JCB 2T FT Hydrostatic Dumper Service Repair Manual

Page 1

Foreword The Operator's Manual

SERVICE MANUAL

You and others can be killed or seriously injured if you operate or maintain the machine without first studying the Operator's Manual. You must understand and follow the instructions in the Operator's Manual. If you do not understand anything, ask your employer or JCB dealer to explain it. Do not operate the machine without an Operator's Manual, or if there is anything on the machine you do not understand. Treat the Operator's Manual as part of the machine. Keep it clean and in good condition. Replace the Operator's Manual immediately if it is lost, damaged or becomes unreadable.

2TFT, 2THS, 2TST, 3.5TST, 3TFT, 3TST

Contents 01 - Machine 06 - Body and Framework

EN - 9813/5250 - ISSUE 1 - 08/2015

09 - Operator Station 15 - Engine 18 - Fuel and Exhaust System 21 - Cooling System 24 - Brakes 25 - Steering System 27 - Driveline 30 - Hydraulic System

This manual contains original instructions, verified by the manufacturer (or their authorized representative).

33 - Electrical System 72 - Fasteners and Fixings 75 - Consumable Products

Copyright 2015 Š JCB SERVICE All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.

www.jcb.com

78 - After Sales


15 - Engine

00 - General 00 - General

(For: Kubota V2203-M)

Health and Safety

This section contains information about the complete engine assembly. For specific engine technical information refer to the technical data section.

Hot Components

Make sure that the correct engine service tools, consumables and torque figures are used when you perform service procedures. Replacement of oil seals, gaskets, etc., and any component that show signs of wear or damage, is expected as a matter of course. It is expected that components will be cleaned and lubricated where required, and that any opened hose or pipe connections will be blanked to prevent excessive loss of hydraulic fluid, engine oil and ingress of dirt.

Basic Description The Kubota engine is a 4 cylinder diesel engine in which the fuel is ignited by compression ignition (C.I.). The engine operates on a four stroke cycle. The engine is started by an electric starter motor. The starter motor turns the engine via a pinion and teeth on the engine flywheel. When the engine runs the crankshaft drives the camshaft though the gears. The camshaft opens and closes the inlet and exhaust valves and through push rods in time with the four stroke cycle. The engine has 16 valves, 2 inlet and 2 exhaust valves for each cylinder. The crankshaft also drives a mechanical high pressure fuel pump via gears. The pump is part of the electronically controlled common rail fuel injection system. Air is drawn into the engine through the inlet manifold and exhaust gases exit through the exhaust manifold.

Touching hot surfaces can burn skin. The engine and machine components will be hot after the unit has been running. Allow the engine and components to cool before servicing the unit. Turning the Engine Do not try to turn the engine by pulling the fan or fan belt. This could cause injury or premature component failure. Notice: The engine and other components could be damaged by high pressure washing systems. Special precautions must be taken if the machine is to be washed using a high pressure system.Make sure that the alternator, starter motor and any other electrical components are shielded and not directly cleaned by the high pressure cleaning system. Do not aim the water jet directly at bearings, oil seals or the engine air induction system. WARNING! To bleed the injectors you must turn the engine. When the engine is turning, there are parts rotating in the engine compartment.Before starting this job make sure that you have no loose clothing (cuffs, ties etc) which could get caught in rotating parts.When the engine is turning, keep clear of rotating parts. Notice: Clean the engine before you start engine maintenance. Obey the correct procedures. Contamination of the fuel system will cause damage and possible failure of the engine. Notice: Do not exceed the correct level of engine oil in the sump. If there is too much engine oil, the excess must be drained to the correct level. An excess of engine oil could cause the engine speed to increase rapidly without control. WARNING! The engine has exposed rotating parts. Switch off the engine before working in the engine compartment. Do not use the machine with the engine cover open.

A mechanical lubrication oil pump is driven by the crankshaft through gears. The pump pressurises and circulates oil for engine lubrication and cooling purposes.

WARNING! Hot oil and engine components can burn you. Make sure the engine is cool before doing this job.Used engine crankcase lubricants contain harmful contaminants. In laboratory tests it was shown that used engine oils can cause skin cancer.

A drive belt again driven by the crankshaft, drives a coolant circulation pump and alternator.

Notice: A drive belt that is loose can cause damage to itself and/or other engine parts. WARNING! Do not open the high pressure fuel system with the engine running. Engine operation causes high fuel pressure. High pressure fuel spray can cause serious injury or death. CAUTION! It is illegal to pollute drains, sewers or the ground. Clean up all spilt fluids and/or lubricants.Used fluids and/or lubricants, filters and contaminated materials must be disposed of in

15 - 4

9813/5250-1

15 - 4


15 - Engine

00 - General 00 - General

accordance with local regulations. Use authorised waste disposal sites.

Technical Data For: Kubota D1703 ...................... Page 15-5 For: Kubota V2203-M .................. Page 15-5

(For: Kubota D1703) Table 6. Data Engine Make Model Bore and stroke Capacity Compression ratio Firing order Rated speed

Description

Kubota D1703-M-E 87 X 92.4mm 1647 cc 22.6:1 1-2-3 2600 RPM (Revolutions Per Minute) Maximum power at 2800 25.7kW / 34.5HP RPM Torque at 2000 RPM 395N·m Direction of rotation Counterclockwise (viewed from the flywheel side) Radiator Radiator cap pressure 0.9bar (13.0psi) Thermostat Type Wax element by-pass blanking Nominal temperature 82°C (179.5°F) Start to open tempera- 79–84°C (174.1– ture 183.1°F) Fully open temperature 93°C (199.3°F) Minimum valve lift fully 10mm open

(For: Kubota V2203-M) Table 7. Data Engine Make Model Bore and stroke Capacity Compression ratio Firing order Rated speed Maximum power at 2800 RPM Direction of rotation

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Description Kubota V2203-M 87 X 92.4mm 2197 cc 22.6:1 1-3-4-2 2600 RPM 32.4kW / 43.5HP Counterclockwise (viewed from the flywheel side) 15 - 5


15 - Engine

00 - General 00 - General

Data Radiator Radiator cap pressure Thermostat Type Nominal temperature Start to open temperature Fully open temperature Minimum valve lift fully open

15 - 6

Description 0.9bar (13.0psi) Wax element by-pass blanking 82°C (179.5°F) 79–84°C (174.1– 183.1°F) 93°C (199.3°F) 10mm

9813/5250-1

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15 - Engine

00 - General 00 - General

Component Identification For: Kubota D1703 ...................... Page 15-7 For: Kubota V2203-M .................. Page 15-8

(For: Kubota D1703) Figure 96. H

J

G

D

E

K

F

C M

B

N

A S

L

P

Q A B C D E F G H

15 - 7

Engine Oil pressure sensor Oil filter Starter motor Rocker cover Glow plug Alternator Dipstick

J K L M N P Q S

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Oil filler cap Thermostat Fan Drive belt Fuel pump ESOS (Engine Shut-Off Solenoid) Drive Plate Drive coupling

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15 - Engine

00 - General 00 - General

(For: Kubota V2203-M) Figure 97. A

K

F

D U M

B E

C P

15 - 8

Intake manifold Speed control lever Engine stop lever Injection pump Fuel feed pump Cooling fan Fan drive pulley Oil filter Water drain cock Oil filler cap

R

N

G J

A B C D E F G H J K

Q

L

T

H

S L M N P Q R S T U

9813/5250-1

Exhaust manifold Alternator Starter motor Oil level gauge Oil pressure switch Flywheel Oil drain plug Oil sump Engine hook

15 - 8


15 - Engine

00 - General 00 - General

Operation For: Kubota 4 Cylinder ................ Page 15-9 For: Kubota D1703 .................... Page 15-12

(For: Kubota 4 Cylinder) The Four Stroke Cycle - 4 Cylinder Engine This section describes the cycle sequence, for the 4 cylinder engine. With the crankshaft positioned as shown, the pistons in numbers 1 and 4 cylinders are at top dead centre and pistons in numbers 2 and 3 cylinders are at bottom dead centre. It is important to note that number 1 cylinder is firing and about to start its power stroke. Rotating the crankshaft a further full rotation would position the pistons as described but the engine would be at a different stage in its four stroke cycle, with number 1 cylinder about to start its Induction stroke. The stages in the four stroke cycle for each cylinder are as follows: Table 8. The Four Stroke Cycle Cylinder num- Piston operaber tion 1 The piston is at the top of its Compression stroke and is about to start its Power stroke. 2 The piston is at the bottom of its Power stroke and is about to start its Exhaust stroke.

15 - 9

Cylinder num- Piston operaber tion 3 The piston is at the bottom of its Induction stroke and is about to start its Compression stroke. 4 The piston is at the top of its Exhaust stroke and is about to start its Induction stroke.

Valve operation Exhaust valves closed, inlet valves about to close Valve Operation Exhaust valves about to close, inlet valves about to open

Firing Order A cylinder is said to be firing, when the fuel / air mixture ignites and the piston is about to start its power stroke. From the stages described, it can be seen that number 1 cylinder will be next to fire. Number 3 cylinder is starting its compression stroke and is next in the cycle, followed by cylinders 4 and 2. The firing order is therefore; 1, 3, 4, 2.

Valve operation Inlet and exhaust valves closed

Inlet valves closed, exhaust valves about to open

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15 - Engine

00 - General 00 - General

CYL1

Figure 98.

CYL2

1

CYL3

CYL4

2

5

A C

B

C G

B

C

B

H

C

B

J

K 4

3

F

745620 745620

G

H

J

K

C

A C

CYL1 CYL2 CYL3 CYL4 A B C

15 - 10

B

A B

B

A

C

A

C

B

Cylinder number 1 Cylinder number 2 Cylinder number 3 Cylinder number 4 Camshaft Camshaft lobe - Inlet valve operation Camshaft lobe - Exhaust valve operation

F 1 2 3 4 5

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Front of engine Exhaust valves Inlet valves Crankshaft Crankshaft gear Camshaft drive gear

15 - 10


15 - Engine

00 - General 00 - General

Four Stroke Cycle

revolution of the crankshaft, thus, in one cycle of a four stroke engine, the crankshaft revolves twice.

Induction

Figure 99.

As the piston travels down the cylinder, it draws filtered air through inlet valves into the cylinder. Compression When the piston reaches the bottom of its stroke the inlet valves close. The piston then starts to rise up the cylinder compressing the air trapped in the cylinder. This causes the temperature and pressure of the air to rise. Fuel is injected into the cylinder when the piston is near to top dead centre.

3

2

Power B

The piston continues to rise after the start of fuel injection causing a further increase in pressure and temperature. The temperature rises to a point at which the fuel/air mixture ignites. A cylinder is said to be firing, when the fuel/air mixture ignites. This combustion causes a very rapid rise in both temperature and pressure. The high pressure generated propels the piston downward turning the crankshaft and producing energy. Exhaust Once the piston has reached the bottom of its travel, the exhaust valves open and momentum stored in the flywheel forces the piston up the cylinder expelling the exhaust gases.

1

C

4

746030

1 2 3 4 A B C BDC TDC

Induction stroke Compression stroke Power stroke Exhaust stroke Camshaft Camshaft lobe - Inlet valve operation Camshaft lobe - Exhaust valve operation Bottom dead centre TDC (Top Dead Centre)

In a running engine these four phases are continuously repeated. Each stroke is half a

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9813/5250-1

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15 - Engine

00 - General 00 - General

Figure 100.

717620

1

2

3

4

B

C

A

C

A

A

B

B

A

C

B

C

1 2 3 4

A B C

Induction stroke Compression stroke Power stroke Exhaust stroke

(For: Kubota D1703) This section describes the cycle sequence for the 3 cylinder engine. The engine will have a power stroke once every 240° of crankshaft angle (720°/3 = 240°). With the crankshaft positioned as shown, the piston in number 2 cylinder is at TDC and pistons in number 15 - 12

Camshaft Camshaft lobe - Inlet valve operation Camshaft lobe - Exhaust valve operation

1 and 3 cylinders are 32° past bottom dead centre (BDC). It is important to note that number 2 cylinder is firing and about to start it's power stroke. Rotating the crankshaft a further 360° would position the pistons as described. However the engine would be at a different stage in it's four stroke cycle, with the number 2 cylinder about to start its induction stroke.

9813/5250-1

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15 - Engine

00 - General 00 - General

Firing Order Figure 101. Typical Three Cylinder Engine

A

B

C

D F

G E

E

F A B C D

E

F

G E F G

Cylinder number 1 Cylinder number 2 Cylinder number 3 Tappet

A cylinder is said to be firing when the fuel/air mixture ignites and the piston is about to start its power stroke. From the stages described, it can be seen that the number 2 cylinder will be next to fire. The number 1

G

Camshaft Camshaft lobe - Exhaust valve operation Camshaft lobe - Inlet valve operation

cylinder is in the middle of its compression stroke and number 3 cylinder is in the middle of exhaust stroke. The firing order is therefore; 1, 3, 2. The stages in the four stroke cycle for each cylinder are as follows:

Table 9. The Four Stroke Cycle Cylinder number 1 2 3

15 - 13

Piston operation The piston is at the middle of its compression and is next in firing order. The piston is at the top of its compression stroke and is about to start its power stroke. The piston is at the middle of its exhaust stroke and will start its induction stroke at the top of the exhaust stroke. 9813/5250-1

Valve operation Inlet and exhaust valves closed Inlet and exhaust valves closed Exhaust valves open fully, inlet valves will open soon.

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15 - Engine

00 - General 00 - General

Four Stroke Cycle Induction

The temperature rises to a point at which the fuel/air mixture ignites. A cylinder is said to be firing when the fuel/air mixture ignites.

As the piston travels down the cylinder, it draws filtered air at atmospheric pressure and ambient temperature through an air filter and inlet valves into the cylinder.

This combustion causes a very rapid rise in both temperature and pressure. The high pressure generated propels the piston downwards turning the crankshaft and producing energy.

Compression

Exhaust

When the piston reaches the bottom of its stroke, the inlet valves close. The piston then starts to rise up the cylinder compressing the air trapped in the cylinder. This causes the temperature and pressure of the air to rise. Fuel is injected into the cylinder when the piston is near to TDC.

Once the piston has reached the bottom of its travel, the exhaust valves open and momentum stored in the flywheel forces the piston up the cylinder expelling the exhaust gases.

Power

In a running engine, these four phases are continuously repeated. Each stroke is half a revolution of the crankshaft, thus, in one cycle of a four stroke engine, the crankshaft revolves twice.

The piston continues to rise after the start of fuel injection, causing a further increase in pressure and temperature. Figure 102.

3

2

B

C

4

1

746030

1 2 3 4 A

15 - 14

Induction stroke Compression stroke Power stroke Exhaust stroke Camshaft

B C BDC TDC

9813/5250-1

Camshaft lobe - Inlet valve operation Camshaft lobe - Exhaust valve operation Bottom dead centre TDC

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15 - Engine

00 - General 00 - General

Figure 103.

717620

1

2

3

4

B

C

A

C

A

B

A

B

A

C

B

C

1 2 3 4

15 - 15

Induction stroke Compression stroke Power stroke Exhaust stroke

A B C

9813/5250-1

Camshaft Camshaft lobe - Inlet valve operation Camshaft lobe - Exhaust valve operation

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15 - Engine

00 - General 00 - General

Clean Notice: Clean the engine before you start engine maintenance. Obey the correct procedures. Contamination of the fuel system will cause damage and possible failure of the engine. Notice: The engine and other components could be damaged by high pressure washing systems. Special precautions must be taken if the machine is to be washed using a high pressure system. Make sure that the alternator, starter motor and any other electrical components are shielded and not directly cleaned by the high pressure cleaning system. Do not aim the water jet directly at bearings, oil seals or the engine air induction system.

9. When the pressure washing is complete move the machine away from the wash area, or alternatively, clean away the material washed from the machine. 10. Before working on specific areas of the engine use a compressed air jet to dry off any moisture. When the area is dry use a soft clean brush to remove any sand or grit particles that remain. 11. When removing components be aware of any dirt or debris that may be exposed. Cover any open ports and clean away the deposits before proceeding Additional cleaning must be carried out prior to working on the high pressure fuel system, refer to: Fuel System - Clean (PIL 18-00).

Before carrying out any service procedures that require components to be removed, the engine must be properly cleaned. Cleaning must be carried out either in the area of components to be removed or, in the case of major work, or work on the fuel system, the whole engine and surrounding machine must be cleaned. Stop the engine and allow it to cool for at least one hour. DO NOT attempt to clean any part of the engine while it is running. 1. Make sure that the electrical system is isolated. 2. Make sure that all electrical connectors are correctly coupled. If connectors are open fit the correct caps or seal with water proof tape. 3. Cover the alternator with a plastic bag to prevent water ingress. 4. Seal the engine air intake, exhaust and breather system. 5. Make sure that the oil filler caps and dipstick are correctly installed. 6. Use a low pressure water jet and soft bristle brush to soak off caked mud or dirt. 7. Apply an approved cleaning and degreasing agent with a brush. Obey the manufacturers instructions. 8. Use a pressure washer to remove the soft dirt and oil. Important: DO NOT aim the water jet directly at oil seals or electrical and electronic components such as ECU (Electronic Control Unit)'s, alternator or fuel injectors. DO NOT place the jet nozzle closer than 600mm (24 in) to any part of the engine or after treatment system including exhaust sensor ECU (if installed).

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9813/5250-1

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15 - Engine

00 - General 00 - General

Remove and Install

Figure 105.

For: Kubota D1703 .................... Page 15-26 For: Kubota V2203-M ................ Page 15-32

A

(For: Kubota D1703) Remove C

1. Make the machine safe. Refer to (PIL 01-03).

D

2. Isolate the battery. Refer to (PIL 33-03). 3. Drain the cooling system. Refer to (PIL 21-00).

A C D E

4. Remove the floorplate. Refer to (PIL 09-78). 5. Remove the rear propshaft. Refer to (PIL 27-47).

E

Alternator Positive terminal 1 Electrical connector Clip 1

6. Remove the air filter assembly. Refer to (PIL 15-24).

11. Remove the terminal cover 2 from the starter motor positive terminal.

7. Remove the terminal cover 1 from the alternator positive terminal.

Figure 106. F

Figure 104.

A G B

A B

F G

Starter motor Terminal cover 2

12. Disconnect the positive terminal 2 from the starter motor.

Alternator Terminal cover 1

8. Make a note of the electrical connector locations to help installation.

13. Remove the starter solenoid connector. Figure 107.

9. Disconnect the positive terminal 1, electrical connector from the alternator. F

10. Release the harness from the clip 1.

J H

F H J

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9813/5250-1

Starter motor Positive terminal 2 Starter solenoid connector

15 - 26


15 - Engine

00 - General 00 - General

Figure 111.

14. Remove the right hand side engine wiring harness.

P

Figure 108.

K

P K

ROPS pin

19. Fold the ROPS back.

Engine wiring harness

Figure 112.

15. Remove the parking brake cable split pin.

Q

16. Disconnect the parking brake cable. Figure 109.

L

Q

M

ROPS

20. Disconnect the coolant temperature sensor. L M

Parking brake cable split pin Parking brake cable

17. Remove the ROPS Structure) split pin.

(Roll-Over

Figure 113.

Protective R

Figure 110. F

G

N

R

Coolant temperature sensor

21. Remove the wiring harness and the hydraulic hose retaining P-clips.

ROPS split pin

18. Remove the ROPS pin.

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9813/5250-1

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15 - Engine

00 - General 00 - General

Figure 114.

Figure 117.

S V

S

W

S

P-clips

22. Disconnect the beacon electrical connectors. Figure 115.

V W

Reverse switch connector Clutch actuator linkage

25. Disconnect the accelerator cable from the pedal. Figure 118. Y

T

X

T

Beacon electrical connector

23. Disconnect the hydraulic oil supply hose and reposition across the engine. Figure 116.

X Y

Accelerator cable Pedal

26. Disconnect the glow plug and oil pressure sensor electrical connectors. Figure 119.

Z U AA

U

Hoses 1

24. Disconnect the reverse switch electrical connector and the clutch actuator linkage.

Z AA

Glow plug connector Oil pressure sensor connector

27. Disconnect the hydraulic hoses 2.

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9813/5250-1

15 - 28


15 - Engine

00 - General 00 - General

Figure 123.

Figure 120.

AG

AB

AB

AF

Hoses 2

28. Remove the bolts 1 and move the steering assembly forward. Figure 121.

AF AG

Bolts 2 Control bracket

31. Move the control bracket to the left hand side of the machine. Figure 124.

AD

AC AG

AC AD

Bolts 1 Steering assembly

29. Secure the steering assembly to the dumper body for access. Figure 122.

AG

Control bracket

32. Install a bolt 2 to secure the control bracket to the chassis for clearance. Figure 125.

AD AE

AF

AD AE

Steering assembly Dumper body

30. Remove the bolts 2 from the control bracket.

15 - 29

AF

Bolt 2

33. Disconnect the left hand side engine wiring harness.

9813/5250-1

15 - 29


15 - Engine

00 - General 00 - General

Figure 126.

Figure 129. AM

AL

K

K

Engine wiring harness

34. Disconnect the fuel supply hose and the fuel spill hose. Figure 127.

AL AM

Clamp 1 Radiator top hose

38. Remove the bolts 3 from the hydraulic pump. 39. Remove the hydraulic pump. Figure 130.

AH

AJ

AH AJ 35. Disconnect connector.

Fuel supply hose Fuel spill hose the

stop

AN

AP

solenoid

AN AP

electrical

Hydraulic pump Bolts 3

40. Remove the clamp 2.

Figure 128.

41. Remove the fuel supply hose. Figure 131.

AK AR

AK

Stop solenoid electrical connector

AQ

36. Loosen the clamp 1 from the radiator top hose.

AQ AR

37. Remove the radiator top hose.

Clamp 2 Fuel supply hose

42. Support the engine and transmission assembly.

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9813/5250-1

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15 - Engine

00 - General 00 - General

Figure 134.

Figure 132.

AT

AX

AS

AS AT

AW

Engine and transmission assembly Lifting equipment

43. Remove the hydrostatic drive pump from the engine as follows: Figure 133.

AW AX

Nuts Exhaust clamp

46. Remove the bolts 5 from the exhaust down pipe. 47. Remove the exhaust down pipe. Figure 135. AZ

AY

AU

AV

AU AV

AY AZ Bolts 4 Hydrostatic drive pump

Bolts 5 Exhaust down pipe

48. Remove the bolts 6 from the left hand side of the exhaust.

43.1.Support the hydrostatic drive pump. 43.2.Remove the bolts 4 from the hydrostatic drive pump. 43.3.Remove the hydrostatic drive pump.

49. Remove the bolts 7 from the left hand side engine mounting bracket 1. 50. Collect the lower and upper washers.

44. Loosen the nuts and remove the exhaust clamp. 45. Collect the gasket.

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15 - Engine

00 - General 00 - General

Figure 136.

54. Remove the bolts 8 from the engine mounting bracket 2. 55. Remove the engine mounting bracket 2. Figure 138.

BB

BA

BE

BD

BF

BC

BE BF

Bolts 8 Engine mounting bracket 2

56. Remove the engine and transmission assembly. Figure 139.

BA BB BC BD

AT

Bolts 6 Bolts 7 Engine mounting bracket 1 Exhaust

AS

51. Remove the bolts 6 from the right hand side of the exhaust pipe. 52. Remove the bolts 7 from the right hand side engine mounting bracket 1. 53. Collect the lower and upper washers. Figure 137. BD BA

AS AT

Engine and transmission assembly Lifting equipment

Install 1. The installation procedure is the opposite of the removal procedure. Additionally do the following step. 2. Tighten the bolts to the correct torque value.

BB

Table 29. Torque Values BC

BA BB BC BD

Bolts 6 Bolts 7 Engine mounting bracket 1 Exhaust

Item BA BB BE

Description Bolts 6 Bolts 7 Bolts 8

Nm 106 106 106

(For: Kubota V2203-M) Remove 1. Make the machine safe. Refer to (PIL 01-03). 2. Isolate the battery. Refer to (PIL 33-03).

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15 - Engine

00 - General 00 - General

Figure 141.

3. Drain the cooling system. Refer to (PIL 21-00). F

4. Open the engine compartment cover. Refer to (PIL 06-06). 5. Remove the rear access panel. Refer to (PIL 06-06).

G

J

6. Remove the floorplate. Refer to (PIL 09-78). 7. Remove the radiator. Refer to (PIL 21-03).

H

8. Remove the rear propshaft. Refer to (PIL 27-47). 9. Remove the air filter assembly. Refer to (PIL 15-24).

F G H J

10. Remove the terminal cover 1 from the alternator positive terminal.

Starter motor Starter motor terminal Terminal cover Starter solenoid connector

11. Make a note of the electrical connector locations to help installation.

17. Remove the right hand side engine wiring harness.

12. Disconnect the positive terminal 1 and the electrical connector from the alternator.

Figure 142.

13. Release the harness from the clip 1. Figure 140.

K

A C B D A B C D E

K

E

Engine wiring harness

18. Remove the ROPS split pin. 18.1.Right-hand side shown, left-hand side similar.

Alternator Terminal cover 1 Alternator positive terminal Electrical connector Clip 1

Figure 143.

14. Remove the terminal cover 2 from the starter motor positive terminal. 15. Disconnect the positive terminal 2 from the starter motor. 16. Remove the starter solenoid connector.

N

N

ROPS split pin

19. Remove the ROPS pin.

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