I

lll.
$Erulue
Manual
ENGINE,FUELAND
ELECTRICALSYSTEMS
(KubotaDiesel)

GSS-1509
July,1984

| TERTATIOTATHARUESTER
.
NORTHAMERICAOPERATIONS
AGRICULTURAL
EQUIPMENT
GROUP
AVENUEr CHICAGO,lLLlNOlS,606ll,
401NOmH MICf{IGAN U.S.A.
Due to a continuousprogramof researchand development,someprocedures,
specificationsand parts
may be altered in a constanteffort to improve our products.

When changesand improvementsare madein our products, periodic revisionsmay

be madeto this
manual to keep it up'todate. It is suggestedthat customerscontact their dealerfor
information on
the latestrevision.

NOTE: Someillustrations in this manual show equipment not currently available. The illustrations
are usedprimarily to coverserviceabilityand may not alwaysrepresentproduction equipment.

L IBRARY FI LI NG I N FO RM ATI O N

1. File this manualand divider in the last

binder of your OPPServiceiManualLibrary.

2. On page15 (Cub Cadetsand Equipment)

of your OPPlibrary index, enter the manual
description,form numberand book filed in
underthe 582, 682,782 and 982 heading.

ENGINE.FUEL AND
EL ECTRI CAL SYSTEM S
(KubotaDiesel)

GSS-1509
Jul y,1984

CA'UTION! Somephotographsin this manualmay showshieldsor coverpanelsremoved

for purposesof clarity. NEVER OPERATE unit without all shieldsand coverpanelsin place.
GeneralContents

page
SafeWork Rules lV & V
Standard TorqueDatafor Nuts& Bolts . Vl-Vlll
Inch-Metric Hardware .. lX
MetricConversionTables X & Xl
S pe ciaToo
l ls Xll-Xvlll

SECTION "{t;l,g
{iti ,''':1::.
. .i
'Yr1;;i1

W *|:ii
;.r j
"

UI
 WORKSAFELY- FOLLOWTHESERULES
This symbol is ured to call your atbntion to instructionsconcerning
your personalrafuty. Bo rure to obccrvoand follow theseinstructions.

6. When operating a power washerto clean a

machine"beforeservicing,be careful at all times
to aoid injury. Maintainproper footing and
balanceat all times. Neverdirect the sprayat
peopleor animals,as high pressurespraycan
causeseriousinjury.

7. lf a portableheateris usedto heat the service

areathe following precautionsmust be observed:

(a) Do not useportableheatersin presence

of volatilematerialssuch as gasolineor
1. To preventaccidentalstarting,alwayspull the paint, as fire or explosionmay result.
hightensionwire(s)off of the sparkplug(s)be-
fore servicingand/oradjustingthe machine. (b) To avoid beingburned,do not touch the
heaterduring operation.

2. To preventinjury,do not allowchildrenor (c) Portableheatersconsumeoxygen and

by-standers
aroundthe machinewhile it is being combustionfumescan be hazardcus.
adjustedand/ or serviced. Heatershould be usedonly in a well
ventilatedarea. Keepa window or door
partiallyopen to provideventilation.
3. Do not wearrings,wrist watchesor loosefit-
ting clothingwhenworkingon machinery, they
could catchon movingpartscausingseriousin- (d) Keepthe heaterat leastfour (4) feet from
jury. Wearsturdy,rough-soledwork shoes. combustiblematerials.
Neveradjustandlorservicea machinein bare (e) Neverusegasolineas fuel.
feet,sandalsor sneakers.

4. Always wear safetyglasseswhen usinga .8. Handlegasolinewith care- it is highly

hammer,chiselor other tools that may cause flammable:
chips to fly.
(a) Useapprovedgasolinecontainer.
5. Be sureto reinstallsafetydevices,guards (b) Neverremovethe fuel tank cap or fill the
or shieldsafter adjustingand/or servicingthe
fuel tank when the engineis running,is
machine. Also, replacemissingor damaged hot, or indoors. Also, do not smoke when
safety and/or instruction decals. working around flammablefuel.

R e v i s e dA u g u s t , 1 9 81
ry
 (c) Avoid fires - be surecontaineror fun- 15. Always usesafety standsin conjunction
nel does not touch the battery. Do not with hydraulicjacksor hoists. Do not rely on
overfill the fuel tank. Wipe up spilled the jack or hoist to carry the load,they could
gasoline. fail. Always usea safetybar to block hydraulic
cylinders.
( d) Replacefuel tank cap securely.

9. Neverusetrouble lightsor electricpowered

tools that havecut and/or damagedcordsor
plugs. Be sureall electrictools are properly
grounded.

10. Neverrun an enginein a confined areasuch

as a garageor storagebuildingany longerthan is
necessary for immediatemoving of the machine
out of or into the area. EXHAUST GASES
ARE TOXIC. OPENING DOORS AND WIN.
DOWSMAY NOT PROVIDE ADEOUATE
VENTILATION.

11. After servicing,be sureall tools, parts,or 16. Whensplittingtractors,or disassembling

servicingequipmentare removedfrom the machines,be sureto usesafetystandsand
machine. adequatesupportsto preventtipping or roll-
over.
12. Electricalstoragebatteriesgiveoff highly
inflammablehydrogengaswhen chargingand
continue to do so for some time after receiving
a steady charge. Do not under any circumstances
allow an electricsparkor an open flame nearthe
battery. Always disconnecta battery cable be-
fore working on the electricalsystem. FESM-97| 6

13. Hydraulicfluid escapingunder pressurecan 17. Usea saferycatch on all hoist hooks. Do
haveenoughforce to penetratethe skin. Hy- not take a chance,the load could slip off of the
draulic fluid may also infect a minor cut or hook.
openingin the skin. lf injured by escaping
fluid, seea doctor at once. Seriousinfection or 18. Usepullersto removebearings,bushings,
reactioncan resultif medicaltreatment is not gears,cylinder sleeves,
etc. when applicable.
givenimmediately. Usehammers,punchesand chiselsonly when
absolutelynecessary.Then, be sureto wear
Do not attempt to repairor tighten hosesthat safety glasses.
are under pressure,when the boom is raised,or
with the tractor enginerunning. Cycle all hy- 19. Be carefulwhen usingcompressed air to
draulic control valvesto relieveall pressure dry parts. Useapprovedair blow guns,do not
beforedisconnectingthe linesor performing exceed30 psi, wear safety glassesor gogglesand
other work on the hydraulicsystem. Make sure useproper shieldingto protect everyonein the
all connectionsare tight and hosesand linesare work area.
in good condition before applyingpressureto
the system. To locatea leak under pressure,use IMPORTANT: The aboveis only a partial list
a small pieceof cardboardor wood. Neveruse of safework rules. In addition, alwaysrefer to
hands. the Operator'sManualfor the specificmachine
for additionalsafework rulesregardingthe
14. When usingan acetylenetorch alwayswear machineoperation.
weldinggogglesand gloves. Keep a "charged"
fire extinguisherwithin reach. Do not weld or
heat areasnearfuel tanks or fuel linesand utilize
proper shieldingaround hydrauliclines.
RevisodAugust,1981
V
 TOROUEDATAFORMETRICNUTSAND BOLTS_
STANDARD

Recommendedtorque for all Standard Unplated Nuts and Bolts, provided:

A. Surface finish is oxide coated, oil quenched or bright.
B. All th r e a d su r fa ce sare cl eanand l ubri catedw i th S A E -30 engi neoi l oi equi val ent(S eeN OTE .I
C. Jo in ts a r e r ig id , th a t i s, no gasketsor compressi bl emateri al sare used.
D. Wh e n r e u sin gn u ts or bol ts use mi ni mum torque val ues.

NOT E; M u ltip ly th e standardtorque by:

.6 5 wh e n fini shedi am nuts are used.
.7 0 wh e n M ol ykote, w hi te l ead or si mi l ar mi xtures are usedas l ubri cants.
.75 when phosphatecoated and oiled bolts or nuts are used.
.8 5 wh e n cadmi um or zi nc di chromatebol ts or nuts are used.
.9 0 wh e n h ardenedsurfacesare used under the nut or bol t head (thi s appl i es
to sta n dardunpl atedhardw areonl y).

FOOT POUNDS

Bolt
Diameter
Cla ss5 .8 C l ass8.8 C l ass9.8 C l ass10.9 C l a ss1 0 .9
Onlv when us€ci*

M i l l i m ete r s M in . Max M in Max Mi n Max M i n. Max Mi n. Max

o 6 I s 10 11 13 10 1' ,I
7 10 14 15 18 19 21 1-1 18
.A
8 IJ 14 20 23 ZJ 28 31 27
l0 z0 28 40 45 45 50 54 ol 4A 3C
12 qJ 49 70 78 78 88 106 83 93
14 70 td 11t 125 124 140 151 170 IJJ 150
16
18
108
149
121
168
172
238
194
268
g I to 233
324
toJ
364
ZUO
245
232
320
20 210 237 JJO 378 458 515 403 453
287 458 3 to ot4 702 549 618
409 581 654 751 890 696 783
* W h e n b o l t p e n e tr a tio nis 1 - 1 /2 tim e s th e d ia m eter the bol t.
of

NE WT O NME T E RS

Bolt (")
Diameter
Cla ss5 .8 C l ass8.8 C l ass9.8 C l ass10.9 Cl as s10.9
OnlV when ussd *
in cast {gray) iron
M i l l i m e te r s M in . Max. M in . Max. Mi n- Max. Mi n. Max. Mi n. Max .

6 7 I 11 12 13 t5 IJ t5
12 19 21 21 24 26 ZJ 23
I 11 ' lo 27 30 34 11
4Z ?'l
10 J9 J6 c9 ol 60 68 1't 64 73
bb 94 106 105 I t6 128 144 113
14 94 106 t5u 'l 69 .r68 189 205 )1n 180 202
16 t40 l04 IJ J toJ lol Jto 280 314
18 202 zlt J IJ JDJ 439 493 386 434
20 285 211
456 : 620 689 546 606
22 389 437 ozz 699 HO 952 744 838
24 493 554 788 886 1072 1206 943 10 6 1
* W h e n b o l t p e n e tr a tio nis
1 - 1 l2 tim e s th e d ia m e terof the bol t.
J u n e1 9 8 1

VI
 S TA N D A R DTOR Q UE DA T A F O R I NCH NUT S A ND B O L T S .
NE W T O N M E T E RS

Re co m m e n d e d to r q u e to r a ll S tandard U npl ated N uts and B ol ts, provi ded:

A. Su r fa ce tin ish is o xid e coated, oi l quenched or bri ght.

B. All th r e a d su r ta ce s a re cl ean and l ubri cated w i th S A E -3O engi ne oi l or equi val ent (S ee N O TE .)

C. Jo in ts a r e r ig id , th a t i s, no gaskets or compressi bl e materi al s a.e used.

D. Wh e n r e u sln g n u ts o r bol ts use mi ni mum torque val ues.
NOT E: M u ltip ly th e standard torque by:
.6 5 wh e n f in a s hed i am nuts are used.
.7 O wh e n M o lykote, w hi te l ead or si mi l ar mi xtures are used as l ubri cants.
.7 5 wh e n p h o sphate coated or oi l ed bol ts or nuts are used.
.8 5 wh e n ca d mi um or zi nc di chromate bol ts or nuts are used.
.9 0 wh e n h a r dened surfaces are used under the nut or bol t head (thi s appl i es
to sta n d a r d unpl ated hardw are onl y).

1 NEWTONMETER:0.738 FOOTPOUND
Type 8 (al l l engths)
T yp e 1 Bol ts
B o l t o r Stu d T yp e 1 6 " le n gth Type 1 B ol ts Type 5 O n l yw h e nu s e dt A l l oth er
D i a me le r Slu d s On ly o r le ss l onger than 6' (al l l engths) in cast(gray)iron appIcati ons
I n c ne s Mrn Max Mrn M ax Man M ax Mi n M ax Mi n M ax . Mi n. Max
1/4 7 8 8 I 5 5 tz 14 15 I8 18 19

5/16 16 tA l5 18 I 11 24 D7
30 34 34 l- B
3/8 28 33 28 33 18 ,19 45 50 56 62 61 68
7 / 16 52 47 5Z 27 JI 72 81 88 100 10? , .1.19
71 79 71 80 42 47 109 122 136 152 156 176
9/1 6 95 109 1 Q2 115 61 69 156 176 t97 217 224 261
5/8 133 149 141 159 84 95 217 244 27 1 305 305 346
3/4 236 265 251 278 149 I70 387 434 442 543 543 6l -t'
7/A 3ao 427 244 27 1 244 27 1 624 7A O 773 868 875 944

1 570 638 360 407 360 407 929 s77 1 160 1303 1916 1479
1 1/8 807 909 516 577 3to 577 I tf,J 1289 1642 1 845 1866 2096
' 11 4 0 l r At 726 162A 2632,
1 1/4 726 814 8r4 1832 231 3 26Q5 ?esa
l 3/8 149'2 16 8 2 950 1065 950 1065 2 13 0 2388 3033 3412 3446 3881
1 1/2 19 9 5 9))q r 255 1418 1255 1418 2822 Jt /o 4030 4532 4579 5149

t W h e n b o lt p e n e tr a tio n ts 1 - 1 1 2tr m e s th e d r ameter ot the bol t.

B OLT TY PE I DE NT I F I CA T I O NCHA RT
IH S.A,E, B O L TH EAD
D E S C R IP TION
TYPE GRADE M A RKIN G.
c1 WIL L HAVE A 9 J ST AND A FD MON OGR A M IN TH E C E N TE R OF TH E H E A D

5
got

5
L o w o r M e d iu m Ca r b on S teel N ot H eat Treated

WIL L HAVE A9 ] AND 3 R A D IA L LIN E S

@ /(.-\
,ua)
Qu e n ch e d a n d T e m p ered Medi unr C arbon S teel
\.- /

I 8 WIL L HAVE AYJAND 6 R A D IA L LIN E S

Qu e n ch e d a n d T e m p ered S pecral C arbon or A l l oy S teel @

' Tlte center mar kr ne idenr lfies the bol t m anui ac tur er

Re vrse d M ar ch 1984

VII
 S TA N D A R DTO R O UEDA T A F O R I NCH NUT S A ND B O L T S_
F O O TP O UNDS

Re co m m e n d e d to r q u s fo r a ll S tandard U npl ated N uts and B ol ts, provi ded:

A. Su r fa ce fin ish is o xid e coated, oi l quenched or bri ght.
B. All th r e a d su r fa ce s a r e cl ean and l ubri cated w i th S A E -3O engi ne oi l or equi val ent (S ee N O TE .)
C. Jo in ts a r s r ig id . th a t is, no gaskets or comprsssi bl e mat€ri al s are used.
D. Wh e n r e u sin g n u ts o r bol ts use mi ni mum torque val ues.

NOT E: M u ltip ly th e standard torguo by:

.6 5 wh e n fin ished j am nuts are used.
.7 0 wh e n M o ly kot€, w hi te l ead or si mi l ar mi xtures are used as l ubri cants.
.7 5 wh o n p h o s phate coated and oi l od bol ts or nuts are used.
.8 5 wh e n ca d mi um or zi nc di chromate bol ts or nuts are used.
.9 O wh e n h a r d ened surfaces are used under the nut or bol t head (thi s appl i es
to sta n d a r d unpl ated hardw are onl y).

1 F OOTP OU N D= 1.355 N E W TON ME TE R S

T y pe 8 ( al l l engths )
B o l t o r Stu d Type 1 T yp € 1 B ol ts Type 1 Bolts Type 5 Onl y w hen usedi A l l other
D i a me ter Stu d s On ly 6 " le ngth l onger than 6' (al l l engths) i n cast {gray)i ron appl i cati ons
o r less
l n chos M in. M ax M in. M ax Mrn M ax Min M ax Mrn Ma Min Ma x .

1/4 5 6 6 7 4 4 I 10 1l 13 13 14

5/16 72 t3 11 13' .7 8 'i 18 . 20, ' .22. J.25r i,,ioi

, i26u
3/A 21 24 21 24 13 14 33 37 41 46 45 50
to ' .:;7& ,'
;, c8r
' 7/16 36 38 35 38 -23 53. ' .6oi r ,4 ,lt,i!Q|
't/2 52 58 52 59 31 35 80 90 10() 112 115 130
9/16 70 80 75 85 45 51 115 tgo ,. tlSr, ,r,:00 ,lii6,. I'ts$,
5/a 98 i1 0 r04 117 62 70 160 180 2o,0 225 225 255
314 174 r9 5 185 206 110 125 285 I 32O 366, 400 .{4g .lori,:
7/8 2AO 315 180 200 180 2o,0 460 575 570 640 845 725
1 420 470 485 300 265 300 645 720,., .866 l ,gsd, 979:, ioeo.
1 -1/A 595 670 3ao 425 380 425 850 950 1210 1360 1375 1545

, rl,
1 -v4
,.
840 945 635 600 635 600 1200 1360,
| 1705 1e?o 1940 2lP.r
1-3lA 11 0 0 1240 700 785 700 785 1570 1 760 2235 2515 2540 2860
' 1 . 1 / ,2 1470 16r() 926 1045 925 1046 2080 23.tO .:297Or i34o 3376. 3796',
"'
i Wh e n b o lt penetr atr on r s 1 - l /2 tr m es the diameter of the bol t

B OL T T Y PE IDENTIFICATION CHART
IH S,A,E, D ESC R IPT IO N E OLT H E A O
ryPE GRADE MA R K IN G.

I
it W I LL HAVEA 9J S T A N D A R D M O N O G R A M I N T H E C E N T E RO F T H E H E A D

5
sor
dz

5
Low or M edium Ca r b o n S t e e l N o t H e a t T r e a t e d

WIL L H A VEA u J A N D 3 R A D IA LLIN E S

@,/r-\
/ rJJt )
Ou e n c h e da n d T e mperedMedi umC arbonS teel '.J-/
I 8 W I LL HAVE A 9T'A N D 6 R A D I A L L I N E S

O uenc hed and Tem p e r e d S p e c i a l C a r b o n o r A l l o y S t e e l @

'T h e ce n l e r m ar king identifies the bolt manutaclu r er

Re vi se dN o v . I 983

wII
 ETRIC HARDWAR
I I{GH-IUI E

NOTE: This unit contains both inch and rhetric The following chart is provided to help you dis-
hardware. Be sure to use the correct inch or tinguish between inch and metric hardware by
metric size and type (class) hardware when re- observingthe headmarkings.
placing or when mounting attachmentsto tapped
holes. Also, use the correct inch or metric tools
with each kind of hardware.

B OLT CLA S S IFICAT I O NA ND I DE NT I F I CA T I O NCHA RT

INCH ME T RI C

SAE IH B O L T HE A D CL A S S BOLT HEAD

G R ADE GRADE MA RK I NG S MA RKI N G S

2 5.8
@
1

q
\?
UJ
8.8
@
/f7\
I I c+
u/ 10.9
@
The followingchart is providedto further help
identify an approximatesize in inch or metric
hardware. THI S lS NO T A RE CO MME NDA T I O N
FOR S UB S T I T UT I O N,
A ND T HE Y A RE NO T
INTE RCHA NG E A B L E Th. isc h a rtis o n ly a me a n s
of quicklydetermining the approximate size.

A p p ro x ima t e
I n c h S e rie s

6 1/4
B 5 / 16
10 3 / 8 , 7/ 1 6
12 1/2
14 9/16
16 5/8
18
20 3/4
22 7/8
24 {I
27' I
I

30 1 -1 / 8 , 1 -1 / 4
36 1 -1 / 2

* Non-preferred

D(
 CONVERSION TABLE
-inches to millimeters-
lncboa MUllmstcrc Inchce Mllllmctcrr Inchea lrlllllmetcrr lochea Millimetarr

1 25.1 26 660.4 5l 1295.4 7g 1930.4

2 50.8 27 6E5.E 52 1320.8 ,a 1955.8
3 76.2 2E 7LL.2 53 13,46.2 7E 19t1.2
I t0 r.8 29 ?36.6 5{ 13?1.6 79 2006.6
5 1 2 ?0. 30 ?62.0 ss 1.39?.0 EO 2032.0

6 152.'l 31 187.4 56 L422.4 81 2067.4

7 L77.E 92 ET2.E 57 L+47.8 82 20s2.E
E 209.2 33 83E.2 58 L473.2 83 2106.2
9 22t.6 34 863.6 59 5
1,19E. 8{ 2133.6
r0 254.O 35 E89.0 60 1524.0 E5 2159.0

ll 279.4 36 91{.4 61 rilg.4 86 2t84.4

L2 304.t 37 939.8 62 1574.8 E7 2209,E
r3 330.2 3E 965.2 63 1600.2 8E 2235.2
1,1 355.6 39 990.6 64 1625.6 89 2260.8
l5 3t1.0 {0 1016.0 65 1651.0 90 2288.0

l6 {06.,1 {l 104r.4 66 16?6.4 91 23LL.4

L7 431.E 42 1066.t 67 1701.8 92 2336.E
IE 457.2 ,13 L092.2 68 L727.2 93 2362.2
19 {62.6 & 1117.6 69 1752.6 94 23E?.6
20 508.0 {5 r143.0 70 I1?E.O 95 2413.0

2L 533.4 46 1168.4 7T 1803.4 96 243E.4

22 558.I 47 1193.8 72 1828.8 97 2463.8
23 584.2 48 L2L9.2 73 1E54.2 9E 24E9.2
24 609.6 49 Lz44.6 74 lE?9.6 99 2514.6
25 835.0 50 L270.0 75 1905.0 100 2t{0. 0

1 incfi - 25.4 millimctlrr

To convert lncbes to milllmeters, tbe inch nalne to be converted sbould be written dowu,
carrled to as maDy declmal places as the deslred accuracy reguires. It sbould ttren be
spltt tnto groups of not more than hro figrrres each. Tbe equlvalent of each grotp shor:ld
tlen be r'ken from the table, proper regard betDg glven to t.heposition of tbe decind
polnt tn each case, e'rt tbe equinalent of the lnch value glven.

For e:camp1e,to couvert 2.4635 tacbes to mlllimeterg:

2.0000 lncbes = S0.90000miJltrneters

.4600 tnches = 11.68400
.0035 lnches = .08890
2.4635 tnches = 62.57290mill irnsfpls
Correct to 3 decirnal places.
2.4636 lnches = 62.673 millimeters
X
 CONVERSION TABLE
-millimeters to inches-
!(llll,neters locbce Ulllln€tcru Iachor Mllltmetcrc lacbes Mtlllmsterg Inches

10 0393?00E 26 I 02fi220 5t 2.00?87{0 76 2 9921260

20 0?E?{016 27 I 0629821 52 2.0472{{L 77 3 03ltl961
3 1lEll02,l 2E 1 1023622 53 2.0E661{2 7E 3 0?0t66I
I 157{8031 29 I t{1?323 g 2.L259842 79 3 1102362
5 196t5039 30 I rE11024 2. 1653643 EO 3 1496063

6 2#22047 31 L.220{724 56 2.2U72A E1 3.18E976,1

7 2?t59055 32 1.259E,r25 57 2.2140945 E2 3.2263,165
E 3r{96063 33 1.2992U16 5E 2.2E34.6{.6 E3 3. 2677t65
9 3543307r u 1.33E5E2? 50 2.322E3{.6 84 3.307086€
10 393?00E 35 1.3??9528 60 2.3622047 E5 3.3484567

1l {330709 36 I 4L73228 61 2.40L574E E6 3. 3656266

L2 r721109 37 I {566929 g2 2.#O%9 E7 3.,1261966
13 51161r0 3E 1 49€0630 63 2. ,rE03150 EE 3. {645669
l{ 56lrE11 39 I 5354331 6{ 2. 5196650 69 3.5039370
15 5905512 ,10 I 5748031 05 2.5590551 90 3.543307t

16 6299213 41 t 6141732 66 2.5584252 9l 3.5E28712

L7 6892913 42 1 6535433 6? 2. 6377953 92 3.622M72
1E ?016614 {3 I 6929134 6E 2.677165{ 93 3.5614173
l9 74t0315 g I 7322E35 69 2. ?165354 grf 3.7007E74
20 ?E?4016 {5 1 ??16535 ?0 2. ?559055 95 3.7{01575

2L E2671t7 {6 I Ell0236 ?l 2.79527ft 96 3 7195216

22 6661{1? 17 I E50393? 72 2.8346{5? 9? 3 ElEE976
23 9055118 ,1E 1 EE9763E 13 2.8740L57 96 3 8582677
24 9148819 49 I 92919]9 74 2.9133858 99 3 8976378
25 9E42520 50 L 9665039 75 2.952?559 100 3 93?006

1 mm - .08937008 incfieg

To convert milllmeters to inches tbe rn{lllmeter rralrre to be couverted should be wrlttea

down, csrrled to as Eauy declmal places as tbe deslred accuracy requlres. It should
then be spllt rp tnto grorps of Dot more thrn two flgures each. The egulv:alent of each
groq sbould then be Fkeu from tbe table, proper regad b€!ry gtven to tbe posltlon of
ttre declmal pofut h each case, rnd tle equtvalent of tbe seveml gF.orps found by addl-
ttron Thls stln vrill be ttre luch equlvalent of tbe m{lltpst€r value glven

For eample to convert 75.384rnillla6sters to lncheg:

75.000 rnrlllnstett = 2.9527559 trches

.380 vnrlllpeters = .0149606
.004 mlllfuneters = .0001574
75.384m{l 1o"L"r = 2.9678739inches
Correct to dectmal places.
75.384rnlll! eters a 2.96787lnches
XI
 S PECI ALTO O LS

Piston Ring Compressor

Application: Use exclusively for pushing in

the piston with ease.

:, , EG - 127877

Piston ring compressor.

PistonRing Tool

Application: Useexclusivelyfor removingor

installingthe pistonring with ease.

EG{27878

Pistonring tool.

Crankshaft Pulley Puller

Application: Use to take off the crankshaft

pulley of all types of dieselenginessafely and I
easilv.
HUU
U!
!I!!
tl
II
n nn
F H E
EG-127879 u ;";
Crankshaftpulley puller.

XII
Diesel Engine CompressionTester

Application: Use to measurediesel engine

compression and to diagnosethe engine for a
major overhaul.

tester.
Compression

Oil hessureTester

Application: A testerto measurelubricating

oil pressurefor all kinds of dieselenginee.

tu
*
*$'n-
EG-127881

Oil pressure
tester.

Valve SeatCutter

Application: Useto reseatvalves.

Angle: 45o
150
Diameter:1.126in.
1.244in.
1.378in. ffi ooo oc> o
r--
1.496in.
1.626in.
2.000in.
ffi
trll l-
:l
ll| EG-127882

Valveseatcutter.

XIII
Radiator CaP Tester

radiator cap pres-

Application: Use to cheek
systems'
sure and leaks from cooling

Radiatorcap tester'

ConnectingRod AlignmentTool

connectingrod
Application: Useto checkthe
alignment.
rod largeend I'D'
an"nfi."Uf.range: Connecting
rod length
i.i'g ar 2.95 in. dia' Connecting
2.56to 12.99in.

Connectingrod alignmenttool'

NozzleTester

fuel injection
Application: Useto checkthe
condition of nozzle'
nrT*"t" and spraying
M""suringrange: 0 to 7112 Psi'

EG-127A49

Nozzletester.

hess Gauge

oil clearance
Application: Useto checkthe
etc'
Uetw"encrankshaftand bearing'
to 0'03 in'
tot"ururingrange: Green- 0'01
Red - 0'02 to 0'06 in'
Blue - 0'04 to 0'09 in'

XIV
Diesel Timing Unit

Division)
Model No. 15-3354 (OTC ServiceTool

clamp
Application: No tools required' Use to
transducer on fuel injection line' The trans'
sends
ducer sens€sthe pulsesin the fuel line and
a signal to the timing unit which counts the
pulsesand displays rpm digitaly to an accuracy
of t 1 rpm. fi
The same pulse signal fires a timing light'
which the mechanic can pick up the top
with
dead
*-
#
center (TDC) mark on the flywheel' The r:t!t\"g:'
-A,i
timing light is adjustable upor-down with
two c
buttons on the tester. Degreesoff top dead
E G - 127898
center are displayed digitally on the unit' si'
multaneouslY with rPm. Dieseltiming unit'Model No' 15-3354.

XV
 NOTE: The following specialtools arenot
available.However,they canbe madefrom the
following illustrations.

Injection PumphessureTester

Application: Useto checkfuel pressureof in-

jectionpumps.

hessure gauge
A (Full scale: More than
6000 psi)

B Coppergasket

c Flange(Material: S45C)

Hex.nut 1.06in. across

D
the flat (Material:S45C)

E Injection pipe

a Adhesiveapplication
Injection pump pressuretester.
Fillet welding on the entire
b
circumference
*Chamfer mm ln.

c1 0.5 0.020

c2 0.5 0.020
*Unit: mm (in.)

XVI
Valve Guide Replacing Tool 1 S O( 7 . 4 8 1

80 (3.15) _3!l_i1.1
Application: Use to pressout and to pressfit
the valve guide.

c'8 ca
tChamfer mm In. c)
ol
Fi

:o
rri
r'.
c1 2.0 0.079 9; 6)
cEi rrt o
o cr-

c2 1 .0 0.039

c3 0.3 0.012 Valveguidereplacingtool.

C^ 1 .0 0.039

rUnit: mm (in.)

140 (5.511
Rocker Arm BushingReplacingTool
25 (O.9B l 12l o.47l

Application: Useto pressout and to pressfit

the rocker arm bushing.

*Chamfer mm ln.

c1 2.0 0.079

c2 1 .0 0.039 EG-127895

c3 0 .3 0 .012 Rocker arm bushingreplacingtool.

CN 1 .0 0.039

*Unit: mm (in.)

XVII
 1 5 0 ( 5 . 9 1)
Idler GearBushingReplacingTool
3 0 ( 1 , 1 8 ) 2 0 (0 .7 9 )

Application: Useto pressout and to pressfit

the idler gearbushing.
o)

rt)
c!
*Chamfer mm in .

c1 2.0 0.079

c2 1 .0 0.039
EG-127896
c3 0 .3 0 .012
ldler gear bearingreplacingtool.
c4 1.0 0 .039

*Unit: mm (in.)

ConnectingRod PistonPin BushingReplacing

1 4 5 ( 5 . 7 1)
Tool

Application: Useto pressout and to pressfit

the connectingrod piston pin bushing.

*Chamfer mm ln. 6
N

(. $
N o
c1 2.O 0.079 rf
r
o

c2 1 .0 0.039 N
o 6

o
ol r

EG-127897
c3 0.3 0 .012

C^ 1 .0 0 .039 Connectingrod pistonpin bushing

replacingtool.
fUnit: mm (in.)

XVIIJ
 ENG I NE

Contents
Page

SPEC|F|CAT|ONS .... L-4

E NG INEVIEW 1.9

SPEC IALNUT A ND B OLTTOROUEDA T A 1.10

TROUBLESHOOTING L-Lz

G ENER ALDESCRIP TION

Tlactor Identification . . . 1-r.5
CylinderNumbers 1- 16
DetailedDescription 1-16
PowerUnit . 1-16
Electric Fuel Pump L-t7
Fuel System 1.-L7
SecondaryFuel Filter 1- 18
Fuel Injection Pump 1-19
Governor L-20
Injection Nozzle 1-26
ElectricalSystem 7-27
StartingSystem L-28
ChargingSystem t-29
CoolingSystem 1-30
WaterPump t -31
CoolingFan . 1-31
Th e r m o stat.... 1-32
Radiator 1-33
RadiatorCap . 1-33
LubricatingSystem 1-34
Oil Pump 1-36
Relief Valve 1-36
Oil Filter Cartridge L-37
Oil hessureSwitch 1-38

S ERVICEHIN T S
AlternatorBelt . 1-39
Removal 1-39
Starter t44
PTO Clutch Assembly L44

1-1
ENGTNEREMOVAL 145

POWER UNIT DISASSEMBLY

Cleaningand Inspection . . 1-50
Reassembly L'50

ENGINE DISASSEMBLYAND ASSEMBLY

Engine Stands 1-51
ExternalComponents.... 1-51
Cylinder Head 1-51
Injection Pump and Levers l--56
Injection Pump and SpeedControl Plate . 1-56
Gear Caseand Flywheel . . . t-57
Pulley and Gear Case . L-57
Flywheel 1-59
Timing Gearsand Camshafts 1-60
Idler Gear 1-60
Gear and Camshaft 1'61
Oil Seal Sleeveand Gear 7-62
Crankshaft and Piston L-62
Main BearingCaseCover l-62
Crankshaft . 1-63
MainBearingCase .....1-64
Piston and ConnectingRod . . . L-65

UNIT SERVICING
Cylinder Head l--66
CylinderHeadSurfaceFlatness .....1-66
ValveStemClearance. ..L-67
ReplacingValve Guide . . 1-68
Valve Seat Width . 1-68
Correcting Valve and Seat L-69
Valve Recessing 1-69
Valve Spring Free Length and Tension . . . . . L-70
ValveSpringSquareness i.... I-70
Rocker Arm and Shaft . 1-71
Rocker Arm Bushing and Shaft Clearance . .l-7I
ReplacingRockerArmBushing.... L-7I
Camshaftand Timing Gears t-72
GearBacklash.. 1,-72
Idler Gear Side Clearance. . 1-73
Idler Gear Oil Clearance. . . 1,-73
CamshaftOil Clearance . . .: . L-74
CamshaftAlignment t-74
Camshaft Lobes Height l-75
Cylinder Block L-7b
Cylinder Liner L-75
CylinderBlocklnspection ....1-75

7-2
Crankshaft 1-76
CrankshaftEnd Play 1-76
ClankshaftAlignment 1-?6
Oil ClearancebetweenCrankshaftJournaland BearingL . ' ' ' L-77
Oil ClearancebetweenCranlshaftJournaland Bearings2 and 3 . . ' \- 77
Oil ClearancebetweenCrankPin and ConnectingRod Bearing . . . 1-78
Crankshaft Sleeve t-79
Piston and ConnectingRod 1-80
PistonPin Hole 1-80
ClearancebetweenPistonPin and Bushing 1-80
PistonRing Gap 1-81
PistonRing Clearance. . 1- 81
ConnectingRod Alignment . . 1-82
LubricatingSystem t-82
Oil Pump 1-82
CoolingSystem 1-84
Thermostat 1- U
WaterPump L-85
RadiatorCap 1-85
Fan and Fan Drive 1-86
Fuel System 1-87
Checkingand Adjustment 1-87
ElectricFuel Pump 7-94
ElectricalSystem L-94
Starter L-94
Alternator and Regulator . . 1- 102
Glow Plug 1- 103

POWER UNIT REASSEMBLVAND INSTALLATION 1-104

CHECKS AND ADJUSTMENTS

Checking Compressionhessure 1-109
Adjusting Valve Clearance . 1- 110
RadiatorScreen 1"111

Some of the illustrations and information in this manual are furnished courtesy of the Kubota Engine
Division.

1 -3
 SPECIFICATIONS

General

TVpe . . . Vertical-inJine, water-cooled, naturally-aspirated,4-cycle diesel

Numberofcylinders.... i.... .....3

Type of cylinder sleeves Dry, replaceable
Injection(fi ring)order. ...1-2-3

Direction of rotation (viewedfrom flywheel end)

. . . Counterclockwise

Boreandstroke . . . . 2.52x2.45 in. (64 x 62.2mm)

Compression ratio 23:l

Total displacement 36.61in. (600 cm3)
Combustionchamber ... Sphericaltype

Horsepower
SAENe tintermittent.... ..15.0hp@3600rpm
SAE Net continuous . t2.75 hp @ 3600 rpm

Governedspeed
M i nim u m . . . . 1 2 0 0 rp m + 1 0 0 r p m - O r p m
Maximum BG00rpm

Governor Centrifugalball, mechanical

Fuel injectionnozzle . . Boschthrottle type

Fuel injection pressure . 199L psi
Injection timing . 27o beforeTDC
Fuel injection pump . . . BoschMD mini pump
Fuel Dieselfuel oil. No. 2-D
Lubricatingoil
Grade . Must meet or exceedCC grade(A?ICD)
Capacity
0.769U.S.gal.(2.91l)
Starting system tZ V, 0,7 kW electricstarterand glow plug
Alternator (charging system)
12 V, 150W
Dry weight (fully equipped)
. . . 136.0lbs.plus

14
NEW DIMENSIONSAND ALLOWABLE WEAR LIMITS

NOTE: Unless specified otherwise, all dimensions are given in inches.

NEW ALLOWABLE
DIMENSION LIMIT

CYLINDER HEAD
Cylinderheadsurfaceflatness 0.0019per 3.94
Gasketthickness: Free 0.0453-0.0512
Tightened 0.0413-0.0453
Gasketshim thickness 0.0079
Compression pres.sure 448 psi 337 psi
Variancebetweencvlinders lO7"

VALVESAND VALVE SEATS_ INTAKE

AND EXHAUST
(cold)
Valveclearance 0.0059-0.0071
Valve seat width 0.055
Valve seat angle 450
Valve face angle 45.50
Valve recessing 0.0295-0.0374 o.i+t
Valve stem to guide clearance . . 0.00118-0.00224 0.0039
Valve stem O.D. 0.23496-0.23543
Valve guide I.D. 0.23661-0.2372L

VALVE TMING
Intakevalve: Open 20obeforeTDC
Closed 45oafterBDC
Exhaust valve: Open . 50o beforeBDC
Closed 15o afterTDC

VALVE SPRINGS
Freelength t.244 1.118
Tilt 0.047
Test length 1.063 1.063
Test load 14.6lbs. 12.3l bs .

ROCKER ARM
Clearancebetweenrocker arm
and bushing 0.00063-0.00268 0.0059
Rocker arm shaft O.D. 0.41232-0.4L276
Rockerarm bushingI.D. 0.41339-0.41500

CAMSHAFT
Camshaftaligament 0.0004 0.0031
Cam lobe lift (intake and exhaust) . . . . . . 1.0583 1.0 563
Camshaft running clearance 0.00197-0.00358 0.0059
Journal O.D. . 1.29662-r.29725
BearingI.D. 1..2992t-t.30020

1-5
 NEW ALLOWABLE
DIMENSION LIMIT

TIMING GEAR
Timing gear backlash . . 0.0016-0.0047 0.0059
Idler gear side clearance . . . 0.0079-0.0201 0.024
Clearancebetween idler gear shaft
and idler gearbushing. . . . 0.00063-0.00177 0.0020
Idler gear shaft O.D. 0.628860.62929
Idler gear bushing I.D. 0.629924.63063

CYLINDER LINER
Cylinderliner I.D. 2.5t969-2.52043 0.0059of wear
Available oversize liner . +0.20

PISTONAND PISTONRINGS
Pistonpin O.D. 0.70870-0.70902
Pistonpin hole I.D. 0.70866-0.70910 o.zroo
Pistonring clearance
Top and secondcompression. . . 0.00335-0.0044L 0.0059
Oil ring 0.0008-0.0024 0.0059
Pistonring gap
Top and secondcompression. . . 0.0098-0.0157 0.0492
Oil ring 0.0079-0.0157 0.0492
Availableoversizepiston rings . +.020

CRANKSHAFT
Crankshaftalignment 0.0008 0.0031
Main bearing running clearance 0.00134-0.004L7 0.0079
Main journalO.D.:
Front and intermediate 7.57227-L.57284
Rear L.72969-L.73032
Main bearingI.D.:
Front and intermediate 1.57418-1.57638
Rear 1.73166-1.73386
Crankpin running clearance 0.00075-0.00319 0.0079
Crankpin O.D. 1.33697-1.33760
Crankpin bearingI.D. . . 1.33835-r..34016
Crankshaft end clearance . . . 0.0059-0.0122 0.020
l^vailable undersize crankshaft bearings . . . -0.008- {.016
Available oversizethrust bearing +{.008- +0.016
Thrust bearing location Flywheelend

CONNECTINGROD
Connectingrod alignment 0.002
Pistonpin bushingI.D. . . 0.70965-0.71024

1€
 NEW ALLOWABLE
DIMENSION LIMIT

CONNECTING ROD - Continued

Piston pin O.D. 0.70870-0.70902
Running clearancebetween piston pin
and piston pin bushing 0.00063-0.00154 0.0059

LUBRICATING SYSTEM
Oil pressure:
At idle speed 10 psi
At rated speed 28 to 64 psi
Oil pump
Rotor lobe clearance 0.0098
Radial clearancebetween outer rotor
and pump body . 0.0059-0.0083 0.0118
End clearancebetween rotor and
cover 0.0031-0.0051 0.0079
Oil filter
Opening pressureof by-passvalve . 14.2psi
of pressure
difference

COOLING SYSTEM
Waterpump and alternatorbelt
Belt deflectionunderload of 21 lbs. 0.28{.35
Deflectionof fan belt . . 0.28{.35
Radiator
Systempressure 20 psi
Radiator cap opening pressure 10 secondsor more of
pressurefalling time
from 13 to 9 psi
Thermostat
Openat 176.9-182.30F
Fully open at 2030F
Full stroke 0.236

FUEL SYSTEM
Injectionpump
Injection timing (static) 19-210beforeTDC
Fuel pressure of pump element:
60 secondsor more of pressurefalling
time from 39.23to 34,32MPa . 5689 to 4978 psi
30 secondsor more of pressurefalling
time from 39.23to 34.32MPa . 5689 to 4978 psi
Fuel pressureof deliveryvalve:
10 secondsor more of pressurefalling
time from 2L.57to 20.59MPa . 3129 to 2987 psi
5 secondsor more of pressurefalling
time from 2L.57to 20,59 MPa . 3129to 2987psi
L-7
 NEW ALLOWABLE
DMENSION LIMTT

FUEL SYSTEM- Continued

Injection nozzle
Fuel injectionpressure,13.73to
1 4 .71 M P a L991to 2133 psi
Fuel pressurcatnozzle seat- no fuel
leakat 12.75MPa 1849 psi

ELECTRICAL SYS-TEM
Starter
Commutator: O.D. ,:t L.22
Out of roundness 0.002
Micaundercut 0.008
Brushlength 0.669 0.453
Glow plug
Resistance(approx.) 1.6 ohm
Alternator
No load output, AC volt or more
@ 5200 rpm . 20 volts
Voltageregulator
Regulatingvoltage L4 to 15 volt

1-8
 E NG I NEVI EW

EG-127730

f f lust. 1-1.782D Tractor equippedwith Kubota 3-cylinderdieselengine.

Left-front view with hood, side panelsand grille support removed.
Tractor equipped with optional 44-C Mower.

E G-12773" t

f lfust.1-2.782DTractorequippedwith Kubota3-cylinderdieselengine.
Right-side
view with hood,sidepanelsand grillesupportremoved.
Tractorequippedwith optional44-CMower.

1-9
 SpecialNut and Bolt TorqueData(ln Foot Pounds)

TIG H TENINGTOROUE SFORS P E CI A LUS EO F S CRE WSB.O L T SA ND NUT S

NOTE: For "O" marked bolts and nuts, apply engine oil to their threads and seatsbefore tightening.
Cylinder head bolts and nuts must be tightened in proper sequenceand at the proper torque.

o Crankshaftbolt 72.3 to 79.6

o Connectingrod bolts . 10.8to 13.11
o Cylinderheadbolts and nuts . 28.9 to 32.ii
o Cylinderheadcovercapnuts 2.9 to 4.il
o Cylinderheadstud L7.4 to 20.tl
Drain plug (engineoil) . 23.9 to 27.1i
o Flywheelbolts 39.8 to 43.4
Flywheelstubshaftscrews . 28 ft. lbs.
Fuel limit capnut 5.8 to 7.',1,
Glow plugs 14.5to 18.11
Injectionpiperetainingnuts 18.1 to 25.i!
o Idler gearshaftbolts . 7.23 to 8.3',1,
o Main bearingbolts: Intermediate. . . L4.5 to L7.lL
Rear . 8.7 to 10.t1
Nozzleholders 36.2 to 50.6
Oil pressureswitch 10.8 to 14.ti
Rockerarm nut 7.23 to 8.3i1

TIGHTENINGTOROUE SFORGE NE RA LUS EO F S CRE WSB,O L T SA ND NUT S

Whenthe tighteningtorquesarenot specified,tightenaccordingto the tablebelow:

Standard Special Special

Nominal Screw and Bolt Screwand Bolt Screwand Bolt
Diameter ss41,s20c s43C,S48C SCr435.SCM435

M6 5.79to 6.87 7.23to 8.32 9.04to 10.49

M8 13.0to 15 . 2 77.4 to 20.3 2L.7to 25.3
M10 28.9to 33.3 35.4to 4L.2 M.8 to 52.I
Ml2 46.3to 53.5 57.1to 66.5 75.9to 86.8
Mt4 79.6to 92.6 9 1 . 1t o 1 0 8 . 5 123.0to 144.7
M16 123.0to 14 L . 0 L44.7to 166.4 191.7to 224.2
M 18 180.8to 209.8 202.5to 235.1 253.2to 296.6
M20 245.9to 289.3 271.2to 318.3 3 6 1 . 7t o 41 9 . 5

1-10
Screw and bolt material gradesare shown by numbers punched on the screw and bolt heads. Prior to
tightening, be sure to check the numbers as shown below.

Punched
Number Screwand Bolt MaterialGrade

None Standardscrewand bolt SS41,S20C

I Specialscrewand bolt S43C,M8C (refined)

9 Specialscrewandbolt SCr435,SCM435(refined)

@--------O
EG.127732

Cylinder head tightening sequence.

1 -1 1
 TR O UBLESHO O TI NG

Reference
Symptom hobable Cause Solution Page

Enginedoesnot start No fuel Replenish fuel

(starterturns) Air in the fuel system Bleed fuel system
Water in the fuel system Replace fuel and repair or
replace fuel system
Fuel pipe clogged Clean
Fuel filter clogged Clean or replace 1-18
Excessivelyhigh viscosityof Use the specified fuel or
fuel or engineoil at low engine oil
temperature
Fuel with low cetanenumber Use the specified fuel
Fuel leak due to loosein- Tighten nut 7-L7
jection pipe retainingnut
Incorrectinjectiontiming Adjust
Fuel camshaftworn Replace
Injection nozzleclogged Clean 1-26
Injection pump malfunc- Repair or replace 1-56
tioning
Fuel pump malfunctioning Check wiring or repair or T-T7
replace
Seizureof crankshaft,cam- Repair or replace
shaft,piston,cylinderliner
or bearing
Compression leak from cyl- Replace head gasket, tighten 1-110
inder cylinder head bolt, glow plug
and nozzle holder
Impropervalveseatalign- Repair or replace 1-69
ment, valvespringbroken,
valveseized
Impropervalvetiming Correct or replace timing gear
Pistonring and liner worn Replace 1-81
Excessivevalveclearance Adjust 1-67
(Starterdoesnot Battery discharged Charge
turn) Startermalfunctioning Repair or replace 7-28
Starterswitch malfunctioning Repair or replace t-28
Wiringdisconnected Connect

Enginerunsrough Fuel filters cloggedor dirty Clean or replace 1-18

Air cleanerclogged Clean or replace
Fuel leak due to looseinjec- Tighten nut t-17
tion pipe retainingnut
Defectivefuel pump Replace 1-19
Injection pump malfunc- Repair or replace 1-19
tioning

L-t2
 Reference
Symptom hobable Cause Solution Page

Engineruns rough Incorrect nozzleopening Adjust L-26

Continued pressure
Injection nozzlestuck or Repair or replace t-26
elogged
Fuel overflow pipe clogged Clean L-L7
Governormalfunctioning Repair t-22

Either white or blue Excessive engineoil Reduceto the specifiedlevel

exhaustgasis ob- Pistonring and liner worn Repairor replace
served or stuck
Incorrectinjection timing Adjust
Deficient compression Adjust top clearance 1-109

Either black or dark Overload Lessenthe load

gray exhaustgasis Low gradefuel used Usethe specifiedfuel
observed Fuel filters clogged Cleanor replace 1-18
Air cleanerclogged Cleanor replace

Deficient output Incorrect injection timing Adjust

Defectivefuel pump Replace L-!7
Engine'smovingpartsseem Repair or replace
to be seizing
Unevenfuel injection Repair or replace the injec- 1-19
tion pump
Deficient nozzleinjection Repair ot replace the nozzle t-26
Compression leak Replace head gasket, tighten 1-109
cylinder head bolt, glow
plug and nozzle holder

Excessivelubricant Pistonring'sgapfacingthe Shift ring gapdirection 1-81

oil consumption samedirection
Oil ring worn or stuck Replace
Pistonring grooveworn Replacethe piston 1-81
Valvestemand guideworn Replace 7-67
Crankshaftbearingand crank Replace r-78
pin bearingworn

Fuel mixed into Injection pump'splunger Replace pump element or 1-19

lubricant oil worn pump

Water mixed into Head gasket defective Replace

lubricant oil Cracked crank ca.seor cvlin- Replace
der head

1 -1 3
 Reference
Symptom ProbableCause Solution Page

Low oil pressure Engineoil insufficient Replenish

Oil strainercloggled Clean L-84
Oil filter cartridgeclogged Replace 'J.-37
Relief valvestuck with dirt Clean l_-36
Relief valvespringweakenor Replace 1-36
broken
Excessiveoil clearanceof Replace L-77
crankshaftbearing
Excesive oil clearanceof Replace 1-78
crank pin bearing
Excessive oil clearanceof Replace L-71
rocker arm bushing
Oil passage clogged Clean 1-35
Different type of oil Use the specified type of oil
Oil pump defective Repair or replace 1-36

High oil pressrue Different type of oil Usethe specifiedtype of oil

Relief valvedefective Replace t.-36

Engine overheats Engineoil insufficient Replenish

Fan belt or alternatorbelt Replaceor adjwt
broken or tensionedim-
properly
Insufficientcoolingwater Replenish 1-30
Radiatornet and radiatorfin Clean 1-33
cloggedwith dust
Insideof radiatorcorroded Cleanor replace 1-33
Coolingwater flow route Cleanor replace L-32
corroded
Defectiveradiator cap Replace 1-33
Defectivewater hose Replace
Defectivethermostat Replace 1.-32
Defectivewater pump Replace 1-31
Defectivemechanicalseal Replace
Overloadrunning Loosenthe load
Defectiveheadgasket Replace
Incorrectinjectiontiming Adjust
Unsuitablefuel used Usethe specifiedfuel

Battery discharges Battery electrolytelevellow Add distilled water and

quickly recharge
Fan or alternatorbelt slips Adjust belt tension or replace
Disconnectedwiring Connect
Defectiveregulator Replace 1.-29
Defectivealternator Replace L-29
Defectivebatterv Replace

t-14
 GENERALDESCRIPTION

Tractor I dentification

numbershown
The model designationand serial
information for the shouldbe
These instructions contain ." ,it" nameplateillustratedbelow
the International regardingthe
maintenance and service of includedin any correspondence
equippedwith
Cril-C.J" TtactorModel?82D' tractor.
engine'
the Kubota 3-cylinder diesel

lllust.1'3.Tractoridentification'

1 -1 5
 CylinderNumbers

givenas In describingthe variousmaintenanceand

The sequenceof cylindernumbersis the
the serviceprocedures,after engine removal,
No. 1, startingfrom the gearcaseend of
The front of the engine will always be designated
engine,closestto the steeringcolumn'
as the gear caseend.
flywheel and power take-off unit are mounted
ui tt front of the tractor, closestto the radia-
"
tor and grille.

DetailedDescriPtion

POWERUNIT (SeeIllust' L-4)

The powerunit, whichconsistsof the Kubota
3-.yiinder dieselengine,radiator,fan assembly
inter-
and powertake-offclutch,togetherwith
in the
connectinghosesand piping arecradled
engineand radiatormount, which is removed
asa unit for servicing.

E G" 127734

lllust.1-4.Powerunit removedfrom chassis'

1.16
 s*,iii EG.127735

lllust. 1-5.Batteryand fuel systemcomponents.

1. Battery 6 . F u e lin je c t io np u mp
2. E lectricfuel pump 7, Secondary fuel filter
3. P rimaryfuelfilter 8. Fuelshut-offvalve
4. Enginestop levercable 9. Air ventplugs
5. Speedcontrollevercable 1 0 . F u e lin je c t io nlin e s

ELECTRIC FUEL PLJMP(See Illust. 1-5) through the enginemountedsecondaryfuel

The electric fuel pump (2) is mounted on a filter (6) to the injectionpump (5). The second-
bracket attached to the battery support. The ary fuel filter is equippedwith a shut-off vaive
pump is energizedin all key switch positions, and two air bleedscrews.
except "OFF."
The injection pump force-feedsthe fuel through
FUEL SYSTEM (See Illust. 1-6) the injectionpipes(3) to the injectionnozzles
The fuel is fed from the fuel tank (1) through (4), whichinjectthe fuel into the cylinders
the tank fuel shut-off valve (10), and primary for combustion.
in-line fuel filter (9) to the inlet side of the
electric fuel pump (7). The excessive fuel in the injection pump and the
injection nozzleis collectedin the fuel overflow
Actuating the key switch (8) energizesthe pipes(2) and returnsto the fuel tank.
electric fuel pump (7) which pumps the fuel

t-L7
 '(

EG-127737

lllust, 16. Fuel system.

1. Fueltank 6. Secondary fuel filter

2. Fueloverflowpipe 7. Electricfuel pump
3. lnjectionpipe 8. Key switch
4, Injectionnozzle 9. Primaryfuel filter
5. lnjectionpump 10. Tank shut-offvalve

SECONDARYFUEL FILTER (SeeIllust. 1-7) As the fuel from the inlet (A) movesthrough
The fuel filter is installedin the fuel line from the filter element(3), the dirt and impurities
the fuel pump to the injection pump. . in the fuel are filtered, allowing only cleanfuel
to enter the inside of the filter element. The
cleanedfuel flows out from outlet (B) to the
injection pump.

1-18
 Before starting or after disassemblingand re-
assembling,loosen the air vent plugs (2) to
bleed the air in the fuel line.

A. ln le t
B. Outlet
1. F u e lc o c k
2. A ir v e n tp lu g
EG-'t27738 3. F ilt e re le me n t
4. F ilt e rc u p

lllust. 1-7. Secondary fuel filter.

FUEL INJECTIONPIIMP (SeeIllust. 1-8)

The injection pump is a BoschMD type mini-
injection pump, which giveshigh injection
quality evenat low enginespeeds.The plunger
is reciprocatedby the cam on the camshaft
with the tappet and forcesthe fuel into the
injection nozzle.

The control rack (4) is pushedor pulled by

the fork leverof the governorand rotatesthe
control sleeve(5) and the plunger,which ha.s
a left-handleadcontrol groove,to vary the
amount of fuel forced into the injection nozzle.

1. De liv e ryv a lv eh o ld e r
2. De liv e ryv a lv es p rin g
3. Deliveryvalve
4. Controlrack
EG.127739 5. Controlsleeve
6. Cy lin d e r
7. P lu n g e r
lllust.1-8.Fuelinjectionpump. 8. P lu n g esrp rin g
9. Tappet

1 -1 9
 1) PumpElement(SeeIllust. 1-9)
The pump elementconsistsof the plunger(4)
and cylinder (3), and their slidingsurfaces
are superprecision-machined to maintainfuel
pressure.

The plungerfits in the control sleevewhich is

engagedwith the controlrack.

The plungerhasa control groovewith a left-

handhelix lead.

1. Feedhole
2. Control groove
3. Cylinder
EG-127740
4. Plunger
lllust. 1-9.Pumpelement.

2) DeliveryValve(Seelllust. 1-10)
The deliveryvalveconsistsof the valve(1) and
the valveseat(2).

The deliveryvalvepreventsthe fuel from flow-

ing backinto the deliverychamberthrough
the injection pipe. It alsopreventsthe fuel

EG-127741
I from dribbling at the injection nozzle.

Whenthe deliverystrokeends,the relief plunger

movesinto the bore of the valveseatand seals
the deliveryline from the deliverychamber.
lllust.1-10.Deliveryvalve. The relief plungerlowersfurther until the valve
seatssuck backthe fuel to preventdribbling
at the injection nozzle.
'1. Valve
2. Valveseat
3. Reliefplunger

1-20
 3) Operationof Pump Element (Seelllust. 1-11.)
1. Before delivery
As the tappet lowers,the plunger(2) alsolowers
and fuel is drawninto the deliverychamber(1)
through the feed hole (5) from the fuel cham-
ber (4).

2. Beginningof delivery
Whenthe plungeris pushedup by the cam and
the headof the plungerclosesthe feed hole,
the pressurein the deliverychamberrisesto
pushthe reliefplunger(3) open.

Fuel is then force-fedinto the injection pipe.

3. Delivery
While the plungeris rising,the deliveryof fuel
continues.

4. End of delivery
Whenthe plungerrisesfurther and the control
groove(6) on its peripherymeetsthe feed hole,
3 EG-127742 4 the fuel returnsto the fuel chamberfrom the
deliverychamberthrough the control groove
lllust.1-11.Operationof pumpelement. and the feed hole.

4) PlungerPosition(SeeIllust. 1'12)
1. Deliverychamber 1. No fuel delivery
2. Plunger At the enginestop positionof the control
3. Reliefplunger rack (3), the lengthwiseslot (1) on the plunger
4. Fuel chamber (2) alignswith the feed hole (5). And the de-
5. Feedhole Iivery chamber(4) is led to the feed hole during
6. Control groove the entirestrokeof the plunger.

The pressurein the deliverychamberdoesnot

build up and no fuel can be forced to the injec-
tion nozzle.

L.2T
 2. Fuel deliverY
The plungeris rotatedby the control rack'
Whenthe plungeris pushedup, the hole is
closed.The pressurein the deliverychamber
buildsup and force'feedsthe fuel to the injec'
tion nozzleuntil the control groove(6) meets
the feedhole.

to the
The amountof the fuel corresponds
distance"A."

1. S lo t
2. Plunger
3. Controlrack
2 4. Deliverychamber
EG-127743
5. F e e dh o le
6. Controlgroove
l l l ust.1-12.Plungerposition.

GOVERNOR (SeeIllust' 1-13)

The governor controls the amount of the fuel
'-
to be fed in the entire speedrange to prevent
\:'i)y'"a
. 7". , , 1 the engine from changing its speed according
to the load.
""nl ,.:!'
- !-
-.1 The fork lever l, (3) is held where two forces on
$.1,/,.i!
it are balanced. One is the force that fork lever
2 pushes,which is causedby the tension of the
i -. t-,:,
|."'
governor spring (4) between the governor lever
(1) and fork lever 2 (5). Another is the com-
'--':i ponent of the centrifugalforce produced by
i\ the steel balls (6) which are rotated by the fuel
camshaft(10).

1. Governorlever 6, Steelball
2. Start spring 7. Governorsleeve
3. Fork lever1 8. Steelball
EG-l27744 4, Governorspring 9. Governorball
5. Fork lever 2 case
l llust. 1-13.Governor. 10. Fuel camshaft

t-22
 1) At Start

JLl The steelbdl (4) hasno centrifugalforce.

t
i' {
q
Fork lever1 (2) is pulled by the start spring(1)
and the control rack (3) movesto the maximum
injection positionfor easystarting.

1. Startspring
4',- 2. Fork lever1
.,,I i
EG-127745 3. Controlrack
4. Steelball
lllust. 1-14.Governorat start position.

2) At Idling
rj! Whenthe speedcontrol lever(2) is set at the
idling position,the governorspring(3) is pulled
slightly.

As the camshaftrotates,the steelballs(8)

increasetheir centrifugalforce and pushthe
governorsleeve(7). Fork lever1 (4) pushed
by the governorsleeve,pushesthe control
rack (5) andthe controlrack compresses the
idlingadjustspring(6).

The control rack is kept at a position wherethe

centrifugalforce is balancedwith the spring
tensionon the controlrack,providingstable
a
I e c.127746
idling.

lllust. 1-15. Governorat idling position.

1. Start spring
2. Speedcontrol lever
3. Governorspring
4. Fork lever 1
5. Control rack
6. ldling adjustspring
7. Governorsleeve
8. Steelball

r-23
 Running (See
3) At Medium or High Speed
Illust' 1'16 and 1'17)
(1) is turned
Whenthe speedcontrol tever
(2) increases the
further, the governorspring
(3) is pulled to
tensionand the control rack
increasethe enginesPeed'
centrifugalforce
The steelballs(4) increasetheir
the
irt" control rack is pushed'decreasing
""J force and
;;;"; speed,until the centrifugal
thJ springtensionarebalanced'
(A'B) with
Whenthe enginespeedis dropped
the increase of the load (a'b)' the centrifugal
and the control
for." of the steelball decreases
the fuel to the
,".f. it pulled. The amount of
higher
iri"*i* nozzleisincreasedto producea
E G -' t27747
load'
enginetorquerequiredfor the
or
lllust.1'16.Governorat medium
highsPeedrunning'

1. SPeedcontrol lever
2. Governor sPring
3. Controlrack
4. Steelball

to 1.
2.
E n g in et o rq u ec u rve
Largeloadtorquecurve
3. Smallloadtorquecurve
4. T o rq u e
E n g in es p e e d
0* EG-127748 5.

lllust.1-17.Torquecurvechart'

t-24
 4) At Maximum Speed Running with an
Overload (See Illust. 1-18)
When the engine is overloaded at the high speeds
and the engine speed drops, the centrifugal
force of the steel balls (6) decreasesand the
governor spring (2) pulls fork lever 1 (1) and 2
(3 ).

Whenfork lever2 contactsthe adjustingscrew

(5), the spring(4) which is built in fork lever 2
beginsto pushthe fork lever 1 to pull the con-
trol rack.

The fuel to the injection nozzleis increased

to run the engineat high speedand torque.

EG-127749
1. Fork lever1 4. SPring
lllust.1-18.Governorat maximumspeed 2. Governorspring 5. Adjustingscrew
runningwith an overload. 3. Fork lever2 6. Steelball

5) To Stopthe Engine(SeeIllust-1-19)
Whenthe stop lever(1) is movedto the stop
position,fork lever1 (2) is pushedand the
controlrack (3) is movedto stop the fuel in-
jection.

1 . Stop lever
2 . Fork lever1
3 . Controlrack
EG-127750

lllust.1-19.Governorat engin€stop.

1-25
 INJECTION NOZZLE (Seelllust. 1-20)
The nozzleis of the throttle type. The needte
valve(10) is pushedagainstthe nozzlebody
(9) bV the nozzlespring (6) with the push rod
(7 ).

The fuel forced from the injection pump pushes

up the needlevalveand is injectedinto the
sub-combustionchamber(4). The excessive
fuel which is not injectedreturnsthrough the
centerchamberof the nozzleholder and the
eyejoint (2) to the fuel tank.

The injection pressurecan be adjustedwith the

adjustingwasher(5) from 1991 to 2133 psi.

EG-127751

lllust.1-20.Injectionnozzle.

1. Fuel overflow pipe

2. Eye joint
3. Nozzleholder body
4. Sub-combustionchamber
5. Adjustingwasher
6. Nozzlespring
7. Pushrod
8. Retainingnut
9. Nozzlebody
10. Needlevalve

7-26
 startingmotor, glow plup, PIO clutch, head'
ELECTRICAL SYSTEM(SeeIllust' 1-21)
lights,taillights,ignition key switch,various
The electricalsystemconsistsof the 12-volt
(rectifier)' ,utaty switches,meters,relays,gaugesand con-
battery, alternatorand regulator
nectingwiring.

GLOW PLUG
INDICATORLIGHT
GRoui,rDaT
RELAY SASE

GR OUN D
AT
P€DESTAL

EG-127752

lllust.1-21.Wiringdiagram'

L-27
 STARTING SYSTEM(Seelllust. L-22 and l-28\
1) StartingMotor
The starteris of the electromagnetic
drive type.

Type of motor DC, Series,Electro-

masxeticdrive
Supply voltage r2v
Ratedoutput 0.7kw
Rate Lessthan 30 seconds
Direction of rotation Clockwise as viewed
from pinion side

1. Solenoidswitch
2. Plunger
3. Spring
EGj27753 4. Shift lever
5, Brush
6. Commutator
lllust. 1-22.Startingmotor. 7. Armature
8. Field coil
9. Overrunningclutch

1. Startingswitch
2. Magneticswitch
3. Holdingcoil
4. Pull-incoil
5. Plunger
6. Rod
7. Shift lever
8. Field coil
9. Commutator
10. Brush
EG-127754 1 1. Armature
12. Spiralspline
13. Overrunningclutch
lllust. 1-23.Startingmotor circuit schematic. 14. Pinion

1-28
 2) Glow Plug
Bu.frroU-.ombustion chamberhasa glow plug
plug is of the quick-
fo, .ury starting' The glow
heatingtYPe.

1. lnsulatingPowder
2. Metaltube
3. Housing
4. Heat coil

lllust. 1-24.Glow Plug'

CHARGING SYSTEM
L) Alternator
pole rotating magnet
The alternator is an 8-8
of stator and
irp. ,"n"rutor, which consists .a
a rotor and is simple in constructton'

magnet poles
The rotor has eight permanent
has eighi
and rotates around the stator' which
coils.

EG-127756 voltageeven
The alternator can produce high
battery
at slow enginerpm and chargethe
during engineidling'

I llust. 1-25.Alternator'

2) Regulator
regulator with
The regulator is a transistorized
SCR.

SCRsturn on
When the battery voltageis low'
current from
to chargethe battery with the
the alternator.

excessively'
When the generatedvoltagerises
they turn off to stoP charging'

EG-127757

lllust. 1-26. Regulator'

t-29
 1. To AC terminal of key switch (yellow)
EG-127758 2. To alternator(light blue)
3. To alternator(light blue)
4. To ground (black)
I ffust.1-27.Alternator/regulator
schematic.

CoolingSystem

The cooling system consistsof a radiator (1),

a centrifugal water pump (4), a suction fan (2)
and a thermostat (3).

The water is cooled through the radiator core,

and the fan behind the radiator pulls the cooling
air through the core to improve cooling.

The water pump sucksthe water from the ra-

diator or from the cylinder block and forces
it into the crankcase.

The thermostat opens or closesaccording to

the water temperature, to allow the water to
flow from the cylinder block to the radiator
while opennor only to the water pump while
closed.
EG-12781'l

Thermostatopening I Approx. 82oC

lllust. 1-28.Coolingsystem. temperature I (180oF)

1 . Ra d iator 4. Waterpump
2. Co o lingfan 5. Cylinderhead
3. Thermostat 6. Cylinderblock

1-30
 WATERPUMP
The water pump is driven by the crankshaft and
a "Y" belt. The rotating impeller (4) in the
water pump sucks the cooled water from the
radiator and sendsit into the water jacket in
the crankcase.

The mechanical seal (3) prevents the water from

entering the bearing unit (L).

EG-127759 COOLING FAN (See Illust. 1-30)

The cooling fan is mounted on a bracket above
lllust. 1-29.Water pump. the flywheel and belt driven from a stub shaft
pulley attached to the flywheel. An idler
pulley is provided for belt tension.
1. unit
B earing
2. Waterpumpbody
3. Mechanicalseal
4. W aterpumpimpeller

trt

og

EG-127760
lllust. 1-30.Coolingfan assembly.

1-31
 Legendfor lllust. 1-30.

1 . Fansupport 10. B allbe a rin g 19. Fan mount bracket 27. Bolt
2. Bolt 11. Spacer 20. ldler support bracket 28. Washer
3. Bolt 12. S pac e r 21. Bolt 29. Washer
4. Fanshaft 13. Fan 22. Spacer 30. Bolt
5. Fanhub 14. P ulley 23. Nut 31. Bolt
6. Specialkey 15. Clip 24. Washer 32. Bolt
7. Lock washer 16. B olt 25. Washer 33. Washer
8. Washer 17. Nut 26. ldler pulley 3 4 . B ol t
9. Washer 18. Lockwasher

THERMOSTAT (Seelllust. 1-31 and 1-32)

The thermostat is of the wax pellet type.

The thermostat controls the flow of the cooling

water to the radiator to keep the proper tem-
perature.

The case,which servesas a valveseat (1), has a

spindle insertedin the pellet (3) which is in-
stalled to the valve (2). The spindle is covered
with the synthetic rubber (5) in the pellet. The
E G -1 2 7 76' l
wax is charged between the pellet and the
lllust. 1-31.Thermostat,valveclosed. rubber-

1. Seat 5. Syntheticrubber 1) At Low Temperatures(Lower than 82oC

2. Valve 6. Wax (solid) [ 180oF] )
3. Pell et 7. Spring The valve (2) is seatedby the spring (7) and the
4. Spindle 8. Leak hole cooling water circulatesin the enginethrough
the water return pipe without running into
the radiator.

Only the air in the water jacket escapesto the

radiator through the leak hole (8) on the ther-
mostat.

2) At High Temperatures(Higher than 82oC

[ 180oF] )
As the water temperature rises,the wax in the
pellet (3) turns liquid and expands,repelling
.
the spindle, which causesthe pellet to lower.
EG-127762
The valve (2) opensto send the cooling water
lllust. 1-32.Thermostat,valveopen. to the radiator.

1. Wax (liquid)

L-32
 RADIATOR
The radiator core consistsof water carrying
tubes(1) and fins (2) at a right angleto the
tubes. The fin is a louverlesscorrugatedtype
which is light in weight,high in heat exchange
A- ratio and lessapt to clog.

The water in the tubes is cooled by the air

flowing throughthe tube wallsand fins.

EG-127763
lllust. 1-33. Radiator

A . Coolingair
1. Tube EG-l27764
2. Fin
lllust. 1-34.Radiatorfins.

1. Louverless
corrugatedfin
2. Louveredcorrugatedfin

RADIATOR CAP
The pressuretype radiatorcap preventsdif-
ferencesin pressurebetweenthe insideand
.- - r - fl- .]- - the outsideof the radiator.
, ,-a l
,/l\

t
Whenthe water temperaturerisesand the
pressurein the radiator increasesabovethe
specifiedpressure,the pressurevalve(1) opens
EG-'t27765 to reducethe internal pressure.Whenthe water
lllust. 1-35.Radiatorcap,pressure
valve. temperaturefalls and a vacuumforms in the
radiator,the vacuumvalve(2) opensto intro-
1. Pressure
valve duceair into the radiator.

EG-127766
lllust.1-36.Radiatorcap,vacuumvalve.

2. V acuumvalve

1-33
 LubricatingSystem

EG-127767

lllust. 1-37. Lubricatingsystem.

1 . P iston 4 . O il s t ra in e r
2 . Oil pump 5. Camshaft
3. Rockerarmand rocker arm shaft 6. Oil filter cartridgeand reliefvalve

The lubricating system consists of an oil strainer, and the rocker arm shaft through the oil passage
an oil pump, a relief valve, an oil filter cartridge in the crankcaseand the shafts to lubricate
and an oil pressureswitch. The oil pump sucks the bearings.
the lubricating oil in the oil pan through the
strainer and sendsit to the oil filter cartridge, Some oil, splashedby the crankshaftor thrown
where the oil is further filtered. off from the bearings,lubricates other engine
parts: the pistons, the cylinder walls, the piston
The filtered oil is forced to the crankshaft, pins, the tappets, the pushrods, the timing
the connecting rods, the idle gear, the camshaft gears,and the inlet and exhaust valves.

t-34
 f
l-@-l
I

6?d
|r/ ffid

E G - 12 7 7 6 8

lllust. 1-38. Engineoil flow diagram.

1. Oil p an 9. Connectingrod big end 16. Tappets

2. Oil strainer 10. Timing gear 17. Camshaft bearing
3. O i l p ump 1 1. Splash 18. Camshaft
4 . R eliefvalve 12. Cylinder 1 9 . Dra in
5. Oil filter cartridge 13. Connectingrod smallend 20. Rockerarm
6. ld legear 14. Piston 21. Oil switch
7. M ainoil gallery 15. Fuel camshaft 22. Rockerarmshaft
8. Mainbearing

1-35
 OIL PUMP
The oil pump is a gearpump, whoserotors have
trochoid lobes. The inner rotor (B) has4 lobes
and the outerrotor (4) has5 lobes,and they
are eccentricallyengagedwith eachother. The
inner rotor, which is drivenby the cranlahaft
through the gears,rotatesthe outer rotor in
the samedirection,varyingthe spacebetween
the lobes.

EG-127769 Whilethe rotors rotate from (A) to (B), the

spaceleadingto the inlet port increases,which
causesthe vacuumto suck in the oil from the
lllust.1-39.Oil pump. inlet port.

Whenthe rotors rotate to (C), the connection

1. lnlet port to the spaceswitchesfrom the inlet port to
2. Outlet port the outlet port.
3. Inner rotor
4. Outer rotor At (D), the spacedecreases and the suckedoil
is dischargedfrom the outlet port.

RELIEF VALVE
The relief valvepreventsdamageto the lubri-
catingsystemdue to the high pressureof the
oil.

The relief valveis a ball type direct acting one,

and is best suited for low pressures.

Whenthe pressureof the oil, forced by the

pump, exceedsthe specifiedvalue,the oil
pushesbackthe ball (2) and escapes to the oil
pan.

lllust.140. Reliefvalve.

1. S pring
2. Ball
3. Valveseat

1-36
 OIL FILTER CARTRIDGE
After lubricating,the lubricatingoil brings
back variousparticlesof grit and dirt to the
oil pan, Thoseparticlesand the impuritiesin
the lubricatingoil can causewearor seizure
of the engineparts. It may alsoimpair the
physicaland chemicalpropertiesof the oil
itself.

EG-127771

The lubricatingoil, which is force-fedby the

lllust. 141, Reliefvalve. pump, is filtered by the filter cartridgewith the
filter element(2). Whenthe filter element
accumulates an excessive amount of dirt and
1. S pring the oil pressure in the inlet line builds up by 14
2. B all psi more than the outlet line, the by-passvalve
3. Valveseat (1) opersto allow the oil to flow from the
inlet into the outlet line, by-passing the fiiter
element.

EG-127772

fffust. 142. By-passvalve- closed.

E G - 127773

1. By-passvalve
2. Filter element lllust. 1-43.By-passvalve- opened.

1.37
 OIL PRESSURE SWITCH
tAl The oil pressureswitch is mounted on the
crankcaseand is led to the lubricating oil pas-
sage.

When the oil pressurefalls below the specified

value, the oil pressurewarning lamp lights.
--o
A. At the properoil pressure
B. 7 psi or less
At loweroil pressure,
E G . 12777 4 1. T e rmin a l
2. I n s u la t o r
lllust.1-44.Oil pressure
switch 3. Spring
at properoil pressure. 4. Rubbergasket
5. Contactrivet
6. Contact
7. Oil switchbody
tBl 8. Key switch

EG-127775

lllust. 1-45. Oil pressureswitch

at 7 psi or lower pressure.

1-38
 SERVI CEHI NTS

Alternator Belt

REMOVAL
To replacethe alternatorbelt, it is necessary
to disconnectthe drive shaft and movethe
engineand radiator mount forward. Usethe
followingprocedure:

1. Raisethe hood andremovethe side

panels. Seelllust. 146.

2. Disconnectthe battery groundcable

from the battery.

3. Removethe nut and washersecuring

the radiator supportto the radiator.

4. Disconnectthe headlightwiring and

removethe hood and grille asan assembly.

lllust. 1-46. Hood latch.

1. Hood
2. Latch
3. Radiatorand grille suPport

1-39
 5. Removethe frame cover. SeeIllust.
147.

f lfust. 147, Frame cover and side panel.

1. Framecover
2. E nginesidepanel

6. Workingthrough the frame coveropen-

ing, removetwo nuts (1, Illust. 148) securing
the drive shaft (2) to the d.ive shaft flange
on the crankshaftpulley. SeeIllust, 149.

ffi
ffi
{J
EG-127777

lllust.1-48.Driveshaft.

1. Flangenuts
2 . Driveshaft

140
 9 g
'/l '
/rsY) EG-127778

lllust. 1-49. Drive shaft flangeand flexible coupling.

1. Crankshaft pu lley 5 . F le x ib led is c s

2. Drive shaft f lange 6. Washer
3. Pilot bearing 7 . Nu t
4. Flangeattachingbolts and washers

741
 7. Slackenthe tensionon the main drive 8. Disconnectthe regulator(19) to alter-
belt (11, Illust. 1-50)and slip the belt from nator (18) wiringeonnector.Checkthat there
the power takeoff pulley. is enoughslackin wiring to starter,glow plugs,
and sendingunits to allow engineto move for-
ward for belt removal.

i *e

EG-127779

f llust. 1-50.Rightfront viewof 782D Tractor

with sheetmetalremoved.

1. Batterycover 11. Main drive belt for mower

2. Bat'tery 12. Tensionbolt
3. Electricfuel pump 13. ldler pulley bracketfor mower
4. Upper radiatorhose 14. Engineand radiatormount
5. Air cleanerhose 15. Flywheel
6. Radiatorcap 16. Enginemounts
7. Radiator 17. Muffler
8. ldler pulley bracket 18. Alternator
9. Bolt 19. Regulator
10. Starter

L42
 9. Closethe fuel shut-off valve at the 10. Closethe fuel shut-offvalve(13, Illust.
fuel tank. 1-51)at the secondaryfuel filter (L4).

EG-127780

lllust.1-51.Powerunit andcomponents.

1. Radiatorcap 13. Fuel shut-off valve

2. Upper radiatorhose 14. Secondaryfuel filter
3. Air cleanerhose 15. Enginemounts
4. Air cleanerhoseclamps 16. Engineand radiatormount
5. Oil filler cap attachingbolts
6. Fuel hose 17. Engineand radiatormount
7. Battery ground cable 18. Main drive belt
L BatterY .19. BatterYground cable
9. Electricfuel pump 20. Ground-to-framecable
10. Enginestop leverand cable 21. Radiator
1 1. Enginespeedcontrol lever 22. Air cleaner
and cable 23. Pre-cleaner
12. Primaryfuel filter

L43
 11. Disconnectthe fuel hose(6) at the 1b. Cut the plastictie which binds the
electricfuel pump (9). Plugboth openings. lower radiatorhoseto the hydraulichoses
underneaththe tractor.
12, Disconnectthe enginestop levercable
(10) and enginespeedcontrol levercable(11) 16. Carefullyslidethe engineand radiator
at the levers. mount forward until the drive shaft clearsthe
drive shaft flange.
13. Disconnectthe battery groundcable(19)
and the ground'to'framecable(20) at the air L7. Replacethe alternatorbelt and adjust
cleanermountingbracket. belt tension.

L4. Removefour bolts (16) and washers 18. Reassemble

in reverseorder of disas-
securingthe engineand radiator mount to the sembly.
tractor frame.

Starter

REMOVAL
To replacethe starter, it is necessaryto remove
the enginefrom the tractor. See"Engine
Removal"pageL45.

PTOClutchAssembly

REMOVAL
To removePTO clutch assemblywith engine
mounted in the chassis,it is necessaryto sep-
arate the clutch so that the parts will clear
the engineand radiator mount.

L44
 ENG I NEREM O VAL

1. Parkthe tractoron a flat levelsurface.. L2. Disconnectpositivecablefrom starter

solenoidterminal. Disconnectswitchspade
2. Closethe shut-off valveat the fuel tank. from solenoidterminal.

3. Raisethe hood. Seelilust. 146. 13. Remove nut and washerfrom alternator's
lower mounting bolt securing the wire cable
4. Removethe batterycover(1,Illust. holder to the engine. Remove wire holder and
1-50). Disconnectthe batterycablesand cable assembly.
removethe battery. Slip the two battery
coverholddown boltsout of the batterv NOTE' Loosely re-install nut and washer
tray. on e4gine.

5. Unhookthe sidepanelspring(2, Illust. L4. Removethe screwsecuringthe wire to

146). the oil sendingunit terminal. Removethe
wire and re-installthe screw.
6. Removethe wing nut and washersecur-
ing eachpanelto the chassis. 15. Disconnectthe two blue alternatorwires
in the wiringhar-
from the wiringconnectors
NOTE: Lock ihe brakepedalin the "down" ness.
position for easeof side panelremoval. The
exhaustmanifoldsidepanelmust be "worked" 16. Loosenhoseclampsand removeinlet
out of position. and outlet fuel hose(6, Illust. 1-51)from the
fuel pump (9). Disconnectand removefuel
7. Disconnectheadlightwiring. hosesfrom the primaryfuel filter (12). Cap
all hosesand inlet and outlet openings.
8. Removenut and washersecuringgrille
supportto radiatorbracket. L7. Disconnectfuel pump positivewire
from the connector.
9. Support hood and grille assemblyand
removetwo bolts and lock washerssecuring 18. Removeone bolt and lock washerfrom
eachside of grillesupport to the tractor frame. eachsideof the battery tray lower mounting
position. Removeone bolt and flat washer
10. Carefullylift hood and grille assembly from eachsideof the battery tray upper mount-
from the tractor. Slidethe two nut platesfrom ing (slottedhole) position.
the groovesin the grille support.
19. Lift out the battery tray with the at-
11. Removethe nut from the belt tension tachedfuel pump, regulatorand circuit breaker.
bolt (12, Illust. 1-50). Pushback on the spring Tie off to the sideof the tractor.
loadedpulley and slip the main drive belt (11)
off of the PTO pulley. 20. Removethe battery-to-groundcable(19,
Illust-1-51),and ground-to-frame
cable(20)
NOTE: Positionfan bladecorrectly to slip at the air cleaner
bracket.
belt from PTO pulley.

L45
 NOTE: The bolts that securethe ground 25. From underneaththe tractor, clip the
cablesto the air cleanerbracket also securethe plastic tie that binds the lower radiator hose
air cleaner, so that the air cleaner is now loose. and hydraulic hosesto the engine and radiator
mount.
2I. Loosen the hose clamp (4) securing'the
air cleaner hose (3) to the engine intake mani- 26. Remove the frame cover (1, Illust. 147).
fold and remove the air cleaner assemblv.
27. Working through the frame cover open-
22. Disconnectthe water temperaturesend- ing, remove two nuts (1, Illust. 148) and
ing unit, glow plug and PTO wiring from their washerssecuring drive shaft to the drive shaft
terminals and connections. flange on the crankshaftpulley.

23. Remove the enginestop lever cable (10) 28. Attach a suitablehoist and chain to the
and enginespeedcontrol lever cable (11-)from enginelifting eyes.
the levers. Remove the cable hold-down clips.
29. Removefour bolts (16, Illust. 1-51) and
NOTE: The top lever (enginestop lever washerssecuringthe engineand radiator mount
t 10 ] ) has a swivel connection, and the attach- (17) to the tractor frame.
ing nut is at the top of the lever. The lower
lever (enginespeedcontrol lever [ 11 ]) is wire 30. Slide the engineand radiator mount for-
connectedand the attaching nut is at the bot- ward to disengagethe drive shaft. Raise the
tom of the lever. assembledpower unit from the tractor chassis.
SeeIllust. 1-52.
24. Disconnectthe fuel return line from
the forward cylinder injector (No. 3 cylinder).
Slide out of plastic tie and plug openings.

,,
,1
'p
tr \
11
t7 1
r*.
7 \,u
Y'
t,
t
'r
[,

lllust. 1-52.Powerunit removedfrom chassis.

146
 POWER UNIT DISASSEMBLY

1. Support the power unit on suitable 4. Loosen the clamp on the lower radiator
blocking on a stable work bench (refer to hose (10) at the radiator (1) and water pump
Illust. 1-53). Leavethe hoist attachedto the outlet. Remove the lower hose.
engine.
5. Loosen the two radiator mounting bolts.
2. Remove the radiator cap and drain the Support the radiator and remove the bolts and
radiator (1) and open the engine block drain radiator with screen.
cock (12).
6. Slide the flexible coupling (g) from the
3. Loosen the clampson the radiator drive shaft flange on the crankshaft pulley. Re-
upper hose (2) and remove the upper hose. move the drive shaft flange from the crankshaft.

E G.127781

lllust. 1-53.Powerunit removed- gearca.se

end of enginefacingforward.

1. Radiator 6. Alternator 11. Hoseclamp

2. Radiatorupper hose 7. Alternator belt 12. Block drain cocx
3. Alternator adjustingbolt 8. Oil filter 13. Cablesupport bracket
4. Exhaustextension 9. Flexiblecoupling 14. Waterpump pulley
5. Muffler 10. Lower radiatorhose 15. Thermostathousing

I-47
 7. Loosenthe alternatoradjustingbolt (3) NOTE: Although the fan faces the front of
and removethe alternatorbelt (7). the tractor, for rebuilding and servicingproce-
dures, this is the rear of the engine.
8. Disassemble the muffler (5) from the ex-
haustextension(4). 10. Remove the bolts and nuts securing the farr
and fan drive support (19) to the support bracket
9. Loosenthe fan drive idler pulley and slip (20). Set the assemblyaside.
the fan belt off of the fan drive pulley (18, Illust.
1-54).

EG.127782

l l l u s t. 1 -5 4 . P o w e r u ni t - radi ator, ai r cl eaner and muffl er removed.

1. Fan blade 11. Enginemounts

2. PTO electricalconnector 12. Engineand radiatormount
3. Lifting eye 13. Timing marks
4. Watertemperaturesendingunit 14. Flywheel
5. Fuel return line fittinq 15. Stub shaft
6. Lifting eye 16. PTO clutch assembly
7. Enginestop lever 17. Radiatormounting holes
8. Enginespeedcontrol lever 18. Fan drive pulley
9. Engineoil dipstick 19. Fan drive support
10. Secondaryfuel filter 20. Support bracket

148
 11. Lock the crankshaft by inserting a bar 13. Drain the engineoil and re'block the
between the two drive shaft flange bolts at the engineon suitableblocking on a stablework
front of the engine. Loosen, but do not remove, bench.
the bolt and washersecuringthe PTO clutch
assembly(16) to the stub shaft (15). 14. Removethe PTO clutch assembly(15,
Illust. 1-55),fan belt and spacer(14).
12. Suppori the engineagainwith the hoist.
Remove the mounts (11) on each side of the en- 15. Removefive screws(13) securingstub
gine and raisethe engineout of the engineand shaft(12) to flywheel(9) and removestub shaft"
radiator mount (12). Remove the secondary
fuel filter (10), and left and right enginemount-
ing plates.

,"rs"
-bb EG-127783

lllust. 1-55. Enginewith PTO clutch assemblyremoved.

1. ldler pulley 7. Fan drive support bracket 13. Screw

2. ldler pulley bracket B. Air cleanerbracket 14. Spacer
3. Adjusting lock bolt 9. Flywheel 15. PTO clutch assembly
4. Pivot bolt 10' Bolt 16' Flat washer
5. Exhaustextension 11. Torque bracket 17' Bolt and lock washer
6. Muff ler support bracket 12. Stub shaft

r49
 16. Removeidler pulley and braeket(2). 18. Removemuffler support bracket (6)
from fan drive support bracket (7).
17. Separateexhaustextension(5) from
muffler support bracket (6).

Cleaningand I nspection

1. Cleanall parts in cleaningsolvent.

2. Inspect bearings,pulleys,shafts,keys
and keywaysfor weat. Replaceas necessary.

3. Inspect bracketsfor cracksor bad welds.

Rcplaceas necessary.

Reassembly

1. Lubricateasrequired.

2. Reassemble
in reverseorder of disas-
sembly.

1-50
 ENGIN E D ISA SSEM BLY
AND ASSEM BLY

EngineStands

1. hepare the enginestands,if desired,

referringto lllust. 1-56.

2. Bolt the enginestandsto the engine

plate mounting holeson the engine.

I I t4

11{
rg=:+- *l 30
1- t1 2\

40 40
I 1.5) I r .5) 200t8l

EG-127784

lllust. 1-56. Engine stands.

External Components

NOTE: Drain enginecooling systemand 2. Removethe intake manifold (23) and

engineoil asoutlined under "EngineRemoval." the exhaustmanifold (8).
Coverall openingsand pressurecleanthe ex-
terior of the engineto facilitate disassembly 3. Removethe cylinderheadcover(7).
and inspection.
4. Removethe alternator(9) and the oil
CYLINDER HEAD filter cartridge(L2).
L ) Injection Pipes,Intake and ExhaustMani-
fold and CylinderHeadCover
1. Removethe injection pipes,overflow
pipesand the nozzleholders(4, Illust. l.-57).

1-51
 EG-127785

lllust.1-57.Powerunit.

1. Radi ator 9. Alternator 1 7 . Mo u n t in gb o lt

2. Radiatorcap 10. Adjustingbott 1 8 . E n g in ea n dra d ia t omo
r unt
3. lnjectiontubes 11. Alternator belt 1 9 . Dip s t ic k
4. Nozzleholder 12. Oil filter cartridge 20. Secondary fuel filter
5. Waterpump 13. Cablesupport 2 1 . Ra d ia t odr ra inc o c k
6. Oil port filt plug 14. Block drain cock 22. Fuelinjectionpump
7. Cylinderheadcover 15. R.H. engineplate 23. Intakemanifolc
B. Exhaustmanifold 16. Oil drain ptug

L-52
Whenreassembling: 2. Remove the rocker arms and shaft assem-
. Apply engineoil to the headcovernuts. bly (1).

3. Remove the push rods and tappets.

Injection
18.1to 25.3ftJbs
pipe nut 4. Loosen the hose clamp (4), and remove
the screws,the nuts and the cylinder head (2).
Overflow 'J.4.5to l-8.1-ft-lbs
pipe nut
Tightening
torque
Head cover
2.9 to 4.3 ftlbs
nut When reassembling:
o Be sure to place the O-ring (5, Illust. 1'58).
Nozzle o Apply engine oil to the head screwsand
36.2to 50.6frlbs
holder nuts. Tighten them in the specifiedsequence
(refer to Illust. 1-59), in severalsteps and to
the specifiedtorque.
2) Rocker Arm and Cylinder Head r After tightening all the screwsand the nuts,
1. Removethe glow plugs(3,Illust. 1-58). run the engine until it warms up and tighten
them againto the specifiedtorque.

Glow
14.5to 18.Lft-lbs
plug

Rocker
7.23to 8.32ftjbs
ETS{
$
Y**i * ,'.';:,:-;---;::'
Tightening
arm nut

torque Cylinder
L7.4 to 20.3 ftlbs
1?27_9Q
e-G_ headstud

Cylinder
headscrew 28.9 to 32.5 ft-lbs
lllust. 1-58.Cylinderhead and nut
and O-ring location.

1. Rockerarm shaft assembly

2. Cylinderhead
3. G low plug
4. Hoseclamp
5. O -ring

1-53
 @-------O

lllust. 1-59.Cylinderheadtighteningsequence.

3) Valve 2. Removethe valvespring retainer (3)

1. Removethe valvecap (5, Illust. 1€0) and the valvespring (2).
and the valvespring collets (4), compressing
the valvespring (2) with the valvespring re-
tainer (3). When reassembling:
o Clean the valve stem and valve guide, and
apply engineoil to them.
o Be sure to adjust the valve clearanceafter
installing the valve.
o Be sure to lap the valve on its seat after re-
placingthe valve,referring to "Correcting
Valve and Seat."

4) Adjusting Valve Clearance

1. Loosen the locknut (2, Illust. 1.61) and
the adjustingscrew (3) on the rocker arm (5).

2. Thrn the adjustingscrewto adjust the

EG" 127787
valveclearanceat the top dead center (T.D.C.)
during compressionstroke of the piston.
lllus t . 1- 60 . C y l i n d e r h e a d a n d v a l v e p a rts.
3. Tighten the locknut and check the valve
clearanceagain after severalturns of the fly-
1. Valve 'wheel.
2. V alvespring
3. Valvespringretainer
4. Collet
5. Valvecap

7-54
 lllust. 1-61.Adjustingvalveclearance.

1. Box wrench
2. Locknut
3. Adjustingscrew
4. Screwdriver
5. Rockerarm
6. Feelergauge
EG-127789

NOTE: To getT.D.C.of piston,find its lllust. 1-62.Timing marks.

((TC"
mark on the flywheeland alignit with
the timing mark on plate(1,Illust. 7-62).
1. T imin gma rko n p la t e
2. Fly wh e ema
l rk in g s
Valve I Factory | 0.00571to
clearance I specification | 0.00728 in.

1-55
 InjectionPump and Levers

INJECTION PUMPAND SPEEDCONTROL

PLATE

1. Removethe socketheadscrews(1, Illust.

163) and removethe injectionpump (4).

2. Removethe bolts(2) with copperwashers

securingthe speedcontrol plate (3) to the en-
grne.

EG-127790

lllust. 1-63. lnjectionpump.

1. Socketheadscrew
2. Bolt with copperwasher
3. Speedcontrol plate
4. lnjectionpump

3. Carefullylift the plateand usinglong

nosepliers,disconnectthe spring(1, Illust.
164) from the lever(2) on the plate(3). Re-
movethe speedcontrolplate.

Whenreassembling:
o Hook the spring(1, Illust. 1-64)to the lever
first and install the speedcontrol plate (3).
o Be sureto placethe copperwashersunder-
neaththe bolts (2, Illust. 163).

EG - 127791

the speedcontrolplate.
lllust.1-64,Removing

1. Spring
2. Lever
3. Speedcontrol plate

1-56
Whenreassembling:
r Slidethe control rack (1, Illust. 1S5) until
its end is flush with the pump housing.
o Positionthe slot (3) on the fork leverjust
under the slot on the crankcase.
r Insert the injection pump so that the con-
trol rack (1) will be pushedby the spring
(2) at its end and the pin (4) on the rack
engages with the slot (3) on the fork lever.

Tightening I lnjection | 7.23 to

torque I pu-p | 7.32ftJbs
lllust. 1-65.Control rack.

1. Control rack
2. Spring
3. Slot
4. Pin

GearCaseand Flywheel

PULLEYAND GEARCASE

1. hepare the flywheel stop tool (Illust.

166) and install it on the flywheel so that the
cranlishaft does not turn.
10 (0.39) di a

?oo(7.87)
A

EG-"t27736 'U nrt : mm (i n.)

lllust. 1-66. Flywheelstop tool.

t-57
 2. Flatten the metallock plate (8, Illust.
1-67) and removethe lock bolt (4). Usinga
puller, removethe pulley (b) from the crank-
shaft.

3. Removethe bolts(L and 2) securing

the gearcase(6) to the cylinderblock (?).

,,': : EG-127793
lllust. 1-67.Gearcaseand pul l e y.

1 . B o lt (in s id eg e a rc a s e )
2 . B o lt
3. Lockplate
4 . B o lt
5 . P u lle y
6. Gearcase
7 . Cy lin d ebr lo c k

4. Disconnectthe spring(8, Illust. 1-6g)

from the lever(5). Removethe gearcase(4).

NOTE: Be sureto removethe bolt (1)

insidethe gearcase(4).

EG-127794

llfust. 1€8. Gearcase- speed

control plate removed.

1. Bolt
2. Pin
3. Spring
4. Gearcase
5. Lever

1-58
When reassembling:
r Be sure to tighten the bolt (1) and hook
the spring (3).
r Install the pulley (1,Illust. 169) to the
crankshaft (3), aligning the marks (2).
. Apply engine oil to the lock bolt. Install
the lock plate and tighten it to the specified
torque. Bend a tang of the lock plate over
a tlat on the bolt head.

98.1to 107.9N.m
LOck
10.0to 11.0kgf.m
screw
72.3 to 79.6 ft-lbs I llust. 1-69. Crankshaft-to-pulley
Tightening
alignmentmarks.
torque
9.81to 11.28N . m
Gear case
1.00to 1.15kgf.m
screw
7 .23 to 8.32 ft-lbs 1. Pulley
2. Alignmentmarks
3. Crankshaft

Flywheel

1. With the flywheel stop tool installed

(Illust. 1-70), remove the flywheel lock bolts
(4).

2. Remove the washerplate (3) and fly-

wheel (2).

When reassembling:
o Place the flywheel washer on the flywheel
and install them to the crankshaft, noting
the location of the holes.

Tightening I Flywheel lllust. 1-70. Flywheelstop tool - installed.

39.8to 43.4 ft-lbs
torque I screw

1. Flywheelstop tool
2. Flywheel
3. Washerplate
4. Bolt

1-59
 TimingGearsand Camshafts

NOTE: Checkthe gearbacklashes

before
disassembly.

IDLER GEAR

1. Removethe retainingring, the thrust

washersand the idler gear(2, Illust. L-71).

EG . 127797

lllust. 1-71.Gears,gearcoverremoved.

1. Camshaftgear
2. ldler gear
3. Crankshaftgear
4. Oil pump drive gear
5. Fuel camshaftgear

Whenreassembling:
o Install the idler gear,aligningthe markson
the gearsreferringto Illust. 1-72.

\i*l'
o-(_)-\ oY,,,,
lllust,1-72.Gearsandtimingmarks.

1. Camshaftgear
2. ldler gear
3. Crankshaftgear
4. Oil pump drive gear
5. Fuel camshaftgear

1€0
GEAR AND CAMSHAFT

1. Removethe bolts(3,Illust.1-73)and
draw out the camshaft(4) with the gearon it.

2. Removethe retainingplate(L).

3. Removethe bolts (5) and draw out the

fuel camshaft(2) with the governorfork assem-
blv.

*t, ec r 277gg

lllust. 1-73.Camshaftgears.

1. Retainingplate
2. Fuel camshaftgear
3. Bolt
4. Camshaft
5. Bolt

When reassembling:
Hook the springto the fork lever1 (1,
Illust. I-74), asshown,beforeinstalling
the fork leverassemblyto the crankcase.
Install the fork leverassemblyso that the
pins on the fork position are evenly apart
from the governor sleeveand make sure
that the fork lever 1 is kept apart from =1r r _ t
the rack plate more than 0.059 in.

o
lllust. 1-74. Fork leversand spring.

1. Fork lever1
2. Fork lever2

1-61
 Oil SealSleeveand Gear

1. Pull out the oil sealsleeve(2, Illust,

1-75) together with the gear(1) using a gear
puller.

When reassembling:
o Install the idler gear before installing the
sleeve.
o Be sure to place the O-ring (3) before in-
stalling the sleeve(2).

E G - 127801

lllust. 1-75.Oil sealsleeveand gear.

1. Gear
2. Oil sealsleeve
3. O-ring

Crankshaftand Piston

MAIN BEARING CASE COVER

1. Remove the bolts (3, Illust. 1-76) se-

curing the main bearingcasecover (2) to the
cylinder block.

2. Lift the cover away from the cylinder

block by threading two bolts into the threaded
holes (4) of the cover. Tighten the two bolts
gradually and evenly until the cover is off.

When reassembling: W''*"

:'tt'' :ttj:
"'
/;;
o Placethe casecover and the gasketnoting
alignment mark, and tighten the bolts. 1-76.Main bearingcasecover"

Tightening | [4ain bearing 1. Alignment mark

7.23to 8.32ftlbs
torque I casebolt 2. Main bearingcasecover
3. Bolt
4. Threadedholes

t82
CRANKSHAFT

1. Remove the oil pan and the strainer.

2. Remove the bolts (4, Illust. 1-77) and

the connectingrod caps(2), and push out the
pistons.

3. Remove the bolts (4) and pull out the

crankshaft (1).

EG - 127803

lllust. 1-77.Main and connectingrod bolts.

1. Crankshaft
2. Connectingrod cap
3. Main bearingbolt
4. Connectingrod bolts

When reassembling: N
o Insert the piston in its cylinder in such a
manner that the mark "1" on its head aligns
with the mark "1" on the crankcase(refer
to Illust. 1-78).
o Align the marks on the side of the connecting
rod and cap.
o Apply engine oil to the bearing surface and
the bolts. Tighten them to the specified
torque.

E G - 127804

1.63
 Oil pan
7.23 to 8.32 ft-lbs
screw

Connecting
10.8to 13.7ftJbs
rod screw
Tightening
torque Main
bearing 14.5to 17.4ftJbs
casescrew

Oil pressure
10.8to 14.5ftlbs
switch
lllust. 1-79.Oil strainerand O-ring.

Whenreassembling:
o Be sureto rnstallthe O-ringon the pipe 1 . O il s t ra in e r
extendingfrom the strainer(referto Illust. 2 . O -rin g
1- 7 9 ) .

MAIN BEARING CASE

1. Remove the bolts (1, Illust. 1-80) and

separatethe bearingcases(refer to Illust. 1-81).

When reassembling:
o Apply engine oil to the bearing surface and
install the bearing caseso that its casting
marks (3, Illust. 1-80) or the holes (4) face
the flywheel.
o Place washerswith their round edge on the E G 127 806
seat of the bolts and apply engineoil to the
bolts and tighten them to the specified
torque. lllust. 1-80.Crankshaftand main
bearingcases.

1. Bolt
2. Main bearingcases
3. Castingmarks
4. Threadedholes

L-64
Whenreassembling:
o Placethe thrust washers(4, trlust. 1€1)
with their oil gtooveoutside.

Main | 14.7 to L9.6 N.m

Tightening
bearing | 1.2 to 1.5 kgf.m
torque
casescrew | 10.8 to 14.5 ft-lbs

EG.127807

lllust. 1-81.Main bearingcase- explodedview.

1. Upper casehalve
2. Bearinginsert
3. Thrust washers(installed)
4. Thrust washers(exploded)
5. Lower casehalve

PISTONAND CONNECTINGROD

1. Removethe retainingring and the piston

pin.

2. Removethe piston ringsusinga piston

ring tool.

Whenreassembling:
o Install the piston ringswith their manufac-
turer's mark up and so that their gapsand
E G- 127808
the expanderwill not be positionedin line
(referto Illust. 1-82).
lllust. 1-82.Properring positioning.

165
Whenreassembling:
o Apply engineoil to the piston pin and the
bushing. Install the connectingrod so that
the mark on its sidepositionsoppositethe
mark "1" on the piston(referto lllust.
1.83).
o Wheninsertingthe piston pin to the piston,
heatthe pistonin oil (176oF)for 10 to L5
minutes.

FittedI.D. | |
of the I Factory I O.OOOO
to
piston pin I specification | 0.0000 in. lllust. 1-83.Properpiston-to-connecting
bushing rod positioning.

1 . Connectingrod marking
2 . Pistonheadmarking

UN I T SERVI CI NG

CylinderHead

CYI INDER HEAD SURFACE FLATT{ESS

1. Cleanthe cylinder head surface.

2. Placethe straight edgeon the cylinder

head and measurethe clearancewith a feeler
gaugeat the positionsshown (refer to Illust.
1-84).

3. If the measurementexceedsthe allowable EG 127810

limit, correct it with a surfacegrinder.

NOTE: Do not place a straight edgeover

the combustion chamberinsert. lllust. 1-84.Checkingcylinder head
surfaceflatness.

Allowable
Flarness I | 9.9020eer
limir | 3.94in.

1-66
VALVE STEM CLEARANCE

valve
1. Remove the carbon from the
guide.

is straight
2. Make sure that the valve stem
guide'
and insert the valve into the valve

tip on
3. Set the dial indicator with its
guide'
the stem near the end of the valve

the
4. Measurethe clearance,moving
exceeds
valve sideways. If the measurement
valve guide
the allowable limit, replace the
or the valve.
zte" f
'r,.)
Clearance
0.00118to
0.00224in'
--. il ig EG 127812

between lllust. 1-86. Checkingclearancebetween

valve stem valve stem and valveguide'
and valve
guide

to
0.23661"
Valveguide
bore I.D. 0.23721tn.

0.23496to
0.23543in.

r{,7
REPLACING VALVE GUIDE

Whenremoving:
o hess out the valveguidetoward the head
coverusinga valveguidereplacingtool.

Wheninstalling:
o Cleanthe valveguidebore and apply engine
oil to the bore, beforeinstallingthe valve
r
_Il-_
.il [.
guide.
o hess in the bushingso that its end comes
flush with the cylinderblock surfaceusing
a valveguidereplacingtool.
ry EG.,27813
o hess in the valveguideuntil its end comes lllust. 1-87. Removingand installing
flush with the cylinderheadsurface. valveguide.

MPORTANT: Reampreciselythe bpre

to the specifieddimensionshownin Illuft.
1-87, after installingthe valveguide. I

VALVE SEATWIDTH

1. Check the valve seat surface and the

width ([a], Illust. 1-88).

2. If the seatwidth is not within the speci-

fied valuesor (b) is not equal to (c), correct
the valve seat referring to "Correcting Valve
and Seat."
EG{27814

Valveseat I Factory
0.055in.
width I specification
lllust. 1-88.Checkingvalveseatwidth.

1-68
 CORRECTING
VALVE AND SEAT

1. Correct the valve using a valve refacer.

2. Correct the valve seat surface using a

valve seat cutter (Code No.: 07909-33102),
following the steps below.

3. Cut the valve seat surface with a 45o l*o

valve seat cutter.
t'a
4. Check the seating surface on the valve
face using a red lead.

5. Cut the valveseatsurfacewith a 15o

valve seat cutter so that width A becomesequal
to B (refer to Illust. 1-89).

6. Check the seating surface using a red E G-127815

lead. If needed, repeat the steps above from 3,

until the valve contacts correctly.
lllust. 1-89. Correctingvalveand seat.
7. Lap the valve onto its seat using lapping
compound, until the valve contacts with its
seat evenly.

NOTE: Before correcting the valveand seat,

check the valvestem and the valveguide, and
repair them if neeessary.

VALVE RECESSING

1. Clean the valve face and install it in

its guide.

2. Measurethe valve recessingwith a depth '-,

gauge. --^ .:\
(,.t1 a -- __--'
iz

-\. )
3. If the recessingexceedsthe allowable )
,, ()
limit, replacethe valve,cylinder head or both.

EG-127816

Factory 0.0295to
specification 0.0374in. lllust. 1-90. Measuring valve recessing.
Valve
recessing
Allowable
0.047in.
limit

169
VALVE SPRING FREE LENGTH AND
TENSION

1. Measurethe free length of the spring

with vernier calipers.

2. Placethe spring on a spring compression

tester and compressto the specified length,
and get the tension.

3. If the measurementis lessthan the

allowable limit, replacethe valve spring.

Factory 31.6mm
specification L.244in.
Free
length
Allowable 28.4mm
limit 1 .1 1 8i n . lllust. 1-91.Measuringvalvespring
free length.
64.7N (27.0mm)
Factory
6.6 ksf (27.0mm)
specification
14.6lbs (1.063in.)
Sprins
't"
tension
5 4 .9N (2 7.0mm )
Allowable
5.6ksf (27.0mm)
limit
1 2 .3l b s(1.063in.)

VALVE SPRING SQUARENESS

1. Placethe spring on the surfaceplate

and a squareat its side.

2. Measurethe maximum distance A (refer

to Illust. L-92), rotating spring.

Valve
Allowable | 1.2 mm EG - 127818
spnng
limit | 0.047in.
squareness

lllust. 1-92.Checkingvalve
spring squareness.

r-74
 RockerArm and Shaft

ROCKERARM BUSHINGAND SHAFT

CLEARANCE

1. Measurethe rocker arm bushing I.D.

with an inside micrometer (refer to Illust. 1-93).

2. Measurethe rocker arm shaft O.D. with

an outside micrometer.

3. U the clearanceexceedsthe allowable

limit, replacethe bushing.

4. If the clearancestill exceedsthe allow-

able limit after replacing the bushing, replace
the rocker arm shaft-

Factory 0.00063to
Rocker )
specification 0.00268in.
arm bushing
and shaft
Allowable
clearance 0.0059in.
limit

Factory 0.41339
to lllust.1-93.Measuringrockerarm shaft
in.
specification 0.41500 and bushing.
BushingI.D.
shaft O.D.
Factory 0.41232
to
specification 0.4L276in.

REPLACING ROCKER ARM BUSHING

When removing:
o hess out the rocker arm bushing using a
rocker arm bushingreplacingtool (refer to
Illust. 1-94).

When installing:
o Cleanthe rocker arm bushing and the bore,
and apply engine oil to them. EG-127820
o hess in the bushing so that its end comes
flush with the rocker arm, using a rocker
arm bushing replacing tool.

IMPORTANT: Be sure to align the oil holes lllust. 1-94. Removingrocker arm bushing.
on the rocker arm and the bushing, and check
that the seam of the bushing position is as
shown in Illust. 1-94.
L.7L
 Camshaftand Timing Gears

GEAR BACKLASH

1. Set a dial indicator (lever type) with

(refer to
its indicator tip on the gear tooth
Illust. 1-95).

2. Move the gear to measurethe backlash'

holding its mating gear'

3. If the backlash exceedsthe allowable

and
limit, check the oil clearanceof the shafts
the gear.

4. If the oil clearanceis proper, replace

the gear.

0.00161to
Oil pump gear Factory
to crank gear specification 0.00484l n. -127821

Idler gear to Factory 0.00169to

crank gear specification 0.00488in.

0.00185to lllust. 1-95.Measuringgearbacklash'

Idler gear to Factory
carn gear specification 0.00484in.

FactorY 0.00181to
Idler gear to specification 0.00488in.
injection PumP
gear oil
Allowable
clearance 0.0059in.
limit

7-72
IDLER GEAR SIDE CLEARANCE

1. Pull the idler gear collar (L) and push

the idler gear(2) and measurethe clearance(A)
between the idler gear and the idler gear collar
with a feeler gauge.

2. If the clearance(A) exceedsthe allow-

able limit, replace the idler gear collar (1).

EG-127822

Factory 0.0079to lllust. 1-96. ldler gearside clearance.

specification 0.0201ln.
Side
clearance
Allowable 1. Co lla r
0.024in.
limit 2. ldlergear
3. B u s h in g
A. Clearance measurement

IDLER GEAR OIL CLEARANCE

1. Measurethe I.D. of the idler gearbushing

with an insidemicrometer(referto Illust. 1-97).

2. Measurethe O.D. of the idler gearshaft

with an outsidemicrometer.

3. If the clearanceexceedsthe allowable

limit, replacethe bushing.

Factory 0.00063
to
specification in.
0.00177
oil
eG-127823
clearance
Allowable
0.0020in.
limit

Bushing Factory 0.62992to lllust. 1-97.Measuringidler gearand shaft.

I.D. specification 0.63063in.

Factory 0.62886to
ShaftO.D.
specification 0.62929in.

L-73
CAMSHAFT OIL CLEARANCE

1. Measurethe I.D. of the camshaftbore

on the crankcasewith an inside micrometer
(refer to Illust. 1-98).

2. Measurethe O.D. of the camshaft jour-

nal.

3. If the clearanceexceedsthe allowable

limit, replacethe shaft.

Factory 0.00197to
specification 0.00358in. EG 127824
oil
clearance
Allowable
0.0059in.
limit lllust. 1-98.Measuringcamshaftano
camshaftbore.
Camshaft Factory 7.2992! to
bore I.D. specification 1.30020in.

Camshaft Factory L.29662to

journal O.D. specification I.29725 in.

CAMSHAFT ALIGNMENT

1. Placethe camshafton the V blocks

and set a dial indicator with its indicator tip
on the intermediatejournal (refer to Illust.
1.ee).
2. Rotate the camshaftin the V block
and get the eccentricity (half of the measure-
ment).

3. If the eccentricity exceedsthe allowable EG-127825

limit, replacethe camshaft.

Factory 0.01mm lllust. 1-99.Checkingcamshaftalignment.

specification 0.0004in.
Eccentricity
Allowable 0.08mm
limit 0.0031in.

r-74
 CA]VI,SHAFT
LOBES HEIGFI

1. Measurethe heightof the camshaft

lobesat their largestO.D. with an outside
micrometer(referto Illust. 1-100).

2. If the measurement is lessthan the

allowablelimit, replacethe camshaft.

Factory
1.0583in.
specification
Cam
height
Allowable
1.0563in.
limit lllust.1-100.Measuring
camshaftlobe.

CylinderBlock

CYLINDER LINER

1. Measurethe I.D. of the cylinderliner

at six positions(refer to Illust. 1-101)with a
cylindergaugeto find the maximum and mini-
mum I.D.'s

2. Get the differencebetweenthe maxi-

mum and the minimum I.D.'s asthe maximum
wear.

3. If the wearexceedsthe allowablelimit, EG 127827

replacethe cylinderliner.
lllu s t .1 -1 0 1Me
. a s u rincgy lin d e rli n e r
insidediameter.
Cylinder Factory 2.59843to
liner I.D. specification 2.59917in.

Maximum Allowable
0.0059in.
wear limit

CYLINDER BLOCK INSPECTION

Carefullyinspectall matingsurfaces,studs,
dowel pins,springs,threadedholes,expansion
plugsand bracketsfor damage.Repairor
replace,asrequired.

L-75
 Crankshaft

CRANKSHAFT END PLAY

1. Set a dial indicator with its indicator

tip touching the end of the crankshaft (refer
to Illust. 1-102).

2. Measurethe end play by moving the

crankshaft to the front and rear.

3. If the play exceedsthe allowable limit,

replacethe side bearing.

NOTE: Oversizeside bearingsare available

if the standardsizeside bearingsdo not meet Iffust. 1-102.Checkingcrankshaft
end play clearancespecifications. end play.

Factory 0.0059to
specification 0.012 2in .
End
play
Allowable
0.020in.
limit

CRANKSHAFT ALIGNMENT

1. Support the crankshaft with V blocks

on the surface plate at both end journals (refer
to Illust. 1-103).

2. Set a dial indicator with its indicator

tip touching the intermediatejournal.

3. Rotate the crankshafton the V blocks

and get the eccentricity (half of the measure- EG-127829
ment).
lllust.1-103.Checking
crankshaft
4. If the eccentricity exceedsthe allowable alignment.
limit, replacethe crankshaft.

Factory
0.0008in.
specification
Eccentricity
Allowable
0.0031in.
limit

L-76
OIL CLEARANCE
BETWEEN CRANKSHAFT
JOURNALAND BEARING1

1. Measurethe I.D. of the crankshaft bear-

ing 1-with an inside micrometer (refer to Illust.
1-104).

2. Measurethe O.D. of the crankshaftfront

journal with an outside micrometer.
)

3. If the oil clearanceexceedsthe allowable

limit, determine which part is worn. Replace
as required.

IMPORTANT: Install the bearing using a

replacingtool, so that its seamfacesthe exhaust
side in the crankcase.

lf lust. 1-1O4.Checkingbearing1 and

Factory 0.00134
to crankshaftfront main journal.
specification 0.00417
in.
oil
clearance
Allowable
0.0079in.
limit

Crankshaft Factory 1.5741 8t o

bearingI.D. specification 1.5763 8in .

Crankshaft Factory L.5722\ to

journal O.D. specification L.57284in.

OIL CLEARANCEBETWEENCRANKSHAFT
JOURNALAND BEARINGS2 AND 3

1. Using an outside micrometer, measure

the O.D. of the main journals. If within speci-
fications, proceed with steps2 through 4.

2. Put a strip of Plastigagelengthwise in

the center of the journal.

3. Install the bearingcap and tighten the

E G- 127831
bolts to the specifiedtorque, and remove the
bearingcap.
lllust. 1-105.Checkingbearingclearance.
4. Measurethe amount of the flattening
with the scale and get the oil clearance(refer
to Illust. 1-105).

L-77
 5. If the oil clearanceexceeds
the- allowable
-' Rear
Iimit, replace the crankshaft
U"urirrg.

NOTE: Undersize bearings Bearing2 Factory

are availablefor 1.73166
to
service. I.D. specification 1.73386
in.
Crankshaft Factory 1.72969to
Tightening journalO.D. specification
Bearing 8.7 t o 1.73032
in.
torque bolts 10.8ft-lbs Intermediate
Factory 0.00134to Bearing 3 Factory
oit specification 0.00417in. 7.574L8to
I.D. specification
clearance 1.57583in.
Allowable
0.0079in. Crankshaft Factory
limit L.57221.to
journal O.D.
specification 1.57284ln.

OIL CLEARANCE BETWEEN lk

CRANK PIN
AND CONNECTINGROD BEARtrV;

1. Usingan outsidemicrometer,
measure
the O.D. of the crankpin journal.
specifications,
ii within
proceedwith steps2 through
(,
4. t"
i'll
(l
the bearingcap. t,i Q

3. Installthe b, l,l
may
sausenor
."JTTf,
fi: il,:"jJff:H"- ,A
' EG-127832
pin. Tightenthe boltsto
the rpu.ifi"l'torqu*,
and removethe cap.
lllust.1-106.Checking crankpin
4. Measurethe amountof bearingclearance.
the flattening
with.the scaleand get the oit
.trrr*.. ir"r.,
to Illust.1-106).

7-78
 allowable
5. If the clearanceexceedsthe 1 0 . 8t o
rod bearing' 13.7 ft-Ibs
limit, replacethe connecting

are availablefor 0.00075to

NOTE: Undersizebearings FactorY
service. specification 0.00319in.
oil
the crankshaft
NOTE: Be surenot to move clearance
*nffiu"u,ing capscre\I/sare tightened'

Connecting FactorY 1 . 33 8 3 5t o
rod bearing specification 1.34016in.
I.D.

FactorY 1.33697to
specification 1.33760in.

(Seelllust' 1-107)
CRANKSHAFT SLEEVE E G-127833

sleeve'
1. Checkthe wearon the crankshaft

allowablelimit
2. If the wearexceedsthe
replacethe crank'
or when the engineoil leaks'
shaft sleeve.

lf fust. 1-1O7.Crankshaftsleeve'

L-79
 Pistonand ConnectingRod

PISTONPIN HOLE (Seelllust' 1-108)

1. Measurethe I.D. of piston pin hole

lengthwiseand widthwiseof the piston with
a cylinder gauge.

2. If the measurementexceedsthe allowable

limit, replacethe Piston. EG-127834

0.70886to lllust. 1-108.Measuringpiston pin l'D'

Piston 0.70910in.
pin hole
I.D. 0.7106in.

CLEARANCEBETWEENPISTONPIN AND
BUSHING(Seelllust.1'109)

the O.D.of the pistonpin with

1. Measure
an outside micrometer.

2. Measurethe I.D. of the piston pin bush'

ing with a cylinder gauge. EG-127835

3. If the clearanceexceedsthe allowable

limit, replacethe bushing.

4. If the clearancestill exceedsthe allow-

able limit after replacing the bushing, replace
the piston pin.

Clearance Factory to
0.00063
in.
0.00154 pistonpin
lllust.1-109,Measuring
between specification
piston
and bushing.
pin and Allowable
0.0059in.
bushing limit

Pistonpin Factory 0.70965to

bushingI.D. specification 0.7t024 in.

Piston pin Factory to

0.70870
o.D. specification in.
0.70902

1-80
PISTON RING GAP (See Illust. 1-110)

1. Insert the piston ring into the eylinder

L'(
and push down to the bottom, where the wear
is least, using a piston head. oo
2. Measurethe ring gap with a feeler gauge.
o
/
\o
3. If the ring gap exceedsthe allowable )/--
limit, replace the ring. / ' l^-) :)
t/u
v
,t/,A
J--,-/
o
Top and
Factory 0.0098to ,,/
r^''\
\-
second -
EG-127836
--l
specification 0.0157in
ring
Piston pistonringgap.
lllust.1-110.Measuring
ring Factory 0.0079to
gap specification 0.015 7in .
oil
ring
Allowable
0.047in.
limit

PISTONRING CLEARANCE (SeeIllust. 1-111)

1. Cleanthe ringsand the ring grooves,

and install eachring in its groove.

2. Measurethe clearancebetweenthe ring

and the groovewith a feelergauge.

3. If the clearanceexceedsthe allowable

limit, replacethe pistonring.

4. If the clearancestill exceedsthe allow-

ablelimit after replacingthe ring, replacethe
piston. E G- 127837

Top lllust.1-111.Checking piston

and Factory 0.00335to ring clearance.
second specification 0.00441in.
Piston ring
ring
clearance Factory 0.0008to
specification 0.0024in.
oil
ring
Allowable
0.O059 in.
limit

1€1
CONNECTING ROD ALIGNMEI{I (SeeIllust.
r-712)
1. Removethe connectingrod bearingand
install the bearingcap.

2. Install the piston pin in the connecting

rod.

3. Install the connectingrod on the con-

nectingrod alignmenttool (CodeNo.: 07909-
31661).

4. Put a gaugeover the piston pin and move

it againstthe faceplate.

5. If the gaugedoesnot fit squarelyagainst

the faceplate,measufethe spacebetweenthe E G-127838
pin of the gaugeand the faceplate.

6. If the measurement exceedsthe allow' lllust. 1-1 12. Checkingconnecting

ablelimit, replacethe connectingrod. rod alignment.

Space
0.0020in.
between I Allowable
(gaugepin span
pin and I limit
at 3.94 in.)
faceplate

LubricatingSystem

OIL PUMP

Pump Rotor and Lobe Clearance(SeeIllust.

1- 1 1 3 )

1. Removethe oil pump from the crank-

case.

2. Removethe screwand the port plate.

lllust. 1-113.Measuringinner and outer

rotor clearance.

142
 3. Measurethe clearancesbetweenthe
outer rotor and the housing,and betweenthe Factory 0.0059to
Clearance
outer and inner rotor with a feelergauge. specification 0.0083in.
between
outer rotor
If the clearanceexceedsthe allowablelimit. Allowable
and housing 0.0118in.
reylace
thepump. limit

Clearance
between AJlowable
0.0098in.
outer and limit
inner rotor

(SeeIllust. 1-114)
Rotor End Clearance

1. Put a strip of Plastigageon the rotor

and install the pump to the crankcasewith
the port plate.

2. Removethe pump and the port plate.

EG-127840
3. Measurethe amount of the flattening
with the scale,and gei the clearance.

4. If the clearanceis not within the speci- lllust.1-114.Measuringrotor end

fications,replacethe pump. clearance.

End I Factory | 0.0031to

clearance I specification | 0.0051 in.

1-83
 CoolingSystem

TIIERMOSTAT

Removal(SeeIllust. 1-115)

1. Removethe thermostatcover.

2. Removethe thermostat.

Whenreassembling:
EG-127841
o Apply liquid gasket(ThreeBond 1215
equivalent)to the gasket.

lllust.1-115.Thermostat,
housing
and cover,

Thermostat Valve OpeningTemperature(See

Illust.1-116)

1. Suspendthe thermostatin the water

by a string with its end insertedbetweenthe
valveand the seat.

2. Heatingthe water gradually,readthe

temperaturewhen the valveopensand leaves
the string.

3. Continueheatingand readthe tempera-

ture when the valveopensapproximately
0.236in.

4. If the measurement is not within the

specifiedvalues,replacethe thermostat.

lllust. 1-116.Testingvalve
| | 176.9 0t o opening temperature.
| | 182.3oFat
O pe n in g lFactory lbeginnin g ,
temperature I specification I below 203oF
at 0.236in.
of opening

L84
WATER PUMP

Disassembly

1. Removethe water pump from the gear

casecover.

2. Removethe pulley and flange(1, Illust.

1-117).

3. hess out the waterpump shaft (2) with

E G-127 843
the impeller(5) on it.

4. Removethe impellerfrom the water f ffust.1-117.Waterpump.

shaft.

seal(4).
5. Removethe mechanical 1. Waterpumpf lange
2. Waterpumpshaft
Whenreassembling: 3. Waterpumpbody
o Apply liquid gasket(ThreeBond 1215or 4. Mechanical
seal
5,lmpeller
I

[olnegasKel,
I r\ r rl I I
equlvalenl)
o Replace the mechanical seal with the new
one.

RADIATOR CAP

RadiatorCap Openinghessure(SeeIllust.
1 -11 8 )

1. Seta radiatortesteron the radiator

cap.

2. Apply the pressureof LB psi and measure

the time for the pressureto fall to 9 psi.

3. If the measurement is lessthan the EG-127844

specifiedvalue,replacethe radiatorcap.

lllust. 1-118.Testingradiatorcap.
More than
Pressure
Factory I 10 seconds
falling
specification I from 13
time
to 9 psi
FAN AND FAN DRTVE 4. Removebolt (15) and flat washer(14) se-
curingpulley(13) to shaft (8). Pull pulley (1-3)
Disassembly, (See
Inspectionand Reassembly from shaftand removekey (10) and spacer(L2).
Illust.1-119)
5. hess shaft(8) out of housing(9). Re-
1. Removefour bolts (1) and lock washers movebearingspacer(6) and bearings(5 and
(2) securingfan (3) to flange(4). Removefan 1 1 ).
to shaft bolt (17) andflat washer(16).
6. Inspectpartsfor wearand replaceas
2. Separatefan from flange(4). required.

3. Pull flange(4) from shaft(8). Remove 7. Reassemble

in reverseorder of disas-
key (7). sembly.

EG - 127845

lllust. 1-119.Fan and fan drive assembly- explodedview.

1. Bolt 6. Spacer 10. Key 14. Washer

2. Lock washer 7. Key 1 1. Bearing 1 5 . Bo l t
3. Fan 8. Shaft 12. Spacer 1 6 . Bo l t
4. Flange 9. Housing 13. Pulley 17. Washer
5. Bearing

146
 Fuel System

CHECKING AND ADJUST}4ENT

Injection Pump

InjectionTiming (SeeIllust. 1-120and 1-121)

1. Removethe injection pipes.

2. Set the speedcontrol leverto the maxi-

mum fuel dischargeposition.
rl
3. T\rrn the flywheel until the fuel fills
;l
up to the hole of the deliveryvalveholder.
f flust.1-120.I njectionpumpandshim.
4. T\rrn the flywheel further and stop turn-
ing when the fuel beginsto flow over again,to
checkthe injection timing. 1 . I n je c t io np u mp
2 . S h im
5. If the "FI" matk doesnot alignwith
the mark on the rear plate,add or removethe
shim (2) to adjustit.

Reference:
o 1.5o to 2.0o at flywheel,0.0059in. of shim.

f lfust.1-121.Timingmarks.

1. Timing mark on plate

2. Flywheelmarkings

147
Pump Element Fuel heesure

1. Install the pressuretester to the fuel

injection pump without the deliveryvalve.

2. With the speedcontrol leverat the max-

imum positionof the fuel injection,rotate the
flywheel to raisethe fuel pressureto 5689 psi.

3. Measurethe faliing time of the fuel

presstuefrom 5689 to 4978 psi.

4. If the measurement is lessthan the allow-

ablelimit, replacethe pump elementor the in-
jection pump assembly.

EG-127847

Factory 60 seconds
Pressure specification or more lllust. 1-122.Pressure
tester.
falling
time Allowable
30 seconds
limit

MPORTAIIT: After replacingthe pump o TestConditions:

element,adjustthe amount of the fuel injec-
tion on the specifiedtest bench. Driving CodeNo. 105784160
stand lDrEsELKrKrCO.LTDI
Reference:
o Test Bench: Nozzle DN12SD12T
CodeNo. 1057600010 (50 Hz')/L05760-
0020(60IIz)IDIESELKIKI co. Lm] Opening
L707psi
pressure

Injection 0,24 in. dia.x 0.08in.

pipe dia.x 23.62in. long

Fuel feed
7 psi
presslue

Test fuel Dieselfuel No. 2-D

0.0728to 0.0768in.
he-stroke
(with valve)

Cam
(SeeIllust. 1-123)
profile

148
 o Data for Adjustment:

Control rack
(from stop Camshaft
position) speed Amount of fuel

0.177in. 1800 rpm Q.07L4 to 0.0751

c. in./100st

0.039in. 1800 rpm lessthan 0.006

c. in./100st

NOTE: If the pump test outlined aboveis

satisfactory,checkdeliveryvalvepressureas
follows:

DeliveryValvesFuel Pressure E G-127848

1. Install the pressuretester(refer to Illust.

L-L22)to the deliveryvalve. f lfust. 1-123.Camprofile.

2. With the speedcontrol leverat the

maximum position of the fuel injection,rotate A. 70
the flywheel to raisethe fuel pressureto 3129 B . 0 . 5 5in .
psi. C. ,|.18
in.
D. 0 . 1 2in .
3. Measurethe falling time of the fuel E. 0 . 5 9in .
pressure
from 3129 to 298? psi. F. 0 . 7 1in .
G. 0 . 4 7in .
4. If the measurement is lessthan the allow-
able limit, replacethe deliveryvalve.

Factory 10 seconds
hessure specification or more
falling
time Allowable
5 seconds
limit

1€9
Injeetion Nozzle

CAUTION! Nevercomein contact

with sprayingdieselfuel underpres-
sure.which can havesufficientforce
to penetratethe skin, causingseriouspersonal
injury. Be surenobody is in the directionof
the spray.

Fuel Injection he*sure (SeeIllust. 1-124)

1. Set the injection nozzleto the nozzle

tester.

2. Measurethe injection pressure.

3. If the measurement is not within the lllust. 1-124.Testinginjectionnozzle.

specifiedvalues,replacethe adjustingwasher
in the nozzleholder to adjustit.

Fuel
Factory | 1991to
injection
specification I 2133 psi
pressure

NOTE: Adjustingwasher(Kubota Assembly

CodeNo. 15841-98101")includes43 sizesas
listedbelow.

Adjusting Thickness Code Adjusting Thicliness Code

Washer in. Number Washer in. Number

0900 0.03543 15481-98501 1200 0.04724 1.5481-98621

0925 0.03642 1548L-98511 t22S 0.04823 15481-98631
0950 0.03740 15481-98521 1250 0.0492t 15481-98641
0975 0.03839 15481-98531 L275 0.05020 15481.98651
1000 0 .0 3 9 3 7 15481-98541 1300 0.05118 15481-98661
1025 0.04035 15481-98551 1325 0.05217 15481-98671
1050 0.04134 15481-98561 1350 0.05315 15481-98681
1075 0.04232 1 5 4 81.98571 1375 0.05413 15481-98691
1100 0.04331 1_5481-98581 1400 0.05512 1M81-98701
7L25 0.04429 15481-98591 L425 0.05610 15481-98711
1150 0.04528 15481-98601 1450 0.05709 1548L-9872L
IL75 0.04626 15481-98611 1475 0.05807 15481-98731

r.-90
ValveSeathessure(SeeIllust. L-125)

1. Set the nozzleto a nozzletester.

2. Raisethe fuel pressureand keep at L849

psi for 10 seconds.

3. U any fuel leak is found, replacethe

noz,zlepiece.

Valve f ffust.1-125,Testingvalveseatpressure.
Factory I No fuel leak at
seat
pressure specification | 1849 psi

SprayingPattern(SeeIllust. L-126)

1. Set the nozzleto a nozzletester and

checkthe nozzlesprayingpattern.

2. If the nozzledoesnot sprayin a good

pattern,replacethe nozzlepiece.

.i,,il:,
x
lllust. 1-126. Checking spray pattern.

1-91
Injection Nozzle(SeeIllust. 1-727)

NozzleHolder

1. Securethe nozzlenut (L) in a vise.

2. Removethe nut (3), the eyejoint (4)

and the plainwasher(5).

3. Removethe nozzleholder (2), and take

out the parts.

Whenreassembling: :,' , :;.r:.,' ,' . EG - 127852

o Assemblethe nozzlein cleanlight oil.
o Install the pushrod (8), noting its direction. f f lust. 1-127.Injectionnozzl e - expl o ded view.

1. Nozzlenut 6. Adjustingwasher
Tightening I Nozzle I 36.2 to 2. Nozzleholder 7. Nozzlespring
torque I holder | 50.6ft-lbs 3. Nut B. Pushrod
4. Eye joint 9. Distancepiece
5. Plainwasher 10. Nozzleoiece

IMPORTANT: The nozzle piece is precisely CAUTION! Neverbleedthe air

finished. Do not use a piece of metal but a while the engineis hot. Nevercome
piece of wood to remove the carbon deposits. in contactwith escaping dieselfuel
After assemblingthe nozzle, be sure to adjust under pressure,which can havesufficient force
the injection pressure(see "Fuel Injection to penetrate the skin, causingserious personal
Pressure"). injury. Be sure to relieve all pressurebefore dis-
connecting. Make sure that no fuel can escape
Air Bleeding from the systembefore applying presstue.
Keep the enginestop lever at the "STOP"
Bleed the air from the fuel system before position to shut off the fuel, while bleeding
attempting to start the enginewhenever: the air.
o The fuel filter has been removed or the fuel
system lines have been disconnected.
o The fuel tank has been empty.
o The enginehas not been run for a long period
of time.

r-92
BleedingFuel System(SeeIllust. L-128and
1 - 12 9 )

1. Fill the fuel tank and openthe fuel

cock.

2. Loosenthe bleedingscrews(L and 2,

Illust. 1-128)at the top of the filter by two
turns.

3. T\rrn ignition key switch to "ON" E G-127853

position to activatefuel pump until bubbles
disappear. lllust. 1-128.Air vent plugs.

4. Tightenthe bleedingscrew(1) andturn

ignitionswiichto "OFF" position. 1. Air vent plug No. 1
2. Air vent plug No. 2
5. T\rrn ignition key switch to "ON"
position againuntil the fuel without air flows
from the loosescrew(2).

6. Tightenthe bleedingscew (2). Turn

ignitionswitchto'.OFF"' position.

NOTE: If the enginewill not start after

the abovebleeding,bleedthe air further in
the system,asfollows.

r Loosenthe plug (1, Illust. 1-129).

o T\rrn ignition key switch to "ON" position,
until the fuel without air flows from the
looseplug.
r Tightenthe plug (1). Turn ignition switch
to "OFF" position.
EG-127854

f f lust. 1-129,Injection,pump air vent plug.

1 . A ir v e n tp lu g

1-93
 ELECTRICFUEL PUMP

NOTE: Thereis no servicerequiredon the

electricfuel pump. If the electricalcircuit to the
fuel pump is completeand the pump is inoperative,
replacethe pump.

ElectricalSystem

STARTER

Testing

No-LoadTest (SeeIllust. 1-130)

1. Connecta cablefrom the negativeter-

minal of the batteryto the body of the starter.

2. Connecta voltmeteracross"B" terminal

and the body of the starter,and an ammeter
acrossthe positiveterminal of the battery and
"B" terminalof the starter.

3. Connecta switchbetween"B" and "S"

terminalsof the starter.and run the starter.

4. The startershouldrun at the specified EG - 127855

rate (seetablebelow).

Supply voltage 1 1 .5 V lllust. 1-130.No-loadtest points.

Current Lessthan 53A

Speed More than 7,000 rpm

NOTE: Testwith a cable and an ammeter

for largecurrent,and a fully charged battery.

L-94
Motor Test (See lllust. 1-131)

1. Disconnectthe connectinglead to n'M"

terminal and connect a voltmeter acrossthe
lead and the body of the starter.

2. Connect a cable between the negative

terminal of the battery and the starter body.

3. Connect an ammeter and a switch in

seriesbetween the positive terminal of the
battery and the connectinglead, and run the
stiuter.
lllust. 1-131.Motor test points.
4. The starter should run at the specified
rate (see"No-Load Test").

Solenoid Switch (SeeIllust. 1-132)

1. Check the continuity across"S" and

"M" terminals,and across"S" terminal and
the body with an ohmmeter.

2. If not continuous, replace.

\* X'&,
':r"':
-127857

lllust. 1-132.Solenoidtest points.

SolenoidSwitch(SeeIllust. 1-133)

1. Removethe screws(3) to separate

the
solenoidswitch.

2. Pull out the plunger(2) and the spring

( 1) .

1. S pring
2 . P lunger
J. Screw E G 127858
l l l ust. 1-133. S ol enoi d sw i tch, di sassem bled.

1-95
End Frame(Seelllust. 1-134)

1. Removethe throughbolts(3) and the

screw(2).

2. Removethe rearend frame.

3. Lift the brushand removethe brush

holder(1).

4. Removethe yoke assembly.

NOTE: Do not missthe thrustwashers lllust. 1-134.End frame, removed.

behindthe commutator.

1 . B ru s hh o ld e r
2. Screw
3 . T h ro u g hb o lt

Armature(SeeIllust. 1-135)

1. Pull out the armature.

2. Removethe plate(1) and the lever(2).

Whenreassembling:
o Installthe lever,notingits direction(refer
to Illust.1-135).

NOTE: Do not overlookthe thrust washers EG 127860

on the front of the armatureshaft.
lllu s t .1 -1 3 5A
. rma t u re .

1. Plate
2. Lever
3. Thrust washers

1-96
 Clutch(SeeIllust. 1-136)
Overrunning

1. Tap in the stop ring (3).

2. Removethe retainerring (2).

3. Removethe stopring (3) and the over-

runningclutch (L).
EG - 127861

Whenreassembling: l l l ust. 1-136. Overrunni ng cl utch and r et ainer .

o Installthe stop ring first, then the retainer
ring, and then pull up the stop ring with a
puller. 1 . O v e rru n n incglu t c h
2 . Re t a in erin
r g
3. Stop ring

Lubrication (SeeIllust. 1-137)

Before reassembling,lubricate the following:

(1) Bearingsin the end frames and the washers.

(2) Sliding surfacebetween the armature shaft
and overrunning clutch (with low viscosity
oil).
(3) Shift lever where it engageswith the plunger
and the overrunning clutch.
(4) Plungerwhere it contacts with solenoid
housing.

EG-127862

lf lust.1-137.Starterlubrication.

L-97
Servicing

Armature Coil (Seelllust. 1-138)

1. Placethe armatureon a growlerto check

for the short circuits,and slowly rotate the
armature,holdingan iron pieceabovethe core.

2. If the iron piecevibratesagainstthe

core,replacethe armature.

3. Checkthe continuityacrosseachsegment I EG-127863

of the commutatorand the armatureshaft.
l l l ust. 1-138. Testi ng armatur e.
4. If continuous,replacethe armature.

Commutator (SeeIllust. 1-139)

1. Rotate the armature in V blocks to check

out-of-roundnessand runout, setting a dial
indicator with its tip on the commutator.

2. If the varianceamong the readingsis more

than the allowablelimit, turn the armature
in the lathe.

3. If the depth of undercut is lessthan

the allowable limit, undercut with a hacksaw
blade or an undercutter.

4. Sand off all burrs with sandpaper.

NOTE: When the smallestradius of the com-

mutator is lessthan the allowablelimit, replace EG-127864
the armature shaft.

Variance on lllust. 1-139.Checkingcommutator.

Allowable
commutator 0.0020in.
limit
o.D.

Commutator Allowable
7.22in.
o.D. limit

Commutator Allowable
0.008in.
undercut limit

1-98
@
1. Check the continuity between the
brushes.

2. If not continuous, replacethe yoke

assembly.

3. Check the continuity acrossthe yoke

and the brush or the connectinglead.

4. If continuous, check for the breakage

EG - 127865
of the insulation.

5. If not repairable,replacethe yoke lllust. 1-140.Testingfield coil.

assembly.

6. Check that the pole and windings are

not loose.

Brush(SeeIllust. 1-141)

1. Cleanoff the brushand checkfor wear.

2. If unevenlyworn, correct.

3. If worn to more than the allowable

limit, replace.

4. Checkthat the brushesmovefreely in

the brushholder.

Factory lllust. 1-141.Brush length.

0.67in .
specification
Brush
length
Allowable
0.453in.
limit

1-99
Brush Spring (SeeIllust. L-142)

1. Pull the brushin the brushholder with

a springscale.

2. Measurethe brush springtension re-

quired to raisethe spring from contact position
with the commutator.

3. If the tension is lessthan the allowable

limit, replacethe spring.

lffust. 1-142.Checkingbrushspring
Factory 3.1 to tension.
specification 5 . 7 lb s
Spring
tension
Allowable
2.0lbs
limit

BrushHolder (Seelllust. 1-143)

1. Checkthe continuity acrossthe insulated

brushholder and the brushholder support.

2. If continuous,replacethe brushholder
assembly.

llfust. 1-143.Checkingbrushholder.

1-100
Overrunning Clutch (See Illust. 1-144)

1. Check the pinion and if worn or damr

aged,replacethe clutch assemblY.

2. Check that the piston turns freely and

smoothly in the overrunning direction and
does not slip in the cranking direction.

3. If the pinion slips or does not turn in

both directions, replace the overrunning clutch
assembly. Y ;!.;;i 1,' ,j ,,..
::L;..;.:,;,' .., .. ...,...., E G - 127869
,,,,.;..

NOTE: Do not wash off the greasein the l l l ust. 1-144. Overrunni ng cl utc h.

ou"*ing clutch with the chemicals or oils'

Solenoid Switch (SeeIllust. 1-145 and 1-146)

o'8" and
1. Check the continuity across
"M" terminals with an ohmmeter, pushingin
the plunger (refer to Illust. 1-145).

2. lf not continuous or if a certain value

is indicated, replacethe solenoid switch.

3. Pull the pull-rod to check the spring

built in the plunger (refer to Illust. 1-146). EG-127870

f llust. 1-145.Checkingsolenoidswitch.

lllust. 1-146.Checkingpull-rodspringtension.

1. Plunger
2. Pull-rod

1-101
Pinion Clearance(SeeIllust. 1-147)

1. Reassemble
the starterwith connecting
leadsunconnected.

2. Connecta cablefrom the negativeter-

minal of the battery to the starterbody and a
cablefrom "S" terminal of the starterto the
positiveterminal of the battery to force out
the pinion.

3. Pushback the pinion slightly to remove

end play,and measurethe pinion clearance. EG-127872

4. If the clearanceis not within the speci-

fied values,add or removethe washerbetween
the solenoidswitch and front end frame. lllust. 1-147.Checkingpinion clearance.

Pinion I Factory | 0.020to

clearance I specification | 0.079in.

ALTERNATOR AND REGULATOR

Testing

No-LoadAlternatorOutput (SeeIllust. 1-148)

1. Disconnectthe leadwiresfrom the alter-

nator.

2. Startthe engineand operatethe alter-

nator at the specifiedspeed.

3. Measurethe output voltagewith a volt-

meter. If the measurement is not within the EG-127873
specifiedvalues,replacethe alternator.
lllust.1-148.Testingno'load
alternatoroutput.
AC 2OV
NoJoad I Factory
or more at
output I specification
5200rpm

1-LO2
RegulatingVoltage(Seelllust. 1-149)

1. Completethe chargingcircuit with a

fully chargedbattery and operatethe alternator
at the specifiedspeed.

2. Measurethe battery voltagewith a volt-

meter.

3. If the measurement is not within the

specifiedvalues,replacethe regulator. EGj27874

lllust. 1-149.Checkingregulator
Regulating I Factory | 14 to 15V output voltage.
voltage I specificationI at 5200rpm

GLOWPLUG

Testing

HeatCoil and Insulation(SeeIllust. 1-150)

1. Disconnectthe leadwiresfrom the glow

plug.

2. Checkthe continuityacrossthe thread

at the end of the glow plug and its housingor
the enginebody with an ohmmeter. EG-127875

3. If the ohmmeterindicates0 ohm or

infinity, replacethe glow plug. lllust. 1-150.Testingglow plug.

APProdmatelv
Heatcoil | Fuctory I 1.6 ohm
resistanceI specification
when cold

1.103
 POWERUNIT REASSEM BLY
AND I NSTALLATI O N

1. Assemble the completeenginewith cyl- 2. Removethe enginestandsand install

inder head,oil pan,gearcase,waterpump, the left andright engineplate(40, Illust. 1-151).
alternator,starter,manifolds,pulleywith
alternatorand waterpump belt, injectionpump, 3. Supportengineon solidblocking.
injectorsand tubing, glow plugs,drain plugs,
oil pressureand temperaturesendingunits, and 4. Installstub shaft (68) usingnew screws
oil filter. (69). Torquescrewsto 28 ft. lbs.

Legendfor lllust. 1-151.

1. M u fflerassembly 31, B o lt 60. Lockwasher

2 . Nu t 32. Externaltooth lockwasher 6 1 . E x t e rn atlo o t h lo c kw a s h e r
3. Gasket 33. Lockwasher 62. Ground-to-battery cable
4. Lockwasher 34, Nu t 63. Ground-to-chassis cable
5 . Bo lt 35. E ng in ea s s e mb ly 6 4 . Nu t
6. Lock washer 36. B o lt 65. L-ockwasher
7 . N ut 37. Flatwasher 66. Air cleaner support
8. Bracket 38, Mo u n tp a d (u p p e r) 67. Absorber
9. N ut 39. Washer 68. Stub shaft
10. Lockwasher 40. E ng in ep la t e 69. Screw(special)
1 1 . l dlerpulleybracket 41. Mo u n tp a d (lo we r) 70. Spacer
12 . Bo lt 42. Lockwasher 7 1 . E n g in ea n dra d ia t om r ount
13 . Washer 43. Nut 72. Washer
1 4 . l dlerpulley 44. B o lt 7 3 . B o lt
1 5 . Bolt 45. Secondary fuel filter 74. Air cleanerassembly
1 6 . Washer 46. B o lt (s h o rt ) 7 5 . B o lt
17. Spacer 47. Locl<washer 7 6 . Nu t
18. Lockwasher 48. B olt (lo n g ) 77. Clamp
1 9 . N ut 49. Nu t 78. Clampscrew
2 0 . Bo lt 50. Lockwasher 79. Air cleanerscreen
2 1 . Washer 51. B olt 80. Torquebracket
22. Lockwasher 52. S up p o rt 8 1 . B o lt
23 . N ut 53. B o lt 8 2 . B e llwa s h e r
24. Clip 54. Lockwasher 8 3 . B o lt
25 . Bo lt 55. Nu t 84. PTOclutchassembly
26. Bracket 56. Lockwasher 85. Washer
27. Bolt 57. Nu t 86. Lockwasher
2 8 . Bo lt 58. Lockwasher 8 7 . B o lt
29. Washer 59. B olt B B . F a nb e lt
30 . Bolt

1.104
P
o
Ctl

EG-127876

lltirst t-15i Porverunii - expiodedvieiv

 CAUTION! It is absolutelynecessary 6. Installthe air cleanersupport(66),
that new screwsare used. These
screwsare a metric patch screwthat 7. Install the torque bracket(80).
require a metric Allen wrench to install and
torque properly. The "patch" on the bolt is 8. Install the fan belt (88) and adjustthe
Loctite #495 thread-lock that has already been belt tension.
applied to the threadsof the screwson the
threadsfarthest from the head of the screw. 9. Slip the spacer(70) overthe stub shaft
Re-torque thesescrewsduring the first few (68). Install the HIO clutch assembly(84)
hours of operation after overhaul. Failure to andsecurewith the bolt (87), lock washer(8G),
follow theseinstructions may causescrewro and flat washer(85).
back out of flywheel and destroy the fan belt.
10. Install the assembled fan and fan drive
5. Install the fan drive support bracket support(L9, Illust. 1-752').
(26), muffler bracket (8), idler pulley bracket
(11), and idler pulley (14).

': : : : r . , : , . ': - : r : : : : . I: : ':

r:tEG-127782

f llust. 1-152.Power unit - radiator,air cleanerand muffler removed.

1-106
 Legendfor lllust. 1-152.

1. Fanblade 1 1 . E n g in emo u n t s
2. PTo electricalconnector 12. Engineand radiatormount
3. Liftingeye 1 3 , T imin gma rk s
4. Watertemperature sending
unit 14. Flywheel
5, Fuelreturnlinefitting 1b. Stubshaft
6. Liftingeye 16. PTOclutchassembly
7. Enginestoplever 17. Radiatormountingholes
8. Enginespeedcontrollever 18. Fandrivepulley
9. E ngineoil dipstick 1 9 . F a nd riv es u p p o rt
10. Secondary fuel filter 20. Supportbracket

1.1. Hook a chainto the two lifting eyes 17. Install the radiatorupper hose(2), and
(3 and 6, Illust. 1-152). lower hose(10).

L2. Usinga suitablehoist, raisethe assembled 18. Raisethe assembled

engineand radiator
power unit and guideit into the engineand mount with the hoist.
radiatormount (1-2).Installthe enginemounts
(11) and securethe assembled powerunit to 19. Positionthe tractor on a flat surface
the engineand radiatormount. and guidethe powerunit onto the tractor
irame.
13. Install the secondaryfuel filter support
(52, Illust.1-151)and filter (45). 20. Align the drive shaft with the flexible
couplingon the engineand slidethe power
L4. Positionthe radiator on the engineand unit into position. Usea drift pin to align the
radiatormount (71) and securewith two bolts engineand radiatormount weldednuts with
(73) and washers(72). the matchingholesin the tractor frame.

15. lnstall the alternatorbelt (7, Illust. 2L. lnstallthe two shorterbolts (46, Illust.
1-153)and adjustthe belt tension. 1-151)and lock washers(47) to the rearmount-
ing holes. Install the two longerbolts (48)
16. Install the drive shaft flangeand flexible and lock washers(47) to the front mounting
coupling(9) on the crankshaftpulley. holes. Tightensecurely.

1-107
 E G-1277a1

l l l u s t. 1 -1 5 3 . Po w e r u n i t removed - gear case end of engi ne faci ng forw ard.

1. Radiator 6. Alternator 11. Hoseclamp

2. Radiatorupper hose 7. Alternatorbelt 12. Block drain cock
3. Alternator adjustingbolt 8 . O il f ilt e r 13. Cablesupport bracket
4. Exhaustextension 9 . F le x ib lec o u p lir, ' 1 14. Waterpump pulley
5. Muffler 10. Lowerradiatorhose i 5. Thermostathousing

22. Working through the frame cover open' 26. Fill the enginewith motor oil, as recorn-
ing, install two nuts (1, Illust. 1-154) and mended in the "Specifications."
washers,securingthe drive shaft to the drive
shaft flange on the crankshaftpulley. 27. Fill the cooling system,as recommended
in the "Specifications."
23. Install the battery tray with attached
fuel pump, voltageregulator and circuit breaker. 28. Fill the fuel tank as recommendedin
the "Specifications."
24. Connect electricalwiring and fuel lines
in the reverseorder of disassemblv. 29. Bleed the fuel system as outlined under
"Bleeding the Fuel System."
25. Connect the enginestop lever cable and
enginespeedcontrol lever cable.

1-108
 30. Start the engine,checkignition timing,
oil pressureand coolingsystemtemperature.
Checkfor leaks. Tightenor replace,asre-
quired. Re-torquebolts asspecifiedunder
separateheadings,asrequired.

31. InstaUfloor plate,hood and grille assem-

bly and sidepanels.

32. Slip mower drive belt over PTO pulley.

Adjust belt tension.

33. Road test tractor and makenecessary

adjustmentsasrequired. SeeOperator'sMan-
ual.

\,-J EG-127777

lllust.1-154.Driveshaft.

1. Flangenuts
2. Drive shaft

CHECKSAND ADJ USTM ENTS

CTilCKINGCOMPRESSION (See
PRESSURE
Illust.1-155)

1. Runthe engineuntil it is warmedup.

2. Stop the engineand removethe air

cleaner,the muffler and all nozzleholders.

3. Seta compression testerwith the adaptor

to the nozzleholder hole.

4. Ttrrn the enginewith the starterat 200

to 300 rpm for 5 to 10 secondsand readthe E G-1
maximum compressionpressure.
lllust.1-155.Checking pressure.
compression

1-109
 5. Measurethe compression
pressureseveral 8. If the pressureincreasesafter applying
times. oil, check the cylinder wall and piston rings.

6. If the measurement doesnot reachtle NOTE: Check the compressionpressure

allowablelimit, apply a smallamount of oil with the specified valve clearance.
to the cylinder wall through tbe nozzleholder
hole and measurethe compressionpressure
again. Factory
448 psi
specification
Compression
7. If the pressureis still lessthan the allow-
pressure
ablelimit, checkthe top clearance, valveand Allowable
337 psi
cylinderhead. limit

ADruSTINGVALVE CLEARANCE(Seepage
1-54)

Checking Top Clearance(See Illust. 1-156)

1. Remove the nozzle holder and lower

the piston in the cylinder.

2. Insert a highquality fuse from the

nozzle holder hole on the piston (except where
it facesthe valveor the combustion chamber
insert).

3. Rotate the flywheel until the piston is

raised and lowered again.

4. Take out the flattened fuse carefully

and measureits thickness with a micrometer. EG-127892

5. If the measurementis not within the

specifiedvalues,check the oil clearancesof the lllust. 1-156.Checkingtop clearance.
crank pin journal and the piston pin.

Top I Factory | 0.0236to

clearance I specification 0.0315in.

1 -1 1 0
Injection Timing (seepage 87), Diesel Timing
Unit (seepage XV), and also see lllust. l-L57.

Air Bleeding the Fuel System (See page 1-92)

lllust. 1-157.Timing the engineusing

dieseltiming unit - Model No. 15-3354.
(SeeSpecialTools section)

RADIATOR SCREEN(SeeIllust. 1-158)

Removescreen(1) and cleanasoften as nec-

essarv.

lllust. 1-158.Radiatorscreen.

1. Screen(partiallyremoved)
2. Radiator

1 -1 1 1