] MODEL NAME AND ENGINE SERIAL NUMBERWhen contacting the manufacture, always specify

G-205-E2B, 05-E2BG, WSMG GENERAL• Month of manufacturee.g. D1105-4A0001“4” indicates 2004 and “A” indicates January.So, 4A indicates that the engine

G-305-E2B, 05-E2BG, WSMG GENERAL2. GENERAL PRECAUTIONS• During disassembly, carefully arrange removed parts in a cleanarea to prevent confusion late

TO THE READERThis Workshop Manual has been prepared to provide servicing personnel withinformation on the mechanism, service and maintenance of 05-E

G-405-E2B, 05-E2BG, WSMG GENERAL3. MAINTENANCE CHECK LISTTo maintain long-lasting and safe engine performance, make it a rule to carry out regular

G-505-E2B, 05-E2BG, WSMG GENERALCAUTION• When changing or inspecting, be sure to level and stop the engine.Q NOTELubricating OilWith the emission con

G-605-E2B, 05-E2BG, WSMG GENERAL4. CHECK AND MAINTENANCE[1] DAILY CHECK POINTSChecking Engine Oil Level1. Level the engine.2. To check the oil le

G-705-E2B, 05-E2BG, WSMG GENERALChecking and Replenish Coolant1. Without recovery tank :Remove the radiator cap (1) and check to see that the coolant

G-805-E2B, 05-E2BG, WSMG GENERAL[2] CHECK POINTS OF INITIAL 50 HOURSChanging Engine OilCAUTION• Be sure to stop engine before changing engine oi

G-905-E2B, 05-E2BG, WSMG GENERALReplacing Oil Filter CartridgeCAUTION• Be sure to stop the engine before changing filter cartridge.1. Remove the oil

G-1005-E2B, 05-E2BG, WSMG GENERAL[3] CHECK POINTS OF EVERY 50 HOURSChecking Fuel Hose1. If the clamp (2) is loose, apply oil to the threads and

G-1105-E2B, 05-E2BG, WSMG GENERAL[4] CHECK POINTS OF EVERY 100 HOURSCleaning Air Cleaner Element1. Remove the air cleaner element.2. Use clean d

G-1205-E2B, 05-E2BG, WSMG GENERALFan Belt Damage and Wear1. Check the fan belt for damage.2. If the fan belt is damaged, replace it.3. Check if the f

G-1305-E2B, 05-E2BG, WSMG GENERAL[5] CHECK POINTS OF EVERY 200 HOURSChanging Engine OilCAUTION• Be sure to stop engine before changing engine oi

105-E2B, 05-E2BG, WSMSAFETY INSTRUCTIONSSAFETY INSTRUCTIONSBEFORE SERVICING AND REPAIRING• Read all instructions and safety instructions in thisman

G-1405-E2B, 05-E2BG, WSMG GENERALReplacing Oil Filter CartridgeCAUTION• Be sure to stop the engine before changing filter cartridge.1. Remove the oil

G-1505-E2B, 05-E2BG, WSMG GENERALReplacing Fuel Filter Element (Element Type)1. Close the fuel cock (3).2. Unscrew the retaining ring (6) and remove

G-1605-E2B, 05-E2BG, WSMG GENERALAnti-Freeze• There are two types of anti-freeze available: use the permanenttype (PT) for this engine.• Before addin

G-1705-E2B, 05-E2BG, WSMG GENERAL[8] CHECK POINTS OF EVERY 1 OR 2 MONTHSRechargingCAUTION• When the battery is being activated, hydrogen and o

G-1805-E2B, 05-E2BG, WSMG GENERALBattery Specific Gravity1. Check the specific gravity of the electrolyte in each cell with ahydrometer.2. When the e

G-1905-E2B, 05-E2BG, WSMG GENERAL[10] CHECK POINTS OF EVERY 800 HOURSChecking Valve ClearanceIMPORTANTQ• Valve clearance must be checked and adj

G-2005-E2B, 05-E2BG, WSMG GENERAL[11] CHECK POINTS OF EVERY 1500 HOURSCAUTION• Check the injection pressure and condition after confirming that

G-2105-E2B, 05-E2BG, WSMG GENERAL[12] CHECK POINTS OF EVERY 3000 HOURSChecking Turbocharger(Turbine Side)1. Check the exhaust port (3) and inlet

G-2205-E2B, 05-E2BG, WSMG GENERALInjection Timing1. Remove the injection pipes.2. Remove the engine stop solenoid.3. Turn the flywheel counterclockwi

G-2305-E2B, 05-E2BG, WSMG GENERALChecking Injection Pump(Fuel Tightness of Pump Element)1. Remove the engine stop solenoid.2. Remove the injection pi

205-E2B, 05-E2BG, WSMSAFETY INSTRUCTIONSSAFETY STARTING• Do not start the engine by shorting across starterterminals or bypassing the safety start sw

G-2405-E2B, 05-E2BG, WSMG GENERAL[13] CHECK POINTS OF EVERY 2 YEARSReplacing Intake Air Line1. Loosen the clamp (2).2. Remove the intake air hos

G-2505-E2B, 05-E2BG, WSMG GENERALReplacing Fuel Hoses and Clamp Bands1. Loosen the clamp (2) and remove the fuel hose (1).2. Replace new fuel hose (1

G-2605-E2B, 05-E2BG, WSMG GENERALChanging Radiator Coolant (L.L.C.)CAUTION• Do not remove the radiator cap when the engine is hot. Thenloosen cap sl

G-2705-E2B, 05-E2BG, WSMG GENERALChanging Radiator Coolant (L.L.C.) (Continued)(Anti-freeze)• There are two types of anti-freeze available: use the p

G-2805-E2B, 05-E2BG, WSMG GENERAL5. SPECIAL TOOLSDiesel Engine Compression Tester (for Nozzle Hole)Code No: 07909-30208 (Assembly) 07909-31251 (G)07

G-2905-E2B, 05-E2BG, WSMG GENERALNOTEQ• The following special tools are not provided, so make them referring to the figure.Injection Pump Pressure Te

G-3005-E2B, 05-E2BG, WSMG GENERALBushing Replacing ToolApplication: Use to press out and press fit the bushing.1. For small end bushing2. For idle ge

G-3105-E2B, 05-E2BG, WSMG GENERALCrankshaft Bearing 1 Replacing ToolApplication: Use to press out and press fit the crankshaft bearing 1.[Press Out][

G-3205-E2B, 05-E2BG, WSMG GENERALCrank Sleeve SetterApplication: Use to fix the crankshaft sleeve.(1) Auxiliary Socket for Pushing(2) Sleeve GuideW10

CONTENTSMECHANISM1. ENGINE BODY ... M-1[1] CLOSED BREATH

305-E2B, 05-E2BG, WSMSAFETY INSTRUCTIONSVENTILATE WORK AREA• If the engine must be running to do some work, makesure the area is well ventilated. Ne

M-105-E2B, 05-E2BG, WSMDIESEL ENGINE1. ENGINE BODY[1] CLOSED BREATHER (NATURAL ASPIRATION TYPE ONLY)Closed breather system has been adopted to

M-205-E2B, 05-E2BG, WSMDIESEL ENGINE[2] GOVERNORQ Three Lever Type Fork Lever (for General)The governor system is a mechanical governor thatused the

M-305-E2B, 05-E2BG, WSMDIESEL ENGINE(Overloaded Operation)The amount of the movement of the fork leverassembly is limited with the fuel limitation bo

M-405-E2B, 05-E2BG, WSMDIESEL ENGINE[3] BOOST COMPENSATORW1013537Boost compensator is the device that reduces blacksmoke during the engine startup a

CONTENTSSERVICING1. TROUBLESHOOTING ...S-12. SERVICING SPECIFICATI

S-105-E2B, 05-E2BG, WSMDIESEL ENGINE1. TROUBLESHOOTINGW1014322Symptom Probable Cause SolutionReference PageEngine Does Not StartNo fuel Replenish fue

S-205-E2B, 05-E2BG, WSMDIESEL ENGINEW1014322Symptom Probable Cause SolutionReference PageEngine Revolution Is Not SmoothFuel filter clogged or dirty

S-305-E2B, 05-E2BG, WSMDIESEL ENGINEW1014322Symptom Probable Cause SolutionReference PageDeficient Output Incorrect injection timing Adjust S-19Engin

S-405-E2B, 05-E2BG, WSMDIESEL ENGINEW1014322Symptom Probable Cause SolutionReference PageHigh Oil Pressure Different type of oil Use specified type o

S-505-E2B, 05-E2BG, WSMDIESEL ENGINE2. SERVICING SPECIFICATIONSENGINE BODYW10138740Item Factory Specification Allowable LimitValve Clearance (Cold)

405-E2B, 05-E2BG, WSMSPECIFICATIONSSPECIFICATIONS* The specification described above is of the standard engine of each model.* Conversion Formula : HP

S-605-E2B, 05-E2BG, WSMDIESEL ENGINEENGINE BODY (Continued)W1013874Item Factory Specification Allowable LimitRocker Arm Shaft to Rocker ArmRocker Ar

S-705-E2B, 05-E2BG, WSMDIESEL ENGINEENGINE BODY (Continued)W10138740Item Factory Specification Allowable LimitIdle Gear Shaft to Gear BushingIdle Ge

S-805-E2B, 05-E2BG, WSMDIESEL ENGINEENGINE BODY (Continued)W10138740Item Factory Specification Allowable LimitPiston Ring Gap[D905-E2B]Top Ring 0.25

S-905-E2B, 05-E2BG, WSMDIESEL ENGINEENGINE BODY (Continued)W10138740Item Factory Specification Allowable LimitCrankshaft to Crankshaft Bearing 2Cran

S-1005-E2B, 05-E2BG, WSMDIESEL ENGINELUBRICATING SYSTEMW10139730COOLING SYSTEMW10135990Item Factory Specification Allowable LimitEngine Oil Pressur

S-1105-E2B, 05-E2BG, WSMDIESEL ENGINEFUEL SYSTEMW10139730Item Factory Specification Allowable LimitInjection Pump Injection Timing(3000 min-1 (rpm))

S-1205-E2B, 05-E2BG, WSMDIESEL ENGINEELECTRICAL SYSTEMW1013973Item Factory Specification Allowable LimitGlow Plug Resistance Approx. 0.9 Ω –Starter

S-1305-E2B, 05-E2BG, WSMDIESEL ENGINE3. TIGHTENING TORQUESScrews, bolts and nuts must be tightened to the specified torque using a torque wrench, se

S-1405-E2B, 05-E2BG, WSMDIESEL ENGINE[2] TIGHTENING TORQUES FOR SPECIAL USE SCREWS, BOLTS ANDNUTSNOTEQ• For “*” marked screws, bolts and nuts

S-1505-E2B, 05-E2BG, WSMDIESEL ENGINE4. CHECKING, DISASSEMBLING AND SERVICING[1] CHECKING AND ADJUSTING(1) Engine BodyCompression Pressure1. Run

505-E2B, 05-E2BG, WSMSPECIFICATIONS* The specification described above is of the standard engine of each model.* Conversion Formula : HP = 0.746 kW, P

S-1605-E2B, 05-E2BG, WSMDIESEL ENGINEValve ClearanceIMPORTANTQ• Valve clearance must be checked and adjusted when engineis cold.1. Remove the cylinde

S-1705-E2B, 05-E2BG, WSMDIESEL ENGINE(2) Lubricating SystemEngine Oil Pressure1. Remove the engine oil pressure switch, and set an oil pressuretester

S-1805-E2B, 05-E2BG, WSMDIESEL ENGINEFan Belt Damage and Wear1. Check the fan belt for damage.2. If the fan belt is damaged, replace it.3. Check if t

S-1905-E2B, 05-E2BG, WSMDIESEL ENGINEThermostat Valve Opening Temperature1. Suspend the thermostat in the water by a string with its endinserted betw

S-2005-E2B, 05-E2BG, WSMDIESEL ENGINEFuel Tightness of Pump Element1. Remove the engine stop solenoid.2. Remove the injection pipes and glow plugs.3.

S-2105-E2B, 05-E2BG, WSMDIESEL ENGINECAUTION• Check the nozzle injection pressure and condition after confirming that there is nobody standing in the

S-2205-E2B, 05-E2BG, WSMDIESEL ENGINENozzle Holder1. Secure the nozzle retaining nut (7) with a vise.2. Remove the nozzle holder (1), and take out pa

S-2305-E2B, 05-E2BG, WSMDIESEL ENGINEBattery Specific Gravity1. Check the specific gravity of the electrolyte in each cell with ahydrometer.2. When t

S-2405-E2B, 05-E2BG, WSMDIESEL ENGINEMotor TestCAUTION• Secure the starter to prevent it from jumping up and downwhile testing the motor.1. Disconnec

S-2505-E2B, 05-E2BG, WSMDIESEL ENGINEMagnet Switch Continuity Test1. Check the continuity across the C terminal (1) and the B terminal(2) with a circ

605-E2B, 05-E2BG, WSMSPECIFICATIONS* The specification described above is of the standard engine of each model.* Conversion Formula : HP = 0.746 kW, P

S-2605-E2B, 05-E2BG, WSMDIESEL ENGINEGlow Plug Continuity1. Remove the glow plug.2. Measure the resistance with a circuit tester between the glowplug

S-2705-E2B, 05-E2BG, WSMDIESEL ENGINERadial Clearance1. If the wheel contact to the housing, replace the turbochargerassembly with new one.W1077353[2

S-2805-E2B, 05-E2BG, WSMDIESEL ENGINETurbocharger (equipped with Turbocharger Model)CAUTION• While the engine is running and or just after it stops,

S-2905-E2B, 05-E2BG, WSMDIESEL ENGINENozzle Heat Seal Service Removal ProcedureIMPORTANTQ• Use a plus (phillips head) screw driver (1) that has adiam

S-3005-E2B, 05-E2BG, WSMDIESEL ENGINECylinder Head and Cylinder Head Gasket (To be continued)1. Loosen the pipe clamps (1), and remove the water retu

S-3105-E2B, 05-E2BG, WSMDIESEL ENGINECylinder Head and Cylinder Head Gasket (Continued)(When reassembling the carbon gasket type)• Replace the cylind

S-3205-E2B, 05-E2BG, WSMDIESEL ENGINEThermostat Assembly1. Remove the thermostat cover mounting screws (1), and removethe thermostat cover (2).2. Rem

S-3305-E2B, 05-E2BG, WSMDIESEL ENGINEGear Case1. Remove the gear case.(When reassembling)• Grease thinly to the oil seal, and install it, ensuring th

S-3405-E2B, 05-E2BG, WSMDIESEL ENGINEBoost Compensator (equipped with Turbocharger Model)IMPORTANTQ• Use the stop solenoid mounting bolt (3) for the

S-3505-E2B, 05-E2BG, WSMDIESEL ENGINEInjection Pump1. Disconnect the start spring (4) on the thrust lever side (5).2. Align the control rack pin (2)

705-E2B, 05-E2BG, WSMSPECIFICATIONS* The specification described above is of the standard engine of each model.* Conversion Formula : HP = 0.746 kW, P

S-3605-E2B, 05-E2BG, WSMDIESEL ENGINECam Gear, Idle Gear 1, 2 and Governor Gear1. Remove the idle gear 2 (7) / idle gear 1 (4).2. Remove the fuel cam

S-3705-E2B, 05-E2BG, WSMDIESEL ENGINE(5) Piston and Connecting RodOil Pan and Oil Strainer1. Remove the oil pan mounting screws (5).2. Remove the oil

S-3805-E2B, 05-E2BG, WSMDIESEL ENGINEPistons1. Turn the flywheel and bring the piston to top dead center.2. Draw out the piston upward by lightly tap

S-3905-E2B, 05-E2BG, WSMDIESEL ENGINEPiston Ring and Connecting Rod1. Remove the piston rings using a piston ring tool.2. Remove the piston pin (7),

S-4005-E2B, 05-E2BG, WSMDIESEL ENGINE(6) Flywheel and CrankshaftFlywheel1. Secure the flywheel to keep it from turning, using a flywheelstopper.2. Re

S-4105-E2B, 05-E2BG, WSMDIESEL ENGINECrankshaft Assembly1. Remove the main bearing case screw 2 (1).2. Pull out the crankshaft assembly.IMPORTANTQ• T

S-4205-E2B, 05-E2BG, WSMDIESEL ENGINE(7) StarterQ Electromagnetic Drive TypeW10375931. Unscrew the C terminal nut (7), and disconnect the connecting

S-4305-E2B, 05-E2BG, WSMDIESEL ENGINEQ Planetary Gear Reduction TypeW12227141. Unscrew the C terminal nut (12), and disconnect the connecting lead.2

S-4405-E2B, 05-E2BG, WSMDIESEL ENGINE(8) AlternatorW12240791. Remove the pulley (1).2. Remove the rear end cover (12).3. Remove the brush holder (11)

S-4505-E2B, 05-E2BG, WSMDIESEL ENGINE[3] SERVICING(1) Cylinder Head and ValvesTop Clearance1. Remove the cylinder head.2. With the piston at TDC, use