KJ-X 50 HERTZ SERIES (engusa)-9Y011-01832 · 2019. 12. 15. · Total displacement 2197 cm3 (134.1...

KJ-X 50 HERTZ SERIES

WORKSHOP MANUALDIESEL GENERATOR

KiSC issued 09, 2009 A

TO THE READER

This Workshop Manual has been prepared to provide servicing personnel withinformation on the mechanism, service and maintenance of KJ-X 50 Hz series. It isdivided into three parts, “General”, “Mechanism” and “Servicing”.

GeneralInformation on the engine identification, the general precautions, maintenance check

list, check and maintenance and special tools are described.

MechanismInformation on the construction and function are included. This part should be

understood before proceeding with troubleshooting, disassembling and servicing.Refer to Diesel Engine Mechanism Workshop Manual (Code No. 9Y021-01875) for

the one which has not been described to this workshop manual.

ServicingInformation on the troubleshooting, servicing specification lists, tightening torque,

checking and adjusting, disassembling and assembling, and servicing which coverprocedures, precautions, factory specifications and allowable limits.

All information illustrations and specifications contained in this manual are based onthe latest product information available at the time of publication.

The right is reserved to make changes in all information at any time without notice.Do to covering many models of this manual, information or picture being used have

not been specified as one model.

August 1999© KUBOTA Corporation 1999


1

KJ-X50 Hz SERIES, WSM SAFETY INSTRUCTIONS

SAFETY INSTRUCTIONS

BEFORE SERVICING AND REPAIRING• Read all instructions and safety instructions in this

manual and on your machine safety decals.• Clean the work area and generator unit.• Place the generator unit on a firm and level ground.• Allow the engine to cool before proceeding.• Stop the engine, and remove the key.• Disconnect the battery negative cable.• Hang a “DO NOT OPERATE” tag on the control

panel.

SAFETY FIRSTThis symbol, the industry’s “Safety Alert Symbol”, is used throughout this manual and on labels on

the machine itself to warn of the possibility of personal injury. Read these instructions carefully.It is essential that you read the instructions and safety regulations before you attempt to repair or use

this unit.

DANGER : Indicates an imminently hazardous situation which, if not avoided, will result indeath or serious injury.

WARNING : Indicates a potentially hazardous situation which, if not avoided, could result indeath or serious injury.

CAUTION : Indicates a potentially hazardous situation which, if not avoided, may result inminor or moderate injury.

IMPORTANT : Indicates that equipment or property damage could result if instructions are notfollowed.

NOTE : Gives helpful information.


2


SAFETY STARTING• Do not start the engine by shorting across starter

terminals or bypassing the safety start switch.• Unauthorized modifications to the engine may impair

the function and / or safety and affect engine life.

SAFETY WORKING• Do not work on the machine while under the influence

of alcohol, medication, or other substances or whilefatigued.

• Wear close fitting clothing and safety equipmentappropriate to the job.

• Use tools appropriate to the work. Makeshift tools,parts, and procedures are not recommended.

• When servicing is performed together by two or morepersons, take care to perform all work safely.

• Do not touch the rotating or hot parts while the engineis running.

• Never remove the radiator cap while the engine isrunning, or immediately after stopping. Otherwise, hotwater will spout out from radiator. Only removeradiator cap when cool enough to touch with barehands. Slowly loosen the cap to first stop to relievepressure before removing completely.

• Escaping fluid (fuel or hydraulic oil) under pressurecan penetrate the skin causing serious injury. Relievepressure before disconnecting hydraulic or fuel lines.Tighten all connections before applying pressure.

• Wear a suitable hearing protective device such asearmuffs or earplugs to protect against objectionableor uncomfortable loud noises.

• Do not open high-pressure fuel system.High-pressure fluid remaining in fuel lines can causeserious injury. Do not disconnect or attempt to repairfuel lines, sensors, or any other components betweenthe high-pressure fuel pump and injectors on engineswith high pressure common rail fuel system.

• High voltage exceeding 100 V is generated in theECU, and is applied to the injector.Pay sufficient caution to electric shock whenperforming work activities.


3


AVOID FIRES• Fuel is extremely flammable and explosive under

certain conditions. Do not smoke or allow flames orsparks in your working area.

• To avoid sparks from an accidental short circuit,always disconnect the battery negative cable first andconnect it last.

• Battery gas can explode. Keep sparks and openflame away from the top of battery, especially whencharging the battery.

• Make sure that no fuel has been spilled on the engine.

VENTILATE WORK AREA• If the engine must be running to do some work, make

sure the area is well ventilated. Never run the enginein a closed area. The exhaust gas contains poisonouscarbon monoxide.

PREVENT ACID BURNS• Sulfuric acid in battery electrolyte is poisonous. It is

strong enough to burn skin, clothing and causeblindness if splashed into eyes. Keep electrolyteaway from eyes, hands and clothing. If you spillelectrolyte on yourself, flush with water, and getmedical attention immediately.

DISPOSE OF FLUIDS PROPERLY• Do not pour fluids into the ground, down a drain, or

into a stream, pond, or lake. Observe relevantenvironmental protection regulations when disposingof oil, fuel, coolant, electrolyte and other harmfulwaste.


4


PREPARE FOR EMERGENCIES• Keep a first aid kit and fire extinguisher handy at all

times.• Keep emergency numbers for doctors, ambulance

service, hospital and fire department near yourtelephone.


5


The following safety decals are installed on the generator.If a decal becomes damaged, illegible or is not on the generator, replace it. The decal part number is listedin the parts list.

SAFETY DECALS


6



7

KJ-X50 Hz SERIES, WSM SPECIFICATIONS

SPECIFICATIONS

* The specification described above is of the standard engine of each model.* Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW

W1014466

Model KJ-S130VX KJ-S170FXG

ener

ator

Type Revolving field, self-excited brushless AC generator

Insulation class H

Frequency 50 Hz

Output 12.5 kVA (12.5 kW) 17.0 kVA (17.0 kW)

Voltage (AC) 110 / 220 V 120 / 240 V 110 / 220 V 120 / 240 V

Current 56.8 A 52.1 A 77.3 A 70.8 A

Number of phases 1

Number of poles 4

Power factor 100%

Eng

ine

Model V2203-E/E2 F2803-E/E2

Type Vertical, water cooled, 4-cycle, diesel engine

Number of cylinders 4 5

Bore × Stroke 87.0 × 92.4 mm (3.43 × 3.64 in.)

Total displacement 2197 cm3 (134.1 cu.in.) 2746 cm3 (167.6 cu.in.)

Rated output 16.9 kW (23.0 PS) 21.1 kW (28.7 PS)

Speed 1500 min-1 (rpm)

Combustion system Spherical combustion chamber

Compression ratio 23 : 1

Cooling system Pressurized radiator, forced circulation with water pump

Lubricating system Forced lubrication by trochoid pump

Lubricating oil Class CF lubricating oil as per API classification is recommended.If this class of lubricating oil is not available, preferably use Class CD or CE lubricating oil.

For details on recommended lubricating oils, see page G-8, 11

Starting system Electric type

Battery 12 V x 80 AH

Fuel tank capacity 37 L (9.8 U.S.gals) 60 L (16 U.S.gals)

Coolant capacity 9.0 L (2.4 U.S.gals) 10.5 L (2.77 U.S.gals)

Engine oil capacity 7.6 L (2.0 U.S.gals) 10.5 L (2.77 U.S.gals)

Net weight 500 kg (1100 lbs) 610 kg (1340 lbs)

Emergency stop mechanism In case of abnormal oil pressure or water temperature


8



W1031094

Model KJ-T130DX KJ-T180VX

Gen

erat

or


Insulation class H

Frequency 50 Hz


Voltage (AC) 220, 380, 415 V

Current 32.8, 19.0, 17.4 A 47.2, 27.3, 25.0 A

Number of phases 3

Number of poles 4

Power factor 80%

Eng

ine

Model D1703-E/E2 V2203-E/E2



Bore × Stroke 87.0 × 92.4 mm (3.43 × 3.64 in.)








Lubricating oil Class CF lubricating oil as per API classification is recommended.If this class of lubricating oil is not available, preferably use Class CD or CE lubricating oil.

For details on recommended lubricating oils, see page G-8, 11



Fuel tank capacity 37 L (9.8 U.S.gals)






9



W1036208

Model KJ-T230FX KJ-T300

Gen

erat

orType Revolving field, self-excited brushless AC generator

Insulation class H

Frequency 50 Hz


Voltage (AC) 220, 380, 415 V 380 V

Current 60.4, 34.9, 32.0 A 45.6 A

Number of phases 3

Number of poles 4

Power factor 80 %

Eng

ine

Model F2803-E/E2 V3300-E2BG



Bore × Stroke 87.0 × 92.4 mm (3.43 × 3.64 in.) 98.0 × 110 mm (3.86 × 4.33 in.)





Compression ratio 23 : 1 22.6 : 1



Lubricating oilClass CF lubricating oil as per API classification is recommended.

If this class of lubricating oil is not available, preferably use Class CD or CE lubricating oil.For details on recommended lubricating oils, see page G-8, 11


Battery 12 V x 80 AH 12 V x 92 AH

Fuel tank capacity 60 L (16 U.S.gals) 60 L (16 U.S.gals)






10


[For AUSTRALIA]


W1040045

Model KJ-S130VX-AUS KJ-S170FX-AUS

Gen

erat

or


Insulation class H

Frequency 50 Hz


Voltage (AC) 240 V

Current 52.1 A 70.8 A

Number of phases 1

Number of poles 4

Power factor 100 %

Eng

ine

Model V2203-E/E2 F2803-E/E2



Bore × Stroke 87.0 × 92.4 mm (3.43 × 3.64 in.)


















11


[For AUSTRALIA]


W1032024

Model KJ-T130DX-AUS KJ-T180VX-AUS KJ-T230FX-AUSG

ener

ator


Insulation class H

Frequency 50 Hz

Output 12.5 kVA (10.0 kW) 18.0 kVA (14.4 kW) 23.0 kVA (18.4 kW)

Voltage (AC) 240 / 415 V

Current 17.4 A 25.0 A 32.0 A

Number of phases 3

Number of poles 4

Power factor 80 %

Eng

ine

Model D1703-E/E2 V2203-E/E2 F2803-E/E2


Number of cylinders 3 4 5

Bore × Stroke 87.0 × 92.4 mm (3.43 × 3.64 in.)

Total displacement 1647 cm3 (100.5 cu.in.) 2197 cm3 (134.1 cu.in.) 2746 cm3 (167.6 cu.in.)

Rated output 12.7 kW (17.3 PS) 16.9 kW (23.0 PS) 21.1 kW (28.7 PS)











Coolant capacity 8.0 L (2.1 U.S.gals) 9.0 L (2.4 U.S.gals) 10.5 L (2.77 U.S.gals)

Engine oil capacity 5.6 L (1.5 U.S.gals) 7.6 L (2.0 U.S.gals) 10.5 L (2.77 U.S.gals)

Net weight 455 kg (1000 lbs) 510 kg (1120 lbs) 620 kg (1370 lbs)



12


[For AUSTRALIA]


W1041583

Model KJ-S240-AUS KJ-T300-AUS

Gen

erat

or


Insulation class H

Frequency 50 Hz


Voltage (AC) 240 V 240 / 415 V

Current 100.0 A 41.7 A

Number of phases 1 3

Number of poles 4

Power factor 100 % 80 %

Eng

ine

Model V3300-E2BG


Number of cylinders 4

Bore × Stroke 98.0 × 110 mm (3.86 × 4.33 in.)

Total displacement 3318 cm3 (202.5 cu.in.)

Rated output 27.6 kW (37.5 PS)



Compression ratio 22.6 : 1







Fuel tank capacity 60 L (16 U.S.gals)

Coolant capacity 9.5 L (2.5 U.S.gals)

Engine oil capacity 13.2 L (3.49 U.S.gals)




13

KJ-X50 Hz SERIES, WSM DIMENSIONS

DIMENSIONS

For General

W1015752

For AUS

W1034807

Model KJ-S130VX KJ-S170FX KJ-T130DX KJ-T180VX KJ-T230FX KJ-T300Length mm (in.) 1488 (58.58) 1610 (63.39) 1393 (54.84) 1488 (58.58) 1613 (63.50) 1717 (67.60)

Width mm (in.) 650 (25.6) 740 (29.1) 650 (25.6) 650 (25.6) 740 (29.1) 824 (32.4)

Height mm (in.) 971 (38.2) 996 (39.2) 971 (38.2) 971 (38.2) 996 (39.2) 1046 (41.18)

Model KJ-S130VX-AUS

KJ-S170FX-AUS

KJ-T130DX-AUS

KJ-T180VX-AUS

KJ-T230FX-AUS

KJ-S240-AUS

KJ-T300-AUS

Length mm (in.) 1518 (59.76) 1643 (64.68) 1423 (56.02) 1518 (59.76) 1643 (64.68) 1717 (67.60) 1717 (67.60)

Width mm (in.) 650 (25.6) 740 (29.1) 650 (25.6) 650 (25.6) 740 (29.1) 824 (32.4) 824 (32.4)

Height mm (in.) 971 (38.2) 996 (39.2) 971 (38.2) 971 (38.2) 996 (39.2) 1046 (41.18) 1046 (41.18)


G GENERAL


CONTENTS

GENERAL

1. GENERATOR IDENTIFICATION.................................................................... G-12. ENGINE IDENTIFICATION............................................................................. G-2

[1] MODEL NAME AND ENGINE SERIAL NUMBER ................................ G-2[2] E2B ENGINE............................................................................................. G-3[3] CYLINDER NUMBER ............................................................................... G-3

3. GENERAL PRECAUTIONS ............................................................................ G-44. LUBRICANTS, FUEL AND COOLANT ......................................................... G-55. TIGHTENING TORQUES ............................................................................... G-6

[1] TIGHTENING TORQUES FOR GENERAL USE SCREWS, BOLTSAND NUTS................................................................................................ G-6

6. MAINTENANCE CHECK LIST....................................................................... G-77. CHECK AND MAINTENANCE....................................................................... G-9

[1] DAILY CHECK .......................................................................................... G-9[2] CHECK POINTS OF INITIAL 50 HOURS ........................................... G-11[3] CHECK POINTS OF EVERY 100 HOURS......................................... G-12[4] CHECK POINTS OF EVERY 250 HOURS......................................... G-14[5] CHECK POINTS OF EVERY 500 HOURS......................................... G-16[6] CHECK POINTS OF EVERY 1000 HOURS....................................... G-17[7] CHECK POINTS OF EVERY 1500 HOURS....................................... G-21[8] CHECK POINTS OF EVERY 3000 HOURS....................................... G-23[9] CHECK POINTS OF EVERY 1 YEAR ................................................ G-26[10]CHECK POINTS OF EVERY 2 YEARS.............................................. G-27

8. SPECIAL TOOLS.......................................................................................... G-31[1] ALL MODELS.......................................................................................... G-31[2] D1703-E/E2, V2203-E/E2, F2803-E/E2 ................................................... G-32[3] V3300-E2BG............................................................................................ G-37


G-1

KJ-X50 Hz SERIES, WSM G GENERAL

1. GENERATOR IDENTIFICATIONWhen contacting your local KUBOTA distributor, always specify

the model name and serial number of generator unit.

W1010481

(1) Model Name and Generator Unit Serial Number

[A] KJ-S130VX(-AUS)KJ-S170FX(-AUS)KJ-T130DX(-AUS)KJ-T180VX(-AUS)KJ-T230FX(-AUS)

[B] KJ-T300(-AUS)KJ-S240-AUS


G-2


2. ENGINE IDENTIFICATION[1] MODEL NAME AND ENGINE SERIAL NUMBER

When contacting the manufacture, always specify your enginemodel name and serial number.

The engine model and its serial number need to be identifiedbefore the engine can be serviced or parts replaced.

Engine Serial NumberThe engine serial number is an identified number for the engine.

It is marked after the engine model number.It indicates month and year of manufacture as follows.

• Year of manufacture

W1010477

Alphabet or Number Year Alphabet or

Number Year

1 2001 F 2015

2 2002 G 2016

3 2003 H 2017

4 2004 J 2018

5 2005 K 2019

6 2006 L 2020

7 2007 M 2021

8 2008 N 2022

9 2009 P 2023

A 2010 R 2024

B 2011 S 2025

C 2012 T 2026

D 2013 V 2027

E 2014

(1) Engine Model Name and Serial Number

[A] D1703-E/E2V2203-E/E2F2803-E/E2

[B] V3300-E2BG


G-3


• Month of manufacture

* Alphabetical letters “I” and “O” are not used.e.g. D1703 - 8 B A001

(a) (b)(c) (d)

W1011076

[2] E2B ENGINE[Example : Engine Model Name D1703-E2B-XXXX or V3300-E2BG-XXXX]The emission controls that have been put into effect in various countries to prevent air pollution will be stepped up.

The time to enforce the regulations differs depending on the engine output classifications.Kubota has been supplying the diesel engines conforming to the emission regulations in respective countries.

Exhaust emissions regulations shift to the second stage. Kubota executed the improvement of the engine accordingto this regulation.

In order to discriminate the engines conforming to Tier 1 / Phase 1 requirements and those conforming to Tier 2 /Phase 2 requirements, we have adopted E2B or E2BG as a new model name for the engines conforming Tier 2 /Phase 2 regulations.

In the after-sale services for E2B or E2BG engines, only use the dedicated parts for E2B or E2BG models and carryout the maintenance services accordingly.

[3] CYLINDER NUMBERThe cylinder numbers of KUBOTA diesel engine are designated

as shown in the figure.The sequence of cylinder numbers is given as No.1, No.2, No.3

and No.4 starting from the gear case side.W1011077

Month Engine Lot Number

January A0001 ~ A9999 B0001 ~ BZ999

February C0001 ~ C9999 D0001 ~ DZ999

March E0001 ~ E9999 F0001 ~ FZ999

April G0001 ~ G9999 H0001 ~ HZ999

May J0001 ~ J9999 K0001 ~ KZ999

June L0001 ~ L9999 M0001 ~ MZ999

July N0001 ~ N9999 P0001 ~ PZ999

August Q0001 ~ Q9999 R0001 ~ RZ999

September S0001 ~ S9999 T0001 ~ TZ999

October U0001 ~ U9999 V0001 ~ VZ999

November W0001 ~ W9999 X0001 ~ XZ999

December Y0001 ~ Y9999 Z0001 ~ ZZ999

(a) Engine Model Name : D1703(b) Year : 8 indicates 2008(c) Month : A or B indicates January(d) Lot number : (0001 ~ 9999 or A001 ~ Z999)


G-4


3. GENERAL PRECAUTIONS• During disassembly, carefully arrange removed parts in a clean

area to prevent confusion later. Screws, bolts and nuts should bereplaced in their original position to prevent reassembly errors.

• When special tools are required, use KUBOTA genuine specialtools. Special tools which are not frequently used should bemade according to the drawings provided.

• Before disassembling or servicing live wires, make sure toalways disconnect the grounding cable from the battery first.

• Remove oil and dirt from parts before measuring.• Use only KUBOTA genuine parts for parts replacement to

maintain engine performance and to ensure safety.• Gaskets and O-rings must be replaced during reassembly.

Apply grease to new O-rings or oil seals before assembling.• When reassembling external or internal snap rings, position them

so that the sharp edge faces against the direction from whichforce is applied.

• Be sure to perform run-in the serviced or reassembled engine.Do not attempt to give heavy load at once, or serious damagemay result to the engine.

W1011734

(1) Grease(2) Force(3) Place the Sharp Edge against the

Direction of Force

(A) External Snap Ring(B) Internal Snap Ring


G-5


4. LUBRICANTS, FUEL AND COOLANT

W1010720

Item Model Capacity Grade

Engine oil

KJ-T130DXKJ-T130DX-AUS

5.6 L1.5 U.S.gals

Class CF lubricating oil as per API classification is recommended.If this class of lubricating oil is not available, preferably use Class CD or CE lubricating oil.For details on recommended lubricating oils, see page G-8, 11.Above 25 °C (77 °F)

SAE 10W-30SAE 10W-40SAE 30

0 °C to 25 °C (32 °F to 77 °F) SAE 10W-30SAE 10W-40SAE 20

Below 0 °C (32 °F)SAE 10W-30SAE 10W-40SAE 10W

KJ-S130VXKJ-T180VX

KJ-S130VX-AUSKJ-T180VX-AUS

7.6 L2.0 U.S.gals

KJ-S170FXKJ-T230FX

KJ-S170FX-AUSKJ-T230FX-AUS

10.5 L2.77 U.S.gals

KJ-T300KJ-S240-AUSKJ-T300-AUS

13.2 L3.49 U.S.gals

Fuel

KJ-S130VXKJ-T130DXKJ-T180VX

KJ-S130VX-AUSKJ-T130DX-AUSKJ-T180VX-AUS

37 L9.8 U.S.gals

Diesel fuel No. 2-D (ASTM D975)KJ-S170FXKJ-T230FX

KJ-T300KJ-S170FX-AUSKJ-T230FX-AUS

KJ-S240-AUSKJ-T300-AUS

60 L16 U.S.gals

Coolant

KJ-T130DXKJ-T130DX-AUS

8.0 L2.1 U.S.gals

Clean water (Soft water)Use antifreeze 50 / 50

KJ-S130VXKJ-T180VX

KJ-S130VX-AUSKJ-T180VX-AUS

9.0 L2.4 U.S.gals

KJ-S170FXKJ-T230FX

KJ-S170FX-AUSKJ-T230FX-AUS

10.5 L2.77 U.S.gals

KJ-T300KJ-S240-AUSKJ-T300-AUS

9.5 L2.5 U.S.gals


G-6


5. TIGHTENING TORQUESScrews, bolts and nuts must be tightened to the specified torque using a torque wrench, several screws bolts and

nuts such as those used on the cylinder head must be tightened in proper sequence and the proper torque.

[1] TIGHTENING TORQUES FOR GENERAL USE SCREWS, BOLTS ANDNUTS

When the tightening torques are not specified, tighten the screws, bolts and nuts according to the table below.

W10371750

Screw and bolt material grades are shown by numbers punched on the screw and bolt heads. Prior totightening, be sure to check out the numbers as shown below.

W1012705

Grade

Nominal UnitDiameter

Standard Screw and Bolt

Special Screw and Bolt

N·m kgf·m lbf·ft N·m kgf·m lbf·ft

M6 7.9 to 9.3 0.80 to 0.95 5.8 to 6.8 9.81 to 11.2 1.00 to 1.15 7.24 to 8.31M8 18 to 20 1.8 to 2.1 13 to 15 24 to 27 2.4 to 2.8 18 to 20M10 40 to 45 4.0 to 4.6 29 to 33 49 to 55 5.0 to 5.7 37 to 41M12 63 to 72 6.4 to 7.4 47 to 53 78 to 90 7.9 to 9.2 58 to 66M14 108 to 125 11.0 to 12.8 79.6 to 92.5 124 to 147 12.6 to 15.0 91.2 to 108

Punched number Screw and bolt material gradeNone or 4 Standard screw and bolt SS41, S20C

7 Special screw and bolt S43C, S48C (Refined)


G-7


6. MAINTENANCE CHECK LISTTo maintain long-lasting and safe engine performance, make it a rule to carry out regular inspections by following

the table below.

* The items listed above (* marked) are registered as emission related critical parts by KUBOTA in the U.S. EPAnonroad emission regulation. As the engine owner, you are responsible for the performance of the requiredmaintenance on the engine according to the above instruction.

W1029462

Service interval

ItemDaily

Initial 50

hours

Every 100

hours

Every 250

hours

Every 500

hours

Every 1000 hours

Every 1500

hours

Every 3000

hours

Every 1

year

Every 2

year

Refe-rence Page

Engine oilChecking G-9

Changing G-11, 14

Oil filter cartridge Replacing G-12, 16

CoolantChecking G-10

Changing G-27

*Air cleaner element (replace the element after 6-times cleanings)

Clearing G-12

Replacing G-29

Fan beltChecking G-12,

15

Replacing G-17

*Fuel hoses and clamp bands

Checking G-13

Replacing G-29

*Intake air lineChecking G-15

Replacing G-29

BatteryChecking G-13

Replacing G-30

Radiator hoses and clamp bands

Checking G-15

Replacing G-30

*Fuel filter Replacing G-16

Water jacket and radiator interior Cleaning G-18

Valve clearance Checking G-19, 20

Electric wiring and loose connections Checking –

*Injection nozzle pressure Checking G-21,

22

*Injection pump Checking G-25

*Injection timing Checking G-23, 24

Generator side bearing Checking G-21


G-8


CAUTION• When changing or inspecting, be sure to level and stop the engine. NOTE

Lubricating OilWith the emission control now in effect, the CF-4 and CG-4 lubricating oils have been developed for use of a low-

sulfur fuel on-road vehicle engines. When an off-road vehicle engine runs on a high-sulfur fuel, it is advisable toemploy the CF, CD or CE lubricating oil with a high total base number. If the CF-4 or CG-4 lubricating oil is used witha high-sulfur fuel, change the lubricating oil at shorter intervals.• Lubricating oil recommended when a low-sulfur or high-sulfur fuel is employed.

: Recommendable X : Not recommendableW1035555

Fuel

Lubricatingoil class

Low sulfur(0.5 % ≥) High sulfur Remarks

CF TBN ≥ 10CF-4 XCG-4 X


G-9


7. CHECK AND MAINTENANCE[1] DAILY CHECK

Checking Engine Oil Level1. Level the engine.2. To check the oil level, draw out the dipstick (1), wipe it clean,

reinsert it, and draw it out again.Check to see that the oil level lies between the two notches.

3. If the level is too low, add new oil to the specified level.IMPORTANT

• When using an oil of different maker or viscosity from theprevious, drain old oil. Never mix two different types of oil.NOTE

• Be sure to inspect the engine, locating it on a horizontalplace. If placed on gradients, accurately, oil quantity maynot be measured.

• Be sure to keep the oil level between upper and lower limitsof the dipstick. Too much oil may cause a drop in output orexcessive blow-by gas. On the closed breather type enginein which mist is sucked through port, too much oil maycaused oil hammer. While too little oil, may seize theengine’s rotating and sliding parts.

W1056278

(1) Dipstick

(a) Maximum(b) Minimum




G-10


Checking and Replenish Coolant

CAUTION• Do not remove the radiator cap until coolant temperature is

below its boiling point. Then loosen the cap slightly torelieve any excess pressure before removing the capcompletely.

1. Remove the radiator cap and check to see that the coolant levelis just below the port.

2. Check to see that the coolant level lies between FULL (A) andLOW (B).

3. If coolant level is too low, check the reason for decreasingcoolant.(Case 1)If coolant is decreasing by evaporation, replenish only fresh, softwater.(Case 2)If coolant is decreasing by leak, replenish coolant of the samemanufacture and type in the specified mixture ratio (fresh, softwater and L.L.C.). If the coolant brand cannot be identified, drainout all of the remaining coolant and refill with a totally new brandof coolant mix.IMPORTANT

• During filling the coolant, air must be vented from the enginecoolant passages. The air vents by jiggling the radiatorupper and lower hoses.

• Be sure to close the radiator cap securely. If the cap is looseor improperly closed, coolant may leak out and the enginecould overheat.

• Do not use an antifreeze and scale inhibitor at the same time.• Never mix the different type or brand of L.L.C..

W1056506

(1) Recovery Tank

(A) FULL(B) LOW




G-11


[2] CHECK POINTS OF INITIAL 50 HOURSChanging Engine Oil

CAUTION• Be sure to stop engine before changing engine oil.

1. Start and warm up the engine for approx. 5 minutes.2. Place an oil pan underneath the engine.3. To drain the used oil, remove the drain plug (1) at the bottom of

the engine and drain the oil completely.4. Screw the drain plug (1).5. Fill new oil up to upper line on the dipstick (2).

IMPORTANT• When using an oil of different maker or viscosity from the

previous one, remove all of the old oil.• Never mix two different types of oil.• Engine oil should have properties of API classification CD/

CE/CF/CF-4/CG-4.• Use the proper SAE Engine Oil according to ambient

temperature.

W1056639

Above 25 °C (77 °F) SAE 30 or SAE 10W-30 SAE 10W-40

0 °C to 25 °C (32 °F to 77 °F) SAE 20 or SAE 10W-30 SAE 10W-40

Below 0 °C (32 °F) SAE 10W or SAE 10W-30 SAE 10W-40

Models Capacity

KJ-T130DX(-AUS) 5.6 L1.5 U.S.gals

KJ-S130VX(-AUS)KJ-T180VX(-AUS)

7.6 L2.0 U.S.gals

KJ-S170FX(-AUS)KJ-T230FX(-AUS)

10.5 L2.77 U.S.gals

KJ-T300(-AUS)KJ-S240-AUS

13.2 L3.49 U.S.gals

(1) Drain Plug(2) Dipstick





G-12


Replacing Oil Filter Cartridge

CAUTION• Be sure to stop the engine before replacing filter cartridge.

1. Remove the oil filter cartridge (1) with the filter wrench.2. Apply a slight coat of oil onto the new cartridge gasket.3. To install the new cartridge, screw it in by hand. Over tightening

may cause deformation of rubber gasket.4. After the new cartridge has been replaced, the engine oil

normally decrease a little. Thus see that the engine oil does notleak through the seal and be sure to read the oil level on thedipstick. Then, replenish the engine oil up to the specified level.IMPORTANT

• To prevent serious damage to the engine, replacementelement must be highly efficient. Use only a KUBOTAgenuine filter or its equivalent.

W1056762

Checking Fan Belt Tension1. Measure the deflection (A), depressing the belt halfway between

the fan drive pulley and alternator pulley at specified force 98 N(10 kgf, 22 lbf).

2. If the measurement is not within the factory specifications, loosenthe alternator mounting screws and relocate the alternator toadjust.

W10356670

[3] CHECK POINTS OF EVERY 100 HOURSCleaning Air Cleaner Element1. Remove the air cleaner element.2. Use clean dry compressed air on the inside of the element.

Pressure of compressed air must be under 205 kPa (2.1 kgf/cm2,30 psi).Maintain reasonable distance between the nozzle and the filter.NOTE

• The air cleaner uses a dry element. Never apply oil to it.• Do not run the engine with filter element removed.• Change the element once a year or every 6th cleaning.

W1045746

(1) Engine Oil Filter Cartridge [A] KJ-S130VX(-AUS)KJ-S170FX(-AUS)KJ-T130DX(-AUS)KJ-T180VX(-AUS)KJ-T230FX(-AUS)


Deflection (A) Factory spec.

KJ-S130VX(-AUS)KJ-S170FX(-AUS)KJ-T130DX(-AUS)KJ-T180VX(-AUS)KJ-T230FX(-AUS)

7.0 to 9.0 mm0.28 to 0.35 in.


10 to 12 mm0.40 to 0.47 in.

(A) Deflection


G-13


Checking Fuel Hoses and Clamp Bands1. If the clamp (1) is loose, apply oil to the threads and securely

retighten it.2. The fuel hose (3) is made of rubber and ages regardless of the

period service.Change the fuel hose together with the clamp every two years.

3. However, if the fuel hose and clamp are found to be damaged ordeteriorate earlier than two years, then change or remedy.

4. After the fuel hose and the clamp have been changed, bleed thefuel system.

CAUTION• Stop the engine when attempting the check and change

prescribed above.

(When bleeding fuel system)1. Loosen the air vent plug (4) of the fuel filter a few turns.2. Screw back the plug when bubbles do not come up any more.3. Open the air vent cock (2) on top of the fuel injection pump.4. If equipped electrical fuel feed pump, turn the key to AC position

and pump the fuel up for 10 to 15 seconds.If equipped mechanical fuel feed pump, set the stop lever on stopposition and crank the engine for 10 to 15 seconds.

5. Close securely the air vent cock after air bleeding.NOTE

• Always keep the air vent cock on the fuel injection pumpclosed except when air is vented, or it may cause the engineto stop.

W1057097

Checking Battery Electrolyte Level1. Check the battery electrolyte level.2. If the level is below than lower level line (2), and the distilled water

to pour level of each cell.

W1047154

(1) Clamp(2) Air Vent Cock(3) Fuel Hose(4) Air Vent Plug



(1) Upper Level Line (2) Lower Level Line


G-14


[4] CHECK POINTS OF EVERY 250 HOURSChanging Engine Oil

CAUTION• Be sure to stop engine before changing engine oil.

1. Start and warm up the engine for approx. 5 minutes.2. Place an oil pan underneath the engine.3. To drain the used oil, remove the drain plug (1) at the bottom of

the engine and drain the oil completely.4. Screw the drain plug (1).5. Fill new oil up to upper line on the dipstick (2).

IMPORTANT• When using an oil of different maker or viscosity from the

previous one, remove all of the old oil.• Never mix two different types of oil.• Engine oil should have properties of API classification CD/

CE/CF/CF-4/CG-4.• Use the proper SAE Engine Oil according to ambient

temperature.

W1021645

Above 25 °C (77 °F) SAE 30 or SAE 10W-30 SAE 10W-40

0 °C to 25 °C (32 °F to 77 °F) SAE 20 or SAE 10W-30 SAE 10W-40

Below 0 °C (32 °F) SAE 10W or SAE 10W-30 SAE 10W-40

Models Capacity

KJ-T130DX(-AUS) 5.6 L1.5 U.S.gals

KJ-S130VX(-AUS)KJ-T180VX(-AUS)

7.6 L2.0 U.S.gals

KJ-S170FX(-AUS)KJ-T230FX(-AUS)

10.5 L2.77 U.S.gals


13.2 L3.49 U.S.gals

(1) Drain Plug(2) Dipstick





G-15


Fan Belt Damage and Wear1. Check the fan belt for damage.2. If the fan belt is damaged, replace it.3. Check if the fan belt is worn and sunk in the pulley groove.4. If the fan belt is nearly worn out and deeply sunk in the pulley

groove, replace it.

W1057475

Checking Intake Air Line1. Check to see if the intake air hose(s) is properly fixed every 250

hours of operation.2. If the clamp is loose, apply oil to the threads and retighten it

securely.3. The intake air hose(s) is made of rubber and tends to age. It must

be changed every two years. Also change the clamp and tightenit securely.IMPORTANT

• To prevent serious damage to the engine, keep out any dustinside the intake air line.

W1029631

Checking Radiator Hoses and Clamp Bands1. Check to see if the radiator hoses are properly fixed every 250

hours of operation or every six months, whichever comes first.2. If the clamp (1) is loose, apply oil to the threads and retighten it

securely.3. The radiator hose (2) is made of rubber and tends to age. It must

be replaced every two years. Also replace the clamp and tightenit securely.

W1029518

(A) Good (B) Bad

(1) Intake Air Hose (2) Clamp

(1) Clamp(2) Radiator Hose




G-16


[5] CHECK POINTS OF EVERY 500 HOURSReplacing Oil Filter Cartridge

CAUTION• Be sure to stop the engine before replacing filter cartridge.

1. Remove the oil filter cartridge (1) with the filter wrench.2. Apply a slight coat of oil onto the new cartridge gasket.3. To install the new cartridge, screw it in by hand. Over tightening

may cause deformation of rubber gasket.4. After the new cartridge has been replaced, the engine oil

normally decrease a little. Thus see that the engine oil does notleak through the seal and be sure to read the oil level on thedipstick. Then, replenish the engine oil up to the specified level.IMPORTANT

• To prevent serious damage to the engine, replacementelement must be highly efficient. Use only a KUBOTAgenuine filter or its equivalent.

W1021505

Replacing Fuel Filter CartridgeWater and dust in fuel are collected in the filter cartridge. So,

change the filter cartridge every 500 hours service. 1. Remove the used filter cartridge with filter wrench.2. Apply a thin film of fuel to the surface of new filter cartridge gasket

before screwing on.3. Then tighten enough by hand.4. Loosen the air vent plug to let the air out.5. Start engine and check for fuel leakage.

W1057596

(1) Engine Oil Filter Cartridge [A] KJ-S130VX(-AUS)KJ-S170FX(-AUS)KJ-T130DX(-AUS)KJ-T180VX(-AUS)KJ-T230FX(-AUS)


(1) Fuel Filter Cartridge [A] KJ-S130VX(-AUS)KJ-S170FX(-AUS)KJ-T130DX(-AUS)KJ-T180VX(-AUS)KJ-T230FX(-AUS)



G-17


[6] CHECK POINTS OF EVERY 1000 HOURSReplacing Fan Belt1. Remove the alternator.2. Remove the fan belt (1).3. Replace new fan belt.4. Install the alternator.5. Check the fan belt tension.

W1052220


KJ-S130VX(-AUS)KJ-S170FX(-AUS)KJ-T130DX(-AUS)KJ-T180VX(-AUS)KJ-T230FX(-AUS)

7.0 to 9.0 mm / 98 N0.28 to 0.35 in. / 98 N(10 kgf, 22 lbf)


10 to12 mm / 98 N0.40 to 0.47 in. / 98 N(10 kgf, 22 lbf)

(1) Fan Belt (A) Deflection


G-18


Cleaning Water Jacket and Radiator Interior

CAUTION• Do not remove the radiator cap when the engine is hot. Then

loosen cap slightly to the stop to relieve any excesspressure before removing cap completely.

1. Stop the engine and let cool down.2. To drain the coolant, open the radiator drain plug (2) and remove

the radiator cap (1). Then radiator cap (1) must be removed tocompletely drain the coolant. And open the drain cock (3). ([B]only.)

3. After all coolant is drained, close the drain plug.4. Fill with clean water and cooling system cleaner.5. Follow directions of the cleaner instruction.6. After flushing, fill with clean water and anti-freeze until the coolant

level is just below the port. Install the radiator cap (1) securely.7. Fill with coolant up to “FULL” (A) mark on the recovery tank (3).8. Start and operate the engine for few minutes.9. Stop the engine and let cool. Check coolant level of radiator and

recovery tank (3) and add coolant if necessary.IMPORTANT

• Do not start engine without coolant.• Use clean, fresh, soft water and anti-freeze to fill the radiator

and recovery tank.• When the anti-freeze is mixed with fresh, soft water, the anti-

freeze mixing ratio must be less than 50 %.• Securely tighten radiator cap. If the cap is loose or

improperly fitted, water may leak out and the engine couldoverheat.

W1038102

(1) Radiator Cap(2) Drain Plug(3) Drain Cock(4) Recovery TankA : FullB : Low




G-19


Checking Valve Clearance (To be continued)[D1703-E/E2, V2203-E/E2, F2803-E/E2]

IMPORTANT• Valve clearance must be checked and adjusted when engine

is cold.1. Remove the head cover.2. Align the “1TC” mark line (3) on the flywheel and projection (2)

on the housing so that the No.1 piston comes to the compressionor overlap top dead center.

3. Check the following valve clearance (1) marked with “ ” using afeeler gauge.

4. If the clearance is not within the factory specifications, adjust withthe adjusting screw.

NOTE• The “1TC” mark line on the flywheel is just for No. 1 cylinder.

There is no “TC” marking for the other cylinders.• No. 1 piston comes to the top dead center position when the

“TC” marking is aligned with the projection (2) in the windowon flywheel-housing. Turn the flywheel 0.26 rad (15 °)clockwise and counterclockwise to see if the piston is at thecompression top dead center or the overlap position. Nowreferring to the table below, readjust the valve clearance (1).(The piston is at the top dead center when both the IN. andEX. valves do not move; it is at the overlap position whenboth the valves move.)

• Finally turn the flywheel 6.28 rad (360 °) and align the “1TC”mark line and the projection (2) perfectly. Adjust all theother valve clearance as required.

• After turning the flywheel counterclockwise twice or threetimes, recheck the valve clearance (1).

• After adjusting the valve clearance (1), firmly tighten the locknut of the adjusting screw.

W10161700

Valve clearance Factory spec. 0.18 to 0.22 mm0.0071 to 0.0086 in.

Valve arrangementAdjustablecylinderlocation of piston

3 Cylinder 4 Cylinder 5 Cylinder

IN. EX. IN. EX. IN. EX.

When No. 1 piston is at compression top dead center

No. 1

No. 2

No. 3

No. 4 – –

No. 5 – – – –

When No. 1 piston is at overlap position

No. 1

No. 2

No. 3

No. 4 – –

No. 5 – – – –

(1) Valve Clearance(2) Projection

(3) 1TC Mark Line


G-20


Checking Valve Clearance (Continued)[V3300-E2BG]


is cold.1. Remove the head cover.2. Align the 1TC mark of flywheel and the convex of flywheel

housing timing windows so that the first piston (gear case side)comes to the compression top dead center.

3. Before adjusting the valve clearance of intake valve, adjust thebridge evenly to the valves stem.

4. Loosen the lock nut (2) and adjust with screw (1).5. Slightly push the rocker arm (intake side) by your fingers and

screw in the adjusting screw slowly until you feel the screw touchthe top of valve stem, then tighten the lock nut.

6. Loosen the lock nut (4) of adjusting screw (3) (push rod side) andinsert the thickness gauge between the rocker arm and thebridge head. Set the adjusting screw to the specified value, thentighten the lock nut.

7. Adjust the clearance between the rocker arm (exhaust side) andthe exhaust valve to the specified value.

NOTE• After adjusting, tighten the lock nut (4) securely.

W1037215



IN. EX

When No.1 piston is at compression top dead center

No. 1

No. 2

No. 3

No. 4

When No.1 piston is at overlap position

No. 1

No. 2

No. 3

No. 4

Tightening torque Cylinder head cover screw6.9 to 11.3 N·m0.7 to 1.15 kgf·m5.1 to 8.32 lbf·ft

(1) Adjusting Screw(2) Lock Nut



G-21


Checking Ball Bearing1. Measure axial dislocation of the outer ring.2. If the axial dislocation exceeds the allowable limit, replace the

bearing.

3. Measure the I.D. of the bearing housing.4. If the wear exceeds the allowable limit, replace the end bracket.

W1022010

[7] CHECK POINTS OF EVERY 1500 HOURS

CAUTION• Check the injection pressure and condition after confirming that there is nobody standing in the direction

the fume goes.• If the fume from the nozzle directly contacts the human body, cells may be destroyed and blood poisoning

may be caused.Nozzle Spraying Condition1. Set the injection nozzle to a nozzle tester, and check the nozzle

spraying condition.2. If the spraying condition is defective, replace the nozzle piece.

W10443270

Axial dislocation Allowable limit 0.05 mm0.002 in.

Bearing housing I.D. Allowable limit 90.02 mm

3.544 in.

(a) Good (b) Bad


G-22


Fuel Injection Pressure1. Set the injection nozzle to a nozzle tester.2. Slowly move the tester handle to measure the pressure at which

fuel begins jetting out from the nozzle.3. If the measurement is not within the factory specifications,

replace the adjusting washer (1) in the nozzle holder to adjust it.(Reference)• Pressure variation with 0.025 mm (0.00098 in.) difference of

adjusting washer thickness.Approx. 590 kPa (6.0 kgf/cm2, 85 psi)

W10182100

Valve Seat Tightness1. Set the injection nozzle to a nozzle tester.2. Raise the fuel pressure, and keep at 12.75 MPa (130.0 kgf/cm2,

1849 psi) for 10 seconds.3. If any fuel leak is found, replace the nozzle piece.

W10444330

Fuel injection pressure Factory spec.13.73 to 14.70 MPa140.0 to 150.0 kgf/cm2

1992 to 2133 psi

(1) Adjusting Washer

Valve seat tightness Factory spec.

No fuel leak at12.75 MPa130.0 kgf/cm2

1849 psi


G-23


[8] CHECK POINTS OF EVERY 3000 HOURSInjection Timing (To be continued)[KJ-S130VX(-AUS), KJ-S170FX(-AUS), KJ-T130DX(-AUS), KJ-T180VX(-AUS), KJ-T230FX(-AUS)]1. Remove the injection pipes and nozzle.2. Set the speed control lever to maximum fuel discharge position.(Reference)• Turn the flywheel with screwdriver.

3. Turn the flywheel counterclockwise (facing the flywheel) until thefuel fills up to the hole of the delivery valve holder (1) for 1stcylinder.

4. Turn the flywheel further and stop turning when the fuel begins toflow over, to get the present injection timing.

5. (The flywheel has mark 1TC and four lines indicating every 0.09rad (5 °) of crank angle from 0.17 rad (10 °) to 0.44 rad (25 °)before mark 1TC.) Calculate the angle which the center of thewindow points out. If the calculation differs from specifiedinjection timing, add or remove the shim to adjust.

(Injection Timing)

NOTE• The sealant is applied to both sides of the soft metal gasket

shim. The liquid gasket is not required for assembling.• Shims are available in thickness of 0.175 mm (7), 0.20 mm

(4), 0.25 mm (5) and 0.30 mm (6). Combine these shims foradjustments.

• The 0.175 mm thick shim is coated only on the lower face.Therefore, do not use the 0.175 mm thick shim as the topshim of the combination (injection pump side), because thiscause oil leakage.

• Addition or reduction of shim (0.05 mm, 0.002 in.) delays oradvances the injection timing by approx. 0.009 rad (0.5 °).

• In disassembling and replacing, be sure to use the samenumber of new gasket shims with the same thickness.

W1023147

Model Injection timing

D1703-E, V2203-EV2203-E2, F2803-E2 0.27 to 0.29 rad (15 ° to 17 °) before T.D.C.

F2803-E 0.28 to 0.31 rad (16 ° to 18 °) before T.D.C.

D1703-E2 0.236 to 0.270 rad (13.5 ° to 15.5 °) before T.D.C.

(1) Delivery Valve Holder(2) Timing Mark(3) Shim (Soft Metal Gasket Shim)(4) 2-holes : 0.20 mm (0.0079 in.) Shim(5) 1-hole : 0.25 mm (0.0098 in.) Shim(6) Without hole : 0.30 mm (0.012 in.)

Shim(7) 2-holes : 0.175 mm (0.00689 in.)

Shim

(A) 3 Cylinder(B) 4 Cylinder


G-24


Injection Timing (Continued)[KJ-T300(-AUS), KJ-S240-AUS]1. Make sure of matching the injection timing align mark (1) of the

injection pump unit and the plate (gearcase), as shown in theillustration.

2. Remove the injection pipes.3. Remove the stop solenoid.4. Turn the flywheel counterclockwise (viewed from flywheel side)

until the fuel fills up to the hole of the delivery valve holder (2) forNo.1 cylinder.

5. After the fuel fills up to the hole of the delivery valve holder forNo.1 cylinder, turn back (clockwise) the flywheel around 1.57 rad(90 °).

6. Turn the flywheel counterclockwise to set at around 0.35 rad(20 °) before T.D.C..

7. Slowly turn the flywheel counterclockwise and stop turning whenthe fuel begins to come up, to get the present injection timing.

8. Check to see the degree on flywheel.The flywheel has mark “1TC”, “10” and “20” for the crank anglebefore the top dead center of No.1 piston.

9. If the injection timing is not within the specification, rotate theinjection pump unit to adjust the injection timing.IMPORTANT

• When installing the injection pump unit to the engine body,follow the correct procedure.See the “Injection Pump Unit”.

(Injection Timing)

W1072910


V3300-E2BG 0.14 to 0.17 rad (8.0 ° to 10 °) before T.D.C.

Tightening torque

Injection pipe retaining nut22.6 to 36.3 N·m2.3 to 3.7 kgf·m16.6 to 26.8 lbf·ft

Injection pump unit mounting nut

17.7 to 20.6 N·m1.8 to 2.1 kgf·m13.0 to 15.2 lbf·ft

(1) Injection Timing Align Mark(2) Delivery Valve Holder

(a) Injection Timing Advanced(b) Injection Timing Retarded


G-25


Checking Injection Pump(Fuel Tightness of Pump Element)1. Remove the engine stop solenoid.2. Remove the injection pipes and glow plugs.3. Install the injection pump pressure tester (1) to the injection

pump.4. Install the injection nozzle (2) jetted with the proper injection

pressure to the injection pump pressure tester (1). (Refer to thefigure.)

5. Set the speed control lever to the maximum speed position.6. Run the starter to increase the pressure.7. If the pressure can not reach the allowable limit, replace the

pump with new one or repair with a Kubota-authorized pumpservice shop.

(Fuel Tightness of Delivery Valve)1. Remove the engine stop solenoid.2. Remove the injection pipes and glow plugs.3. Set a pressure tester to the fuel injection pump.4. Install the injection nozzle (2) jetted with the proper injection

pressure to the injection pump pressure tester (1).5. Run the starter to increase the pressure.6. Stop the starter when the fuel jets from the injection nozzle. After

that, turn the flywheel by hand and raise the pressure to approx.13.73 MPa (140.0 kgf/cm2, 1991 psi).

7. Now turn the flywheel back about half a turn (to keep the plungerfree). Maintain the flywheel at this position and clock the timetaken for the pressure to drop from 13.73 to 12.75 MPa (140.0 to130.0 kgf/cm2, 1991 to 1849 psi).

8. Measure the time needed to decrease the pressure from 13.73 to12.75 MPa (140.0 to 130.0 kgf/cm2, 1991 to 1849 psi).

9. If the measurement is less than allowable limit, replace the pumpwith new one or repair with a Kubota-authorized pump serviceshop.

NOTE• Never try to disassemble the injection pump assembly. For

repairs, you are strongly requested to contact a Kubota-authorized pump service shop.

W1022357

Fuel tightness of pump element Allowable limit

13.73 MPa140.0 kgf/cm2

1991 psi

Fuel tightness of delivery valve

Factory spec.

10 seconds13.73 → 12.75 MPa140.0 → 130.0 kgf/cm2

1991 → 1849 psi

Allowable limit


1991 → 1849 psi

(1) Injection Pump Pressure Tester(2) Injection Nozzle(3) Protection Cover for Jetted Fuel

[A] D1703-E/E2V2203-E/E2F2803-E/E2

[B] V3300-E2BG


G-26


[9] CHECK POINTS OF EVERY 1 YEARReplacing Air Cleaner Element1. Remove used air cleaner element.2. Replace new air cleaner element.

NOTE• The air cleaner uses a dry element. Never apply oil to it.• Do not run the engine with filter element removed.

W1020554


G-27


[10] CHECK POINTS OF EVERY 2 YEARSChanging Radiator Coolant (L.L.C.)



1. Stop the engine and let cool down.2. To drain the coolant, open the radiator drain plug (2) and remove

the radiator cap (1). Then radiator cap (1) must be removed tocompletely drain the coolant. And open the drain cock (3). ([B]only.)

3. After all coolant is drained, close the drain plug.4. Fill with clean water and cooling system cleaner.5. Follow directions of the cleaner instruction.6. After flushing, fill with clean water and anti-freeze until the coolant

level is just below the port. Install the radiator cap (1) securely.7. Fill with coolant up to “FULL” (A) mark on the recovery tank (3).8. Start and operate the engine for few minutes.9. Stop the engine and let cool. Check coolant level of radiator and

recovery tank (3) and add coolant if necessary.IMPORTANT

• Do not start engine without coolant.• Use clean, fresh, soft water and anti-freeze to fill the radiator

and recovery tank.• When the anti-freeze is mixed with fresh, soft water, the anti-

freeze mixing ratio must be less than 50 %.• Securely tighten radiator cap. If the cap is loose or

improperly fitted, water may leak out and the engine couldoverheat.

W1024599

(1) Radiator Cap(2) Drain Plug(3) Drain Cock(4) Recovery TankA : FullB : Low




G-28


Changing Radiator Coolant (L.L.C.) (Continued)(Anti-freeze)• There are two types of anti-freeze available: use the permanent

type (PT) for this engine.• Before adding anti-freeze for the first time, clean the radiator

interior by pouring fresh, soft water and draining it a few times.• The procedure for mixing water and anti-freeze differs according

to the make of the anti-freeze and the ambient temperature.Basically, it should be referred to SAE J1034 standard, morespecifically also to SAE J814c.

• Mix the anti-freeze with fresh, soft water, and then fill into theradiator.IMPORTANT

• When the anti-freeze is mixed with fresh, soft water, the anti-freeze mixing ratio must be less than 50 %.

* At 1.01 × 100000 Pa (760 mmHg) pressure (atmospheric). Ahigher boiling point is obtained by using a radiator pressure capwhich permits the development of pressure within the coolingsystem.

NOTE• The above data represents industrial standards that

necessitate a minimum glycol content in the concentratedanti-freeze.

• When the coolant level drops due to evaporation, add fresh,soft water only to keep the anti-freeze mixing ratio less than50 %. In case of leakage, add anti-freeze and fresh, softwater in the specified mixing ratio.

• Anti-freeze absorbs moisture. Keep unused anti-freeze in atightly sealed container.

• Do not use radiator cleaning agents when anti-freeze hasbeen added to the coolant.(Anti-freeze contains an anti-corrosive agent, which willreact with the radiator cleaning agent forming sludge whichwill affect the engine parts.)

W1024852

Vol %anti-freeze

Freezing point Boiling point*

°C °F °C °F

40 –24 –11 106 223

50 –37 –35 108 226


G-29


Replacing Fuel Hoses and Clamp Bands1. Loosen the clamp (1) and remove the fuel hose (3).2. Replace new fuel hose (3) and new clamp (1).3. Tighten the clamp (1).

CAUTION• Stop the engine when attempting the check and change

prescribed above.

(When bleeding fuel system)1. Loosen the air vent plug (4) of the fuel filter a few turns.2. Screw back the plug when bubbles do not come up any more.3. Open the air vent cock (2) on top of the fuel injection pump.4. If equipped electrical fuel feed pump, turn the key to AC position

and pump the fuel up for 10 to 15 seconds.If equipped mechanical fuel feed pump, set the stop lever on stopposition and crank the engine for 10 to 15 seconds.

5. Close securely the air vent cock after air bleeding.NOTE

• Always keep the air vent cock on the fuel injection pumpclosed except when air is vented, or it may cause the engineto stop.

W1057873

Replacing Intake Air Line1. Loosen the clamp (2).2. Remove the intake air hose (1) and clamp (2).3. Replace new intake air hose (1) and new clamp (2).4. Tighten the clamp (2).

NOTE• To prevent serious damage to the engine, keep out any dust

inside the intake air line.

W1023867

(1) Clamp(2) Air Vent Cock(3) Fuel Hose(4) Air Vent Plug



(1) Intake Air Hose (2) Clamp


G-30


Replacing Battery

CAUTION• When the battery is being activated, hydrogen and oxygen

gases in the battery are extremely explosive. Keep opensparks and flames away from the battery at all times,especially when charging the battery.

• When charging battery, remove battery vent plugs.• When disconnecting the cable from the battery, start with

the negative terminal first. When connecting the cable to thebattery, start with the positive terminal first.

• Never check battery charge by placing a metal object acrossthe posts.

1. Disconnect the negative terminal and positive terminal.2. Remove the battery holder.3. Remove the used battery.4. Replace the new battery.5. Tighten the battery holder.6. Connect the positive terminal.7. Connect the negative terminal.

W1023996

Replacing Radiator Hoses and Clamp Bands



1. Drain the coolant.2. Loosen the clamp bands (1).3. Remove the upper hose (2) and lower hose (3).4. Replace new upper / lower hose (2), (3) and clamp bands (1).5. Tighten the clamp bands.6. Fill with clean water and anti-freeze until the coolant level is just

below the port. Install the radiator cap securely.

W1057988

(1) Clamp(2) Upper Hose(3) Lower Hose




G-31


8. SPECIAL TOOLS[1] ALL MODELS

Diesel Engine Compression TesterCode No: 07909-30208 (Assembly) 07909-31251 (G)

07909-30934 (A to F) 07909-31271 (I)07909-31211 (E and F) 07909-31281 (J)07909-31231 (H)

Application: Use to measure diesel engine compression anddiagnosis of need for major overhaul.

W1024200

Oil Pressure TesterCode No: 07916-32032Application: Use to measure lubricating oil pressure.

W1043073

(1) Gauge(2) L Joint(3) Adaptor A(4) Adaptor B(5) Adaptor C(6) Adaptor E

(7) Adaptor F(8) Adaptor G(9) Adaptor H

(10) Adaptor I(11) Adaptor J

(1) Gauge(2) Cable(3) Threaded Joint(4) Adaptor 1

(5) Adaptor 2(6) Adaptor 3(7) Adaptor 4(8) Adaptor 5


G-32


[2] D1703-E/E2, V2203-E/E2, F2803-E/E2NOTE

• The following special tools are not provided, so make them referring to the figure.Injection Pump Pressure TesterApplication: Use to check fuel tightness of injection pumps.

W10252400

Valve Guide Replacing ToolApplication: Use to press out and press fit the valve guide.

W1025017

A Pressure gauge full scale : More than 29.4 MPa (300 kgf/cm2, 4267 psi)

B PF 1/2

C Copper gasket

D Flange (Material : Steel)

E Hex. nut 27 mm (1.1 in.) across the plat

F Adhesive application

G Fillet welding on the enter circumference

H Retaining nut

I 17 mm dia. (0.67 in. dia.)

J 8 mm dia. (0.3 in. dia.)

K 1.0 mm (0.039 in.)

L 17 mm dia. (0.67 in. dia.)

M 6.10 to 6.20 mm dia. (0.241 to 0.244 in. dia.)

N 8 mm (0.3 in.)

O 4 mm (0.2 in.)

P 11.97 to 11.99 mm dia. (0.4713 to 0.4720 in. dia.)

Q PF 1/2

R 23 mm (0.91 in.)

S 17 mm (0.67 in.)

T 4 mm (0.2 in.)

U 12.00 to 12.02 mm dia. (0.4725 to 0.4732 in. dia.)

V 100 mm (3.94 in.)

W M12 × P1.5

X 5 mm (0.2 in.)

A 225 mm (8.86 in.)

B 70 mm (2.8 in.)

C 45 mm (1.8 in.)

D 20 mm dia. (0.79 in. dia.)

E 12.7 to 12.9 mm dia. (0.500 to 0.507 in. dia.)

F 7.50 to 7.60 mm dia. (0.296 to 0.299 in. dia.)

G 25 mm dia. (0.98 in. dia.)

H 7.70 to 8.00 mm dia. (0.304 to 0.314 in. dia.)

I 5 mm (0.2 in.)

J 20 mm dia. (0.79 in. dia.)

K 13.5 to 13.8 mm dia. (0.532 to 0.543 in. dia.)

L 8.90 to 9.10 mm (0.351 to 0.358 in.)

C1 Chamfer 1.0 mm (0.039 in.)


C0.3 Chamfer 0.3 mm (0.01 in.)


G-33


Bushing Replacing ToolsApplication: Use to press out and to press fit the bushing.1. For small end bushing

2. For idle gear bushing

W1025500

Flywheel StopperApplication: Use to loosen and tighten the flywheel screw.

W10259480

A 162 mm (6.38 in.)

B 35 mm (1.4 in.)

C 27 mm (1.1 in.)

D 35 mm dia. (1.4 in. dia.)



A 175 mm (6.89 in.)

B 40 mm (1.6 in.)

C 38 mm (1.5 in.)




A 20 mm (0.79 in.)

B 15 mm (0.59 in.)

C 10 mm dia. (0.39 in. dia.)

D 30 mm (1.2 in.)

E 8 mm (0.3 in.)

F 200 mm (7.87 in.)


G-34


Crankshaft Bearing 1 Replacing Tool [D1703, V2203] (Serial No. : below 3R9999)[F2803]Application: Use to press out and press fit the crankshaft bearing 1.1. Extracting tool

2. Inserting tool

W1026139

Crankshaft Bearing 1 Replacing Tool[D1703, V2203] (Serial No. above 3S0001)Application: Use to press out and press fit the crankshaft bearing 1.1. Extracting tool

2. Inserting tool

W1025644

A 135 mm (5.31 in.)

B 72 mm (2.8 in.)

C 40 mm radius (1.6 in. radius)

D 10 mm (0.39 in.)

E 20 mm (0.79 in.)

F 20 mm dia. (0.79 in. dia.)

G 56.80 to 56.90 mm dia. (2.237 to 2.240 in. dia.)


A 130 mm (5.12 in.)

B 72 mm (2.8 in.)


D 9 mm (0.4 in.)

E 4 mm (0.2 in.)

F 20 mm (0.79 in.)

G 20 mm dia. (0.79 in. dia.)

H 68 mm dia. (2.7 in. dia.)

I 51.80 to 51.90 mm dia. (2.040 to 2.043 in. dia.)

J 56.80 to 56.90 mm dia. (2.237 to 2.240 in. dia.)

A 135 mm (5.31 in.)

B 72 mm (2.8 in.)


D 10 mm (0.39 in.)

E 20 mm (0.79 in.)

F 20 mm dia. (0.79 in. dia.)

G 64.80 to 64.90 mm dia. (2.552 to 2.555 in. dia.)


A 130 mm (5.12 in.)

B 72 mm (2.8 in.)


D 9 mm (0.4 in.)

E 4 mm (0.2 in.)

F 20 mm (0.79 in.)

G 20 mm dia. (0.79 in. dia.)





G-35


Socket Wrench for Crank Pulley Nut (46 mm Deep SocketWrench)Application: Use to loosen and tighten the fan drive pulley mounting

nut.

W1044361

Auxiliary Socket for Fixing Crankshaft Sleeve (To be continued)Application: Use to fix the crankshaft sleeve of the diesel engine.

W1027695

A 100 mm (3.94 in.)

B 25.0 mm (0.984 in.)

C 27.0 mm (1.06 in.)

D 45.0 mm dia. (1.77 in. dia.)

E 35.0 mm dia. (1.38 in. dia.)

F 62.5 mm dia. (2.46 in. dia.)

G 46.0 mm (1.81 in.)

A 80.0 mm (3.15 in.)

B

D1703, V2203(Serial No.: below 3R9999) /F2803

52.10 to 52.30 mm (2.052 to 2.059 in.)

D1703, V2203(Serial No. : above 3S0001)

60.10 to 60.30 mm (2.367 to 2.374 in.)

C 80.0 mm dia. (3.15 in. dia.)

D 85.0 mm dia. (3.35 in. dia.)

E

D1703, V2203(Serial No.: below 3R9999) /F2803

52.10 to 52.30 mm dia. (2.052 to 2.059 in. dia.)


60.10 to 60.30 mm dia. (2.367 to 2.374 in. dia.)

F 26.30 to 26.40 mm (1.036 to 1.039 in.)

G 25.85 to 25.90 mm (1.018 to 1.019 in.)

H 15.0 mm (0.591 in.)

I 5.0 mm (0.20 in.)

(1) Stopper(2) Sleeve Guide

(3) Auxiliary Socket for Pushing


G-36


Auxiliary Socket for Fixing Crankshaft Sleeve (Continued)Application: Use to fix the crankshaft sleeve of the diesel engine.

W1027898

J 42.0 mm (1.65 in.)

K 30.50 to 30.60 mm (1.201 to 1.204 in.)

L 23.0 mm (0.906 in.)

M 20.0 mm (0.787 in.)

N 2.0 mm (0.079 in.)

O 31.911 to 31.950 mm dia. (1.2564 to 1.2578 in. dia.)

P 30.0 mm dia. (1.18 in. dia.)

Q 5.0 mm dia. (0.20 in. dia.)

R 0.09 rad (5 °)

S 25.0 mm dia. (0.984 in. dia.)

T 60.0 mm dia. (2.36 in. dia.)


V 10.0 mm (0.394 in.)

W 0.04 mm dia. (0.002 in. dia.)

X 140 mm (5.51 in.)

Y 120 mm (4.72 in.)

Z 110 mm (4.33 in.)

a 50.0 mm (1.97 in.)

b 39.90 to 40.00 mm (1.571 to 1.574 in.)

c 25.0 mm (0.984 in.)

d 90.0 mm dia. (3.54 in. dia.)

e 81.0 mm dia. (3.19 in. dia.)

f 80.10 to 80.15 mm dia. (3.154 to 3.155 in. dia.)

g 30.0 mm dia. (1.18 in. dia.)

h 5.0 mm dia. (0.20 in. dia.)

i 70.0 mm (2.76 in.)

j 50.0 mm (1.97 in.)

k 40.0 mm dia. (1.57 in. dia.)




R1 1.0 mm radius (0.039 in. radius)



(2) Sleeve Guide (3) Auxiliary Socket for Pushing


G-37


[3] V3300-E2BGNOTE

• The following special tools are not provided, so make them referring to the figure.Injection Pump Pressure TesterApplication: Use to check fuel tightness of injection pumps.

0

A Pressure gauge full scale : More than 29.4 MPa (300 kgf/cm2, 4267 psi)

B PF 1/2

C Copper gasket

D Flange (Material : Steel)

E Hex. nut 27 mm (1.1 in.) across the plat

F Adhesive application

G Fillet welding on the enter circumference

H Retaining nut

I 17 mm dia. (0.67 in. dia.)

J 8 mm dia. (0.3 in. dia.)

K 1.0 mm (0.039 in.)

L 17 mm dia. (0.67 in. dia.)

M 6.10 to 6.20 mm dia. (0.241 to 0.244 in. dia.)

N 8 mm (0.3 in.)

O 4 mm (0.2 in.)

P 11.97 to 11.99 mm dia. (0.4713 to 0.4720 in. dia.)

Q PF 1/2

R 23 mm (0.91 in.)

S 17 mm (0.67 in.)

T 4 mm (0.2 in.)


V 100 mm (3.94 in.)

W M12 × P1.5

X 5 mm (0.2 in.)


G-38


Small End Bushing Replacing ToolApplication: Use to press out and to press fit the small end bushing.

[Press out]

[Press fit]

W1040702

Idle Gear Bushing Replacing ToolApplication: Use to press out and to press fit the bushing.

W1040289

A 157 mm (6.18 in.)

B 14.5 mm (0.571 in.)

C 120 mm (4.72 in.)

D 30.0 mm dia. (1.18 in. dia.)

E 32.95 mm dia. (1.297 in. dia.)

F 20 mm dia. (0.79 in. dia.)

a 6.3 μm (250 μin.)

b 6.3 μm (250 μin.)



A 157 mm (6.18 in.)

B 14.5 mm (0.571 in.)

C 120 mm (4.72 in.)

D 30.0 mm dia. (1.18 in. dia.)

E 42.00 mm dia. (1.654 in. dia.)

F 20 mm dia. (0.79 in. dia.)

a 6.3 μm (250 μin.)

b 6.3 μm (250 μin.)



A 196 mm (7.72 in.)

B 37.5 mm (1.48 in.)

C 150 mm (5.91 in.)

D 44.95 mm dia. (1.770 in. dia.)


F 20 mm dia. (0.79 in. dia.)

a 6.3 μm (250 μin.)

b 6.3 μm (250 μin.)




G-39


Gear Case Oil Seal Replacing ToolApplication: Use to press fit the oil seal.

W1041529

A 148.8 mm (5.858 in.)

B 50 mm (2.0 in.)

C 18.8 mm (0.740 in.)

D 13.7 to 13.9 mm (0.540 to 0.547 in.)

E 11 mm (0.43 in.)

F 18 mm dia. (0.71 in. dia.)

G 38 mm dia. (1.5 in. dia.)



J 79.5 mm dia. (3.13 in. dia.)

K 87 mm dia. (3.4 in. dia.)

L 12 mm (0.47 in.)

M 40 mm (1.6 in.)

N 120 mm (4.72 in.)


G-40


Valve Guide Replacing ToolApplication: Use to press out and press fit the valve guide.

Intake valve guide

Exhaust valve guide

W1038887

A 225 mm (8.86 in.)

B 70 mm (2.8 in.)

C 45 mm (1.8 in.)

D 20 mm dia. (0.79 in dia.)



G 25 mm dia. (0.98 in. dia.)


I 5 mm (0.2 in.)

J 20 mm dia. (0.79 in.dia.)


L 8.90 to 9.10 mm (0.351 to 0.358 in.)




A 225 mm (8.86 in.)

B 80 mm (3.1 in.)

C 40 mm (1.6 in.)

D 20 mm dia. (0.79 in dia.)



G 14.5 to 15.5 mm dia. (0.571 to 0.610 in.dia.)


I 5 mm (0.2 in.)



L 9.90 to 10.1 mm (0.390 to 0.397 in.)





G-41


Auxiliary Socket for Fixing Crankshaft SleeveApplication: Use to fix the crankshaft sleeve of the diesel engine.

W1041815

A Rmax = 12.5 S

B 94.5 to 95.0 mm dia. (3.72 to 3.74 in. dia.)

C 40 mm dia. (1.6 in. dia.)


E 12 mm (0.47 in.)

F 7.90 to 8.10 mm (0.311 to 0.318 in.)

G 20 mm (0.79 in.)

H 130 mm dia. (5.12 in. dia.)



K 3 mm dia. (0.1 in.dia.)

L 15 mm (0.59 in.)

M 10 mm (0.39 in.)

N 90 mm (3.5 in.)

O 115 mm (4.53 in.)

P 16.9 to 17.1 mm (0.666 to 0.673 in.)




C0.2 Chamfer 0.2 mm (0.008 in.)



G-42


Injection Pump Gear PullerApplication: Use for remove the injection pump gear from governor

shaft.

W1042094

Engine StandApplication: Use to support engine.

W1033645

A 10 mm dia. (0.39 in.dia.)

B M16 × Pitch 1.5

C 19 mm (0.75 in.)

D 0.5 mm radius (0.02 in. radius)

E 0.87 rad (50 °)

F 10 mm (0.39 in.)

G 20 mm (0.79 in.)

H 5 mm (0.2 in.)

I 95 mm (3.7 in.)

J 125 mm (4.92 in.)

K 5 mm (0.2 in.)

L M16 × Pitch 1.5

M 30 mm (1.2 in.)

N 9.5 mm (0.37 in.)

O 11 mm (0.43 in.)

P 9.5 mm (0.37 in.)

Q 14.5 mm (0.571 in.)

R 5.5 mm radius (0.22 in. radius)

S 20 mm (0.79 in.)

T 20 mm (0.79 in.)

U 80 mm (3.1 in.)

W 12 mm (0.47 in.)


A 480 mm (18.9 in.)

B 50 mm (2.0 in.)

C 108.5 mm (4.272 in.)

D 262.5 mm (10.33 in.)

E 12.5 mm (0.492 in.)

F 237.5 mm (9.350 in.)

G 142.5 mm (5.610 in.)

H 95 mm (3.7 in.)

I 14 mm dia. (0.55 in. dia.)

J 40 mm radius (1.6 in. radius)

K 210 mm (8.27 in.)

L 190 mm (7.48 in.)

M 100 mm (3.94 in.)

N 6 mm (0.2 in.)

O 6 mm (0.2 in.)

P 25 mm dia. (0.98 in. dia.)

C10 Chamfer 10 mm (0.39 in.)


G-43


Flywheel StopperApplication: Use to loosen and tighten the flywheel screw.

W1042515

Tool for Aligning the Crankcase 1 and 2Application: Use for aligning the crankcase 1 and 2.

W1047882

A 140 mm (5.51 in.)

B 80 mm (3.1 in.)

C 49.3 mm (1.94 in.)

D 49.3 mm (1.94 in.)

E 23.8 mm (0.937 in.)

F 23.8 mm (0.937 in.)

G 11 mm dia. (0.43 in. dia.)

H 56.5 mm (2.22 in.)

I 56.5 mm (2.22 in.)

J 8 mm (0.3 in.)

A 115 mm (4.53 in.)

B 56 mm (2.2 in.)

C 17 mm (0.67 in.)

D 20 mm (0.79 in.)

E 14 mm dia. (0.55 in. dia.)

F 11 mm dia. (0.43 in. dia.)

G 14 mm dia. (0.55 in. dia.)

H 17.5 mm (0.689 in.)

I 17.5 mm (0.689 in.)

J 35 mm (1.4 in.)

K 19 mm (0.75 in.)


G-44


Jig for Governor Connecting RodApplication: Use for connecting the governor connecting rod to the

rack pin of the fuel injection pump assembly.

W1115114

A 1 mm radius (0.04 in. radius)

B Chamfer 0.2 mm (0.008 in.)

C Chamfer 2 mm (0.08 in.)


E Chamfer 1 mm (0.04 in.)

F Chamfer 0.1 mm (0.004 in.)

G 1 mm radius (0.04 in. radius)

H Chamfer 0.2 mm (0.008 in.)

I 8 mm radius (0.3 in. radius)

J 1 mm radius (0.04 in. radius)

K 1 mm radius (0.04 in. radius)

L Chamfer 0.2 mm (0.008 in.)

M Chamfer 0.2 mm (0.008 in.)

N 29 mm (1.1 in.)

O 6 mm (0.2 in.)

P 10.7 mm (0.421 in.)

Q 35 mm (1.4 in.)

R 99.3 mm (3.91 in.)

S 45.65 to 45.75 mm (1.798 to 1.801 in.)

T 145 mm (5.71 in.)

U 16.15 to 16.35 mm (0.6359 to 0.6437 in.)

V 3 mm (0.1 in.)

W 10 mm (0.39 in.)

X 8 mm (0.3 in.)

(1) Material: S45C-D (2) Permanent Magnet: 8 mm dia. (0.3 in. dia.)Thickness: 3 mm (0.1 in.)


1 ENGINE


CONTENTS

SERVICING

1. TROUBLESHOOTING ......................................................................................S-1[1] D1703-E/E2, V2203-E/E2, F2803-E/E2 ......................................................S-1[2] V3300-E2BG...............................................................................................S-4

2. SERVICING SPECIFICATIONS ......................................................................S-7[1] D1703-E/E2, V2203-E/E2, F2803-E/E2 ......................................................S-7[2] V3300-E2BG.............................................................................................S-13

3. TIGHTENING TORQUES ..............................................................................S-19[1] TIGHTENING TORQUES FOR SPECIAL USE SCREWS, BOLTS

AND NUTS...............................................................................................S-19(1) D1703-E/E2, V2203-E/E2, F2803-E/E2..............................................S-19(2) V3300-E2BG.......................................................................................S-20

4. CHECKING, DISASSEMBLING AND SERVICING......................................S-21[1] CHECKING AND ADJUSTING ...............................................................S-21

(1) Engine Body........................................................................................S-21(2) Lubricating System .............................................................................S-24(3) Cooling System...................................................................................S-25(4) Fuel System ........................................................................................S-27(5) Electrical System ................................................................................S-32

[2] DISASSEMBLING AND ASSEMBLING..................................................S-37(1) D1703-E/E2, V2203-E/E2, F2803-E/E2..............................................S-37(2) V3300-E2BG.......................................................................................S-53(3) Starter .................................................................................................S-75(4) Alternator ............................................................................................S-77

[3] SERVICING ..............................................................................................S-78(1) Cylinder Head and Valves ..................................................................S-78(2) Timing Gears ......................................................................................S-86(3) Piston and Connecting Rod ................................................................S-90(4) Crankshaft...........................................................................................S-94(5) Cylinder.............................................................................................S-102(6) Oil Pump ...........................................................................................S-103(7) Starter ...............................................................................................S-104(8) Alternator ..........................................................................................S-107


S-1

KJ-X50 Hz SERIES, WSM ENGINE

1. TROUBLESHOOTING[1] D1703-E/E2, V2203-E/E2, F2803-E/E2

W1217350

Symptom Probable Cause Solution Reference Page

Engine Does Not Start

No fuel Replenish fuel G-13Air in the fuel system Vent air G-13Water in the fuel system Change fuel and

repair or replace fuel system

–

Fuel hose clogged Clean or replace G-13Fuel filter clogged Replace G-16Excessively high viscosity of fuel or engine oil at low temperature

Use specified fuel or engine oil

7 to 12, G-5

Fuel with low cetane number Use specified fuel 7 to 12Fuel leak due to loose injection pipe retaining nut Tighten retaining nut S-38Incorrect injection timing Adjust S-27Fuel camshaft worn Replace S-45Injection nozzle clogged Clean or replace S-31, 32Injection pump malfunctioning Repair or replace S-29, 30,

42Seizure of crankshaft, camshaft, piston, cylinder or bearing

Repair or replace S-45 to 49S-94 to 101

Compression leak from cylinder Replace head gasket, tighten cylinder head screw, glow plug and nozzle holder

S-38, 39, 40

Improper valve timing Correct or replace timing gear

S-45

Piston ring and cylinder worn Replace S-47, 48, 49, 92, 93,102

Excessive valve clearance Adjust S-22Stop solenoid malfunctioning Replace –

Starter Does Not Run Battery discharged Charge –Starter malfunctioning Repair or replace S-104, 105,

106Key switch malfunctioning Replace –Wiring disconnected Connect –


S-2


W1219251


Engine Revolution Is Not Smooth

Fuel filter clogged or dirty Replace G-16Air cleaner clogged Clean or replace G-12Fuel leak due to loose injection pipe retaining nut Tighten retaining nut S-38Injection pump malfunctioning Repair or replace S-29, 30,

42Incorrect nozzle opening pressure Adjust S-31Injection nozzle stuck or clogged Repair or replace S-31, 32Governor malfunctioning Repair S-42, 43,

45Either White or Blue Exhaust Gas Is Observed

Excessive engine oil Reduce to specified level

G-9

Piston ring and cylinder worn or stuck Repair or replace S-47, 48, 49, 92, 93,

102Incorrect injection timing Adjust S-27

Either Black or Dark Gray Exhaust Gas Is Observed

Overload Reduce the load –Low grade fuel used Use specified fuel 7 to 12Fuel filter clogged Replace G-16Air cleaner clogged Clean or replace G-12Deficient nozzle injection Repair or replace

nozzleS-31, 32

Deficient Output Incorrect injection timing Adjust S-27Engine’s moving parts seem to be seizing Repair or replace –Injection pump malfunctioning Repair or replace S-29, 30,

42Deficient nozzle injection Repair or replace

nozzleS-31, 32

Compression leak Check the compression pressure and repair

S-21

Air cleaner dirty or clogged Clean or replace G-12Excessive Lubricant OIl Consumption

Piston ring’s gap facing the same direction Shift ring gap direction

S-48

Oil ring worn or stuck Replace S-47, 48, 49

Piston ring groove worn Replace piston S-47, 48, 49

Valve stem and valve guide worn Replace S-81, 82Crankshaft bearing and crank pin bearing worn Replace S-52, 95 to

99Oil leaking due to defective seals or packing Replace –


S-3


W1211178


Fuel Mixed into Lubricant Oil

Injection pump’s plunger worn Repair or replace S-29, 30, 42

Deficient nozzle injection Repair or replace nozzle

S-31, 32

Injection pump broken Replace S-42Water Mixed into Lubricant Oil

Head gasket defective Replace S-40Cylinder block or cylinder head flawed Replace S-40

Low Oil Pressure Engine oil insufficient Replenish G-9Oil strainer clogged Clean S-46Relief valve stuck with dirt Clean –Relief valve spring weaken or broken Replace –Excessive oil clearance of crankshaft bearing Replace S-51Excessive oil clearance of crankpin bearing Replace S-47, 48,

49Excessive oil clearance of rocker arm Replace S-39Oil passage clogged Clean –Different type of oil Use specified type of

oilG-5

Oil pump defective Replace S-46High Oil Pressure Different type of oil Use specified type of

oilG-5

Relief valve defective Replace –Engine overheated Engine oil insufficient Replenish G-9

Fan belt broken or elongated Replace or adjust S-25Coolant insufficient Replenish G-5Radiator net and radiator fin clogged with dust Clean –Inside of radiator corroded Clean or replace –Coolant flow route corroded Clean or replace –Radiator cap defective Replace S-26Overload running Reduce the load –Head gasket defective Replace S-40Incorrect injection timing Adjust S-27Unsuitable fuel used Use specified fuel 7 to 12

Battery Quickly Discharged

Battery electrolyte insufficient Replenish distilled water and charge

G-13

Fan belt slips Adjust belt tension or replace

G-12

Wiring disconnected Connect –Rectifier defective Replace S-108Alternator defective Replace S-35Battery defective Replace –


S-4


[2] V3300-E2BG

W1213581


Engine Does Not Start

No fuel Replenish fuel G-13Air in the fuel system Vent air G-13Water in the fuel system Change fuel and

repair or replace fuel system

–

Fuel hose clogged Clean or replace G-13Fuel filter clogged Replace G-16Excessively high viscosity of fuel or engine oil at low temperature

Use specified fuel or engine oil

7 to 12, G-5

Fuel with low cetane number Use specified fuel 7 to 12Fuel leak due to loose injection pipe retaining nut Tighten retaining nut S-53Incorrect injection timing Adjust S-28Fuel camshaft worn Replace S-63, 64Injection nozzle clogged Clean or replace S-31, 32Injection pump malfunctioning Repair or replace S-29, 30,

65, 66Seizure of crankshaft, camshaft, piston, cylinder or bearing

Repair or replace S-68 to 74S-94 to 101

Compression leak from cylinder Replace head gasket, tighten cylinder head screw, glow plug and nozzle holder

S-53, 54, 55, 56

Improper valve timing Correct or replace timing gear

S-68

Piston ring and cylinder worn Replace S-70, 71, 92, 93, 102

Excessive valve clearance Adjust S-23Stop solenoid malfunctioning Replace –

Starter Does Not Run Battery discharged Charge –Starter malfunctioning Repair or replace S-104, 105,

106Key switch malfunctioning Replace –Wiring disconnected Connect –

Engine Revolution Is Not Smooth

Fuel filter clogged or dirty Replace G-16Air cleaner clogged Clean or replace G-12Fuel leak due to loose injection pipe retaining nut Tighten retaining nut S-53Injection pump malfunctioning Repair or replace S-29, 30,

65, 66Incorrect nozzle opening pressure Adjust S-31Injection nozzle stuck or clogged Repair or replace S-31, 32Governor malfunctioning Repair S-60, 61


S-5


W1215489


Either White or Blue Exhaust Gas Is Observed

Excessive engine oil Reduce to specified level

G-9

Piston ring and cylinder worn or stuck Repair or replace S-70, 71, 92, 93, 102

Incorrect injection timing Adjust S-28Either Black or Dark Gray Exhaust Gas Is Observed

Overload Reduce the load –Low grade fuel used Use specified fuel 7 to 12Fuel filter clogged Replace G-16Air cleaner clogged Clean or replace G-12Deficient nozzle injection Repair or replace

nozzleS-31, 32

Deficient Output Incorrect injection timing Adjust S-28Engine’s moving parts seem to be seizing Repair or replace –Injection pump malfunctioning Repair or replace S-29, 30,

65, 66Deficient nozzle injection Repair or replace

nozzleS-31, 32

Compression leak Check the compression pressure and repair

S-21

Air cleaner dirty or clogged Clean or replace G-12Excessive Lubricant OIl Consumption

Piston ring’s gap facing the same direction Shift ring gap direction

S-70

Oil ring worn or stuck Replace S-70, 71Piston ring groove worn Replace piston S-70, 71Valve stem and valve guide worn Replace S-81, 82Crankshaft bearing and crank pin bearing worn Replace S-71, 74,

95, 99Oil leaking due to defective seals or packing Replace –

Fuel Mixed into Lubricant Oil

Injection pump’s plunger worn Repair or replace S-29, 30, 65, 66

Deficient nozzle injection Repair or replace nozzle

S-31, 32

Injection pump broken Replace S-65Water Mixed into Lubricant Oil

Head gasket defective Replace S-55, 56Cylinder block or cylinder head flawed Replace S-55, 56


S-6


W1212776


Low Oil Pressure Engine oil insufficient Replenish G-9Oil strainer clogged Clean S-69Relief valve stuck with dirt Clean –Relief valve spring weaken or broken Replace –Excessive oil clearance of crankshaft bearing Replace S-74Excessive oil clearance of crankpin bearing Replace S-70, 71Excessive oil clearance of rocker arm Replace S-54Oil passage clogged Clean –Different type of oil Use specified type of

oilG-5

Oil pump defective Replace S-103, 104High Oil Pressure Different type of oil Use specified type of

oilG-5

Relief valve defective Replace –Engine overheated Engine oil insufficient Replenish G-9

Fan belt broken or elongated Replace or adjust S-25Coolant insufficient Replenish G-5Radiator net and radiator fin clogged with dust Clean –Inside of radiator corroded Clean or replace –Coolant flow route corroded Clean or replace –Radiator cap defective Replace S-26Overload running Reduce the load –Head gasket defective Replace S-55, 56Incorrect injection timing Adjust S-28Unsuitable fuel used Use specified fuel 7 to 12

Battery Quickly Discharged

Battery electrolyte insufficient Replenish distilled water and charge

G-13

Fan belt slips Adjust belt tension or replace

G-12

Wiring disconnected Connect –Rectifier defective Replace S-108Alternator defective Replace S-35Battery defective Replace –


S-7


2. SERVICING SPECIFICATIONS[1] D1703-E/E2, V2203-E/E2, F2803-E/E2ENGINE BODY

W1040597

Item Factory Specification Allowable LimitValve Clearance (When Cold) 0.18 to 0.22 mm

0.0071 to 0.0086 in.–

Compression Pressure(When Cranking with Starting Motor)

Difference among Cylinders

3.24 to 3.72 MPa / 290 min-1 (rpm)

33.0 to 38.0 kgf/cm2 / 290 min-1 (rpm)470 to 540 psi /290 min-1 (rpm)

–

2.55 MPa / 290 min-1 (rpm)26.0 kgf/cm2 /

290 min-1 (rpm)370 psi /

290 min-1 (rpm)

10 % or lessTop Clearance 0.55 to 0.70 mm

0.022 to 0.027 in.–

Cylinder Head Surface Flatness – 0.05 mm / 500 mm0.002 in. / 19.7 in.

Valve Recessing Protrusion

Recessing

0.05 mm0.002 in.

0.15 mm0.0059 in.

–

0.40 mm0.016 in.

Valve Stem to Valve Guide

Valve Stem

Valve Guide

Clearance

O.D.

I.D.

0.040 to 0.070 mm0.0016 to 0.0027 in.

7.960 to 7.975 mm0.3134 to 0.3139 in.

8.015 to 8.030 mm0.3156 to 0.3161 in.

0.10 mm0.0039 in.

–

–

Valve Face Angle (Intake)

Angle (Exhaust)

1.0 rad60 °

0.79 rad45 °

–

–

Valve Seat Angle (Intake)

Angle (Exhaust)

1.0 rad60 °

0.79 rad45 °

–

–

Valve Seat Width (Intake)

Width (Exhaust)

2.12 mm0.0835 in.

2.12 mm0.0835 in.

–

–

Valve Timing (Intake Valve) Open

Close

0.21 rad (12 °)before T.D.C.

0.63 rad (36 °)after B.D.C.

–

–


S-8


ENGINE BODY (Continued)

W1041845

Item Factory Specification Allowable LimitValve Timing (Exhaust Valve) Open

Close

1.05 rad (60 °)before B.D.C.

0.21 rad (12 °)after T.D.C.

–

–

Valve Spring Free Length

Setting Load / Setting Length

Tilt

41.7 to 42.2 mm1.65 to 1.66 in.

118 N / 35.0 mm12.0 kgf / 35.0 mm26.5 lbf / 1.38 in.

–

41.2 mm1.62 in.

100 N / 35.0 mm10.2 kgf / 35.0 mm

22.5 lbf /1.38 in.

1.0 mm0.039 in.

Rocker Arm Shaft to Rocker Arm

Rocker Arm Shaft

Rocker Arm

Oil Clearance

O.D.

I.D.

0.016 to 0.045 mm0.00063 to 0.0017 in.

13.973 to 13.984 mm0.55012 to 0.55055 in.

14.000 to 14.018 mm0.55119 to 0.55188 in.

0.10 mm0.0039 in.

–

–

Push Rod Alignment – 0.25 mm0.0098 in.

Tappet to Tappet Guide

Tappet

Tappet Guide

Oil Clearance

O.D.

I.D.

0.020 to 0.062 mm0.00079 to 0.0024 in.

23.959 to 23.980 mm0.94327 to 0.94409 in.

24.000 to 24.021 mm0.94489 to 0.94570 in.

0.07 mm0.003 in.

–

–

Timing GearCrank Gear to Idle Gear

Idle Gear to Cam Gear

Idle Gear to Injection Pump Gear

Crank Gear to Oil Pump Gear

Backlash

Backlash

Backlash

Backlash

0.04150 to 0.1122 mm0.001634 to 0.004417

in.

0.04150 to 0.1154 mm0.001634 to 0.004543

in.

0.04150 to 0.1154 mm0.001634 to 0.004543

in.

0.04150 to 0.1090 mm0.001634 to 0.004291

in.

0.15 mm0.0059 in.

0.15 mm0.0059 in.

0.15 mm0.0059 in.

0.15 mm0.0059 in.

Idle Gear Side Clearance 0.12 to 0.48 mm0.0048 to 0.018 in.

0.9 mm0.04 in.


S-9



W1043006

Item Factory Specification Allowable LimitIdle Gear Shaft to Idle Gear Bushing

Idle Gear Shaft

Idle Gear Bushing

Oil Clearance

O.D.

I.D.

0.025 to 0.066 mm0.00099 to 0.0025 in.

37.959 to 37.975 mm1.4945 to 1.4950 in.

38.000 to 38.025 mm1.4961 to 1.4970 in.

0.10 mm0.0039 in.

–

–

Camshaft Side Clearance 0.070 to 0.22 mm0.0028 to 0.0086 in.

0.30 mm0.012 in.

Camshaft Alignment – 0.01 mm0.0004 in.

Cam Height (Intake and Exhaust)

33.47 mm1.318 in.

33.42 mm1.316 in.

Camshaft Journal to Cylinder Block Bore

Camshaft Journal

Cylinder Block Bore

Oil Clearance

O.D.

I.D.

0.050 to 0.091 mm0.0020 to 0.0035 in.

39.934 to 39.950 mm1.5722 to 1.5728 in.

40.000 to 40.025 mm1.5748 to 1.5757 in.

0.15 mm0.0059 in.

–

–

Piston Pin Bore I.D. 25.000 to 25.013 mm0.98426 to 0.98476 in.

25.05 mm0.9862 in.

Second Ring to Ring Groove Clearance 0.0930 to 0.120 mm0.00367 to 0.00472 in.

0.20 mm0.0079 in.

Oil Ring to Ring Groove Clearance 0.020 to 0.052 mm0.00079 to 0.0020 in.

0.15 mm0.0059 in.

Top Ring Ring Gap 0.30 to 0.45 mm0.012 to 0.017 in.

1.25 mm0.0492 in.

Second Ring Ring Gap 0.30 to 0.45 mm0.012 to 0.017 in.

1.25 mm0.0492 in.

Oil Ring Ring Gap 0.25 to 0.45 mm0.0099 to 0.017 in.

1.25 mm0.0492 in.

Connecting Rod Alignment – 0.05 mm0.002 in.

Piston Pin to Small End Bushing

Piston Pin

Small End Bushing

Oil Clearance

O.D.

I.D.

0.014 to 0.036 mm0.00056 to 0.0014 in.

25.004 to 25.011 mm0.98441 to 0.98468 in.

25.025 to 25.040 mm0.98524 to 0.98582 in.

0.15 mm0.0059 in.

–

–

Crankshaft Alignment – 0.02 mm0.0008 in.


S-10



W1044270

Item Factory Specification Allowable LimitCrankshaft Journal to Crankshaft Bearing 1[D1703, V2203](Serial No. : below 3R9999)[F2803]

Crankshaft Journal

Crankshaft Bearing 1

Oil Clearance

O.D.

I.D.

0.0400 to 0.118 mm0.00158 to 0.00464 in.

51.921 to 51.940 mm2.0442 to 2.0448 in.

51.980 to 52.039 mm2.0465 to 2.0487 in.

0.20 mm0.0079 in.

–

–

Crankshaft Journal to Crankshaft Bearing 1[D1703, V2203](Serial No. : above 3S0001)

Crankshaft Journal


Oil Clearance

O.D.

I.D.

0.0400 to 0.118 mm0.00158 to 0.00464 in.

59.921 to 59.940 mm2.3591 to 2.3598 in.

59.980 to 60.039 mm2.3615 to 2.3637 in.

0.20 mm0.0079 in.

–

–

Crankshaft Journal to Crankshaft Bearing 2[D1703, V2203](Serial No. : below 3R9999)[F2803]

Crankshaft Journal


Oil Clearance

O.D.

I.D.

0.0400 to 0.104 mm0.00158 to 0.00409 in.

51.921 to 51.940 mm2.0442 to 2.0448 in.

51.980 to 52.025 mm2.0465 to 2.0482 in.

0.20 mm0.0079 in.

–

–

Crankshaft Journal to Crankshaft Bearing 2[D1703, V2203](Serial No. : above 3S0001)

Crankshaft Journal


Oil Clearance

O.D.

I.D.

0.0400 to 0.104 mm0.00158 to 0.00409 in.

59.921 to 59.940 mm2.3591 to 2.3598 in.

59.980 to 60.025 mm2.3615 to 2.3631 in.

0.20 mm0.0079 in.

–

–

Crankpin to Crankpin Bearing

Crankpin

Crankpin Bearing

Oil Clearance

O.D.

I.D.

0.025 to 0.087 mm0.00099 to 0.0034 in.

46.959 to 46.975 mm1.8488 to 1.8494 in.

47.000 to 47.046 mm1.8504 to 1.8522 in.

0.20 mm0.0079 in.

–

–

Crankshaft[D1703, V2203](Serial No. : below 3R9999)[F2803]

Side Clearance 0.15 to 0.35 mm0.0059 to 0.013 in.

0.5 mm0.02 in.

Crankshaft[D1703, V2203](Serial No. : above 3S0001)

Side Clearance 0.15 to 0.31 mm0.0059 to 0.012 in.

0.5 mm0.02 in.


S-11



W1045485

LUBRICATING SYSTEM

W1051333

COOLING SYSTEM

W1046673

Item Factory Specification Allowable LimitCylinder Bore (Standard) I.D. 87.000 to 87.022 mm

3.4252 to 3.4260 in.87.150 mm3.4311 in.

Cylinder Bore (Oversize) I.D. 87.500 to 87.522 mm3.4449 to 3.4457 in.

87.650 mm3.4508 in.

Engine Oil Pressure At Idle Speed

At Rated Speed

More than 98 kPa1.0 kgf/cm2

14 psi

300 to 440 kPa3.0 to 4.5 kgf/cm2

43 to 64 psi

50 kPa0.5 kgf/cm2

7 psi

250 kPa2.5 kgf/cm2

36 psiEngine Oil Pressure Switch Working

Pressure50 kPa

0.5 kgf/cm2

7 psi

–

Inner Rotor to Outer Rotor Clearance 0.03 to 0.14 mm0.0012 to 0.0055 in.

0.2 mm0.008 in.

Outer Rotor to Pump Body Clearance 0.11 to 0.19 mm0.0044 to 0.0074 in.

0.25 mm0.0098 in.

Inner Rotor to Cover Clearance 0.105 to 0.150 mm0.00414 to 0.00590 in.

0.2 mm0.008 in.

Fan Belt Tension 7.0 to 9.0 mm (0.28 to 0.35 in.) deflection at

98 N (10 kgf, 22 lbf) of force

–

Thermostat Valve Opening Temperature(At Beginning)

Valve Opening Temperature (Opened Completely)

69.5 to 72.5 °C157.1 to 162.5 °F

85 °C185 °F

–

–

Radiator Water Tightness No leak at specified pressure

–

Radiator Cap Pressure Falling Time

More than 10 seconds for pressure fall

from 90 to 60 kPafrom 0.9 to 0.6 kgf/cm2

from 10 to 9 psi

–


S-12


FUEL SYSTEM

W1050119

ELECTRICAL SYSTEM

W1124497

Item Factory Specification Allowable LimitInjection Pump[D1703-E, V2203-E, V2203-E2, F2803-E2]

Injection Timing 0.27 to 0.29 rad(15 to 17 °) before T.D.C.

–

Injection Pump[F2803-E]

Injection Timing 0.28 to 0.31 rad(16 to 18 °) before T.D.C.

–

Injection Pump[D1703-E2]

Injection Timing 0.236 to 0.270 rad(13.5 to 15.5 °) before T.D.C.

–

Pump Element Fuel Tightness – 13.73 MPa140.0 kgf/cm2

1991 psiDelivery Valve Fuel Tightness 10 seconds

13.73 → 12.75 MPa140.0 → 130.0 kgf/cm2

1991 → 1849 psi

5 seconds13.73 → 12.75 MPa

140.0 →130.0 kgf/cm2

1991 → 1849 psiInjection Nozzle Injection Pressure 13.73 to 14.70 MPa

140.0 to 150.0 kgf/cm2

1992 to 2133 psi

–

Injection Nozzle Valve Seat Valve Seat Tightness

When the pressure is 12.75 MPa

(130.0 kgf/cm2, 1849 psi), the valve seat must

be fuel tightness.

–

StarterCommutator

Mica

Brush

O.D.

Under Cut

Length

30.0 mm1.18 in.

0.45 to 0.75 mm0.018 to 0.029 in.

15.0 mm0.591 in.

29.0 mm1.14 in.

0.20 mm0.0079 in.

11.0 mm0.433 in.

Alternator

Stator

Rotor

Slip Ring

Brush

No-load voltage

Resistance

Resistance

O.D.

Length

More than 13.5 V

Less than 1.0 Ω

2.9 Ω

14.4 mm0.567 in.

10.5 mm0.413 in.

–

–

–

14.0 mm0.551 in.

8.4 mm0.33 in.

Glow Plug Resistance Approx. 0.9 Ω –


S-13


[2] V3300-E2BGENGINE BODY

W11261120

Item Factory Specification Allowable LimitCylinder Head Surface Flatness – 0.05 mm

0.002 in.Top Clearance 0.72 to 0.90 mm

0.029 to 0.035 in. –

Compression Pressure 4.31 MPa /250 min−1 (rpm)44.0 kgf/cm2 /

250 min−1 (rpm)626 psi /

250 min−1 (rpm)

3.26 MPa / 250 min−1 (rpm)33.2 kgf/cm2 /

250 min−1 (rpm)472 psi /

250 min−1 (rpm)Variance Among Cylinders – 10 % or lessValve Seat Angle (Intake)

Angle (Exhaust)

Width

1.0 rad60 °

0.79 rad45 °

2.12 mm0.0835 in.

–

–

–

Valve Face Angle (Intake)

Angle (Exhaust)

1.0 rad60 °

0.79 rad45 °

–

–

Valve Recessing Intake

Exhaust

−0.20 to 0 mm−0.0078 to 0 in.

−0.050 to 0.15 mm−0.0020 to 0.0059 in.

−0.4 mm−0.02 in.

−0.4 mm−0.02 in.


Valve Stem

Valve Guide


Valve Stem

Valve Guide

Clearance (Intake)

O.D. (Intake)

I.D. (Intake)

Clearance (Exhaust)

O.D. (Exhaust)

I.D. (Exhaust)

0.055 to 0.085 mm0.0022 to 0.0033 in.

6.960 to 6.975 mm0.2741 to 0.2746 in.

7.030 to 7.045 mm0.2768 to 0.2773 in.

0.040 to 0.070 mm0.0016 to 0.0027 in.

7.960 to 7.975 mm0.3134 to 0.3139 in.

8.015 to 8.030 mm0.3156 to 0.3161 in.

0.1 mm0.004 in.

–

–

0.1 mm0.004 in.

–

–

Valve Clearance (Cold) 0.23 to 0.27 mm0.0091 to 0.010 in.

–


S-14



W1127908

Item Factory Specification Allowable LimitIntake Valve Timing Open

Close

0.24 rad (14 °)before T.D.C.

0.63 rad (36 °)after B.D.C.

–

–

Exhaust Valve Timing Open

Close

0.79 rad (45 °)before B.D.C.

0.30 rad (17 °)after T.D.C.

–

–

Valve Spring Free Length (Intake)

Free Length(Exhaust)

Tilt

35.1 to 35.6 mm1.39 to 1.40 in.

41.7 to 42.2 mm1.65 to 1.66 in.

–

34.6 mm1.36 in.

41.2 mm1.62 in.

1.0 mm0.039 in.

Valve Spring Setting Load / Setting Length (Intake)

Setting Load / Setting Length (Exhaust)

63.5 N / 31.5 mm6.48 kgf / 31.5 mm14.3 lbf / 1.24 in.

118 N / 35.0 mm12.0 kgf / 35.0 mm26.5 lbf / 1.38 in.

45.9 N / 31.5 mm

4.68 kgf / 31.5 mm10.3 lbf /1.24 in.

100 N / 35.0 mm10.2 kgf / 35.0 mm22.5 lbf / 1.38 in.

Rocker Arm Shaft to Rocker Arm

Rocker Arm Shaft

Rocker Arm

Clearance

O.D.

I.D.

0.016 to 0.045 mm0.00063 to 0.0017 in.

15.973 to 15.984 mm0.62886 to 0.62929 in.

16.000 to 16.018 mm0.62993 to 0.63062 in.

0.15 mm0.0059 in.

–

–

Valve Arm Bridge and Valve Arm Bridge Shaft

Valve Arm Bridge

Valve Arm Bridge Shaft

Clearance

I.D.

O.D.

0.018 to 0.042 mm0.00071 to 0.0016 in.

9.050 to 9.065 mm0.3563 to 0.3568 in.

9.023 to 9.032 mm0.3553 to 0.3555 in.

0.15 mm0.0059 in.

–

–

Push Rod Alignment – 0.25 mm0.0098 in.


S-15



W1129677

Item Factory Specification Allowable LimitTappet to Tappet Guide

Tappet Guide Bore

Tappet

Clearance

I.D.

O.D.

0.020 to 0.062 mm0.00079 to 0.0024 in.

24.000 to 24.021 mm0.94489 to 0.94570 in.

23.959 to 23.980 mm0.94327 to 0.94409 in.

0.07 mm0.003 in.

–

–

Camshaft Side Clearance

Alignment

0.070 to 0.22 mm0.0028 to 0.0086 in.

–

0.30 mm0.012 in.

0.01 mm0.0004 in.

Cam Height Intake

Exhaust

37.63 mm1.481 in.

38.96 mm1.534 in.

37.13 mm1.462 in.

38.46 mm1.514 in.

Camshaft

Camshaft Journal

Camshaft Bearing

Oil Clearance

O.D.

I.D.

0.050 to 0.091 mm0.0020 to 0.0035 in.

45.934 to 45.950 mm1.8085 to 1.8090 in.

46.000 to 46.025 mm1.8111 to 1.8120 in.

0.15 mm0.0059 in.

–

–

Timing GearIdle Gear 1 to Crank Gear

Idle Gear 1 to Cam Gear

Idle Gear 1 to Idle Gear 2

Idle Gear 2 to Injection Pump Gear

Backlash

Backlash

Backlash

Backlash

0.0490 to 0.193 mm0.00193 to 0.00759 in.

0.0490 to 0.189 mm0.00193 to 0.00744 in.

0.0440 to 0.185 mm0.00174 to 0.00728 in.

0.0440 to 0.177 mm0.00174 to 0.00696 in.

0.22 mm0.0087 in.

0.22 mm0.0087 in.

0.22 mm0.0087 in.

0.22 mm0.0087 in.

Idle Gear Shaft 1, 2 to Idle Gear 1, 2 Bushing

Idle Gear 1, 2 Bushing

Idle Gear 1, 2 Shaft

Oil Clearance

I.D.

O.D.

0.050 to 0.091 mm0.0020 to 0.0035 in.

45.025 to 45.050 mm1.7727 to 1.7736 in.

44.959 to 44.975 mm1.7701 to 1.7706 in.

0.10 mm0.0039 in.

–

–

Idle Gear Side Clearance 0.15 to 0.30 mm0.0059 to 0.011 in.

0.9 mm0.04 in.

Piston Pin Bore I.D. 30.000 to 30.013 mm1.1811 to 1.1816 in.

30.05 mm1.183 in.


S-16



W11316590

Item Factory Specification Allowable LimitSecond Ring to Ring Groove Clearance 0.093 to 0.120 mm

0.00367 to 0.00472 in.0.20 mm0.0079 in.

Oil Ring to Ring Groove Clearance 0.020 to 0.060 mm0.00079 to 0.0023 in.

0.15 mm0.0059 in.

Piston Ring Gap Top Ring

Second Ring

Oil Ring

0.30 to 0.45 mm0.012 to 0.017 in.

0.30 to 0.45 mm0.012 to 0.017 in.

0.25 to 0.45 mm0.0099 to 0.017 in.

1.25 mm0.0492 in.

1.25 mm0.0492 in.

1.25 mm0.0492 in.

Connecting Rod Alignment – 0.05 mm0.002 in.

Piston Pin to Small End Bushing

Piston Pin

Small End Bushing

Clearance

O.D.

I.D.

0.020 to 0.040 mm0.00079 to 0.0015 in.

30.006 to 30.011 mm1.1814 to 1.1815 in.

30.031 to 30.046 mm1.1824 to 1.1829 in.

0.15 mm0.0059 in.

–

–

Crankshaft Side Clearance

Alignment

0.15 to 0.31 mm0.0059 to 0.012 in.

–

0.50 mm0.020 in.

0.02 mm0.0008 in.

Crankshaft Journal to Crankshaft Bearing

Crankshaft Journal

Oil Clearance

O.D.

0.018 to 0.062 mm0.00071 to 0.0024 in.

74.977 to 74.990 mm2.9519 to 2.9523 in.

0.20 mm0.0079 in.

–

Crank Pin to Pin Bearing

Crank Pin

Oil Clearance

O.D.

0.018 to 0.051 mm0.00071 to 0.0020 in.

52.977 to 52.990 mm2.0857 to 2.0862 in.

0.20 mm0.0079 in.

–

Cylinder Bore I.D. 98.000 to 98.022 mm3.8582 to 3.8591 in.

98.15 mm3.864 in.

Cylinder Bore (Oversize) I.D. 98.500 to 98.522 mm3.8780 to 3.8788 in.

98.65 mm3.884 in.


S-17


LUBRICATING SYSTEM

W11335240

COOLING SYSTEM

W10135990

Item Factory Specification Allowable LimitEngine Oil Pressure At Idle Speed

At Rated Speed

–

200 to 390 kPa2.0 to 4.0 kgf/cm2

29 to 56 psi

50 kPa0.5 kgf/cm2

7 psi

150 kPa1.5 kgf/cm2

21 psiEngine Oil Pressure Switch Working Pressure 40 to 50 kPa

0.4 to 0.6 kgf/cm2

6 to 8 psi

–

Inner Rotor to Outer Rotor Clearance 0.040 to 0.16 mm0.0016 to 0.0062 in.

0.3 mm0.01 in.

Outer Rotor to Pump Body Clearance 0.100 to 0.184 mm0.00394 to 0.00724 in.

0.3 mm0.01 in.

Inner Rotor to Cover Clearance 0.025 to 0.075 mm0.00099 to 0.0029 in.

0.225 mm0.00886 in.

Relief Valve Working Pressure 887 kPa9.04 kgf/cm2

129 psi

–

Thermostat Valve Opening Temperature

Valve Opening Temperature(Opened Completely)

74.5 to 78.5 °C166.1 to 173.3 °F

90 °C194 °F

–

–

Radiator Water Tightness No leak at specified pressure

–

Radiator Cap Air Leakage 10 seconds or more 90 → 60 kPa

0.9 → 0.6 kgf/cm2

10 → 9 psi

–

Fan Belt Tension 10.0 to 12.0 mm / 98 N0.394 to 0.472 in. / 98 N

(10 kgf, 22 lbf)

–


S-18


FUEL SYSTEM

W11353580

ELECTRICAL SYSTEM

W1137041

Item Factory Specification Allowable LimitInjection Timing 0.14 to 0.17 rad

(8.0 to 10 °)before T.D.C.

–

Pump Element Fuel Tightness – 13.73 MPa140.0 kgf/cm2

1991 psiDelivery Valve Fuel Tightness 10 seconds

13.73 → 12.75 MPa140.0 → 130.0 kgf/cm2

1991 → 1849 psi

5 seconds13.73 → 12.75 MPa

140.0 → 130.0 kgf/cm2

1991 → 1849 psiFuel Injection Nozzle Injection Pressure

Valve Seat Tightness

13.73 to 14.70 MPa140.0 to 150.0 kgf/cm2

1992 to 2133 psi

When the pressure is 12.75 MPa

(130.0 kgf/cm2, 1849 psi), the valve seat must

be fuel tightness.

–

–

Commutator O.D. 32 mm1.3 in.

31.4 mm1.24 in.

Mica Undercut 0.5 mm0.02 in.

0.2 mm0.008 in.

Brush (Starter) Length 18.0 mm0.709 in.

11.0 mm0.433 in.

Alternator No-load Voltage 14 V at 4000 min-1 (rpm)

–

Rotor Coil Resistance 2.8 to 3.3 Ω –Slip Ring O.D. 22.7 mm

0.894 in.22.1 mm0.870 in.

Brush (Alternator) Length 18.5 mm0.728 in.

5.0 mm0.20 in.

Glow Plug Resistance(at cold occasion)

Approx. 1.0 Ω –


S-19


3. TIGHTENING TORQUESScrews, bolts and nuts must be tightened to the specified torque using a torque wrench, several screws, bolts and

nuts such as those used on the cylinder head must be tightened in proper sequence and at the proper torque.

[1] TIGHTENING TORQUES FOR SPECIAL USE SCREWS, BOLTS ANDNUTS

NOTE• In removing and applying the screws, bolts and nuts marked with "*", pneumatic wrench or similar

pneumatic tool, if employed, must be used with enough care not to get them seized.• For "*" marked screws, bolts and nuts on the table, apply engine oil to their threads and seats before

tightening.

(1) D1703-E/E2, V2203-E/E2, F2803-E/E2

W1091652

Section Item Size x Pitch N·m kgf·m lbf·ftEngine *Cylinder head cover screw M6 x 1.0 9.81 to 11.2 1.00 to 1.15 7.24 to 8.31

*Cylinder head cover cap nut M8 x 1.25 7 to 8 0.7 to 0.9 5 to 6*Cylinder head screw M11 x 1.25 93.2 to 98.0 9.50 to 10.0 68.8 to 72.3*Main bearing case screw 1 M9 x 1.25 46 to 50 4.7 to 5.2 34 to 37*Main bearing case screw 2 M10 x 1.25 69 to 73 7.0 to 7.5 51 to 54*Flywheel screw M12 x 1.25 98.1 to 107 10.0 to 11.0 72.4 to 79.5*Connecting rod screw M8 x 1.0 45 to 49 4.5 to 5.0 33 to 36*Rocker arm bracket screw M8 x 1.25 24 to 27 2.4 to 2.8 18 to 20*Rocker arm bracket nut M8 x 1.25 24 to 27 2.4 to 2.8 18 to 20*Idle gear shaft screw M8 x 1.25 24 to 27 2.4 to 2.8 18 to 20Fan drive pulley mounting nut M30 x 1.5 138 to 156 14.0 to 16.0 102 to 115Fan drive pulley screw M16 x 1.5 314 to 333 32.0 to 34.0 232 to 245*Bearing case cover mounting screw M8 x 1.25 24 to 27 2.4 to 2.8 18 to 20

Glow plug M10 x 1.25 20 to 24 2.0 to 2.5 15 to 18Nozzle holder assembly M20 x 1.5 49 to 68 5.0 to 7.0 37 to 50Nozzle holder – 35 to 39 3.5 to 4.0 26 to 28Oil pressure switch R 1/8 15 to 19 1.5 to 2.0 11 to 14Injection pipe retaining nut M12 x 1.5 25 to 34 2.5 to 3.5 18 to 25Overflow pipe assembly retaining nut M12 x 1.5 20 to 24 2.0 to 2.5 15 to 18

Camshaft set screw M8 x 1.25 24 to 27 2.4 to 2.8 18 to 20Alternator’s pulley nut – 58.4 to 78.9 5.95 to 8.05 43.1 to 58.2Starter’s terminal B mounting nut M8 5.9 to 11 0.60 to 1.2 4.4 to 8.6


S-20


(2) V3300-E2BG

W1013236

Item Size x Pitch N·m kgf·m lbf·ftCylinder head cover screw – 6.87 to 11.2 0.700 to 1.15 5.07 to 8.31*Cylinder head screw M12 x 1.25 98.1 to 107 10.0 to 11.0 72.4 to 79.5*Connecting rod screw M10 x 1.25 79 to 83 8.0 to 8.5 58 to 61*Flywheel screw M12 x 1.25 98.1 to 107 10.0 to 11.0 72.4 to 79.5*Crankshaft screw M16 x 1.5 255 to 274 26.0 to 28.0 188 to 202*Main bearing case screw M14 x 1.5 138 to 147 14.0 to 15.0 102 to 108Rocker arm bracket screw M10 x 1.25 49 to 55 5.0 to 5.7 37 to 41Nozzle holder assembly M20 x 1.5 49 to 68 5.0 to 7.0 37 to 50Nozzle holder – 35 to 39 3.5 to 4.0 26 to 28Injection pipe retaining nut M12 x 1.5 23 to 36 2.3 to 3.7 17 to 26Overflow pipe assembly retaining nut M12 x 1.5 20 to 24 2.0 to 2.5 15 to 18Oil switch taper screw R 1/8 15 to 19 1.5 to 2.0 11 to 14Oil cooler joint screw – 40 to 44 4.0 to 4.5 29 to 32Oil pump cover screw – 7.9 to 9.3 0.80 to 0.95 5.8 to 6.8Glow plugs M10 x 1.25 20 to 24 2.0 to 2.5 15 to 18Starter’s terminal B mounting nut M8 x 1.25 9.8 to 11 1.0 to 1.2 7.3 to 8.6Injection pump gear mounting nut M14 x 1.5 74 to 83 7.5 to 8.5 55 to 61Injection pump unit mounting nut M8 x 1.25 18 to 20 1.8 to 2.1 13 to 15

Gear case coverM8 x 1.25 (7T) 24 to 27 2.4 to 2.8 18 to 20M8 x 1.25 (10T) 33 to 36 3.3 to 3.7 24 to 26

Relief valve retaining screw – 69 to 78 7.0 to 8.0 51 to 57Idle gear mounting screw M8 x 1.25 24 to 27 2.4 to 2.8 18 to 20Plate mounting screw M8 x 1.25 24 to 27 2.4 to 2.8 18 to 20Camshaft set screw M8 x 1.25 24 to 27 2.4 to 2.8 18 to 20Flywheel housing mounting screw M12 x 1.25 78 to 90 7.9 to 9.2 58 to 66Crankcase 2 mounting screw M10 x 1.25 49 to 55 5.0 to 5.7 37 to 41Injection pump mounting screw M8 x 1.25 24 to 27 2.4 to 2.8 18 to 20Injection pump mounting nut M8 x 1.25 18 to 20 1.8 to 2.1 13 to 15Governor weight mounting nut M12 x 1.25 63 to 72 6.4 to 7.4 47 to 53Fuel camshaft stopper mounting screw – 7.9 to 9.3 0.80 to 0.95 5.8 to 6.8Governor housing mounting screw M6 x 1.0 9.81 to 11.2 1.00 to 1.15 7.24 to 8.31Anti-rotation nut M5 x 0.8 2.9 to 4.0 0.29 to 0.41 2.1 to 2.9Bearing case cover mounting screw M8 x 1.25 24 to 27 2.4 to 2.8 18 to 20Alternator pulley nut – 58.4 to 78.9 5.95 to 8.05 43.1 to 58.2


S-21


4. CHECKING, DISASSEMBLING AND SERVICING[1] CHECKING AND ADJUSTING(1) Engine Body

Compression Pressure1. Run the engine until it is warmed up.2. Stop the engine and disconnect the 2P connector from the stop

solenoid in order not to inject fuel.3. Remove the air cleaner, the muffler and all injection nozzles.4. Set a compression tester with the adaptor H to the nozzle hole.5. Keep the engine stop lever at “Stop Position”.6. While cranking the engine with the starter, measure the

compression pressure.7. Repeat steps 4 through 6 for each cylinder.8. If the measurement is below the allowable limit, apply a small

amount of oil to the cylinder wall through the nozzle hole andmeasure the compression pressure again.

9. If the compression pressure is still less than the allowable limit,check the top clearance, valve and cylinder head.

10.If the compression pressure increases after applying oil, checkthe cylinder wall and piston rings.NOTE

• Check the compression pressure with the specified valveclearance.

• Always use a fully charged battery for performing this test.• Variances in cylinder compression values should be under

10 %.

W1018639

Compression pressure

Factory spec.

D1703-E/E2V2203-E/E2F2803-E/E2

3.24 to 3.72 MPa33.0 to 38.0 kgf/cm2

470 to 540 psi

V3300-E2BG4.31 MPa44.0 kgf/cm2

626 psi

Allowable limit

D1703-E/E2V2203-E/E2F2803-E/E2

2.55 MPa26.0 kgf/cm2

370 psi

V3300-E2BG3.26 MPa33.2 kgf/cm2

472 psi

(A) D1703-E/E2V2203-E/E2F2803-E/E2

(B) V3300-E2BG


S-22


Valve Clearance (To be continued)[D1703-E/E2, V2203-E/E2, F2803-E/E2]


is cold.1. Remove the head cover.2. Align the “1TC” mark line (3) on the flywheel and projection (2)

on the housing so that the No.1 piston comes to the compressionor overlap top dead center.

3. Check the following valve clearance (1) marked with “ ” using afeeler gauge.

4. If the clearance is not within the factory specifications, adjust withthe adjusting screw.

NOTE• The “1TC” mark line on the flywheel is just for No. 1 cylinder.

There is no “TC” marking for the other cylinders.• No. 1 piston comes to the top dead center position when the

“TC” marking is aligned with the projection (2) in the windowon flywheel-housing. Turn the flywheel 0.26 rad (15 °)clockwise and counterclockwise to see if the piston is at thecompression top dead center or the overlap position. Nowreferring to the table below, readjust the valve clearance (1).(The piston is at the top dead center when both the IN. andEX. valves do not move; it is at the overlap position whenboth the valves move.)

• Finally turn the flywheel 6.28 rad (360 °) and align the “1TC”mark line and the projection (2) perfectly. Adjust all theother valve clearance as required.

• After turning the flywheel counterclockwise twice or threetimes, recheck the valve clearance (1).

• After adjusting the valve clearance (1), firmly tighten the locknut of the adjusting screw.

W10607180



3 Cylinder 4 Cylinder 5 Cylinder

IN. EX. IN. EX. IN. EX.

When No. 1 piston is at compression top dead center

No. 1

No. 2

No. 3

No. 4 – –

No. 5 – – – –

When No. 1 piston is at overlap position

No. 1

No. 2

No. 3

No. 4 – –

No. 5 – – – –

(1) Valve Clearance(2) Projection

(3) 1TC Mark Line


S-23


Checking Valve Clearance (Continued)[V3300-E2BG]


is cold.1. Remove the head cover.2. Align the 1TC mark of flywheel and the convex of flywheel

housing timing windows so that the first piston (gear case side)comes to the compression top dead center.

3. Before adjusting the valve clearance of intake valve, adjust thebridge evenly to the valves stem.

4. Loosen the lock nut (2) and adjust with screw (1).5. Slightly push the rocker arm (intake side) by your fingers and

screw in the adjusting screw slowly until you feel the screw touchthe top of valve stem, then tighten the lock nut.

6. Loosen the lock nut (4) of adjusting screw (3) (push rod side) andinsert the thickness gauge between the rocker arm and thebridge head. Set the adjusting screw to the specified value, thentighten the lock nut.

7. Adjust the clearance between the rocker arm (exhaust side) andthe exhaust valve to the specified value.

NOTE• After adjusting, tighten the lock nut (4) securely.

W1091976



IN. EX

When No.1 piston is at compression top dead center

No. 1

No. 2

No. 3

No. 4

When No.1 piston is at overlap position

No. 1

No. 2

No. 3

No. 4

Tightening torque Cylinder head cover screw6.9 to 11.3 N·m0.7 to 1.15 kgf·m5.1 to 8.32 lbf·ft




S-24


(2) Lubricating SystemEngine Oil Pressure1. Remove the engine oil pressure switch, and set an oil pressure

tester (Code No.: 07916-32032). (Adaptor screw size : PT 1/8)2. Start the engine. After warming up, measure the oil pressure of

both idling and rated speeds.3. If the oil pressure is less than the allowable limit, check the

following.• Engine oil insufficient.• Oil pump defective• Oil strainer clogged• Oil filter cartridge clogged• Oil gallery clogged• Excessive oil clearance• Foreign matter in the relief valve

(When reassembling)• After checking the engine oil pressure, tighten the engine oil

pressure switch to the specified torque.

[D1703-E/E2, V2203-E/E2, F2803-E/E2]

[V3300-E2BG]

W1034952

Engine oil pressure

At idle speed

Factory spec.

More than 98 kPa 1.0 kgf/cm2

14 psi

Allowable limit

50 kPa0.5 kgf/cm2

7 psi

At rated speed

Factory spec.

300 to 440 kPa3.0 to 4.5 kgf/cm2

43 to 64 psi

Allowable limit

250 kPa2.5 kgf/cm2

36 psi

Engine oil pressure

At idle speed

Allowable limit

50 kPa0.5 kgf/cm2

7 psi

At rated speed

Factory spec.

200 to 390 kPa2.0 to 4.0 kgf/cm2

29 to 56 psi

Allowable limit

150 kPa1.5 kgf/cm2

21 psi

Tightening torque Oil pressure switch15 to 19 N·m1.5 to 2.0 kgf·m11 to 14 lbf·ft

(A) D1703-E/E2V2203-E/E2F2803-E/E2

(B) V3300-E2BG


S-25


(3) Cooling SystemFan Belt Tension1. Measure the deflection (A), depressing the belt halfway between

the fan drive pulley and alternator pulley at specified force 98 N(10 kgf, 22 lbf).

2. If the measurement is not within the factory specifications, loosenthe alternator mounting screws and relocate the alternator toadjust.

W1059386

Fan Belt Damage and Wear1. Check the fan belt for damage.2. If the fan belt is damaged, replace it.3. Check if the fan belt is worn and sunk in the pulley groove.4. If the fan belt is nearly worn out and deeply sunk in the pulley

groove, replace it.

W1020602

CAUTION• When removing the radiator cap, wait at least ten minutes after the engine has stopped and cooled down.

Otherwise, hot water may gush out, scalding nearby people.Radiator Water Leakage 1. Pour a specified amount of water into the radiator.2. Set a radiator tester and an adaptor and raise the water pressure

to the specified pressure.3. Check the radiator for water leaks.4. For water leak from the pinhole, replace the radiator or repair with

the radiator cement. When water leak is excessive, replace theradiator.

NOTE• The pressure of the leak test is different from each radiator

specification.Thus, do the leak test, refer to the test pressure of eachradiator specification.

W10389070


D1703-E/E2V2203-E/E2F2803-E/E2

7.0 to 9.0 mm0.28 to 0.35 in.

V3300-E2BG 10 to 12 mm0.40 to 0.47 in.

(A) Deflection

(A) Good (B) Bad

Radiator water leakage test pressure Factory spec. No leak at specified

pressure


S-26


Radiator Cap Air Leakage1. Set a radiator tester and an adaptor on the radiator cap.2. Apply the specified pressure 90 kPa (0.9 kgf/cm2, 10 psi), and

measure the time for the pressure to fall to 60 kPa (0.6 kgf/cm2,9 psi).

3. If the measurement is less than the factory specification, replacethe radiator cap.

W10387530

Thermostat Valve Opening Temperature1. Suspend the thermostat in the water by a string with its end

inserted between the valve and seat.2. Heating the water gradually, read the temperature when the

valve opens and leaves the string.3. Continue heating and read the temperature when the valve

opens approx. 6 mm (0.2 in.).4. If the measurement is not within the factory specifications,

replace the thermostat.

W1035849

Pressure falling time Factory spec.

More than 10 secondsfor pressure fall from90 to 60 kPa(from 0.9 to 0.6 kgf/cm2,from 10 to 9 psi)

Thermostat’s valve opening temperature

Factory spec.

D1703-E/E2V2203-E/E2F2803-E/E2

69.5 to 72.5 °C157.1 to 162.5 °F

V3300-E2BG 74.5 to 78.5 °C166.1 to 173.3 °F

Temperature at which thermostat completely opens

Factory spec.

D1703-E/E2V2203-E/E2F2803-E/E2

85 °C185 °F

V3300-E2BG 90 °C194 °F


S-27


(4) Fuel SystemInjection Timing (To be continued)[D1703-E/E2, V2203-E/E2, F2803-E/E2]1. Remove the injection pipes and nozzle.2. Set the speed control lever to maximum fuel discharge position.(Reference)• Turn the flywheel with screwdriver.

3. Turn the flywheel counterclockwise (facing the flywheel) until thefuel fills up to the hole of the delivery valve holder (1) for 1stcylinder.

4. Turn the flywheel further and stop turning when the fuel begins toflow over, to get the present injection timing.

5. (The flywheel has mark 1TC and four lines indicating every 0.09rad (5 °) of crank angle from 0.17 rad (10 °) to 0.44 rad (25 °)before mark 1TC.) Calculate the angle which the center of thewindow points out. If the calculation differs from specifiedinjection timing, add or remove the shim to adjust.

(Injection Timing)

NOTE• The sealant is applied to both sides of the soft metal gasket

shim. The liquid gasket is not required for assembling.• Shims are available in thickness of 0.175 mm (7), 0.20 mm

(4), 0.25 mm (5) and 0.30 mm (6). Combine these shims foradjustments.

• The 0.175 mm thick shim is coated only on the lower face.Therefore, do not use the 0.175 mm thick shim as the topshim of the combination (injection pump side), because thiscause oil leakage.

• Addition or reduction of shim (0.05 mm, 0.002 in.) delays oradvances the injection timing by approx. 0.009 rad (0.5 °).

• In disassembling and replacing, be sure to use the samenumber of new gasket shims with the same thickness.

W1063324


D1703-E, V2203-EV2203-E2, F2803-E2 0.27 to 0.29 rad (15 to 17 °) before T.D.C.

F2803-E 0.28 to 0.31 rad (16 to 18 °) before T.D.C.

D1703-E2 0.236 to 0.270 rad (13.5 to 15.5 °) before T.D.C.

(1) Delivery Valve Holder(2) Timing Mark(3) Shim (Soft Metal Gasket Shim)(4) 2-holes : 0.20 mm (0.0079 in.) Shim(5) 1-hole : 0.25 mm (0.0098 in.) Shim(6) Without hole : 0.30 mm (0.012 in.)

Shim(7) 2-holes : 0.175 mm (0.00689 in.)

Shim

(A) 3 Cylinder(B) 4 Cylinder


S-28


Injection Timing (Continued)[V3300-E2BG]1. Make sure of matching the injection timing align mark (1) of the

injection pump unit and the plate (gearcase), as shown in theillustration.

2. Remove the injection pipes.3. Remove the stop solenoid.4. Turn the flywheel counterclockwise (viewed from flywheel side)

until the fuel fills up to the hole of the delivery valve holder (2) forNo.1 cylinder.

5. After the fuel fills up to the hole of the delivery valve holder forNo.1 cylinder, turn back (clockwise) the flywheel around 1.57 rad(90 °).

6. Turn the flywheel counterclockwise to set at around 0.35 rad(20 °) before T.D.C..

7. Slowly turn the flywheel counterclockwise and stop turning whenthe fuel begins to come up, to get the present injection timing.

8. Check to see the degree on flywheel.The flywheel has mark “1TC”, “10” and “20” for the crank anglebefore the top dead center of No.1 piston.

9. If the injection timing is not within the specification, rotate theinjection pump unit to adjust the injection timing.IMPORTANT

• When installing the injection pump unit to the engine body,follow the correct procedure.See the “Injection Pump Unit”.

(Injection Timing)

W1095214


V3300-E2BG 0.14 to 0.17 rad (8.0 ° to 10 °) before T.D.C.

Tightening torque

Injection pipe retaining nut22.6 to 36.3 N·m2.3 to 3.7 kgf·m16.6 to 26.8 lbf·ft



(1) Injection Timing Align Mark(2) Delivery Valve Holder

(a) Injection Timing Advanced(b) Injection Timing Retarded


S-29


Fuel Tightness of Pump Element1. Remove the engine stop solenoid.2. Remove the injection pipes and glow plugs.3. Install the injection pump pressure tester (1) to the injection

pump.4. Install the injection nozzle (2) jetted with the proper injection

pressure to the injection pump pressure tester (1). (Refer to thefigure.)

5. Set the speed control lever to the maximum speed position.6. Run the starter to increase the pressure.7. If the pressure can not reach the allowable limit, replace the

pump with new one or repair with a Kubota-authorized pumpservice shop.



W1017430

Fuel tightness of pump element Allowable limit

13.73 MPa140.0 kgf/cm2

1991 psi


[A] D1703-E/E2V2203-E/E2F2803-E/E2

[B] V3300-E2BG


S-30


Fuel Tightness of Delivery Valve1. Remove the engine stop solenoid.2. Remove the injection pipes and glow plugs.3. Set a pressure tester to the fuel injection pump.4. Install the injection nozzle (2) jetted with the proper injection

pressure to the injection pump pressure tester (1).5. Run the starter to increase the pressure.6. Stop the starter when the fuel jets from the injection nozzle (2).

After that, turn the flywheel by the hands and raise the pressureto approx. 13.73 MPa (140.0 kgf/cm2, 1991 psi).

7. Now turn the flywheel back about half a turn (to keep the plungerfree). Maintain the flywheel at this position and clock the timetaken for the pressure to drop from 13.73 to 12.75 MPa (140.0 to130.0 kgf/cm2, 1991 to 1849 psi).

8. Measure the time needed to decrease the pressure from 13.73 to12.75 MPa (140.0 to 130.0 kgf/cm2, 1991 to 1849 psi).

9. If the measurement is less than allowable limit, replace the pumpwith new one or repair with a Kubota-authorized pump serviceshop.



W1017786

Fuel tightness of delivery valve

Factory spec.


1991 → 1849 psi

Allowable limit


1991 → 1849 psi


[A] D1703-E/E2V2203-E/E2F2803-E/E2

[B] V3300-E2BG


S-31


CAUTION• Check the injection pressure and condition after confirming that there is nobody standing in the direction

the fume goes.• If the fume from the nozzle directly contacts the human body, cells may be destroyed and blood poisoning

may be caused.Nozzle Spraying Condition1. Set the injection nozzle to a nozzle tester, and check the nozzle

spraying condition.2. If the spraying condition is defective, replace the nozzle piece.

W10181310

Fuel Injection Pressure1. Set the injection nozzle to a nozzle tester.2. Slowly move the tester handle to measure the pressure at which

fuel begins jetting out from the nozzle.3. If the measurement is not within the factory specifications,

replace the adjusting washer (1) in the nozzle holder to adjust it.(Reference)• Pressure variation with 0.025 mm (0.00098 in.) difference of

adjusting washer thickness.Approx. 590 kPa (6.0 kgf/cm2, 85 psi)

W10972720

Valve Seat Tightness1. Set the injection nozzle to a nozzle tester.2. Raise the fuel pressure, and keep at 12.75 MPa (130.0 kgf/cm2,

1849 psi) for 10 seconds.3. If any fuel leak is found, replace the nozzle piece.

W10183690

(a) Good (b) Bad

Fuel injection pressure Factory spec.13.73 to 14.70 MPa140.0 to 150.0 kgf/cm2

1992 to 2133 psi

(1) Adjusting Washer

Valve seat tightness Factory spec.

No fuel leak at12.75 MPa130.0 kgf/cm2

1849 psi


S-32


Nozzle Holder1. Secure the nozzle retaining nut (7) with a vise.2. Remove the nozzle holder (1), and take out parts inside.(When reassembling)• Assemble the nozzle in clean fuel oil.• Install the push rod (4), noting its direction.• After assembling the nozzle, be sure to adjust the fuel injection

pressure.

W1018491

(5) Electrical System

CAUTION• To avoid accidental short circuit, be sure to attach the positive cable to the positive terminal before the

negative cable is attached to the negative terminal.• Never remove the battery cap while the engine is running.• Keep electrolyte away from eyes, hands and clothes. If you are spattered with it, wash it away completely

with water immediately.• Keep open sparks and flames away from the battery at all times. Hydrogen gas mixed with oxygen

becomes very explosive.IMPORTANT

• If the machine is to be operated for a short time without battery (using a slave battery for starting), useadditional current (lights) while engine is running and insulate terminal of battery. If this advice isdisregarded, damage to alternator and regulator may result.

Battery Voltage1. Stop the engine.2. Measure the voltage with a circuit tester between the battery

terminals.3. If the battery voltage is less than the factory specification, check

the battery specific gravity and recharge the battery.

W10125620

Tightening torque

Nozzle holder35 to 39 N·m3.5 to 4.0 kgf·m26 to 28 lbf·ft

Overflow pipe assembly retaining nut

20 to 24 N·m2.0 to 2.5 kgf·m15 to 18 lbf·ft

Nozzle holder assembly49 to 68 N·m5.0 to 7.0 kgf·m37 to 50 lbf·ft

(1) Nozzle Holder(2) Adjusting Washer(3) Nozzle Spring(4) Push Rod

(5) Distance Piece(6) Nozzle Piece(7) Nozzle Retaining Nut

Battery voltage Factory spec. More than 12 V

(1) Positive Terminal (2) Negative Terminal


S-33


Battery Specific Gravity1. Check the specific gravity of the electrolyte in each cell with a

hydrometer.2. When the electrolyte temperature differs from that at which the

hydrometer was calibrated, correct the specific gravity readingfollowing the formula mentioned in (Reference).

3. If the specific gravity is less than 1.215 (after it is corrected fortemperature), charge or replace the battery.

4. If the specific gravity differs between any two cells by more than0.05, replace the battery.NOTE

• Hold the hydrometer tube vertical without removing it fromthe electrolyte.

• Do not suck too much electrolyte into the tube.• Allow the float to move freely and hold the hydrometer at eye

level.• The hydrometer reading must be taken at the highest

electrolyte level.(Reference)• Specific gravity slightly varies with temperature. To be exact, the

specific gravity decreases by 0.0007 with an increase of 1 °C(0.0004 with an increase of 1 °F) in temperature, and increasesby 0.0007 with a decreases of 1 °C (0.0004 with a decrease of 1°F).Therefore, using 20 °C (68 °F) as a reference, the specific gravityreading must be corrected by the following formula :- Specific gravity at 20 °C = Measured value + 0.0007 ×

(electrolyte temperature – 20 °C)- Specific gravity at 68 °F = Measured value + 0.0004 ×

(electrolyte temperature – 68 °F)

At an electrolyte temperature of 20 °C (68 °F)

W1019017

Specific Gravity State of Charge

1.260 Sp. Gr. 100 % Charged




1.140 Sp. Gr. Very Little Useful Capacity

1.110 Sp. Gr. Discharged

(a) Good(b) Bad

(c) Bad


S-34


Motor Test

CAUTION• Secure the starter to prevent it from jumping up and down

while testing the motor.1. Disconnect the battery negative cable from the battery.2. Disconnect the battery positive cable from the battery.3. Disconnect the leads from the starter B terminal.4. Remove the starter from the engine.5. Connect a jumper lead from the starter C terminal (1) to the

battery positive terminal (2).6. Connect a jumper lead momentarily between the starter’s body

and the battery negative terminal (3).7. If the motor does not run, starter is failure.

Repair or replace the starter.NOTE

• B terminal : It is the terminal which connects the cable fromthe battery to the starter.

• C terminal : It is the terminal which connects the cable fromthe motor to the magnet switch.

W1019297

Magnetic Switch Test1. Disconnect the battery negative cable from the battery.2. Disconnect the battery positive cable from the battery.3. Disconnect the leads from the starter B terminal.4. Remove the starter from the engine.5. Connect a jumper lead from the starter S terminal (1) to the

battery positive terminal (2).6. Connect a jumper lead momentarily between the starter’s body

and the battery negative terminal (3).7. If the pinion gear does not pop out, the magnetic switch is failure.

Repair or replace the starter.NOTE

• B terminal : It is the terminal which connects the cable fromthe battery to the starter.

• S terminal : It is the terminal which connects the cable fromthe starter switch to the magnet switch.

0000010743E

(1) C Terminal(2) Positive Terminal(3) Negative Terminal

[A] D1703-E/E2V2203-E/E2F2803-E/E2

[B] V3300-E2BG

(1) S Terminal(2) Positive Terminal(3) Negative Terminal

[A] D1703-E/E2V2203-E/E2F2803-E/E2

[B] V3300-E2BG


S-35


Magnet Switch Continuity Test1. Check the continuity across the C terminal (1) and the B terminal

(2) with a circuit tester, pushing in the plunger.2. If not continuous or if a certain value is indicated, replace the

magnet switch.

W1063967

Alternator on Unit Test(Before testing)• Before alternator on unit test, check the battery terminal

connections, circuit connection, fan belt tension, chargingindicator lamp, fuses on the circuit, and abnormal noise from thealternator.

• Prepare full charged battery for the test.NOTE

• Be careful not to touch the rotating engine parts whileengine is running.Keep safety distance from the engine rotating parts.

1. Start the engine.2. When the engine is operating measure the voltage between two

battery terminals. If the voltage is between 13.8 V and 14.8 V,the alternator is operating normally.

3. If the results of alternator on unit test are not within thespecifications, disassemble the alternator and check the eachcomponent part for finding out the failure. See the“DISASSEMBLING AND ASSEMBLING” and “SERVICING” foralternator.

0000010745E

(1) C Terminal(2) B Terminal

[A] D1703-E/E2V2203-E/E2F2803-E/E2

[B] V3300-E2BG

Regulating voltage at no load Factory spec. 13.8 to 14.8 V at 25 °C

(77 °F)




S-36


Glow Plug Lead Terminal Voltage1. Turn the key switch to the “GLOW (or PREHEAT)” position, and

measure the voltage with a circuit tester between the leadterminal and the engine body.

2. If the voltage differs from the battery voltage, the wiring harnessor main switch is faulty.

0000010725E

Glow Plug Continuity1. Remove the glow plug.2. Measure the resistance with a circuit tester between the glow

plug terminal and the glow plug housing.3. If the factory specification is not indicated, glow plug is faulty.

0000010726E

VoltageMain switch key at GLOW (or PREHEAT)

Approx. battery voltage

Resistance Factory spec. Approx. 0.9 Ω


S-37


[2] DISASSEMBLING AND ASSEMBLING(1) D1703-E/E2, V2203-E/E2, F2803-E/E21) Cylinder Head and Valves

Cylinder Head Cover1. Remove the lead (4).2. Remove the breather hose (1).3. [a] D1703-E2, V2203-E2

Remove the cylinder head cover screws (3).[b] D1703-E, V2203-E / [c] F2803-E, F2803-E2Remove the cylinder head cover cap nuts (8).

4. Remove the cylinder head cover (2).(When reassembling)• Check to see if the cylinder head cover gasket (5) is not

defective.

W1060460

Tightening torque

Cylinder head cover screw9.81 to 11.2 N·m1.00 to 1.15 kgf·m7.24 to 8.31 lbf·ft

Cylinder head cover cap nut


(1) Breather Hose(2) Cylinder Head Cover(3) Cylinder Head Cover Screw(4) Lead(5) Cylinder Head Cover Gasket(6) Breather Valve(7) Plate(8) Cylinder Head Cover Cap Nut

[a] D1703-E2, V2203-E2[b] D1703-E, V2203-E, F2803-E[c] F2803-E2


S-38


Injection Pipes1. Loosen the screws on the pipe clamps (1).2. Detach the injection pipes (2).(When reassembling)• Blow out dust inside the pipes.

W1060970

Nozzle Holder Assembly and Glow Plug1. Remove the overflow pipe assembly (3).2. Remove the nozzle holder assemblies (4) using a 21 mm deep

socket wrench.3. Remove the copper gasket and heat seal (5).4. Remove the glow plugs (2).(When reassembling)• Replace the copper gasket and heat seal with new one.

W1020917

Nozzle Heat Seal Service Removal ProcedureIMPORTANT

• Use a plus (phillips head) screw driver (1) that has adiameter which is bigger than the heat seal hole (Approx. 6mm (1/4 in.)).

1. Drive screw driver (1) lightly into the heat seal hole.2. Turn screw driver three or four times each way.3. While turning the screw driver, slowly pull the heat seal (4) out

together with the injection nozzle gasket (3).4. If the heat seal drops, repeat the above procedure.(When reassembling)• Heat seal and injection nozzle gasket must be changed when the

injection nozzle is removed for cleaning or for service.

W1021255

Tightening torque Injection pipe retaining nut25 to 34 N·m2.5 to 3.5 kgf·m18 to 25 lbf·ft

(1) Pipe Clamp (2) Injection Pipe

Tightening torque




Glow plug20 to 24 N·m2.0 to 2.5 kgf·m15 to 18 lbf·ft

(1) Lead(2) Glow Plug(3) Overflow Pipe Assembly

(4) Nozzle Holder Assembly(5) Heat Seal

(1) Plus Screw Driver(2) Injection Nozzle

(3) Injection Nozzle Gasket(4) Heat Seal


S-39


Rocker Arm and Push Rod1. Remove the rocker arm bracket screws (D1703-E2, V2203-E2)

or nuts (D1703-E, V2203-E, F2803-E, F2803-E2).2. Detach the rocker arm assembly (1).3. Remove the push rods (2).(When reassembling)• When putting the push rods (2) onto the tappets (3), check to see

if their ends are properly engaged with the grooves.IMPORTANT

• After installing the rocker arm, be sure to adjust the valveclearance.

W1021437

Tightening torque

Rocker arm bracket screw24 to 27 N·m2.4 to 2.8 kgf·m18 to 20 lbf·ft

Rocker arm bracket nut24 to 27 N·m2.4 to 2.8 kgf·m18 to 20 lbf·ft

(1) Rocker Arm Assembly(2) Push Rod

(3) Tappet


S-40


Cylinder Head1. Loosen the pipe clamp (2), and remove the water return pipe (1).2. Remove the cylinder head screw in the order of (v or r or n) to (a).3. Lift up the cylinder head (3) to detach.4. Remove the cylinder head gasket (4) and O-ring (5).(When reassembling)• Replace the cylinder head gasket (4) with a new one.• Securely fit the O-ring (5) to the pin pipe (6).• Tighten the cylinder head screws after applying sufficient oil.• Tighten the cylinder head screws in diagonal sequence starting

from the center in the order of (a) to (n or r or v).• Tighten them uniformly, or the head may deform in the long run.• Retighten the cylinder head screws after running the engine for

30 minutes.

W1021755

Tightening torque Cylinder head screw93.2 to 98.0 N·m9.50 to 10.0 kgf·m68.8 to 72.3 lbf·ft

(1) Return Pipe(2) Pipe Clamp(3) Cylinder Head(4) Cylinder Head Gasket(5) O-ring(6) Pin Pipe

(v or r or n) to (a): To Loosen(a) to (n or r or v): To Tighten(A) Gear Case Side(B) Flywheel Side


S-41


Thermostat Assembly1. Remove the thermostat cover mounting screws, and remove the

thermostat cover (1).2. Remove the thermostat assembly (3).(When reassembling)• Replace the thermostat cover gasket (2) with new one.

W10363950

Tappets1. Remove the tappets (1) from the crankcase.(When reassembling)• Visually check the contact between tappets and cams for proper

rotation. If defect is found, replace tappets.• Before installing the tappets, apply engine oil thinly around them.

IMPORTANT• Do not change the combination of tappet and tappet guide.

W1022001

Valves1. Remove the valve caps (3).2. Remove the valve spring collet (4), pushing the valve spring

retainer (5) by valve spring replacer (1).3. Remove the valve spring retainer (5), valve spring (6) and valve

stem seal (2).4. Remove the valve (7).(When reassembling)• Wash the valve stem and valve guide hole, and apply engine oil

sufficiently.• After installing the valve spring collets (4), lightly tap the stem to

assure proper fit with a plastic hammer.IMPORTANT

• Do not change the combination of valve and valve guide.

W1022102

(1) Thermostat Cover(2) Thermostat Cover Gasket

(3) Thermostat Assembly

(1) Tappet

(1) Valve Spring Replacer(2) Valve Stem Seal(3) Valve Cap(4) Valve Spring Collet

(5) Valve Spring Retainer(6) Valve Spring(7) Valve


S-42


2) Timing Gears and CamshaftInjection Pump1. Remove the injection pump cover (3) with the engine stop lever

(2).2. Remove the injection pump mounting screws and nuts.3. Align the control rack pin (4) with the groove (5) on the

crankcase, then remove the injection pump.4. Remove the injection pump timing shims (6).5. In principle, the injection pump should not be disassemble.(When reassembling)• Install the injection pump so that its control rack pin (4) engages

with the groove (5) of fork lever 1 (1).• Install the injection pump cover with the arm of engine stop lever

(2) at the right of the arm of fork lever 1 (1).• Replace the injection pump cover gasket with new one.• The sealant is applied to both sides of the shim (soft metal gasket

shim). The liquid gasket is not required for assembling.• The 0.175 mm thick shim is coated only on the lower face.

Therefore, do not use the 0.175 mm thick shim as the top shim ofthe combination (injection pump side), because this cause oilleakage.

• Addition or reduction of shims (0.05 mm, 0.002 in.) delays oradvances the injection timing by approx. 0.009 rad (0.5 °).

• In disassembling and replacing, be sure to use same number ofnew shims with the same thickness.

• Refer to figure left to check the thickness of the shims.

W1023637

Start Spring1. Remove the start spring (1) from the gear case.(When reassembling)• Be careful not to drop the start spring into the gear case.• Hook the start spring so that the longer hook is on the fork lever

side.

W1025252

(1) Fork Lever 1(2) Engine Stop Lever(3) Injection Pump Cover(4) Control Rack Pin(5) Groove(6) Shim(7) 2-holes : 0.20 mm (0.0079 in.) Shim

(8) 1-hole : 0.25 mm (0.0098 in.) Shim(9) Without hole : 0.30 mm (0.012 in.)

Shim(10) 2-holes : 0.175 mm (0.00689 in.)

Shim(A) 3 Cylinder(B) 4 Cylinder

(1) Start Spring


S-43


Governor SpringNOTE

• Specific tool (1) :1.2 mm diameter hard wire with its end hooked, overalllength 200 mm (7.87 in.).The tip of wire is bent like the hook to hang governorsprings.

1. Disconnect the governor spring (3) from the fork lever (2).(When reassembling)• Fix the governor spring to the speed control lever, and pull the

spring or wire through the window of the injection pump, andspring will be able to be hooked on the governor fork with ease.Bend the end of the governor spring to prevent if from falling off.

W1148604

Speed Control Plate1. Remove the speed control plate (1) and governor spring (2).(When reassembling)• Be careful not to drop the governor spring (2) in the gear case.• Replace the speed control plate gasket with new one.

W1072059

(1) Specific Tool(2) Fork Lever

(3) Governor Spring

(1) Speed Control Plate (2) Governor Spring


S-44


Fan Drive Pulley1. Lock the flywheel not to turn using the flywheel stopper.2. [D1703, V2203]

Remove the fan drive pulley mounting nut (1) using 46 mm deepsocket wrench (3).[F2803]Remove the fan drive pulley screws.

3. Remove the fan drive pulley (2) with gear puller (4).4. [D1703, V2203]

Remove the feather key.(When reassembling)• Apply grease to the splines of coupling.• [F2803]

Install the pulley to the crankshaft, aligning the marks (5) onthem.

• Tighten the fan drive pulley mounting nut or the fan drive pulleyscrew to the specified torque.

W1025370

Gear Case1. Remove the hour meter gear case (if equipped).2. Remove the gear case (1).3. Remove the O-rings (2).(When reassembling)• Replace the gear case gasket and O-rings (2).• Replace the hour meter gear case gasket with new one.• Check to see if there are four O-rings (2) inside the gear case (1).• Apply a thin film of engine oil to the oil seal (3), and install it,

noting the lip come off.• Before installing the gear case gasket, apply a non-drying

adhesive.

W1024531

Tightening torque

Fan drive pulley mounting nut


Fan drive pulley screw314 to 333 N·m32.0 to 34.0 kgf·m232 to 245 lbf·ft

(1) Nut(2) Fan Drive Pulley(3) 46 mm Deep Socket Wrench(4) Gear Puller(5) Mark

(A) F2803

(1) Gear Case(2) O-ring

(3) Oil Seal


S-45


Crankshaft Oil Slinger1. Remove the crankshaft collar (3).2. Remove the O-ring (2).3. Detach the crankshaft oil slinger (1).(When reassembling)• Insert the crankshaft collar (3) after install the gear case to

cylinder body.

W1024731

Idle Gear1. Remove the external snap ring.2. Detach the idle gear collar.3. Detach the idle gear (2).(When reassembling)• Check to see each gear is aligned with its aligning mark

- Idle gear (2) and crank gear (4)- Idle gear (2) and cam gear (3)- Idle gear (2) and injection pump gear (1)

W1024941

Camshaft1. Remove the camshaft set screw (1) and draw out the camshaft

(2).(When reassembling)• When installing the idle gear, be sure to align the alignment

marks on gears.

W1025098

Fuel Camshaft and Fork Lever Assembly1. Remove the fuel feed pump.2. Detach the fuel camshaft stopper (1).3. Remove the three fork lever holder mounting screws (2).4. Draw out the fuel camshaft assembly (5), (6) and fork lever

assembly (3), (4), (7) at the same time.(When reassembling)• After installation, check to see that the fork lever 1 (3) and lever

2 (4) are fixed to the fork lever shaft, and that they can turnsmoothly in the holder (7).

W1025309

(1) Crankshaft Oil Slinger(2) O-ring

(3) Crankshaft Collar

(1) Injection Pump Gear(2) Idle Gear(3) Cam Gear

(4) Crank Gear(5) Oil Pump Drive Gear

Tightening torque Camshaft set screw24 to 27 N·m2.4 to 2.8 kgf·m18 to 20 lbf·ft

(1) Camshaft Set Screw (2) Camshaft

(1) Fuel Camshaft Stopper(2) Fork Lever Holder Mounting Screw(3) Fork Lever 1(4) Fork Lever 2

(5) Injection Pump Gear(6) Fuel Camshaft(7) Fork Lever Holder


S-46


Oil Pump1. Remove the nut.2. Draw out the oil pump drive gear (2) with gear puller (1).3. Remove the four oil pump mounting screws. Detach the oil pump

(3).

W1025581

Crank Gear1. Draw out the crank gear (2) with a puller (1).2. Remove the feather key.

W1076123

3) Connecting Rod and PistonOil Pan and Oil Strainer1. Remove the oil pan mounting screws.2. Remove the oil pan (3) by lightly tapping the rim of the pan with

a wooden hammer.3. Remove the oil pan gasket (2).4. Remove the oil strainer (1) and O-ring (4).(When reassembling)• After cleaning the oil strainer (1), check to see that the filter mesh

in clean, and install it.• Visually check the O-ring (4), apply engine oil, and install it.• Securely fit the O-ring (4) to the oil strainer (1).• Replace the oil pan gasket (2) with new one.• To avoid uneven tightening, tighten oil pan mounting screws in

diagonal order from the center.

W1025687

(1) Gear Puller(2) Oil Pump Drive Gear

(3) Oil Pump

(1) Crank Puller (2) Crank Gear

(1) Oil Strainer(2) Oil Pan Gasket

(3) Oil Pan(4) O-ring


S-47


Pistons (To be continued)1. Completely clean carbon (1) in the cylinders.2. Remove the connecting rod cap (3).3. Turn the flywheel and bring the piston to top dead center.4. Draw out the piston upward by lightly tapping it from the bottom

of the crankcase with the grip of a hammer.5. Draw out the other piston in the same method as above.

W1026909

(1) Carbon(2) Connecting Rod Screw

(3) Connecting Rod Cap(4) Connecting Rod


S-48


Pistons (Continued)(When reassembling)• Before inserting piston into the cylinder, apply enough engine oil

to the piston.• When inserting the piston into the cylinder, face the mark on the

connecting rod to the injection pump.IMPORTANT

• Do not change the combination of cylinder and piston. Makesure of the position of each piston by marking. For example,mark “1” on the No. 1 piston.

• Place the piston rings with their gaps at 0.79 rad (45 °) fromthe piston pin’s direction as shown in the figure.

• Carefully insert the pistons using a piston ring compressor(1).

W1027404

Piston Ring and Connecting Rod (To be continued)1. Remove the piston rings (1), (2), (3) using a piston ring tool.2. Remove the piston pin (9), and separate the connecting rod (7)

from the piston (6).

W1026376

Tightening torque Connecting rod screw45 to 49 N·m4.5 to 5.0 kgf·m33 to 36 lbf·ft

(1) Piston Ring Compressor

(A) Top Ring Gap(B) Second Ring Gap

(C) Oil Ring Gap(D) Piston Pin Hole

(a) 0.79 rad (45 °)

(1) Top Ring(2) Second Ring(3) Oil Ring(4) Piston Pin Snap Ring(5) Fan-Shaped Concave(6) Piston

(7) Connecting Rod(8) Mark(9) Piston Pin

(A) Serial No. : below 4P9999(B) Serial No. : above 4Q0001


S-49


Piston Ring and Connecting Rod (Continued)(When reassembling)• When installing the rings, assemble the rings so that the

manufacturer’s mark (9) near the gap faces the top of the piston(3).

• When installing the oil ring (8) onto the piston (3), place theexpander joint (6) on the opposite side of the oil ring gap (7).

• Apply engine oil to the piston pin (4).• When installing the connecting rod (2) to the piston (3), immerse

the piston (3) in 80 °C (176 °F) oil for 10 to 15 minutes and insertthe piston pin (4) to the piston (3).

• When installing the connecting rod (2) to the piston (3), align themark (1) on the connecting rod (2) to the fan-shaped concave (5).NOTE

• Mark the same number on the connecting rod (2) and thepiston (3) so as not to change the combination.

W1076292

(1) Mark(2) Connecting Rod(3) Piston(4) Piston Pin(5) Fan-Shaped Concave

(6) Expander Joint(7) Oil Ring Gap(8) Oil Ring(9) Manufacturer’s Mark


S-50


4) CrankshaftFlywheel1. Fit the stopper to the flywheel (1).2. At first, remove two pieces of the flywheel screws (2).3. Insert two pieces of the flywheel guide screws (3) in the holes.4. Remove the all flywheel screws (2).5. Remove the flywheel (1) slowly along the flywheel guide screws

(3).(When reassembling)• Insert two pieces of the flywheel guide screws (3).• Check to see that there are no metal particles left on the flywheel

mounting surfaces.• Apply engine oil to the threads and the undercut surface of the

flywheel bolt and fit the bolt.

W1026863

Bearing Case Cover1. Remove the bearing case cover mounting screws. First, remove

inside screws (5) and then outside screws (3).2. Screw two removed screws into the screw hole of bearing case

cover (6) to remove it.IMPORTANT

• The length of inside screws (5) and outside screws (3) aredifferent. Do not take a mistake using inside screws andoutside screws.

(When reassembling)• Fit the bearing case gasket (1) and the bearing case cover gasket

(2) with correct directions.• Install the bearing case cover (6) to position the casting mark

“UP” on it upward.• Apply engine oil to the oil seal lip and take care that it is not rolled

when installing.• Tighten the bearing case cover mounting screws with even force

on the diagonal line.

W10292140

Tightening torque Flywheel screw98.1 to 107 N·m10.0 to 11.0 kgf·m72.4 to 79.5 lbf·ft

(1) Flywheel(2) Flywheel Screw

(3) Flywheel Guide Screw

Tightening torque Bearing case cover mounting screw


(1) Bearing Case Gasket(2) Bearing Case Cover Gasket(3) Bearing Case Cover Mounting Screw(4) Oil Seal

(5) Bearing Case Cover Mounting Screw(6) Bearing Case Cover

(a) Upside


S-51


CrankshaftNOTE

• Before disassembling, check the side clearance ofcrankshaft. Also check it during reassembling.

1. Remove the main bearing case screw 2 (1).2. Pull out the crankshaft assembly (4), taking care not to damage

the crankshaft bearing 1 (3).(When reassembling)

IMPORTANT• Install the crankshaft sub assembly (4), aligning the screw

hole of main bearing case 2 (2) with the screw hole ofcylinder block.

• When tightening the main bearing case screw 2 (1), apply oilto the screw and screw by hand before tightening thespecific torque.If not smooth to screw by hand, align the screw holesbetween the cylinder block and the main bearing case.

W1066311

Tightening torque Main bearing case screw 269 to 73 N·m7.0 to 7.5 kgf·m51 to 54 lbf·ft

(1) Main Bearing Case Screw 2(2) Main Bearing Case 2

(3) Crankshaft Bearing 1(4) Crankshaft Assembly


S-52


Main Bearing Case Assembly1. Remove the two main bearing case screws 1 (8), and remove the

main bearing case assembly being careful with thrust bearingand crankshaft bearing.

2. Remove the main bearing case 1, 2 as above.(When reassembling)• Clean the oil passage in the main bearing case.• Apply clean engine oil on the bearings.• Install the main bearing case assemblies in the original positions.

Since diameters of main bearing cases vary, install them in orderof makings (A, B for 3 cylinders, A, B, C for 4 cylinders and A, B,C, D for 5 cylinders) from the gear case side.

• Match the alignment numbers (1) and mark (2) on the mainbearing case.

• When installing the main bearing case 1 and 2, face the mark“FLYWHEEL” to the flywheel.

• Install the thrust bearing with its oil groove (9) facing outward.• Confirm that the main bearing case moves smoothly after

tightening the main bearing case screw 1 (8) to the specifiedtorque.

W1027366

Tightening torque Main bearing case screw 146 to 50 N·m4.7 to 5.2 kgf·m34 to 37 lbf·ft

(1) Alignment Number(2) Alignment Mark(3) A(4) B(5) C

(6) D(7) No Mark(8) Main Bearing Case Screw 1(9) Oil Groove


S-53


(2) V3300-E2BG1) Cylinder Head and Valves

Cylinder Head Cover and Nozzle Holder1. Remove the injection pipes (3) and overflow pipes (2).2. Remove the glow plugs (1).3. Remove the nozzle holder assembly (4) and copper gaskets (5).4. Remove the heat seal (6).5. Remove the head cover (7).(When reassembling)• Check to see that the cylinder head cover gasket is not defective.• Be sure to place the heat seal.• Tighten the head cover mounting bolts to specified torque.• Mount the check valve with the ↓ mark toward the tank.

W1049737

Nozzle Heat Seal Service Removal ProcedureIMPORTANT

• Use a plus (phillips head) screw driver (1) that has adiameter which is bigger than the heat seal hole (Approx. 6mm (1/4 in.)).

1. Drive screw driver (1) lightly into the heat seal hole.2. Turn screw driver three or four times each way.3. While turning the screw driver, slowly pull the heat seal (4) out

together with the injection nozzle gasket (3).4. If the heat seal drops, repeat the above procedure.(When reassembling)• Heat seal and injection nozzle gasket must be changed when the

injection nozzle is removed for cleaning or for service.

W1139845

Tightening torque

Cylinder head cover screw6.87 to 11.2 N·m0.700 to 1.15 kgf·m5.07 to 8.31 lbf·ft

Injection pipe retaining nut23 to 36 N·m2.3 to 3.7 kgf·m17 to 26 lbf·ft




Glow plug20 to 24 N·m2.0 to 2.5 kgf·m15 to 18 lbf·ft

(1) Glow Plug (2) Overflow Pipe(3) Injection Pipe(4) Nozzle Holder Assembly

(5) Copper Gasket(6) Heat Seal(7) Head Cover

(1) Plus Screw Driver(2) Injection Nozzle

(3) Injection Nozzle Gasket(4) Heat Seal


S-54


Rocker Arm and Push Rod1. Remove the rocker arm (3) as a unit.2. Remove the push rods (1).3. Remove the bridge arm (4).(When reassembling)• When putting the push rods onto the tappets (2), check to see if

their ends are properly engaged with the grooves.IMPORTANT

• After reassembling the rocker arm, be sure to adjust thevalve clearance.

W1050212

Tightening torque Rocker arm bracket screw49 to 55 N·m5.0 to 5.7 kgf·m37 to 41 lbf·ft

(1) Push Rod(2) Tappet

(3) Rocker Arm (4) Bridge Arm


S-55


Cylinder Head and Tappet1. Loosen the pipe band, and remove the water return pipe (1).2. Disconnect the fuel pipe (2) first and then the fuel filter (3).3. Remove the IN. / EX. Manifold.4. Remove the cylinder head screw in the order of (18) to (1), and

remove the cylinder head.5. Remove the cylinder head gasket.6. Remove the tappets (4) from the crank case.(When reassembling)• Replace the head gasket with a new one.• Before installing the tappets (4), apply engine oil thinly around

them.• When mounting the gasket, set it to the knock pin hole. Take

care not to mount it reversely.• The cylinder head should be free of scratches and dust.• Take care for handling the gasket not to damage it.• Install the cylinder head.• Tighten the cylinder head screw gradually in the order of (1) to

(18) after applying engine oil.• Be sure to adjust the valve clearance. See the “Valve

Clearance”.• It is not necessary to retighten the cylinder head screw after

running the engine for 30 minutes.IMPORTANT

• When replace the piston, piston pin bush, connecting rod orcrankpin bearing, select the cylinder head gasket thicknessto meet with the top clearance refer to the “SelectingCylinder Head Gasket”.NOTE

• Mark the cylinder number to the tappets to preventinterchanging.

W1170923

Tightening torque Cylinder head mounting screw

98.1 to 107 N·m10.0 to 11.0 kgf·m72.4 to 79.5 lbf·ft

(1) Return Pipe(2) Fuel Pipe(3) Fuel Filter(4) Tappet

A : Gear Case SideB : Flywheel Side


S-56


Selecting Cylinder Head Gasket Replacing the Cylinder Head Gasket

1. Make sure the notch mark (a), (b) or (c) of cylinder head gasket(1) in advance.

2. Replace the same notch mark (a), (b) or (c) as the originalcylinder head gasket (1).

Selecting the Cylinder Head Gasket• Select the cylinder head gasket (1) thickness to meet with the top

clearance when replacing the piston, piston pin bush, connectingrod or crankpin bearing.

1. Measure the piston head’s protrusion or recessing from thecrankcase cylinder face (4 spots per each piston and average offour pistons) using the dial gauge as shown in figure.

2. Select the suitable cylinder head gasket refer to the table below.

W1022965

Valve1. Remove the valve cap (3) and the valve spring collets (1)

compressing the valve spring (5) with the valve spring retainer(4).

(When reassembling)• Install the intake valve spring with its small-pitch end downward

(at the head side).• Wash the valve stem and valve guide hole, and apply engine oil

sufficiently.• After installing the valve spring collets, lightly tap the stem to

assure proper fit with a plastic hammer.

W1053044

Notch Mark of Cylinder Head Gasket

Thickness of cylinder head gasket

Part Code

Piston Head’s protrusion or recessing from the level of Crankcase cylinder face.(average of 4 pistons)

Before tightening

After tightening

2 notches (a)

0.90 mm0.035 in.

0.80 mm0.031 in.

1C020-03310

-0.070 to +0.049 mm-0.0027 to +0.0019 in.

1 notch (b) 1.00 mm0.0394 in.

0.90 mm0.035 in.

1C020-03600

+0.0500 to +0.149 mm+0.00197 to +0.00586 in.

Without notch (c)

1.05 mm0.0413 in.

0.95 mm0.037 in.

1C020-03610

+0.150 to +0.200 mm+0.00591 to +0.00787 in.

(1) Cylinder Head Gasket(2) Measuring Point(A) Gear Case Side(B) Flywheel Side

(a) 2 Notches(b) 1 Notch(c) Without Notch

(1) Valve Spring Collet(2) Arm Bridge (3) Valve Cap(4) Valve spring Retainer (5) Valve Spring(6) Valve Stem Seal

(7) Valve(8) Large Pitch(9) Smaller Pitch

(10) Install the spring with its smaller-pitch end downward (at the head side)


S-57


2) ThermostatThermostat Assembly1. Remove the thermostat cover mounting screws, and remove the

thermostat cover (1).2. Remove the thermostat assembly (3).(When reassembling)• Apply a liquid gasket (Three Bond 1215 or equivalent) only at the

thermostat cover side of the gasket (2).• Attach the thermostat with its hole facing toward the air suction

side.

W1072747

3) Injection NozzleNozzle Holder1. Secure the nozzle retaining nut (7) with a vise.2. Remove the nozzle holder (1), and take out parts inside.(When reassembling)• Assemble the nozzle in clean fuel oil.• Install the push rod (4), noting its direction.• After assembling the nozzle, be sure to adjust the fuel injection

pressure.

W1089102

(1) Thermostat Cover(2) Thermostat Cover Gasket

(3) Thermostat Assembly(4) Hole

Tightening torque

Nozzle holder35 to 39 N·m3.5 to 4.0 kgf·m26 to 28 lbf·ft

Overflow pipe nut20 to 24 N·m2.0 to 2.5 kgf·m15 to 18 lbf·ft


(1) Nozzle Holder(2) Adjusting Washer(3) Nozzle Spring(4) Push Rod

(5) Distance Piece(6) Nozzle Piece(7) Nozzle Retaining Nut


S-58


4) Injection Pump UnitInjection Pump Unit (To be continued)(Removing the fuel injection pump unit)1. Detach the gear cover for the fuel injection pump unit from the

gearcase.2. Place the piston of the 4th cylinder at the top dead center in the

compression stroke. Fix the flywheel with the flywheel stopper.IMPORTANT

• Look for the align mark on the idle gear 2. Using a whitemarking pen or the like, put an align mark on the engagedtooth of the idle gear. This helps to reassemble these gearsin mesh later.NOTE

• When the already existing align marks align with each other,there is no need to put another align mark.

3. Unscrew the two plugs (3) of the injection pump unit.4. Tighten the upper fuel cam shaft lock screw (5) until it comes into

contact with the fuel cam shaft. Make sure the cam shaft doesnot move any longer.

5. Tighten the lower fuel cam shaft lock screw (5) until it comes intocontact with the fuel cam shaft.NOTE

• Never overtighten the lock screws when they have come intocontact with the cam shaft. Otherwise the injection pumpitself may get damaged.

• Use of a socket set screw (dog point type) in recommendedfor best results. Such screw can be constructed as shownin figure (a).

6. Loosen the injection pump gear mounting nut. Using the specificgear puller, take out the gear (6).NOTE

• Be careful not to drop the key.7. Disconnect the lubricating oil pipe (4).8. Loosen the three injection pump unit mounting nut (2).9. Remove the injection pump unit support (1) and take out the

injection pump unit.

W1175054

A M8 × Pitch 1.25

B 5.0 mm dia. (0.20 in. dia.)

C 4.0 mm (0.16 in.)

D 45 mm (1.8 in.)

E 10 mm (0.39 in.) : Conspicuously Painted

(1) Injection Pump Unit Support(2) Injection Pump Unit Mounting Nut(3) Plug(4) Lubricating Oil Pipe

(5) Fuel Cam Shaft Lock Screw(Socket Set Screw Dog Point Type)

(6) Injection Pump Gear


S-59


Injection Pump Unit (Continued)(Reassembling the fuel injection pump unit)1. Place the piston of the 4th cylinder at the top dead center in the

compression stroke. Fix the flywheel with the flywheel stopper.2. Place the injection pump gear (1) back into the gear case

position. Make sure of aligning the align marks of the injectionpump gear (1) and the idle gear 2 (3).

3. Install the injection pump unit to the injection pump gear (1).NOTE

• When installing the injection pump unit to the injectionpump gear, make sure that the key is fit in the keyway ofinjection pump gear.

4. Temporarily tighten the injection pump gear mounting nut byhand.

5. Fix the injection pump unit and tighten the injection pump gearmounting nut to the specified torque.

6. Take off the fuel cam shaft lock screws (4) and tighten the plugs(5) for plugging.

7. Loose the injection pump unit mounting nuts (7) for aligning theinjection timing.

8. Moving the injection pump unit clockwise (viewed from gear caseside), align the injection timing marks (6) on the injection pumpunit and on the gear case.

9. Tighten the injection pump unit mounting nut (7) to the specifiedtorque.

10.Reconnect the lubricating oil pipe (8) and place the injectionpump unit support and the gear cover of the injection pump unit.

11.Remove the flywheel stopper.12.Check the injection timing. (See the “Injection Timing”.)13.If the injection timing is not within the specification, repeat (7) to

(12) again.

W1176586

Tightening torque

Injection pump gear mounting nut




(1) Injection Pump Gear(2) Align mark of the Injection Gear(3) Idle Gear 2(4) Fuel Cam Shaft Lock Screw

(Socket Set Screw Dog Point Type)

(5) Plug(6) Align Mark(7) Injection Pump Unit Mounting Nut(8) Lubricating Oil Pipe


S-60


Governor Housing Assembly1. Remove the injection pump unit from the engine. (See the

“Injection Pump Unit”.)2. Remove the governor lubricating pipe (3).3. Remove the stop solenoid (1).4. Detach the sight cover (2) from the injection pump unit.5. Unhook the start spring (7) from the rack pin (6) of injection pump

assembly.6. Remove the nut (5).

NOTE• Be careful not to drop the nut inside.

7. Slide off the governor connecting rod (4) from the rack pin ofinjection pump assembly.

8. For convenient sake, temporarily hook the start spring on therack pin hole of the governor connecting rod.

9. Remove the governor housing mounting screws.10.Detach the governor housing assembly (8) from the injection

pump unit.(When reassembling)• When reassembling the inside parts, put the oil on each inside

part slightly.• After sliding on the governor connecting rod to the rack pin,

tighten the nut with the specified torque with using the jig forkeeping the governor connecting rod horizontal. (See theReplacing Injection Pump Assembly.)

• After tightening the nut, hook the start spring on the rack pin.• Check the movement of control rack of injection pump assembly

by the stop lever.NOTE

• When installing the governor housing assembly to theinjection pump unit, be careful not to damage O-ring (9).

• When linking the governor connecting rod to the rack pin ofinjection pump, use the jig for keeping the governorconnecting rod horizontal. Otherwise the control rack maybe stuck, and causes to be difficult to start the engine orhunting of governor. (See the Replacing Injection PumpAssembly.)

W1137126

Tightening torque

Governor housing mounting screw


Anti-rotation nut2.9 to 4.0 N·m0.29 to 0.41 kgf·m2.1 to 2.9 lbf·ft

(1) Stop Solenoid(2) Sight Cover(3) Governor Lubricating Pipe(4) Governor Connecting Rod(5) Anti-Rotation Nut

(6) Rack Pin(7) Start Spring(8) Governor Housing Assembly(9) O-ring


S-61


Governor Fork Lever Assembly1. Pull off the governor fork lever shaft (1) with the extra bolt (Dia :

4 mm, Pitch : 0.7 mm, Length : more than 25 mm) (2).2. Unhook the governor spring (3) at the governor fork lever (4)

side.3. Remove the governor fork lever assembly from the governor

housing (5).(When reassembling)• After reassembling the governor housing assembly, check the

movement of the governor fork lever assembly, the speed controllever and the stop lever.NOTE

• When assembling the inside parts, put the oil on each insidepart slightly.

• Be careful not to deform the start spring.

W1139749

(1) Governor Fork Lever Shaft(2) Extra Bolt

(Dia : 4 mm, Pitch : 0.7 mm, Length : more than 25 mm)

(3) Governor Spring(4) Governor Fork Lever(5) Governor Housing


S-62


Governor Lever1. Remove the speed control lever (1) and the return spring (2).2. Remove the governor lever assembly (4) from the governor

housing.3. Remove the start spring (5) and the stop spring (3).

W1142375

Stop Lever1. Remove the stop lever (1) and the return spring (2).2. Remove the stop lever shaft (3).

W1143531

(1) Speed Control Lever(2) Return Spring(3) Stop Spring

(4) Governor Lever Assembly(5) Start Spring

(1) Stop Lever(2) Return Spring

(3) Stop Lever Shaft


S-63


Fuel Camshaft and Governor Weight (To be continued)1. Separate the governor housing assembly from the injection

pump unit. (See the “Injection Pump Unit”.)2. Remove the governor sleeve (1).3. Remove the injection pump assembly (2).4. Remove the cover (3).5. Remove the fuel camshaft lock screws.6. Fix the fuel camshaft with open end wrench (4), and remove the

governor weight mounting nut and the governor weight (5).7. Loosen the fuel camshaft stopper mounting screws and remove

the fuel camshaft stopper (6).8. Pull out the fuel camshaft (9) and bearings (7) together.9. After removing the bearing’s cir-clip (8), press out the bearings.

NOTE• Do not use the fuel camshaft lock screws, when removing

the governor weight mounting nut. Otherwise, the lock boltsor injection pump housing might get damage.

(When reassembling)• Press the bearings into the fuel camshaft.• Set the cir-clip at the gear side’s bearing.• Install the fuel camshaft and bearings to the injection pump

housing.• Attach the fuel camshaft stopper and tighten the fuel camshaft

stopper mounting screws with the specified torque.• Attach the governor weight to the fuel camshaft and tighten the

governor weight mounting nut with specified torque.

W1144178

Tightening torque

Injection pump mounting screw


Injection pump mounting nut


(1) Governor Sleeve(2) Injection Pump Assembly(3) Cover(4) Open End Wrench (24 mm)(5) Governor Weight

(6) Fuel Camshaft Stopper(7) Bearing(8) Cir-clip (9) Fuel Camshaft

(10) Key Way of Fuel Camshaft


S-64


Fuel Camshaft and Governor Weight (Continued)(When reassembling)• Fix the fuel camshaft with lock bolts as the key way of fuel

camshaft (10) is upward.• Install the injection pump assembly to the injection pump

housing.• Attach the O-ring and the cover and tighten the cover mounting

screws.• Install the governor sleeve to the fuel camshaft.• Check the movement of the governor sleeve.

NOTE• Be careful not to damage the O-ring.• Be careful the direction of the governor sleeve.• When reassembling the inside parts, put the oil on each

inside part slightly.

W1146489

Tightening torque

Fuel camshaft stopper mounting screw


Governor weight mounting nut


(1) Governor Sleeve(2) Injection Pump Assembly(3) Cover(4) Open End Wrench (24 mm)(5) Governor Weight

(6) Fuel Camshaft Stopper(7) Bearing(8) Cir-clip (9) Fuel Camshaft

(10) Key Way of Fuel Camshaft


S-65


Replacing Injection Pump Assembly (If necessary)• The injection pump can be replaced with the crankshaft in

whatever position.1. Disconnect all injection pipes (1).2. Disconnect the fuel pipe (6) and fuel overflow pipe (4).3. Disconnect the connector (2) from the stop solenoid. Then

remove the stop solenoid (3).4. Detach the sight cover (7) from the injection pump unit.5. Unhook the start spring (10), and remove the anti-rotation nut (9).6. Slide off the governor connecting rod (8) from the rack pin of

injection pump assembly.7. Remove the injection pump mounting screws and nuts, and take

out the injection pump assembly (5).NOTE

• Be careful not to drop the anti-rotation nut (9).• Be careful not to deform the start spring.• When taking out the injection pump assembly, be careful not

to hit it against the governor connecting rod.(When reassembling)• Install the new injection pump according to the installing

procedure.

W1182379

(1) Injection Pipe(2) Connector(3) Stop Solenoid(4) Fuel Overflow Pipe(5) Injection Pump Assembly

(6) Fuel Pipe(7) Sight Cover (8) Governor Connecting Rod(9) Anti-Rotation Nut

(10) Start Spring


S-66


Installing Procedure of Injection Pump Assembly (To becontinued)1. Install the fuel injection pump assembly (1) in its unit (2), and

hook the governor connecting rod to the rack pin of the fuelinjection pump assembly.

2. Place the service jig (3) in the stop solenoid mounting hole of thefuel injection pump unit.

3. Make sure the permanent magnet at the tip of the service jig isattracted to the governor connecting rod (4). To do this, turn thejig a little clockwise and counterclockwise and look into the fuelinjection pump unit sight hole to see if the governor connectingrod (4) moves right and left accordingly.

4. Slightly tighten the anti-rotation nut of the governor connectingrod.

5. Holding down the service jig (3) by hand, tighten up the anti-rotation nut (5) to the specified torque.

6. Hook the start spring (6) to the rack pin (7).

W1069371

(1) Fuel Injection Pump Assembly(2) Fuel Injection Pump Unit(3) Service Jig(4) Governor Connecting Rod

(5) Anti-rotation Nut(6) Start Spring(7) Rack Pin


S-67


Installing Procedure of Injection Pump Assembly (Continued)1. Move the stop lever (1) and visually check to see if the fuel

injection pump control rack comes smoothly back to the startposition by the counter force of the start spring.

2. If the control rack fails to move back smoothly, remove the startspring and the anti-rotation nut, take the above steps from 2 ofthe former page again.

3. Finally fit the sight cover and the stop solenoid back into place.

W1069772

Fan Drive Pulley1. Set the stopper to the flywheel.2. Remove the crankshaft screw (2).3. Draw out the fan drive pulley (1).(When reassembling)

W1185033

5) Water PumpWater Pump1. Remove the pipe band and the water pipe (1).2. Remove the water pump (2).(When reassembling)• When mounting the water pump, take care not to forget mounting

the O-ring and not to let it out of position.

W1187742

Tightening torque

Anti-rotation nut2.9 to 4.0 N·m0.29 to 0.41 kgf·m2.1 to 2.9 lbf·ft

Injection pump mounting screw


Injection pump mounting nut


(1) Stop Lever (2) Sliding Point between Governor Fork Lever and Governor Connecting Rod

Tightening torque Crankshaft screw255 to 274 N·m26.0 to 28.0 kgf·m188 to 202 lbf·ft

(1) Fan Drive Pulley (2) Crankshaft Screw

(1) Water Pipe (2) Water Pump


S-68


6) Gear Case and Timing GearsGear Case Cover1. Remove the gear case cover.(When reassembling)• Confirm that the liquid gasket coating surface is free of water,

dust and oil in order to maintain sealing effect.• Carefully apply the adhesive evenly. (Refer to the figure on the

left.)NOTE

• When mounting the adhesive-applied parts, take care to fitthem to the mating parts.

• Assemble the adhesive-applied parts within ten minutes.• Apply a liquid gasket (Three Bond 1217D) to the gear case

cover.

W1189218

Relief Valve1. Remove the relief valve retaining screw (1).2. Remove the relief valve (2), the spring (3) and the packing (4).

W1081251

Idle Gear and Camshaft1. Remove three set screws of the idle gear and draw out the idle

gear 1, 2.2. Remove two set screws of the camshaft stopper and draw out the

camshaft.(When reassembling)• Set the crankshaft at the top dead center of No. 1 and 4 cylinder

and the camshaft key to the top position and align the marks ofidle gear 1 (3) and idle gear 2 (2) to assemble them. (Refer to thefigure on the left.)

• Mount the injection pump gear (1) after installing the gear case.

W1189797

Tightening torque

Gear case cover mounting screw (7T)


Gear case cover mounting screw (10T)


(1) Liquid Gasket

Tightening torque Relief valve retaining screw


(1) Relief Valve Retaining Screw(2) Relief Valve

(3) Spring(4) Packing

Tightening torque

Camshaft set screw24 to 27 N·m2.4 to 2.8 kgf·m18 to 20 lbf·ft

Idle gear mounting screw24 to 27 N·m2.4 to 2.8 kgf·m18 to 20 lbf·ft

(1) Injection Pump Gear(2) Idle Gear 2(3) Idle Gear 1

(4) Cam Gear(5) Crank Gear


S-69


Plate (Gear Case)1. Remove the three plate mounting screws (1). Detach the plate

(2).(When reassembling)• Apply Three Bond 1217D adhesive or equivalent over the

shaded zones on both sides of the gasket that will be sandwichedbetween the crankcase and plate.

• Be sure to fix the O-rings (3).

W1057656

7) Piston and Connecting RodOil Pan and Oil Strainer1. Unscrew the oil pan mounting screws and remove the oil pan (1).2. Unscrew the oil strainer mounting screw, and remove the oil

strainer (2).(When reassembling)• Install the oil strainer, using care not to damage the O-ring.• Apply liquid gasket (Three Bond 1217D) to the oil pan as shown

in the figure.• Confirm that the liquid gasket coating surface is free of water,

dust and oil in order to maintain sealing effect.• Carefully apply the adhesive evenly.

NOTE• When mounting the adhesive-applied parts, take care to fit

them to the mating parts.• Assemble the adhesive-applied parts within ten minutes.• To avoid uneven tightening, tighten mounting screws in

diagonal order from the center.• After cleaning the oil strainer, install it.• Attach the oil pan with its central drain plug facing toward

the air suction side.

W1057949

Tightening torque Plate mounting screw24 to 27 N·m2.4 to 2.8 kgf·m18 to 20 lbf·ft

(1) Plate Mounting Screw(2) Plate(3) O-ring

(4) Gasket(5) Liquid Gasket

(1) Oil Pan(2) Oil Strainer

(3) Liquid Gasket


S-70


Connecting Rod Cap1. Remove the connecting rod screws (1) from connecting rod cap.2. Remove the connecting rod caps.(When reassembling)• Align the marks (a) with each other. (Face the marks toward the

injection pump.)• Apply engine oil to the connecting rod screws and lightly screw it

in by hand, then tighten it to the specified torque.If the connecting rod screw won’t be screwed in smoothly, cleanthe threads.If the connecting rod screw is still hard to screw in, replace it.

• When using the existing crank pin metal again, put tally marks onthe crank pin metal and the connecting rod in order to keep theirpositioning.

• Fit the crank pin metal in place : its centrally groove side towardthe connecting rod, and the non-grooved side toward the cap.

W1058252

Piston1. Turn the flywheel and set a piston to the top dead center.2. Pull out the piston upward by lightly tapping it from the bottom of

the crankcase with the grip of a hammer.(When reassembling)• Before inserting the piston into the cylinder, apply enough engine

oil to the cylinder.• When inserting the piston into the cylinder, face the mark on the

connecting rod to the injection pump.IMPORTANT

• Do not change the combination of cylinder and piston.Make sure of the position of each piston by marking. Forexample, mark “1” on the No. 1 position.

• When inserting the piston into the cylinder, place the gap ofthe top ring on the opposite side of the combustion chamberand stagger the gaps of the second ring and oil ring markinga right angle from the gap of the top ring.

• Carefully insert the pistons using a piston ring compressor(1). Otherwise, their chrome-plated section may bescratched, causing trouble inside the liner.

W1058433

Tightening torque Connecting rod screw79 to 83 N·m8.0 to 8.5 kgf·m58 to 61 lbf·ft

(1) Connecting Rod Screw (a) Mark

(1) Piston Ring Compressor

(a) 0.79 rad (45 °)

(A) Top Ring Gap(B) Second Ring Gap(C) Oil Ring Gap(D) Piston Pin Hole


S-71


Piston Ring and Connecting Rod1. Remove the piston rings using a piston ring tool.2. Put the fan shaped concave (8) on the piston as shown in figure.3. Remove the piston pin (7), and separate the connecting rod (6)

from the piston (5).(When reassembling)• Be sure to fix the crankpin bearing and the connecting rod are

same I.D. colors.• When installing the ring, assemble the rings so that the

manufacture’s mark (12) near the gap faces the top of the piston.• When installing the oil ring onto the piston, place the expander

joint (10) on the opposite side of the oil ring gap (11).• Apply engine oil to the piston pin.• When installing the piston pin, immerse the piston in 80 °C (176

°F) oil for 10 to 15 minutes and insert the piston pin to the piston.• Assemble the piston to the connecting rod with the aligning the

direction of the fan shaped concave (8) of piston head and themark (9) of connecting rod.

• The end faces of the oil ring are plated with hard chrome. Inputting the piston into the cylinder, be careful not to get the oil ringscratched by the cylinder. Use the piston ring fitter to tighten upthe oil ring. If the ring’s planting is scratched, it may get stuck onthe cylinder wall, causing a serious trouble.IMPORTANT

• Mark the same number on the connecting rod and the pistonso as not to change the combination.

W1059589

(1) Top Ring(2) Second Ring(3) Oil Ring(4) Piston Pin Snap Ring(5) Piston(6) Connecting Rod(7) Piston Pin(8) Fan Shaped Concave(9) Mark

(10) Expander Joint

(11) Oil Ring Gap(12) Manufacture’s Mark

(A) Connecting Rod ID Color : Blue or Yellow (without Color)

(B) Crankpin Bearing ID Color : Blue or Yellow (without Color)


S-72


8) Flywheel and CrankshaftFlywheel1. Install the stopper to the flywheel so that the flywheel does not

turn.NOTE

• Do not use an impact wrench. Serious damage will occur.2. Detach the flywheel screws.3. Remove the flywheel.(When reassembling)• Apply engine oil to the flywheel screws.• Before fitting the flywheel and the crankshaft together, wipe oil,

dust and other foreign substances off their mating faces.• The flywheel and the crankshaft are fitting together in just one

position. Make sure they are tightly fit and drive the bolts.

W1060354

Bearing Case CoverNOTE

• Before disassembling, check the side clearance ofcrankshaft. Also check it during reassembly.

1. Remove the bearing case over mounting screws.2. Screw two removed screws into the screw hole (2) of bearing

case cover to remove it.(When reassembling)

IMPORTANT• In case of replacing the oil seal, use caution when installing

the seal in the bearing case cover as not to install it tilted.The seal should be flush with the cover.

• Confirm that the liquid gasket coating surface is free ofwater, dust and oil in order to maintain sealing effect.

• Apply liquid gasket (Three Bond 1217D) to the bearing casecover as shown in the figure.

• Before installing the bearing case cover / oil seal assembly,lube the seal, be careful not to damage the seal whileinstalling the assembly.Install the bearing case cover / oil seal assembly to positionthe casting mark “UP” on it upward.

• Tighten the bearing case cover mounting screws with evenforce on the diagonal line.NOTE

• When mounting the adhesive-applied parts, take care to fitthem to the mating parts.

• Assemble the adhesive-applied parts within ten minutes.

W1060482

Tightening torque Flywheel screw98.1 to 107 N·m10.0 to 11.0 kgf·m72.4 to 79.5 lbf·ft

Tightening torque Bearing case cover mounting screw


(1) Top Mark “UP”(2) Screw Hole

(3) Liquid Gasket


S-73


Flywheel Housing1. Remove the flywheel housing.(When reassembling)• Tighten the flywheel housing mounting screws with even force on

the diagonal line.• Make sure the crank cases 1 and 2 are clean. Install them in

position, referring to the flywheel housing’s contoured face.

W1060705

Crankcase 21. Remove the crankcase 2 (1).(When reassembling)

IMPORTANT• Make sure the crankcase 1 and 2 are clean.• Apply liquid gasket (Three Bond 1217D) to the crankcase 2

as shown in the figure.• Tighten the crankcase 2 mounting screws with even force on

the diagonal line.• Confirm that the liquid gasket coating surface is free of

water, dust and oil in order to maintain sealing effect.• Carefully apply the adhesive evenly.

NOTE• When mounting the adhesive-applied parts, take care to fit

them to the mating parts.• Assemble the adhesive-applied parts within ten minutes.

W1060825

Crankcase 1 and Crankcase 2(When reassembling)• Match the crankcase 1 and 2, referring to the flywheel housing’s

contoured face.• Tighten the crankcase 2 mounting screws loosely.• Tighten up the jig to the specified torque same as the flywheel

housing screw. This helps to minimize the level differencebetween the crankcase 1 and the crankcase 2 (at the flywheelside). Possible gap must be 0.05 mm (0.002 in.) or smaller.

W1111351

Tightening torque Flywheel housing mounting screw


(1) Flywheel Housing

Tightening torque Crankcase 2 mounting screw


(1) Crankcase 2 (2) Liquid Gasket

Tightening torque

Crankcase 2 mounting screw


Flywheel housing mounting screw


(1) Crankcase 1(2) Gap to be smaller than 0.05 mm

(0.0020 in.)

(3) Flywheel Housing(4) Crankcase 2(5) Jig


S-74


Crankshaft1. Remove the main bearing case.2. Remove the crankshaft.(When reassembling)• Reassemble the main bearing case having the same number as

the one engraved on the crankcase, and set the casting mark “F/ W SIDE” on the main bearing case facing towards the flywheelside.

• Reassemble the thrust bearing (2), with the oil groove facingoutside, into both side of the fourth main bearing case (1).

• Apply oil to the bearing case screws and tighten them to thespecified torque.

W1061157

Tightening torque Main bearing case screw138 to 147 N·m14.0 to 15.0 kgf·m102 to 108 lbf·ft

(1) 4th Main Bearing Case(2) Thrust Bearing

(3) F / W SIDE Mark


S-75


(3) Starter1) D1703-E/E2, V2203-E/E2, F2803-E/E2

W1222714

1. Unscrew the C terminal nut (3), and disconnect the connecting lead.2. Remove the two through bolts (1).3. Detach the motor.4. Remove the end frame (8).5. Remove the brush from the brush holder while holding the spring up.6. Remove the brush holder (9).7. Draw out the armature (5) from the yoke (4).8. Remove the housing (13).9. Remove the idle gear (7) and the overrunning clutch (6).10.Remove the magnet switch cover (10).11.Remove the plunger (11).

NOTE• Do not damage to the brush and commutator.

(When reassembling)• Apply grease (DENSO No. 50 or equivalent) to the idle gear and overrunning clutch portions.

W1059634

(1) Through Bolt(2) Brush(3) C Terminal Nut(4) Yoke(5) Armature(6) Overrunning Clutch(7) Idle Gear(8) End Frame(9) Brush Holder

(10) Magnet Switch Cover(11) Plunger(12) B Terminal Nut(13) Housing

Tightening torque B terminal nut5.9 to 11 N·m0.60 to 1.2 kgf·m4.4 to 8.6 lbf·ft


S-76


2) V3300-E2BG

W1260607

Disassembling Motor1. Disconnect the solenoid switch (3).2. Remove the 2 through bolts (11) and the 2 brush holder lock bolts. Take out the rear bracket (15) and the brush

holder.3. Disconnect the armature (12) and the yoke (13). Remove also the ball (9) from the tip of the armature.4. Remove the set of packings (10), the 4 planetary gears (8) and another packing.5. Take out the shaft assembly (7). Take note of the position of the lever (5).

IMPORTANT• Before disconnecting the yoke, put tally marks on the yoke and the front bracket.• Take note of the positions of the set of packings and the setup bolt.• Apply grease to the gears, bearings, shaft’s sliding part and ball.

NOTE• Do not damage to the brush and commutator.

(When reassembling)• Apply grease (NIPPONDENSO No. 50 or equivalent) to the parts indicated in the figure.

W1124225

(1) Gear(2) Front Bracket(3) Solenoid Switch(4) Overrunning Clutch(5) Drive Lever(6) Internal Gear(7) Shaft Assembly(8) Planetary Gear(9) Ball

(10) Set of Packings(11) Through Bolt(12) Armature(13) Yoke(14) Brush Holder(15) Rear Bracket

Tightening torque B terminal nut9.8 to 11 N·m1.0 to 1.2 kgf·m7.3 to 8.6 lbf·ft


S-77


(4) Alternator

W1224079

1. Remove the pulley (1).2. Remove the rear end cover (12).3. Remove the brush holder (11).4. Remove the IC regulator (10).5. Remove the four screws holding the stator lead wires.6. Remove the rectifier (9).7. Remove the rear end frame (8).8. Press out the rotor (6) from drive end frame (2).9. Remove the retainer plate (5).10.Press out the bearing (4) from drive end frame (2) with a press and jig.11.Lightly secure the rotor with a vise to prevent damage, and remove the bearing (7) with a puller.(When reassembling)

W1224556

(1) Pulley(2) Drive End Frame(3) Stator(4) Bearing(5) Retainer Plate(6) Rotor(7) Bearing(8) Rear End Frame(9) Rectifier

(10) IC Regulator(11) Brush Holder(12) Rear End Cover

Tightening torque Pulley nut58.4 to 78.9 N·m5.95 to 8.05 kgf·m43.1 to 58.2 lbf·ft


S-78


[3] SERVICING(1) Cylinder Head and Valves

Top Clearance1. Remove the cylinder head (remove the cylinder head gasket

completely).2. Bring the piston to its top dead center fasten 1.5 mm dia. 5 to 7

mm long fuse wires to 3 to 4 spots on the piston top with greaseso as to avoid the intake and exhaust valves and the combustionchamber ports.

3. Bring the piston to its middle position, install the cylinder head,and tighten the cylinder head screws to specification. (Headgasket must be changed to new one.)

4. Turn the crank shaft until the piston exceeds its top dead center.5. Remove the cylinder head, and measure squeezed fuse wires for

thickness.6. If the measurement is not within the specified value, check the oil

clearance of the crankpin journal and the piston pin.NOTE

• After checking the top clearance, be sure to assemble thecylinder head with a new cylinder head gasket.

W1020190

Top Clearance Factory spec.

D1703-E/E2V2203-E/E2F2803-E/E2

0.55 to 0.70 mm0.022 to 0.027 in.

V3300-E2BG 0.72 to 0.90 mm0.029 to 0.035 in.

Tightening torque

Cylinder head screws

D1703-E/E2V2203-E/E2F2803-E/E2


V3300-E2BG98.1 to 107 N·m10.0 to 11.0 kgf·m72.4 to 79.5 lbf·ft

(1) Piston(2) Fuse

[A] D1703-E/E2V2203-E/E2F2803-E/E2

[B] V3300-E2BG


S-79


Cylinder Head Surface Flatness1. Clean the cylinder head surface.2. Place a straightedge on the cylinder head’s four sides (A), (B),

(C) and (D) and two diagonal (E) and (F) as shown in the figure.3. Measure the clearance with a feeler gauge.4. If the measurement exceeds the allowable limit, correct it with a

surface grinder.IMPORTANT

• Do not place the straightedge on the combustion chamber.• Be sure to check the valve recessing after correcting.

W1027737

Cylinder Head Flaw1. Prepare an air spray red check.2. Clean the surface of the cylinder head with the detergent (2).3. Spray the cylinder head surface with the red permeative liquid

(1). Leave it five to ten minutes after spraying.4. Wash away the read permeative liquid on the cylinder head

surface with the detergent (2).5. Spray the cylinder head surface with the white developer (3).6. If flawed, it can be identified as red marks.

W1076542

Cylinder head surface flatness Allowable limit 0.05 mm

0.002 in.

[A] D1703-E/E2V2203-E/E2F2803-E/E2

[B] V3300-E2BG

(1) Red Permeative Liquid(2) Detergent

(3) White Developer


S-80


Valve Recessing1. Clean the cylinder head surface, valve face and valve seat.2. Insert the valve into the valve guide.3. Measure the valve recessing with a depth gauge.4. If the measurement exceeds the allowable limit, replace the

valve.5. If it still exceeds the allowable limit after replacing the valve,

replace the cylinder head.

[D1703-E/E2, V2203-E/E2, F2803-E/E2]

[V3300-E2BG]

W10768800

Valve recessing

Factory spec.

Intake and exhaust valve

(Protrusion)0.050 mm (0.0020 in.)

to(Recessing)0.15 mm (0.0059 in.)

Allowable limit (Recessing)0.4 mm (0.02 in.)

Valve recessing

Factory spec.

Intake valve

(Protrusion)0 mm (0 in.)


Exhaust valve

(Protrusion)0.15 mm (0.0059 in.)


Allowable limit (Recessing)0.4 mm (0.02 in.)

(1) Cylinder Head Surface

(A) Recessing(B) Protrusion

[A] D1703-E/E2V2203-E/E2F2803-E/E2

[B] V3300-E2BG


S-81


Clearance between Valve Stem and Valve Guide1. Remove carbon from the valve guide section.2. Measure the valve stem O.D. with an outside micrometer.3. Measure the valve guide I.D. with a small hole gauge, and

calculate the clearance.4. If the clearance exceeds the allowable limit, replace the valves.

If it still exceeds the allowable limit, replace the valve guide.

[D1703-E/E2, V2203-E/E2, F2803-E/E2]

[V3300-E2BG]

W10774950

Clearance between valve stem and valve guide

Factory spec. 0.040 to 0.070 mm0.0016 to 0.0027 in.

Allowable limit 0.10 mm0.0039 in.

Valve stem O.D. Factory spec. 7.960 to 7.975 mm0.3134 to 0.3139 in.

Valve guide I.D. Factory spec. 8.015 to 8.030 mm0.3156 to 0.3161 in.

Clearance between valve stem and valve guide

Factory spec.

Intake valve

0.055 to 0.085 mm0.0022 to 0.0033 in.

Exhaust valve

0.040 to 0.070 mm0.0016 to 0.0027 in.


Valve stem O.D. Factory spec.

Intake valve

6.960 to 6.975 mm0.2741 to 0.2746 in.

Exhaust valve

7.960 to 7.975 mm0.3134 to 0.3139 in.

Valve guide I.D. Factory spec.

Intake valve

7.030 to 7.045 mm0.2768 to 0.2773 in.

Exhaust valve

8.015 to 8.030 mm0.3156 to 0.3161 in.


S-82


Replacing Valve Guide(When removing)1. Press out the used valve guide using a valve guide replacing tool.

(See page “SPECIAL TOOLS”.)(When installing)1. Clean a new valve guide and valve guide bore, and apply engine

oil to them.2. Press in a new valve guide using a valve guide replacing tool.3. Ream precisely the I.D. of the valve guide to the specified

dimension.

[D1703-E/E2, V2203-E/E2, F2803-E/E2]

[V3300-E2BG]

IMPORTANT• Do not hit the valve guide with a hammer during

replacement.

W10278890

Valve Seating1. Coat the valve face lightly with prussian blue and put the valve on

its seat to check the contact.2. If the valve does not seat all the way around the valve seat or the

valve contact is less than 70 %, correct the valve seating asfollows.

3. If the valve contact does not comply with the reference value,replace the valve or correct the contact of valve seating.

W10282190

Valve guide I.D.(Intake and exhaust) Factory spec. 8.015 to 8.030 mm

0.3156 to 0.3161 in.

Valve guide I.D. Factory spec.

Intake valve

7.030 to 7.045 mm0.2768 to 0.2773 in.

Exhaust valve

8.015 to 8.030 mm0.3156 to 0.3161 in.

(A) When Removing (B) When Installing

Valve seat width Factory spec. 2.12 mm0.0835 in.

(1) Correct(2) Incorrect

(3) Incorrect


S-83


Valve Lapping1. Apply compound evenly to the valve lapping surface.2. Insert the valve into the valve guide. Lap the valve onto its seat

with a valve flapper or screwdriver.3. After lapping the valve, wash the compound away and apply oil,

then repeat valve lapping with oil.4. Apply prussian blue to the contact surface to check the seated

rate. If it is less than 70 %, repeat valve lapping again.IMPORTANT

• When valve lapping is performed, be sure to check the valverecessing and adjust the valve clearance after assemblingthe valve.

W10288140

Correcting Valve and Valve SeatNOTE

• Before correcting the valve and seat, check the valve stemand the I.D. of valve guide section, and repair them ifnecessary.

• After correcting the valve seat, be sure to check the valverecessing.

1) Correcting Valve1. Correct the valve with a valve refacer.

2) Correcting Valve Seat1. Slightly correct the seat surface with a 1.0 rad (60 °) (intake

valve) or 0.79 rad (45 °) (exhaust valve) valve seat cutter.2. Resurface the seat surface with a 0.52 rad (30 °) valve seat cutter

to intake valve seat and with a 0.26 rad (15 °) valve seat cutter toexhaust valve seat so that the width is close to specified valveseat width (2.12 mm, 0.0835 in.).

3. After resurfacing the seat, inspect for even valve seating, apply athin film of compound between the valve face and valve seat, andfit them with valve lapping tool.

4. Check the valve seating with prussian blue. The valve seatingsurface should show good contact all the way around.

W10283500

Valve face angle Factory spec.

IN. 1.0 rad60 °

EX. 0.79 rad45 °

Valve seat angle Factory spec.

IN. 1.0 rad60 °

EX. 0.79 rad45 °

(1) Valve Seat Width(2) Identical Dimensions

(A) Check Contact(B) Correct Seat Width(C) Check Contact(a) 0.26 rad (15 °) or 0.52 rad (30 °)(b) 0.79 rad (45 °) or 1.0 rad (60 °)(c) 0.52 rad (30 °) or 0.26 rad (15 °)


S-84


Free Length and Tilt of Valve Spring1. Measure the free length (B) of valve spring with vernier calipers.

If the measurement is less than the allowable limit, replace it.2. Put the valve spring on a surface plate, place a square on the

side of the valve spring.3. Check to see if the entire side is in contact with the square.

Rotate the valve spring and measure the maximum tilt (A).If the measurement exceeds the allowable limit, replace it.

4. Check the entire surface of the valve spring for scratches.If there is any defect, replace it.

[D1703-E/E2, V2203-E/E2, F2803-E/E2]

[V3300-E2BG]

W10289350

Valve Spring Setting Load1. Place the valve spring on a tester and compress it to the same

length it is actually compressed in the engine.2. Read the compression load on the gauge.3. If the measurement is less than the allowable limit, replace it.

[D1703-E/E2, V2203-E/E2, F2803-E/E2]

[V3300-E2BG]

W10784360

Tilt (A) Allowable limit 1.0 mm0.039 in.

Free length (B)

Factory spec.

Intake and exhaust valve

41.7 to 42.2 mm1.65 to 1.66 in.

Allowable limit

41.2 mm1.62 in.

Tilt (A) Allowable limit 1.0 mm0.039 in.

Free length (B)

Factory spec.

Intake valve

35.1 to 35.6 mm1.39 to 1.40 in.

Exhaust valve

41.7 to 42.2 mm1.65 to 1.66 in.

Allowable limit

Intake valve

34.6 mm1.36 in.

Exhaust valve

41.2 mm1.62 in.

(A) Tilt (B) Free Length

Setting load / setting length

Factory spec. Intake

and exhaust valve

118 N / 35.0 mm12.0 kgf / 35.0 mm26.5 lbf / 1.38 in.

Allowable limit

100 N / 35.0 mm10.2 kgf / 35.0 mm22.5 lbf / 1.38 in.

Setting load / setting length

Factory spec.

Intake valve

63.5 N / 31.5 mm6.48 kgf / 31.5 mm14.3 lbf / 1.24 in.

Exhaust valve

120 N / 35.0 mm12.0 kgf / 35.0 mm26.5 lbf / 1.38 in.

Allowable limit

Intake valve

45.9 N / 31.5 mm4.68 kgf / 31.5 mm10.3 lbf / 1.24 in.

Exhaust valve

100 N / 35.0 mm10.2 kgf / 35.0 mm22.5 lbf / 1.38 in.


S-85


Oil Clearance between Rocker Arm and Rocker Arm Shaft1. Measure the rocker arm shaft O.D. with an outside micrometer.2. Measure the rocker arm I.D. with an inside micrometer, and then

calculate the oil clearance.3. If the oil clearance exceeds the allowable limit, replace the rocker

arm and measure the oil clearance again. If it still exceeds theallowable limit, replace also the rocker arm shaft.

[D1703-E/E2, V2203-E/E2, F2803-E/E2]

[V3300-E2BG]

W1029150

Push Rod Alignment1. Place the push rod on V blocks.2. Measure the push rod alignment.3. If the measurement exceeds the allowable limit, replace the push

rod.

W10292900

Oil Clearance between Tappet and Tappet Guide Bore1. Measure the tappet O.D. with an outside micrometer.2. Measure the I.D. of the tappet guide bore with a cylinder gauge,

and calculate the oil clearance.3. If the oil clearance exceeds the allowable limit or the tappet is

damaged, replace the tappet.

W1029366

Oil clearance of rocker arm shaft and bearing



Rocker arm shaft O.D. Factory spec. 13.973 to 13.984 mm0.55012 to 0.55055 in.

Rocker arm I.D. for shaft Factory spec. 14.000 to 14.018 mm0.55119 to 0.55188 in.

Oil clearance of rocker arm shaft and bearing



Rocker arm shaft O.D. Factory spec. 15.973 to 15.984 mm0.62886 to 0.62929 in.

Rocker arm I.D. for shaft Factory spec. 16.000 to 16.018 mm0.62993 to 0.63062 in.

Push rod alignment Allowable limit 0.25 mm0.0098 in.

Oil Clearance between tappet and tappet guide bore



Tappet O.D. Factory spec. 23.959 to 23.980 mm0.94327 to 0.94409 in.

Tappet guide bore I.D. Factory spec. 24.000 to 24.021 mm0.94489 to 0.94570 in.


S-86


(2) Timing GearsTiming Gear Backlash1. Set a dial indicator (lever type) with its tip on the gear tooth.2. Move the gear to measure the backlash, holding its mating gear.3. If the backlash exceeds the allowable limit, check the oil

clearance of the shafts and the gear.4. If the oil clearance is proper, replace the gear.

[D1703-E/E2, V2203-E/E2, F2803-E/E2]

[V3300-E2BG]

W1029564

Backlash between crank gear and idle gear



Backlash between idle gear and cam gear

Factory spec. 0.04150 to 01154 mm0.001634 to 0.004543 in.


Backlash between idle gear and injection pump gear



Backlash between crank gear and oil pump gear



Backlash between crank gear and idle gear 1

Factory spec.

0.0490 to 0.193 mm0.00193 to 0.00759 in.

Backlash between idle gear 1 and cam gear

0.0490 to 0.189 mm0.00193 to 0.00744 in.

Backlash between idle gear 1 and idle gear 2

0.0440 to 0.185 mm0.00174 to 0.00728 in.

Backlash between idle gear 2 and injection pump gear

0.0440 to 0.177 mm0.00174 to 0.00696 in.

[A] D1703-E/E2V2203-E/E2F2803-E/E2

[B] V3300-E2BG


S-87


Idle Gear Side Clearance1. Set a dial indicator with its tip on the idle gear.2. Measure the side clearance by moving the idle gear to the front

and rear.3. If the measurement exceeds the allowable limit, replace the idle

gear collar.

W1029843

Camshaft Side Clearance1. Set a dial indicator with its tip on the camshaft.2. Measure the side clearance by moving the cam gear to the front

to rear.3. If the measurement exceeds the allowable limit, replace the

camshaft stopper.

W1030012

Camshaft Alignment1. Support the camshaft with V blocks on the surface plate at both

end journals.2. Set a dial indicator with its tip on the intermediate journal.3. Measure the camshaft alignment.4. If the measurement exceeds the allowable limit, replace the

camshaft.

W1031413

Idle gear side clearance

Factory spec.

D1703-E/E2V2203-E/E2F2803-E/E2

0.12 to 0.48 mm0.0048 to 0.018 in.

V3300-E2BG 0.15 to 0.30 mm0.0059 to 0.011 in.


[A] D1703-E/E2V2203-E/E2F2803-E/E2

[B] V3300-E2BG

Camshaft side clearance



[A] D1703-E/E2V2203-E/E2F2803-E/E2

[B] V3300-E2BG

Camshaft alignment Allowable limit 0.01 mm0.0004 in.


S-88


Cam Height1. Measure the height of the cam at its highest point with an outside

micrometer.2. If the measurement is less than the allowable limit, replace the

camshaft.

[D1703-E/E2, V2203-E/E2, F2803-E/E2]

[V3300-E2BG]

W1031532

Oil Clearance of Camshaft Journal1. Measure the camshaft journal O.D. with an outside micrometer.2. Measure the cylinder block bore I.D. for camshaft with a cylinder

gauge, and calculate the oil clearance.3. If the oil clearance exceeds the allowable limit, replace the

camshaft.

[D1703-E/E2, V2203-E/E2, F2803-E/E2]

[V3300-E2BG]

W10299330

Intake and exhaust cam height

Factory spec. 33.47 mm1.318 in.


Intake and exhaust cam height

Factory spec.

Intake valve

37.64 mm1.481 in.

Exhaust valve

38.96 mm1.534 in.

Allowable limit

Intake valve

37.13 mm1.462 in.

Exhaust valve

38.46 mm1.514 in.

Oil clearance of camshaft journal



Camshaft journal O.D. Factory spec. 39.934 to 39.950 mm1.5722 to 1.5728 in.

Camshaft bearing I.D. Factory spec. 40.000 to 40.025 mm1.5748 to 1.5757 in.

Camshaft journal O.D. Factory spec. 45.934 to 45.950 mm1.8085 to 1.8090 in.

Camshaft bearing I.D. Factory spec. 46.000 to 46.025 mm1.8111 to 1.8120 in.


S-89


Oil Clearance between Idle Gear Shaft and Idle Gear Bushing1. Measure the idle gear shaft O.D. with an outside micrometer.2. Measure the idle gear bushing I.D. with an inside micrometer,

and calculate the oil clearance.3. If the oil clearance exceeds the allowable limit, replace the

bushing.If it still exceeds the allowable limit, replace the idle gear shaft.

[D1703-E/E2, V2203-E/E2, F2803-E/E2]

[V3300-E2BG]

W1030933

Replacing Idle Gear Bushing(When removing)1. Press out the used idle gear bushing using an idle gear bushing

replacing tool. (See page “SPECIAL TOOLS”.)(When installing)1. Clean a new idle gear bushing and idle gear bore, and apply

engine oil to them.2. Press in a new bushing using an idle gear bushing replacing tool,

until it is flush with the end of the idle gear.

W1031083

Clearance between idle gear shaft and idle gear bushing

Factory spec.

D1703-E/E2V2203-E/E2F2803-E/E2

0.025 to 0.066 mm0.00099 to 0.0025 in.

V3300-E2BG 0.050 to 0.091 mm0.0020 to 0.0035 in.


Idle gear bushing I.D. Factory spec. 38.000 to 38.025 mm1.4961 to 1.4970 in.

Idle gear shaft O.D. Factory spec. 37.959 to 37.975 mm1.4945 to 1.4950 in.

Idle gear 1, 2 bushing I.D. Factory spec. 45.025 to 45.050 mm

1.7727 to 1.7736 in.

Idle gear 1, 2 shaft O.D. Factory spec. 44.959 to 44.975 mm1.7701 to 1.7706 in.

[A] D1703-E/E2V2203-E/E2F2803-E/E2

[B] V3300-E2BG

(A) When Removing (B) When Installing


S-90


(3) Piston and Connecting RodPiston Pin Bore I.D.1. Measure the piston pin bore I.D. in both the horizontal and

vertical directions with a cylinder gauge.2. If the measurement exceeds the allowable limit, replace the

piston.

W1031817

Oil Clearance between Piston Pin and Small End Bushing1. Measure the piston pin O.D. where it contacts the bushing with

an outside micrometer.2. Measure the small end bushing I.D. with an inside micrometer,

and calculate the oil clearance.3. If the oil clearance exceeds the allowable limit, replace the

bushing. If it still exceeds the allowable limit, replace the pistonpin.

[D1703-E/E2, V2203-E/E2, F2803-E/E2]

[V3300-E2BG]

W1031982

Piston pin bore I.D.

Factory spec.

D1703-E/E2V2203-E/E2F2803-E/E2

25.000 to 25.013 mm0.98426 to 0.98476 in.

V3300-E2BG 30.000 to 30.013 mm1.1811 to 1.1816 in.

Allowable limit

D1703-E/E2V2203-E/E2F2803-E/E2

25.05 mm0.9862 in.

V3300-E2BG 30.05 mm1.183 in.

Oil clearance between piston pin and small end bushing

Factory spec.

D1703-E/E2V2203-E/E2F2803-E/E2

0.014 to 0.036 mm0.00056 to 0.0014 in.

V3300-E2BG 0.020 to 0.040 mm0.00079 to 0.0015 in.


Piston pin O.D. Factory spec. 25.004 to 25.011 mm0.98441 to 0.98468 in.

Small end bushing I.D. Factory spec. 25.025 to 25.040 mm0.98524 to 0.98582 in.

Piston pin O.D. Factory spec. 30.006 to 30.011 mm1.1814 to 1.1815 in.

Small end bushing I.D. Factory spec. 30.031 to 30.046 mm1.1824 to 1.1829 in.


S-91


Replacing Connecting Rod Small End Bushing(When removing)1. Press out the used small end bushing using a small end bushing

replacing tool. (See page “SPECIAL TOOLS”.)(When installing)1. Clean a new small end bushing and bore, and apply engine oil to

them.[D1703-E/E2, V2203-E/E2, F2803-E/E2]2. Using a small end bushing replacing tool, press in a new bushing

taking due care to see that the position of the connecting rod oilhole matches the bushing hole.

[V3300-E2BG]2. Insert a new bushing onto the tool and press-fit it with a press so

that the seam (1) of bushing positions as shown in the figure, untilit is flash with the connecting rod.

W1032140

Connecting Rod AlignmentNOTE

• Since the I.D. of the connecting rod small end bushing is thebasis of this check, check bushing for wear beforehand.

1. Install the piston pin into the connecting rod.2. Install the connecting rod on the connecting rod alignment tool.3. Put a gauge over the piston pin, and move it against the face

plate.4. If the gauge does not fit squarely against the face plate, measure

the space between the pin of the gauge and the face plate.5. If the measurement exceeds the allowable limit, replace the

connecting rod.

W10314620

(1) Seam(A) When removing(B) When installing(C) 0.26 rad (15 °)

[A] V3300-E2BG

Connecting rod alignment Allowable limit 0.05 mm

0.002 in.


S-92


Piston Ring Gap1. Insert the piston ring into the lower part of the liner (the least worn

out part) with the piston.2. Measure the ring gap with a feeler gauge.3. If the gap exceeds the allowable limit, replace the ring.

[D1703-E/E2, V2203-E/E2, F2803-E/E2]

[V3300-E2BG]

W1032246

Top ringFactory spec. 0.30 to 0.45 mm

0.012 to 0.017 in.


Second ringFactory spec. 0.30 to 0.45 mm

0.012 to 0.017 in.


Oil ringFactory spec. 0.25 to 0.45 mm

0.0099 to 0.017 in.


Top ring and Second ring




0.0099 to 0.017 in.



S-93


Clearance between Piston Ring and Groove1. Clean the rings and the ring grooves, and install each ring in its

groove.2. Measure the clearance between the ring and the groove with a

feeler gauge or depth gauge.3. If the clearance exceeds the allowable limit, replace the piston

ring.4. If the clearance still exceeds the allowable limit with new ring,

replace the piston.

[D1703-E/E2, V2203-E/E2, F2803-E/E2]

[V3300-E2BG]

W1032489

Second ringFactory spec. 0.0930 to 0.120 mm

0.00367 to 0.00472 in.



0.00079 to 0.0020 in.


Top ring : a

Factory spec.

More than 0.2 mm 0.008 in.

Second ring 0.0930 to 0.120 mm0.00367 to 0.00472 in.

Oil ring 0.020 to 0.060 mm0.00079 to 0.0023 in.

Second ringAllowable limit

0.20 mm0.0079 in.

Oil ring 0.15 mm0.0059 in.

(A) Top Ring (Key Stone Type) (B) Second ring, Oil Ring


S-94


(4) CrankshaftSide Clearance of Crankshaft1. Set a dial indicator with its tip on the end of the crankshaft.2. Measure the side clearance by moving the crankshaft to the front

and rear.3. If the measurement exceeds the allowable limit, replace the

thrust bearings.4. If the same size bearing is useless because of the crankshaft

journal wear, replace it with an oversize one referring to the tableand figure.

[D1703, V2203] (Serial No. : below 3R9999)[F2803]

[D1703, V2203] (Serial No. : above 3S0001)[V3300-E2BG]

(Reference)[D1703-E/E2, V2203-E/E2, F2803-E/E2]• Oversize dimensions of crankshaft journal

[V3300-E2BG]• Oversize dimensions of crankshaft journal.

W1032880

Crankshaft side clearance



Crankshaft side clearance



Oversize 0.2 mm0.008 in.

0.4 mm0.02 in.

Dimension A 54.50 to 54.70 mm2.146 to 2.153 in.

54.60 to 54.80 mm2.150 to 2.157 in.

Dimension B 26.20 to 26.25 mm1.032 to 1.033 in.

26.40 to 26.45 mm1.040 to 1.041 in.

Dimension C 2.8 to 3.2 mm radius0.11 to 0.12 in. radius

2.8 to 3.2 mm radius0.11 to 0.12 in. radius

(0.4 S)The crankshaft journal must be fine-finished to higher than ∇∇∇∇.

Oversize 0.2 mm0.008 in.

0.4 mm0.02 in.

Dimension A 169.10 to 169.15 mm6.6575 to 6.6594 in.

169.20 to 169.25 mm6.6615 to 6.6633 in.

Dimension B 29.20 to 29.25 mm1.150 to 1.151 in.

29.40 to 29.45 mm1.158 to 1.159 in.

Dimension C 2.8 to 3.2 mm radius0.11 to 0.12 in. radius


(0.8 S)The crankshaft journal must be fine-finished to higher than ∇∇∇∇.

[A] D1703-E/E2V2203-E/E2F2803-E/E2

[B] V3300-E2BG


S-95


Crankshaft Alignment1. Support the crankshaft with V blocks on the surface plate at both

end journals.2. Set a dial indicator with its tip on the intermediate journal.3. Measure the crankshaft alignment.4. If the measurement exceeds the allowable limit, replace the

crankshaft.

W1033001

Oil Clearance between Crankpin and Crankpin Bearing (To beContinued)1. Clean the crankpin and crankpin bearing.2. Put a strip of plastigage on the center of the crankpin.3. Install the connecting rod cap and tighten the connecting rod

screws to the specified torque, and remove the cap again.4. Measure the amount of the flattening with the scale, and get the

oil clearance.5. If the oil clearance exceeds the allowable limit, replace the

crankpin bearing.6. If the same size bearing is useless because of the crankpin wear,

replace it with an undersize one referring to the table and figure.NOTE

• Never insert the plastigage into the crankpin oil hole.• Be sure not to move the crankshaft while the connecting rod

screws are tightened.

[D1703-E/E2, V2203-E/E2, F2803-E/E2]

(Reference)• Undersize dimensions of crankpin

W1033106

Crankshaft alignment Allowable limit 0.02 mm0.0008 in.

Oil clearance between crankpin and crankpin bearing



Crankpin O.D. Factory spec. 46.959 to 46.975 mm1.8488 to 1.8494 in.

Crankpin bearing I.D. Factory spec. 47.000 to 47.046 mm1.8504 to 1.8522 in.

Undersize 0.2 mm0.008 in.

0.4 mm0.02 in.

Dimension A 3.3 to 3.7 mm radius0.13 to 0.14 in. radius


*Dimension B 1.0 to 1.5 mm relief0.040 to 0.059 in. relief

1.0 to 1.5 mm relief0.040 to 0.059 in. relief

Dimension C 46.759 to 46.775 mm dia.1.8409 to 1.8415 in. dia.

46.559 to 46.575 mm dia.1.8331 to 1.8336 in. dia.

(0.4 S)The crankpin must be fine-finished to higher than ∇∇∇∇.*Holes to be de-burred and edges rounded with 1.0 to 1.5 mm (0.040 to 0.059 in.) relief.


S-96


Oil Clearance between Crankpin and Crankpin Bearing(Continued)

[V3300-E2BG]

IMPORTANT• STD size crankpin bearing.

To replace it with a specific STD service part, make sure thecrankpin bearing has the same ID color as the connectingrod.

(Reference)• Undersize dimensions of crankshaft journal

W1106119

Crankpin O.D. Factory spec. 52.977 to 52.990 mm2.0857 to 2.0862 in.

Oil clearance between crankpin and crankpin bearing



ID Color

Connecting rod Crankpin bearing

Large-end in. dia. Class Part code Center wall thick

Blue 56.010 to 56.020 mm2.2052 to 2.2055 in. L 1C020-22311 1.496 to 1.501 mm

0.05890 to 0.05909 in.

Yellow or

without color

56.000 to 56.010 mm2.2048 to 2.2051 in. S 1C020-22331 1.491 to 1.496 mm

0.05870 to 0.05889 in.


0.4 mm0.02 in.





Dimension C 52.777 to 52.790 mm dia.2.0779 to 2.0783 in. dia.

52.577 to 52.590 mm dia.2.0700 to 2.0704 in. dia.

(0.8 S)The crankshaft journal must be fine-finished to higher than ∇∇∇∇.*Holes to be de-burred and edges rounded with 1.0 to 1.5 mm (0.040 to 0.059 in.) relief.

(1) ID Color(2) Crankpin Bearing

(3) Center Wall Thick


S-97


Oil Clearance between Crankshaft Journal and CrankshaftBearing 1 (D1703-E/E2, V2203-E/E2, F2803-E/E2)1. Measure the O.D. of the crankshaft journal with an outside

micrometer.2. Measure the I.D. of the crankshaft bearing 1 with an inside

micrometer, and calculate oil clearance.3. If the clearance exceeds the allowable limit, replace the

crankshaft bearing 1.4. If the same size bearing is useless because of the crankshaft

journal wear, replace it with an undersize one referring to thetable and figure.

[D1703, V2203] (Serial No. : above 3S0001)



W1033717

Oil clearance between crankshaft journal and crankshaft bearing 1



Crankshaft journal O.D. Factory spec. 59.921 to 59.940 mm2.3591 to 2.3598 in.

Crankshaft bearing 1 I.D. Factory spec. 59.980 to 60.039 mm

2.3615 to 2.3637 in.



2.0465 to 2.0487 in.


0.4 mm0.02 in.





Dimension C


59.721 to 59.740 mm dia.

2.3513 to 2.3519 in. dia.

59.521 to 59.540 mm dia.

2.3434 to 2.3440 in. dia.

D1703, V2203 (Serial No. : below 3R9999) / F2803

51.721 to 51.740 mm dia.

2.0363 to 2.0370 in. dia.

51.521 to 51.540 mm dia.

2.0284 to 2.0291 in. dia.



S-98


Replacing Crankshaft Bearing 1 (D1703-E/E2, V2203-E/E2,F2803-E/E2)(When removing)1. Press out the used crankshaft bearing 1 using a crankshaft

bearing 1 replacing tool. (See page “SPECIAL TOOLS”.)(When installing)1. Clean a new crankshaft bearing 1 and crankshaft journal bore,

and apply engine oil to them.2. Using a crankshaft bearing 1 replacing tool, press in a new

bearing 1 (2) so that its seam (1) directs toward the exhaustmanifold side. (See figure.)

W1033946

Dimension (A) Factory spec. 4.20 to 4.50 mm0.166 to 0.177 in.

(1) Seam(2) Crankshaft Bearing 1

(3) Cylinder Block(A) Dimension


S-99


Oil Clearance between Crankshaft Journal and CrankshaftBearing 2 (D1703-E/E2, V2203-E/E2, F2803-E/E2)1. Put a strip of plastigage on the center of the journal.2. Install the bearing case and tighten the baring case screws 1 to

the specified torque, and remove the bearing case again.3. Measure the amount of the flattening with the scale and get the

oil clearance.4. If the clearance exceeds the allowable limit, replace the

crankshaft bearing 2.5. If the same size bearing is useless because of the crankshaft

journal wear, replace it with an undersize one referring to thetable and figure.NOTE

• Be sure not to move the crankshaft while the bearing casescrews are tightened.

[D1703, V2203] (Serial No. : above 3S0001)



W1083821

Oil clearance between crankshaft and crankshaft bearing 2





2.3615 to 2.3631 in.



2.0465 to 2.0482 in.


0.4 mm0.02 in.





Dimension C


59.721 to 59.740 mm dia.

2.3513 to 2.3519 in. dia.

59.521 to 59.540 mm dia.

2.3434 to 2.3440 in. dia.

D1703, V2203 (Serial No. : below 3R9999) / F2803

51.721 to 51.740 mm dia.

2.0363 to 2.0370 in. dia.

51.521 to 51.540 mm dia.

2.0284 to 2.0291 in. dia.



S-100


Oil Clearance between Crankshaft Journal and CrankshaftBearing (V3300-E2BG)1. Clean the crankshaft journal and crankshaft bearing.2. Put a strip of plastigage gauge (Code No.: 07909-30241) on the

center of the journal.IMPORTANT

• Never insert the press gauge into the oil hole of the journal.3. Install the main bearing case and tighten the screws to the

specified torque, and remove the cases again.4. Measure the amount of the flattening with the scale and get the

oil clearance.5. If the clearance exceeds the allowable limit, replace the

crankshaft bearing.

(Reference)• Undersize crankshaft bearing

• Undersize dimensions of crankshaft journal

W1110110


Oil clearance between crankshaft journal and crankshaft bearing



Undersize Bearing Code Number Marking

0.2 mm0.008 in. Crankshaft bearing 02 1C020-23910 020 US

0.4 mm0.02 in. Crankshaft bearing 04 1C020-23920 040 US

Undersize

Dimension

0.2 mm0.008 in.

0.4 mm0.02 in.

A 2.8 to 3.2 mm radius0.11 to 0.12 in. radius


*B 1.0 to 1.5 mm relief0.040 to 0.059 in. relief


C 74.777 to 74.790 mm dia.2.9440 to 2.9444 in. dia.

74.577 to 74.590 mm dia.2.9361 to 2.9366 in. dia.



S-101


Replacing Crankshaft Sleeve1. Remove the used crankshaft sleeve (3).2. Set the sleeve guide (2) to the crankshaft (5).3. Set the stopper (1) to the crankshaft (5) as shown in figure.

(D1703, V2203, F2803)4. Heat a new sleeve to a temperature between 150 and 200 °C

(302 and 392 °F), and fix the sleeve to the crankshaft (5) asshown in figure.

5. Press fit the sleeve using the auxiliary socket for pushing (4).(Refer to “SPECIAL TOOLS”.)NOTE

• Mount the sleeve with its largely chamfered surface facingoutward.

• Should heating is not enough, a sleeve might stop halfway,so careful.

W1033503

(1) Stopper(2) Sleeve Guide(3) Crankshaft Sleeve(4) Auxiliary Socket for Pushing(5) Crankshaft

[A] D1703-E/E2V2203-E/E2F2803-E/E2

[B] V3300-E2BG


S-102


(5) CylinderCylinder Wear1. Measure the I.D. of the cylinder at the six positions (see figure)

with a cylinder gauge to find the maximum and minimum I.D.’s.2. Get the difference (Maximum wear) between the maximum and

the minimum I.D.’s.3. If the wear exceeds the allowable limit, bore and hone to the

oversize dimension. (Refer to “Correcting Cylinder”.)4. Visually check the cylinder wall for scratches. If deep scratches

are found, the cylinder should be bored. (Refer to “CorrectingCylinder”.)

W1034389

Correcting Cylinder (Oversize)1. When the cylinder is worn beyond the allowable limit, bore and

hone it to the specified dimension.

2. Replace the piston and piston rings with oversize ones.Oversize : 0.50 mm (0.020 in.)NOTE

• When the oversize cylinder is worn beyond the allowablelimit, replace the cylinder block with a new one.

W1034448

Cylinder I.D.

Factory spec.

D1703-E/E2V2203-E/E2F2803-E/E2

87.000 to 87.022 mm3.4252 to 3.4260 in.

V3300-E2BG 98.000 to 98.022 mm3.8583 to 3.8591 in.

Allowable limit

D1703-E/E2V2203-E/E2F2803-E/E2

87.150 mm3.4311 in.

V3300-E2BG 98.150 mm3.8642 in.

Variance among cylinder Allowable limit 10 % or less

(A) Top(B) Middle(C) Bottom (Skirt)

(a) Right-angled to Piston Pin(b) Piston Pin Direction

Oversize cylinder I.D.

Factory spec.

D1703-E/E2V2203-E/E2F2803-E/E2

87.500 to 87.522 mm3.4449 to 3.4457 in.

V3300-E2BG 98.500 to 98.522 mm3.8780 to 3.8788 in.

Allowable limit

D1703-E/E2V2203-E/E2F2803-E/E2

87.650 mm3.4508 in.

V3300-E2BG 98.650 mm3.8839 in.

FinishingHone to 2.2 to 3.0 μmRz

∇∇∇(0.000087 to 0.000118 in.R max.)

(1) Cylinder I.D. (Before Correction) (2) Cylinder I.D. (Oversize)


S-103


(6) Oil Pump1) D1703-E/E2, V2203-E/E2, F2803-E/E2

Rotor Lobe Clearance1. Measure the clearance between lobes of the inner rotor and the

outer rotor with a feeler gauge.2. Measure the clearance between the outer rotor and the pump

body with a feeler gauge.3. If the clearance exceeds the factory specifications, replace the oil

pump rotor assembly.

W1035296

Clearance between Rotor and Cover1. Put a strip of plastigage onto the rotor face with grease.2. Install the cover and tighten the screws.3. Remove the cover carefully, and measure the width of the press

gauge with a sheet of gauge.4. If the clearance exceeds the factory specifications, replace oil

pump rotor assembly.

W1035444

2) V3300-E2BGRotor Lobe Clearance1. Measure the clearance between lobes of the inner rotor and the

outer rotor with a feeler gauge.2. If the clearance exceeds the allowable limit, replace the oil pump

rotor assembly.

W1071254

Clearance between inner rotor and outer rotor



Clearance between outer rotor and pump body



Clearance between inner rotor and cover



Clearance between inner rotor and outer rotor




S-104


Clearance between Outer Rotor and Pump Body1. Measure the clearance between the outer rotor and the pump

body with a feeler gauge.2. If the clearance exceeds the allowable limit, replace the oil pump

rotor assembly.

W1071334

Clearance between Rotor and Cover1. Put a strip of plastigage onto the rotor face with grease.2. Install the cover and tighten the screws with the specified torque.3. Remove the cover carefully, and measure the amount of the

flattening with the scale and get the clearance.4. If the clearance exceeds the allowable limit, replace oil pump

rotor assembly and the cover.

W1148218

(7) StarterCommutator and Mica1. Check the contact of the commutator for wear, and grind the

commutator with emery paper if it is slightly worn.2. Measure the commutator O.D. with an outside micrometer at

several points.3. If the minimum O.D. is less than the allowable limit, replace the

armature.4. If the difference of the O.D.'s exceeds the allowable limit, correct

the commutator on a lathe to the factory specification.5. Measure the mica undercut.6. If the undercut is less than the allowable limit, correct it with a saw

blade and chamfer the segment edges.

Clearance between outer rotor and pump body



Clearance between rotor and cover



Commutator O.D.

Factory spec.

D1703-E/E2V2203-E/E2F2803-E/E2

30.0 mm1.18 in.

V3300-E2BG 32.0 mm1.26 in.

Allowable limit

D1703-E/E2V2203-E/E2F2803-E/E2

29.0 mm1.14 in.

V3300-E2BG 31.4 mm1.24 in.

Mica under cut

Factory spec.

D1703-E/E2V2203-E/E2F2803-E/E2

0.45 to 0.75 mm0.018 to 0.029 in.

V3300-E2BG 0.50 mm0.020 in.


(1) Segment(2) Depth of Mica(3) Mica

(a) Correct(b) Incorrect


S-105


W1155802

Brush Wear1. If the contact face of the brush is dirty or dusty, clean it with emery

paper.2. Measure the brush length (A) with vernier caliper.3. If the length is less than the allowable limit, replace the yoke

assembly and brush holder.

W1156360

Brush Holder1. Check the continuity across the brush holder and the holder

support with a circuit tester.2. If it conducts, replace the brush holder.

W1156895

Armature Coil1. Check the continuity across the commutator and armature coil

core with resistance range of circuit tester.2. If it conducts, replace the armature.3. Check the continuity across the segments of the commutator with

resistance range of circuit tester.4. If it dose not conduct, replace the armature.

W1156507

Brush length (A)

Factory spec.

D1703-E/E2V2203-E/E2F2803-E/E2

15.0 mm0.591 in.

V3300-E2BG 18.0 mm0.709 in.



S-106


Field Coil1. Check the continuity across the lead (1) and brush (2) with a

circuit tester.2. If it dose not conduct, replace the yoke assembly.3. Check the continuity across the brush (2) and yoke (3) with a

circuit tester.4. If it conducts, replace the yoke assembly.

W1156968

(1) Lead(2) Bush

(3) Yoke


S-107


(8) AlternatorBearing1. Check the bearing for smooth rotation.2. If it does not rotate smoothly, replace it.

W1019790

Stator1. Measure the resistance across each lead of the stator coil with

resistance range of circuit tester.2. If the measurement is not within factory specification, replace it.3. Check the continuity across each stator coil lead and core with

resistance range of circuit tester.4. If infinity is not indicated, replace it.

W1019964

Rotor1. Measure the resistance across the slip rings.2. If the resistance is not the factory specification, replace it.3. Check the continuity across the slip ring and core with resistance

range of circuit tester.4. If infinity is not indicated, replace it.

W1020094

Slip Ring1. Check the slip ring for score.2. If scored, correct with an emery paper or on a lathe.3. Measure the O.D. of slip ring with vernier calipers.4. If the measurement is less than the allowable limit, replace it.

W1020208

Resistance Factory spec. Less than 1.0 Ω

Resistance Factory spec. 2.9 Ω

Slip ring O.D.

D1703-E/E2V2203-E/E2F2803-E/E2

Factory spec.

14.4 mm0.567 in.

Allowable limit

14.0 mm0.551 in.

V3300-E2BG

Factory spec.

22.7 mm0.894 in.

Allowable limit

22.1 mm0.870 in.


S-108


Brush Wear1. Measure the brush length with vernier calipers.2. If the measurement is less than allowable limit, replace it.3. Make sure that the brush moves smoothly.4. If the brush is defective, replace it.

W1020329

Rectifier1. Check the continuity across each diode of rectifier with resistance

range of circuit tester.2. The rectifier is normal if the diode in the rectifier conducts in one

direction and does not conduct in the reverse direction.W1020452

IC Regulator1. Check the continuity across the B terminal (2) and the F terminal

(1) of IC regulator with resistance range of circuit tester.2. The IC regulator is normal if the conducts in one direction and

does not conduct in the reverse direction.

W1020645

Brush length

D1703-E/E2V2203-E/E2F2803-E/E2

Factory spec.

10.5 mm0.413 in.

Allowable limit

8.4 mm0.33 in.

V3300-E2BG

Factory spec.

18.5 mm0.728 in.

Allowable limit

5.0 mm0.20 in.

(1) F Terminal (2) B Terminal


2 GENERATOR


CONTENTS

MECHANISM

1. GENERATING METHOD.............................................................................. 2-M1[1] GENERAL PRINCIPLE........................................................................... 2-M1[2] PRINCIPLE OF OPERATION................................................................ 2-M2

2. STRUCTURE ................................................................................................. 2-M3[1] STATOR................................................................................................... 2-M3[2] EXCITER.................................................................................................. 2-M4[3] ROTOR .................................................................................................... 2-M4[4] AVR (Automatic Voltage Regulator)......................................................... 2-M4

3. AUTOMATIC VOLTAGE REGULATOR (AVR) ........................................... 2-M5[1] AVR CONNECTION DIAGRAM............................................................. 2-M5[2] GENERAL................................................................................................ 2-M6[3] CONSTANT-VOLTAGE CHARACTERISTICS ....................................... 2-M6[4] V/Hz CHARACTERISTICS ..................................................................... 2-M6[5] ADJUSTMENT......................................................................................... 2-M6[6] VOLTAGE ADJUSTMENT (VR1)........................................................... 2-M6[7] STABILITY ADJUSTMENT (VR2).......................................................... 2-M7[8] VOLT PER HERTZ ADJUSTER ........................................................... 2-M7[9] INITIAL EXCITATION ............................................................................. 2-M7

4. STATOR COIL WINDING ............................................................................ 2-M8[1] STATOR COIL CONNECTION WAYS AND OUTPUT TERMINAL

CONNECTION......................................................................................... 2-M85. EMERGENCY RELAY CIRCUIT.................................................................. 2-M9

[1] GENERAL................................................................................................ 2-M9[2] INSTRUCTIONS .................................................................................... 2-M10[3] FLOW CHART ...................................................................................... 2-M11

6. EARTH ......................................................................................................... 2-M127. WIRING DIAGRAM ..................................................................................... 2-M13

[1] GENERATOR DIAGRAM...................................................................... 2-M13[2] ENGINE CIRCUIT DIAGRAM.............................................................. 2-M22

(1) D1703-E/E2, V2203-E/E2, F2803-E/E2........................................... 2-M22(2) V3300-E2BG.................................................................................... 2-M23


2-M1

KJ-X50 Hz SERIES, WSM GENERATOR

1. GENERATING METHOD[1] GENERAL PRINCIPLE

W10346150

When the coil rotates in the field, an alternating electromotive force occurs, although the details of the principle arenot described here.

The KJ-X60 Hz series diesel generators use a brushless rotating field coil system in which the armature coils (1),(6) in the figure are fixes and the field coil rotate to generate an electromotive force.

Direct current from the automatic voltage regulator (AVR) (7) flows through the exciter field coil (5) to generate acurrent in the exciter armature coil (4). Diodes (3) rectify this current to provide the energizing current for poles of thefield coil (2).

In this case, the part, which is same as an armature, including the conductor coil is known as a stator because itis fixed. On the other hand, the field pole is known as a rotor as it rotates.

When the rotor of the P pole rotates n times a minute, the frequency f is as follows.

f = (P / 2) x (n / 60) (Hz) ∴ n = (120 x f) / P min-1(rpm)

P = 4 poles in KJ-X Seriesn = 1500 min-1(rpm)

f = (4 / 2) x (1500 / 60) = 50 (Hz)

Thus the number of rotations is provided by the frequency and the poles number.This number of rotations is known as synchronous speed. Also, generator rotating at this speed is known as a

synchronous generator.The electromotive force generated per single line of magnetic flux is proportional to the value given in the below

formula wherein n is the number of rotor revolutions min-1(rpm), P the number of pole and φ (wb) the number ofmagnetic lines of flux.

e = φ / { (1 / P) x (60 / n)} = (n / 60) x P x φ

If there are two serial conductors, the total electromotive power is shown here.

E = P x (n / 60) x 2 x φ

E : Voltagen : Rotation Speedφ : Field Current

(1) Armature Coil(2) Field Coil(3) Diode(4) Exciter Armature Coil(5) Exciter Field Coil(6) Armature Coil(7) AVR(8) F-(9) F+

(10) Exciter Field Current


2-M2


[2] PRINCIPLE OF OPERATIONThe AVR is fed by auxiliary winding (4) located in the stator. The winding (4) with shunt characteristic (delivering

a voltage proportional to the generator’s output voltage).When starting the residual magnetism creates a current in the exciter armature (1). This current is rectified by the

rotating diodes (2) and feeds the main field (3).The induced voltage in the auxiliary winding (4) is then used to increase the excitation power via the AVR (6) to the

exciter field (7) to ensure a rapid and smooth build up of output voltage in the main stator winding (5).The voltage sensing for the AVR (6) is taken from the output leads (phase V-W).

W1021040

(1) Exciter Armature Coil(2) Rotating Diodes

(3) Main Field Coil(4) Auxiliary Winding

(5) Main Stator Winding (Armature Coil)

(6) AVR(7) Exciter Field Coil


2-M3


2. STRUCTURE

[1] STATORThe armature coil (2) is wound around the core slot

(3) where generating AC voltage.Beside the armature coils, the stator is wrapped with

auxiliary winding which function as the AVR powersource.

W1016322

(1) End Cover(2) Stator Core(3) Frame

(4) Exciter Armature Coil(5) Core Rotor(6) Fan

(7) Cover(8) Exciter Field Coil

(9) Bearing(10) Diode Stack

(1) Core(2) Armature Coil

(3) Slot


2-M4


[2] EXCITERThough composed of a stator and rotor, these parts

differ from the output stator / rotor combination, in thatthe stator has the field winding (F+, F-) and the rotor thearmature winding. A diode and Surge-absorber areconnected to the rotor. The diode converts the ACsupply generated by the armature winding into DC, andsends this DC to the output rotor (field winding).

W1016445

[3] ROTORThe main field coil (3), exciter armature coil (1),

bearing, and cooling fan are all mounted on the sameshaft.

The silicon diode stack and Surge-absorber arelocated exciter armature core. The silicon diode stackrectifies the exciter armature coil output to produce thecurrent which energizes the poles of the field coil,inducing electrical current in the rotor armature coil.

When the current flows in the coil, the temperature ofthe coil increases by joule heat.

The fan (2) cools the coil in order to keep thetemperature down to at least the regulated one.

W1016374

[4] AVR (Automatic Voltage Regulator)AVR works so that the current for field coil comply

with load condition.Functioning is controlled using auxiliary winding and

the voltage detected on the output side (V phase-Wphase).

W1016606

(1) Exciter Armature Coil(2) Cooling Fan

(3) Rotor Field Coil


2-M5


3. AUTOMATIC VOLTAGE REGULATOR (AVR)[1] AVR CONNECTION DIAGRAM

NOTE• The AVR is optimally adjusted upon shipment from the factory and does not require adjustment under

ordinary circumstances. Do not touch adjustment parts.

W1017183

SYMBOL NAME OF PARTS SYMBOL NAME OF PARTSG GENERATOR EX EXCITERF1 GENERATOR FIELD F2 EXCITER FIELDS SURGE ABSORBER AVR AUTO. VOLT. REGULATORSi SILICON RECTIFIER F FUSE (2A)


2-M6


[2] GENERALNOTE

• It is hazardous to proceed to any high voltage test on the alternator without having previouslydisconnected all connections to voltage regulator.Damages occurring to AVR in such conditions will not be considered in a warranty claim.

[3] CONSTANT-VOLTAGE CHARACTERISTICSThe output (magnetic field exciting current) is controlled in order to keep the generator terminal voltage nearly at a

constant level even when the load or the frequency fluctuates. In a frequency range below the V/Hz working point(around 90 % of rated frequency for normal operation), however, the V/Hz characteristics are applied.

[4] V/Hz CHARACTERISTICSWhen the frequency drops with the generator voltage

at a constant level, the exciting current increases to getthe generator over-excited. If continuously over-excited,the generator may overheat itself and burn out in theworst case. To cope with this problem, the generator isgiven the V/Hz characteristics, as shown in figure, inwhich the generator voltage drops as the frequencydecreases. When the load is turned on, therefore, thevoltage is suppressed until the specified frequency isreached again. This also helps improve the drive’s loadhandling capacity.

W1014019

[5] ADJUSTMENTThe AVR (Automatic Voltage Regulator) has been factory-adjusted to optimum settings. In case of readjustment,

pay enough attention to the voltage, frequency, load and other factors.

[6] VOLTAGE ADJUSTMENT (VR1)To adjust the voltage, slowly turn the VOLT. ADJ. (VR1) control. Clockwise turn increases the voltage, and

counterclockwise turn decreases it. When an external voltage regulator (HT) is used, set its control to the centerposition first and then turn the VR1 control to the rated voltage.

(A) Terminal Voltage (B) Frequency


2-M7


[7] STABILITY ADJUSTMENT (VR2)Use the STAB. ADJ. (VR2) control to adjust the voltage stability. Clockwise turn increases the damping factor, and

counterclockwise turn decreases it.The higher the damping factor is, the slowly the response is, but the better the stability is. The lower the damping

factor, on the other hand, the higher the response but the worse the stability.

[8] VOLT PER HERTZ ADJUSTERVolt per hertz adjuster is optimally adjusted upon shipment from the factory and does not require adjustment under

ordinary circumstance.

[9] INITIAL EXCITATIONA 12 V or 24 V battery is used for initial excitation. Stop the generator, disconnect the AVR cable, and connect the

battery’s positive and negative cables to the generator’s F+ and F– terminals, respectively, for just 2 or 3 seconds.(Connect and run the generator.)

If the residual voltage is not yet high enough, take the following steps to obtain higher one. Add a 25 W / 1 kΩ orso variable resistor in series with the generator’s F+ and F- terminals. Make a short-circuit with the variable resistorto give initial excitation. Then gradually increase the resistance and disconnect the variable resistor.


2-M8


4. STATOR COIL WINDING[1] STATOR COIL CONNECTION WAYS AND OUTPUT TERMINAL

CONNECTION

W1022919

Connection code Voltage (V) Factory connectionThree phase

AVR terminals : E3-200 (V-W)

Three phase

AVR terminals : E3-200 (CV-CW)

Single phase

AVR terminals : E3-200 (U-V)


2-M9


5. EMERGENCY RELAY CIRCUIT[1] GENERAL

This is an automatic engine stopping device. Thisdevice senses any abnormal situation on engine andrelated parts, such as oil pressure, or water temperature,occurring during engine operation, and activates the stopsolenoid to cut off fuel to the fuel injection pump and stopthe engine.

This relay has two independent timer functions, astart relay and a stop relay.

The start relay does not activate this relay for aspecified time period after the engine has started.

IMPORTANT• When this device stops the engine, it may be that

some minor damages to the engine has occurred.To limit engine damage as mush as possible,please do not make the faulty assumption that itis a perfectly safety device.

W1014496

(1) Emergency Relay


2-M10


[2] INSTRUCTIONS

W1014579

1. Circuit configurationAs shown in the block diagram above, Emergency Relay-1 (EG-1) comprises a delay timer for preventing the startof fault detection till the rise of oil pressure: a sensor input circuit for checking the oil pressure and the watertemperature: a drive timer for energizing a stop solenoid (11) for a given time period in case of a fault input from asensor: a drive circuit for a relay: and a relay for energizing the stop solenoid (11).

2. Details of the circuit - Delay timer circuit

Sets the delay time between the disengagement of the starter and the start of sensing. The timer operates onvoltage from terminal 50 of the key switch (1).

- Sensor input circuit (9)Monitors the oil switch (4) and the water temperature switch (3). When either of these switches is grounded forabout 4 ms or more, the circuit will decide that sensor trouble has occurred, and provide output to the drive timer.

- Drive timer circuitSets the time for which to operate the stop solenoid (11). Upon receipt of an output from the sensor input circuit(9), the timer will start to operate.

- Drive circuit (7)Drives the relay circuit (8) for a given delay time upon receipt of an output from the drive timer.Consists of a power transistor, and a diode to remove surge volts from the relay.

- Relay circuit (8)Provides output to the stop solenoid (11) through a power relay. A varistor is incorporated to prevent surgevoltage that would be otherwise generated when current to the stop solenoid (11) is cut off.

3. Operating principle EG-1 controls so that:- While an attempt was made to start the engine with the key switch (1) in the start position (50), the oil switch (4)

and water temperature switch (3) do not operate for fault detection.- When the key switch (1) is returned to the ON position (AC), from the position mentioned in step above, a state

will occur where fault detection is possible after an elapse of 9±3 seconds (at starter starting voltage and 20°C(68°F)).

- When the key switch (1) is turned to OFF after the start of the engine, or the water temperature switch (3) or oilswitch (4) detects a fault, the stop solenoid (11) will be energized for 10±3 seconds (at 12 V and 20°C (68°F)),and then disenergized.

(1) Key Switch (2) Battery (12 V) (3) Water Temperature Switch(4) Oil Switch(5) Emergency Relay

(6) Timer Circuit (Start Delay Circuit) (7) Drive Circuit(8) Relay Circuit

(9) Sensor Input Circuit(10) Timer Circuit (Stop Relay Circuit)(11) Stop Solenoid


2-M11


[3] FLOW CHART


2-M12


6. EARTH NOTE• To avoid electric shock, connect a grounding

cable to the ground terminal and ground it asshown in the figure. Use a 3 mm2 or larger coppergrounding cable whose grounding resistance isbelow 10Ω.

Ground the generator as much as possible.The end user, equipment owner or operator must

contact his local, state, county or municipal electric codedepartment to determine the approved generatorgrounding method to be used in his application orlocation.

Recommendations in the NEC, NFPA and OSHAregulations must be followed to assure compliance andsafe operation.

A grounding lug is provided on the KUBOTAgenerator frame for earth grounding depending on local,state, national or OSHA requirements.

One possible connection method for construction siteuse is as follows :

W1015027

(1) Generator Ground Terminal(2) #6 AWG Flexible Copper Ground connection(3) Metal Ground rod or Building Cold Water Pipe system Per

N.E.C. Cord


KJ-S130VX (110 / 220 V, 120 / 240 V), KJ-S170FX (110 / 200 V, 120 / 240 V)

[1] GENERATOR DIAGRAM

2-M13

KJ-X50 HZ SERIES, WSM GENERATOR

7. WIRING DIAGRAM

3EJADABGP001A

KJ-S170FX-50KJ-S130VX-50KJ-S170FX-50KJ-S130VX-50

17

5012.51712.5

70.952.177.356.8


KJ-T130DX (127 / 220 V), KJ-T180VX (127 / 220 V), KJ-T230FX (127 / 220 V)

2-M14


3EJADABGP002A

KJ-T230FX-50KJ-T180VX-50KJ-T130DX-50

2318 5012.5

60.447.232.8



2-M15


3EJADABGP003A


2318 5012.5

34.927.319.0



2-M16


3EJADABGP004A


2318 50 240/415

12.5

32.025.017.4


KJ-S130VX-AUS (240 V), KJ-S170FX-AUS (240 V)

2-M17


3EJADABGP005A

1) Marked tube Nos. indicated as circled numbers.2) Cable color indicated as alphabet inside boxes.3) MLFC5.5 require vinyl cap U : Red, V : White, W : Blue, O : Black4) Unspecified lines are for MLFC 1.25.

RWL

REDWHITEBLUE

BYG

BLACKYELLOWGREEN

V3 U4 V4 U5 V5U2 V2 U3

A N

F

A N

F

A N

F

A N

F

A N

F

A N

F

A N

F

A N

F

U20

U30

U40

U50

V20

U21

V21

U31

V31

U41

V41

U51

V51

V30

V40

V50


KJ-T130DX-AUS (240 / 415 V), KJ-T180VX-AUS (240 / 415 V), KJ-T230FX-AUS (240 / 415 V),

2-M18


3EJADABGP006A

1) Marked tube Nos. indicated as circled numbers.2) Cable color indicated as alphabet inside boxes.3) MLFC5.5 require vinyl cap U : Red, V : White, W : Blue, O : Black4) Unspecified lines are for MLFC 1.25

Circuit Breaker (NFB) Capacity KJ-T130DX-AUS ...... 20A KJ-T180VX-AUS ...... 30A KJ-T230FX-AUS ...... 40A

0 0 U1 V1 W1U V W

U

CU

V

CV

W

CW

0

0

A N

F

A N

F

A N

F

A N

F

A N

F

A N

FNL1

L2

L3

E

RWL

REDWHITEBLUE

BYG

BLACKYELLOWGREENKJ-T230FX-AUS-50

KJ-T180VX-AUS-50KJ-T130DX-AUS-50

2318 50 240/415

12.5

32.025.017.4

03

05

04

U12

V12

W12


KJ-T300 (380 V)

2-M19


3EJADABGP007A

007

E3

006

200

CU

F+ F-

Aux.winding

E3WBR R L

200 7 6V Y GY OR

F+4 3 F-

U

T1

T7

T2

T10

T4

T5

T8

T3

T9

T11

T6

T12

CVV

WCWOO

Ulk

GRAYRED GYR

VL

VIOLETBLUE ORANGE

WHITEWOR

Code

4

BRCode

7

E3200

6

3

Wiring colorBROWN

3

12

VR

F+F-

FUSE

Wiring colorYELLOWY

LKCT

E

OFF

OFF

LK

k l

57 3 1

S

R

T

7 35 1

T-R

S-T

R-S

OFF

OFF

AS 68 4 2 VS 8 46 2

NFB

V

W

O

Wiring of the Engine Circuit.To Terminals

Wiring of the Engine Circuit.To Terminals

PLF

AV R

[ G E N E R AT O R ] [ C O N T R O L PA N E L ]

VA


KJ-S240-AUS (240 V)

2-M20


Wiring of the Engine Circuit to Terminals

Wiring of the Engine Circuit, to Terminals

Function

Neutral

Earth

Active

Wiring color

Light Blue

Green Yellow

BROWN

Code

LB

GY

BR

E

V

UFUSE

VR

3

12

200

E3

006

7

6007

OR

67E3

L GYBR WYVR

F-3F+4200

E3

200

3

4

F+

F-

Wiring of the Engine Circuit to fuse 10A

9897531

642

NFB

N

CTLK

lk

CTLK

lk

U

V

F-F+

Aux.winding

V1U1

V2U2

VN

U

AV R


PLVFA

9Y0210183ELT001US


KJ-T300-AUS (240 / 415 V)

2-M21


9Y0210183ELT002US


AV R

LB

3331

3432

U

V

W

23211311AS

OFF

N24221412

RELAYTHERMAL

Wiring of the Engine Circuit to fuse 10A

97986 4 2

5 3 1

l

L

k

KCT

O

W

E

V

U

246OFF

VS

T-R

S-T

8

135

NFB

R-S

OFF

l

LCT

l

L

k

K

k

K

7

VR

21

3

CT

O

W

CW

V

U

CU

CV

O

Wiring of the Engine Circuit

T6

T12

T11

T9

T3

T8

T5

T10

T4

T2

T7

T1

4

200

4

F+

3

200

F-

007

006E3

6

7

E3

3 F-47 6 F+

WORGYYVL

200E3

BR R

Function

Neutral

Earth

Active

Wiring color

Light Blue

Green Yellow

BROWN

Code

LB

GY

BR

Wiring of the Engine Circuit, To Terminals

F-F+

1U

W V

74

28511

129

6

10

3

Aux.winding FUSE

A V F PL


(1) D1703-E/E2, V2203-E/E2, F2803-E/E2

[2] ENGINE CIRCUIT DIAGRAM

2-M22


3EJADABGP008A

*


(2) V3300-E2BG

2-M23


3EJADABGP009A

Main switch

3R

1.25

GR

1.25

WY1.25B2B

Wiring not requiredCN7-1 and CN7-2(Panel side)

8 1096 731 2 4 5

Starter

Alternator

L

M6

IG

Fuse(F2)

BatterySide of engine

Slow blow fuse

3L

5.5RM8B

ST

60

5.5R

1.25WY2G

5.5R

CN7-1

TB3

5.5R

60

3L

3R3L

3Y

46

51

321.25WY

3L

1.25L1.25W

2G1.25B3L1

2

1.25W1.25L

2G

45

63

Base

3LWiring of the Thermal relay

10A

14

3L

3L

125

3

Oil switch

Water temp. switch

Glow plug

Electric fuel feed pump

Pull

Hold

Solenoid

3ATB11.25Y

1.25GL

3R3R3R

1.25W

1.25L

87

910 10

87

9

CN7-2

11

1.25B

1.25B

1.25Y1.25GL

223

45

43

52Y

78

67

68

1.25WR1.25Y

2B

3Y

991010

1.25B

Starter relay

1.25

G

(F3)Fuse

1.25

B

1.25

GL

1.25L

3A

Fuse(F1)

2Y

1.25GL

1.25G50

RS1RS2

1.25GLB

1.25L1.25W

AC30OSWS

O1.25B

1.25Y1.25R1.25B

19EU

1.25B

Wiring of the AVR terminals

Wiring of the generator terminals

50

3L1.

25L2R

2G 2G

30AC

TB2

1.25B19

3L

302G

Hour meter

AC50

2R2L 19

1.25B

1.25

GW

ON GLOFF 0

321

ST

3R

53 1

2 1.25

R 3Y

5 2

3Y

53 1

2

3 1

1.25

WR

1.25

WG

Connection tableTerminalKey position

Emergency relay (EG-20)

123

0ONHEATSTART

OFF30 AC 19 50

ACEGO NB50

LLSWSOS

1.25

WR

1.25

L

Glow relay Solenoid relay

1.25BR1.25WB

1.25

L1.

25W

1.25

B1.

25W

R1.

25G

1.25

WG

1.25

Y

1.25

GL

1.25

WR

1.25

L1.

25G

1.25

G

1.25B

GCharge

Cover open

YYB

Glow

WGWBBY

RBRL

BY

YYB

BRWB

Monitor lamp

Oil pressure

Water temp

L

RW

RS2SH

GL1 GL2PP RS1

Relay unit

1.25

GW

RG2

RST1

2G

RG1

LS1950

AC

1.25

GR

1.25

R2R

EGO

NBRS

T2L

1.25

WY

1.25

B1.

25G

1.25

B


CONTENTS

SERVICING

1. TROUBLESHOOTING ....................................................................................2-S1[1] EVIDENT PHYSICAL DEFECTS (OVERHEATING, NOISE,

VIBRATIONS ...) .......................................................................................2-S1[2] VOLTAGE FAULTS .................................................................................2-S2[3] ENGINE CIRCUIT TROUBLESHOOTING..............................................2-S4

2. SERVICING SPECIFICATIONS ....................................................................2-S63. TIGHTENING TORQUES ..............................................................................2-S8

[1] TIGHTENING TORQUES FOR SPECIAL USE SCREWS, BOLTSAND NUTS...............................................................................................2-S8

4. CHECKING, DISASSEMBLING AND SERVICING......................................2-S9[1] CHECKING AND ADJUSTING ...............................................................2-S9

(1) Initial Excitation Method ......................................................................2-S9(2) Control Panel ......................................................................................2-S9(3) Emergency Relay Activates ..............................................................2-S11

[2] DISASSEMBLING AND ASSEMBLING................................................2-S13(1) External Component .........................................................................2-S13(2) Generator..........................................................................................2-S13

[3] SERVICING ............................................................................................2-S16(1) Terminal Voltage for Each Part During Normal Periods (No-load

Periods).............................................................................................2-S16(2) Stator Coil .........................................................................................2-S16(3) Rotor Coil ..........................................................................................2-S17(4) Exciter Coil ........................................................................................2-S18


2-S1


1. TROUBLESHOOTINGNOTE

• In order to replace the parts in safety, remove negative terminal of battery so as to prevent the battery andthe parts from short-circuiting.

• To avoid errors on delivery of spare parts, all information marked on nameplates should be supplied onparts orders, in particular model and serial number of the alternator. Also give the parts numbers from theparts list.

[1] EVIDENT PHYSICAL DEFECTS (OVERHEATING, NOISE, VIBRATIONS...)

W1011938

Fault Action Origin of fault

A

Excessive overheating of bearing (temp. of bearing over 80 °C) (With or without abnormal bearing noise)

Replace bearing • If the bearing has turned blue or if the grease has turned black, change the bearing.

• Bearing race badly locked (moving in its housing).

• Bracket misalignment.

B

Excessive overheating of alternator frame (temperature 30 °C (86 °F) above ambient)

Check• Air inlets and outlets of

alternator• Measuring equipment

(voltmeter-Ammeter)• Ambient temperature

• Air flow (inlet-outlet) partially clogged or hot air is being recycled either from alternator or prime mover.

• Alternator overloaded.• Fan belt slips.

C

Excessive vibration and humming noise coming from the alternator

Stop the gen-set and check the installation and others

• Three phase alternator is single phase loaded in excess of acceptable level.

Start up with no-load: if humming persists …

• Short-circuit in the alternator stator.

D

Alternator damaged by a significant impact which is followed by humming and vibration

Stop the gen-set immediately

• Short-circuit in external circuit.• Break or deterioration in the coupling.• Break or twist in shaft extension.• Shifting or short-circuit of the main field

winding.• Bursting or unlocking of the fan.• Diode burnt, regulator, rectifier bridge

damaged.

E

Smoke, sparks, of flames issuing from the alternator

Stop the gen-set immediately

• Short-circuit in external circuit (including wiring between alternator and control board).

• Object fallen into the machine.• Short-circuit or flash in stator winding.


2-S2


[2] VOLTAGE FAULTS

W1012329

Defect Action Measure Origin of fault

F

No voltage at no load or start up

Disconnect lead wires F+ and F– from AVR.Connect a battery of 12 or 24 volts for two or three seconds to disconnected lead wires F+ and F– on the AVR

• The alternator builds up and voltage is correct after battery removal

• Lack of residual magnetism.• Check voltage between F– and F+ of

the AVR (correct value about 15 V).• V < 10 V exciter faulty.• Fault in rotating diodes.

• The alternator builds up but voltage does not reach nominal value after battery removal

• Check the connection of the auxiliary leads to the AVR.

• Readjust the voltage adjuster (VR) voltage.

• The alternator builds up but voltage collapses after battery removal

• AVR failure.

• The alternator builds up but no voltage and no frequency

• Check the connection of the sensing leads to the AVR (2 A Fuse).

• Exciter windings shorted or open circuit (check winding).

• Rotating diodes burnt (check diodes).• Main field winding open circuit (check

resistance).

G

Voltage too high

Adjust potentiometer voltage

• No adjustment of voltage, measure voltage between F+ and F– on AVR

• Defecting circuit (200 and E3) open.• AVR faulty.

H

Voltage oscillation

SetVR2Stab. ADJ

• If no result • Check speed for possible cycle irregularity.

• Check out put connections.• Faulty AVR.• Speed below nominal on load.• A rotating diode is open circuit.• Auxiliary winding is open circuit (check

resistance values).• Short-circuit on main field (check

resistance).• Exciter armature winding faulty (check

resistance).• Engine’s speed is not steady.

I

Voltage correct on no-load, too low on load

Run on no-load and check voltage between F+ and F–

• Voltage between F– and F+ is < 12 V (D.C.)

• Check speed.

• Voltage between F– and F+ is < 10 V (D.C.)

• Fault in rotating diodes.• Short-circuit in main field, check

resistance.• Exciter armature field faulty (check

values).


2-S3


W1012878

Defect Action Measure Origin of fault

J

Voltage collapses during normal operation

Check the regulator, the surge suppressor, the rotating diodes and replace any defective part

• The output voltage does not return the nominal value

• Exciter winding faulty (check values).• Main field faulty (check values).• Faulty exciter armature.


2-S4


[3] ENGINE CIRCUIT TROUBLESHOOTING Engine Circuit Troubleshooting Sequence Chart


2-S5



2-S6


2. SERVICING SPECIFICATIONSGENERATING UNIT (To be continued)

W1020122

ModelItem KJ-S130VX KJ-S170FX KJ-T130DX KJ-T180VX KJ-T230FX KJ-T300

Frequency (Hz) 50Generator Type PX-316 KU1 PX-319 KU1 PX-312 KU3 PX-316 KU3 PX-319 KU3 PX-322 KE3Voltage (V) 110 /

220120 / 240

110 / 220

120 / 240 220, 380, 415 380

Current (A)56.8 52.1 77.3 70.8

32.819.017.4

47.227.325.0

60.434.932.0

45.6

Exciter field (Ω) 31.2 34.7 41.1 45.8 48.3Exciter armature (Ω) 0.553 0.605 0.553 0.605 0.581Stator coil (U-V) (Ω)

0.170 0.140

(220 V)0.197

(380 V, 415 V)0.789

(220 V)0.132

(380 V, 415 V)0.529

(220 V)0.104

(380 V, 415 V)0.415

(380 V)0.324

Auxiliary winding (Ω) 1.33 1.25 1.36 1.16 1.08 0.97Rotor field coil (Ω) 2.9 3.51 2.54 2.90 3.51 3.64

Air gapmm (in.)

Main stator Side 1.4 (0.055)

Exciter side 0.8 (0.03)Bearing 6308ZZRegulated voltage value (%) ±3.5

Circuit breaker capacity (A)

60 100 75

(220 V)40

(380 V, 415 V)

20

(220 V)50

(380 V, 415 V)

30

(220 V)75

(380 V, 415 V)

40

50


2-S7


GENERATING UNIT (Continued)

W1017763

Model

Item

KJ-S130VX-

AUS

KJ-S170FX-

AUS

KJ-T130DX-

AUS

KJ-T180VX-

AUS

KJ-T230FX-

AUS

KJ-S240-AUS

KJ-T300-AUS

Frequency (Hz) 50Generator Type PX-316

KU1PX-319

KU1PX-312

KU3PX-316

KU3PX-319

KU3PX-322

KE1PX-322

KE3Voltage (V) 110 /

220120 / 240

110 / 220

120 / 240 220, 380, 415 240 240 / 415

Current (A)56.8 52.1 77.3 70.8

32.819.017.4

47.227.325.0

60.434.932.0

100.0 41.7

Exciter field (Ω) 31.2 34.7 41.1 45.8 36.1 48.3Exciter armature (Ω) 0.553 0.605 0.553 0.605 0.575 0.581Stator coil (U-V) (Ω)

0.170 0.140

(220 V)0.197

(380 V, 415 V)0.789

(220 V)0.132

(380 V, 415 V)0.529

(220 V)0.104

(380 V, 415 V)0.415

0.1155 0.324

Auxiliary winding (Ω) 1.33 1.25 1.36 1.16 1.08 1.11 0.97Rotor field coil (Ω) 2.9 3.51 2.54 2.90 3.51 3.64

Air gapmm (in.)

Main stator Side 1.4 (0.055)

Exciter side 0.8 (0.03)

Bearing 6308ZZRegulated voltage value (%) ±3.5

Circuit breaker capacity (A)

60 100 75

(220 V)40

(380 V, 415 V)

20

(220 V)50

(380 V, 415 V)

30

(220 V)75

(380 V, 415 V)

40

100 50


2-S8


3. TIGHTENING TORQUESScrews, bolts and nuts must be tightened to the specified torque using a torque wrench, several screws, bolts and

nuts such as those used on the cylinder head must be tightened in proper sequence and at the proper torque.

[1] TIGHTENING TORQUES FOR SPECIAL USE SCREWS, BOLTS ANDNUTS

NOTE• In removing and applying the screws, bolts and nuts marked with "*", pneumatic wrench or similar

pneumatic tool, if employed, must be used with enough care not to get them seized.• For "*" marked screws, bolts and nuts on the table, apply engine oil to their threads and seats before

tightening.

W1091652

Section Item Size x Pitch N·m kgf·m lbf·ftGenerator Rotor mounting screw M8 18 to 21 1.8 to 2.2 13 to 15

Stator mounting screw – 20 to 27 2.0 to 2.8 15 to 20End bracket mounting screw M10 20 to 27 2.0 to 2.8 15 to 20Adapter mounting screw M10 36 to 43 3.6 to 4.4 26 to 31


2-S9


4. CHECKING, DISASSEMBLING AND SERVICING[1] CHECKING AND ADJUSTING(1) Initial Excitation Method

Flashing the FieldThe alternator is self exciting from the residual magnetism of the

magnetic circuit of the exciter. When first tested (at the factory) thismagnetic circuit is magnetized but after a breakdown it may benecessary to remagnetize.

IMPORTANT• If the connection has the wrong polarity or different position

(such as F+ and F- side) magnetization is reversely reduced.W1071816

(2) Control PanelCircuit Breaker (CB)1. Test for continuity between the each upper and lower breaker

terminals with an ohmmeter.2. Confirm that there is continuity when the breaker switch in “ON”.3. If there is no continuity, it indicates that the contacts are faulty.

Replace the breaker.NOTE

• When there is a short-circuit in the wiring, the circuit breakertrips off. If this happens, eliminate the cause, then reset thecircuit breaker. If the circuit breaker holds, test the load forfaults.* In the switchable type, a sub-breaker turns OFF first andmain breaker doesn’t.

• When there is an over-current, the thermal relay operates theshunt trip on the main circuit breaker. If this happens,remove the load then turn the circuit breaker ON again(Reset the breaker.).* The thermal relay does not work if the battery voltage fallsbelow 70 to 80 % prescribed level. Be aware of good batterycare.

W1019844

AC Ammeter1. Test for continuity between the ammeter terminals with an

ohmmeter.2. Replace the ammeter if there is no continuity.

W1072360


2-S10


Voltage Adjuster (Potentiometer)1. Measure the resistance of the 1-2 connection with an ohmmeter.2. Place an ohmmeter on the 1-3 connection and check the

variation in resistance while turning the knob.3. If the factory specification is not indicated, replace the adjuster.

W1072462

Current Transformer CT1 and CT2 (CT for Ammeter)1. Disconnect the lead wires from one side of the transformer.2. Test for continuity between the transformer terminals with an

ohmmeter.3. Replace the transformer if there is no continuity.

W1072713

Lamp Timer (for Glow Plug)1. Remove the lamp timer (1) from inside of the panel.2. Connect the battery (4), lamp timer (1) and bulb (2) as shown in

the figure3. The bulb (2) light up when contacting the lead wire 1 (3) with

positive terminal of the battery (4) and goes off approximately 6seconds late, the lamp relay is proper.

W1121405

Resistance Factory spec.

1-2 0 Ω

1-3 Vary smoothly from 0 to 1 kΩ

(1) Potentiometer (2) Hole

(1) Lamp Timer(2) Bulb

(3) Lead Wire 1(4) Battery (12 V)


2-S11


(3) Emergency Relay ActivatesNOTE

• When emergency relay activates and engine has stopped, check the cause and repair it.Stop Solenoid Circuit1. Disconnect the stop solenoid connector (1). Connect the

voltmeter (+) side to the connector (2) opposite to the stopsolenoid, and the voltmeter (−) side to an unpainted portion of theengine frame (Ground). The voltmeter’s range mustaccommodate DC 50 V. Turn the key switch to “ON”, and thento “OFF” in this situation.

2. Normally, the battery voltage will appear (DC 12 V) when the keyswitch is “ON” and after 10 ±3 sec., it will go to 0 V.

W1121855

Emergency Relay Circuit1. When the engine is running at rated rpm’s connect the lead wires

to the terminal of the oil switch (1) or the water temperaturesensor.

2. Also ground the other end of the lead wires to an unpaintedportion of the engine frame.

(In normal operation)• The stop solenoid activates and the engine stops automatically.• As the stop solenoid is activated again after 10 ± 3 seconds of its

first engagement, a ‘tick’ sound can be heard.

W1072817

Oil Switch1. The oil switch (1) has continuity when the engine is stopped and

has no continuity while the engine is running.2. Replace the oil switch (1) if it is defective.

W1074063

Water Temperature Sensor1. Insert the water temperature sensor (1) in the engine oil, and

continue the circuit when the oil temperature rises to 112 to 118°C (234 to 244 °F).

2. Check that the resistance is 0 ohm in case water temperaturesensor is defective.

IMPORTANT• Be careful when handling the water temperature sensor so

that you do not drop it.• When assembling the sensor, apply sealing agent to the

threads, and then screw it in firmly.• Make a test run after installation, to check for any water

leaks.

W1074271

(1) Stop Solenoid Connector (2) Connector

(1) Oil Switch

Resistance (Switch terminal -Chassis)

In normal state Infinity

At pressure over approx. 98 kPa (1.0 kgf/cm2, 14 psi)

0 Ω

(1) Oil Switch

Water temperature sensor Factory spec.

Water temperature above than 112 to 118 °C (234 to 244 °F). Contact ON.

(1) Water Temperature Sensor


2-S12


Engine Stop Solenoid Test1. Disconnect the 1P connector from the engine stop solenoid.2. Remove the engine stop solenoid from the engine.3. Connect the jumper leads from the battery positive terminal (2) to

the 1P connector, and from the battery negative terminal (1) tothe engine stop solenoid body.

4. If the solenoid plunger is not attracted, the engine stop solenoidis faulty.

W1075754

(1) Negative Terminal (2) Positive Terminal


2-S13


[2] DISASSEMBLING AND ASSEMBLING(1) External Component

NOTE• The below procedure is given for model KJ-T160DX. Procedure will vary according to model.

Cover, Panel, Control Panel and Bonnet1. Place the generator unit on firm and level surface.2. Remove the inspection cover 2 (4), 1 (5), and open the drain cock

to drain coolant.3. Remove the drain plug and drain engine oil. 4. Disconnect the battery negative cable.5. Close the fuel cock and disconnect the fuel hose from the fuel

filter.6. Disconnect the fuel return hose from the injection nozzle.7. Remove the air cleaner (11).8. Remove the rear inspection cover.9. Disconnect the battery positive cable.10.Remove the battery inspection cover and remove the battery

(10).11.Remove the inspection cover for AVR and disconnect the output

cable (u.v.w) and AVR controlled wirings at the each terminal.12.Disconnect the wiring connectors between the control panel (7)

and generator unit.13.Remove the control panel (7).14.Remove the each side cover.15.Remove the exhaust muffler cap (3).16.Remove the bonnet cover (2).17.Remove the control panel bracket.18.Remove the radiator (8) with bracket.

W1068967

(2) GeneratorEnd Bracket1. Loosen the mounting screws for the frame and the end bracket

evenly.2. Hook the gear puller until it clicks onto the rear cover’s

outerfearence, and then pull off the cover.(When reassembling)• Check the rubber O-ring and spring washer are in place.• Clean dirt from the bearing housing when assembling.

Also apply oil to the outer surfaces of the bearing housing.• Keeping the bracket level with the bearing’s outer race, press the

bearing and bearing housing together (perform by hand).Check the bearing has fit inside the housing, then while holdingthe housing still, tap the bearing into place with a wooden mallet.

W1069197

(1) Handling Hook(2) Bonnet Cover(3) Muffler and Cap(4) Inspection Cover 2(5) Inspection Cover 1(6) Front Cover

(7) Control Panel(8) Radiator(9) Fuel Tank

(10) Battery(11) Air Cleaner(12) Side Panel

Tightening torque End bracket mounting screw



2-S14


Checking Ball Bearing1. Measure axial dislocation of the outer ring.2. If the axial dislocation exceeds the allowable limit, replace the

bearing.

3. Measure the I.D.of the bearing housing.4. If the wear exceeds the allowable limit, replace the end bracket.

W1116881

Stator Assembly1. Remove the spread-proof rubber (1) mounting nut.2. Hoist up the engine and the generator, keeping them level (above

than spread-proof rubber).3. Set a base (2) under the engine (not under the oil pan).4. When removing the engine, support it on a base or stands.5. Remove the bracket and stator mounting screws.6. Remove the bracket, then stator and check for any damage to the

winding.(When reassembling)• Handle the generator so as not to damage the winding.

Also be careful when putting it down.• Clean all fitting parts of the engine and frame when assembling.

W1069357

Axial dislocation Allowable limit 0.05 mm0.002 in.

Bearing housing I.D. Allowable limit 90.02 mm

3.544 in.

Tightening torque Stator mounting screw20 to 24 N·m2.0 to 2.5 kgf·m15 to 18 lbf·ft

(1) Spread-proof Rubber (2) Base


2-S15


Rotor Assembly1. To avoid damage to the rotor, suspend the rotor with a sling

enough to keep it from lifting, and leave it suspended.2. Remove the rotor mounting screws (6).3. Remove the rotor assembly (1), take care not to damage the

winding.(When reassembling)• Clean any oil and dirt from the mounting surfaces of the rotor and

flywheel. If this is not done correctly, it will result in damage ofrotor and stator caused by loose fittings.

• Handle carefully to avoid damaging the winding.

W1069561

Tightening torque

Rotor mounting screw18 to 21 N·m1.8 to 2.2 kgf·m13 to 15 lbf·ft

Adapter mounting screw36 to 43 N·m3.6 to 4.4 kgf·m26 to 31 lbf·ft

(1) Rotor Assembly(2) Flywheel(3) Flywheel Housing

(4) Adaptor(5) Adapter Mounting Screw(6) Rotor Mounting Screw


2-S16


[3] SERVICINGIMPORTANT

• The resistance described hereafter are the value based on corresponded to the temperature of 20 °C (68°F).The resistance measured outside t1 °C can be converted into that at 20 °C (68 °F) with the following formula: R = {(273 + 20) / (273 + t1)}x R1

Where t1 is the temperature when the resistance is measured and R1 is the resistance measured at t1.Example : If the resistance measured at a temperature of 30 °C (86 °F) is 10 Ω.t1 = 30 °C R1 = 10 Ω R = {(273 + 20) / (273 + 30)} x 10 = 9.67 Ω

*The resistance should be 9.67 Ω at a temperature of 20 °C (68 °F)

(1) Terminal Voltage for Each Part During Normal Periods (No-load Periods)Output Terminal1. With the NFB in the “ON” position, measure the voltage in each

phase and each line.2. If the factory specification is not indicated, inspect the output

circuit or the wiring harness. (Refer to wiring diagram.)

W1070126

(2) Stator CoilMain Armature Winding1. Test for continuity between coil leads with a mΩ meter. Many

kind of wiring have been arranged in the stator depending on thevoltage variation.

2. If the resistance is not as specified, replace the stator coil orcontact service station.

* Measurement is not possible with a regular tester.W1070258

Auxiliary Winding1. Measure the coil resistance between each auxiliary winding 3-4.2. If the factory specification is not indicated, replace the stator coil

or contact service station.

W1070378

Output voltage Factory spec. Rated voltage 5 %

Resistance Factory spec. Refer to “SERVICING, SPECIFICATIONS”

Resistance Factory spec. Refer to “SERVICING, SPECIFICATIONS”


2-S17


Grounding of Stator Coil1. Measure the insulation resistance between each stator winding

and lamination with a MΩ meter.2. Reading should be more than 1 MΩ at 500 V.3. If continuous, replace the stator coil or contact service station.

W1070462

(3) Rotor CoilThere are two kinds of winding in the rotor assembly, the one is rotor field coil and the other is exciter armature coil.

Main Field Winding and Exciter Armature Winding1. Remove the field coil end at the diode stack board.2. Measure the coil resistance between each end of field coil.3. If the resistance is not as specified, replace the rotor assembly or

contact service station.

W1070562

Grounding of Rotor Coil1. Connect leads of a megaohmmeter between each lead (1) and

exciter rotor laminations (2).2. Reading should be more than 1 MΩ at 500 V.3. If continuous, replace the rotor assembly or contact service

station.

W1070811

Silicon Diodes Stack and Surge-absorber1. Disconnect the exciter armature coil at the connection terminal

on diode board.2. Loosen the two mounting bolts for the diode stack and remove it.3. Check the polarity of diode stack leads carefully. It is a good idea

to tag them (+, -, ~) during disassembly.4. A diode in a good condition enables the current to flow in only one

direction from anode to cathode.W1070905

Resistance Factory spec.

Rotor field coil

Refer to “SERVICING SPECIFICATIONS”Exciter

armature coil

(1) Rotor Field Coil (2) Exciter Armature Coil

(1) Lead (2) Lamination


2-S18


(4) Exciter CoilExciter Field Winding1. Measure the coil resistance between each lead with a miliohm

meter.2. If the resistance is not as specified, replace the exciter coil

assembly or contact service station.

W1071549

Grounding of Exciter Field Coil1. Measure the insulation resistance between each lead and the

laminations with a megaohmmeter.2. A reading should be more than 1 MΩ at 500 V.3. If continuous, replace the exciter coil assembly or contact service

station.W1071657

Resistance Factory spec. F– - F+ Refer to “SERVICING

SPECIFICATIONS”


Editor : Farm and Industrial Machinery International Service DepartmentAddress : 64, Ishizu-Kitamachi, Sakai-Ku, Sakai-City, Osaka, 590-0823, JapanPhone : +81-72-241-1129Fax : +81-72-245-2484E-mail : [email protected]

KUBOTA CorporationPrinted in Japan 2009. 09, S, EI, EI, engusa

1999. 08, S, EI, EI, engusa Code No.9Y011-01832

KJ-X 50 HERTZ SERIES (engusa)-9Y011-01832 · 2019. 12. 15. · Total displacement 2197 cm3 (134.1...

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Transcript of KJ-X 50 HERTZ SERIES (engusa)-9Y011-01832 · 2019. 12. 15. · Total displacement 2197 cm3 (134.1...