WSM 60

WORKSHOP MANUAL
COMBINE HARVESTER
DC-60-PH
KiSC issued 08, 2010 A

CONTENTS
TO THE READER ALARM SYSTEM
TO THE READER CONTENTS
INFORMATION MECHANISM
CONTENTS 1. MECHANISM ............................................ 7-M1
INFORMATION ELECTRICAL SYSTEM
1. SAFETY FIRST ............................................ I-1 CONTENTS
2. FOR YOUR SAFETY OPERATION.............. I-2 MECHANISM
3. WARNING LABELS DESIGNED FOR 1. CIRCUIT DIAGRAM.................................. 8-M1
SAFE OPERATION .................................... I-19 2. WIRING DIAGRAM................................... 8-M2
GENERAL SERVICING
CONTENTS 1. CHECKING ................................................ 8-S1
GENERAL ENGINE
1. MECHANISM...............................................G-1 CONTENTS
2. FOR SAFE OPERATION.............................G-3 GENERAL
MAINTENANCE 1. SPECIFICATIONS .....................................9-G1
CONTENTS 2. TIGHTENING TORQUE ............................9-G2
SERVICING 3. SPECIAL TOOLS.......................................9-G3
1. PERIODIC CHECK LIST ........................... 1-S1 MECHANISM
2. CHECKING AND ADJUSTMENTS............ 1-S5 1. ENGINE BODY ......................................... 9-M1
2. LUBRICATING SYSTEM .......................... 9-M3
REAPING PORTION
3. COOLING SYSTEM.................................. 9-M5
CONTENTS
4. FUEL SYSTEM ......................................... 9-M7
MECHANISM
5. INTAKE / EXHAUST SYSTEM ................. 9-M9
1. MECHANISM............................................ 2-M1
SERVICING
SERVICING
1. TROUBLESHOOTING............................... 9-S1
1. CHECKING AND ADJUSTMENT .............. 2-S1
2. SERVICING SPECIFICATIONS
2. DISASSEMBLING AND
(V2403-M-DI-T).......................................... 9-S6
ASSEMBLING ........................................... 2-S5
3. ENGINE BODY ........................................ 9-S11
THRESHING PORTION 4. LUBRICATING SYSTEM ......................... 9-S45
CONTENTS 5. COOLING SYSTEM................................. 9-S47
MECHANISM 6. FUEL SYSTEM ........................................ 9-S49
1. MECHANISM............................................ 3-M1 7. ELECTRICAL SYSTEM ........................... 9-S51
SERVICING 8. TURBOCHARGER .................................. 9-S58
ASSEMBLING ........................................... 3-S1
TRAVELING PORTION
CONTENTS
MECHANISM
1. MECHANISM............................................ 4-M1
SERVICING
ASSEMBLING ........................................... 4-S1
HYDRAULIC SYSTEM
CONTENTS
MECHANISM
1. MECHANISM............................................ 5-M1
SERVICING
1. CHECKING AND MAINTENANCE ............ 5-S1
HST
CONTENTS
MECHANISM
1. MECHANISM............................................ 6-M1
SERVICING
1. TROUBLESHOOTING............................... 6-S1
2. CHECKING AND ADJUSTMENT .............. 6-S3
3. DISASSEMBLING ..................................... 6-S4

TO THE READER
This Workshop Manual has been prepared to provide servicing personnel with information on the
mechanism, service and maintenance of DC-60-PH. It is divided into three parts, "General",
"Mechanism" and "Servicing".
Q General
Information on the machine body and engine identifications, the general precautions, tightening
torque and special tools are described.
Q Mechanism
Information on the construction and function are included.This part should be understood before
proceeding with troubleshooting, disassembling and servicing.
Q Servicing
Information on the troubleshooting, checking and adjusting, disassembling and assembling, and
servicing which cover procedures, precautions, factory specifications and allowable limits.
All information illustrations and specifications contained in this manual are based on the latest
product information available at the time of publication.
Specifications and other content contained in this manual are subject to change without prior notice.
August 2010
© KUBOTA Corporation 2010

I INFORMATION

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

2. FOR YOUR SAFETY OPERATION................................................................................................ I-2
[1] FOR YOUR SAFETY OPERATION, INSTRUCTIOMS MENTIONED BELOW MUST
BE FOLLOWED........................................................................................................................ I-2
(1) General Precautions........................................................................................................... I-2
(2) Precautions before Operation............................................................................................. I-4
(3) Precautions for Traveling, Entering/exiting the Field, and Parking..................................... I-6
(4) Precautions during Operation............................................................................................. I-8
(5) Considerations when Storing after Use ............................................................................ I-10
(6) Considerations During Checking and Maintenance ......................................................... I-11
(7) Precautions for Transportation ......................................................................................... I-17
3. WARNING LABELS DESIGNED FOR SAFE OPERATION......................................................... I-19
[1] DESCRIPRION OF WARNING LABELS AND LABELED POSITION.................................... I-19
[2] WARNING LABEL MAINTENANCE ....................................................................................... I-26

DC-60-PH, WSM INFORMATION
1. SAFETY FIRST
SAFETY FIRST
• This symbol, the Safety Alert Symbol, is used throughout this manual and on labels on the machine
itself to warn of the possibility of personal injury. Read these instructions carefully.
• It is essential that you read the instructions and safety regulations before you attempt to repair this unit.
DANGER
• Indicates an imminently hazardous situation which will result in death or serious injury if you do not
follow the instruction.
WARNING
• Indicates a potentially hazardous situation which could result in death or serious injury if you do not
follow the instruction.
CAUTION
• Indicates a potentially hazardous situation which may result in injury if you do not follow the
instruction.
IMPORTANT
• Indicates that machinery damage or failure could be caused if you do not follow the instruction.
NOTE
• Indicates useful information for operation.
(Reference)
• Indicates other suggestions for your reference.
9Y1210019INI0002US0
I-1

2. FOR YOUR SAFETY OPERATION

Before using the combine harvester, carefully read the operator's manual and fully understand the machine and
information to ensure safe operation. For your safety operation, instructions mentioned below must be followed; in
addition, pay particular attention to the DANGER, WARNING, CAUTION, (IMPORTANT), and (NOTE)
warnings in this manual.
9Y1210019INI0003US0
[1] FOR YOUR SAFETY OPERATION, INSTRUCTIOMS MENTIONED

BELOW MUST BE FOLLOWED
(1) General Precautions
Carefully read the operator's manual and
warning labels on the combine harvester for
correct operation and work sequence.
• In addition to the precautions provided in this book,
pay enough attention to safety. Warning Labels must
be clean at all times.
(Failure to do so)
• May result in death or serious injury.
9Y1210019INI0004US0
Do not operate when you don't feel well.

• The operation needs the right response and
judgement. Do not operate the machine when you
are;
– Drunk
– Lacking sleep
– Pregnant
– Overworked or sick
– Under 16 years of age
(Failure to do so)
• May lead to unexpected accidents.
9Y1210019INI0005US0
Both the operator and assistant(s) must wear

clothes suitable for work.
• Do not wear loose-fitting clothes.
• Button cuffs tightly.
• Do not wear a neckerchief. Do not have a towel
around your head or waist either.
• Do not wear sandals or slippers.
(Failure to do so)
• Loose clothing may become caught in rotating
parts and levers or slippery footwear may cause
serious injury.
(1) Hard Hat (4) Non-skid Shoes
(2) Tight Cuffs (5) Neat Pants Bottom
(3) Well-fitting Clothes
9Y1210019INI0006US0
I-2

Children and persons who cannot understand the
operator's manual or the warning labels should
never attempt to operate the combine harvester.
• If you lend the combine harvester to others or allow
others to operate the machine, instruct them to read
the operator's manual while explaining the proper
procedures for safe operation.
(Failure to do so)
• May result in death or serious injury.
9Y1210019INI0007US0
Do not modify the combine harvester.

(Failure to do so)
• May lead to improper function causing
unexpected accidents.
9Y1210019INI0008US0
Do not jump in or out of the operator's seat.

• When getting on/off the combine harvester, firmly
grasp the handrail while parked on level grounded
and watch your step.
(Failure to do so)
• May result in the operator falling from the
machine causing serious injury.
9Y1210019INI0009US0
No one other than the operator should ride in the

combine harvester.
• Do not jump onto the operator's seat or jump out of
the seat while the combine harvester is moving.
(Failure to do so)
• You may be thrown off or hit by the combine
harvester causing death or serious injury.
9Y1210019INI0010US0
I-3

Avoid operating and traveling in the combine
harvester during the night.
• If you are forced to operate at night, use the head
light and the work lamp.
• If you are forced to travel at night, use the rear work
lamp.
(Failure to do so)
• May result in traffic accidents or the operator
falling from the machine causing death or
serious injury.
9Y1210019INI0011US0
(2) Precautions before Operation

Adequate ventilation must be provided to remove
the exhaust gas when you operate indoors.
• To let in fresh air, extend the exhaust pipe outdoors
or keep the door and windows open.
(Failure to do so)
• The exhaust gas from the engine is toxic. May
cause life-threatening poisoning.
9Y1210019INI0012US0
No fire or flame is allowed during refueling. Do not

smoke or hold an open flame near the fuel.
• Be sure to turn off the engine and take out the main
switch key during refueling.
• Thoroughly wipe off fuel or oil spills, if any.
(Failure to do so)
• May lead to fire.
9Y1210019INI0013US0
Check the surrounding area and ensure safety

before starting the combine harvester.
Q Sit in the operator's seat and set main shift lever
to the (STOP) position before starting the engine.
Threshing and reaping clutch levers should be
set to the (OFF) position and horn sounded.
Q Horn should be sounded when you start driving
or when putting the threshing and reaping clutch
levers in gear.
(Failure to do so)
• Bystanders may become caught in rotating parts
or the machine causing serious injury.
9Y1210019INI0014US0
I-4

Q Those who operate the machine for the first time
must run it at low speed.
(Failure to do so)
• May lead to unexpected accidents.
9Y1210019INI0015US0
Perform daily check before operation.

Q Conduct periodic inspections with the checklist
(refer to the operator's manual) before operation.
If any abnormalities are observed, do not operate
until abnormality is corrected.
(Failure to do so)
• Faulty maintenance may lead to serious injury.
9Y1210019INI0016US0
Q Be sure to turn off the engine and take out the

main switch key during inspection, servicing,
cleaning, and refueling.
Q Be sure to reinstall the safety and protective
covers back into their respective positions.
(Failure to do so)
• You may become caught in rotating parts
causing serious injury.
9Y1210019INI0017US0
Q Completely remove any straw accumulated

around the muffler, belt cover, and battery.
(Failure to do so)
9Y1210019INI0018US0
I-5

Q Keep children away from the machine during
inspection and maintenance.
(Failure to do so)
• Children may become caught in rotating parts or
the machine causing serious injury.
9Y1210019INI0019US0
Be sure to turn off the engine and take out the

main switch key when you open/close the engine
room side cover, thresher side cover, or thresher
upper cover.
• Open/close each cover while parking on level
ground.
• Lock the stopper in position when the thresher side
cover is open.
• Do not start the engine while any of the covers are
open.
(Failure to do so)
9Y1210019INI0020US0
(3) Precautions for Traveling, Entering/exiting the Field, and Parking

Observe the following instructions when
traveling.
• Combine harvester may not be driven on the public
highway by law. Transport it by the truck.
• Make sure to set the threshing and reaping clutch
levers into the (OFF) position. No one other than the
operator should ride in combine harvester.
• Make sure to discharge all paddy.
• When shifting the sub shift lever, stop traveling and
set the main shift lever to the (STOP) position while
parked on level ground.
• Do not set the sub shift lever to the P (parking brake)
position while driving.
• Put back the auxiliary deck to make the combine
harvester narrower.
• Raise the reaper and install the lock plate to prevent
the reaper from falling.
(Failure to do so)
• May cause human injury or damage objects. In
addition, poor balance increases the risk of
falling.
9Y1210019INI0021US0
I-6

Do not rapidly change direction while driving fast.
• Reduce travel speed (run at low speed) and slowly
move the power steering lever to change the
direction.
(Failure to do so)
• You may be thrown off the combine harvester or
it may turn over.
9Y1210019INI0022US0
Slow down the travel speed while traversing a

slope.
• Do not operate the power steering lever or the sub
shift lever on the slope.
• Do not travel sideways or change direction on the
slope.
(Failure to do so)
• Combine harvester may run out of control or turn
over.
9Y1210019INI0023US0
Do not travel on elevated, narrow roads (banks).

• Be careful when driving through farm roads and pay
attention to the uneven shoulders of a road.
• Do not drive near ditches, holes, or banks.
• When visibility is poor due to puddles or overgrown
grass, alight the combine harvester and check area
prior to operation.
(Failure to do so)
• The combine harvester may lose balance and
turn over.
9Y1210019INI0024US0
Use the bridges to enter/exist fields where much

difference in ground level.
• Where the difference in ground height is more than
10 cm, use the standard bridges 4 times the length
of the difference in ground height.
• Place the bridges in the perpendicular to a border.
(Failure to do so)
turn over.
9Y1210019INI0025US0
I-7

Approach ridge at a perpendicular angle at slow
speed to cross.
• Where the difference in ground height is more than
10 cm, use a standard bridges 4 times the length of
the difference in ground height.
(Failure to do so)
turn over.
9Y1210019INI0026US0
Set the sub shift lever to (P) (parking brake) and

apply the parking brake on a level ground area when
you park or leave the combine harvester. Lower the
reaper until it touches the ground. Be sure to turn off
the engine and then remove the main switch key.
• If you are forced to park on a slope, place the stop
blocks under the crawlers to prevent the combine
harvester from moving.
(Failure to do so)
• The combine harvester may roll causing an
unexpected accident.
9Y1210019INI0027US0
(4) Precautions during Operation

When working with others, use the horn, etc. to
signal operations.
• Using the horn as a signal, get the understanding
from an assistant before turning on the engine,
engaging clutches, and using switches.
• When the assistant approaches the combine
harvester, he or she must make it known to the
operator.
(Failure to do so)
• May lead to an unexpected accident as visibility
of others is restricted during operation.
9Y1210019INI0028US0
Pay particular attention to looking to the rear

before corner-reaping.
(Failure to do so)
• Improper handling may cause the combine
harvester to fall or turn over.
9Y1210019INI0029US0
I-8

Keep away from the reaper and supply crops in
small amounts to perform throw away threshing
• Park the combine harvester on level ground, turn off
the reaper, and apply the parking brake.
• Do not stand in front of the reaper.
• Assistants should sit in the operator's seat and be
ready to turn off the engine if necessary.
• Raise the reaper and the reel to the highest position.
Install the lock plate to prevent the reaper from falling
and then throw crops little by little.
• Button cuffs tightly. Do not wear gloves, headbands
or wear towels around your head or neck, etc.
(Failure to do so)
• You may become caught in the reel causing
serious injury.
9Y1210019INI0030US0
If any abnormalities are observed, immediately
turn off the engine and remove the main switch key.
• When removing twine/clogging, checking paddy or
cleaning, disengage the threshing and reaping
clutch levers to the (OFF) position. Be sure to turn off
engine.
• Wear thick gloves when removing the straw stuck in
the thresher. Remove little by little.
• Do not touch the edge of blade with hands.
(Failure to do so)
• You may become caught in moving parts (chain,
etc.) causing serious injury.
9Y1210019INI0031US0
Be sure to reattach safety covers.
• Do not operate without reattaching belt/chain covers
and cleaning port.
(Failure to do so)
9Y1210019INI0032US0
Do not operate on surfaces where the angle of

inclination is over 5 degrees.
• Stop traveling and move to a level ground area.
Make sure the combine harvester is not lean to one
side and then resume the operation.
(Failure to do so)
• You may lose control of the combine harvester
causing fall down.
9Y1210019INI0033US0
I-9

(5) Considerations when Storing after Use

Do not park the combine harvester on straw or dry
weeds/grass.
(Failure to do so)
• Straw and dry weeds/grass burn easy and may
catch fire.
9Y1210019INI0034US0
Be sure to turn off the engine and remove the

main switch key before checking or cleaning.
(Failure to do so)
• You may become caught in the combine
harvester causing serious injury.
9Y1210019INI0035US0
When checking or cleaning, be sure to stop the

engine and wait until each part sufficiently cools
down.
• Do not touch the engine or muffler right after
stopping the engine.
(Failure to do so)
• May result in serious burns.
9Y1210019INI0036US0
Check the engine body, muffler, wiring inside belt

cover, battery and its surrounding area for any
accumulated straw. Remove as necessary.
(Failure to do so)
9Y1210019INI0037US0
When cleaning, do not touch blade edge.

(Failure to do so)
• May result in serious injury.
9Y1210019INI0038US0
I-10

Keep any naked flame (match, lighter, cigarette)
away from the battery. Be careful not to short
battery.
(Failure to do so)
• Hydrogen gas may generate from the battery and
cause an explosion.
9Y1210019INI0039US0
Check the electrical wiring such as the wire

harness and the battery cable for damage and
disconnection.
(Failure to do so)
• A short in the electrical wiring may cause fire.
9Y1210019INI0040US0
When putting a cover over the combine harvester,

wait until the engine and muffler sufficiently cool
down.
(Failure to do so)
9Y1210019INI0041US0
(6) Considerations During Checking and Maintenance

Precautions for inspection and maintenance on
each part.
(Failure to do so)
• Faulty maintenance may lead to serious injury.
9Y1210019INI0042US0
I-11

Do not recklessly dispose or burn waste.
• Use a container when draining waste oil.
• Do not dispose waste oil into river, pond, ocean or
earth.
• When disposing/burning waste oil, fuel, cooling
water, coolant, solvent, filters, batteries, rubber
products and other hazardous materials, consult
with the seller or an industrial waste disposer. Be
sure to conform to the rules when disposing waste.
(Failure to do so)
• May pollute the environment and you may be
punished by law.
9Y1210019INI0043US0
When checking, servicing, replacing or cleaning
parts, be sure to park the combine harvester on level
ground. Shift the clutch levers to the (OFF) position
and apply the parking brake. Be sure to turn off the
engine and remove the main switch key.
(Failure to do so)
9Y1210019INI0044US0
Lock with the stopper in position when the

thresher side cover is open.
(Failure to do so)
9Y1210019INI0045US0
I-12

Do not start the engine with the engine room side
cover, thresher side cover or thresher upper cover
open.
(Failure to do so)
9Y1210019INI0046US0
When replacing heavy items like the sieve case,

replace with two people or more.
(Failure to do so)
• Falling may result in serious injury.
9Y1210019INI0047US0
When checking, adjusting or cleaning with the

reaper raised, lock the hydraulic cylinder and place
stop blocks under the reaper to prevent the reaper
from falling.
• Be sure to stop the engine and apply the parking
brake before operation.
• Do not go under the reaper or place your hand or foot
below the reaper.
(Failure to do so)
harvester, causing serious injury.
9Y1210019INI0048US0
When adjusting/replacing the reaping blade or

received blade, wear gloves and do not touch the
blade edges with your hands.
(Failure to do so)
• May result in serious injury.
9Y1210019INI0049US0
I-13

Be sure to reinstall the safety covers in their
respective positions.
(Failure to do so)
• You may become caught in rotating parts,
9Y1210019INI0050US0
When detaching the battery, disconnect the

negative (-) battery cable first.
• Keep any naked flame (match, lighter, cigarettes)
away from the battery. Also, avoid sparks due to
battery cable shorts.
• When installing the battery, reconnect the positive
(+) battery cable first to the positive (+) terminal.
(Failure to do so)
• Serious burns or explosion may result.
9Y1210019INI0051US0
Do not use or charge the battery when the battery

electrolyte is below the lower (lowest level) limit.
• When the battery electrolyte is below the limit,
immediately refill the electrolyte. It should be
between the (UPPER LEVEL) (upper limit) and
(LOWER LEVEL) (lower limit).
• To charge the battery, remove it from the machine.
• Charge the battery in a well-ventilated area.
• Carefully read accompanying documents and follow
instructions when connecting the booster cable with
the discharged battery.
(Failure to do so)
• Using/charging the battery when the battery
electrolyte is below the LOWER (lowest level)
limit could cause shortened the battery life or
may result in explosion.
9Y1210019INI0052US0
Avoid direct contact with the electrolyte (dilute
sulfuric acid).
• If you get the battery electrolyte in your eyes, rinse
well with water and see a doctor.
• If you get the electrolyte on your skin or clothes,
immediately rinse thoroughly with water.
(Failure to do so)
• May result in blindness or serious burns.
9Y1210019INI0053US0
I-14

Do not use unspecified batteries.
• Use a battery specified in the manual.
(Failure to do so)
• May cause an accident.
9Y1210019INI0054US0
When opening the radiator cap or reserve tank,

wait until the engine has cooled down considerably.
• Stop the engine and wait for 30 minutes or longer
before removing radiator cap. Gradually open the
cap to reduce steam pressure.
(Failure to do so)
• Hot water or steam may gush out, causing
serious burns or injury.
9Y1210019INI0055US0
I-15

Replace the fuel hose, radiator hose and drain
hose every 2 years.
• Periodically replace the rubber products, since they
deteriorate over time.
(Failure to do so)
• Fuel or hot water may leak out, causing serious
burns or injury.
9Y1210019INI0056US0
When checking the fuel injection pipe or

hydraulic pipe for a leakage of high-pressure oil, use
a cardboard or plate.
• Do not touch the high-pressure oil with your hands.If
you come into contact with the high-pressure oil,
immediately consult a doctor.
(Failure to do so)
• The oil may penetrate your skin, causing
gangrene.
9Y1210019INI0057US0
I-16

(7) Precautions for Transportation

Load/unload the combine harvester on/from the
truck onto a level surface.
• Before loading/unloading the combine harvester,
make sure the bridges are not leaning to one side.
• Park the truck and apply the parking brake. Set the
shift lever in (R) (reverse) or (FIRST) position and
then place the stop blocks under the crawlers to
prevent the truck from moving.
• If at all possible, work with your assistant(s) and
ensure good communication with them.
• Make sure no one else is near around the bridges.
(Failure to do so)
• The bridges may fall off or the truck may move,
causing the combine harvester to fall.
9Y1210019INI0058US0
Use bridges meeting the standard for loading/
unloading.
• Bridge requirements
More than 4 times the height of the
Length
truck bed
Width More than 55 cm
Quantity One pair
A bridge that can support a weight
Strength
of 2800 kg or more
• Use the bridges with hooks or a non-skid surface.
• The bridges should be square with the truck bed
when placed.
(Failure to do so)
• The bridges may slip off or move, causing the
combine harvester to fall.
9Y1210019INI0059US0
Make sure to discharge all paddy before
loading/unloading.
(Failure to do so)
• You may lose control of the combine harvester,
causing it to fall.
9Y1210019INI0060US0
I-17

Loading/unloading the combine harvester
on/from the truck should be performed at slow
speed.
• When loading, travel forwards. When unloading,
travel backwards.
(Failure to do so)
• You may lose control of the combine harvester,
causing it to fall.
9Y1210019INI0061US0
Drive only straight while on the bridges.

• Do not use the power steering lever or the sub shift
lever on the bridges.
• To change direction, move to level ground or the
truck bed first and then correct the direction.
(Failure to do so)
• May result in quick turning or loss of control,
causing the combine harvester to fall.
9Y1210019INI0062US0
On the truck, lower the reaper until it touches the

ground and apply the parking brake.
• Set the sub shift lever to the (P) (parking brake)
position.
• Use the specified (ROPE HOOK (for 4 places)) and
firmly fasten to the truck bed.
• Be sure to set a stopper.
(Failure to do so)
• The combine harvester may move, resulting in
an accident.
9Y1210019INI0063US0
Avoid sudden acceleration, sudden braking and

quick turning.
(Failure to do so)
• The combine harvester may move, causing an
accident.
9Y1210019INI0064US0
I-18

3. WARNING LABELS DESIGNED FOR SAFE

OPERATION
[1] DESCRIPRION OF WARNING LABELS AND LABELED
POSITION
I-19

I-20

I-21

I-22

I-23

I-24

I-25

9Y1210552INI0001US0
[2] WARNING LABEL MAINTENANCE

Carefully read the warning label and follow the instructions.
• Warning labels should be kept clean and free of spots at all times.
• Wash warning labels with soap and water when they become dirty. Clean them up with a soft cloth.
When washed with thinner or engine oil, the letters or symbols may disappear.
• When the combine harvester is washed with a high-pressure washing machine, warning labels may peel off. Do
not direct the high-pressure water directly at labels.
• Damaged or lost labels should be replaced with new ones. Order new labels from your supplier.
• When attaching a new label, polish the surface clean and wait until it dries. Attach the label to its original position.
• When changing parts with an affixed label, replace the label and parts at the same time.
9Y1210019INI0066US0
I-26

G GENERAL

GENERAL
CONTENTS
1. MECHANISM................................................................................................................................ G-1
[1] SPECIFICATIONS.................................................................................................................. G-1
[2] POWER TRAIN ...................................................................................................................... G-2
2. FOR SAFE OPERATION.............................................................................................................. G-3
[1] IDENTIFICATION ................................................................................................................... G-3
[2] GENERAL PRECAUTIONS ................................................................................................... G-3
[3] HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING .............................. G-6
[4] TIGHTENING TORQUE ......................................................................................................... G-8
[5] SPECIAL TOOLS ................................................................................................................. G-10

DC-60-PH, WSM GENERAL
1. MECHANISM
[1] SPECIFICATIONS
Model name DC-60
Type Grain hopper
Overall length 4800 mm
Dimensions Overall width 2175 mm
Overall height 2500 mm (Pre-cleaner)
Body weight 2450 kg
Name V2403-M-DI-TE2-CKMS1
Type Water-cooled 4 stroke cycle 4 cylinder form diesel engine
Total displacement 2.434 L (2434 cc)
Output / Speed 44.1 kW (60 PS) / 2700 rpm
Engine
Applicable fuel Diesel fuel (light oil)
Tank capacity 60 L
Starting system Starter
Battery 12 V, 52 Ah
Center
1150 mm
distance
Width ×
Ground 400 × 1545 mm
Crawler contact length
Average
ground
Running 19.7 kPa (0.20 kgf/cm2)
contact
portion pressure
Minimum ground clearance 255 mm (Transmission case bottom to ground)
Speed shift system Hydrostatic transmission system (HST)
Number of speed shift steps Forward stepless, Backward stepless (Each sub-shift consists of 2 traveling speeds)
Forward
Travel speed (sub-shift) Low speed (L): 0 to 1.30 m/s, High speed (H): 0 to 1.80 m/s
Reverse
Turning system Brake turning
Pick-up system Reel pick-up
Turning circle
diameter × 900 × 1828 mm
Width
Reel
Height
Reaping adjustment Hydraulic
portion system
Reaping width (Distance
2000 mm
between edge of dividers)
Width of reaping blade 1905 mm
Range of reaping height
−19 to 800 mm (At the tip of reaping blade)
(Raising and lowering)
Threshing system Axial flow type (threshing tooth type)
Type of
threshing Round-bar, tooth bar
Threshing tooth blade
Threshing drum Diameter ×
620 × 1615 mm
portion Width
Turning speed 560 rpm
Tailings return system Auger
Grain sorting system Shaking, wind selection (3 different airflow selection)
Concave area (4 pieces) 1.456 m2
Grain output Grain hopper 420 L
Applicable crop Rice
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G-1

[2] POWER TRAIN
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G-2

2. FOR SAFE OPERATION

[1] IDENTIFICATION
When inquiring about this combine harvester, check the
combine harvester model name and the machine body
manufacturing serial number, the engine model name and the
manufacturing serial number, and the hour-meter reading.
(1) Combine Harvester (2) Machine Body Manufacturing Serial
(Model Name, Machine Body Number
Manufacturing Serial Number, (3) Engine Manufacturing Serial
Engine Mode Name, Engine Number
Manufacturing Serial Number)
9Y1210019GEG0003US0
[2] GENERAL PRECAUTIONS

CAUTION
• Open/Close (Turn off the engine before opening.)
• Be sure to park the harvester on level ground and set the sub-shift to parking position to inspect or
adjust.
• Check all parts with the engine turned (OFF) except parts where the engine should be turned on during
inspection. Similarly, the thresher clutch and reaper clutch should be turned (OFF).
• When the reaper is raised during operation, lock the hydraulic cylinder to prevent the reaper from falling.
• When changing oil or coolant, do not discharge waste oil or coolant into the ground, river, or sewerage
to prevent environmental pollution. Instead, use a container.
• During disassembly, carefully arrange removed parts in a clean area to prevent confusion later on. Bolts and nuts
should be installed in their original position to prevent reassembly errors.
• When special tools are required, use KUBOTA genuine special tools. Special tools not frequently used should be
made according to the drawings provided.
• When washing parts, use a commercially available industrial cleaner. In addition, use a specified functioning oil
to wash hydraulic parts.
• During disassembly/assembly, protect removed parts against "dust" and "metal chips".
• When disassembling/servicing parts where voltage is applied, disconnect the negative (-) cable from the battery
first.
• Remove oil and dirt from parts before measuring.
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G-3

KUBOTA Genuine Parts
• Use only KUBOTA genuine products for parts replacement to
maintain machine performance and to assure safety.
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Oil Seals
• Packings and O-rings must be replaced during reassembly.
• Generally, oil seal lips should be attached in the direction of the
object that must be airtight. (for exceptional cases, different
instructions will be given.)
• Apply grease to new O-rings or oil seals before assembling.
(1) Apply Grease
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Snap Rings
• When reassembling external snap rings or internal snap rings,
as shown left, they must be positioned so that cornered section
faces against the force direction.
(1) Face the Sharp Edge Against the (A) For External snap rings
Direction from which Force is (B) For Internal snap rings
Applied.
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Spring Pin
• When inserting spring pins, as shown left, the split (alignment
mark) must face the force direction.
(1) For Moving in Parallel (2) For Rotating
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Split Pin
• Replace with a new split pin and fully split to prevent pulling out.
In general, single side splits are used, and the instruction
isgiven separately if a double split (anchor split) must be used.
• Tighten a grooved nut in the specified torque, align the hole of
the split pin to the tighten direction and use an S sp.
(1) Single split (3) S split
(2) double split
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G-4

Chain Joint and Split Pin
Joint (clip)
• When assembling, opening section must face backwards in the
direction from which the chain moved forward.
Split pin
• When assembling, opening section must face the direction from
which the chain moved forward.
(1) Direction of Chain Moving
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Wash with High-pressure Washing Machine

Instructions mentioned in the high-pressure washing machine
manual and attached labels must be followed. Improper use may
lead to injury, damage or malfunction.
CAUTION
• Be sure to set the nozzle to dispersion and then wash the
combine harvester at a distance of 2 meters or more to
prevent damage. If washed with direct projection or at an
improper distance;
1. Electrical wiring damage or disconnection could result,
causing fire.
2. Hydraulic hose damage could result, causing injury when
high-pressure oil gushes out.
3. May lead to equipment damage, breakdown or malfunction.
(Example)
1. Seals or warning labels may be peeled off.
2. If water enters electronic components, the engine or
transmission, a malfunction may result.
3. Rubber products including oil seals, resin products and
glass products may be damaged.
4. Coatings and gildings may be peeled off.
(1) Direct Shoot is Strictly Prohibited. (A) Direct Shoot
(2) Improper Distance is Strictly (B) Dispersion Projection
Prohibited. (C) Less than 2 m
(D) More than 2 m
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G-5

[3] HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND

WIRING
Battery
• When removing the battery cables, disconnect the negative
cable first. When installing the battery cables, connect the
positive cable first.
• Apply grease to battery or terminal to prevent corrosion.
• Be sure to attach battery terminals and fit terminal cover.
• Keep the battery clean and protect against dirt or dust.
IMPORTANT
• When charging the battery, remove the cell-cap and
provide adequate ventilation. Keep away from flames.
(During charging, hydrogen gas may generate from the
battery causing explosion.)
• When charging the battery while still installed, disconnect
the negative battery cable and remove the cell-cap.
• To connect the battery charger to the battery, turn off the
battery charger first. Connect the positive clip from the
battery charger to the positive terminal on the battery.
Similarly, the negative clip from the battery charger should
be connected to the negative terminal on the battery.
(A) When Disconnecting (B) When Connecting
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Fuse, Fusible Link, Slow Blow Fuse
• When a fuse blows, replace with specified capacity. If a fuse
other than specified is used, electrical wiring damage or fire may
result.
(1) Fuse (3) Slow Blow Fuse
(2) Fusible Link
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Wiring
• Securely tighten wiring terminals. Loose connections may lead
to malfunction or fire.
• Wiring must be kept away from rotating parts or hot parts.
• A protective cover should be installed over places of potential
damage.
• Damaged wiring must be fixed with electrical insulating tape or
mouse-proof tape; otherwise, replace with new wiring.
(1) Check Contact Portion without Rust (3) Contacted
(2) Loose Connections May Cause
Malfunction
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G-6

Connectors
• To disconnect connectors, release the lock first. Do not
forcefully pull on the wire harness. (Two types of locks are
available : push and pull types.)
• Handle with care when a waterproof connector with O-ring is
used. Improper handling may cause the O-ring to drop.
• Check that the terminal is not protruding from the connector.
• After the connector is attached, check the connection for
backlash. Too mush space between the female terminals
causes backlash.
• When waterproof bond is applied, apply the bond around the
connector after connecting.
(1) Pull Type (3) Connector Is Securely Attached
(2) Push Type (4) Attached without Backlash
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Handling of Circuit Tester

• Follow the instructions described in the circuit tester manual and
use as prescribed.
• When measuring resistance, turn off the main switch on the item
for measurement.
• When measuring the change of resistance value in the variable
resistor, use analog type. Measure changes slowly.
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Cleaning
• Do not throw water on electrical parts such as connectors, the
main switch and starter motor.
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G-7

[4] TIGHTENING TORQUE

Refer to the torque table below when tightening nuts or bolts not specified in this manual.
Tightening torque for common nuts and bolts
Bolt size Lower torque standard (4T) General torque standard Higher torque standard (7T)
Nominal
Pitch N·m kgf·m N·m kgf·m N·m kgf·m
diameter
M6
0.8 3.9 to 6.9 0.40 to 0.70 3.9 to 11.8 0.40 to 1.20 7.8 to 11.8 0.80 to 1.20
(6 mm)
M8
1.25 9.8 to 15.7 1.00 to 1.60 9.8 to 29.4 1.00 to 3.00 19.6 to 29.4 2.00 to 3.00
(8 mm)
M10
1.25 18.6 to 30.4 1.90 to 3.10 18.6 to 53.9 1.90 to 5.50 39.2 to 53.9 4.00 to 5.50
(10 mm)
M10
1.5 17.6 to 29.4 1.80 to 3.00 17.7 to 51.0 1.80 to 5.20 36.3 to 51.0 3.70 to 5.20
(10 mm)
M12
1.25 34.3 to 53.9 3.50 to 5.50 34.3 to 103.0 3.50 to 10.50 73.6 to 103.0 7.50 to 10.50
(12 mm)
M12
1.5 34.3 to 49.0 3.50 to 5.00 34.3 to 88.3 3.50 to 9.00 68.6 to 88.3 7.00 to 9.00
(12 mm)
M12
1.75 29.4 to 49.0 3.00 to 5.00 29.4 to 83.4 3.00 to 8.50 58.8 to 83.4 6.00 to 8.50
(12 mm)
M14
1.5 49.0 to 78.5 5.00 to 8.00 49.0 to 147.1 5.00 to 15.00 98.1 to 147.1 10.00 to 15.00
(14 mm)
M14
2.0 46.1 to 75.5 4.70 to 7.70 46.1 to 137.3 4.70 to 14.00 93.2 to 137.3 9.50 to 14.00
(14 mm)
M16
1.5 73.6 to 107.9 7.50 to 11.00 73.6 to 225.6 7.50 to 23.00 147.1 to 225.5 15.00 to 23.00
(16 mm)
M16
2.0 69.6 to 103.9 7.10 to 10.60 69.6 to 215.7 7.10 to 22.00 137.3 to 215.7 14.00 to 22.00
(16 mm)
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G-8

Hydraulic Joint
Hydraulic hose joint
Diameter of Tightening torque
Hose size
threads N·m kgf·m
02 1/8 13.7 to 15.7 1.4 to 1.6
03
1/4 22.6 to 27.5 2.3 to 2.8
04
05
3/8 45.1 to 53.0 4.6 to 5.4
06
Cap nut of hydraulic pipe

Tightening torque
Diameter of pipe
N·m kgf·m
4 mm dia. × t1.0 mm 19.6 to 29.4 2.0 to 3.0
6 mm dia. × t1.0 mm 24.5 to 34.3 2.5 to 3.5
8mm dia. × t1.0 mm 29.4 to 39.2 3.0 to 4.0
10mm dia. × t1.0 mm 39.2 to 49.0 4.0 to 5.0
12mm dia. × t1.0 mm 49.0 to 68.6 5.0 to 7.0
15mm dia. × t1.0 mm 107.9 to 117.7 11.0 to 12.0
18mm dia. × t1.0 mm 107.9 to 117.7 11.0 to 12.0
Adaptor, elbow, and nipple

Diameter of Tightening torque
Item
threads N·m kgf·m
PF 1/8 44.1 to 53.9 4.5 to 5.5
PF 1/4 73.5 to 83.4 7.5 to 8.5
Nipple with O-ring
PF 3/8 93.2 to 103.0 9.5 to 10.5
PF 1/2 112.8 to 122.6 11.5 to 12.5
PF 1/8 22.6 to 26.5 2.3 to 2.7
PF 1/4 35.3 to 43.1 3.6 to 4.4
Elbow with O-ring
PF 3/8 53.9 to 63.7 5.5 to 6.5
PF 1/2 73.5 to 83.4 7.5 to 8.5
PF 1/8 9.8 to 14.7 1.0 to 1.5
PF 1/4 29.4 to 34.3 3.0 to 3.5
Adaptor
PF 3/8 49.0 to 68.6 5.0 to 7.0
PF 1/2 68.6 to 88.3 7.0 to 9.0
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G-9

[5] SPECIAL TOOLS

Puller
Application
• Extracting gear or bearing
Code No.
• 07916-09032
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Adaptor C1
Application
• Use for checking the relief valve set pressure.
Adaptor C1
• For raising and lowering valve of the reaper and the reel
A 50 mm
B 16 mm
C 25 mm
D 3 mm
E 30 °
F 30 °
G 30 °
H 5.5 mm dia.
I PF 1/4
J PF 1/8 Threaded depth 10 mm, Drill depth 12 mm
K PF 1/4 Threaded depth 15 mm, Drill depth 18 mm
L 90 °
M 23 mm dia.
N 23 mm
O 90 °
P 26.6 mm
Q 9 mm dia.
C1 Chamfer 1 mm
R1 1 mm radius
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G-10

Adaptor D, 58
Application
• Use for checking the relief valve set pressure.
Adaptor D
• For raising and lowering valve of the reaper and the direction
valve
A 35 mm
B 15 mm
C 10 mm
D 4 mm dia.
E 45 °
F 30 °
G 45 °
H PF 1/4 Threaded depth 15 mm, Drill depth 20 mm
I PT 1/8
J 21 mm
K 24.2 mm
R0.5 0.5 mm radius
Adaptor 58
• For HST charge relief valve
A 35 mm
B 15 mm
C 10 mm
D 4 mm dia.
E 45 °
F 30 °
G 45 °
H PF 1/4 Threaded depth 15 mm, Drill depth 20 mm
I PT 1/4
J 21 mm
K 24.2 mm
R0.5 0.5 mm radius
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G-11

Steering Clutch Spring Mounting Tool
Application
• Steering clutch spring disassembling, assembling tool
A 180 mm H 38 mm dia.
B 119.6 to 120.4 mm I 4.5 mm
C 65 mm J 9 mm
D 10 mm dia. (for 2 places) K M8 × 1.25
E Welding 4 points (20 mm) L Flange nut
F 65 mm dia. M Length : More than 80 mm
G 42 mm dia.
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G-12

Tools for Feeder Conveyor Reversing Shaft (Sliding Hammer)
Application
• Tools for feeder conveyor reversing shaft
A 27 mm O 14.5 mm dia.
B 23 mm P 80 mm dia.
C M14 × 2.0 Q 40 mm radius
D 25 mm R 30 mm radius
E 25 mm S 10 mm radius
F 60 mm T 5 mm
G M16 × 1.5 U 120 mm
H M14 × 2.0
I M14 × 2.0 V M14 x 2.0 Threaded depth 30 mm
J 25 mm
K 25 mm W 50 mm dia.
L 450 mm X 25 mm dia.
M 54 mm dia. Y 10 mm
N 40 mm dia. Z 110 mm
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G-13

1 MAINTENANCE

SERVICING
CONTENTS
1. PERIODIC CHECK LIST .............................................................................................................1-S1

2. CHECKING AND ADJUSTMENTS..............................................................................................1-S5
[1] AROUND ENGINE AND CLEANING PORT .........................................................................1-S5
[2] LUBRICANT, FUEL, COOLANT..........................................................................................1-S10
[3] FILTER, ELEMENT, HOSE .................................................................................................1-S18
[4] BELT....................................................................................................................................1-S23
[5] CHAIN .................................................................................................................................1-S28
[6] WIRE ...................................................................................................................................1-S30
[7] OTHER CHECKING AND ADJUSTMENTS ........................................................................1-S32

DC-60-PH, WSM MAINTENANCE
1. PERIODIC CHECK LIST

Measures: check, adjustment, cleaning, tightening (band), charge
Check, Refer-
Check and replacement intervals
Check item Measures ence
(Indication or hourmeter)
/ change page
Engine portion
Initial or after replacement: After 50 hours, every 100 hours
Adjust
Fan drive belt thereafter 1-S23
Replace Every 500 hours
Cleaning Every 50 hours (Outer element only)
Air cleaner element (inner, outer) Every 300 hours 1-S19
Replace
(Replace both inner and outer elements at the same time.)
Tighten Every 150 hours or 6 months, whichever comes first
Air cleaner hose 1-S21
Replace Every 300 hours or 2 years whichever comes first
Fuel filter cartridge Replace Every 400 hours 1-S20
Engine oil filter cartridge Replace Every 200 hours (Replace when changing engine oil) 1-S20
Water separator Cleaning Every 50 hours 1-S20
Fuel hose 1-S21
Fuel strainer Cleaning Every 100 hours 1-S19
Tighten Every 300 hours or 2 years whichever comes first
Oil drain hose 1-S21
Radiator hose 1-S21
Water drain hose 1-S21
Dustproof screen, radiator fins, oil cooler fins Cleaning Every 50 hours 1-S5
Acceleration wire Replace Every 300 hours 1-S30
Engine stop wire Replace Every 300 hours 1-S31
Hour meter cable Replace Every 300 hours –
*The intervals shown in the above table may vary depending on operation conditions, crops and maintenance
service (repair, check).
IMPORTANT
• After replacing a belt, chain, or wire, be sure to check and make adjustments after a break-in.
1-S1

Check, Refer-
/ change page
Traveling, operating portion
Adjust
Traveling (transmission) drive belt thereafter 1-S24
Power brake wire Replace Every 300 hours –
Transmission drive belt tension pulley Replace Every 800 hours –
Initial: After 50 hours, every 300 hours thereafter (Replace when
HST oil filter cartridge Replace 1-S22
replacing the hydraulic oil tank)
Initial: After 50 hours, every 300 hours thereafter (Replace when
Cleaning
Hydraulic oil tank filter replacing the hydraulic oil tank) 1-S22
Adjust
Crawler thereafter 1-S35
Reassem-
Every 200 hours
Crawler drive sprocket ble –
Rear wheels, track rollers, carrier rollers Replace Every 800 hours –
Crawler guide (front, rear) Replace Every 800 hours –
IMPORTANT
1-S2

Check, Refer-
/ change page
Reaper portion
Adjust
Reaper drive belt thereafter 1-S25
Adjust
Feeder conveyor counter drive belt thereafter 1-S25
Feeder conveyor counter drive belt tension
Replace Every 300 hours –
roller
Adjust
Reel drive belt thereafter 1-S26
Adjust
Auger drum drive chain thereafter 1-S28
Adjust
Reel counter chain thereafter 1-S28
Reel counter chain tension roller Replace Every 300 hours –
Adjust
Reaper drive chain thereafter 1-S30
Adjust
Feeder conveyor chain thereafter 1-S29
Adjust Every 100 hours
Reaping blade 1-S32
Collecting finger shaft, finger guide, bracket Adjust Every 300 hours –
Reaper clutch wire Replace Every 400 hours 1-S31
IMPORTANT
1-S3

Check, Refer-
/ change page
Threshing portion
Adjust
Thresher drive belt thereafter 1-S24
Adjust
Threshing drum drive belt thereafter 1-S26
Adjust
Grain and tailings auger drive belt thereafter 1-S27
Grain and tailings auger drive belt tension
roller
Adjust Initial or after replacement: after 20 hours, every 100 hours thereafter
Shaking drive belt 1-S27
Shaking drive belt tension roller Replace Every 300 hours –
Tailings auger drive chain Replace Every 500 hours –
Exchange Every 250 hours
Threshing tooth, threshing tooth bar Adjust Every 250 hours –
Exchange Every 250 hours –
Concave
Grain vertical and horizontal auger shafts Replace Every 500 hours –
Tailings vertical and horizontal auger shafts Replace Every 500 hours –
Each auger shaft vane Replace Every 500 hours –
Each plate Replace Every 500 hours –
Each liner Replace Every 500 hours –
Each seal cloth, sponge Replace Every 300 hours –
All tension arms, fulcrum bushings Replace Every 500 hours –
Hopper
Discharge port boot Replace Every 500 hours –
Electrical portion
Charge When the engine becomes difficult to start
Battery G-6
Replace When the engine will not start
Check Every 50 hours
Wire harness, battery cable –
Replace If damaged
Fuse, slow blow fuse –
Replace If damaged
Lamp (bulb) –
Replace If damaged
Horn switch –
Replace If damaged
IMPORTANT
9Y1210552MAS0003US0
1-S4

2. CHECKING AND ADJUSTMENTS

[1] AROUND ENGINE AND CLEANING PORT
IMPORTANT
• Be sure to close the cleaning port cover after cleaning.
Reference
Place Cleaning time (Time: Hour)
Page
Pre-cleaner 1-S5
Dustproof screen 1-S5
Around engine Oil cooler Clean : Every 50 hours 1-S6
Radiator 1-S6
Around muffler exhaust pipe 1-S6
Reaper portion Feeder conveyor upper cover Clean : After harvesting season 1-S6
Inside threshing portion 1-S7
Right/left cleaning port of grain horizontal
1-S7, 1-S8
auger
Bottom cover of grain horizontal auger and
1-S8
tailings reprocessing horizontal auger
Clean : During the reaping process and after
Threshing portion
Inside of tailings reprocessing auger thrower harvesting is complete
1-S8
case
Cleaning port of tailings vertical auger case 1-S8
Cleaning port of grain auger bevel gear case 1-S8
Inside grain hopper 1-S9
Traveling portion Around crawler drive sprocket Clean : Every day 1-S9
9Y1210552MAS0004US0
Pre-cleaner
• Keep it clean and protect against dirt or dust. Dirt or dust must
not be allowed to pile up higher than the white line (3) on the
collector (2) side.
(1) Knob Nut (3) White Line
(2) Collector (4) Dirt or Dust
9Y1210019MAS0003US0
Dustproof Screen
• Open the dustproof cover (1) and clean the dustproof screen (2)
from the inside using compressed air.
IMPORTANT
• Do not use hard materials such as the spatula or the screw
driver, and do not use in a high-pressure washing machine.
(1) Dustproof Cover (2) Dustproof Screen
9Y1210019MAS0004US0
1-S5

Oil Cooler Fin, Radiator Fin Cover
• Open the dustproof cover (1) and clean the radiator fin cover (2)
and the oil cooler fin (3) from the inside using the compressed
air.
IMPORTANT
• Do not use hard materials such as the spatula or the screw
driver, and do not use in a high-pressure washing machine.
(1) Dustproof Cover (3) Oil Cooler Fin
(2) Radiator Fin Cover
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Muffler
1. Remove remaining straw and soil from the muffler pipe (1) and
wipe clean.
(1) Muffler Pipe
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Inside the Feeder Conveyor

1. Lower the reaper and turn off the engine.
2. Remove the left side cover 1 (1), 2 (2), and 3 (3).
3. Remove the feeder upper cover 1 (4) and 2 (5).
4. Clean inside the feeder conveyor.
IMPORTANT
(1) Left Side Cover 1 (4) Feeder Upper Cover 1
(2) Left Side Cover 2 (5) Feeder Upper Cover 2
(3) Left Side Cover 3
9Y1210325MAS0007US0
1-S6

Inside Threshing Portion
1. Open the threshing drum side cover (1).
2. Open the threshing drum top cover (2).
3. Remove the mounting bolt (4) of the concave (3), and remove
the concave (3).
4. Clean the top face of the chaff sieve (5) and around the sieve
case (6).
(1) Side Cover (4) Bolt
(2) Top Cover (5) Chaff Sieve
(3) Concave (6) Sieve Case
9Y1210325MAS0001US0
Left Cleaning Port of Grain Horizontal Auger

• Remove the left side cover 3 (1), and remove the mounting bolts
(3) and left cleaning port cover (2).
IMPORTANT
(1) Left Side Cover 3 (3) Bolt
(2) Left Cleaning Port Cover
9Y1210325MAS0008US0
1-S7

Right Cleaning Port of Grain Horizontal Auger
• Remove the mounting bolt (2) of the right cleaning port cover
(1), and then remove the right cleaning port cover (1).
IMPORTANT
(1) Right Cleaning Port Cover (2) Bolt
9Y1210019MAS0010US0
Bottom Cover of Grain Horizontal Auger and Tailings

Reprocessing Horizontal Auger
1. Remove the left side cover 3.
2. Remove the grain auger left cleaning port.
3. Remove the mounting bolts of the bottom cover (1) (2), and then
remove the bottom cover (1) (2) of the grain horizontal auger
and the tailings reprocessing horizontal auger.
IMPORTANT
(1) Bottom Cover of the Grain (2) Bottom Cover of the Tailings
Horizontal Auger Reprocessing Horizontal Auger
9Y1210019MAS0011US0
Cleaning Port of Tailings Reprocessing Auger Thrower Case
and Tailings Vertical Auger Case
1. Remove and clean the cleaning port cover of tailings vertical
auger (1).
2. Remove the mounting nuts (3) of the tailings reprocessing
auger thrower case (2), and then remove and clean the tailings
reprocessing auger thrower case (2) together with the drive
chain case for tailings vertical auger (4).
IMPORTANT
(1) Cleaning Port Cover of Tailings (3) Mounting Nut
Vertical Auger (4) Drive Chain Case for Tailings
(2) Tailings Reprocessing Auger Vertical Auger
Thrower Case
9Y1210019MAS0012US0
Cleaning Port of Grain Auger Bevel Gear Case

1. Remove and clean the grain auger bevel gear case cleaning
port covers 1 (1) and 2 (2).
IMPORTANT
• Be sure to close the cleaning port covers after cleaning.
(1) Cleaning Port Cover 1 (2) Cleaning Port Cover 2
9Y1210019MAS0013US0
1-S8

Inside Grain Hopper
• Remove the mounting bolt of the grain hopper upper cover (1),
and then remove the grain hopper upper cover (1).
IMPORTANT
(1) Upper Cover
9Y1210019MAS0014US0
Around Crawler Drive Sprocket

• Wipe off the traveling portion (including around the transmission
case, the drive sprocket (1), the track roller, etc.).
(1) Drive Sprocket
9Y1210019MAS0015US0
1-S9

[2] LUBRICANT, FUEL, COOLANT

IMPORTANT
• Use only KUBOTA genuine parts when replacing parts.
Capacity, specified Check and replacement Reference
Location Type
quantity intervals (Time: Hour) page
Inspection: Before and after
Fuel Fuel Approx. 60 L Diesel fuel 1-S11
operation
Inspection: Before and after
operation
Engine oil 9L SAE15W-40 CF Replacement: 50 hours for the 1-S11
first time. Every 100 hours
thereafter
Inspection: Every 100 hours
UDT oil Replacement: 50 hours for the
Transmission case oil Approx. 6.0 L 1-S12
Shell Donax TD thereafter
Inspection: Every 100 hours
Caltex TDH Fluid
Replacement: 50 hours for the
Hydraulic oil tank oil 16.0 L KBT 1-S12
thereafter
Castrol Agri TDF
Inspection and replenishment:
Threshing drum drive Mobil Fluid 423 or Every 100 hours
2.1 L 1-S13
gear case oil 424 Replacement: When
disassembled
Reaping blade drive
chain, front auger drum
Oil Lubrication: During operation, 1-S13
drive chain, reel drive
counter chain before and after harvesting
season
Reaping blade, front
1-S14
auger drum finger
Belt tension arm fulcrum
for traveling
(transmission) drive belt
Belt tension arm fulcrum D10W30 or M90 or
Adequate amount
for thresher drive belt M80D
for threshing drum drive
Lubrication: Every 50 hours 1-S14
belt
for grain and tailings
auger drive belt
for the sieve case
shaking drive belt
Track roller 1-S15
Feeder conveyor fulcrum 1-S15
Grease Adequate amount Grease Supplement: Every 50 hours
Reaper hydraulic
1-S16
cylinder fulcrum
Pure water and
Approx. 8.5 L
KUBOTA antifreeze
(Reserve tank: Inspection: Before and after
Water Radiator (Coolant) (long life coolant) Mix 1-S17
Approx. 1.1 L operation
ratio (50 %
included)
concentration)
9Y1210552MAS0005US0
1-S10

Fuel
• Replenish fuel to the fuel tank. Check the fuel quantity by the
hose gauge (2) on the fuel tank.
IMPORTANT
• During refueling, the fuel strainer (3) should not be
removed.
Type Diesel fuel (light oil)
Capacity Approx. 60 L
(1) Fuel Tank (3) Fuel Strainer

(2) Hose Gauge
9Y1210019MAS0017US0
Engine Oil
1. Remove the rear engine cover (3).
2. Remove the oil gauge (2) and check the engine oil amount. It
should be between the upper limit and the lower limit on the oil
gauge.
[Replacement]
1. Remove the rear engine cover (3).
2. Remove the oil supply plug (4).
3. Remove the oil drain plug (5) and drain the oil.
Type SAE15W-40 CF
Capacity 9L
(1) Front Engine Cover (A) Specified Amount

(2) Oil Gauge
(3) Rear Engine Cover
(4) Oil Supply Plug
(5) Oil Drain Plug
9Y1210325MAS0010US0
1-S11

Transmission Case Oil
1. Remove the oil level check bolt (1) (oil level check port) and
confirm if oil overflows.
[Replacement]
Type UDT oil
Specified amount 6.0 L
(1) Oil Level Check Bolt (3) Oil Drain Plug

(2) Oil Supply Plug
9Y1210019MAS0019US0
Hydraulic Oil Tank Oil
1. Remove the thresher left side cover 1 (1) and 2 (2).
2. Remove the oil level check plug (3) (oil level check port) and
[Replacement]
Type UDT oil
(1) Left Side Cover 1 (4) Oil Supply Plug

(2) Left Side Cover 2 (5) Oil Drain Plug
(3) Oil Level Check Plug
9Y1210325MAS0011US0
1-S12

Threshing Drum Drive Gear Case Oil
1. Remove the left side cover 1 (1) and 2 (2).
2. Disconnect the connector (3) from the head light.
3. Remove the threshing drum front cover (4).
4. Remove the oil level check plug (5) (oil level check port) and
[Replacement]
Type UDT oil
(1) Left Side Cover 1 (5) Oil Level Check Plug

(2) Left Side Cover 2 (6) Oil Supply Plug
(3) Connector (7) Oil Drain Plug
(4) Threshing Drum Front Cover
9Y1210325MAS0012US0
Reaper Drive Chain, Front Auger Drum Drive Chain and Reel
Drive Counter Chain Lubrication
1. Apply oil to the chain from the lubricating ports (1), (2), (3) of the
reaper right side cover top (4), bottom (5) and the feeder
conveyor right side cover (6).
(1) Lubricating Port of Reaper Drive (4) Top of Reaper Right Side Cover
Chain (5) Bottom of Reaper Right Side Cover
(2) Lubricating Port of Front Auger (6) Feeder Conveyor Right Side Cover
Drive Chain
(3) Lubricating Port of Reel Drive
Counter Chain
9Y1210019MAS0022US0
1-S13

Lubrication for Reaping Blade and Front Auger Drum Finger
• Raise the reel and apply oil entire reaping blade (1) and the front
auger drum finger guide (2).
(1) Reaping Blade (2) Front Auger Drum Finger Guide
9Y1210019MAS0023US0
Lubricating and Greasing to Each Belt Tension Arm Fulcrum

1. Lubricate the belt tension arm fulcrum (1) of the reel drive belt.
2. Lubricate the belt tension arm fulcrum (3) of the threshing drive
belt.
3. Lubricate the belt tension arm fulcrum (6) of the sieve case
shaking drive belt.
4. Fill grease up from the grease nipple for the belt tension arm
fulcrum (2) of the traveling (transmission) drive belt.
fulcrum (4) of the threshing drum drive belt.
fulcrum (5) of the grain auger and trailings reprocessing drive
belt.
IMPORTANT
• Make sure no oil gets on the belt. If oil gets on the belt, be
sure to wipe it off.
• When lubricating with the reaper raised, be sure to place
the lock plate to prevent the reaper from falling.
(1) Belt Tension Arm Fulcrum of Reel (4) Belt Tension Arm Fulcrum of
Drive Belt Threshing Drum Drive Belt
(2) Belt Tension Arm Fulcrum of (5) Belt Tension Arm Fulcrum of Grain
Traveling (Transmission) Drive Belt Auger and Trailings Reprocessing
(3) Belt Tension Arm Fulcrum of Drive Belt
Threshing Drive Belt (6) Belt Tension Arm Fulcrum of Sieve
Case Shaking Drive Belt
9Y1210552MAS0002US0
1-S14

Greasing to Track Roller, Rear Wheel and Carrier Roller
• Fill grease up from the grease nipples (4) for all track rollers (1),
the rear wheel (crawler tension roller) (2) and the carrier roller
(3).
(1) Track Roller (3) Carrier Roller
(2) Rear Wheel (4) Grease Nipple
(Crawler Tension Roller)
9Y1210019MAS0025US0
Greasing to Feeder Conveyor Fulcrum Part

1. Remove the left side cover 1 and 2 of the threshing portion.
2. Remove the feeder conveyor upper right cover (1).
3. Fill grease up from the grease nipples (2).
(1) Feeder Conveyor Upper Right [A] Right Fulcrum Part
Cover [B] Left Fulcrum Part
(2) Grease Nipple
9Y1210019MAS0026US0
1-S15

Greasing to Reaper Hydraulic Cylinder Fulcrum Part
1. Raise the reaper portion, and fill grease up from the grease
nipple (1) for the fulcrum part of the reaper cylinder (2).
IMPORTANT
• When filling grease, be sure to put the lock plate (3) to
prevent the reaper from falling.
(1) Grease Nipple (3) Lock Plate
(2) Reaper Cylinder
9Y1210019MAS0027US0
1-S16

Radiator (Coolant)
• Check the coolant level in the reserve tank (1). It should be
within (A) level between LOW-line (3) and FULL-line (2).
[Replacement]
1. Remove the radiator cap (5) and the drain plug (4) to drain
coolant.
Type Pure water or antifreeze
Specified amount 8.5 L (Reserve tank : 1.1 L is included)
Q Handling precautions for antifreeze

1. Use ethylene glycol (EG) type of antifreeze.
2. When switching to LLC, pour pure water into the radiator body
and drain 2 to 3 times to clean inside.
3. Prior to pouring into the radiator, the LLC should be mixed well
with pure water at a ratio according to the target temperature.
4. LLC supply
• Supply pure water to compensate for the amount
evaporated.
• In the event coolant leaks, replenish using LLC from the
same manufacturer at the original ratio.
• Avoid using different brands together. If mixed, differing
additives prevent the coolant from achieving the desired
performance in a sufficient manner.
5. When LLC is used, the radiator anti-fur form powder should be
avoided. LLC contains corrosion-proof agent so if anti-fur form
powder is added, it can cause generation of sludge and this can
damage engine parts.
6. Long life coolant specified by KUBOTA has a 2-year life span.
Replace it with new coolant every 2 years.
Guaranteed antifreeze temperature
Undiluted
solution
10 15 20 25 30 35 40 45 50 55
mix ratio
(%)
Guaran-
teed anti-
freeze −4 −5 −8 −11.5 −15 −20 −25 −30 −35 −43
tempera-
ture (°C)
(1) Reserve Tank (A) Specified amount

(2) Full-line
(3) Low-line
(4) Drain Plug
(5) Radiator Cap
9Y1210019MAS0028US0
1-S17

[3] FILTER, ELEMENT, HOSE

IMPORTANT
• Use only KUBOTA genuine parts for the parts replacement.
Check and replacement Reference
Part Name Part No.
intervals (Time : Hours) Page
Clean: Every 50 hours
Outer 59800-26110
Air cleaner element Replacement: Every 300 hours 1-S19
Inner 54936-26150 Replacement: Every 300 hours
Fuel strainer 5H400-26750 Clean: Every 100 hours 1-S19
Water separator 58201-25740 Clean: Every 50 hours 1-S20
Fuel filter cartridge 15224-4301-3 Replacement: Every 400 hours 1-S20
Engine related Replacement: 50 hours for the

parts first time. Every 200 hours for the
Engine oil filter cartridge 16414-3243-2 second time or later. (It should be 1-S20
replaced when engine oil is
changed)
Fuel hose See page 1-S21 1-S21
Hose for engine oil drainage 5H400-21232 Inspection: Every 150 hours 1-S21
Inlet hose for air cleaner See page 1-S21 Replacement : Every 300 hours 1-S21
Radiator hose See page 1-S21 1-S21
Replacement: 50 hours for the
first time. Every 300 hours for the
HST oil filter cartridge K7561-1407-0 second time or later. (It should be 1-S22
replaced when hydraulic oil is
changed)
Hydraulic device
related parts Clean : 50 hours for the first time.
Every 300 hours for the second
time or later.
Hydraulic oil tank filter (strainer) 52600-27380 1-S22
Replacement: Every 600 hours
(It should be replaced when
hydraulic oil is changed)
9Y1210552MAS0006US0
1-S18

Air Cleaner Element
• Display part (6) of the dust indicator (5) located on the back of
the air cleaner part will turn red when the element of the air
cleaner is clogged. Clean the outer element (2).
• After cleaning, press the reset button (7) of the dust indicator (5)
to deactivate the red alarm.
1. Remove the dust cup (1) from air cleaner and then take out the
outer element (2).
2. Clean the outer element (2) using compressed air (205 kPa,
2.1 kgf/cm2 or below) if dirty by dust. Spray it from inside of the
outer element (2) to outside to clean up.
3. For persistent stains on the outer element (2), early
replacement is recommended. The inner element (3) should be
replaced at the same time.
IMPORTANT
• Do not remove inner elements (3) other than the one you
are replacing. Do not reuse it after the cleaning.
• If the dust cup (1) is attached to the air cleaner, the
evacuator valve (4) should face the ground.
(1) Dust Cup (6) Display Part
(2) Outer Element (7) Reset Button
(3) Inner Element
(4) Evacuator Valve (A) Topside
(5) Dust Indicator (B) Downside
9Y1210019MAS0030US0
Fuel Strainer
• Remove the fuel cap (1) and clean the fuel strainer (2) with
diesel fuel or spray the compressed air if dirty or clogged.
IMPORTANT
• During replenishing fuel, the fuel strainer (2) should be
attached.
(1) Fuel Cap (2) Fuel Strainer
9Y1210019MAS0031US0
1-S19

Water Separator
1. When the water has collected in the cup (3) of the water
separator, the red float (2) in the cup (3) will be raised to the
white line (drain position) (6). In this case, remove the cup (3)
and drain the water.
2. During water drainage or cleaning, remove the rear engine
cover and the cup (3). Clean the inside with diesel fuel.
(Reference)
• Do install the red float (2).
• After water drainage or cleaning, the air bleeding should be
performed before starting the engine.
(1) O-ring (4) Ring Gear
(2) Red Float (5) Fuel Open/close Lever
(3) Cup (6) White Line (Drain Position)
9Y1210019MAS0032US0
Fuel Filter Cartridge

1. Remove the rear engine cover and then set the fuel open/close
lever of the water separator to the CLOSE position.
2. Remove the fuel filter cartridge (1).
3. When replacing with a new filter cartridge (1), apply fuel to
O-ring (2) and then tighten it manually. Do not use the filter
wrench.
(1) Fuel Filter Cartridge (2) O-ring
9Y1210019MAS0033US0
Engine Oil Filter Cartridge

• Engine oil filter cartridge should be replaced when the engine oil
is changed. (See page 1-S11.)
1. Remove the rear engine cover.
2. Remove the engine oil filter cartridge (1).
3. When replacing with a new engine oil filter cartridge (1), apply
engine oil to O-ring and then tighten it manually.
4. Supply the engine oil and be sure that the oil is leveled in the
specified amount.
(1) Engine Oil Filter Cartridge
9Y1210552MAS0014US0
1-S20

Fuel Hose
1. Check the fuel hose (1) to (5) for deterioration and the hose
clamp for loose connections.
Part Name Part No.
(1) Fuel tube 1 5T051-25810
(2) Fuel tube 2 5T051-25820
(3) Fuel tube 3 5T051-25830
(4) Fuel tube 4 5T051-25850
(5) Fuel tube 5 5T051-25840
(1) Fuel Hose 1 (4) Fuel Hose 4

(2) Fuel Hose 2 (5) Fuel Hose 5
(3) Fuel Hose 3
9Y1210019MAS0035US0
Hose for Engine Oil Drainage
1. Check the drain hose (1) of the engine oil for deterioration and
the hose clamp for loose connections.
(1) Drain Hose of Engine Oil
9Y1210019MAS0036US0
Inlet Hose for Air Cleaner

1. Check the inlet hose (1) and (2) of the air cleaner for
deterioration and the hose clamp for loose connections.
Part Name Part No.
(1) Inlet hose 1 5T051-25463
(2) Inlet hose 2 5T051-25452
(1) Inlet Hose 1 for Air Cleaner (2) Inlet Hose 2 for Air Cleaner
9Y1210019MAS0037US0
Radiator Hose
1. Check the radiator hose (1), (2) and the water drain hose (3) for
deterioration and the hose clamp for loose connections.
Part Name Part No.
(1) Radiator hose 1 5H473-25560
(2) Radiator hose 2 5H473-25570
(3) Water drain hose 5T051-25541
(1) Radiator Hose 1 (3) Water Drain Hose

(2) Radiator Hose 2
9Y1210019MAS0038US0
1-S21

HST Oil Filter Cartridge
• The cartridge should be replaced when the hydraulic oil tank oil
1. Remove the HST oil filter cartridge (1).
2. When replacing with a new HST oil filter cartridge (1), apply
UDT oil to O-ring and then tighten it manually.
(1) HST Oil Filter Cartridge
9Y1210552MAS0007US0
Hydraulic Oil Tank Filter (Strainer)

• The strainer should be replaced when the hydraulic oil tank oil
1. Loosen the hexagonal part of the hydraulic oil tank filter (1)
using a wrench. Remove the hydraulic oil tank filter (1) and
clean it with diesel fuel.
(1) Hydraulic Oil Tank Filter
9Y1210552MAS0008US0
1-S22

[4] BELT
IMPORTANT
• Use only KUBOTA genuine parts for the belt replacement.
Check and
Size (Number of Reference
Part name Code No. replacement intervals
belts) page
(Time: Hour)
Inspection: 50 hours for
the first time. Every 100
Engine cooling fan drive belt 17111-97010 A40.5 (1) hours thereafter. 1-S23
Replacement: Every
500 hours
Engine room
Thresher drive belt 5T051-11571 SC54 cog (2) Inspection: 20 hours for 1-S24
Traveling (transmission) hours thereafter.
5T051-11421 SB59 Cog (2) Replacement: Every 1-S24
drive belt
300 hours
Reaper drive belt 5T051-64651 SB54 (1) Inspection: 20 hours for 1-S25
Feeder conveyor counter
Reaper portion 5T051-56461 SB46 (1) hours thereafter. 1-S25
drive belt
Replacement: Every
Reel drive belt 5T051-54551 SB107 (1) 300 hours 1-S26
Threshing drum drive belt 5T051-65852 SC96 (2) Inspection: 20 hours for 1-S26
Threshing Grain auger and tailings
5T051-66351 SB104 (1) hours thereafter. 1-S27
portion reprocessing auger drive belt
Replacement: Every
Shaking drive belt 5T051-64571 SB66 (1) 300 hours 1-S27
9Y1210552MAS0009US0
Engine Cooling Fan Drive Belt
1. Remove the front engine cover.
2. To check the amount of deflection (A), push your finger against
the center of the engine cooling fan drive belt (1).
3. If the measurement is not within factory specifications, loose the
mounting bolt (3) of the alternator (2) and the adjustment bolt
(4), and then adjust the belt tension of the engine cooling fan
drive belt (1) pulling the alternator (2).
7 to 9 mm / pushing with
Amount of deflection (A) Factory specification Approx. 60 to 70 N
(6 to 7 kgf)
(1) Engine Cooling Fan Drive Belt (A) Amount of Deflection

(2) Alternator
(3) Mounting Bolt
(4) Adjustment Bolt
9Y1210019MAS0042US0
1-S23

Thresher Drive Belt
1. Set the threshing clutch lever (2) to the ON position.
2. Measure the inner distance (A) of the belt tension spring (3)
hooks.
3. If the measurement is not within factory specifications, adjust
with the turnbuckle (4).
IMPORTANT
• When replacing the thresher drive belt (1), both 2 belts
should be changed at the same time.
Inner distance (A) of belt
Factory specification 378 to 382 mm
tension spring hooks
(1) Thresher Drive Belt (A) Inner Distance of Belt Tension

(2) Threshing Clutch Lever Spring Hooks
(3) Belt Tension Spring
(4) Turnbuckle
9Y1210019MAS0043US0
Traveling (Transmission) Drive Belt

hooks.
2. If measurement is not within the factory specifications, adjust
with the adjustment nut (3) on the belt tension bolt (4).
IMPORTANT
• When reassembling the belt tension spring (2) and the belt
tension bolt (4), the hook part of the belt tension spring (2)
should be installed at 90 degrees against the hook part of
the belt tension bolt (4). Be sure that the belt tension spring
(2) is not twisted.
(1) Traveling (Transmission) Drive Belt (A) Inner Distance of Belt Tension
(2) Belt Tension Spring Spring Hooks
(3) Adjustment Nut
(4) Belt Tension Bolt
9Y1210019MAS0044US0
1-S24

Reaper Drive Belt
1. Set the reaping clutch lever (2) to the ON position.
hooks.
with the adjustment nut (4).
(1) Reaper Drive Belt (A) Inner Distance of Belt Tension

(2) Reaping Clutch Lever Spring Hooks
(4) Adjustment Nut
(5) Reaper Clutch Wire
9Y1210019MAS0045US0
Feeder Conveyor Counter Drive Belt

1. Remove the threshing drum gear case cover (7).
2. Put the engine acceleration lever (1) forward until it stops (idling
status), and then set the feeder conveyor counter clutch lever
(2) to the position (B).
3. Adjust the distance (A) between the accelerator restrain rod 2
(3) and the accelerator restrain rod (4) with the mounting bolt (5)
on the accelerator restrain rod 2 (3).
Distance (A) Factory specification 13 to 15 mm
(1) Engine Acceleration Lever (A) Distance

(2) Feeder Conveyor Counter Drive (B) Move the Lever up to be ON
Clutch Lever
(3) Accelerator Restrain Rod 2
(4) Accelerator Restrain Rod
(5) Mounting Bolt
(6) Feeder Conveyor Counter Drive
Belt
(7) Threshing Drum Gear Case Cover
9Y1210019MAS0046US0
1-S25

Reel Drive Belt
1. Remove the right top reel cover.
hooks.
3. If the measurement is not within the factory specifications,
adjust with the adjustment nut (3).
(1) Reel Drive Belt (A) Inner Distance of Belt Tension

(3) Adjustment Nut
9Y1210019MAS0047US0
Threshing Drum Drive Belt

1. Remove the left side cover 1, 2 and 3 of the thresher.
hooks.
(1) Threshing Drum Drive Belt (A) Inner Distance of Belt Tension
(3) Adjustment Nut
9Y1210019MAS0048US0
1-S26

Grain Auger and Tailings Reprocessing Auger Drive Belt
hooks.
(1) Grain Auger and Tailings (A) Inner Distance of Belt Tension
Reprocessing Auger Drive Belt Spring Hooks
(3) Adjustment Nut
9Y1210019MAS0049US0
Sieve Case Shaking Drive Belt

hooks.
(1) Sieve Case Shaking Drive Belt (A) Inner Distance of Belt Tension
(3) Adjustment Nut
9Y1210019MAS0050US0
1-S27

[5] CHAIN
IMPORTANT
• Use only KUBOTA genuine parts for the chain replacement.
Number
Reference
Part Name Part No. of Cleaning time (Time: Hour)
Page
chains
Front auger drum drive chain 5T051-49301 1 Inspection : 20 hours for the 1-S28
Reel drive counter chain 5T051-49401 1 first time. Every 100 hours for 1-S28
Reaper portion the second time or later.
Feeder conveyor chain 5T051-46301 1 Replacement : Every 500 1-S29
Reaper drive chain 5T051-46401 1 hours 1-S30
Threshing Tailings reprocessing vertical Replacement : Every 500
5T051-68610 1 3-S17
portion auger drive chain hours
9Y1210552MAS0010US0
Front Auger Drum Drive Chain
1. Remove the right chain cover.
2. Measure the inner distance (A) of the chain tension spring (2)
hooks.
4. If the inner distance (A) of chain tension spring hooks can not
be adjusted by the adjustment nuts (3) due to much stretch of
the front auger drum drive chain (1), remove the half chain.
(1) Front Auger Drum Drive Chain (A) Inner Distance of Chain Tension
(2) Chain Tension Spring Spring Hooks
(3) Adjustment Nut
(4) Chain Joint Part
9Y1210019MAS0052US0
Reel Drive Counter Chain

• Non-adjustable (Automatic tension) (Remove the half link when
chain has become loose.)
(1) Reel Drive Counter Chain (3) Half Link in Chain
(2) Chain Joint
9Y1210019MAS0053US0
1-S28

Feeder Conveyor Chain
1. Remove the feeder cover (1) and check the clearance (A)
between the feeder conveyor plate (2) and bottom plate (3).
2. If the measurement is not within the normal adjustment, loosen
the left and right mounting bolts (4), (5).
3. Loosen the tension bolts (6), (7) and then adjust with the
adjustment nuts (8), (9).
• The right and left tension bolts (6), (7) should be adjusted
equally.
Clearance (A) between
feeder conveyor plate Factory specification 0.5 to 2 mm
and bottom plate
(1) Feeder Cover (6) Left Tension Bolt

(2) Feeder Conveyor Plate (7) Right Tension Bolt
(3) Bottom Plate (8) Left Adjustment Nut
(4) Left Side Mounting Bolt (9) Right Adjustment Nut
(5) Right Side Mounting Bolt (A) Clearance
9Y1210325MAS0016US0
1-S29

Reaper Drive Chain
1. Measure distance (A) of tension gauge (1).
2. If the measurement is out of the factory specifications, adjust
3. If adjustment is not possible, remove half link.
Tension gauge dimension
(A)
(1) Tension Gauge (A) Tension Gauge Dimension

(2) Adjustment Nut
(3) Chain Joint
(4) Half Link in Chain
9Y1210019MAS0055US0
[6] WIRE
IMPORTANT
• Use only KUBOTA genuine parts for the wire replacement.
Check and replacement Reference
Part Name Part No.
intervals Page
Engine acceleration wire 5T051-32551 Inspection : Every 50 hours 1-S30
Engine stop wire 5T051-36251 Replacement : Every 300 hours 1-S31
Around driver's
Inspection : 50 hours for the first
seat
time. Every 100 hours for the
Reaper clutch wire 5T051-32541 1-S25
second time or later.
Replacement : Every 500 hours
9Y1210552MAS0011US0
Engine Acceleration Wire
1. When the speed adjustment lever (1) on the engine side is set
to the lowest speed (a), the engine acceleration lever (2) should
be set in the lowest speed position (b) at the cover long hole (3).
Use the adjustment nut (4) to adjust.
2. When the engine acceleration lever (2) is set to the highest
speed, the clearance (d) between the engine acceleration lever
and the cover long hole should be 5 to 8 mm. Use the
adjustment nut (4) to adjust. (If measurement is not within the
factory specification 5 to 8 mm, adjust the clearance to 8 mm as
close as possible.)
(1) Speed Adjustment Lever on Engine (a) Lowest Speed Position
Side (b) Lowest Speed Position
(2) Engine Acceleration Lever (c) Highest Speed Position
(3) Cover Long Hole (d) Clearance
(4) Adjustment Nut
9Y1210019MAS0057US0
1-S30

Engine Stop Wire
1. When the engine stop knob (1) is pressed down completely,
check and the adjust clearance (A) between the screw (3) at the
end of the engine stop wire (2) on the engine side and the
engine stop lever pin (4).
2. When the engine stop knob (1) is pulled, adjust the stroke (B) of
the engine stop knob (1) to be within the factory specifications
by the adjustment nut (5).
Clearance (A) Factory specification 0 to 2 mm
Stroke (B) Factory specification 32 to 42 mm
(1) Engine Stop Knob (A) Clearance

(2) Engine Stop Wire (B) Stroke
(3) Screw
(4) Engine Stop Lever Pin
(5) Adjustment Nut
9Y1210019MAS0058US0
Reaper Clutch Wire

• Refer to the reaper drive belt adjustment (see page 1-S25).
9Y1210552MAS0012US0
1-S31

[7] OTHER CHECKING AND ADJUSTMENTS

CAUTION
• Park on level ground and stop the engine for checking and adjustments.
9Y1210019RPS0001US0
Adjustment of Reaping Blade and Knife Clip
DANGER
• Do not touch the blade.
• For detaching and attaching the reaping blade, wear
protective gloves and hold both ends with other people.
1. Remove the reaping blade as one unit.
2. Remove dirt, rust, etc. using a wire brush.
3. Adjust the clearance (A) between the reaping blade (1) and
knife clip (2) by adding or removing a shim (4).
4. Lubricate the entire reaping blade and confirm that it moves to
the left and right smoothly.
the reaping blade and Factory specification 0.3 to 1.0 mm
knife clip
(1) Reaping Blade (A) Clearance

(2) Knife Clip
(3) Received Blade
(4) Adjusting Shim
9Y1210019RPS0002US0
Clearance between Tip of Spiral Plate on Front Auger Drum
and the Talbe
1. The clearance (A) between the tip of spiral plate on front auger
drum and the table is 6 to 8 mm.
2. To adjust the clearance, loosen the nuts (1) on the left and right
sides of the front auger drum height adjustment plate (2), and
adjust with the adjustment bolts (3) on the both sides.
The clearance (A)
between the tip of spiral
plate on front auger drum
and the table
(1) Nut (A) Clearance

(2) Front Auger Drum Height
Adjustment Plate
(3) Adjustment Bolt
9Y1210019MAS0062US0
1-S32

Clearance between Tip of Front Auger Drum Finger and Table
1. Make sure that the clearance (A) between the tip of the front
auger drum finger and the table is 6 to 8 mm.
2. To adjust the clearance, loosen 2 mounting bolts (1) on the
adjustment shaft and then turn the adjustment shaft with a
screwdriver inserted into the hole of the shaft.
tip of front auger drum Factory specification 6 to 8 mm
finger and table
(1) Mounting Bolt (A) Clearance

9Y1210019MAS0063US0
1-S33

Clearance between the Reel Tine and Tip of Spiral Plate on
Front Auger Drum
1. Lower the reel to its lowest position and mount in the bolt hole
(5) position.
2. Remove the upper right reel cover.
3. Measure the clearance (A) between the tip of the reel tine (1)
and the tip of spiral plate (2) on the front auger drum.
4. If the measurement is not within factory specifications, loosen
the bolt (4) on the right side of the reel and adjust the tine angle.
5. After making adjustments, make sure the tip of the tine (1) is not
touching the received blade (7).
reel tine and tip of spiral Factory specification 20 to 40 mm
(1) Tine (6) Hole

(2) Tip of Spiral Plate (7) Received Blade
(3) Bracket (8) Front Auger Drum Finger
(4) Adjustment Bolt
(5) Bolt (A) Clearance
9Y1210019MAS0064US0
1-S34

Crawler
• Apply grease to the crawler tension bolt (5).
1. Jack up the chassis frame to bring the crawler 10 cm (B) off the
ground.
2. Remove the snap pin (1) and then remove the turn lock plate
(2).
3. Adjust the clearance (A) between the crawler (3) and 4th track
roller (4) with the crawler tension bolt (5) to be the factory
specifications.
crawler and 4th truck Factory specification 10 to 15 mm
roller
Clearance (B) between
Reference Approx. 10 cm
ground and crawler
(1) Snap Pin (A) Clearance

(2) Turn Lock Plate (B) Distance
(3) Crawler
(4) 4th Track Roller
(5) Crawler Tension Bolt
9Y1210019MAS0065US0
Thresher Drive Belt Retainer 1, 2

1. When the threshing clutch lever is positioned to the OFF
position, the thresher drive shaft pulley (1) should fully stop. To
set this function, adjust the clearance to set this function, adjust
the clearance (A), (B) between the retainer 1 (2) 2 (3) and the
thresher drive belt (4) loosing the mounting bolts of the retainer
1 (2) 2 (3) when the threshing clutch lever is the ON position.
2. The retainer 2 (3) should be attached at 90 ° against the
thresher drive belt (4), and then adjust the clearance (B).
• Protect for the come-out the belt from the pulley or the driving
without the tension of the thresher drive belt.
Clearance (A) Factory specification 27 to 29 mm
Clearance (B) Factory specification 7 to 9 mm
(1) Thresher Drive Shaft Pulley (A) Clearance

(2) Retainer 1 (B) Clearance
(3) Retainer 2
(4) Thresher Drive Belt
9Y1210019MAS0066US0
1-S35

Chaff Sieve
1. Remove the cleaning port cover of the left side of the thresher.
(See page1-S7 on the left, "Cleaning Port of Grain Horizontal
Auger")
2. Remove the mounting bolts (2) for the chaff sieve adjustment
arm.
3. Measure the chaff sieve clearance (A) for each set position of
the mounting bolt (2) for the chaff sieve adjustment arm (1).
4. If the measure value is not within factory specifications, the rod
and/or ring of the chaff sieve (3) or chaff sieve adjustment arm
(1) may have become deformed.Inspect and repair.
Chaff sieve adjustment
Factory specification
arm set position
Fully closed (4) 9.4 mm
(5) 16.5 mm
Clearance
(6) 22.9 mm
between chaff
sieves (A) Standard position when
28.5 mm
shipped (7)
Fully open (8) 33 mm
(1) Chaff Sieve Adjustment Arm (A) Clearance between chaff sieve
(2) Bolt
(3) Chaff Sieve
(4) Step 1 (Fully Closed)
(5) Step 2
(6) Step 3
(7) Step 4 (Standard Position when
Shipped)
(8) Step 5 (Fully Open)
9Y1210552MAS0013US0
1-S36

2 REAPING PORTION

MECHANISM
CONTENTS
1. MECHANISM.............................................................................................................................. 2-M1
[1] STRUCTURE ....................................................................................................................... 2-M1

DC-60-PH, WSM REAPING PORTION
1. MECHANISM
[1] STRUCTURE
Feeder Conveyor
(1) Feeder Conveyor Drum (4) Feeder Conveyor Chain (7) 27T Sprocket (10) Feeder Conveyor Drive Shaft
(2) Feeder Conveyor Drum Shaft (5) Feeder Conveyor Counter (8) Feeder Conveyor Drive Shaft (11) Feeder Conveyor Drive Pulley
(3) Feeder Conveyor Plate Drive Pulley Cover
(6) 22T Sprocket (9) 27T Sprocket
9Y1210019RPM0001US0
Front Auger Drum
(1) Drum Bracket (3) Crankshaft Bracket (5) Crankshaft (7) Crankshaft Bracket
(2) Fixed Shaft (4) Finger Bracket (6) Front Auger Drum Finger (8) Front Auger Drum Drive
Sprocket
9Y1210019RPM0002US0
2-M1

SERVICING
CONTENTS
1. CHECKING AND ADJUSTMENT ................................................................................................2-S1

[1] REAPING BLADE..................................................................................................................2-S1
[2] FRONT AUGER DRUM.........................................................................................................2-S2
[3] REEL .....................................................................................................................................2-S3
2. DISASSEMBLING AND ASSEMBLING ......................................................................................2-S5
[1] REAPING BLADE..................................................................................................................2-S5
[2] SEPARATION OF THE REEL ...............................................................................................2-S8
[3] SEPARATION OF FRONT AUGER DRUM ..........................................................................2-S9
[4] SEPARATION OF THE REAPER PORTION ......................................................................2-S12
[5] REPLACING FRONT AUGER DRUM FINGER BRACKET ................................................2-S13
[6] SEPARATION OF THE FEEDER CONVEYOR ..................................................................2-S15
[7] SEPARATION OF THE FEEDER CONVEYOR ..................................................................2-S16

1. CHECKING AND ADJUSTMENT

[1] REAPING BLADE
CAUTION
• Park on level ground and stop the engine for checking and adjustments.
9Y1210019RPS0001US0
Adjustment of Reaping Blade and Knife Clip
DANGER
• For detaching and attaching the reaping blade, wear
protective gloves and hold both ends with other people.
1. Remove the reaping blade as one unit.
2. Remove dirt, rust, etc. using a wire brush.
3. Adjust the clearance (A) between the reaping blade (1) and
knife clip (2) by adding or removing a shim (4).
4. Lubricate the entire reaping blade and confirm that it moves to
the left and right smoothly.
the reaping blade and Factory specification 0.3 to 1.0 mm
knife clip
(1) Reaping Blade (A) Clearance

(2) Knife Clip
(3) Received Blade
(4) Adjusting Shim
9Y1210019RPS0002US0
2-S1

[2] FRONT AUGER DRUM

Clearance between Tip of Spiral Plate on Front Auger Drum
and Table
1. Confirm that the clearance (A) between the end of the spiral
plate on the front auger drum and the table is 6 to 8 mm.
2. To adjust the clearance, loosen the left and right nuts (1) on the
front auger drum height adjustment plate (2), and then adjust
the left and right sides of the front auger drum height adjustment
bolts (3).
the tip of the front auger Factory specification 6 to 8 mm
spiral plate and the table
(1) Nut (A) Clearance

Adjustment Plate
(3) Adjustment Bolt
9Y1210019RPS0003US0
Clearance between Tip of Front Auger Drum Finger and Table

1. Make sure that the clearance (A) between the tip of the front
auger drum finger and the table is 6 to 8 mm.
2. To adjust the clearance, loosen 2 mounting bolts (1) on the
adjustment shaft and then turn the adjustment shaft with a
screwdriver inserted into the hole of the shaft.
tip of front auger drum Factory specification 6 to 8 mm
finger and table

9Y1210019RPS0004US0
2-S2

[3] REEL
Clearance between the Reel Tine and the Tip of Spiral Plate on
Front Auger Drum
1. Lower the reel to its lowest position and mount in the bolt hole
(5) position.
2. Remove the upper right reel cover.
3. Measure the clearance (A) between the tip of reel tine (1) and
the tip of spiral plate (2) on front auger drum.
4. If the measurement is not within factory specifications, loosen
the bolt (4) on the right side of the reel and adjust the tine angle.
5. After making adjustments, make sure the tip of the tine (1) is not
touching the received blade (7).
reel tine and tip of spiral Factory specification 20 to 40 mm
(1) Reel Tine (6) Hole

(2) Tip of Spiral Plate (7) Received Blade
(3) Bracket (8) Front Auger Drum Finger
(4) Adjustment Bolt
9Y1210019RPS0005US0
2-S3

Clearance between Scraper and Tip of Spiral Plate on Front
Auger Drum
1. Confirm that the clearance between the scraper (1) and the tip
of spiral plate (2) on the front auger is 1 to 6 mm.
2. To adjust the clearance, loosen the scraper mounting bolt (3)
and then adjust the clearance moving the scraper (1) up or
down.
scraper and tip of spiral Factory specification 1 to 6 mm
(1) Scraper (A) Clearance

(2) Spiral Plate on Front Auger Drum
(3) Bolt
9Y1210019RPS0006US0
2-S4

2. DISASSEMBLING AND ASSEMBLING

[1] REAPING BLADE
CAUTION
• For detaching and attaching the reaping blade, wear protective gloves and hold both ends with other
people.
9Y1210019RPS0007US0
Reaping Blade
1. Remove the right side covers (1), (2) on the reaper portion.
(1) Side Cover (2) Side Cover
2. Remove the reaping blade side guard (3).

(3) Reaping Blade Side Guard
3. Remove 2 pairs of mounting bolts and nuts (5) from the rod ends
(4).
4. Remove the mounting bolt (7) on the reaping blade drive arm
(6). Remove the reaping blade drive arm (6).
(4) Rod Ends (6) Reaping Blade Drive Arm
(5) Bolt, Nut (7) Bolt
(When reassembling)
• When reassembling the rod ends, install the bolt stopper
parts (projections) (8) facing outwards as shown in the
diagram.
• Assemble in a manner so that the oil seal (15) groove faces
outwards.
(8) Bolt Stopper Parts (Projections) (15) Oil Seal
(To be continued)
2-S5

(Continued)
(When reassembling)
• When reassembling the reaping blade drive arm (11) to the
reaping blade drive shaft 2 (10), set the bearing holder
mounting part (9) parallel to the side plate of the reaper
portion.
• As shown in the picture, assemble so the reaping blade
drive arm (11) faces directly down. Here, make sure the
reaping blade (13) is centered between received blades
(14).
(9) Bearing Holder Mounting Part (11) Reaping Blade Drive Arm
(10) Reaping Blade Drive Shaft 2
(When reassembling)
• When assembling the reaping blade drive arm (11), ensure
that it is parallel to the rod end (12).
Projection (A) Reference value 10.5 mm
(12) Rod Ends (14) Received Blade

(13) Reaping Blade
5. Slide the reaping blade (13) to the right to pull out the entire
reaping blade unit.
9Y1210019RPS0008US0
2-S6

Reaping Blade Drive Shaft 2
1. Remove the bearing holder (1) of the reaping blade drive shaft
2 and then remove the bearing.
(1) Bearing Holder
2. Remove the external snap ring (2) and then remove reaping
blade drive shaft 2 (4).
3. Remove the front auger drum drive chain (3).
(When reassembling)
Internal dimensions of
front auger drum drive Factory specification 149 to 151 mm
chain tension spring
(2) External Snap Ring (4) Reaping Blade Drive Shaft 2

(3) Front Auger Drum Drive Chain (12) Internal Snap Ring
(When reassembling)
• Ensure that the bearing holder part (5) of reaping blade
drive shaft 2 (4) is set to its correct position.
As shown in the left picture, the pin (6) must be assembled
inside from the center of the bearing holder (5).
Assemble the bearing holder part (5) so that the internal
snap ring (12) faces outside.
(4) Reaping Blade Drive Shaft 2 (6) Pin
(5) Bearing Holder Part
4. Remove the reaper drive chain cover (7).

5. Loosen the tension on the chain and then remove the reaper
drive chain (8).
(When reassembling)
Reaper drive chain
tension gauge Factory specification 9 to 11 mm
dimensions
(7) Reaper Drive Chain Cover (8) Reaper Drive Chain
6. Remove the mounting bolts (10) of the reaping blade drive shaft
1 (9).
7. Remove the reaping blade drive shaft 1 (9).
(When reassembling)
• If the reaping blade drive cam (11) has been removed,
tighten with the prescribed tightening torque.
230 to 250 N·m
Tightening torque Reaping blade drive cam
23.50 to 25.40 kgf·m
(9) Reaping Blade Drive Shaft 1 (11) Reaping Blade Drive Cam
(10) Bolt
9Y1210019RPS0009US0
2-S7

[2] SEPARATION OF THE REEL

Reel
1. Remove the right side cover.
2. Remove the reel drive belt (1).
(When reassembling)
Reel drive belt tension
spring internal dimension
(1) Reel Drive Belt
3. Remove the front and rear adjustment bolts (2) for the left and
right reel positions.
(When reassembling)
• Apply grease to the inside of the front and rear adjustment
part for the reel position.
(2) Bolt
4. Remove the reel as one unit.

9Y1210019RPS0010US0
2-S8

[3] SEPARATION OF FRONT AUGER DRUM

Front Auger Drum
1. Remove the front auger drum drive chain (1).
2. Remove the reel drive counter chain (2).
3. Remove the reel. (See the previous section.)
4. Remove the reaping blade and then remove the reaping blade
drive shaft 2. (See [1] Reaping Blade on page 2-S5)
(When reassembling)
Internal dimensions of
front auger drum drive Factory specification 149 to 151 mm
tension spring
(1) Front Auger Drum Drive Chain (2) Reel Drive Counter Chain
5. Remove the mounting bolt (4) and then remove the front auger
drum drive gear (3).
(When reassembling)
• Apply loctite bond to the threads of the mounting bolt (4) of the
front auger drive gear before reassembling.
(3) Front Auger Drum Drive Gear (4) Bolt
6. Remove the left and right drum covers (5) and (6).
7. Remove the left and right dividers (7).
8. Remove the left and right side covers (8) of the front auger
drum.
(5) Right Drum Cover (7) Divider
(6) Left Drum Cover (8) Drum Side Cover
[Right side]
1. Remove 3 mounting bolts (1) of the bearing holder for the front
auger drum shaft.
2. Remove the front auger drum height adjustment bolt (2).
3. Remove the hydraulic piping (3) for the reel cylinder.
(1) Bolt (3) Hydraulic Piping
Adjustment Bolt
4. Remove 8 mounting nuts (4) on the front auger drum height

adjustment plate and then remove the front auger drum height
adjustment plate (5).
(4) Nut (5) Front Auger Drum Height
Adjustment Plate
(To be continued)
2-S9

(Continued)
5. Remove the nut (7) of the right side stationary shaft.
6. Remove the mounting bolt and nut (6) of the crankshaft.
(6) Bolt, Nut (7) Nut
7. Remove 6 mounting bolts (8) of the right bracket on the front

auger drum drive shaft.
8. Remove the right bearing holder (9) and right side stationary
shaft together.
(8) Bolt (9) Drum Bracket
[Left side]
1. Remove the mounting bolt and nut (1) of the crankshaft.
(1) Bolt, Nut
2. Remove the hydraulic piping (2) for the reel cylinder.

4. Remove the position stabilization bolts (4) of the front auger
drum finger.
(2) Hydraulic Piping (4) Bolt
(3) Bolt
5. Remove 8 mounting nuts (5) from the front auger drum height
adjustment plate and then remove the front auger drum height
adjustment plate (6).
Adjustment Plate
(To be continued)
2-S10

(Continued)
6. Remove 3 mounting bolts (7) of the left side stationary shaft
drum bracket for the front auger drum.
7. Pull out the crankshaft bracket together with the drum bracket
and stationary shaft through the cut section in the side plate.
(7) Bolt (8) Cut Section
9Y1210019RPS0011US0
2-S11

[4] SEPARATION OF THE REAPER PORTION

Reaper Portion
IMPORTANT
• Work on a level concrete surface.
• Work with the engine speed at 2000 rpm or higher, the
sub-shift lever set to "LOW SPEED" and set the main-shift
lever to the "LOWEST SPEED".
1. Lay down a piece of wood with a height of approximately 30 cm
under the reaper portion to make detaching and attaching of the
reaper portion easier. Also, insertion of another piece of wood
into the lower side of the divider tip and placing it a little towards
the front makes attaching/detaching of the reaper easier.
2. Remove the hydraulic piping (1) used to raise and lower the
reel.
3. Remove the cover (2) and then remove the chain (3).
(When reassembling)
Reaper drive chain
tension gauge Factory specification 9 to 11 mm
dimensions
(1) Hydraulic Piping Used to Raise and (3) Chain

Lower the Reel
(2) Cover
4. Remove the cover (4).

5. Disconnect the working light connector (5).
(4) Cover (5) Working Light Connector
6. Remove 2 mounting bolts (6) on the reaper.

(6) Reaper Mounting Bolt
7. Start the engine, lower the feeder conveyor, and after

confirming that the reaper portion has been disengaged, back
the machine up.
9Y1210325RPS0001US0
2-S12

[5] REPLACING FRONT AUGER DRUM FINGER BRACKET

Finger Bracket
1. Remove the drum covers (1) on the front auger drum.
(When reassembling)
• Ensure that there is no clearance between the front auger
drum and the drum covers (1).
(1) Drum Cover
2. Remove the mounting bolt and nut (2) on the left side
crankshaft.
(2) Bolt, Nut
3. Remove the finger mounting bolts (3) and then remove the front
auger drum fingers (4).
4. Remove the finger guide (5).
(When reassembling)
• Apply the screw lock tight bond to the finger mounting
bolts (3) and reassemble.
(3) Finger Mounting Bolt (5) Finger Guide
(4) Front Auger Drum Finger
5. Remove the hydraulic pipe (6) for the reel cylinder.

(6) Hydraulic Pipe (7) Front Auger Drum Height
Adjustment Bolt
7. Remove 8 mounting nuts (8) on the front auger drum height

adjustment plate (10) and 2 finger position fixing bolts (9).
Remove the front auger drum height adjustment plate (10).
(9) Bolt Adjustment Plate
(To be continued)
2-S13

(Continued)
8. Remove 3 mounting bolts (11) of the bearing holder on the fixed
shaft at left side of the front auger drum.
9. Pull out the drum bracket, the fixed shaft and the crankshaft
bracket together through the plate cut part.
(11) Bolt
10. Pull out the finger brackets (12).

(When reassembling)
• Apply grease to the inner surface of the finger brackets and
reassemble.
(12) Finger Bracket
9Y1210019RPS0013US0
2-S14

[6] SEPARATION OF THE FEEDER CONVEYOR

Feeder
1. Disassemble the reaper portion. (See the previous section.)
2. Remove the front threshing drum cover (1).
3. Remove the left side covers 1 (2) and 2 (3).
(1) Front Threshing Drum Cover (3) Left Side Cover 2
(2) Left Side Cover 1
4. Remove the reaper drive belt and the feeder conveyor counter
drive belt.
5. Remove the wire harness (6) and hydraulic hose (5).
6. Remove the eight feeder mounting bolts and nuts (7).
7. Remove the joint pin of the front side of the cylinder for raising
and lowering the reaper portion.
(4) Reaper Drive Chain (6) Wire Harness
(5) Hydraulic Hose (7) Bolt, Nut
8. Separate the feeder conveyor.

(When reassembling)
• Insert the upper and lower rubber sheets of the thresher
ports into the thresher.
9Y1210325RPS0003US0
2-S15

[7] SEPARATION OF THE FEEDER CONVEYOR

Feeder Conveyor Plate
1. Remove the feeder conveyor upper cover.
2. Loosen the two feeder conveyor chain tension bolts (1) and then
the tension bolt (2). Remove in the same manner for the other
side.
(1) Bolt (2) Chain Tension Bolt
3. Remove the left and right chain joints (3) (nut).

(When reassembling)
• Apply loctite bond to the threads of the chain joint (3) and
then tighten on an M6 nut and lock nut.
(3) Chain Joint
4. Remove the feeder conveyor chain.

5. Remove the mounting nuts of the feeder conveyor plate (4) and
then remove the feeder conveyor plate (4).
(4) Feeder Conveyor Plate
(When reassembling)
• Use the chain tension bolt (2) to adjust the clearance (A)
between the feeder conveyor plate (4) and the bottom plate.
Measure the clearance (A) at the 3rd feeder conveyor plate
(4) position from the front of the reaper (a) as shown in the
left diagram.
• When assembling the feeder conveyor plate (4), be sure to
assemble it in the rotation direction shown in the drawing.
• Apply loctite bond to the feeder conveyor plate mounting
nuts.
feeder conveyor and Factory specification 0.5 to 2 mm
bottom plate
(4) Feeder Conveyor Plate (a) Reaping Portion Side

(A) Clearance (b) Threshing Portion Side
(To be continued)
2-S16

(Continued)
(When reassembling)
• Assemble the nuts (5) facing to the side plate of the feeder
conveyor at the joint part of the feeder conveyor chain.
(5) Nut
(When reassembling)
• Tighten the nut (5) of the feeder conveyor chain so that the
length (B) is set to between 25.2 and 25.8 mm.
9Y1210019RPS0015US0
Feeder Conveyor Drum

1. Remove 2 fixing bolts (2) of the feeder conveyor drum (3) and
the chain tension bolt (1).
Remove with same procedure for the other side.
2. Remove the chain joint of the feeder conveyor chain.
3. Remove the feeder conveyor chain.
4. Remove the feeder conveyor drum (3).
(1) Chain Tension Bolt (3) Feeder Conveyor Drum
(2) Bolt
(When reassembling)
• When reassembling the feeder conveyor drum, ensure that
the drum joint surface (4) is set in relation to the rotation
direction as shown in the drawing.
(4) Drum Joint Surface
9Y1210019RPS0016US0
2-S17

Feeder Conveyor Drive Shaft
1. Remove the pulley mounting nuts and then remove the pulley
(1).
2. Remove the key (2).
3. Remove the pulley mounting nuts and then remove the pulley
(6).
4. Remove the internal snap ring (7).
5. Remove the cover guide (10) rivets (11) and then place the
cover guide (10) on the pipe cover L (9) side.
6. Remove the pipe cover (8) and then remove the 2 mounting
bolts (3) for the 27T gears (4).
7. Push out the feeder conveyor drive shaft (5) in the direction of
the arrow and remove the 27T gears (4), pipe cover L (9), and
cover guide (10).
(When reassembling)
• Apply loctite bond to the mounting bolts (3) and
reassemble.
• Apply grease on the entire circumference around the arrow
(A) section.
• Assemble the pipe cover (8) on the left side of the machine.
• After assembling the pipe cover (8), fill the notch with PVC
adhesive.
• Assemble the pipe cover L (9) and cover guide (10).
• Move the cover guide (10) to the left side of the machine.
• Attach the pipe cover L (9) and cover guide (10) using rivets
(11).
(1) Pulley (7) Internal Snap Ring
(2) Key (8) Pipe Cover
(3) Bolt (9) Pipe Cover L
(4) 27T Gear (10) Cover Guide
(5) Feeder Conveyor Drive Shaft (11) Rivet
(6) Pulley
9Y1210019RPS0017US0
2-S18

3 THRESHING PORTION

MECHANISM
CONTENTS
1. MECHANISM.............................................................................................................................. 3-M1
[1] STRUCTURE ....................................................................................................................... 3-M1

DC-60-PH, WSM THRESHING PORTION
1. MECHANISM
[1] STRUCTURE
Grain Auger
(1) Grain Vertical Auger Vane (3) Grain Auger Bevel Gear Case (5) Grain Auger Drive Pulley (6) Bearing Case
(2) Grain Vertical Auger Shaft (4) Grain Horizontal Auger Shaft
9Y1210019THM0001US0
3-M1

Tailings Auger
(1) Tailings Reprocessing Vertical (3) Tailings Reprocessing Vertical (4) Tailings Reprocessing (5) Tailings Reprocessing Auger
Auger Shaft Auger Drive Chain Case Horizontal Auger Shaft Drive Pulley
(2) Tailings Reprocessing Vertical
Auger Bevel Gear Case
9Y1210019THM0002US0
Winnower Fan
(1) Thresher Drive Pulley (2) Winnower Fan Plate (3) Thresher Drive Counter Pulley
9Y1210019THM0003US0
3-M2

Threshing Drum
(1) Front Twine Prevention Plate (2) Threshing Tooth (3) Rear Twine Prevention Plate (4) Deformed Threshing Tooth
9Y1210019THM0004US0
Sieve Case Shaking
(1) Sieve Case Shaking Drive (3) Shaking Arm Shaft 2 (4) Shaking Arm (5) Shaking Arm Shaft 1
Pulley
(2) Balance Weight
9Y1210019THM0005US0
3-M3

Threshing Drum Drive Gear Case
(1) Feeder Conveyor Counter (3) Feeder Conveyor Counter (4) Threshing Drum Drive Shaft 2 (5) Threshing Drum Drive Shaft 1
Drive Pulley Drive Shaft
(2) Shim
9Y1210019THM0006US0
3-M4

SERVICING
CONTENTS

[1] THRESHING DRUM..............................................................................................................3-S1
[2] SIEVE CASE .........................................................................................................................3-S7
[3] WINNOWER FAN................................................................................................................3-S10
[4] GRAIN AUGER ...................................................................................................................3-S12
[5] TAILINGS REPROCESSING AUGER ................................................................................3-S16


[1] THRESHING DRUM
Concave
1. Remove 3 mounting bolts of the top roof and open the top roof.
2. Remove the mounting bolts (1), and remove the concaves.
(1) Bolt
9Y1210019THS0001US0
Threshing Tooth
1. Remove 3 mounting bolts of the top roof, and open the top roof.
2. Remove the mounting bolts of the threshing tooth complete unit
(1), and then remove the threshing tooth complete unit (1).
(1) Threshing Tooth Complete Unit
9Y1210019THS0002US0
3-S1

Threshing Drum Drive Gear Case Complete Unit
1. Remove the left side covers 1 (1) and 2 (2).
(1) Left Side Cover 1 (2) Left Side Cover 2
2. Disconnect the work light connector 1 (3), and remove the

threshing drum drive gear case cover (4).
(3) Work Light Connector 1 (4) Threshing Drum Drive Gear Case
Cover
3. Remove the threshing drum drive belt (5).

4. Remove the reaper drive belt (6).
5. Remove the belt tension wire (7) for the reaper clutch and the
return spring (8) for the belt tension arm.
(5) Threshing Drum Drive Belt (7) Belt Tension Wire
(6) Reaper Drive Belt (8) Return Spring
6. Remove the retainer 1 (9) and the retainer 2 (10) of the feeder
conveyor counter drive belt (11), and then remove the feeder
conveyor counter drive belt (11).
(9) Retainer 1 (11) Feeder Conveyor Counter Drive
(10) Retainer 2 Belt
7. Remove 8 mounting bolts (12) of the threshing drum drive gear

case and then remove the threshing drum drive gear case as a
complete unit.
(When reassembling)
• Tighten the mounting bolts (12) to the prescribed
tightening torque.
• Apply grease to spline of the threshing drum drive shaft 2.
Mounting bolt of threshing 87.8 to 91.8 N·m
Tightening torque
drum drive gear case 8.60 to 9.00 kgf·m
(12) Bolt
9Y1210019THS0003US0
3-S2

Disassembling Threshing Drum Drive Gear Case
(1) Feeder Conveyor Counter (3) Feeder Conveyor Counter (4) Threshing Drum Drive Shaft 2 (5) Threshing Drum Drive Shaft 1
Drive Pulley Drive Shaft
(2) Shim
9Y1210019THS0004US0
CAUTION
• Be sure to install the flat washer (1) as shown in the picture
when removing the threshing drum drive pulley (3) by the
gear puller. It is dangerous the threshing drum drive pulley
(3) may come rushing out without a flat washer (1) pulling
by the gear puller.
1. Remove the mounting nut (2) of the threshing drum drive pulley
(3), and then remove the spring washer.
2. With the flat washer (1) set, install the nut (2), and then remove
the threshing drum drive pulley (3) using the gear puller.
(1) Flat Washer (3) Threshing Drum Drive Pulley
(2) Nut
IMPORTANT
• When removing the feeder conveyor counter drive shaft,
never hammer the shaft because it is made of soft material.
1. Remove the mounting nut of the feeder conveyor counter drive
pulley, and remove the spring washer.
2. With the flat washer set, install the nut. Remove the feeder
conveyor counter drive pulley using the gear puller.
3. Remove the oil seal, and remove the internal snap ring.
4. Check whether the shim is mounted.
5. Use the slide hammer (4) to remove the feeder conveyor
counter drive shaft.
(When reassembling)
• If the shim is mounted, be sure to install it in the original
position.
Type of Shims (0.2 mm, 0.8 mm, 1.0 mm and 1.2 mm).
Bevel gear backlash Factory specification 0.1 to 0.3 mm
(4) Slide Hammer

9Y1210019THS0005US0
3-S3

Threshing drum drive gear case can be disassembled as shown in the figure below.
(1) Oil Seal
(2) Shim
(3) Bearing
(4) Feeder Conveyor Counter
Drive Shaft
(5) Bearing
(6) Bevel Gear
(7) External Snap Ring
(8) Bearing
(9) Bevel Gear
(10) Threshing Drum Drive Shaft 2
(11) Bearing
(12) Oil Seal
(13) O-ring
(15) Bevel Gear
(16) Bearing
(17) Threshing Drum Drive Shaft 1
(18) Bearing
(19) Shim
(20) Internal Snap Ring
(21) Oil Seal
(22) Threshing Drum Drive Pulley
(23) Threshing Drum Gear Case
Cover
(When reassembling)
• Tighten the mounting bolts of the threshing drum drive gear case cover to the prescribed tightening
torque.
Mounting bolt of threshing 54.1 to 58.2 N·m
Tightening torque
drum drive gear case cover 5.30 to 5.70 kgf·m
Threshing drum Type UDT oil

drive gear case oil Specified amount 2.1 L
9Y1210552THS0001US0
3-S4

Threshing Drum
1. Remove the rear threshing drum cover (1) and the dust
discharge cover (2).
(1) Rear Threshing Drum Cover (2) Dust Discharge Cover
2. Open the top panel (3) and remove the lower fulcrum of the gas
spring (4).
3. Close the top panel (3) and remove the 6 mounting bolts of the
top panel, and then remove the top panel (3).
(3) Top Panel (4) Gas Spring
4. Remove the thresher drum drive belt, reaper drive belt, and
feeder reversing drive belt. (See page 3-S2.)
5. Remove the threshing drum drive gear case (5) as complete
unit.
(When reassembling)
Mounting bolts of threshing 87.8 to 91.8 N·m
Tightening torque
drum drive gear case 8.60 to 9.00 kgf·m
(5) Threshing Drum Drive Gear Case
6. Remove the threshing drum shaft mounting bolt (6) of the

bearing case.
7. Remove the snap ring (7).
8. Remove 4 mounting bolts (8) of the bearing case, and remove
the bearing case.
(When reassembling)
Bearing case mounting 54.1 to 58.2 N·m
Tightening torque
bolts 5.30 to 5.70 kgf·m
(6) Bolt (8) Bolt

(7) Snap Ring
9. Remove the threshing drum complete unit (9).

(9) Threshing Drum Complete Unit
(To be continued)
3-S5

(Continued)
(When reassembling)
• Confirm that the clearance (A) between the threshing teeth
and concave is 17 to 19 mm.
Clearance between
threshing tooth and Factory specification 16 to 20 mm
concave (A)
(A) Clearance
10. Threshing drum can be disassembled as shown in the diagram below.
(When reassembling)
• Apply loctite bond to the threads of bolts (1) and (3) before assembly.
54.1 to 58.1 N·m
Tightening torque Bolts (1), (2), and (3)
5.30 to 5.70 kgf·m
9Y1210552THS0004US0
3-S6

[2] SIEVE CASE

Sieve Case
CAUTION
• Use 2 persons to remove the sieve case.
1. Remove the sieve case shaking drive belt (1).
(1) Sieve Case Shaking Drive Belt
2. Remove the plate (2).

(When reassembling)
• Be sure not to install the plate (2) upside-down.
If you mistake to install the plate (2) upside-down, the plate
(2) and the sieve case may touch when moving the sieve
case.
Confirm that there is a clearance between the plate (2) and
sieve case.
(2) Plate
3. Remove 6 mounting bolts (3) of the sieve case for left and right
sides.
(When reassembling)
24.5 to 32.4 N·m
Tightening torque Sieve case mounting bolts
2.40 to 3.20 kgf·m
(3) Bolt
4. Remove the sieve case (4).

(4) Sieve Case
9Y1210019THS0008US0
3-S7

Rubber Sheet Arrangement
1. Locate rubber sheet 1 (1) by the side of the grain horizontal
auger, and rubber sheet 2 (2) by the side of the tailings
horizontal auger.
(1) Rubber Sheet 1 (2) Rubber Sheet 2
2. Install the rubber sheets 3 (3) and 4 (4) as shown in the picture.
3. Install the rubber sheet 5 (5) to the side of the tailings horizontal
auger, and install rubber sheet 6 (6) to the external side of
rubber sheet 5 (5).
9Y1210019THS0009US0
3-S8

Assembling and Disassembling Sieve Case
1. Remove 4 mounting bolts of the straw rack frame (1), and
remove the straw rack frame (1) from the sieve case (2).
2. Remove 2 fixing bolts and 1 turning fulcrum bolt of the chaff
sieve adjustment arm (3), and remove the chaff sieve
adjustment arm (3).
3. Remove 8 mounting bolts of the chaff sieve assembly (4), and
remove the chaff sieve assembly (4) from the sieve case (2).
4. Remove 8 mounting nuts of the grain sieve (5) at the back side
of the chaff sieve assembly (4), and remove the grain sieve (5).
5. Remove the left and right side of the bearing at the front side of
the sieve case (2) by the puller.
(1) Straw Rack Frame (4) Chaff Sieve Assembly
(2) Sieve Case (5) Grain Sieve
(3) Chaff Sieve Adjustment Arm (6) Chaff Sieve
9Y1210325THS0001US0
Assembling and Disassembling Chaff Sieve Assembly

1. Remove the split pins, and remove the chaff sieve link (3), the
chaff sieve retainer 1 (2) and the chaff sieve retainer 2 (4), and
remove the chaff sieve (1).
(When reassembling)
• The plain washers (5) are mounted at the positions that indicate
in the picture. Do not forget them for assembling.
(1) Chaff Sieve (4) Chaff Sieve Retainer 2
(2) Chaff Sieve Retainer 1 (5) Plain Washer
(3) Chaff Sieve Link
9Y1210325THS0002US0
3-S9

[3] WINNOWER FAN

[Right Side]
1. Remove the retainer (1) of the thresher drive belt.
(1) Retainer
2. Remove the thresher drive belt (2).

3. Remove 3 mounting bolts of the muffler exhaust pipe (4), and
move the exhaust pipe (4).
4. Remove the thresher drive pulley (3).
(2) Thresher Drive Belt (4) Exhaust Pipe
(3) Thresher Drive Pulley
5. Remove 4 mounting bolts (5) of the bearing holder.

(5) Bolt
[Left Side]
1. Remove the threshing drum drive belt (1).
(1) Threshing Drum Drive Belt
(To be continued)
3-S10

(Continued)
2. Remove the winnower wind force adjustment plate (2).
(When reassembling)
• Be sure to install a flat washer (4) in between 2 pieces of the
winnower wind force adjustment plate (2).
(2) Winnower Wind Force Adjustment (4) Flat Washer
Plate
(3) Bolt
3. Remove 4 mounting bolts of the winnower fan support plate (5),

and then remove the winnower fan as a complete unit.
(5) Winnower Fan Support Plate
9Y1210019THS0010US0
3-S11

Disassembling and Assembling of Winnower Fan
Winnower fan can be disassembled according to the figure on
the left.
(When reassembling)
• Assemble setting the bent part position of the winnower
fan plate correctly.
• There is the flat part around the center of the winnower fan
drive shaft (3).
The length from the flat part to the end of the winnower fan
drive shaft (3) is different to one and the other.
Assemble the longer length side of the winnower fan drive
shaft (3) to the left side of the machine.
• The distance (A) between the winnower fan plate (2) and the
side plate surface should be within 18 to 20 mm.
• The clearance (C) between the wind direction plate (7) and
the winnower fan plate (2) should be within 6 to 8 mm.
• The clearance (B) between the edge of the fan case (5) and
winnower fan plate (2) should be within 5 mm or longer.
• Apply the screw lock tight bond to the mounting bolts (4),
(6), and secure.
(1) Winnower Fan Arm (A) Distance
(2) Winnower Fan Plate (B) Clearance
(3) Winnower Fan Shaft (C) Clearance
(4) Bolt
(5) Fan Case
(6) Bolt
(7) Wind Direction Plate
9Y1210019THS0011US0
[4] GRAIN AUGER

Grain Horizontal Auger Shaft
1. After loosing the mounting nut of the grain auger drive pulley,
remove the grain auger and tailings reprocessing auger drive
belts (2).
2. Remove the grain auger drive pulley (1).
(1) Grain Auger Drive Pulley (2) Grain Auger and Tailings
Reprocessing Auger Drive Belts
3. Remove 4 mounting bolts (3) for fixing the outside plate and the
bearing case.
4. Remove the grain horizontal auger towards the left side of the
machine.
(3) Bolt
9Y1210019THS0012US0
3-S12

Grain Vertical Auger Shaft
1. Remove the wire harness (1) of the grain sensor and back
buzzer from the grain hopper.
(1) Wire Harness
2. Remove the stay (2) and the assistant guard (3).

3. Remove 4 mounting bolts of the grain hopper, and remove the
grain hopper (4).
(2) Stay (4) Grain Hopper
(3) Assistant Guard
4. Remove 4 mounting bolts (6) of the grain vertical auger case

(5), and remove 4 mounting bolts (8) of the grain auger bevel
gear case (7), and then remove the grain vertical auger case (5)
along with the grain vertical auger shaft.
(5) Grain Vertical Auger Case (7) Grain Auger Bevel Gear Case
(6) Bolt (8) Bolt
5. Remove the upper part mounting bolts of the grain vertical

auger shaft.
6. Remove the grain vertical auger shaft setting the positions of
the grain scatter plate (9) and the notch (10) of the grain vertical
auger case.
(9) Grain Scatter Plate (10) Notch
(To be continued)
3-S13

(Continued)
(When reassembling)
• When assembling the grain vertical auger shaft (11) and the
grain horizontal auger shaft (12), set the auger terminal
edges (15), (16) of the grain horizontal auger shaft (12) to be
vertical up-down positions, and then set the auger
beginning edges (13), (14) of the grain vertical auger shaft
(11) to be lateral front-rear positions.
(After reassembling both shafts, confirm that both auger
edges (13) (14) and (15) (16) are not touched each other
turning the grain auger shafts by hands.)
(11) Grain Vertical Auger Shaft (A) Machine Front Side
(12) Grain Horizontal Auger Shaft (B) Machine Rear Side
(13) Auger Beginning Edge of Grain
Vertical Auger Shaft
(14) Auger Beginning Edge of Grain
(15) Auger Terminal Edge of Grain
Horizontal Auger Shaft
(16) Auger Terminal Edge of Grain
9Y1210019THS0020US0
3-S14

Grain Auger Bevel Gear Case
1. Remove 4 mounting bolts of the grain auger bevel gear case
(6), and remove the grain auger bevel gear case (6).
(6) Grain Auger Bevel Gear Case
Grain auger bevel gear case can be disassembled according to the figure below.
(1) Vertical Bevel Gear Shaft
(2) Oil Seal
(4) Bearing
(5) Bevel Gear
(6) Grain Auger Bevel Gear
Case
(7) Bearing
(8) Bevel Gear
(9) Bearing
(11) Oil Seal
(12) Horizontal Bevel Gear Shaft
(13) Grain Horizontal Auger Shaft
(14) Grain Vertical Auger Shaft
(When reassembling)
• Apply grease to the splines of vertical bevel gear shaft (1) and horizontal bevel gear shaft (12).
• Apply grease to the internal and external surfaces of the oil seal (2), (11).
• Add 35 to 45 g grease to the inside of the grain auger bevel gear case (6).
9Y1210019THS0015US0
3-S15

[5] TAILINGS REPROCESSING AUGER

Tailings Reprocessing Horizontal Auger Shaft
1. After loosing the mounting nut of the tailings reprocessing auger
drive pulley (2), and remove the grain auger and tailings
reprocessing auger drive belt (1).
(1) Grain Auger and Tailings (2) Tailings Reprocessing Auger Drive
Reprocessing Auger Drive Belt Pulley
2. Remove 3 mounting bolts (3) of the bearing case.

(3) Bolt
3. Remove 3 mounting nuts (5) of the tailings reprocessing thrower

case cover (4).
(4) Tailings Reprocessing Thrower (5) Nut
Case Cover
4. Remove the tailings reprocessing vertical auger drive chain

case (6) and the tailings reprocessing horizontal auger shaft (7)
as a complete unit.
(6) Tailings Reprocessing Vertical (7) Tailings Reprocessing Horizontal
Auger Drive Chain Case Auger Shaft
9Y1210019THS0016US0
3-S16

Tailings Reprocessing Vertical Auger Drive Chain Case
(1) Chain Case Cover

(2) Chain
(3) 14T Sprocket
(5) Bearing
(7) Tailings Reprocessing
Vertical Auger Drive Chain
Case
(8) Oil Seal
Thrower Case Cover
(12) 13T Sprocket
(14) Bearing
Vertical Auger Bevel Gear
Case
(17) Oil Seal
(When reassembling)
• Apply grease to chain (2), 14T sprocket (3) and 13T sprocket (12).
• Add 15 to 25 g grease to the inside of the tailings reprocessing vertical auger bevel gear case (16).
• Apply grease to the splines of the 14T sprocket (3) and 13T sprocket (12).
• Apply grease to the internal and external surfaces of the oil seals (8), (17).
9Y1210552THS0003US0
3-S17

Tailings Reprocessing Vertical Auger Shaft
1. Disconnect the connector of the tailings reprocessing auger
rotation detection sensor (1).
2. Remove 2 mounting bolts of upper part of the tailings
reprocessing vertical auger case.
(1) Tailings Reprocessing Auger (2) Bolt
Rotation Detection Sensor
3. Remove the mounting bolts (3), (4) of the tailings reprocessing

vertical auger case and the tailings reprocessing thrower case,
and then remove the tailings reprocessing vertical auger case
and the tailings reprocessing thrower case as a complete unit.
(3) Bolt (4) Bolt
4. Remove the upper part mounting bolts of the tailings

reprocessing vertical auger shaft.
5. Remove the tailings reprocessing vertical auger shaft setting
the positions of the tailings scatter plate (5) and the notch (6) of
the tailings vertical auger case.
(5) Tailings Scatter Plate (6) Notch
9Y1210019THS0018US0
3-S18

Tailings Reprocessing Vertical Auger Bevel Gear Case
Tailings reprocessing vertical auger bevel gear case can be disassembled according to the below.
(2) Bearing
Vertical Auger Drive Shaft
(4) Bearing
(5) Bevel Gear
(7) Oil Seal
(9) Bearing
(10) 16T Bevel Gear
Vertical Augur Bevel Gear
Case
(When reassembling)
• Add 15 to 25 g grease to the tailings reprocessing vertical auger bevel gear case (11).
• Apply grease to the spline of the tailings reprocessing vertical auger drive shaft (3).
• Apply grease to the internal and external surfaces of the oil seal (7) and secure.
9Y1210019THS0019US0
3-S19

4 TRAVELING PORTION

MECHANISM
CONTENTS
1. MECHANISM.............................................................................................................................. 4-M1
[1] STRUCTURE ....................................................................................................................... 4-M1

DC-60-PH, WSM TRAVELING PORTION
1. MECHANISM
[1] STRUCTURE
Structure
(1) Crawler Drive Sprocket (6) Right Brake Piston (11) Left Brake Piston (16) Parking Brake Claw
(2) 14T Gear (7) Axle Shaft (12) Steering Clutch Shaft (17) Parking Brake Plate
(3) HST Output Shaft (8) 19T-24T Gear (13) 16T-35T Gear (18) Thrust Collar
(4) 25T Gear (9) 1st Shaft (14) Intermediate Shaft (19) Brake Disk
(5) 40T-45T Gear (10) Steering Clutch 16T Gear (15) 39T Gear
9Y1210019TPM0001US0
4-M1

Neutral (When Driving Straight-ahead)
The output power from HST is transmitted from 14T gear (2) to 25T gear (4).
14T gear (2) is in constant meshing engagement with 25T gear (4). The power is transmitted from 25T gear (4)
to 1st shaft (9), and to the sub-shift gear 19T-24T gears (8). (The figure on gear meshing shows the low-speed
position of the sub-shift lever.)
The power is transmitted from 19T-24T gear (8) to 40T-45T gear (5). When driving straight ahead, the left and
right steering clutch 16T gears (10) are in mesh with 40T-45T gear (5). The power from the 40T-45T gear (5) is
transmitted via the left and right steering clutch 16T gears (10), to the left and right 16T-35T gears (13), 39T gears
(15), the axle shaft (7), and to the crawler drive sprocket (1).
9Y1210019TPM0002US0
Steering Clutch OFF
Tilting slightly the power steering lever to the left or right, causes the oil to flow into the brake pistons (6) (11), then
the brake pistons (6) (11) are moved. The brake piston (6) makes to move the thrust collar (18) and the steering clutch
16T gear (10). The steering clutches 16T gears (10) and 40T-45T gears (5) are disengaged in mesh, and the steering
clutch turns OFF. Consequently, the power to the intermediate shaft is cut.
9Y1210019TPM0003US0
Steering Brake ACTUATE
Tilting fully the power steering lever from the steering clutch OFF situation raises the oil pressure to the right brake
piston (6). The right brake piston (6) pushes the thrust collar (18) strongly to pressure the brake disks (19), as a result,
the right steering clutch 16T gear is fixed so that the right crawler drive sprocket is stop completely. Then the right
steering brake is actuated. The oil pressure on the right brake piston (6) depends on the tilt angle of the power steering
lever. Greater angles lead to higher oil pressure.
9Y1210019TPM0004US0
Brake ON
(5) 40T-45T Gear (18) Thrust Collar

(6) Right Brake Piston (19) Brake Disk
(10) Steering Clutch 16T Gear
9Y1210019TPM0006US0
4-M2

Sub-shift
High-speed Position
(5) 40T-45T Gear (8) 19T-24T Gear
Low-speed Position
(5) 40T-45T Gear (8) 19T-24T Gear
Parking Brake ON Position
(5) 40T-45T Gear (16) Parking Brake Claw

(8) 19T-24T Gear (17) Parking Brake Plate
9Y1210019TPM0005US0
4-M3

SERVICING
CONTENTS

[1] TRACK FRAME .....................................................................................................................4-S1
[2] TRANSMISSION ...................................................................................................................4-S5


[1] TRACK FRAME
Crawler
1. Jack up the machine frame.
2. Remove the snap pin (2) of the crawler tension bolt (1) and the
turn lock plate (3).
3. Loosen the crawler tension bolt (1) fully.
4. Remove the front and rear crawler guide.
5. Using the crow bar etc., remove the crawler (4) first from the
crawler tension roller (rear wheel) (5), and then remove it from
the crawler drive sprocket.
(When reassembling)
• After jacking up the machine, adjust the tension of the
crawler (4).
(Refer to Maintenance chapter : Adjustment of Crawler
Tension on Page 1-S35.)
Clearance between
crawler and 4th truck Factory specification 10 to 15 mm
roller
(1) Crawler Tension Bolt (4) Crawler

(2) Snap Pin (5) Crawler Tension Roller
(3) Turn Lock Plate (Rear Wheel)
9Y1210552TPS0001US0
Crawler Guide
1. Jack up the machine frame.
2. After loosening the crawler tension bolt, remove the mounting
bolts (4) for the rear crawler guide (2), and then remove the rear
crawler guide (2).
3. Remove the mounting bolts (3) for the front crawler guide (1),
and remove the crawler guides (1).
(When reassembling)
• Confirm the position the front and rear crawler guide (1) (2)
because of different shapes.
• Apply the screw lock tight bond to the crawler guide
mounting bolts (3), (4).
(1) Front Crawler Guide (3) Bolt
(2) Rear Crawler Guide (4) Bolt
9Y1210019TPS0002US0
4-S1

Track Roller 180
1. Remove the crawler and the front and rear crawler guides.
2. Remove the track roller mounting bolt (12) inside the track
frame, and remove the track roller (1) as a complete unit.
(When reassembling)
• Apply grease inside space of the bearings (3).
• Apply grease after cleaning up the dust around the seal lip
and exterior of the oil seal (6).
• Install the oil seal (6) using the jig. Outer and inner oil seals
should be installed separately and horizontally. Confirm
that the seal lip is not twisted. Push the outer oil seal all the
way in the track roller (7).
• Apply the screw lock tight bond to the bolt (4) and tighten.
• Apply grease to all diagonal hatching part in the figure
below, and then grease to the O-ring of the plug (10) and
assemble.
• Apply the screw lock tight bond to the track roller mounting
bolt (12) inside the track frame and tighten.
(1) Track Roller (12) Bolt
(2) Collar
(3) Bearing
(4) Bolt
(5) Track Roller Shaft
(6) Oil Seal
(7) Track Roller
(8) Shaft Collar
(9) Flat Washer
(10) Plug
(12) Bolt
9Y1210019TPS0003US0
4-S2

Carrier Roller
1. Loosen the crawler tension bolt.
2. Remove the carrier roller mounting bolt (12) inside the track
frame, and remove the carrier roller (1) as a complete unit.
(When reassembling)
• Apply grease after cleaning up the dust around the seal lip
• Install the oil seal (6) using the jig. Outer and inner oil seals
should be installed separately and horizontally. Confirm
that the seal lip is not twisted. Push the outer oil seal all the
way in the carrier roller (7).
• Do not apply grease or oil to the external surface of the
outer and the internal surface of the oil seal (6).
(When greasing up by the grease nipple, the outer oil seal
of the oil seal (6) might slip out from the carrier roller (7).)
• Apply the screw lock tight bond to the bolt (4) and tighten.
assemble.
• Apply the screw lock tight bond to the carrier roller
mounting bolt (12) inside the track frame and tighten.
(1) Carrier Roller (12) Bolt
(2) Collar
(3) Bearing
(4) Bolt
(5) Carrier Roller Shaft
(6) Oil Seal
(7) Carrier Roller
(8) Shaft Collar
(9) Flat Washer
(10) Plug
(12) Bolt
9Y1210019TPS0004US0
4-S3

Tension Roller 255 (Rear Wheel)
1. Remove the crawler.
2. Remove the crawler tension roller (1) and the tension frame as
a complete unit.
IMPORTANT
• When reassembling the nut (8), confirm the inclined face
(A) of the nut (8) is positioned to up-and-down against the
crawler tension roller shaft (9).
(When reassembling)
Apply grease after cleaning up the dust around the seal lip
• Install the oil seal (11) using the jig. Push the outer oil seal
all the way in the crawler tension roller (1).
• Apply the screw lock tight bond to the crawler tension
roller mounting bolt (14) and tighten.
assemble.
• Apply grease to the surface portions (a) that contact the
end portions and secure.
39.2 to 64.7 N·m
Tightening torque Tension roller mounting bolt
4.00 to 6.00 kgf·m
(1) Crawler Tension Roller (5) Washer

(2) Crawler Tension Bolt (6) Bolt
(3) Turn Lock Plate (7) Holder
(4) Spacer (8) Nut
(1) Crawler Tension Roller

(2) Crawler Tension Bolt
(3) Turn Lock Plate
(4) Spacer
(5) Washer
(6) Bolt
(7) Holder
(8) Nut
(9) Crawler Tension Roller Shaft
(10) Collar
(11) Oil Seal
(12) Bearing
(13) Flat Washer
(14) Crawler Tension Roller
Mounting Bolt
(15) Plug
(A) Inclined Face

9Y1210019TPS0005US0
4-S4

[2] TRANSMISSION
Separating Left Side Case of Transmission Case
1. Remove the reaper and the feeder conveyor.
2. Remove the crawlers.
3. Discharge the transmission case oil and the hydraulic oil tank
oil.
4. Remove the traveling (transmission) drive belt (1).
5. Remove the HST drive pulley (2).
6. Remove the return hose 1 (6) and 2 (5) for the direction
hydraulic unit (4), and the hose (7).
7. Remove the axle shaft holder (8).
8. Remove the brake case (10).
9. Set the steering clutch spring assembling jig (11) and remove
the external snap ring (12).
10. Remove the assembling jig (11), the outside collar (one with the
smaller inside diameter) and the inside collar (one with the
larger inside diameter) of the steering clutch return spring.
(When reassembling)
• Apply the screw lock tight bond to the HST drive pulley
mounting nut (3) and tighten.
• Apply the screw lock tight bond to the axle shaft holder
mounting bolts (9) and tighten.
• Before reassembling, apply grease to the O-ring of the
brake case (10) to avoid damaging.
• When assembling the brake case (10), set the sub-shift
lever to the parking brake position, and then assemble in
meshing engagement with the brake disks and the spline
part of the steering clutch 16T gear by turning the brake
case (10). Do not assemble by tapping with a hammer, etc.
• Set the assembling jig (11) to push the steering clutch
return spring for installing the external snap ring.
(For the assembling jig, see page G-12.)
HST drive pulley mounting 59 to 61 N·m
Tightening torque
nut 6.0 to 6.2 kgf·m
39.2 to 53.9 N·m

Tightening torque Axle shaft mounting bolt
4.0 to 5.5 kgf·m
(1) Traveling (Transmission) Drive Belt (7) Hose

(2) HST Drive Pulley (8) Axle Shaft Holder
(3) Nut (9) Bolt
(4) Direction Hydraulic Unit (10) Brake Case
(5) Return Hose 2 (11) Assembling Jig
(6) Return Hose 1 (12) External Snap Ring
(To be continued)
4-S5

(Continued)
11. Remove 2 bolts (13) for fixing with the main frame.
12. Remove all mounting bolts of the left transmission case.
13. Remove the left transmission case with the axle shaft as a
complete unit, from the right side transmission case (14).
(When reassembling)
• Apply a thin layer of the liquid gasket bond to the gasket or
the matching surface of the transmission case.
• Apply the screw lock tight bond to the main frame
mounting bolts (13).
• Prevent the liquid gasket bond from flowing into the oil
passage (15).
(13) Bolt (16) Parking Brake Claw
(14) Right Side Transmission Case (17) Parking Brake Plate
(15) Oil Passage
9Y1210552TPS0002US0
4-S6

Disassembling Transmission Case
The transmission case can be disassembled as shown in the figure below.
(1) Right Side Transmission Case (5) Steering Clutch Shaft (9) Needle Bearing (12) Axle Shaft
(2) 14T Gear (6) Intermediate Shaft (10) Thrust Collar (13) Crawler Drive Sprocket Boss
(3) Sub-shift Shift Fork (7) Left Brake Case (11) Left Side Transmission Case (14) Crawler Drive Sprocket
(4) 1st Shaft (8) Left Brake Piston
9Y1210019TPS0007US0
(When reassembling)
• Apply oil to the brake piston (1), the O-ring (2) and the
sliding part of the transmission case (3) before
reassembling the brake piston (1).
• When reassembling the thrust needle bearing (4), the cover
(5) side should be faced to the brake piston (1) side.
• Surface A (6) of the thrust needle bearing (4) should be
faced to the thrust collar (7) side.
(1) Brake Piston (5) Cover
(2) O-ring (6) Surface A
(3) Transmission Case (7) Thrust Collar
(4) Thrust Needle Bearing
9Y1210019TPS0008US0
4-S7

Axle Shaft Oil Seal
1. Remove the mounting bolt (6) of the crawler drive sprocket (1),
and remove the crawler drive sprocket (1).
2. Remove the mounting bolt (3) of the crawler drive sprocket boss
(2), and remove the crawler drive sprocket boss (2).
3. Remove the oil seal (10).
(When reassembling)
• Apply grease to the oil seal (10) and the O-ring (7) before
reassembling, to avoid damage.
• Confirm that the collar (11) and the internal snap ring (8) as
a spacer are set in their positions before assembling the oil
seal (10).
• Outer and inner oil seals of the oil seal (10) should be
installed separately and surely.
(Install the outer oil seal all the way to touch with the
internal snap ring (8), and install horizontally the inner oil
seal all the way to touch with the collar (11) surely.)
• Apply grease to the lubber packing (4) and (A) portion.
• Apply a washer (5).
• Apply the screw lock tight bond to the mounting bolts (6) of
the crawler drive sprocket (1), and the mounting bolts (3) of
the crawler drive sprocket boss (2), and tighten.
Crawler drive sprocket 137.2 N·m
Tightening torque
boss mounting bolt 14 kgf·m
Crawler drive sprocket 137.2 N·m

Tightening torque
mounting bolt 14 kgf·m
(1) Crawler Drive Sprocket (8) Internal Snap Ring

(2) Crawler Drive Sprocket Boss (9) Bearing
(3) Bolt (10) Oil Seal
(4) Lubber Packing (11) Collar
(5) Washer
(6) Bolt (A) Grease Applied Portion
(7) O-ring
9Y1210019TPS0009US0
4-S8

5 HYDRAULIC SYSTEM

MECHANISM
CONTENTS
1. MECHANISM.............................................................................................................................. 5-M1
[1] GENERAL ............................................................................................................................ 5-M1
[2] REAPER AND REEL RAISING AND LOWERING HYDRAULIC UNIT................................ 5-M3
(1) Neutral (Reaper and Reel Portions) ............................................................................... 5-M4
(2) Raising (Reaper and Reel Portions)............................................................................... 5-M5
(3) Lowering (Reaper and Reel Portions) ............................................................................ 5-M6
[3] DIRECTION HYDRAULIC UNIT........................................................................................... 5-M7

DC-60-PH, WSM HYDRAULIC SYSTEM
1. MECHANISM
[1] GENERAL
General (Hydraulic Circuit)
The hydraulic devices for the combine harvesters can be classified into the following 4 main functions.
• Raising and lowering the reaper portion
• Raising and lowering the reel
• Direction correction and turning the combine harvester
• HST (Hydrostatic transmission)
The dedicated hydraulic pump D is equipped for turning on and off the steering clutch and the steering brake, and
the hydraulic pump HR for raising and lowering the reaper portion and the reel portion.
As the hydraulic unit, there are 2 units as the direction hydraulic unit and the reaper and reel raising and lowering
unit.
To raise and lower the reaper or the reel and to turn the machine, use each operating lever to move the hydraulic
spool in the hydraulic unit so that oil flow can be switched to each hydraulic actuator.
9Y1210019HYM0001US0
Hydraulic Pump
(1) Hydraulic Pump HR (2) Hydraulic Pump D

9Y1210019HYM0002US0
Hydraulic Oil Tank
(1) Hydraulic Oil Tank

9Y1210019HYM0003US0
Direction Hydraulic Unit
(1) Direction Hydraulic Unit

9Y1210019HYM0004US0
5-M1

Reaper and Reel Raising and Lowering Hydraulic
Unit
(1) Reaper and Reel Raising

and Lowering Hydraulic Unit
9Y1210019HYM0005US0
Reaper Cylinder
(1) Reaper Cylinder

9Y1210019HYM0006US0
Reel Cylinder
(1) Reel Cylinder

9Y1210019HYM0007US0
5-M2

[2] REAPER AND REEL RAISING AND LOWERING HYDRAULIC

UNIT
Reaper and Reel Raising and Lowering Hydraulic Unit (Circuit Diagram)
(1) Reaper Cylinder (4) Hydraulic Pump HR (8) Power Steering Lever (12) Reel Raising and Lowering
(2) Reaper and Reel Raising and (5) Hydraulic Oil Tank (9) Reel Cylinder Lever
Lowering Hydraulic Unit (6) Check Valve (10) Relief Valve (13) Raising Position
(3) Reaper Raising and Lowering (7) Check Valve (11) Reel Raising and Lowering (14) Neutral Position
Valve Valve (15) Lowering Position
9Y1210019HYM0008US0
Relief Valve
The relief valve of 14.7 to 15.7 MPa (150 to
160 kgf/cm2) is provided to set the maximum pressure
for actuating the hydraulic cylinder. If becoming the
overload situation in the hydraulic circuit, the relief valve
is opened to leak the hydraulic oil for protecting the
hydraulic devices.
(1) From Hydraulic Pump HR (3) To Reaper and Reel Raising
(2) To Hydraulic Oil Tank and Lowering Spool
9Y1210019HYM0009US0
5-M3

Reaper and Reel Raising and Lowering Spool
(1) Reaper Raising and (2) Reel Raising and Lowering

Lowering Spool Spool
9Y1210019HYM0010US0
Reaper and Reel Raising and Lowering Check Valve
(1) Check Valve 1 (A) For Reaper Portion

(Orifice 1.8 mm dia.) (B) For Reel Portion
(2) Check Valve 2
(Orifice 1.3 mm dia.)
(3) Spring
(4) Plug
(5) Check Valve 1 (No Orifice)
(6) Spring
(7) Check Valve 2
(8) Plug
9Y1210019HYM0011US0
Relief Valve
(1) Valve Sheet (4) Shim

(2) Poppet (5) Plug
(3) Spring
9Y1210019HYM0012US0
(1) Neutral (Reaper and Reel Portions)

Reaper Raising and Lowering Valve
1. When the power steering lever is in the neutral
position, the hydraulic oil from the pump port P flows
to the reel raising and lowering valve (1).
(1) To Reel Raising and [A] Reaper Raising and
Lowering Valve Lowering Valve
P : Pump Port
9Y1210019HYM0013US0
5-M4

Reel Raising and Lowering Valve
1. When the reel raising and lowering lever is in the
neutral position, the hydraulic oil coming from the
reaper raising and lowering valve flows from the
pump port P to the hydraulic oil tank (1) through the
tank port T.
(1) To Hydraulic Oil Tank [B] Reel Raising and Lowering
Valve
P : Pump Port
T : Tank Port
9Y1210019HYM0014US0
(2) Raising (Reaper and Reel Portions)

Raising Reaper
1. When the power steering lever is set in the raise
position, the reaper raising and lowering spool (4)
moves left as shown in the figure.
2. The hydraulic oil from the pump port P pushes open
the check valve 1 (1) to flow through the orifice
(1.8 mm dia.) of the check valve 1 (1), and then
pushes open the check valve 2 (2) to flow to the
reaper cylinder (3), causing the reaper to be raised.
(1) Check Valve 1 [A] Reaper Raising and
(Orifice 1.8 mm dia.) Lowering Valve
(2) Check Valve 2 P : Pump Port
(3) To Reaper Cylinder
(4) Reaper Raising and
Lowering Spool
9Y1210552HYM0001US0
Raising Reel
1. When the reel raising and lowering lever is set in the
raise position, the reel raising and lowering spool (4)
moves left as shown in the figure.
2. The hydraulic oil from the pump port P pushes open
the check valve 1 (1) and pushes the check valve 2
(2) to flow through the orifice (1.3 mm dia.) to the reel
cylinder (3), causing the reel to be raised.
The hydraulic oil flow through the orifice
(1.3 mm dia.) regulates raising and lowering speeds.
(1) Check Valve 1 (No Orifice) [B] Reel Raising and Lowering
(2) Check Valve 2 Valve
(Orifice 1.3 mm dia.) P : Pump Port
(3) To Reel Cylinder
(4) Reel Raising and Lowering
Spool
9Y1210019HYM0016US0
5-M5

(3) Lowering (Reaper and Reel Portions)

Lowering Reaper
1. When the power steering lever is set in the lower
position, the reaper raising and lowering spool (6)
moves right as shown in the figure.
2. The hydraulic oil from the pump port P pushes the
poppet (1) to push open the check valve 1 (2).
3. Since the check valve 1 (2) opens, the hydraulic oil
enters to the reaper raising and lowering valve from
the reaper cylinder (4) due to the weight of the reaper
portion, and then passes the orifice 1.3 mm dia. of
the check valve 2 (3), and then passes the orifice
1.8 mm dia. of the check valve 1 (2), and flows to the
tank port T, causing the reaper portion to be lowered.
Oil flow through the orifice (1.3 mm dia.) regulates
the reaper portion lowering speed.
(1) Poppet [A] Reaper Valve
(Orifice 1.8 mm dia,) T : Tank Port
(3) Check Valve 2
(4) From Reaper Cylinder
(5) To Hydraulic Oil Tank
(6) Reaper Raising and
Lowering Spool
9Y1210552HYM0002US0
Lowering Reel
1. When the reel portion raising and lowering lever is
set in the lower position, the reel raising and
lowering spool (6) moves right as shown in the
figure.
2. The hydraulic oil from the pump port P pushes the
poppet (1) to push open the check valve 1 (2).
3. Since the check valve 1 (2) opens, the hydraulic oil
enters to the reel raising and lowering valve from the
reel cylinder (4) due to the weight of the reel portion,
the hydraulic oil pushes open the check valve 2 (3),
and passes the check valve 1 (2), and flows to the
tank port T, causing the reel portion to be lowered.
(1) Poppet [B] Reel Raising and Lowering
(2) Check Valve 1 (No Orifice) Valve
(Orifice 1.3 mm dia.) T : Tank Port
(4) From Reel Cylinder
(5) To Hydraulic Oil Tank
(6) Reel Raising and Lowering
Spool
9Y1210019HYM0018US0
5-M6

[3] DIRECTION HYDRAULIC UNIT

Direction Hydraulic Unit (Circuit Diagram)
(1) Direction Change Spool (4) Left Brake Piston (6) Power Steering Lever (8) Hydraulic Oil Tank
(2) Hydraulic Pump D (5) Right Brake Piston (7) Direction Hydraulic Unit (9) Variable Relief Valve
(3) Check Valve
9Y1210019HYM0019US0
Variable Relief Valve
The variable relief valve regulates the hydraulic oil
pressure to activate the brake piston (see 4-M2 page)
controlling the hydraulic oil flow coming to B port of the
direction hydraulic unit from the brake pistons which are
existed in the transmission case.
When inclining the power steering lever to right or
left, the turning arm (6) moves in conjunction with the
power steering lever, and pushes the spring holder (5)
constantly. (At the same time, the turning arm (6) makes
to move the direction change spool (7) to right or left.)
The inclined amount of the power steering lever is
directly proportional to the moving amount of the spring
holder (5) pushing by the turning arm (6).
If the spring holder (5) is pushed much, the relief
spring (4) and the valve spring (3) are compressed so
that the valve opening pressure of the poppet (2) is
higher, causing the high pressure of the hydraulic oil in
the hydraulic oil circuit
The variable relief valve of 17.6 to 19.6 MPa (18 to
20 kgf/cm2) is provided to set the maximum pressure for
actuating the brake pistons.
(1) Valve P: From Hydraulic Pump D
(2) Poppet R: To Right Brake Piston
(3) Valve Spring L: To Left Brake Piston
(4) Relief Spring B: From Brake Piston
(5) Spring Holder T: To Hydraulic Oil Tank
(6) Turning Arm
(7) Direction Change Spool
9Y1210552HYM0003US0
5-M7

Neutral
1. The hydraulic oil from the hydraulic pump D flows
into the P port of the direction change spool (7), and
flows from the T port back to the hydraulic oil tank
when the power steering lever is in the neutral
position.
(6) Turning Arm P: From Hydraulic Pump D
(7) Direction Change Spool R: To Right Brake Piston
L: To Left Brake Piston
B: From Brake Piston
T: To Hydraulic Oil Tank
9Y1210019HYM0021US0
Steering Clutch OFF

1. When the power steering lever is moved slightly to
the left or right, the turning arm (6) turns a little so
that the direction change spool (7) moves left or
right.
2. The hydraulic oil from the hydraulic pump D flows in
from the P port. The shift in the direction change
spool (7) causes the hydraulic oil flows to the L port
or the R port, which pushes the brake piston in the
transmission case, resulting in the steering clutch
gear disengaging.
(6) Turning Arm P: From Hydraulic Pump D
(7) Direction Change Spool R: To Right Brake Piston
L: To Left Brake Piston
B: From Brake Piston
T: To Hydraulic Oil Tank
9Y1210019HYM0022US0
Working Steering Brake
1. If the power steering lever is moved further than the
steering clutch disengage position, the turning arm
is also turned further to move the direction change
spool further left or right as well.
2. Further turning the turning arm pushes the spring
holder, and then compresses the relief spring of the
poppet, causing higher hydraulic oil pressure in the
oil circuit.
Therefore the brake piston in the transmission case
moves more to pressurize the brake disks, and then
the steering brake works to turn sharply the combine
harvester.
P : From Hydraulic Pump D B : From Brake Piston
R : To Right Brake Piston
9Y1210019HYM0023US0
5-M8

Working Variable Relief Valve
Choking the hydraulic oil passage from the brake
piston to the hydraulic oil tank, the hydraulic oil pressure
in the oil circuit is increased so that the pushing force of
the brake disks is increased.
Pushing the spring holder (3) by the turning arm (4),
the relief spring (2) and the valve spring (5) is
compressed so that the poppet (1) is pushed, causing
the hydraulic oil pressure coming back from the brake
piston is increased.
As the power steering lever is moved further, the
pressure of the hydraulic oil which returns from the brake
piston is increased.
This variable relief valve works as the relief valve for
making the maximum pressure in the entire oil circuit, so
when the power steering lever is moved furthest,
ultimately, the hydraulic oil pushes open the poppet (1)
so that the hydraulic oil flows back to the hydraulic oil
tank.
Variable relief pressure is regulated with a bolt. (Set
pressure is 1.76 to 1.96 MPa (18 to 20 kgf/cm2).)
(1) Poppet P : From Hydraulic Pump D
(2) Relief Spring R : To Right Brake Piston
(3) Spring Holder B : From Brake Piston
(4) Turning Arm
(5) Valve Spring
9Y1210019HYM0024US0
5-M9

SERVICING
CONTENTS
1. CHECKING AND MAINTENANCE ..............................................................................................5-S1

1. CHECKING AND MAINTENANCE

Maximum Pressure of Variable Relief Valve for Direction
Hydraulic Unit
1. Remove the hose (1) from the hydraulic pump D to the direction
hydraulic unit, and install the adaptor C1 (2) and adaptor D (3)
for measuring the relief valve maximum pressure, and then
install the pressure gauge (4) (measuring range : 0 to
50 kgf/cm2).
2. Set the sub-shift lever to neutral, start the engine, and after
running the engine to warm it up, set engine revolution to the
maximum setting.
3. Move the power steering lever as far as possible to the left or
right. Measure the maximum pressure of the variable relief
valve.
4. If the maximum pressure is not within the factory specifications,
adjust the maximum pressure with the adjustment bolt (5).
Maximum pressure of 1.76 to 1.96 MPa
variable relief valve 18 to 22 kgf/cm2
(1) Hose (4) Pressure Gauge

(2) Adaptor C1 (5) Adjustment Bolt
(3) Adaptor D
9Y1210019HYS0001US0
Maximum Pressure of Relief Valve for Reaper and Reel Raising
and Lowering Hydraulic Unit
1. Remove the hose (1) of the reaper and reel raising and lowering
hydraulic unit and the reaper cylinder or the reel cylinder, and
install the adaptor C1 (2) and the adaptor D (3), and then install
the pressure gauge (4) (measuring range : 0 to 400 kgf/cm2).
2. Start the engine and run to warm up, and then set engine
revolutions to the maximum setting.
3. Measure the maximum pressure while keeping the power
steering lever in the reaper raise position or the reel raising and
lowering lever in the reel raise position.
4. If the maximum pressure is not within the factory specifications,
remove the plug for the relief valve and adjust with increasing or
decreasing the number of the shims (see 5-M4 page).
Maximum pressure of 14.7 to 15.7 MPa
relief valve 150 to 160 kgf/cm2
(1) Hose (3) Adaptor D

(2) Adaptor C1 (4) Pressure Gauge
9Y1210552HYS0001US0
5-S1

6 HST

MECHANISM
CONTENTS
1. MECHANISM.............................................................................................................................. 6-M1
[1] GENERAL ............................................................................................................................ 6-M1

DC-60-PH, WSM HST
1. MECHANISM
[1] GENERAL
The HST (hydrostatic transmission) is comprised of a pair of the variable capacity pump and the fixed capacity
motor, the charge pump, the oil filter cartridge, the check and high pressure relief valves, the charge relief valve, etc.
The HST is directly tied to the transmission case. The pulley of the engine output shaft and the HST drive pulley
are connected by the belt so that the engine power is transmitted to the HST. The HST drive pulley drives the HST
input shaft so that the pump in the HST is driven. The output power from the motor in the HST is transmitted to the
transmission by 14T gear of the motor output shaft.
The rotation direction and speed of the motor output shaft is changed by the movement of the HST lever (trunnion
shaft), which is moved by the main shift lever in the operator's seat via the HST rod.
The hydraulic oil of the HST is used the oil in the hydraulic oil tank. The hydraulic oil tank is used in conjunction
with other hydraulic devices, but the HST is equipped with the dedicated oil filter and the oil filter cartridge (10 microns
mesh) separated from the other hydraulic circuits.
(1) HST
(2) Oil Cooler
(1) Check and High Pressure (3) Oil Filter Cartridge

Relief Valve (for Forward) (4) Pump Shaft (Input Shaft)
(2) Check and High Pressure (5) Motor Shaft (Output Shaft)
Relief Valve (for Reverse)
6-M1

DC-60-PH, WSM HST
(1) Check and High Pressure (6) Trunnion Shaft

Relief Valve (7) Charge Pump
(5) Charge Relief Valve (8) HST Lever
(1) Pump Shaft (Input Shaft) (4) Check and High Pressure (6) Check Valve (9) Fixed Capacity Motor
(2) Oil Filter Cartridge Relief Valves (7) Orifice (10) Motor Shaft (Output Shaft)
(3) Charge Pump (5) Variable Capacity Pump (8) Charge Relief Valve (11) Oil Cooler
9Y1210019TRM0001US0
6-M2

DC-60-PH, WSM HST
Charge Pump and Charge Relief Valve
The pump and motor inside of the HST are
connected using a closed oil circuit, but there is an
internal hydraulic oil leak. Therefore, the charge pump
(1) is installed to compensate for the oil amount leaked.
The oil filter cartridge (10 microns mesh) is equipped
after discharging oil by the charge pump (1).
The hydraulic oil passed from the oil filter cartridge
pushes open the check valve of the check and high
pressure relief valve to compensate for the oil amount
leaked at the low pressure side in the oil circuit. Surplus
oil pushes open the charge relief valve (2), and then the
oil flows to inside of the HST housing, and goes back to
the hydraulic oil tank via the drain hose and the oil
cooler.
The maximum pressure of the low-pressure oil circuit
is regulated by the charge relief valve (2) (5.2 to
7.2 kgf/cm2).
(1) Charge Pump (2) Charge Relief Valve
9Y1210019TRM0002US0
6-M3

DC-60-PH, WSM HST
Check and High Pressure Relief Valves
The check and high pressure relief valves include
the forward valve (1) and the reverse valve (2), and they
are different things.
There are the orifices (7) to leak the hydraulic oil at
the check valve (3) as the forward side 1.0 mm dia. and
the reverse side 0.6 mm dia.. These orifices (7) need to
get the neutral range of the main shift lever.
When the high pressure relief valves (5) of the check
and high pressure relief valves (1) (2) are closed, the
combine harvester can be moved for forward of reverse.
If becoming an overload situation for the traveling
portion, the combine harvester stops moving because of
opening the high pressure relief valve (5). Therefore the
traveling ability of the combine harvester is regulated by
the maximum setting pressure (350 kgf/cm2) of the high
pressure relief valve (5). To open the high pressure relief
valve (5) because of an overload situation for the
traveling portion, it works to prevent damages for the
hydraulic devices.
When the combine harvester moves forward, the
high pressure relief valve (5) of the check and high
pressure relief valve (1) is closed for keeping the high oil
pressure to travel the combine harvester. Meanwhile,
the hydraulic oil from the charge pump pushes open the
check valve (3) of the check and high pressure relief
valve (2) for reversing to compensate the hydraulic oil in
the oil circuit of low pressure side.
(1) Check and High Pressure (4) Check Valve Spring
Relief Valve (for Forward) (5) High Pressure Relief Valve
(2) Check and High Pressure (6) High Pressure Relief Valve
Relief Valve (for Reverse) Spring
(3) Check Valve (7) Orifice
9Y1210019TRM0003US0
6-M4

SERVICING
CONTENTS
1. TROUBLESHOOTING.................................................................................................................6-S1
2. CHECKING AND ADJUSTMENT ................................................................................................6-S3
3. DISASSEMBLING .......................................................................................................................6-S4
[1] DISASSEMBLING AND ASSEMBLING OF HST ..................................................................6-S4

DC-60-PH, WSM HST
1. TROUBLESHOOTING
CAUTION
• Do not disassemble the HST unless necessary. When HST trouble is suspected, perform the following
troubleshooting and checking, confirm the cause and then disassemble, while paying attention to the
following items.
1. Do not use the wire brush or the sand paper on the sliding surface of the hydraulic portion as it is precisely
processed. Remove dust with compressed air. Wash with the hydraulic oil.
2. Check the damage, wear and breakage for the sliding portions of each part. If detected, exchange both sliding
and slided parts as an assembly parts.
3. Do not wash the seal parts with a washing solvent designed for use with the metal parts. Remove the dust with
the compressed air. Soak the seal parts in hydraulic oil. Preferably, change the seal parts for new ones.
6-S1

DC-60-PH, WSM HST
9Y1210019TRS0001US0
6-S2

DC-60-PH, WSM HST
2. CHECKING AND ADJUSTMENT

Neutral Adjustment
1. Start the engine and set the sub-shift lever to the low speed
position.
2. Set the engine revolution to 2000 rpm or higher. Inspect
whether the combine harvester is stopped when the main shift
lever is in the neutral position.
3. If the combine harvester moves, adjust with the length of the
HST rod (1) to stop it.
(1) HST Rod
9Y1210019TRS0002US0
Charge Relief Valve Pressure
1. Remove the plug for the charge pressure measuring port (1) in
the HST. Install the charge pressure measuring adaptor (see
SPECIAL TOOLS G-11). Install the pressure gauge.
2. Run the engine to warm it up. Measure the pressure when the
engine is idling and at maximum revolution.
3. If the pressure when the engine is in maximum revolution is less
than 3.2 kgf/cm2, check for the filter clogging, the charge pump
failure and the HST (pump or motor) failure (wear or damage).
Charge relief valve
pressure Factory specification 6.2 to 7.2 kgf/cm2
(when engine 2700 rpm)
(1) Measuring Port

9Y1210552HSS0002US0
6-S3

DC-60-PH, WSM HST
3. DISASSEMBLING
[1] DISASSEMBLING AND ASSEMBLING OF HST
Charge Pump
1. Remove the pump cover. Remove each outer rotor, inner rotor
and the key.
9Y1210019TRS0004US0
Port Block, Valve Plate

1. Remove the port block (3). Remove the valve plates (1), (2).
(When reassembling)
• Note that the valve plates (1), (2) for the shape of the pump
side are different from one for the motor side. Secure the
valve plates with fishtail (notch on the port edge) to the
pump side (4).
• Apply functioning oil (UDT oil) to the valve plates (1), (2).
(1) Valve Plate (Motor Side) (3) Port Block
(2) Valve Plate (Pump Side) (4) Pump Side
9Y1210019TRS0005US0
Cylinder Block, Piston

1. Remove the cylinder blocks (3), the pistons (2) and the retainer
plates (1).
(When reassembling)
• Apply the hydraulic oil (UDT oil) to the entire piston (2).
(1) Retainer Plate (3) Cylinder Block
(2) Piston
9Y1210019TRS0006US0
6-S4

DC-60-PH, WSM HST
Fixed Swash Plate, Input Shaft, Output Shaft
1. Remove the fixing bolt (1) of the fixed swash plate.
(1) Bolt
2. Remove the fixed swash plate (3), the output shaft (2) and the
input shaft (4).
(2) Output Shaft (4) Input Shaft
(3) Fixed Swash Plate
9Y1210019TRS0007US0
Variable Swash Plate

1. Remove the internal snap rings (1) for the bearings (2).
2. Remove the bearings (2) and then remove the variable swash
plate (3).
(1) Internal Snap Ring (3) Variable Swash Plate
(2) Bearing
9Y1210019TRS0008US0
6-S5

7 ALARM SYSTEM

MECHANISM
CONTENTS
1. MECHANISM.............................................................................................................................. 7-M1
[1] GENERAL ............................................................................................................................ 7-M1
[2] CONTROL CONTENTS ....................................................................................................... 7-M2

DC-60-PH, WSM ALARM SYSTEM
1. MECHANISM
[1] GENERAL
Meter Panel
The meter panel is equipped with 5 alarm lamps (the
water temperature alarm, the charge alarm, the engine
oil pressure alarm, the grain full alarm, and the tailings
reprocessing auger clogging alarm).
Turning the main switch from OFF to ON, it lights up
the charge alarm lamp and the engine oil pressure alarm
lamp, and it sounds continuously the electronic buzzer.
Starting the engine, it stops the electronic buzzer
and turns off the charge alarm and engine oil pressure
alarm lamps.
Further, the engine oil pressure alarm lamp turns ON
and the electronic buzzer sounds continuously when the
engine is stopped to prevent you from forgetting to return
the main switch to the OFF position.
9Y1210019WSM0001US0
7-M1

[2] CONTROL CONTENTS

Water Temperature Alarm
The engine cooling water (coolant) temperature is
detected by the water temperature sensor (2) mounted
to the water flange for the engine. If the cooling water
temperature exceeds approx. 115 °C while the threshing
clutch switch is ON by putting the threshing clutch lever
ON, the horn sounds intermittently and the water
temperature alarm lamp (1) turns ON.
If the cooling water temperature drops to 108 °C or
lower, the water temperature alarm lamp (1) turns OFF.
During the cooling water alarm is in operation, if the
threshing clutch switch is OFF by putting the threshing
clutch lever OFF, it stops sounding the horn.
(1) Water Temperature Alarm (2) Water Temperature Sensor
Lamp
9Y1210019WSM0002US0
Charge Alarm
When the charge signal from the IC regulator in the
alternator (2) is ON (approx. 0 V) while the engine runs
at idling revolution speed or higher, the charge alarm
lamp (1) turns ON. It does not sound neither the
electronic buzzer nor the horn.
(1) Charge Alarm Lamp (2) Alternator
(Built-in IC Regulator)
9Y1210019WSM0003US0
7-M2

Engine Oil Pressure Alarm
When the engine oil pressure switch (2) signal is ON
(0 V) while the engine runs at idling speed or higher, the
electronic buzzer sounds continuously and the engine oil
pressure alarm lamp (1) turns ON.
Further, the engine oil pressure alarm lamp turns ON
and the electronic buzzer sounds continuously when the
engine is stopped to prevent you from forgetting to return
the main switch to the OFF position.
(1) Engine Oil Pressure Alarm (2) Engine Oil Pressure Switch
Lamp
9Y1210019WSM0004US0
7-M3

Tailings Reprocessing Auger Clogging Alarm
Stopping the rotation of the tailings reprocessing
vertical auger shaft while the threshing clutch switch is
ON by putting the threshing clutch lever (2) ON, it detects
by the tailings reprocessing auger rotation detection
sensor (3), it sounds intermittently the horn and turns ON
the tailings reprocessing auger clogging alarm lamp (1).
(1) Tailings Reprocessing Auger (3) Tailings Reprocessing Auger
Clogging Alarm Lamp Rotation Detection Sensor
(2) Threshing Clutch Lever
9Y1210019WSM0005US0
7-M4

Grain Full Alarm
Turning ON the grain full sensor (2) in the grain
hopper while the threshing clutch switch is ON by putting
the threshing clutch lever ON, it sounds intermittently the
horn and turns ON the grain full alarm lamp (1).
(1) Grain Full Alarm Lamp (2) Grain Full Sensor
9Y1210019WSM0006US0
Back Alarm
Setting the main shift lever to the backward position,
it turns ON the back switch (1), and it sounds the back
buzzer (2) intermittently.
(1) Back Switch (2) Back Buzzer
9Y1210019WSM0007US0
7-M5

8 ELECTRICAL SYSTEM

MECHANISM
CONTENTS
1. CIRCUIT DIAGRAM ................................................................................................................... 8-M1

2. WIRING DIAGRAM..................................................................................................................... 8-M2

DC-60-PH, WSM ELECTRICAL SYSTEM
1. CIRCUIT DIAGRAM
8-M1

2. WIRING DIAGRAM
8-M2

SERVICING
CONTENTS
1. CHECKING..................................................................................................................................8-S1
[1] POWER SUPPLY, GROUND ................................................................................................8-S1
[2] STARTER DEVICE ...............................................................................................................8-S2
[3] CHARGING DEVICE .............................................................................................................8-S4
[4] LIGHT DEVICE......................................................................................................................8-S5
[5] RELAY...................................................................................................................................8-S6
[6] SENSOR ...............................................................................................................................8-S6
[7] HORN, BUZZER....................................................................................................................8-S8
[8] ALARM UNIT .........................................................................................................................8-S8

1. CHECKING
• The following inspection is a way of judging whether a sensor or actuator is defective or whether the problem lies
with the wiring.
Basically, the inspection should be conducted while the relevant connector is disconnected.
9Y1210019ELS0001US0
[1] POWER SUPPLY, GROUND

Slow Blow Fuse
IMPORTANT
• Change the defective slow blow fuse after the cause is
confirmed. Use a new fuse of the same capacity.
Inspection Factory specification
Terminal 1 - Terminal 2 Conduction
Slow Blow Fuse 60 A
(1) Slow Blow Fuse

9Y1210019ELS0002US0
Fuse
IMPORTANT
• Fuse case
Alternator 15 A
Work light relay 10 A
Meter, buzzer, alarm unit 15 A
Work light 25 A
1. Inspect fuses in the fuse case.
(Reference)
• There are the spare fuses (10 A, 15 A, 25 A) in the fuse case.
(1) Fuse Case
9Y1210325ELS0001US0
Ground
1. Inspect whether the ground wire is securely connected to the
machine body.
9Y1210019ELS0004US0
8-S1

[2] STARTER DEVICE

Power Supply to Starter Motor
Power supply to B terminal
(+) (−) Factory specification
Starter B terminal Machine body 11 to 14 V
Power supplies to pull-in and holding coil in the starter motor

(+) (−) Factory specification
11 to 14 V when main
Starter S terminal Machine body switch is positioned at
START
If the above power supplies are within the factory specifications

when the main switch is positioned at START, the slow blow fuse,
the main switch, the starter relay and the wire harness are operating
normally.
(1) B Terminal (2) S Terminal
9Y1210019ELS0005US0
Starter Relay
5H276-41250 relay (C terminal)
Measured items Measurement Factory specification
Coil Terminal 3 - Terminal 5 Conduction
Terminal 1 - Terminal 2 Infinity
Terminal
(1) Starter Relay

9Y1210019ELS0006US0
Engine Start Conditions
Part for inspection Conditions

Main shift lever Neutral (Safety switch : Conduction)
Threshing clutch lever OFF (Thresher safety switch : Conduct)
(2) Threshing Clutch Lever (3) Main Shift Lever

9Y1210019ELS0007US0
8-S2

Main Switch
52200-99510 starter switch
(1) Main Switch

9Y1210019ELS0008US0
8-S3

[3] CHARGING DEVICE

Alternator (Built-in IC Regulator)
Power supply to B terminal
1. Remove the B terminal wire (A) of the alternator (4).
2. If the following measured voltage is the same as that for the
battery voltage (11 to 14 V), the slow blow fuse and wire
harness are operating normally.
Measured item (+) (−) Factory specification
Power supply to B B terminal Machine Approx. 12 V
terminal wire (A) body (Main switch: off)
(1) B Terminal (A) Red (B Terminal Wire)

(2) Connector (B) Brown / White (IG Terminal Wire)
(3) Voltmeter (C) Yellow / Red (L Terminal Wire)
(4) Alternator
Power supply for IG terminal

1. Remove the connector (2) of the alternator (4).
battery voltage (11 to 14 V), the fuse and wire harness are
operating normally.
IG terminal wire
Power supply for IG (B) (brown / Machine Approx. 12 V
terminal white) wire body (Main switch: on)
harness side
Charge alarm lead wire (L terminal)

1. Remove the connector (2) of the alternator (4).
battery voltage (11 to 14 V), the wire harness is operating
normally.
L terminal wire
Charge alarm lead (C) (yellow / red) Machine Approx. 12 V
wire wire harness body (Main switch: on)
side

(4) Alternator
(To be continued)
8-S4

(Continued)
Voltage generated without load
1. Connect the B terminal wire (A) and the connector (2) of the
alternator (4) as before.
2. Connect the B terminal (1) to the IG terminal wire (B) with other
lead wire (5).
3. Start the engine and idle it.
4. Disconnect the battery ground cable.
5. If the following measured voltage is higher than 14 V, it is
normal.
Voltage generated B terminal Machine Higher than 14 V
without load (1) body (Engine: idling)

(4) Alternator
(5) Lead Wire
9Y1210019ELS0009US0
[4] LIGHT DEVICE

Light Switch
56713-41220 combination switch
(1) Light Switch (3) White / Red

(2) White (4) Red / White
9Y1210019ELS0010US0
8-S5

[5] RELAY
Work Light Relay, Starter Relay, Dust Discharge Fan Relay
5H276-41250 relay (C terminal)
Measured items Measurement Factory specification
Coil Terminal 3 - Terminal 5 Conduction
Terminal 1 - Terminal 2 Infinity
Terminal
(1) Work Light Relay (3) Dust Discharge Fan Relay

(2) Starter Relay
9Y1210019ELS0011US0
[6] SENSOR
Tailings Reprocessing Auger Rotation Detection Sensor
5K200-71130 sensor assembly (rotation)
Measurement Factory specification
4 times of ON and OFF per one
Terminal 1 - Terminal 2
rotation of sensor shaft
(1) Tailings Reprocessing Auger

Rotation Detection Sensor
9Y1210019ELS0012US0
Safety Switch (Main Shift Lever Neutral Switch)

Back Switch
52320-42882
Switch condition Measurement Factory specification
Push Terminal 1 - Terminal 2 Conduction
Free Terminal 1 - Terminal 2 Infinity
(1) Back Switch (2) Safety Switch

(Main Shift Lever Neutral Switch)
9Y1210019ELS0013US0
8-S6

Threshing Clutch Switch, Thresher Safety Switch
59700-42882
Switch Factory
Measured items Measurement
condition specification
Terminal 2 - Push Infinity

Threshing clutch switch
Terminal 4 Free Conduction
Terminal 1 - Push Conduction

Thresher safety switch
Terminal 3 Free Infinity
(1) Threshing Clutch Switch (A) Normal Close

Thresher Safety Switch (B) Normal Open
9Y1210019ELS0014US0
Water Temperature Sensor

59700-42250
Measured items Factory specification
More than 115 ± 3 °C : Conduction
Sensor terminal - Machine body
Less than 108 °C : Infinity
(1) Water Temperature Sensor

9Y1210019ELS0015US0
Engine Oil Pressure Switch

1A024-39010
Measured items Factory specification
When engine is stopped : Conduction
Switch terminal - Machine body
When engine is in operation : Infinity
(1) Engine Oil Pressure Switch

9Y1210019ELS0016US0
Horn Switch
38240-32410
(1) Horn Switch

9Y1210019ELS0017US0
8-S7

Grain Full Sensor
58062-11370
(1) Grain Full Sensor

9Y1210019ELS0018US0
[7] HORN, BUZZER

Horn, Electronic Buzzer
54711-41554
Measured
Measurement Factory specification
Item
Horn Terminal 1 - Terminal 2 Approx. 5 Ω
Connect the battery (+) terminal to
the electronic buzzer (+) (red wire)
with other lead wire, and connect
Electronic the battery (−) terminal to the
Terminal 1 - Terminal 2
buzzer electronic buzzer (−) (black wire)
with other lead wire to confirm that
the electronic buzzer sounds
continuously
(1) Horn (2) Electronic Buzzer

9Y1210019ELS0019US0
Back Buzzer
32751-96860
1. Connect the battery (+) terminal to the back buzzer (+) (red
wire) with other lead wire, and connect the battery (−) terminal
to the back buzzer (−) (black wire) with other lead wire to
confirm that the back buzzer sounds intermittently.
(1) Back Buzzer
9Y1210019ELS0020US0
[8] ALARM UNIT

Alarm Unit
5H470-31721
1. The alarm unit (1) can not inspect using the normal electric
circuit tester. If there is the abnormal action on the alarm
system, inspect the wires or the sensors that are connected to
the alarm unit. If there are normal, change the new alarm unit,
and then re-inspect.
(1) Alarm Unit
9Y1210019ELS0021US0
8-S8

9 ENGINE

GENERAL
CONTENTS
1. SPECIFICATIONS...................................................................................................................... 9-G1
2. TIGHTENING TORQUE ............................................................................................................. 9-G2
3. SPECIAL TOOLS ....................................................................................................................... 9-G3

DC-60-PH, WSM ENGINE
1. SPECIFICATIONS
Model V2403-M-DI-TE2-CKMS1
Type Vertical type water-cooled 4-cycle diesel
Number of cylinders 4
Bore × stroke 87 × 102.4 mm
Total displacement 2.434 L
Type of combustion chamber Direct injection type
44.1 kW / 2700 rpm
Output
60 PS / 2700 rpm
Firing order 1-3-4-2
Rotation direction Counterclockwise (viewed from the flywheel side)
Fuel Injection Pump Bosch K type mini-pump
Primary valve opening pressure: 18.6 MPa (190 kgf/cm2)
Fuel injection pressure
Secondary valve opening pressure: 22.6 MPa (230 kgf/cm2)
Compression ratio 20.2
Fuel used Diesel fuel
Applicable lubricant Diesel Engine SAE15W-40 CF
Lubricant capacity 9L
Coolant capacity 8.5 L
Dry weight 188 kg
Starting system Electric starting with starter motor
Starter motor 12 V 2.0 kW
(Electrical) charging generator 12 V 720 W
9Y1210325END0001US0
9-G1

2. TIGHTENING TORQUE
Many screws and nuts used in the engine parts are specialized, and tightening torque significantly influences the
performance and durability of the engine. Make sure to use a torque wrench to properly tighten the screws and nuts
shown in the following table. When multiple screws and nuts are used to tighten a single part (e.g., cylinder head),
apply half the prescribed torques first for temporary tightening, then tighten using the prescribed torques.
Screw diameter × Tightening torque

Tightening locations
pitch (mm) N·m kgf·m
* Cylinder head cover M6 × 1.0 6.87 to 11.27 0.7 to 1.15
Cylinder head M11 × 1.25 93.17 to 98.06 9.5 to 10.0
Main bearing case 1 M9 × 1.25 46.1 to 50.99 4.7 to 5.2
Main bearing case 2 M10 × 1.25 68.65 to 73.54 7.0 to 7.5
Flywheel M12 × 1.25 98.1 to 107.9 10.0 to 11.0
Connecting rod M8 × 1.0 44.13 to 49.03 4.5 to 5.0
Rocker arm bracket M8 × 1.25 23.54 to 27.45 2.4 to 2.8
Idle gear shaft M8 × 1.25 23.54 to 27.45 2.4 to 2.8
Bearing case cover M8 × 1.25 23.54 to 27.45 2.4 to 2.8
* Engine oil pressure switch PT 1/8 14.7 to 19.61 1.5 to 2.0
Injection pipe nut M12 × 1.25 24.6 to 34.3 2.5 to 3.5
* Glow plug M10 × 1.25 14.71 to 19.61 1.5 to 2.0
* Glow plug wire M4 × 0.7 0.99 to 1.76 0.1 to 0.18
* Injection nozzle clamp M10 × 1.25 25.5 to 29.4 2.6 to 3.0
Crankshaft nut M30 × 1.5 137.3 to 156.9 14.0 to 16.0
Alternator pulley – 39.3 to 53.9 4.0 to 5.5
Apply the engine oil to the whole body (the screws and seating surface) of screws and nuts marked with a * sign, and
tighten them.
9Y1210019END0002US0
Tightening torques for the standard screws, the nuts and the plugs not described above
Tightening torque
Screw size Factory specification Allowable range
N·m kgf·m N·m kgf·m
M4 T7 2.0 0.2 1.57 to 2.25 0.16 to 0.23
M5 T7 3.4 0.35 2.85 to 4.02 0.29 to 0.41
M6 T7 11 1.1 9.81 to 11.27 1.0 to 1.15
M8 T7 25 2.6 23.54 to 27.45 2.4 to 2.8
M10 T7 52 5.3 49.04 to 55.89 5.0 to 5.7
M12 T7 84 8.6 77.5 to 90.2 7.9 to 9.2
M14 T7 137 14 123.6 to 147.0 12.6 to 15.0
R1/8 11 1.1 9.81 to 11.76 1.0 to 1.2
R3/8 34 3.5 29.5 to 39.2 3.0 to 4.0
R1/2 64 6.5 58.9 to 68.6 6.0 to 7.0
9Y1210019END0003US0
9-G2

3. SPECIAL TOOLS
Compression Tester for Diesel Engine
Code No.
• 07909-39081 (Assembly)
• Adaptor L code No. : 07909-31301
• Adaptor K code No. : 07909-31291
• Adaptor M code No. : 07909-31311
Application
• To measure the compression pressure (for the glow plug)
(1) Gauge (4) Adaptor K
(2) Hose (5) Adaptor L
(3) L joint (6) Adaptor M
9Y1210019END0004US0
Oil Pressure Tester for Engine
Code No.
• 07916-32032
Application
• To measure the lubricant pressure
(1) Gauge (5) Adaptor 2
(2) Cable (6) Adaptor 3
(3) Screw joint (7) Adaptor 4
(4) Adaptor 1 (8) Adaptor 5
9Y1210019END0005US0
Valve Guide Replacing Tool

Application
• To press out and press fit the valve guide
Material
• Steel (S43C)
A 20 mm dia.
B 11.7 to 11.9 mm dia.
C 6.5 to 6.6 mm dia.
D 225 mm
E 70 mm
F 45 mm
G 25 mm dia.
H 5 mm
I 6.7 to 7.0 mm dia.
J 20 mm dia.
K 12.5 to 12.8 mm dia.
L 8.9 to 9.1 mm
C1 Chamfer 1.0 mm
C2 Chamfer 2.0 mm
C0.3 Chamfer 0.3 mm
9Y1210019END0006US0
9-G3

Crankshaft Sleeve Placement Tool
Code No.
• 07916-32091
Application
• To fix the crankshaft sleeve
Material
• Steel (SC43C)
(1) Stopper (3) Crankshaft Sleeve
(2) Sleeve Guide (4) Insertion Socket
9Y1210019END0007US0
Idle Gear Bushing Replacing Tool

Application
• To press out and press fit the idle gear bushing
Material
• Steel (S43C)
A 162 mm
B 35 mm
C 27 mm
D 35 mm dia.
E 27.90 to 27.95 mm dia.
F 25.00 to 25.01 mm dia.
9Y1210019END0008US0
Connecting Rod Small End Bushing Replacing Tool
Application
• To press out and press fit the small end bushing
Material
• Steel (S43C)
A 175 mm
B 40 mm
C 38 mm
D 45.0 mm dia.
E 41.90 to 41.95 mm dia.
F 37.95 to 37.97 mm dia.
9Y1210019END0009US0
9-G4

Crankshaft Metal 1 Replacing Tools
[1] For removing
Application
• To press out the idle gear bushing
Material
• Steel (S43C)
A 135 mm
B 72 mm
C 40 mm radius
D 10 mm
E 20 mm
F 20 mm dia.
G 64.8 to 64.9 mm dia.
H 59.8 to 59.9 mm dia.
[2] For press-fitting
Application
• To press fit the idle gear bushing
Material
• Steel (S43C)
A 130 mm
B 72 mm
C 40 mm radius
D 9 mm
E 4 mm
F 20 mm
G 20 mm dia.
H 68 mm dia.
I 59.8 to 59.9 mm dia.
J 64.8 to 64.9 mm dia.
9Y1210019END0010US0
9-G5

MECHANISM
CONTENTS
1. ENGINE BODY........................................................................................................................... 9-M1

[1] HEAD COVER...................................................................................................................... 9-M1
[2] COMBUSTION CHAMBER .................................................................................................. 9-M1
[3] CRANKCASE ....................................................................................................................... 9-M1
[4] PISTON AND PISTON RINGS ............................................................................................. 9-M2
2. LUBRICATING SYSTEM............................................................................................................ 9-M3
[1] GENERAL ............................................................................................................................ 9-M3
[2] OIL PUMP ............................................................................................................................ 9-M3
[3] RELIEF VALVE .................................................................................................................... 9-M4
[4] OIL COOLER........................................................................................................................ 9-M4
[5] ENGINE OIL PRESSURE SWITCH ..................................................................................... 9-M4
3. COOLING SYSTEM ................................................................................................................... 9-M5
[1] GENERAL ............................................................................................................................ 9-M5
[2] BOTTOM BYPASS SYSTEM ............................................................................................... 9-M6
4. FUEL SYSTEM........................................................................................................................... 9-M7
[1] GENERAL ............................................................................................................................ 9-M7
[2] FUEL INJECTION PUMP ..................................................................................................... 9-M7
[3] FUEL INJECTION NOZZLE ................................................................................................. 9-M8
[4] GOVERNOR......................................................................................................................... 9-M8
5. INTAKE / EXHAUST SYSTEM ................................................................................................... 9-M9
[1] TURBOCHARGER ............................................................................................................... 9-M9

1. ENGINE BODY
[1] HEAD COVER
Cylinder Head Cover
The cylinder head cover (1) is lifted by the rubber
packing (2) approx. 0.5 mm from the cylinder head to
reduce the noise of combustion from the cylinder head.
(1) Cylinder Head Cover (2) Rubber Packing
9Y1210019ENM0002US0
[2] COMBUSTION CHAMBER

Combustion Chamber
Direct injection type is used as the combustion
method, and a reentrant-shaped combustion chamber is
located at the top of the piston (3). Compressed intake
air generates excess flow (swirl) along the side of this
combustion chamber to produce stable and good
combustion by uniform fuel atomization.
(1) Injection Nozzle (3) Piston
(2) Combustion Chamber
9Y1210019ENM0003US0
[3] CRANKCASE
Crankcase
The tunnel type of the crankcase with unitary
construction provides great rigidity to the crankshaft
bearing.
The crankcase has a hollow core (1) of cooling water
passage already cast inside the cylinder-to-cylinder
water jacket. It has improved the cooling performance by
flowing smoother cooling water.
(1) Hollow Core
9Y1210019ENM0004US0
9-M1

[4] PISTON AND PISTON RINGS

Piston and Piston Rings
The reentrant-shaped combustion chamber is
formed at the top of the piston to generate squish for a
better mixing of the atomized fuel.
The 2 struts molded into the piston are designed to
reduce slap noise by minimizing the piston diameter
change due to thermal expansion, which contributes to
an overall noise level reduction.
The piston is coated with the molybdenum disulfide
around the skirt, causing the high familiar of the piston
and cylinder to prevent burning.
• The top ring is a plane type with the surface treated
by the gas nitriding reaction (GNR) and has a barrel
face (arc-shaped) whose sliding surface fits well with
the cylinder wall.
• The second ring is an inner-cut type, and hard
chrome plating is applied to the outer circumference.
• The oil ring is a narrow-face type (a ring with narrow
contact surface) with the surface treated by gas
nitriding reaction (GNR) to provide proper oil control
using shapes that can follow the oscillation
movement.
(1) Top Ring (4) Second Ring (Turbo)
(2) Second Ring (5) Offset
(3) Oil Ring
9Y1210019ENM0005US0
9-M2

2. LUBRICATING SYSTEM
[1] GENERAL
General of Lubricating System
(1) Rocker Arm

(2) Engine Oil Pressure Switch
(3) Rocker Arm Shaft
(4) Valve
(5) Idle Gear
(6) Crankshaft
(7) Oil Pump
(8) Oil Strainer
(9) Relief Valve
(10) Push Rod
(11) Tappet
(12) Camshaft
(13) Piston
(14) Connecting Rod
(15) Oil Cooler
(16) Engine Oil Filter Cartridge
(17) Piston Pin
The engine oil lubricates friction parts after the oil strainer (8) removes large dirt, the oil pump (7) pumps it up,
and the engine oil filter cartridge (16) removes foreign objects.
The lubrication of friction parts is performed using the forced-feed lubrication by the oil pump (7) and the splash
lubrication by the leaked oil from the forced-feed parts.
The forced-feed lubrication is employed for the crankshaft (6), the connecting rod (14), the camshaft (12), the
rocker arm shaft (3), the idle gear (5) and the turbocharger. The splash lubrication is employed for the piston pin (17),
the fuel camshaft, the tappet (11) and the push rod (10).
9Y1210019ENM0020US0
[2] OIL PUMP

Oil Pump
The oil pump utilizes a trochoid pump and is driven
by the crankshaft.
The inner rotor (3) has 4 gears and the outer rotor (4)
5 gears, and these gears are eccentrically meshed. The
inner rotor (3) is driven by the oil pump drive shaft and
rotates the outer rotor (4) in the same direction. This
rotation causes a volume change of the portion
surrounded by the rotors' gears to perform the pumping
action.
(1) Outlet Port (3) Inner Rotor
(2) Inlet Port (4) Outer Rotor
9Y1210019ENM0007US0
9-M3

[3] RELIEF VALVE

Relief Valve
Fed by the oil pump, the engine oil is supplied to
each part after filtration by the filter element (2) of the
engine oil filter cartridge.
Prior the engine oil filter cartridge, the relief valve (3)
is provided to keep the oil pressure constant and vent the
excess oil to the oil pan.
The oil comes in from the outer circumference
surface of the filter element (2) and goes through the
inside.
The bypass valve (1) is installed inside the engine oil
filter cartridge so that the engine oil can run bypassing
the filter element when the passage resistance
increases to 98 kPa (1 kgf/cm2) due to a clogged dirty
filter element (2).
(1) Bypass Valve (4) Relief Valve Cover
(2) Filter Element (5) Relief Valve Spring
(3) Relief Valve
9Y1210019ENM0008US0
[4] OIL COOLER

Oil Cooler
The unit is equipped with a water-cooled oil cooler
(1).
The oil cooler provides proper lubrication by
reducing the rise of the oil temperature during engine
operation. The oil runs inside the cooler plate and is
cooled down as the coolant runs outside the cooler plate.
(1) Oil Cooler
9Y1210019ENM0009US0
[5] ENGINE OIL PRESSURE SWITCH

Engine Oil Pressure Switch
When the oil pressure falls to 49 kPa (0.5 kgf/cm2) or
lower, the engine oil pressure switch is activated to turn
ON the warning light by creating an electrical circuit.
(1) Engine Oil Pressure Alarm (6) Rubber
Light (7) Hydraulic Pressure
(2) Battery
(3) Lubricant Path (A) Engine Not Running
(4) Crankcase (B) Engine Running
(5) Contact Rivet
9Y1210019ENM0010US0
9-M4

3. COOLING SYSTEM
[1] GENERAL
General of Cooling System
The engine cooling system uses a forced-feed circulation type operated by the water pump (2). The coolant
temperature is properly maintained by the thermostat (4). The coolant, which is sucked in from the lower tank of the
radiator (1) by the water pump (2), cools the cylinders and combustion chamber as it runs through the water jacket in
the crankcase (6) and the cylinder head (5) before returning to the radiator (1).
Further, a bottom bypass system is used to improve cooling performance. When the coolant temperature is low
in the engine, the thermostat (4) is kept closed, and the coolant directly enters the pump, bypassing the radiator (1)
via the bypass pipe to help raise the temperature by circulating within the engine.
When the coolant temperature reaches the valve opening temperature (71 °C), the thermostat (4) will open to let
the coolant run through the radiator (1) to perform cooling.
(1) Radiator
(2) Water Pump
(3) Fan
(4) Thermostat
(5) Cylinder Head
(6) Crankcase
9Y1210019ENM0011US0
9-M5

[2] BOTTOM BYPASS SYSTEM

Bottom Bypass System
When the coolant temperature is low in the engine,
the thermostat (1) is kept closed to let the coolant
circulate within the engine via the bypass pipe (2).
Therefore the coolant reaches quickly to proper
temperature so that it prevents from the wearing of each
engine part by the engine over-cooling. When the
coolant temperature reaches the valve opening
temperature at the thermostat (1), the thermostat (1) will
gradually open as the bypass pipe (2) circuit closes so
that the full volume of hot coolant runs through the
radiator to keep the cooling performance of the engine.
(1) Thermostat (A) Thermostat Closed
(2) Bypass Pipe (B) Thermostat Open
9Y1210019ENM0012US0
9-M6

4. FUEL SYSTEM
[1] GENERAL
General of Fuel System
The fuel feed pump (7) performs the fuel suction from the fuel tank (1) through the water separator (5) and the
fuel filter cartridge (6) to send the fuel injection pump (4).
The fuel injection pump (4) subsequently pressurizes fuel to the fuel injection nozzles (3) in accordance with the
fuel injection timing of each cylinder in the engine, and injects fuel to the combustion chamber.
(1) Fuel Tank (3) Fuel Injection Nozzle (5) Water Separator (Sedimenter) (7) Fuel Feed Pump
(2) Fuel Return Pipe (4) Fuel Injection Pump (6) Fuel Filter Cartridge
9Y1210019ENM0013US0
[2] FUEL INJECTION PUMP

Fuel Injection Pump
The fuel injection pump uses a Bosch K type
mini-pump that is small, lightweight, and reliable. As
shown in the figure, the structure comprises the plunger
(9), the tappet (1), the control rack (2), and the delivery
valve (7), etc.
The dumping valve (5) provided in the delivery valve
holder (3) allows a stable fuel injection from idling to the
maximum revolution without irregular injection,
cavitation or secondary injection.
(1) Tappet (7) Delivery Valve
(2) Control Rack (8) Cylinder
(3) Delivery Valve Holder (9) Plunger
(4) Dumping Valve Spring (10) Pump Element
(5) Dumping Valve (11) Control Sleeve
(6) Delivery Valve Spring (12) Plunger Spring
9Y1210019ENM0014US0
9-M7

[3] FUEL INJECTION NOZZLE

Direct Injection Type
The fuel injection nozzle uses 2 springs type nozzle
that is effective in reducing the nitrogen oxides (Nox) and
the particulate matter. Further, 2 springs type nozzle is
designed to improve the low and medium speed stability
and reduce the noise level.
As shown in the figure, 2 nozzle springs are provided
for each push rod in this structure. There is a clearance
of pre-lifted (A) between No.1 push rod (2) and No.2
push rod (5), which allows fuel injection to occur in 2
phases.
The nozzle operates as follows :
1. When the fuel pressure in the nozzle (1) rises to the
valve opening pressure according to No.1 spring (3),
the nozzle (1) will be lifted by the amount of the
pre-lifted (A) to initiate fuel injection (throttle
injection).
2. If the fuel pressure in the nozzle (1) continues to
increase beyond the combined pressure of No.1
spring (3) and No.2 spring (4), the nozzle (1) will be
fully lifted (B) to start main fuel injection.
(1) Nozzle (A) Pre-lifted
(2) No.1 Push Rod (B) Fully Lifted
(3) No.1 Spring
(4) No.2 Spring
(5) No.2 Push Rod
9Y1210019ENM0015US0
[4] GOVERNOR
Governor
The engine uses a mechanical all-speed governor
that utilizes the balance between the centrifugal force of
the steel ball (6) and the tension of the governor spring 1
(4), 2 (3), and the fuel injection amount is controlled
across the rotation range from idling to the maximum
revolution.
The torque spring (7) is built in the fork lever 1 (1)
and contributes to a mechanical toughness with higher
torque under an overload situation by increasing the fuel
injection amount.
(1) Fork Lever 1 (5) Maximum Speed Adjustment
(2) Fork Lever 2 Screw
(3) Governor Spring 2 (6) Steel Ball
(4) Governor Spring 1 (7) Torque Spring
(8) Control Rack
9Y1210019ENM0016US0
9-M8

5. INTAKE / EXHAUST SYSTEM

[1] TURBOCHARGER
Turbocharger
(1) Lock Nut

(2) Thrust Bearing
(3) Snap Ring
(4) O-ring
(5) Thrust Sleeve
(6) Piston Ring
(7) Turbine Wheel
(8) Turbine Housing
(9) Waste Gate Actuator
(10) Compressor Wheel
(11) Piston Ring
(12) Oil Deflector
(13) Bearing
(14) Snap Ring
9Y1210019ENM0017US0
Turbocharger Body
The turbocharger comprises the turbine housing (8), the turbine wheel (7), the compressor housing, the
compressor wheel (10), and bearing housing, etc.
The turbocharger is mounted to the exhaust manifold, and the exhaust gas is accelerated and blown against the
turbine wheel (7) as it enters the turbine housing (8) to rotate the turbine wheel (7). When the turbine wheel (7) rotates,
the compressor wheel (10) that is installed on the same shaft will rotate simultaneously to compress and supply the
air to the combustion chamber.
As the turbine wheel (7) and the compressor wheel (10) rotate approx. 200000 times max. on the same shaft,
they are supported by a full floating type bearing, and a thrust bearing (2) is provided to receive the axial load.
The lubrication for the bearings is operated by the diversion of lubricants from the lubricants passage to the
bearing housing ; the lubricants subsequently return to the oil pan.
9Y1210019ENM0018US0
Boost Control
This turbocharger is equipped with the waste gate system that controls boost at the high revolutions.
To exert the effect of the turbocharger at low and medium speeds, the system is designed to improve the torque
at low and medium speeds by operating at high revolutions to increase the boost, and supply a large volume of air to
the combustion chamber.
If the engine revolution speed keeps increasing in this condition, however, the durability of the engine and the
turbine may be compromised due to the excessive increase of the boost. When the boost reaches the set pressure,
the release control system is activated by making the boost bypass the turbine of the exhaust gas.
9Y1210019ENM0019US0
9-M9

SERVICING
CONTENTS
1. TROUBLESHOOTING.................................................................................................................9-S1
2. SERVICING SPECIFICATIONS (V2403-M-DI-T)........................................................................9-S6
3. ENGINE BODY..........................................................................................................................9-S11
[1] SEPARATING ENGINE.......................................................................................................9-S11
[2] CHECKING AND ADJUSTMENT ........................................................................................9-S14
(1) Valve Clearance ............................................................................................................9-S14
(2) Compression Pressure ..................................................................................................9-S15
[3] DISASSEMBLING AND ASSEMBLING ..............................................................................9-S15
(1) Cylinder Head and Valve...............................................................................................9-S15
(2) Fuel Injection Pump.......................................................................................................9-S20
(3) Gear Case .....................................................................................................................9-S23
(4) Timing Gear and Camshaft ...........................................................................................9-S24
(5) Piston and Connecting Rod...........................................................................................9-S25
(6) Crankshaft .....................................................................................................................9-S28
[4] SERVICING .........................................................................................................................9-S31
(1) Cylinder Head................................................................................................................9-S31
(2) Timing Gear...................................................................................................................9-S35
(3) Piston, Connecting Rod and Crankshaft .......................................................................9-S37
(4) Crankcase .....................................................................................................................9-S43
4. LUBRICATING SYSTEM...........................................................................................................9-S45
[1] CHECKING..........................................................................................................................9-S45
[2] SERVICING .........................................................................................................................9-S45
(1) Oil Pump........................................................................................................................9-S45
5. COOLING SYSTEM ..................................................................................................................9-S47
[1] CHECKING..........................................................................................................................9-S47
[2] DISASSEMBLING, ASSEMBLING AND SERVICING ........................................................9-S47
6. FUEL SYSTEM..........................................................................................................................9-S49
[1] FUEL INJECTION NOZZLE ................................................................................................9-S49
(1) Checking and Adjustment..............................................................................................9-S49
[2] FUEL INJECTION PUMP ....................................................................................................9-S50
(1) Checking and Adjustment..............................................................................................9-S50
7. ELECTRICAL SYSTEM.............................................................................................................9-S51
[1] STARTER MOTOR .............................................................................................................9-S51
(1) Disassembling and Assembling.....................................................................................9-S51
(2) Servicing........................................................................................................................9-S51
[2] ALTERNATOR ....................................................................................................................9-S53
(1) Disassembling and Assembling.....................................................................................9-S53
(2) Checking and Maintenance ...........................................................................................9-S55
8. TURBOCHARGER ....................................................................................................................9-S58
[1] CHECKING..........................................................................................................................9-S58
[2] COMPLETE REPLACEMENT OR REASSEMBLY .............................................................9-S59

1. TROUBLESHOOTING
Reference
Symptom Probable Cause Solution
Page
The Engine Does Not Engine body
Start Incorrect valve clearance (low compression Adjust valve 9-S14
pressure) clearance
Compression leakage from the cylinder to the Replace the cylinder 9-S17
outside (low compression pressure) head gasket
Tighten the cylinder 9-S15 to
head bolt, the glow 9-S17
plugs and the fuel
injection nozzle
holders
Compression leakage in the combustion Replace the piston 9-S27
chamber (low compression pressure) rings
Incorrect valve timing (low compression Inspect the timing 9-S24
pressure) gear
Incorrect valve seat contact Replace the valve 9-S19
spring
Repair the valve seat 9-S33 to
contact 9-S34
Seizure the crankshaft, the camshaft, the piston, Repair or replace 9-S24,
or the bearing 9-S29
Increased combustion chamber volume (low Correct the valve 9-S31
compression pressure) recessing amount
Fuel system
No fuel (in the fuel tank and the fuel pipe) Fill up the fuel –
The fuel with high viscosity is used Replace with the –
designated fuel
The fuel with low cetane number is used Replace with the –
designated fuel
The water is mixed in the fuel Replace with the –
designated fuel
The fuel filter cartridge is clogged Replace the fuel filter 1-S20
cartridge
Fuel leakage from the fuel injection pipe nut Tighten the nut 9-S16
The fuel pipe is clogged Clean or replace –
Defective the fuel injection nozzle Replace 9-S16,
9-S50
Incorrect fuel injection timing Adjust 9-S50
The fuel injection pump is defective Replace assembly 9-S20,
9-S50
The engine stop wire is defective Inspect and adjust or 1-S31
replace
Electrical system
Low battery capacity Replace with the –
battery with the
designated capacity
Battery over-discharge Charge or replace –
9-S1

Reference
Page
The Engine Does Not The starter motor is defective Repair or replace 9-S51 to
Start 9-S53
Defective or faulty wiring Inspect and repair –
Defective the main switch Repair or replace –
Blown the fuse Replace after solving –
problem
Fuel system
The control rack of fuel injection pump is fixed Repair the fuel 9-S20,
injection pump or 9-S50
replace assembly
Electrical system
The Engine Speed is Intake / exhaust system
Irregular, and the The air cleaner is clogged Clean the air cleaner 1-S19
Exhaust Gas is White element using the
or Blue compressed air, or
replace
Fuel system
cartridge
Fuel leakage from the fuel injection pipe nut Tighten the nut 9-S16
The fuel injection nozzle is defective Replace 9-S16,
9-S50
The fuel return pipe is clogged Correct the bend or –
clean
The fuel injection pump is defective Replace assembly 9-S20,
9-S50
Engine body
The piston ring and the piston are worn out Replace the piston 9-S27,
ring and the piston 9-S38
Worn cylinder Repair the cylinder 9-S43
Increased combustion chamber volume (low Correct the valve 9-S31
compression pressure) recessing amount
Lubricating system
The oil is oversupplied Reduce oil to the –
specified amount
Fuel system
The fuel injection timing is incorrect Adjust 9-S50
Intake / exhaust system
The oil return pipe is deformed or clogged Inspect and clean or –
replace the oil return
pipe
9-S2

Reference
Page
The Exhaust Gas is Engine body
Black or Dark Gray, Overload Reduce the load –
or the Output is
Shortage Compression leakage from the cylinder to the Tighten the cylinder 9-S16,
outside head bolts, the glow 9-S17
plugs and the fuel
injection nozzle
holders
The engine moving parts (piston and crank) are Repair or replace –
slightly seizured
Fuel system
The low grade fuel is used Replace with the –
designated fuel
cartridge
The fuel atomizing state is incorrect Replace the fuel 9-S16,
injection nozzle 9-S49
assembly
The fuel injection amount is not uniform Replace the fuel 9-S20,
injection pump 9-S50
assembly
Intake / exhaust system
The air cleaner is clogged Clean or replace the 1-S19
air cleaner element
The Engine Oil is Engine body
Overconsumed Oil leakage from the tightening points and plugs Tighten to the –
prescribed torque
The crankshaft oil seal, O-ring or the gasket are Replace –
defective
The valve stem seal is defective Replace the seal 9-S19
The Piston ring gaps are set to the same Change the gaps 9-S26 to
direction direction 9-S27
The oil ring is worn out or stuck Replace 9-S26 to
9-S27
The piston ring groove is worn out Replace the piston 9-S26,
and the piston rings 9-S27,
9-S29
The Fuel is Mixed in Fuel system
the Engine Oil The fuel injection pump is defective Replace the fuel 9-S20,
injection pump 9-S50
assembly
The Water is Mixed in Engine body
the Engine Oil The cylinder head gasket is broken Replace 9-S17
The cylinder head is cracked Replace 9-S17
The o-ring and the packing in the water passage Replace 9-S23
between the gear case and the crankcase are
damaged
9-S3

Reference
Page
The Engine Oil Lubricating system
Pressure is Low The Oil is shortage Replenish the oil to 1-S11
the specified amount
Poor oil quality Replace with the 1-S11
designated oil
The Oil filter cartridge is clogged Replace the oil and 1-S20
the oil filter cartridge
The relief valve is defective Repair or replace 9-S45
The oil clearance is excessive in metals Replace the metal, 9-S38 to
the bushing or the 9-S42
shaft
The oil passage is clogged Clean –
The oil pump is defective Replace 9-S45 to
9-S46
The assembly of oil hole and plug is defective or Inspect and repair –
failed
The Engine Oil Lubricating system
Pressure is High Low oil temperature Keep operating until –
the oil temperature
rises
Poor oil quality Replace with the –
designated oil
The relief valve is defective Repair or replace 9-S45
Engine Overheating Cooling system
The fan belt is loose or cut Adjust or replace 1-S23
The coolant is low Replenish to the 1-S17
specified amount
The radiator net and the radiator fin are clogged Clean –
The coolant is dirty Replace the coolant 1-S17
The radiator and the radiator cap are defective Inspect and replace 9-S47
The cooling water passage is clogged Clean –
The cooling air passage is insufficient Make sure of –
sufficient cooling air
passage
The thermostat is defective Replace 9-S47
The mechanical seal of the water pump is Replace 9-S48
defective
9-S4

Reference
Page
Engine Overheating Engine body
Continuous overload operation Reduce the load –
The cylinder head gasket is broken Replace 9-S17
(decreased coolant)
The tightening of the cylinder head bolt is Tighten with the 9-S17
insufficient prescribed torque
Lubricating system
The oil is shortage Replenish oil to the 1-S11
specified amount
Fuel system
The low grade fuel is used Replace with the –
designated fuel
The Battery Electrical system
Discharge is Too The fan belt is loose Adjust or replace 1-S23
Much
Deteriorated battery Replace –
The electrolytes is shortage Supply the distilled –
water and electrical
charging
The alternator and the regulator are defective Repair or replace 9-S53 to
9-S57
The Charge Lamp Electrical system
Does Not Light Up Defective or faulty wiring Inspect and repair –
9-S57
Blown fuse Replace –
The Charge Alarm Electrical system
Lamp Does Not Turn The fan belt is loose or cut Adjust or replace 1-S23
OFF
9-S57
9Y1210552ENS0001US0
9-S5

2. SERVICING SPECIFICATIONS (V2403-M-DI-T)

ENGINE GENERAL ITEMS
Item Factory specification Allowable limit
Maximum bare revolution speed 2920 rpm or less –
Minimum bare idling revolution speed 1100 to 1150 rpm –
Compression pressure (when you crank the engine with the 2.94 to 3.24 MPa 2.35 MPa
starter motor : 250 to 270 rpm) 30 to 33 kgf/cm2 24 kgf/cm2
Compression pressure: Difference among cylinders – 10 % or less
98 kPa or more
At idle speed –
Engine oil pressure 1.0 kgf/cm2 or more
(oil temperature 85 °C to 95 °C) 294 to 441 kPa 245 kPa
At rated speed
3.0 to 4.5 kgf/cm2 2.5 kgf/cm2
Valve clearance (when cold) 0.18 to 0.22 mm –
Intake: Open 9 ° before T.D.C. –
Intake: Close 45 ° after B.D.C. –
Valve timing
Exhaust: Open 50 ° before B.D.C. –
Exhaust: Close 12 ° after T.D.C. –
6.00 ° to 7.50 °
Fuel injection timing –
before T.D.C.
No. 1 valve open 18.64 MPa
–
pressure 190 kgf/cm2
Fuel injection pressure
No. 2 valve open 22.55 MPa
–
pressure 230 kgf/cm2
Opening
temperature
69.5 to 72.5 °C –
(when the valve
starts to open)
Thermostat Opening
temperature
(when the valve 85 °C –
opened
completely)
Inspection of water leakage from radiator No water leakage at 137 kPa (1.4 kgf/cm2)
Maintain 59 kPa (0.6 kgf/cm2) or more for
Inspection of radiator cap 10 seconds after applying pressure to
88 kPa (0.9 kgf/cm2)
Deflection amount is approx. 7 to 9 mm
Fan belt tension when pushing 60 to 70 N (6 to 7 kgf)
at the center of belt
9Y1210019ENS0002US0
9-S6

CYLINDER HEAD
Flatness of cylinder head surface – 0.05 / 500 mm
Top clearance 0.60 to 0.70 mm –
Intake 2.12 mm –
Width of valve seat surface
Exhaust 2.12 mm –
Intake 60 ° –
Valve seat angle
Exhaust 60 ° –
Intake 45 ° –
Valve face angle
Exhaust 45 ° –
Intake 37.5 mm –
Outside diameter of valve head
Exhaust 32 mm –
Intake 0.65 to 0.85 mm 1.2 mm
Valve recessing
Exhaust 0.65 to 0.85 mm 1.2 mm
Clearance between valve stem and valve Intake 0.040 to 0.070 mm 0.1 mm
guide Exhaust 0.040 to 0.070 mm 0.1 mm
Intake 7.960 to 7.975 mm –
Outside diameter of valve stem
Exhaust 7.960 to 7.975 mm –
Intake 8.015 to 8.030 mm –
Inside diameter of valve guide
Exhaust 8.015 to 8.030 mm –
Valve spring
Intake 41.7 to 42.2 mm 41.2 mm
Free length
Exhaust 41.7 to 42.2 mm 41.2 mm
117.7 N / 35 mm 100 N / 35 mm
Intake
12.0 kg / 35 mm 10.2 kg / 35 mm
Setting load / setting length
117.7 N / 35.0 mm 100 N / 35.0 mm
Exhaust
12.0 kg / 35.0 mm 10.2 kg / 35.0 mm
Tilt – 1.0 mm
Oil clearance between rocker arm and rocker arm shaft 0.016 to 0.045 mm 0.1 mm
Inside diameter of rocker arm 14.000 to 14.018 mm –
Outside diameter of rocker arm shaft 13.973 to 13.984 mm –
9Y1210019ENS0003US0
TAPPET
Oil clearance between tappet and tappet guide 0.020 to 0.062 mm 0.07 mm
Inside diameter of tappet guide 24.000 to 24.021 mm –
Outside diameter of tappet 23.959 to 23.980 mm –
9Y1210019ENS0004US0
9-S7

TIMING GEAR
Idle gear and crank gear Backlash 0.0415 to 0.1122 mm 0.15 mm
Idle gear and cam gear Backlash 0.0415 to 0.1154 mm 0.15 mm
Idle gear and fuel camshaft gear Backlash 0.0415 to 0.1154 mm 0.15 mm
Crank gear and oil pump gear Backlash 0.0415 to 0.1090 mm 0.15 mm
Oil clearance between idle gear bushing and idle gear shaft 0.025 to 0.066 mm 0.10 mm
Inside diameter of idle gear bushing 38.000 to 38.025 mm –
Outside diameter of idle gear shaft 37.959 to 37.975 mm –
Side clearance of idle gear 0.12 to 0.48 mm 0.9 mm
9Y1210019ENS0005US0
CAMSHAFT
Oil clearance between camshaft journal and crankcase bore 0.050 to 0.091 mm 0.15 mm
Inside diameter of crankcase bore 40.000 to 40.025 mm –
Outside diameter of camshaft journal 39.934 to 39.950 mm –
Intake 33.90 mm 33.85 mm
Cam height
Exhaust 33.90 mm 33.85 mm
Bend of camshaft – 0.01 mm
Side clearance of camshaft 0.07 to 0.22 mm 0.3 mm
9Y1210019ENS0006US0
CRANKSHAFT AND FLYWHEEL
Oil clearance between crankshaft journal and
0.040 to 0.118 mm 0.2 mm
crankshaft bearing 1
Inside diameter of crankshaft bearing 1 59.980 to 60.039 mm –
Outside diameter of crankshaft journal 59.921 to 59.940 mm –
Oil clearance between crankshaft journal and
0.040 to 0.118 mm 0.2 mm
Inside diameter of crankshaft bearing 2 59.980 to 60.025 mm –
Outside diameter of crankshaft journal 59.921 to 59.940 mm –
Side clearance of crankshaft 0.15 to 0.31 mm 0.5 mm
Thickness of side metal 1.97 to 2.00 mm –
Oversize of side metal +0.2, +0.4 mm –
Bend of crankshaft – 0.02 mm
Face runout of flywheel – 0.15 mm
Oil clearance between crankpin and crankpin bearing 0.025 to 0.087 mm 0.2 mm
Outside diameter of crankpin 46.959 to 46.975 mm –
Inside diameter of crankpin bearing 47.000 to 47.046 mm –
Undersize of crankpin bearing −0.2, −0.4 mm –
9Y1210019ENS0007US0
9-S8

CONNECTING ROD
Oil clearance between connecting rod small end bushing and
0.014 to 0.038 mm 0.15 mm
piston pin
Inside diameter of connecting rod small end bushing 25.025 to 25.040 mm –
Outside diameter of piston pin 25.002 to 25.011 mm –
Bend and torsion (alignment) of connecting rod – 0.05 mm
9Y1210019ENS0008US0
PISTON AND PISTON RINGS
Oil Clearance between small end bushing and piston pin 0.014 to 0.038 mm 0.15 mm
Inside diameter of small end bushing 25.000 to 25.013 mm 25.05 mm
Outside diameter of piston pin 25.002 to 25.011 mm –
Ring clearance 0.25 to 0.35 mm 1.25 mm
Clearance
between piston
– –
Top ring ring and ring
groove
Ring thickness – –
Ring groove width – –
Clearance
between piston
0.093 to 0.128 mm 0.20 mm
Second ring ring and ring
groove
Ring thickness 1.942 to 1.962 mm –
Ring groove width 2.055 to 2.070 mm –
Clearance
between piston
0.020 to 0.060 mm 0.15 mm
Oil ring ring and ring
groove
Ring thickness 3.970 to 3.990 mm –
Ring groove width 4.010 to 4.030 mm –
9Y1210019ENS0009US0
CRANKCASE
Flatness of crankcase top surface – –
Inside diameter of cylinder 87.000 to 87.022 mm 87.17 mm
Difference between maximum worn part and minimum worn part
– 0.15 mm
of cylinder
Recessing 0.27 mm to
Piston recessing and projection –
projection 0.02 mm
9Y1210019ENS0010US0
9-S9

OIL PUMP
Clearance between inner rotor and outer rotor 0.03 to 0.14 mm 0.2 mm
Clearance between outer rotor and pump body 0.11 to 0.19 mm 0.25 mm
Clearance between inner rotor and cover 0.105 to 0.150 mm 0.2 mm
9Y1210019ENS0011US0
STARTER
Outside diameter of commutator 35 mm 34 mm
Elliptical angle of commutator outside diameter 0.02 mm 0.05 mm
Undercut of commutator mica 0.45 to 0.75 mm 0.2 mm
Length of brush 15.0 mm 9.0 mm
9Y1210019ENS0012US0
ALTERNATOR
Outside diameter of slip ring 14.4 mm 14.0 mm
Resistance of rotor coil 2.9 Ω –
Length of brush (protrusion length from brush holder) 10.5 mm 8.4 mm
9Y1210019ENS0013US0
GLOW PLUG
Resistance of glow plug Approx. 0.9 Ω –
9Y1210019ENS0014US0
9-S10

3. ENGINE BODY
[1] SEPARATING ENGINE
Separating Engine
1. Separate the reaper. (See page 2-S12.)
2. Separate the feeder convertor. (See page 2-S15.)
3. Remove the operator's seat.
4. Drain the engine oil.
5. Drain the coolant.
6. Drain the oil in the hydraulic oil tank.
7. Remove the fuel tank.
8. Disconnect the negative cable of the battery (1).
(1) Battery
9. Remove the traveling (transmission) drive belt (2) and the

thresher drive belt (3).
(2) Traveling (transmission) drive Belt (3) Thresher drive Belt
10. Open the dustproof cover (4), and remove the radiator net, the
dustproof cover stay, the grain bag hanger (5) and the front and
rear sides of the engine cover.
(4) Dustproof Cover (5) Grain Bag Hanger
11. Remove the mounting bolts of the engine frame (6) and remove
the engine frame (6).
(6) Engine Frame
(To be continued)
9-S11

(Continued)
12. Remove the radiator stay (8), and remove the radiator (7) after
removing the upper and lower radiator hoses.
(7) Radiator (8) Radiator Stay
13. Remove the fuel filter cartridge (9) and the water separator (10)
together with the stay (11) that mounts them.
(9) Fuel Filter cartridge (11) Stay
(10) Water Separator
14. Remove the wire harness of the glow plug.

15. Remove the engine acceleration wire (12).
16. Remove the engine stop wire (13).
17. Remove the hour meter cable (14).
18. Remove the hoses 1, 2 and 3 from the hydraulic pump.
(12) Engine Acceleration Wire (14) Hour Meter Cable
(13) Engine Stop Wire
19. Remove the wire harnesses of the alternator (16) and the starter
motor (17).
20. Remove the wire harnesses of the water temperature sensor
(15) and the engine oil pressure switch (18).
(15) Water Temperature Sensor (17) Starter Motor
(16) Alternator (18) Engine Oil Pressure Switch
(To be continued)
9-S12

(Continued)
21. Remove 4 mounting nuts (20) of the engine base from the
underside.
22. Remove the muffler exhaust pipe (19).
(19) Muffler Exhaust Pipe (20) Nut
23. Lift and separate the engine from the machine.

9Y1210552ENS0002US0
9-S13

[2] CHECKING AND ADJUSTMENT

(1) Valve Clearance
Valve Clearance
IMPORTANT
• Make sure that the engine is cold before performing
checking and adjusting of the valve clearance (A).
• Remove the glow plug from each cylinder so that the
compressive force will not occur.
• Make sure to adjust the valve clearance (A) first and then fix
the adjustment screw using the lock nut.
1. Remove the head cover.
2. Align the 1TC mark (1) of the cooling fan drive pulley with the
timing gauge needle (2) so that No.1 cylinder will arrive at the
Top Dead Center. The compression Top Dead Center of No.1
cylinder is located at a position that comes after one rotation of
the flywheel from the overlap of No.1 cylinder's intake and
exhaust valves.
3. Measure the valve clearance (A) with the O sign in the table
below, and adjust with the adjustment screw if the measurement
is not within the factory specification.
4. Next, measure the valve clearance (A) with P sign in the table
below after one rotation of the flywheel, and adjust with the
adjustment screw if the measurement is not within the factory
specification.
0.18 to 0.22 mm
Valve clearance (A) Factory specification
(when cold)
Firing order : 1 → 3 → 4 → 2
Cylinder No. 1 2 3 4
Valve
IN. EX. IN. EX. IN. EX. IN. EX.
sequence
No.1 cylinder
compression
O O O O
Top Dead
Center
No.4 cylinder
compression
P P P P
Top Dead
Center
(1) 1TC Mark (A) Valve Clearance

(2) Timing Gauge Needle
9Y1210019ENS0016US0
9-S14

(2) Compression Pressure

Compression Pressure
CAUTION
• Turn the engine for 2 to 3 seconds before measuring, to
make sure that the engine runs smoothly.
1. After running the engine to warm it up, stop the engine, remove
the air cleaner and the muffler and remove all the glow plugs.
2. Connect a compression tester (adaptor K,
code No. 07909-31291) for the diesel engine to the glow plug
hole of the cylinder to measure the pressure.
3. While pulling the engine stop knob, run the starter motor for five
seconds, and read the value at which the gauge needle stops.
Perform measuring at least twice and judge getting the average
value.
2.94 to 3.24 MPa
30 to 33 kgf/cm2
Compression pressure
2.35 MPa
Allowable limit
24 kgf/cm2
Pressure difference
Allowable limit Within 10 %
among cylinders
Measurement conditions :
The battery is fully charged (engine speed 250 to 270 rpm)
Specified valve clearance
9Y1210019ENS0017US0
[3] DISASSEMBLING AND ASSEMBLING

Engine Disassembling and Reassembling
• Demount the engine from the combine harvester to separate it as a complete unit.
9Y1210019ENS0018US0
(1) Cylinder Head and Valve

Exterior Parts
1. Remove the fan (5), the alternator (4), the air cleaner flange (6),
the inlet hose (3), the turbocharger (2) and the muffler (7).
2. Remove the fuel injection pipe and remove the cylinder head
cover (1).
IMPORTANT
• Make sure not to let any dirt enter the injection pump and
the nozzle.
(1) Cylinder Head Cover (5) Fan
(2) Turbocharger (6) Air Cleaner Flange
(3) Inlet Hose (7) Muffler
(4) Alternator
9Y1210019ENS0019US0
9-S15

Fuel Injection Nozzle and Glow Plug
1. Remove the fuel return pipe.
2. Remove the fuel injection nozzle holder assembly (2).
3. Remove the glow plug (1).
(When reassembling)
• Replace newly the packing of the fuel injection nozzle.
9.8 to 11.3 N·m
Fuel return pipe
1.0 to 1.15 kgf·m
25.5 to 29.4 N·m
Tightening torque Fuel injection nozzle
2.6 to 3.0 kgf·m
19.6 to 24.5 N·m
Glow plug
2.0 to 2.5 kgf·m
(1) Glow Plug (2) Fuel Injection Nozzle Holder

Assembly
9Y1210019ENS0020US0
Rocker Arm and Push Rod
1. Gradually loosen the mounting screws of the rocker arm bracket
from the outside screw to the inside screw and remove the
rocker arm assembly (1).
2. Remove the push rods (2).
(When reassembling)
• Tighten the rocker arm assembly (1) from the inside screw
to the outside screw.
• Ensure that the lower end of the push rods (2) are
positioned in the groove part of the tappet (3).
• When assembling the push rod (2) to the tappet (3), make
sure to keep the original position.
• After installing the rocker arm assembly (1), make sure to
adjust the valve clearance. (See page 9-S14.)
Valve clearance
Factory specification 0.18 to 0.22 mm
(when cold)
23.5 to 27.5 N·m

Tightening torque Rocker arm bracket
2.4 to 2.8 kgf·m
(1) Rocker Arm Assembly (3) Tappet

(2) Push Rod
9Y1210552ENS0003US0
9-S16

Cylinder Head
1. Detach the clamp (1) from the bypass pipe (3) and remove the
bypass pipe (2).
2. Remove the cylinder head (3). Loosen the cylinder head screws
in the order (r → a), which is the reverse of the tightening order
(a → r), as shown in the figure.
3. Remove the cylinder head gasket.
(When reassembling)
• Replace newly the cylinder head gasket.
• The cylinder head gasket should be replaced with the same
type of gasket by checking the identification mark (5) (see
the table below) of the gasket that was mounted.
• Apply the engine oil to the head screws and tighten.
• Repeat the tightening sequence two or three times so that
the screws are gradually tightened in the order (a → r) as
shown in the figure.
93.1 to 98.0 N·m
Tightening torque Cylinder head screw
9.5 to 10.5 kgf·m
Identification mark Part No.

15 1G790-03600
20 1G790-03310
25 1G790-03610
30 1G790-03620
35 1G790-03630
(1) Clamp (A) Gear Case Side

(2) Bypass Pipe (B) Flywheel Side
(3) Cylinder Head
(4) Gasket
(5) Identification Mark
9Y1210019ENS0022US0
9-S17

Selection of Cylinder Head Gasket
IMPORTANT
• When the piston, the piston pin, the bushing, the
connecting rod, or the crank pin bearing are replaced,
measure the projection of the piston to replace the cylinder
head gasket.
• Measure the projection (the average of 4 cylinders) of the
piston from the crankcase top surface and select the
cylinder head gasket.
1. Before measuring, move the piston to Top Dead Center, gently
tap the top surface of the piston using a plastic hammer to lower
the space of the oil clearance between the crankpin of the
crankshaft and the crankpin bearing of the connecting rod, and
measure the projection of the piston using a dial gauge (1).
2. Measure 4 points for each cylinder to calculate the average, and
find the average of all cylinders to select a head gasket.
3. If a piston projection in any cylinder exceeds the maximum
value of the selected gasket, select the next grade cylinder head
gasket.
(Make sure that it is within the projection range of the piston.)
4. If the minimum value is smaller than any of those projections
and falls within the projection range of the piston one grade
lower, no action is required.
5. If the degree of the projection exceeds the criteria of 3 or 4 or
the identification marks "15 to 35" cannot be selected, inspect
the piston pin, the piston, the connecting rod, and the crankshaft
to reselect the cylinder head gasket.
Identification
Projection of piston (mm) Part No.
mark
0.475 to 0.525 15 1G790-03600
0.525 to 0.575 20 1G790-03310
0.575 to 0.625 25 1G790-03610
0.625 to 0.675 30 1G790-03620
0.675 to 0.725 35 1G790-03630
(1) Dial Gauge (2) Measurement Points

9Y1210019ENS0023US0
Tappet
1. Remove the tappet (1).
(When reassembling)
• Apply the engine oil to the tappet (1) before reassembling.
IMPORTANT
• When assembling the tappet (1) to the tappet guide, make
sure to keep the original position.
(1) Tappet
9Y1210019ENS0024US0
9-S18

Intake / Exhaust Valve
1. Remove the valve cap (2).
2. Remove the collets (3) with a valve spring replacer (1).
3. Loosen the replacer (1) and remove the spring retainer (4), the
spring (5) and the valve (7). Make sure to arrange the valve (7)
so that it can be installed to the original position.
(When reassembling)
IMPORTANT
• Make sure to keep the position of the valve and the valve
guide.
• Make sure to apply oil to the valve stem part and insert it to
the guide.
• After spring (5) reassembly, make sure to sit well the spring
(5) by gently tapping the valve stem part in the axial
direction using a plastic hammer.
(1) Valve Spring Replacer (5) Spring
(2) Valve Cap (6) Stem Seal
(3) Collets (7) Valve
(4) Spring Retainer
9Y1210019ENS0025US0
9-S19

(2) Fuel Injection Pump

Fuel Injection Pump Unit
1. Remove the engine stop cover (1) and the idling adjustment
device (2).
2. Remove the engine stop lever (3) and the engine stop guide (5).
3. Remove the oil supply cap.
4. Align the control rack pin (7) of the fuel injection pump (4) with
the groove (8) of the pump mounting seating surface to remove
the fuel injection pump (4).
IMPORTANT
• Before the fuel injection pump (4) removal, make sure to
remove the engine stop cover (1), the idling adjustment
device (2), the engine stop lever (3), and the engine stop
guide (5).
(When reassembling)
IMPORTANT
• Reassemble the fuel injection pump (4) to the original
position before reassembling the engine stop cover (1), the
idling adjustment device (2), the engine stop lever (3) and
the engine stop guide (5).
• Before reassembling the fuel injection pump (4), turn the
fuel camshaft that the key position of the fuel camshaft is
located at lower-right 45 ° position as seen from the gear
case side. It is easy to assemble the fuel injection pump (4)
with this position of the fuel camshaft.
• Replace newly the gasket (6) of the idling adjustment
device (2).
• Reassemble the engine guide (5) and the engine stop lever
(3), making sure that the lever operates properly. Make sure
that the positional relationship shown in Fig [A] is
established.
44.1 to 49.0 N·m
Tightening torque Idling adjustment device
4.5 to 5.0 kgf·m
(1) Engine Stop Cover (7) Control Rack Pin

(2) Idling Adjustment Device (8) Groove
(3) Engine Stop Lever
(4) Fuel Injection Pump [A] The positions of the engine stop
(5) Engine Stop Guide guide and the engine stop lever
(6) Gasket
9Y1210019ENS0026US0
9-S20

Governor Spring and Speed Control Plate
1. Remove the injection pump cover.
2. Unscrew the mounting screw and nut of the speed control plate
(6).
3. Use a tool (1) to remove the governor springs 1 (2) and 2 (4)
from the fork lever (3).
4. With your fingers, set the speed control lever (5) to straight
position against the cover as illustrated in the figure [A].
5. Remove the speed control lever (5), and simultaneously remove
the governor springs 1 (2) and 2 (4).
(Reference)
• Tool (1):
Mount a hook at the tip of a wire of 200 mm in length and 1.2
mm in diameter.
Use this tool for governor spring disassembly and reassembly.
(1) Tool (4) Governor Spring 2

(2) Governor Spring 1 (5) Speed Control Lever
(3) Fork Lever (6) Speed Control Plate
(To be continued)
9-S21

(Continued)
(When reassembling)
1. Attach the governor springs 2 (4) and 1 (2) to the lever of
the speed control plate (6).
2. With a tool (1), hook the governor spring 1 (2) from the fuel
injection pump side.
While gently pulling the governor spring 1 (2), assemble the
speed control plate (6) to the gear case.
3. With a tool (1), mount the governor spring 2 (4) to the fork
lever (3).
4. With a tool (1), mount the governor spring 1 (2) to the fork
lever (3).
(When reassembling)
• Make sure that the governor springs 1 (2) and 2 (4) are
securely mounted to the fork lever (3).
• After reassembling the governor springs, make sure that
the speed control lever (5) is set at the minimum speed
position.
• Make sure that the speed control lever (5) returns to the
minimum speed position after being set to the maximum
speed position.
• When the engine reassembly is completed, inspect and
adjust the idling revolution.
(1) Tool (4) Governor Spring 2

(2) Governor Spring 1 (5) Speed Control Lever
(3) Fork Lever (6) Speed Control Plate
9Y1210019ENS0027US0
9-S22

(3) Gear Case

Crankshaft Nut and Engine Cooling Fan Drive Pulley
1. Remove the mounting screw of the engine cooling fan and
remove the pulley.
2. Install the flywheel stopper to fix the flywheel.
3. Unscrew the nut (1) of the fan drive pulley (2).
4. Remove the pulley (2) with the gear puller (3).
(When reassembling)
• Apply the engine oil to the thread part and the seating
surface of the nut (1).
Engine cooling fan drive 137.3 to 156.9 N·m
Tightening torque
pulley 14.0 to 16.0 kgf·m
(1) Nut (3) Gear Puller

(2) Fan Drive Pulley
9Y1210019ENS0028US0
Gear Case Cover

1. Remove the screws and remove the gear case cover (1).
2. Remove the O-rings (2).
(When reassembling)
• Apply the liquid packing (THREE-BOND CO. TB1215 or
equivalent) to the packing of the gear case cover.
• When reassembling the crankshaft oil seal (3) and the
O-ring (2), be careful not to cause any damage.
• When reassembling the crankshaft collar, apply the engine
oil to the oil seal (3) to prevent burr on the lip.
23.5 to 27.5 N·m
Tightening torque Gear case cover
2.4 to 2.8 kgf·m
(1) Gear Case Cover (3) Oil Seal

(2) O-ring
9Y1210019ENS0029US0
9-S23

Crankshaft Oil Slinger
1. Remove the crankshaft collar (3).
2. Remove the O-ring (2).
3. Remove the crankshaft oil slinger (1).
(When reassembling)
• Reassemble the crankshaft collar (3) after the gear case
has been mounted to the crankcase.
(1) Crankshaft Oil Slinger (3) Crankshaft Collar
(2) O-ring
9Y1210019ENS0030US0
(4) Timing Gear and Camshaft

Idle Gear
1. Remove the snap ring.
2. Remove the collar of the idle gear (2).
3. Remove the idle gear (2).
(When reassembling)
• Align each of 3 "alignment marks" (6) of the idle gear (2)
with the respective marks of the crankshaft gear (4), the
camshaft gear (3) and the fuel camshaft gear (1).
(1) Fuel Camshaft Gear (4) Crankshaft Gear
(2) Idle Gear (5) Oil Pump Gear
(3) Camshaft Gear (6) Alignment Marks
9Y1210019ENS0031US0
Camshaft
1. Remove the mounting screws (2) of the camshaft and slowly
pull out the camshaft (1).
(When reassembling)
• Align the "alignment marks" of each gear and make sure to
reassemble the idle gear last.
23.5 to 27.5 N·m
Tightening torque Camshaft
2.4 to 2.8 kgf·m
(1) Camshaft (2) Screw

9Y1210019ENS0032US0
Fuel Camshaft
1. Remove the fuel camshaft stopper (1).
2. Remove the mounting screws (2) of the fork lever holder.
3. Simultaneously remove the fuel camshaft (6), the fuel camshaft
gear (5), the fork levers 1 (3) and 2 (4) and the fork lever holder
(7).
(1) Fuel Camshaft Stopper (5) Fuel Camshaft Gear
(2) Screw (6) Fuel Camshaft
(3) Fork Lever 1 (7) Fork Lever Holder
(4) Fork Lever 2
9Y1210019ENS0033US0
9-S24

Oil Pump
1. Remove the mounting nut of the oil pump drive gear (1).
2. Remove the oil pump drive gear (1) with the gear puller (2).
3. Remove the mounting screw of the oil pump (3) and remove the
oil pump (3).
(1) Oil Pump Drive Gear (3) Oil Pump
(2) Gear Puller
9Y1210019ENS0034US0
Crank Gear
1. Remove the crank gear (1) with the gear puller (2).
2. Remove the feather key.
(1) Crank Gear (2) Gear Puller
9Y1210019ENS0035US0
(5) Piston and Connecting Rod

Oil Pan, Oil Strainer
1. Remove the mounting screws of the oil pan (1).
2. Remove the oil pan (1).
3. Remove the gasket (2) of the oil pan (1).
4. Remove the oil strainer (3) and the O-ring (4).
(When reassembling)
• Clean the oil strainer (3).
• Apply the engine oil to the O-ring (4) of the oil strainer (3)
and mount securely.
• Apply the liquid packing (THREE-BOND CO. TB1215 or
equivalent) to the oil pan mounting surface.
• Tighten the mounting screws of the oil pan (1) diagonally
starting from the middle.
• Mount the oil pan (1) in the direction that the drain plug will
face on the gear case side.
(1) Oil Pan (3) Oil Strainer
(2) Gasket (4) O-ring
9Y1210019ENS0036US0
9-S25

Piston
1. Remove any carbon (1) from the cylinder.
2. Remove the connecting rod screws (2) and remove the
connecting rod cap (3).
3. Set the piston (5) to the Top Dead Center position turning the
flywheel, and push out the connecting rod assembly to the
cylinder head side using a hammer handle or other tool.
4. Make sure to arrange the piston (5) and the connecting rod
assembly so that they can be mounted to the original position.
(When reassembling)
• Apply the engine oil to the crankpin bearing and the
cylinder.
• When reassembling the connecting rod, face the
connecting rod mark to the fuel injection pump mark.
IMPORTANT
• Make sure not to change the position of the cylinder and
piston assembly (5).
• When mounting the piston (5) and the connecting rod
assembly to the cylinder, make sure to set the piston ring's
clearance direction as shown in the figure, and securely
tighten with a piston ring compressor.
• Apply the engine oil to the connecting rod screws (2),
screw them by hand as far as they can go, and tighten to
the prescribed torques.
44.1 to 49.0 N·m
Tightening torque Connecting rod screw
4.5 to 5.0 kgf·m
(1) Carbon (A) Top Ring Clearance

(2) Connecting Rod Screw (B) Second Ring Clearance
(3) Connecting Rod Cap (C) Oil Ring Clearance
(4) Connecting Rod (D) Piston Pin Hole
(5) Piston (a) 120 °
(6) Code No.
9Y1210019ENS0037US0
9-S26

Piston Ring, Connecting Rod
1. Remove the piston rings (1), (2) and (3) with a piston ring tool.
2. Remove the piston pin (7) to separate the piston (5) and the
connecting rod (6), and arrange them as not to change the
combination.
(When reassembling)
• Reassemble the piston (5) and the connecting rod (6) with
that the FW mark (9) on the top surface of the piston, faces
the flywheel side and with the connecting rod mark (8)
faces the fuel injection pump side.
• When reassembling the piston pin (7), raise the
temperature of the piston (5) to 80 to 100 °C with a piston
heater or other device, and apply oil to the piston.
• Reassemble the oil ring (3) with that the expander joint (10)
locates at 180 ° opposite to the oil ring clearance (11).
• Reassemble each piston ring with the mark (12) facing up.
(1) Top Ring (7) Piston Pin
(2) Second Ring (8) Mark
(3) Oil Ring (9) FW Mark
(4) Piston Pin Snap Ring (10) Expander Joint
(5) Piston (11) Oil Ring Clearance
(6) Connecting Rod (12) Piston Ring Mark
9Y1210019ENS0038US0
9-S27

(6) Crankshaft
Flywheel
1. Install the flywheel stopper to fix the flywheel (1).
2. Remove 2 mounting screws (2) of the flywheel first.
3. Install the flywheel guide screws (3) as another part with a
proper length to 2 holes of screws which were removed.
4. Remove the rest the mounting screws (2) of the flywheel.
5. Install other long screws into the screw holes on the outer
circumference surface of the flywheel so that the flywheel can
be held by hand.
6. Slowly remove the flywheel (1) in along with the flywheel guide
screws (3).
(When reassembling)
• Wipe all dirt and dust off the mounting surface the of the
crankshaft for the flywheel (1).
• Apply the oil to the flywheel mounting screws (2).
98.0 to 107.8 N·m
Tightening torque Flywheel mounting screw
10.0 to 11.0 kgf·m
(1) Flywheel (3) Flywheel Guide Screw

(2) Flywheel Mounting Screw
9Y1210019ENS0039US0
Bearing Case Cover
1. Remove the mounting screws (3), (6) of the bearing case cover
(5).
Remove the inside screws (6) before the outside screws (3).
2. Install 2 screws that were previously unscrewed into 2 screw
outside holes of the bearing case cover (5), and remove the
bearing case cover (5).
(When reassembling)
• Correctly mount the bearing case gasket (1) and the
bearing case cover gasket (2).
• Apply the engine oil to the lip and the outer circumference
of the oil seal (4) of the bearing case cover (5) to prevent
burr on the lip.
• When reassembling, be careful not to cause misalignment
between parts.
• Repeatedly tighten the mounting screws of the bearing
case cover (5) a few times in a diagonal pattern so that they
gradually tighten.
23.5 to 27.5 N·m
Tightening torque Bearing case cover screw
2.4 to 2.8 kgf·m
(1) Bearing Case Gasket (5) Bearing Case Cover

(2) Bearing Case Cover Gasket (6) Screw
(3) Screw
(4) Oil Seal (a) Upper Side
9Y1210019ENS0040US0
9-S28

Crankshaft
1. Remove the bearing case screw 2 (1).
2. Rotate the crankshaft to align the notch of the crank case with
the pin of the crankshaft, and remove the crankshaft together
with the bearing case 2 (2).
Be careful not to damage the crankshaft metal (3).
(When reassembling)
• Clean the oil passage of the crankshaft with compressed
air.
• When reassembling the crankshaft, make sure to align the
screw holes of the crank case and the bearing case.
• Apply the engine oil to the screw thread part of the bearing
case 2 (2), screw the screws by hand as far as they can go,
and tighten to the prescribed torque.
68.6 to 73.5 N·m
Tightening torque Bearing case screw 2
7.0 to 7.5 kgf·m
(1) Bearing Case Screw 2 (3) Crankshaft Metal

(2) Bearing Case 2
9Y1210019ENS0041US0
9-S29

Bearing Case
1. Remove the bearing case screw 1 (8) and remove the bearing
case from the crankshaft.
2. Arrange the bearing case and the bearing so as not to change
the combination.
(When reassembling)
• Clean the oil passage of the bearing case using
compressed air.
• When assembling, apply the engine oil to the bearings.
• When assembling the bearing case, make sure to align the
number (1) and the mark (2).
• Reassemble the bearing case starting with the smaller
outside diameter from the gear case side, with the flywheel
mark facing the flywheel side.
• When reassembling the side metal, place it close to the
crankshaft, with the oil groove (7) facing outside.
• Apply the engine oil to the screw, and repeat tightening a
few times in order to gradually increase the tightening
torque, and make sure that the bearing case moves turning
smoothly.
46.1 to 50.9 N·m
Tightening torque Bearing case screw 1
4.7 to 5.2 kgf·m
(1) Number (5) Mark C

(2) Mark (6) No Mark
(3) Mark A (7) Oil Groove
(4) Mark B (8) Bearing Case Screw 1
9Y1210019ENS0042US0
9-S30

[4] SERVICING
(1) Cylinder Head
Flatness of Cylinder Head
1. Clean the cylinder head surface.
2. Measure 6 clearances of A to F shown in the figure with the
straight edge tool and the thickness gauge.
3. If the measurement exceeds the allowable limit, replace the
cylinder head. The valve recessing and the valve seating must
be inspected at this stage.
Flatness of cylinder head Allowable limit 0.05 mm / 100 mm
9Y1210019ENS0043US0
Crack Check of Cylinder Head Surface (Also Applicable to

Crankcase)
1. Clean the cylinder head surface.
2. Check for cracks with the crack check liquid (the red check).
3. If a crack is found, replace the cylinder head.
9Y1210019ENS0044US0
Valve Recessing
1. Clean the cylinder head surface, the valve and the valve seat,
and measure the valve recessing amount with inserting the
valve into the valve guide.
valve, and lap the valve after correcting the valve seating.
Valve recessing
Allowable limit 1.2 mm
9Y1210019ENS0045US0
9-S31

Clearance between Valve Stem and Valve Guide
1. Clean the valve and the inner surface of the valve guide.
2. Measure the outside diameter of the valve stem.
3. Measure the inside diameter of the valve guide to calculate the
clearance.
valve and the valve guide.
Clearance between the Factory specification 0.040 to 0.070 mm
valve stem and the valve
guide Allowable limit 0.1 mm
Inside diameter of valve

guide
Outside diameter of
valve stem
9Y1210019ENS0046US0
Replacement of the Valve Guide

1. Use the special tools (see page 9-G3) to remove the valve guide
from the underside of the cylinder head using the press.
2. After application of oil to the outer surface of the valve guide,
place the spacer (1) with the specified projection measurement
(10 mm) on the cylinder head to press into it from the top
surface.
3. After the press-in it, perform reaming to achieve the factory
specification shown below.
IMPORTANT
• After processing, be careful not to displace the center
position of the valve guide.If the center position is
displaced, it will cause a defective valve seat contact.
Projection measurement
Factory specification 10 ± 0.2 mm
of valve guide
Inside diameter of
valve guide
(1) Spacer (10 mm) (A) Removal

(2) 10 mm (B) Press-in
(C) Intake Valve Guide (Short Length)
(D) Exhaust Valve Guide
(Long Length)
9Y1210552ENS0004US0
9-S32

Inspection of Valve Seating
1. Clean the valve seat surface.
2. Check whether there is any damage or dents on the valve seat.
3. If the inspection reveals that the valve seat surface width is too
broad or not uniform, repair or replace the valve and the valve
seat.
(1) Good (3) Bad
(2) Bad
9Y1210019ENS0048US0
Correction of Valve
IMPORTANT
• Before repairing valves, check the clearance between the
valve stem and the valve guide, and replace the valve if the
measurement exceeds the allowable limit.
1. Use a valve refacer to repair the valve.
2. After the repair, measure the valve recessing, and replace the
valve if the measurement exceeds the allowable limit.
Intake valve : 45 °
Valve face angle Factory specification
Exhaust valve : 45 °
9Y1210019ENS0049US0
Correction of Valve Seat
IMPORTANT
• The clearance between the valve guide and the valve stem
must be within the allowable limits as the valve seat will be
repaired relative to the valve guide. If the clearance
exceeds the allowable limit, the valve seat should be
repaired after replacing the valve guide and reaming to
achieve the factory specification.
• If a valve seat cutter is used to ream the seat surface, make
sure to select an appropriate size for the valve diameter.
1. Repair the seat surface roughly with a valve seat cutter of 45 °
for intake and exhaust valves.
2. Mount the valve and check the contact of the valve face and the
valve seat with red lead primer.
3. With the 15 ° valve seat cutter, ream the top portion of the valve
seat until it starts to hit the surface of the valve face center.
4. Repair the seat surface again by a 45 ° valve seat cutter and
visually inspect the valve contact.
5. Repeat procedures 3 and 4 until proper contact is achieved.
IMPORTANT
• The valve recessing must be within the factory
specification after the valve seat repair.
Width of valve seat
Factory specification Intake / exhaust 2.12 mm
surface
Contact of the valve seat

Factory specification 70 % or more
surface
(A) Checking Contact Surfaces (a) Same Width

(B) Repairing Seat Width (b) Valve Seat Width
(C) Checking Contact Surfaces (c) 15 °
(d) 15 °
(e) 45 °
9Y1210019ENS0050US0
9-S33

Valve Lapping
After valve repair or replacement, or valve seat repair, the valve
should be lapped.
1. Apply the compound uniformly on the valve contact surface.
2. Insert the valve into the valve guide, move the valve upward and
downward as it is rotated by a valve flapper, and lap the valve
with by gently tapping the valve seat.
3. Clean off the compound and apply the engine oil to the valve
seat part for lapping.
4. Apply the red lead primer to the contact surface and repeat
lapping procedures until a contact surface of 70 % or more is
achieved.
9Y1210019ENS0051US0
Free Length of Valve Spring
1. Measure the free length of the spring.
2. Replace springs that exceed the allowable limit.
Free length of Factory specification 41.7 to 42.2 mm
valve spring Allowable limit 41.2 mm
(1) Free Length of Spring (2) Spring Perpendicularity

9Y1210019ENS0052US0
Tilt of Valve Spring

1. Stand the spring on the surface plate and turn it to measure the
maximum value of the tilt.
2. Replace any springs that exceed the allowable limit.
Tilt of valve spring Allowable limit 1.0 mm
9Y1210019ENS0053US0
Setting Load of Valve Spring
1. Set the valve spring on the spring tester, compress it to the set
length to read the load.
2. Replace any springs that exceed the allowable limit.
117.7 N / 35 mm
Setting load / setting 12.0 kgf / 35 mm
length 100 N / 35 mm
Allowable limit
10.2 kgf / 35 mm
9Y1210019ENS0054US0
Oil Clearance between Rocker Arm and Rocker Arm Shaft

1. Measure the inside diameter of the rocker arm and the outside
diameter of the rocker arm shaft to calculate the oil clearance.
rocker arm assembly. If the measurement continues to exceed
the allowable limit, replace the rocker arm shaft also.
Oil Clearance between Factory specification 0.016 to 0.045 mm
rocker arm and rocker
arm shaft Allowable limit 0.1 mm
Inside diameter of
rocker arm
Outside diameter of
rocker arm shaft
9Y1210019ENS0055US0
9-S34

Oil Clearance between Tappet and Tappet Guide
1. Measure the outside diameter of the tappet and the inside
diameter of the tappet guide of the crankcase to calculate the oil
clearance.
2. If the measurement exceeds the allowable limit or any damage
is found on the sliding surface, replace the tappet.
Oil clearance between Factory specification 0.020 to 0.062 mm
tappet and tappet guide Allowable limit 0.07 mm
Inside diameter of tappet

guide
Outside diameter of
tappet
9Y1210019ENS0056US0
Bend of Push Rod
1. Place the push rod on a V-block (measurement tool).
2. Measure the bend of the push rod.
3. Replace any push rods that exceed the allowable limit.
Bend of push rod Allowable limit 0.25 mm
9Y1210019ENS0057US0
(2) Timing Gear

Backlash of Timing Gear
1. Set the dial gauge (lever type) on a gear tooth and measure the
backlash with the engaging gear fixed.
2. If the measurements exceed the allowable limits, inspect each
gear and oil clearance of the shaft, etc.
Backlash between Factory specification 0.0415 to 0.1122 mm
crankshaft gear and idle
gear Allowable limit 0.15 mm
Backlash between idle Factory specification 0.0415 to 0.1154 mm

gear and camshaft gear Allowable limit 0.15 mm
Backlash between idle Factory specification 0.0415 to 0.1154 mm

gear and fuel camshaft
Backlash between Factory specification 0.0415 to 0.1090 mm

crankshaft gear and oil
pump drive gear Allowable limit 0.15 mm
9Y1210019ENS0058US0
Side Clearance of Idle Gear
1. Set the dial gauge on the idle gear.
2. Measure the side clearance by moving the idle gear back and
forth.
3. If the measurement exceeds the allowable limit, replace the idle
gear collar.
Side clearance of idle Factory specification 0.12 to 0.48 mm
9Y1210019ENS0059US0
9-S35

Side Clearance of Camshaft
1. Set the dial gauge on the camshaft gear.
2. Measure the side clearance by moving the cam gear back and
forth.
camshaft stopper.
Side clearance of Factory specification 0.07 to 0.22 mm
camshaft Allowable limit 0.3 mm
9Y1210019ENS0060US0
Oil Clearance between Idle Gear Bushing and Idle Gear Shaft
1. Measure the inside diameter of the idle gear bushing and the
outside diameter of the idle gear shaft to calculate the oil
clearance.
bushing.
idle gear bushing and
idle gear shaft Allowable limit 0.10 mm
Inside diameter of idle

gear bushing
Outside diameter of idle

gear shaft
9Y1210019ENS0061US0
Replacement of Idle Gear Bushing
1. Replace the bushing with special tools (see page 9-G4).
2. After the press-in, perform reaming to achieve the factory
specification shown above.
(A) Removal (B) Press-in
9Y1210552ENS0005US0
Bend of Camshaft
1. Put the camshaft on the V-block on the level surface plate, and
set the dial gauge perpendicular to the journal at the center of
the camshaft.
2. Measure the amount of runout by slowly rotating the camshaft.
The bend is half amount of the runout.
3. Replace the camshaft that exceeds the allowable limit.
Bend of camshaft Allowable limit 0.01 mm
9Y1210019ENS0063US0
9-S36

Cam Height of Camshaft
1. Measure the maximum height of the cam.
2. Replace the camshaft that exceeds the allowable limit.
Factory specification 33.90 mm
Cam height of camshaft
9Y1210019ENS0064US0
Oil Clearance between Camshaft Journal and Crankcase Bore

1. Measure the inside diameter of the camshaft bore of the crank
case and the outside diameter of the camshaft journal to
calculate the oil clearance.
camshaft.
camshaft journal and
crankcase bore Allowable limit 0.15 mm
Inside diameter of the

camshaft bore
Outside diameter of the

camshaft journal
9Y1210019ENS0065US0
(3) Piston, Connecting Rod and Crankshaft

Inside Diameter of Piston Pin Boss
1. Measure the inside diameter of the piston pin boss in the
horizontal and vertical directions.
2. Replace the piston that exceeds the allowable limit.
Inside diameter of piston Factory specification 25.000 to 25.013 mm
pin boss Allowable limit 25.05 mm
9Y1210019ENS0066US0
9-S37

Oil Clearance between Small End Bushing and Piston Pin
1. Measure the inside diameter of the small end bushing and the
outside diameter of the piston pin center to calculate the oil
clearance.
bushing.
Oil Clearance between Factory specification 0.014 to 0.038 mm
small end bushing and
piston pin Allowable limit 0.15 mm
Inside diameter of small

end bushing
Outside diameter of
piston pin
9Y1210019ENS0067US0
Replacement of Small End Bushing
1. Replace the bushing with the special tools (see page 9-G4).
IMPORTANT
• After pressing the bushing into the connecting rod, make
sure that the inside diameter of the bushing is within 25.025
to 25.040 mm and there is no deformation of the bushing.
• The oil hole should pass through the connecting rod and
the bushing.
Further, make sure that there is no burr on the bushing
side.
(A) Removal (B) Press-in
9Y1210552ENS0006US0
Ring Clearance of Piston Ring

1. Push the piston ring into the lower part of the cylinder with the
piston.
(Measure at the minimum worn part of the cylinder.)
2. Measure the ring clearance with the thickness gauge.
3. If the measurements exceed the allowable limit, replace the
piston ring assembly.
Top ring : 0.25 to 0.35 mm
Second ring :
Ring clearance of piston Factory specification
0.40 to 0.55 mm
ring Oil ring : 0.25 to 0.45 mm
9Y1210019ENS0069US0
Clearance between Piston Ring and Ring Groove
1. Remove any carbon from the ring groove.
2. Insert new piston rings into each groove, and measure the
clearances at 5 or 6 points on the outer circumference of the
piston ring groove.
3. If the measurements exceed the allowable limit, replace the
piston.
Clearance between Factory specification 0.093 to 0.128 mm
second ring and ring
groove Allowable limit 0.20 mm
Clearance between oil Factory specification 0.020 to 0.060 mm

ring and ring groove Allowable limit 0.15 mm
9Y1210019ENS0070US0
9-S38

Bend and Torsion (Alignment) of Connecting Rod
(Reference)
• Make sure that the inside diameter is within the allowable limit
as this measurement will be used as the base of the small end
bushing.
1. Remove the crank pin metal from the connecting rod and tighten
the connecting rod screw.
2. Attach the connecting rod to a connecting rod aligner.
3. Insert the piston pin into the small end, put the aligner gauge on
the piston pin to measure the clearances between 3 pins of the
aligner gauge and the aligner.
4. Replace any connecting rods that exceed the allowable limit.
Bend and torsion
(alignment) of Allowable limit 0.05 mm
connecting rod
9Y1210019ENS0071US0
Side Clearance of Crankshaft
1. Set the dial gauge perpendicular to the camshaft end.
2. Measure the movement of the dial gauge by pushing and pulling
the crankshaft.
3. If the measurement exceeds the allowable limit, replace the side
metal.
4. If the measurement continues to exceed the allowable limit after
the replacement of the side metal, use the oversize side metal.
IMPORTANT
• Make sure to face the oil groove of the side metal to the
bearing case.
Side clearance of Factory specification 0.15 to 0.31 mm
crankshaft Allowable limit 0.5 mm
(Reference)
• Oversize side metal
Oversize 0.2 mm 0.4 mm
A 26.20 to 26.25 mm 26.40 to 26.45 mm
B 54.0 to 54.7 mm 54.6 to 54.8 mm
C 2.8 to 3.2 mm radius 2.8 to 3.2 mm radius
Surface finish roughness of the side metal contact portion : Rmax =

0.8S
9Y1210019ENS0072US0
Bend of Crankshaft
1. Put the crankshaft on the V-block on the surface plate and set
the dial gauge perpendicular to the journal at the center of the
crankshaft.
2. Measure the amount of runout by slowly rotating the crankshaft.
The bend is half amount of the runout.
3. Replace the crankshaft that exceeds the allowable limit.
Bend of crankshaft Allowable limit 0.02 mm
9Y1210019ENS0073US0
9-S39

Oil Clearance between Crankpin and Crankpin Bearing
1. Put the press gauge on the inner surface of the crankpin bearing
with grease.
(The press gauge should be mounted where it will not enter the
crankpin's oil hole.)
2. Tighten the connecting rod cap with the prescribed torque.
3. Remove the connecting rod cap, and measure the oil clearance
according to the crushed width of the press gauge.
crankpin bearing.
the replacement, use the undersize bearing.
(See page 9-S42.)
IMPORTANT
• The press gauge should be mounted where it will not enter
the crankpin's oil hole.
crankpin and crankpin
bearing Allowable limit 0.2 mm
Inside diameter of
crankpin bearing
Outside diameter of
crankpin
CAUTION
• When tightening the connecting rod cap, make sure to fix
the crankshaft to prevent rotation.
44.1 to 49 N·m
Tightening torque Connecting rod cap
4.5 to 5.0 kgf·m
(Reference)
• Undersize bearing
Undersize 0.2 mm 0.4 mm
A 3.3 to 3.7 mm radius 3.3 to 3.7 mm radius
B 1.0 to 1.5 mm radius 1.0 to 1.5 mm radius
C 46.759 to 46.775 mm 46.559 to 46.575 mm
Surface finish roughness of the crankpin contact : Rmax = 0.8S

9Y1210019ENS0074US0
9-S40

Oil Clearance between Crankshaft Journal and Crankshaft
bearing 1
1. Measure the inside diameter of the crankshaft bearing 1 and the
outside diameter of the journal of the crankshaft front end to
calculate the oil clearance.
camshaft bearing 1.
the replacement, use the undersize bearing. (See page 9-S42.)
crankshaft journal and
crankshaft bearing 1 Allowable limit 0.2 mm
Outside diameter of
crankshaft journal
Inside diameter of
(Reference)
C 59.721 to 59.740 mm 59.521 to 59.540 mm
Surface finish roughness of the crank journal contact : Rmax = 0.8S

9Y1210552ENS0007US0
Replacement Crankshaft Bearing 1

1. Replace the crankshaft bearing 1 with the special tools (see
page 9-G5).
IMPORTANT
• Press into the crankshaft bearing 1 that the joint (1) faces
to the direction of the muffler.
• Press into the crankshaft bearing 1 (2) down to the depth of
(A) measurement (4.2 to 4.5 mm) from the crankcase (3) end
surface.
(1) Joint (3) Crankcase
(2) Crankshaft Bearing 1
9Y1210552ENS0008US0
9-S41

Oil Clearance between Crankshaft Journal and Crankshaft
bearing 2
1. Put the press gauge on the inner surface of the crankshaft
bearing 2 with grease.
2. Tighten the main bearing case with the prescribed torque.
3. Remove the main bearing case, and measure the oil clearance
according to the crushed width of the press gauge.
camshaft bearing 2.
the replacement, use the undersize bearing. (Refer to the table
below.)
IMPORTANT
• The press gauge should be mounted where it will not enter
the crankshaft journal's oil hole.
crankshaft journal and
crankshaft bearing 2 Allowable limit 0.2 mm
Outside diameter of
crankshaft journal
Inside diameter of
CAUTION
• When tightening the big end of the connecting rod, make
sure to fix the crankshaft to prevent rotation.
46.1 to 51 N·m
Tightening torque Bid end of connecting rod
4.7 to 5.2 kgf·m
(Reference)
C and D 59.721 to 59.740 mm 59.521 to 59.540 mm
Surface finish roughness of the crank journal contact : Rmax = 0.8S

9Y1210019ENS0077US0
Crankshaft Sleeve
1. Inspect the wear on the crankshaft sleeve (1).
2. If the measurement exceeds the allowable limit or there is an
engine oil leakage, replace the crankshaft sleeve.
Wear of crankshaft
sleeve
(1) Crankshaft Sleeve

9Y1210019ENS0078US0
9-S42

Replacement of the Crankshaft Sleeve
1. Remove the crankshaft sleeve (3).
2. Set the sleeve guide (2) on the crankshaft (5).
3. Set the stopper (1) on the crankshaft (5) as shown in the figure
on the left.
4. Increase the temperature of the new crankshaft sleeve (3) up to
150 to 200 °C, and press the crankshaft sleeve (3) into the
crankshaft with the insertion socket tool (4) as shown in the
figure on the left.
IMPORTANT
• When mounting the sleeve, the larger chamfer side should
be placed on the outside.
(1) Stopper (4) Insertion Socket Tool
(2) Sleeve Guide (5) Crankshaft
(3) Crankshaft Sleeve
9Y1210019ENS0079US0
(4) Crankcase
Inside Diameter of Cylinder
1. With the cylinder gauge, measure the inside diameter of the
cylinder at 6 points shown in the figure. And calculate the
difference between the maximum and minimum values of the
cylinder inside diameter.
Inside diameter of Factory specification 87.000 to 87.022 mm
cylinder Allowable limit 87.17 mm
Difference between the

minimum and maximum Allowable limit 0.15 mm
worn parts of the cylinder
(a) Perpendicular direction to the (b) Same direction to piston pin

piston pin
9Y1210019ENS0080US0
9-S43

Oversize (+0.25 mm) of Cylinder
• If the cylinder is made the boring and honing process to be
oversize, use +0.25 mm oversize of the piston and the piston
ring.
Inside diameter of Factory specification 87.250 to 87.272 mm
cylinder Allowable limit +0.15 mm
Finish roughness of
Factory specification Hone Rz = 2.2 to 3.0
honing process
(1) Inside Diameter of Cylinder (2) Inside Diameter of Cylinder

(Before Processing) (After Processing)
9Y1210019ENS0081US0
9-S44

4. LUBRICATING SYSTEM
[1] CHECKING
Engine Oil Pressure
1. Inspect the engine oil amount.
2. Remove the engine oil pressure switch, and install the oil
pressure tester (see page 9-G3).
Mounting: PT1/8
3. Start the engine and wait until it warms up.
(Increase the oil temperature to 85 to 95 °C.)
4. Measure the pressure at idling and rated revolutions.
5. If the measurement is lower than the allowable limit, inspect the
oil filter, the oil pump, the oil passage and the oil clearance of
the crankshaft, etc.
98 kPa
At idling 1.0 kgf/cm2
Factory or more
specifica-
tion At rated
294 to 441 kPa
Engine oil pressure revolutions
3.0 to 4.5 kgf/cm2
(2600 rpm)
At rated
Allowable 245 kPa
revolutions
limit 2.5 kgf/cm2
(2600 rpm)
(When reassembling)
14.7 to 19.6 N·m
Tightening torque Engine oil pressure switch
1.5 to 2.0 kgf·m
9Y1210552ENS0009US0
[2] SERVICING
(1) Oil Pump
Clearance between Inner Rotor and Outer Rotor
1. Align the convex parts of the inner and outer rotors, and
measure the clearance with the thickness gauge.
rotor assembly.
Clearance between inner Factory specification 0.03 to 0.14 mm
rotor and outer rotor Allowable limit 0.2 mm
9Y1210019ENS0083US0
Clearance between Outer Rotor and Pump Body

1. Measure the clearance between the outer rotor and the pump
body.
rotor assembly.
Clearance between outer Factory specification 0.11 to 0.19 mm
rotor and pump body Allowable limit 0.25 mm
9Y1210019ENS0084US0
9-S45

Clearance between Inner Rotor and Cover
1. Put the press gauge on the side surface of the inner rotor within
the pump body.
2. Mount the cover and tighten with the prescribed torque.
3. Remove the cover slowly, and measure the crushed width of the
press gauge.
rotor assembly.
Clearance between inner Factory specification 0.105 to 0.150 mm
rotor and cover Allowable limit 0.2 mm
9Y1210019ENS0085US0
9-S46

5. COOLING SYSTEM
[1] CHECKING
Inspection of Water Leakage from Radiator
1. Pour the specified amount of the coolant into the radiator.
2. Warm up the engine.
3. Attach the radiator tester, and apply pressure up to 137 kPa
(1.4 kgf/cm2).
4. Check there is no water leak. If the water leak is found, replace
or repair the radiator.
Inspection of water No leaks at 137 kPa
leakage from radiator (1.4 kgf/cm2)
9Y1210019ENS0086US0
Inspection of Radiator Cap
1. Install the radiator tester to the radiator cap, and pressurize to
88.3 kPa (0.9 kgf/cm2). It is normal if the radiator cap maintains
59 kPa (0.6 kgf/cm2) or more for 10 seconds. Replace if the
defective parts.
Maintain 59 kPa
(0.6 kgf/cm2) or more for
Inspection of radiator cap Factory specification 10 seconds after applying
pressure at 88 kPa
(0.9 kgf/cm2)
9Y1210019ENS0087US0
[2] DISASSEMBLING, ASSEMBLING AND SERVICING

Thermostat
1. Remove the thermostat cover (2).
2. Remove the thermostat (1).
(When reassembling)
• Lightly coat the gasket to the thermostat cover (2) using the
liquid packing (THREE BOND 1215 or equivalent).
(1) Thermostat (2) Cover
9Y1210019ENS0088US0
Valve Opening Temperature of Thermostat

1. Press down the thermostat valve, and pinch the thread between
the valve and the sheet.
2. Place the thermostat and thermometer in the container, and
gradually raise the water temperature using the gas burner.
3. Take the thread, and float the thermostat in the water.
4. As the water temperature rises, the valve will open, and the
thermostat will separate from the thread. Measure the
temperature at this time (valve opening temperature).
5. Raise the temperature further, and measure the temperature
when the valve has lifted approx. 8 mm (fully open
temperature).
6. Replace the thermostat that do not open even if the temperature
rises above the factory specifications.
Valve opening
temperature of Factory specification 69.5 to 72.5 °C
thermostat
Fully open temperature

Factory specification 85 °C
(lift amount 8 mm)
9Y1210019ENS0089US0
9-S47

Water Pump
1. Remove the water pump body (3) from the gear case.
2. Push out the pump shaft (2) from the impeller (5) side towards
the pulley boss (1).
3. Remove the mechanical seal (4) from the water pump body (3).
(When reassembling)
• Replace the mechanical seal (4) with a new part.
• After mounting to the gear case, check manually that the
pump shaft (2) rotates smoothly.
(1) Pulley Boss (6) 3.5 mm
(2) Pump Shaft (7) Align the Water Pump Body and the
(3) Water Pump Body Pump Shaft Bearing Surfaces.
(4) Mechanical Seal (8) Clearance to Impeller
(5) Impeller
9Y1210019ENS0090US0
9-S48

6. FUEL SYSTEM
[1] FUEL INJECTION NOZZLE
(1) Checking and Adjustment
Nozzle Fume Condition
CAUTION
• When inspecting using the nozzle tester, testing
atomization may harm the skin, so do not approach the
mist.
1. Set the fuel injection nozzle on the nozzle tester.
2. Spray fuel from the nozzle, and inspect the atomized fume
condition.
3. If the atomization is lopsided or directional, replace the fuel
injection nozzle assembly.
(Reference)
• For the atomization test, test with the hand lever operation
speed on the nozzle tester using 4 to 6 strokes or quicker per
second.
• If the lever operation of the nozzle tester is slow, the 2-steps
open valve nozzle atomization will be rough compared to the
ordinary nozzles.
(A) 4 to 6 times or quicker per second (B) 3 times or less per second
9Y1210019ENS0091US0
Fuel Tightness of Fuel Injection Nozzle

1. Set the fuel injection nozzle on the nozzle tester.
2. Pressurize to the fuel tightness pressure 16.67 MPa
(170 kgf/cm2), and if fuel does not leak from the nozzle tip after
10 seconds, the nozzle condition is good.
3. Replace the fuel injection nozzle assembly if defective.
Fuel tightness of fuel No fuel leaks at 16.67 MPa
injection nozzle (170 kgf/cm2)
9Y1210019ENS0092US0
9-S49

[2] FUEL INJECTION PUMP

(1) Checking and Adjustment
Fuel Injection Timing
1. Remove all the fuel injection pumps and the glow plugs.
2. Set the speed adjustment lever to the maximum rotations
position.
3. Rotate the flywheel counterclockwise, and check that fuel
emerges from the delivery holder (1) on the fuel injection pump.
Return the flywheel clockwise approx. 90 °.
4. Rotate the flywheel counterclockwise (i.e., left), and stop
rotating it where the angle mark 20 ° (5) is aligned with the
timing gauge needle (2).
5. Slowly rotate it further from this position, and when the fuel
starts to spout from the delivery holder (1) on the fuel injection
pump, measure the angle of the fuel injection timing by the
timing gauge needle (2), the angle mark 10 ° (4) and the angle
mark 20 ° (5).
6. If checking again that the fuel starts to spout, rotate clockwise
(i.e., right) 90 ° or more.
7. If the fuel injection timing is not within the factory specification,
adjust adding or removing the shim on the fuel injection pump
mounting surface.
Fuel injection timing Factory specification T.D.C. −6.00 ° to −7.50 °
(Reference)
• Check the fuel injection timing if the fuel injection pump has
been replaced.
• If the fuel injection timing is too fast, add the shim
If the fuel injection timing is too slow, remove the shim
A shim of 0.20 mm thickness changes the crank angle approx.
2 °.
(1) Delivery Holder (4) Angle Mark 10 °
(2) Timing Gauge Needle (5) Angle Mark 20 °
(3) T.D.C. Mark 1TC
9Y1210019ENS0093US0
Identification of Shims
(1) Two Holes : 0.20 mm Shim (3) No Holes : 0.30 mm Shim

(2) One Hole : 0.25 mm Shim (4) Three Holes : 0.35 mm Shim
9Y1210019ENS0094US0
9-S50

7. ELECTRICAL SYSTEM
[1] STARTER MOTOR
(1) Disassembling and Assembling
Motor
1. Disconnect the lead wire (9) from the magnetic is switch
assembly (8).
2. Remove the screw (6) and remove the end frame (4), the yoke
(2), and the armature (1).
3. Remove the screw (5), and remove the brush holder (3) from
the end frame (4).
(When reassembling)
• Apply grease to spline A of the armature (1) end.
(1) Armature (7) Nut
(2) Yoke (8) Magnetic Switch
(3) Brush Holder (9) Lead Wire
(4) End Frame
(5) Screw A : Spline
(6) Screw
9Y1210019ENS0095US0
Magnetic Switch
1. Remove the mounting screw of the magnetic switch cover (1).
2. As shown in the figure on the left, remove the overrunning clutch
(2), the ball (3), the spring (4), the gear (5), the roller (6), and the
retainer (7).
(When reassembling)
• Apply grease to the teeth surface of the gear (5), the
overrunning clutch (2), and the ball (3).
(1) Magnetic Switch Cover (5) Gear
(2) Overrunning Clutch (6) Roller
(3) Ball (7) Retainer
(4) Spring
9Y1210019ENS0096US0
Plunger
1. Remove the end cover (1).
2. Remove the plunger (2).
(1) End Cover (2) Plunger
9Y1210019ENS0097US0
(2) Servicing
Motor Test
CAUTION
• The starter may move unexpectedly if it is not secured.
Make sure to secure the starter to the vice when checking.
1. Remove the connecting lead wire from C terminal, and connect
the lead wire directly to the battery's positive terminal.
2. Connecting the battery's negative terminal to the body of the
starter motor for approx. 1 second, confirm that the motor is
running smoothly.
9Y1210019ENS0098US0
9-S51

Overrunning Clutch
1. Secure the overrunning clutch, and turn the pinion in the starter
rotation direction. Check that it is not turning in the opposite
direction.
2. Check the pinion, and clean or replace in the event of finding
any rust, friction or damage.
9Y1210019ENS0099US0
Commutator
1. Check that the commutator surface of the brush contact has no
dirt, burnout damage or stepped abrasion.
2. Light stepped abrasion can be repaired using the fine sand
paper.
3. Measure the outside diameter of the commutator, and replace
the armature if the measurement exceeds the allowable limit.
4. If the mica (3) undercut depth exceeds the allowable limit, repair
using a saw blade.
Make sure to remove any burr resulting from repairs to the
segment (1) corner.
Outside diameter of Factory specification 35 mm
commutator Allowable limit 34 mm
Elliptical angle of Factory specification 0.02 mm

commutator outside
diameter Allowable limit 0.05 mm
Undercut of commutator Factory specification 0.45 to 0.75 mm

mica Allowable limit 0.2 mm
(1) Segment (a) Correct Usage of Saw Blade

(2) Undercut (b) Incorrect Usage of Saw Blade
(3) Mica
9Y1210019ENS0100US0
Wear of Brush
1. If the contact surface of the brush is affected by dirt or dust, use
the sandpaper to clean and adjust.
2. Measure the length of the brush (A) .
3. Replace the brush, the brush holder and the yoke if the length
of brush (A) exceeds the allowable limit, or the brush has
damage that may cause a significant decrease of the direct
contact surface area with the commutator.
Factory specification 15.0 mm
Length of brush (A)
(A) Length of Brush

9Y1210019ENS0101US0
9-S52

Insulation Test of Brush Holder
1. Examine the insulation of the brush holder and the holder
support.
2. Replace if the conduction is detected.
9Y1210019ENS0102US0
Armature Coil
1. Check the conduction between the commutator and the
armature core.
2. Replace the armature if the conduction is detected.
9Y1210019ENS0103US0
Feed Coil
1. Check the resistance value between the lead wire (1) and brush
(2).
2. It is a normal if the resistance value is 0 Ω.
3. Check the conduction between the brush (2) and the yoke (3).
4. If no conduction detected, this is correct.
5. Replace the yoke (3) if defective.
(1) Lead Wire (3) Yoke
(2) Brush
9Y1210019ENS0104US0
[2] ALTERNATOR
(1) Disassembling and Assembling
Pulley
1. Fixing the hexagonal part of the shaft with the box wrench,
loosen the pulley nut, and remove the pulley.
IMPORTANT
• Make sure to use the hexagonal box wrench. The
dodecagon type may break the corners and result in slip.
58.3 to 78.9 N·m
Tightening torque Pulley mounting nut
5.95 to 8.05 kgf·m
9Y1210019ENS0105US0
9-S53

Rear End Cover
1. Remove the screws and B terminal nuts that fix the rear end
cover, and then remove the rear end cover.
9Y1210019ENS0106US0
Brush Holder
1. Remove the screws and the brush holder (1).
(1) Brush Holder
9Y1210019ENS0107US0
IC Regulator
1. Remove the screws and IC regulator (1).
IMPORTANT
• Due to the screw lengths being different, make sure to
arrange the removed screws and make sure that they are
reattached to their original position.
(1) IC Regulator
9Y1210019ENS0108US0
Rectifier
1. Remove the rectifier (1) screw and the stator leading line, and
then remove the rectifier (1).
(1) Rectifier
9Y1210019ENS0109US0
Rear End Frame

1. Remove the nut and screw, and then remove the rear end frame
(1).
(1) Rear End Frame
9Y1210019ENS0110US0
9-S54

Rotor
1. Use the blocks (2) to place the drive end frame (3) in a level
position, and use the press to remove the rotor (1).
(1) Rotor (3) Drive End Frame
(2) Block
9Y1210019ENS0111US0
Retainer Plate
1. Remove the screws, and then remove the retainer plate (1).
(1) Retainer Plate
9Y1210019ENS0112US0
Drive End Side Bearing

1. Use the blocks (2) to place the drive end frame (3) in a level
position, and align the jig to the bearing and remove using a
press.
(1) Jig (3) Drive End Frame
(2) Block
9Y1210019ENS0113US0
Slip Ring Side Bearing

1. Use the puller (3) to remove the bearing (2).
IMPORTANT
• As the bearing (2) is used for high speed operations, make
sure to use a properly designated product during
replacement, and avoid any shock to the bearing (2).
(1) Rotor (3) Puller
(2) Bearing
9Y1210019ENS0114US0
(2) Checking and Maintenance

Bearing
1. Turn the bearing manually.
2. Check for abnormal sound or no resistance.
3. Replace the abnormal parts.
9Y1210019ENS0115US0
9-S55

Stator
1. Use the circuit tester to measure the resistance between the
lead wires.
2. It is a normal if the resistance value is 1 Ω or less.
3. Measure the resistance value between the stator core and the
lead wire.
4. The infinite resistance value is normal.
5. Replace if the abnormal parts.
IMPORTANT
• This is not due to broken wire on the stator coil unit, so if
there is no conduction, check the leading line connection
carefully.
Resistance value Factory specification 1.0 Ω or less
9Y1210019ENS0116US0
Rotor
1. Use the circuit tester to measure the resistance between the slip
rings.
2. It is a normal if the resistance value is within 2.8 to 3.3 Ω.
3. Measure the resistance value between the slip ring and the rotor
core.
4. The infinite resistance value is normal.
5. Replace if the abnormal parts.
Resistance value Factory specification 2.9 Ω
9Y1210019ENS0117US0
Slip Ring
1. Check that the slip ring is free from dirt or damage.
2. If dirt is detected, clean the slip ring using a cloth soaked in
alcohol.
3. Correct light damage using sandpaper (No. 500 to 600).
4. Measure the outside diameter of the slip ring.
5. Replace if this exceeds the allowable limits.
Outside diameter of Factory specification 14.4 mm
slip ring Allowable limit 14.0 mm
9Y1210019ENS0118US0
Brush
1. Measure the length of the brush extending from the brush
holder.
2. Replace the parts if the measurement exceeds the allowable
limits.
3. Check that the brush can move smoothly within the brush
holder.
Protrusion length of Factory specification 10.5 mm
brush Allowable limit 8.4 mm
9Y1210019ENS0119US0
9-S56

Rectifier
1. Check for the conduction in each rectifier diode using the diode
range of the circuit tester.
2. It is a normal if detecting the conduction in diode's direction of
flow, with no conduction detected in the reverse direction.
B terminal (positive red tester)
E terminals (negative black tester)
↑ conduction
↓ conduction
P1 to P4 terminals
P1 to P4 terminals (positive red tester)
(negative black tester)
(Reference)
• The rectifier quality cannot be determined by the resistance
value in the flow direction. Based on the diode characteristics,
the current direction is subject to considerable change
depending on the electrical voltage, so the tester display
depends on the differences in the tester type and the resistance
range. Consequently, the quality of the rectifier can be
determined based on the degree of difference in resistance
value in the flow and reverse directions.
(A) Red (+) (B) Black (–)
9Y1210019ENS0120US0
9-S57

8. TURBOCHARGER
[1] CHECKING
Inspection of Exhaust Gas Leaks from Turbine
• Inspect the exhaust gas leaks at the exhaust inlet and outlet
ports of the turbine housing (1).
• If the leak is significant, retighten the screws and the nuts, or
replace the gasket.
(1) Turbine Housing
9Y1210019ENS0121US0
Inspection of Air Leaks from Compressor

• Inspect air leaks at the outlet port on the compressor cover (1).
• If the leak is significant, retighten the screws and nuts, or
replace the gasket.
(1) Compressor Cover
9Y1210019ENS0122US0
Inspection of Rotation of Rotor and Shaft

• When the engine output decreases, or the exhaust temperature
increases, check whether the rotor can be easily rotated by
hand.
• If the rotation is heavy, inspect the insides of the compressor
and the turbine.
• If dirt has significantly accumulated, clean the compressor
wheel, the compressor cover, the shaft, and the turbine wheel
and the housing.
9Y1210019ENS0123US0
Inspection of Side Clearance of Rotor

• Press the compressor wheel and the turbine wheel in the axial
direction to measure the side clearance in the thrust direction.
IMPORTANT
• If the side clearance in the thrust direction (A) is 0.12 mm
or greater, replace the turbocharger as an assembly.
Side clearance in thrust
direction (A)
9Y1210019ENS0124US0
Inspection of Radial Direction Movement of Rotor

• Press the compressor wheel around the circumference (up,
down, left and right) of the housing, and inspect whether there
is any difference in the movement length or contact.
• Conduct the same inspection on the turbine wheel side.
IMPORTANT
• If the wheel of the rotor contacts to the inner surface of the
housing, replace the turbocharger as an assembly.
9Y1210019ENS0125US0
9-S58

[2] COMPLETE REPLACEMENT OR REASSEMBLY

IMPORTANT
• If the turbocharger is remounted to the engine, or the oil
lubrication is insufficient after replacement or other
procedures, pour 10 to 20 cc of new engine oil into the
lubricant inlet, and rotate the rotor manually to properly
lubricate the bearings.
• The air cleaner must be installed during operations.
• After starting the engine, check whether there are any
strange noises or vibrations. If there is a problem, turn OFF
the engine immediately, and investigate the cause.
• If the oil pressure falls while the turbocharger is running,
turn OFF the engine immediately.
• Make sure that there are no leaks from the intake, the
exhaust, or the oil pipe.
• Although servicing and cleaning of the turbocharger may
be allowed only for replacement assembly part, the
assembly's condition must be maintained even if a
malfunction occurs. Consequently, avoid disassembly
unless there is a special reason.
• The adjustment points are sealed. Do not break the seal.
(1) Coupling Screw (4) Bearing Housing
(2) Turbine Shaft (5) Compressor Housing
(3) Turbine Housing
9Y1210019ENS0126US0
9-S59

EDITOR:
KUBOTA FARM & INDUSTRIAL MACHINERY SERVICE, LTD.
64, ISHIZU-KITAMACHI, SAKAI-KU, SAKAI-CITY, OSAKA, 590-0823, JAPAN
PHONE : (81)72-241-1129
FAX : (81)72-245-2484
E-mail : ksos-pub@kubota.co.jp
KUBOTA Corporation Printed in Japan 2010. 08, S, El, EI, e Code No.9Y111-05530

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WORKSHOP MANUAL

KiSC issued 08, 2010 A

KiSC issued 08, 2010 A

KiSC issued 08, 2010 A

KiSC issued 08, 2010 A

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

KiSC issued 08, 2010 A

KiSC issued 08, 2010 A

2. FOR YOUR SAFETY OPERATION

[1] FOR YOUR SAFETY OPERATION, INSTRUCTIOMS MENTIONED

Do not operate when you don't feel well.

Both the operator and assistant(s) must wear

KiSC issued 08, 2010 A

Do not modify the combine harvester.

Do not jump in or out of the operator's seat.

No one other than the operator should ride in the

KiSC issued 08, 2010 A

(2) Precautions before Operation

No fire or flame is allowed during refueling. Do not

Check the surrounding area and ensure safety

KiSC issued 08, 2010 A

Perform daily check before operation.

Q Be sure to turn off the engine and take out the

Q Completely remove any straw accumulated

KiSC issued 08, 2010 A

Be sure to turn off the engine and take out the

(3) Precautions for Traveling, Entering/exiting the Field, and Parking

KiSC issued 08, 2010 A

Slow down the travel speed while traversing a

Do not travel on elevated, narrow roads (banks).

Use the bridges to enter/exist fields where much

KiSC issued 08, 2010 A

Set the sub shift lever to (P) (parking brake) and

(4) Precautions during Operation

Pay particular attention to looking to the rear

KiSC issued 08, 2010 A

Do not operate on surfaces where the angle of

KiSC issued 08, 2010 A

(5) Considerations when Storing after Use

Be sure to turn off the engine and remove the

When checking or cleaning, be sure to stop the

Check the engine body, muffler, wiring inside belt

When cleaning, do not touch blade edge.

KiSC issued 08, 2010 A

Check the electrical wiring such as the wire

When putting a cover over the combine harvester,

(6) Considerations During Checking and Maintenance

KiSC issued 08, 2010 A

Lock with the stopper in position when the

KiSC issued 08, 2010 A

When replacing heavy items like the sieve case,

When checking, adjusting or cleaning with the

When adjusting/replacing the reaping blade or

KiSC issued 08, 2010 A

When detaching the battery, disconnect the

Do not use or charge the battery when the battery

KiSC issued 08, 2010 A

When opening the radiator cap or reserve tank,