wsm V3307-DI-T-E2B Workshop Manual

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Page 1

WORKSHOP MANUAL

KiSC issued 01, 2009 A

DIESEL ENGINE

V3307-DI-T-E2B

Page 2

TO THE READER

KiSC issued 01, 2009 A

This Workshop Manual has been prepared to provide servicing personnel with information on the mechanism, service and maintenance of V3307-DI-T-E2B. It is divided into three parts, “General”, “Mechanism” and “Servicing”.

Q General

Information on the engine identification, the general precautions, maintenance check list, check and maintenance and special tools are described.

Q Mechanism

Information on the construction and function are included. This part should be understood before proceeding with troubleshooting, disassembling and servicing.

Refer to Diesel Engine Mechanism Workshop Manual (Code No. 9Y021-01876) for the one which has not been described to this workshop manual.

Q Servicing

Information on the troubleshooting, servicing specification lists, tightening torque, checking and adjusting, disassembling and assembling, and servicing which cover procedures, precautions, factory specifications and allowable limits.

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

The right is reserved to make changes in all information at any time without notice.

Due to covering many models of this manual, information or picture being used, have not been specified as one model.

December 2008

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V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

SAFETY INSTRUCTIONS

SAFETY FIRST

This 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 in

death or serious injury.

WARNING : Indicates a potentially hazardous situation which, if not avoided, could result in

death or serious injury.

CAUTION : Indicates a potentially hazardous situation which, if not avoided, may result in

minor or moderate injury.

Q IMPORTANT : Indicates that equipment or property damage could result if instructions are not

followed.

Q NOTE : Gives helpful information.

BEFORE SERVICING AND REPAIRING

• Read all instructions and safety instructions in this manual and on your engine safety decals.

• Clean the work area and engine.

• Park the machine 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 in operator station.

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V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

SAFETY INSTRUCTIONS

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 while fatigued.

• Wear close fitting clothing and safety equipment appropriate 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 more persons, take care to perform all work safely.

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

• Never remove the radiator cap while the engine is running, or immediately after stopping. Otherwise, hot water will spout out from radiator. Only remove radiator cap when cool enough to touch with bare hands. Slowly loosen the cap to first stop to relieve pressure before removing completely.

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

• Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.

• Do not open high-pressure fuel system. High-pressure fluid remaining in fuel lines can cause serious injury. Do not disconnect or attempt to repair fuel lines, sensors, or any other components between the high-pressure fuel pump and injectors on engines with high pressure common rail fuel system.

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

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V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

SAFETY INSTRUCTIONS

AVOID FIRES

• Fuel is extremely flammable and explosive under certain conditions. Do not smoke or allow flames or sparks in your working area.

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

• Battery gas can explode. Keep sparks and open flame away from the top of battery, especially when charging 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 engine in a closed area. The exhaust gas contains poisonous carbon monoxide.

PREVENT ACID BURNS

• Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, clothing and cause blindness if splashed into eyes. Keep electrolyte away from eyes, hands and clothing. If you spill electrolyte on yourself, flush with water, and get medical attention immediately.

DISPOSE OF FLUIDS PROPERLY

• Do not pour fluids into the ground, down a drain, or into a stream, pond, or lake. Observe relevant environmental protection regulations when disposing of oil, fuel, coolant, electrolyte and other harmful waste.

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V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

SAFETY INSTRUCTIONS

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 your telephone.

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V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

SPECIFICATIONS

Model V3307-DI-T-E2B

Number of Cylinder 4

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

Bore × Stroke 94.0 × 120 mm (3.70 × 4.72 in.)

Total Displacement 3331 cm

ISO Net Continuous

ISO / SAE Net Intermittent

SAE Gross Intermittent

47.1 kW / 2600 min

(63.2 HP / 2600 min

53.7 kW / 2600 min

(72.0 HP / 2600 min

55.4 kW / 2600 min

(74.3 HP / 2600 min

Maximum Bare Speed 2820 min

Minimum Bare Idling Speed 775 to 825 min

Combustion Chamber Reentrant Type, Center Direct Injection Type (E-CDIS)

Fuel Injection Pump Bosch PFR4KZ Type Mini Pump

Governor All speed mechanical governor

Direction of Rotation Counter-clockwise (Viewed from flywheel side)

Injection Nozzle Bosch P Type

Injection Timing 0.0087 rad (0.50 °) after T.D.C.

Firing Order 1-3-4-2

Injection Pressure

1st stage 18.63 MPa (190.0 kgf/cm

2nd stage 22.56 MPa (230.0 kgf/cm

Compression Ratio 20.0

Lubricating System Forced lubrication by trochoid pump

Oil Pressure Indicating Electrical Type Switch

Lubricating Filter Full Flow Paper Filter (Cartridge Type)

Cooling System Pressurized radiator, forced circulation with water pump

Starting System Electric Starting with Starter

Starting Motor 12 V, 3.0 kW

Starting Support Device By Glow Plug in Combustion Chamber

EGR None

Battery 12 V, 120 AH equivalent

Charging Alternator 12 V, 540 W

Recommended fuels vary depending on the contents of the emission control regulations, the ambient

Fuel

Lubricating Oil

temperature, and the fuel specifications. Therefore, please refer to the detailed description on page

Class CF lubricating oil as per API classification is recommended.

For details on recommended lubricating oils, see page G-6 and page G-9.

Lubricating Oil Capacity 11.2 L (2.96 U.S.gals)

Weight (Dry) 271 kg (597 lbs)

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

(203.3 cu.in.)

-1

(rpm)

-1

(rpm)

G-6.

(rpm) (rpm))

, 2702 psi),

, 3271 psi),

SPECIFICATIONS

W1028103

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V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

PERFORMANCE CURVES

Q V3307-DI-T-E2B

PERFORMANCE CURVES

(1) Brake Horsepower (2) Engine Speed

(3) B.S.F.C. (4) Torque

(5) Gross Intermittent Torque (6) Gross Intermittent B.H.P.

(7) Gross Intermittent B.S.F.C.

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V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

DIMENSIONS

Q V3307-DI-T-E2B

DIMENSIONS

Page 10

GENERAL

KiSC issued 01, 2009 A

CONTENTS

1. ENGINE IDENTIFICATION ............................................................................. G-1

[1] MODEL NAME AND ENGINE SERIAL NUMBER ................................ G-1

[2] E2B ENGINE............................................................................................. G-3

[3] CYLINDER NUMBER ............................................................................... G-3

2. GENERAL PRECAUTIONS ............................................................................ G-4

3. MAINTENANCE CHECK LIST ....................................................................... G-5

4. CHECK AND MAINTENANCE ....................................................................... G-7

[1] DAILY CHECK POINTS........................................................................... G-7

[2] CHECK POINTS OF INITIAL 50 HOURS ............................................. G-9

[3] CHECK POINT OF EVERY 50 HOURS ............................................. G-11

[4] CHECK POINTS OF EVERY 250 HOURS......................................... G-12

[5] CHECK POINTS OF EVERY 500 HOURS......................................... G-14

[6] CHECK POINT OF EVERY 1000 HOURS ......................................... G-17

[7] CHECK POINTS OF EVERY 1 OR 2 MONTHS ............................... G-18

[8] CHECK POINTS OF EVERY 1500 HOURS....................................... G-20

[9] CHECK POINTS OF EVERY 3000 HOURS....................................... G-21

[10]CHECK POINTS OF EVERY 1 YEAR ................................................ G-24

[11]CHECK POINTS OF EVERY 2 YEARS.............................................. G-25

5. SPECIAL TOOLS.......................................................................................... G-28

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V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

1. ENGINE IDENTIFICATION

[1] MODEL NAME AND ENGINE SERIAL NUMBER

When contacting the manufacture, always specify your engine

model name and serial number.

The engine model and its serial number need to be identified

before the engine can be serviced or parts replaced.

Q Engine Serial Number

The 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

Alphabet or

Number

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

Year

Alphabet or

Number

G GENERAL

Yea r

(1) Engine Model Name and Serial

Number

W1010477

G-1

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V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

G GENERAL

• Month of manufacture

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

* Alphabetical letters “I” and “O” are not used. e.g. V3307-T

- 7 V A001

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

(a) Engine Model Name : V3307-DI-T (b) Year : 7 indicates 2007 (c) Month : U or V indicates October (d) Lot number : (0001 ~ 9999 or A001 ~ Z999)

W1024938

G-2

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V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

G GENERAL

[2] E2B ENGINE

[Example : Engine Model Name V3307-DI-T-E2B-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 according to 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 as a new model name for the engines conforming Tier 2 / Phase 2 regulations.

In the after-sale services for 07-E2B series engines, only use the dedicated parts for E2B models and carry out the maintenance services accordingly.

[3] CYLINDER NUMBER

The 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 front cover side.

W1011077

G-3

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V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

2. GENERAL PRECAUTIONS

• During disassembly, carefully arrange removed parts in a clean area to prevent confusion later. Screws, bolts and nuts should be replaced in their original position to prevent reassembly errors.

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

• Before disassembling or servicing live wires, make sure to always 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 which force is applied.

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

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

Direction of Force

G GENERAL

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

W1011734

G-4

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V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

G GENERAL

3. MAINTENANCE CHECK LIST

To maintain long-lasting and safe engine performance, make it a rule to carry out regular inspections by following

the table below.

Service Interval

1500

hrs

Every

3000

hrs

Every

1 year

Every 250 hrs

Every

Item

Changing engine oil ,, ,

Replacing oil filter cartridge ,,

*Checking fuel hoses and clamp bands ,

*Cleaning air cleaner element (Replace the element after 6 times cleanings)

Cleaning fuel filter (Element type) ,

Checking battery electrolyte level ,

Checking radiator hoses and clamp bands ,

*Checking intake air line ,

Checking fan belt tension and damage ,,

*Replacing fuel filter cartridge ,

Replacing fan belt ,

Cleaning radiator interior ,

Checking valve clearance ,

Recharging battery ,

*Checking injection nozzle condition (spraying, pressure and valve seat tightness)

*Checking turbocharger ,

*Checking fuel injection pump ,

*Checking injection timing (spill timing) ,

*Replacing air cleaner element ,

Changing radiator coolant (L.L.C.) ,

Replacing radiator hoses and clamp bands ,

*Replacing fuel hoses and clamp bands ,

*Replacing intake air line ,

Replacing battery ,

Initial

50 hrs

Every 50 hrs

Every

500 hrs

Every

1000

hrs

Every 1

or 2

months

• When the battery is used for less than 100 hours in a year, check its electrolyte yearly. (for refillable battery’s only)

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

Every

years

W1029462

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

Q NOTE Changing interval of engine oil :

API service classification : above CD grade Ambient temperature : below 35 °C (95 °F)

CAUTION

Model Interval

V3307-DI-T-E2B 500 Hrs or 1 year whichever comes first

Initial 50 Hrs

G-5

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V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

G GENERAL

Q NOTE Engine Oil :

• Refer to the following table for the suitable American Petroleum Institute (API) classification of engine oil according to the engine type (with internal EGR, external EGR or non-EGR) and the Fuel Type Used : (Low Sulfur, Ultra Low Sulfur or High Sulfur Fuels).

Engine oil classification (API classification)

Fuel Type

High Sulfur Fuel [0.05 % (500 ppm) ≤ Sulfur Content <

0.50 % (5000 ppm)]

Engines with non-EGR Engines with internal EGR

(If the "CF-4, CG-4, CH-4, or CI-4" engine oil is used with a high-sulfur fuel, change the engine oil at shorter intervals. (approximately half))

Engines with external EGR

–

Low Sulfur Fuel [Sulfur Content <

0.05 % (500 ppm)] or Ultra Low Sulfur Fuel [Sulfur Content <

CF, CF-4, CG-4, CH-4 or CI-4

CF or CI-4

(Class CF-4, CG-4 and CH-4 engine oils cannot be used on EGR type engines.)

0.0015 % (15 ppm)]

EGR : Exhaust Gas Re-circulation

W1024941

• CJ-4 classification oil is intended for use in engines equipped with DPF (Diesel Particulate Filter) and is

Not Recommended for use in Kubota E2 specification engines.

• Oil used in the engine should have API classification and Proper SAE Engine Oil Viscosity according to the ambient temperatures where the engine is operated.

• With strict emission control regulations now in effect, the CF-4 and CG-4 engine oils have been developed for use with low sulfur fuels, for On-Highway vehicle engines. When a Non-Road engine runs on high sulfur fuel, it is advisable to use a "CF or better" classification engine oil with a high Total Base Number (a minimum TBN of 10 is recommended).

Fuel :

• Cetane Rating : The minimum recommended Fuel Cetane Rating is 45. A cetane rating greater than 50 is preferred, especially for ambient temperatures below −20 °C (−4 °F) or elevations above 1500 m (5000 ft).

• Diesel Fuel Specification Type and Sulfur Content % (ppm) used, must be compliant with all applicable emission regulations for the area in which the engine is operated.

• Use of diesel fuel with sulfur content less than 0.10 % (1000 ppm) is strongly recommended.

• If high-sulfur fuel (sulfur content 0.50 % (5000 ppm) to 1.0 % (10000 ppm)) is used as a diesel fuel, change

the engine oil and oil filter at shorter intervals. (approximately half)

• DO NOT USE Fuels that have sulfur content greater than 1.0 % (10000 ppm).

• Diesel fuels specified to EN 590 or ASTM D975 are recommended.

• No.2-D is a distillate fuel of lower volatility for engines in industrial and heavy mobile service. (SAE J313 JUN87)

• Since KUBOTA diesel engines of less than 56 kW (75 hp) utilize EPA Tier 4 and Interim Tier 4 standards, the use of low sulfur fuel or ultra low sulfur fuel is mandatory for these engines, when operated in US EPA regulated areas. Therefore, please use No.2-D S500 or S15 diesel fuel as an alternative to No.2-D, and use No.1-D S500 or S15 diesel fuel as an alternative to No.1-D for ambient temperatures below −10 °C (14 °F).

1) SAE : Society of Automotive Engineers

2) EN : European Norm

3) ASTM : American Society of Testing and Materials

4) US EPA : United States Environmental Protection Agency

5) No.1-D or No.2-D, S500 : Low Sulfur Diesel (LSD) less than 500 ppm or 0.05 wt.%

No.1-D or No.2-D, S15 : Ultra Low Sulfur Diesel (ULSD) 15 ppm or 0.0015 wt.%

G-6

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V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

4. CHECK AND MAINTENANCE

[1] DAILY CHECK POINTS

Checking Engine Oil Level

1. 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.

IMPORTANTQ

• When using an oil of different maker or viscosity from the previous one, drain old oil. Never mix two different types of oil.

NOTEQ

• Be sure to inspect the engine, locating it on a horizontal place. If placed on gradients, accurately, oil quantity may not be measured.

• Be sure to keep the oil level between upper and lower lines of the dipstick (1). Too much oil may cause a drop in output or excessive blow-by gas. On the closed breather type engine in which mist is sucked through port, too much oil may caused oil hammer. While too little oil, may seize the engine’s rotating and sliding parts.

(1) Dipstick (2) Oil Filler Plug

G GENERAL

(a) Upper Line (b) Lower Line

W1035676

G-7

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V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

G GENERAL

Checking and Replenish Coolant

1. Without recovery tank (2) : Remove the radiator cap (1) and check to see that the coolant level is just below the port. With recovery tank (2) : Check to see that the coolant level lies between FULL (A) and LOW (B).

2. If coolant level is too low, check the reason for decreasing coolant. (Case 1) If coolant is decreasing by evaporation, replenish only fresh, soft water. (Case 2) If coolant is decreasing by leak, replenish coolant of the same manufacture and type in the specified mixture ratio (fresh, soft water and L.L.C.). If the coolant brand cannot be identified, drain out all of the remaining coolant and refill with a totally new brand of coolant mix.

CAUTION

• Do not remove the radiator cap (1) until coolant temperature is below its boiling point. Then loosen the cap slightly to relieve any excess pressure before removing the cap completely.

IMPORTANTQ

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

• Be sure to close the radiator cap (1) securely. If the cap is loose or improperly closed, coolant may leak out and the engine could overheat.

• Do not use an antifreeze and scale inhibitor at the same time.

• Never mix the different type or brand of L.L.C..

(1) Radiator Cap (2) Recovery Tank

A : FULL B : LOW

W1035779

G-8

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V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

[2] CHECK POINTS OF INITIAL 50 HOURS

Changing 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).

IMPORTANTQ

• 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 (See page G-6).

• Use the proper SAE Engine Oil according to ambient temperature.

Above 25 °C (77 °F)

0 °C to 25 °C (32 °F to 77 °F)

Below 0 °C (32 °F)

G GENERAL

SAE 30 or SAE 10W-30 SAE 15W-40

SAE 20 or SAE 10W-30 SAE 15W-40

SAE 10W or SAE 10W-30 SAE 15W-40

Engine oil capacity

Tightening torque Drain plug

(1) Drain Plug (2) Dipstick (3) Oil Filler Plug

11.2 L

2.96 U.S.gals

45 to 53 N·m

4.5 to 5.5 kgf·m 33 to 39 lbf·ft

(a) Upper Line (b) Lower Line

W1016604

Replacing Oil Filter Cartridge

CAUTION

• Be sure to stop the engine before changing 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 not leak through the seal and be sure to read the oil level on the dipstick. Then, replenish the engine oil up to the specified level.

IMPORTANTQ

• To prevent serious damage to the engine, replacement element must be highly efficient. Use only a KUBOTA genuine filter or its equivalent.

(1) Engine Oil Filter Cartridge

W1017137

G-9

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V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

G GENERAL

Checking Fan Belt Tension

1. Measure the deflection (A), depressing the fan belt (2) 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, loosen the alternator mounting screws (1) and relocate the alternator to adjust.

Deflection (A) Factory spec.

10.0 to 12.0 mm

0.394 to 0.472 in.

(1) Alternator Mounting Screw (2) Fan Belt

(A) Deflection

W1208957

Checking Fan Belt Damage and Wear

1. 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.

(A) Good (B) Bad

W1033474

G-10

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V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

[3] CHECK POINT OF EVERY 50 HOURS

Checking Fuel Hoses and Clamp Bands

1. If the clamp band (2) is loose, apply oil to the threads and securely retighten it.

2. The fuel hose (1) is made of rubber and ages regardless of the period service. Change the fuel pipe together with the clamp band (2) every two years.

3. However, if the fuel hose (1) and clamp bands (2) are found to be damaged or deteriorate earlier than two years, then change or remedy.

4. After the fuel hose (1) and the clamp bands (2) have been changed, bleed the fuel system.

CAUTION

• Stop the engine when attempting the check and change prescribed above.

(When bleeding fuel system)

1. Fill the tank with fuel and open the cock.

2. Loosen the air vent coupling bolt of fuel filter a few turns.

3. When there is no more air bubbles in the fuel coming out of this coupling bolt, tighten the coupling bolt.

4. Open the air vent cock (3) on the top of fuel injection pump.

5. If equipped electrical fuel feed pump, turn the key on AC position and pump the fuel up for 10 to 15 seconds. If equipped mechanical fuel feed pump, set the stop lever on stop position and crank the engine for 10 to 15 seconds.

6. Close securely the air vent cock (3) after air bleeding.

IMPORTANTQ

• Except when venting the air, be sure to keep closed the air vent coupling bolt of the fuel injection pump. Otherwise, the engine may stall.

(1) Fuel Hose (2) Clamp Band

G GENERAL

(3) Air Vent Cock

W1035921

G-11

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V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

[4] CHECK POINTS OF EVERY 250 HOURS

Checking Fan Belt Tension

1. Measure the deflection (A), depressing the fan belt (2) 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, loosen the alternator mounting screws (1) and relocate the alternator to adjust.

Deflection (A) Factory spec.

G GENERAL

10.0 to 12.0 mm

0.394 to 0.472 in.

(1) Alternator Mounting Screw (2) Fan Belt

(A) Deflection

W1014131

Checking Fan Belt Damage and Wear

1. 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.

(A) Good (B) Bad

W1209480

Cleaning Air Cleaner Element

1. 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/cm 30 psi). Maintain reasonable distance between the nozzle and the filter.

NOTEQ

• 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

G-12

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V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

G GENERAL

Cleaning Fuel Filter (Element Type only)

1. Close the fuel cock (3).

2. Unscrew the retaining ring (6) and remove the filter cup (5), and rinse the inside with kerosene.

3. Take out the element (4) and dip it in the kerosene to rinse.

4. After cleaning, reassemble the fuel filter, keeping out dust and dirt.

5. Bleed the fuel system.

IMPORTANTQ

• If dust and dirt enter the fuel, the fuel injection pump and injection nozzle will wear quickly. To prevent this, be sure to clean the filter cup (5) periodically.

(1) Cock Body (2) Air Vent Plug (3) Fuel Cock

(4) Filter Element (5) Filter Cup (6) Retaining Ring

W1046058

Checking Radiator Hoses and Clamp Bands

1. 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 band is loose, apply oil to the threads and retighten it securely.

3. The water hose is made of rubber and tends to age. It must be replaced every two years. Also replace the clamp band and tighten it securely.

(1) Upper Hose (2) Lower Hose

W1029518

Checking Battery Electrolyte Level (for Refillable Battery’s only)

1. 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.

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

W1047154

Checking Intake Air Line

1. Check to see if the intake air hose (1) is properly fixed every 250 hours of operation.

2. If the clamp bands (2) are loose, apply oil to the threads and retighten them securely.

3. The intake air hose (1) is made of rubber and tends to age. It must be change every two years. Also change the clamp bands (2) and tighten them securely.

IMPORTANTQ

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

(1) Intake Air Hose (2) Clamp Band

W1029631

G-13

Page 24

V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

[5] CHECK POINTS OF EVERY 500 HOURS

Changing 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).

IMPORTANTQ

• 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 (See page G-6).

• Use the proper SAE Engine Oil according to ambient temperature.

Above 25 °C (77 °F)

0 °C to 25 °C (32 °F to 77 °F)

Below 0 °C (32 °F)

G GENERAL

SAE 30 or SAE 10W-30 SAE 15W-40

SAE 20 or SAE 10W-30 SAE 15W-40

SAE 10W or SAE 10W-30 SAE 15W-40

Engine oil capacity

Tightening torque Drain plug

(1) Drain Plug (2) Dipstick (3) Oil Filler Plug

11.2 L

2.96 U.S.gals

45 to 53 N·m

4.5 to 5.5 kgf·m 33 to 39 lbf·ft

(a) Upper Line (b) Lower Line

W1014590

Replacing Oil Filter Cartridge

CAUTION

• Be sure to stop the engine before changing 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.

IMPORTANTQ

• To prevent serious damage to the engine, replacement element must be highly efficient. Use only a KUBOTA genuine filter or its equivalent.

(1) Engine Oil Filter Cartridge

W1015117

G-14

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KiSC issued 01, 2009 A

G GENERAL

Replacing Fuel Filter Cartridge (Cartridge Type)

Water 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.

(1) Fuel Filter Cartridge

W1037062

Replacing Fan Belt

1. Remove the alternator (1).

2. Remove the fan belt (2).

3. Replace new fan belt.

4. Install the alternator.

5. Check the fan belt tension.

10.0 to 12.0 mm / 98 N

Deflection (A) Factory spec.

0.394 to 0.472 in. / 98 N (10 kgf, 22 lbf)

(1) Alternator (2) Fan Belt

(A) Deflection

W1052220

Cleaning Water Jacket and Radiator Interior

CAUTION

• Do not remove the radiator cap (1) when the engine is hot. Then loosen cap slightly to the stop to relieve any excess pressure 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 to completely drain the coolant. And open the drain cock of engine body.

3. After all coolant is drained, close the drain plug (2).

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.

IMPORTANTQ

• Do not start engine without coolant.

• Use clean, fresh, soft water and anti-freeze to fill the radiator and recovery tank (3).

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

• Securely tighten radiator cap (1). If the cap is loose or improperly fitted, water may leak out and the engine could overheat.

(1) Radiator Cap (2) Drain Plug (3) Recovery Tank

A : Full B : Low

W1038102

G-15

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KiSC issued 01, 2009 A

G GENERAL

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, more specifically also to SAE J814c.

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

IMPORTANTQ

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

Vol %

anti-freeze

40 –24 –11 106 223

50 –37 –35 108 226

Freezing point Boiling point*

°C °F °C °F

* At 1.013 × 100000 Pa (760 mmHg) pressure (atmospheric). A

higher boiling point is obtained by using a radiator pressure cap which permits the development of pressure within the cooling system.

NOTEQ

• The above data represents industrial standards that necessitate a minimum glycol content in the concentrated anti-freeze.

• When the coolant level drops due to evaporation, add fresh, soft water only to keep the anti-freeze mixing ratio less than 50 %. In case of leakage, add anti-freeze and fresh, soft water in the specified mixing ratio.

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

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

W1039218

G-16

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V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

[6] CHECK POINT OF EVERY 1000 HOURS

Checking Valve Clearance

IMPORTANTQ

• Valve clearance must be checked and adjusted when engine is cold.

1. Remove the high pressure pipes, glow lead, glow plugs and the cylinder head cover.

2. Align the 1TC mark of flywheel and the convex of flywheel housing timing windows so that the first piston (front cover side) comes to the compression top dead center.

[Adjustable type of valve bridge arm]

3. Before adjusting the valve clearance, adjust the valve bridge arm evenly to the valve stem.

4. Loosen the lock nut (2) of adjusting screw (1) and adjust with screw.

5. Slightly push the rocker arm with your fingers and screw in the adjusting screw (1) slowly until you feel the screw touch the top of valve stem, then tighten the lock nut (2).

6. Loosen the lock nut (4) of adjusting screw (3) (push rod side) and insert the feeler gauge between the rocker arm and the head of valve bridge arm. Set the adjusting screw (3) to the specified value, then tighten the lock nut.

[Adjustment unnecessary type of valve bridge arm]

3. Loosen the lock nut (4) of adjusting screw (3) (push rod side) and insert the feeler gauge between the rocker arm and the head of valve bridge arm. Set the adjusting screw (3) to the specified value, then tighten the lock nut.

Valve clearance (A) Factory spec.

G GENERAL

0.13 to 0.17 mm

0.0052 to 0.0066 in.

NOTEQ

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

Valve arrangement Adjustment cylinder Location of piston

When No.1 piston is at compression top dead center

When No.1 piston is at overlap position

Cylinder head cover screw

Tightening torque

Injection pipe retaining nut

(1) Adjusting Screw (2) Lock Nut (3) Adjusting Screw (4) Lock Nut

1st ,,

2nd ,

3rd ,

4th

1st

2nd ,

3rd ,

4th ,,

A : Valve Clearance

IN. EX.

9.81 to 11.2 N·m

1.00 to 1.15 kgf·m

7.24 to 8.31 lbf·ft

23 to 36 N·m

2.3 to 3.7 kgf·m 17 to 26 lbf·ft

W1047000

G-17

Page 28

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KiSC issued 01, 2009 A

[7] CHECK POINTS OF EVERY 1 OR 2 MONTHS

Recharging

CAUTION

• When the battery is being activated, hydrogen and oxygen gases in the battery are extremely explosive. Keep open sparks 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 the battery, start with the positive terminal first.

• Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.

1) Slow Charging

1. Add distilled water if the electrolyte level is low. When charging, the amount of electrolyte should be slightly lower than the specified level to prevent overflow.

2. Connect the battery to the charging unit, following the manufacture’s instructions.

3. As the electrolyte generates gas while charging, remove all port caps.

4. The electrolyte temperature must not exceed 40 °C (104 °F) during charging. If it exceed 40 °C (104 °F), decrease the charging amperage or stop charging for a while.

5. When charging several batteries in series, charge at the rate of the smallest battery in the line.

2) Quick Charging

1. Determine the proper charging current and charging time with the tester attached to the quick charger.

2. Determine the proper charging current as 1/1 of the battery capacity. If the battery capacity exceeds 50 Ah, consider 50 A as the maximum.

Q Precaution for Operating a Quick Charger

• Operate with a quick charger differs according to the type. Consult the instruction manual and use accordingly.

G GENERAL

W1052658

G-18

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KiSC issued 01, 2009 A

G GENERAL

Battery Specific Gravity (for Refillable Battery’s only)

1. 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 reading following the formula mentioned in (Reference).

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

4. If the specific gravity differs between any two cells by more than

0.05, replace the battery.

NOTEQ

• Hold the hydrometer tube vertical without removing it from the 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 increases by 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 gravity reading 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)

Specific Gravity State of Charge

1.260 Sp. Gr. 100 % Charged

1.230 Sp. Gr. 75 % Charged

1.200 Sp. Gr. 50 % Charged

1.170 Sp. Gr. 25 % Charged

1.140 Sp. Gr. Very Little Useful Capacity

1.110 Sp. Gr. Discharged

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

(a) Good (b) Bad

W1012763

G-19

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KiSC issued 01, 2009 A

G GENERAL

[8] CHECK POINTS OF EVERY 1500 HOURS

CAUTION

• Check the nozzle injection pressure and condition after confirming that there is nobody standing in the direction the spray goes.

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

Checking Nozzle Spraying Condition

1. Attach the injection nozzle to the nozzle tester, and check the nozzle spraying condition.

2. If the spraying condition is defective, replace the injection nozzle assembly or repair at Kubota-authorized nozzle service shop.

(a) Good (b) Bad

W10371670

Checking Nozzle Injection Pressure

1. Attach the injection nozzle to the 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 injection nozzle assembly or repair at Kubotaauthorized nozzle service shop.

NOTEQ

• Injection nozzle gasket must be replaced when the injection nozzle is removed for checking.

Injection pressure (1st stage)

Factory spec.

Checking Valve Seat Tightness

1. Attach the injection nozzle to the nozzle tester.

2. Raise the fuel pressure, and keep at 16.67 MPa (170.0 kgf/cm 2418 psi) for 10 seconds.

3. If any fuel leak is found, replace the injection nozzle assembly or repair at Kubota-authorized nozzle service shop.

Valve seat tightness Factory spec.

18.64 to 19.61 MPa

190.0 to 200.0 kgf/cm 2703 to 2844 psi

W1037280

No fuel leak at

16.67 MPa

170.0 kgf/cm 2418 psi

W10374150

G-20

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KiSC issued 01, 2009 A

[9] CHECK POINTS OF EVERY 3000 HOURS

Checking Turbocharger (Turbine Side)

1. Check the exhaust port (2) and inlet port (4) side of turbine housing (3) to see if there is no exhaust gas leak.

2. If any gas leak is found, retighten the bolts and nuts or replace the gasket ((1) or (5)) with new one.

(Compressor Side)

1. Check the inlet hose (9) of the compressor cover (6) to see if there is no air leak.

2. If any air leak is found, change the clamp band (7) and / or inlet hoses (9).

3. Check the intake hose (8) and the clamp band (7) to see if there is not loose or crack.

4. If any loose or crack is found, tighten the clamp band (7) or change the hose ((8) or (9)) to prevent dust from entry.

(Radial Clearance)

1. If the wheel contact to the housing, replace the turbocharger assembly with new one.

(1) Gasket (2) Exhaust Port (3) Turbine Housing (4) Inlet Port (5) Gasket

G GENERAL

(6) Compressor Cover (7) Clamp Band (8) Intake Hose (9) Inlet Hose

W1022082

G-21

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KiSC issued 01, 2009 A

G GENERAL

Checking Injection Timing

1. Make sure of matching the injection timing align mark (1) of the injection pump unit and the flywheel housing, as shown in the illustration.

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 (3) for No.1 cylinder.

5. After the fuel fills up to the hole of the delivery valve holder (3) for No.1 cylinder, turn back (clockwise) the flywheel around 1.6 rad (90 °).

6. Turn the flywheel counterclockwise to set at around 0.17 rad (10 °) before T.D.C..

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

8. Check to see the degree on flywheel. The flywheel has mark “1TC” for the crank angle before the top dead center of No.1 piston.

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

IMPORTANTQ

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

0.00436 rad before T.D.C. to 0.0218 rad

Injection timing Factory spec.

after T.D.C. (0.250 ° before T.D.C. to

1.25 ° after T.D.C.)

Injection pipe retaining nut

Tightening torque

Injection pump unit mounting nut

(1) Injection Timing Align Mark (2) Injection Pump Unit Mounting Nut (3) Delivery Valve Holder

23 to 36 N·m

2.3 to 3.7 kgf·m 17 to 26 lbf·ft

18 to 20 N·m

1.8 to 2.1 kgf·m 13 to 15 lbf·ft

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

W1036105

G-22

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KiSC issued 01, 2009 A

G GENERAL

Checking Injection Pump (Fuel Tightness of Pump Element)

1. Remove the engine stop solenoid.

2. Remove the injection pipes.

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 the figure.)

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 pump service shop.

(Fuel Tightness of Delivery Valve)

1. Remove the engine stop solenoid.

2. Remove the injection pipes.

3. Install 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 hand and raise the pressure to approx. 18.63 MPa (190.0 kgf/cm

, 2702 psi).

7. Now turn the flywheel back about half a turn (to keep the plunger free). Maintain the flywheel at this position and clock the time taken for the pressure to drop from 18.63 to 17.65 MPa (from

190.0 to 180.0 kgf/cm

8. Measure the time needed to decrease the pressure from 18.63 to

17.65 MPa (from 190.0 to 180.0 kgf/cm

, from 2702 to 2560 psi).

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

Fuel tightness of pump element

Fuel tightness of delivery valve

Allowable limit

Factory spec.

Allowable limit

18.63 MPa

190.0 kgf/cm 2702 psi

10 seconds

18.63 → 17.65 MPa

190.0 → 180.0 kgf/cm 2702 → 2560 psi

5 seconds

18.63 → 17.65 MPa

190.0 → 180.0 kgf/cm 2702 → 2560 psi

NOTEQ

• Never try to disassemble the injection pump assembly. For repairs, you are strongly requested to contact a Kubotaauthorized pump service shop.

(1) Injection Pump Pressure Tester (2) Injection Nozzle

(3) Protection Cover for Jetted Fuel

W1022357

G-23

Page 34

V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

[10] CHECK POINTS OF EVERY 1 YEAR

Changing 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).

IMPORTANTQ

• 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 (See page G-6).

• Use the proper SAE Engine Oil according to ambient temperature.

Above 25 °C (77 °F)

0 °C to 25 °C (32 °F to 77 °F)

Below 0 °C (32 °F)

G GENERAL

SAE 30 or SAE 10W-30 SAE 15W-40

SAE 20 or SAE 10W-30 SAE 15W-40

SAE 10W or SAE 10W-30 SAE 15W-40

Engine oil capacity

Tightening torque Drain plug

(1) Drain Plug (2) Dipstick (3) Oil Filler Plug

11.2 L

2.96 U.S.gals

45 to 53 N·m

4.5 to 5.5 kgf·m 33 to 39 lbf·ft

(a) Upper Line (b) Lower Line

W1036031

Replacing Air Cleaner Element

1. Remove used air cleaner element.

2. Replace new air cleaner element.

NOTEQ

• The air cleaner uses a dry element. Never apply oil to it.

• Do not run the engine with filter element removed.

W1020554

G-24

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V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

[11] CHECK POINTS OF EVERY 2 YEARS

Changing Radiator Coolant (L.L.C.)

CAUTION

• Do not remove the radiator cap (1) when the engine is hot. Then loosen cap slightly to the stop to relieve any excess pressure before removing cap completely.

1. Stop the engine and let cool down.

3. After all coolant is drained, close the drain plug (2).

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.

IMPORTANTQ

• Do not start engine without coolant.

• Use clean, fresh, soft water and anti-freeze to fill the radiator and recovery tank (3).

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

• Securely tighten radiator cap (1). If the cap is loose or improperly fitted, water may leak out and the engine could overheat.

(1) Radiator Cap (2) Drain Plug (3) Recovery Tank

G GENERAL

A : Full B : Low

(To be continued)

W1024599

G-25

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KiSC issued 01, 2009 A

G GENERAL

(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.

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

IMPORTANTQ

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

Vol %

anti-freeze

40 –24 –11 106 223

50 –37 –35 108 226

Freezing point Boiling point*

°C °F °C °F

* At 1.013 × 100000 Pa (760 mmHg) pressure (atmospheric). A

higher boiling point is obtained by using a radiator pressure cap which permits the development of pressure within the cooling system.

NOTEQ

• The above data represents industrial standards that necessitate a minimum glycol content in the concentrated anti-freeze.

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

W1024852

Replacing Radiator Hoses and Clamp Bands

CAUTION

• Do not remove the radiator cap when the engine is hot. Then loosen cap slightly to the stop to relieve any excess pressure before removing cap completely.

1. Drain the coolant.

2. Loosen the clamp bands.

3. Remove the upper hose (1) and lower hose (2).

4. Replace new upper / lower hose (1), (2) and clamp bands.

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.

(1) Upper Hose (2) Lower Hose

W1024178

G-26

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KiSC issued 01, 2009 A

G GENERAL

Replacing Fuel Hoses and Clamp Bands

1. Loosen the clamp band (2) and remove the fuel hose (1).

2. Replace new fuel hose (1) and new clamp band (2).

3. Tighten the clamp band (2).

CAUTION

• Stop the engine when attempting the check and change prescribed above.

(When bleeding fuel system)

1. Fill the tank with fuel and open the cock.

2. Loosen the air vent coupling bolt of fuel filter a few turns.

3. When there is no more air bubbles in the fuel coming out of this coupling bolt, tighten the coupling bolt.

4. Open the air vent cock (3) on the top of fuel injection pump.

6. Close securely the air vent cock (3) after air bleeding.

IMPORTANTQ

• Except when venting the air, be sure to keep closed the air vent coupling bolt of the fuel injection pump. Otherwise, the engine may stall.

(1) Fuel Hose (2) Clamp Band

(3) Air Vent Cock

W1020090

Replacing Intake Air Line

1. Loosen the clamp bands (2).

2. Remove the intake air hose (1) and clamp bands (2).

3. Replace new intake air hose (1) and new clamp bands (2).

4. Tighten the clamp bands (2).

NOTEQ

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

(1) Intake Air Hose (2) Clamp Band

W1023867

Replacing Battery

CAUTION

• 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 the battery, start with the positive terminal first.

• Never check battery charge by placing a metal object across the 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

G-27

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KiSC issued 01, 2009 A

5. SPECIAL TOOLS

G GENERAL

Diesel Engine Compression Tester

Code No : 07909-30208 (Assembly) Application : Use to measure diesel engine compression and

diagnostics of need for major overhaul.

(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

W1024200

Oil Pressure Tester

Code No : 07916-32032 Application : Use to measure lubricating oil pressure.

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

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

W1024318

G-28

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KiSC issued 01, 2009 A

NOTEQ

• The following special tools are not provided, make them referring to the figure.

Injection Pump Pressure Tester

Application : Use to check fuel tightness of injection pumps.

Pressure gauge full scale : More than 29.4 MPa

(300 kgf/cm

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 8.0 mm dia. (0.31 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 8.0 mm (0.31 in.)

O 4.0 mm (0.16 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 4.0 mm (0.16 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 5.0 mm (0.20 in.)

, 4270 psi)

G GENERAL

W10252400

G-29

Page 40

V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

Glow Plug Adapter

Application : Use to check compression pressure through glow plug hole.

A 3.0 mm dia. (0.12 in. dia.) through hole L 1.0 rad (60 °)

B 17.0 mm (0.669 in.) M 1.0 mm (0.039 in.)

C 16.0 mm dia. (0.630 in. dia.) P0.5 N 17.0 mm (0.669 in.)

D 13.0 mm dia. (0.512 in. dia.) O 61.5 mm (2.42 in.)

E 9.5 mm dia. (0.37 in. dia.) P 15.0 mm (0.591 in.)

F M8 x 1.0 Q 10.0 mm (0.394 in.)

G 6.50 to 6.70 mm dia. (0.256 to 0.263 in. dia.) R 100 mm (3.94 in.)

H 2.145 to 2.148 rad (122.9 to 123.1 °) S 79.5 mm (3.13 in.)

I 4.90 to 5.50 mm dia. (0.193 to 0.216 in. dia.) T 204.5 mm (8.051 in.)

J 0.52 rad (30 °) C1.5 Chamfer 1.5 mm (0.059 in.)

K 5.0 mm (0.20 in.)

G GENERAL

(1) Material : SS400

G-30

Page 41

V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

G GENERAL

Small End Bushing Replacing Tool

Application : Use to press out and to press fit the small end bushing.

[Press out]

A 157 mm (6.181 in.)

B 14.0 mm (0.5512 in.)

C 120 mm (4.7244 in.)

D 27.4 mm dia. (1.0787 in. dia.)

E 30.95 mm dia. (1.2185 in. dia.)

F 20 mm dia. (0.7874 in. dia.)

a 6.3 μm (250 μin.)

b 6.3 μm (250 μin.)

C1 Chamfer 1.0 mm (0.039 in.)

C2 Chamfer 2.0 mm (0.079 in.)

[Press fit]

A 157 mm (6.181 in.)

B 14.0 mm (0.5512 in.)

C 120 mm (4.7244 in.)

D 27.4 mm dia. (1.0787 in. dia.)

E 42.000 mm dia. (1.6535 in. dia.)

F 20 mm dia. (0.7874 in. dia.)

a 6.3 μm (250 μin.)

b 6.3 μm (250 μin.)

C1 Chamfer 1.0 mm (0.039 in.)

C2 Chamfer 2.0 mm (0.079 in.)

W1040702

Idle Gear Bushing Replacing Tool

Application : Use to press out and to press fit the bushing.

A 196 mm (7.72 in.)

B 25.0 mm (0.984 in.)

C 150 mm (5.91 in.)

D 34.5 mm dia. (1.36 in. dia.)

E 38.075 to 38.100 mm dia. (1.4991 to 1.5000 in. dia.)

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

a 6.3 μm (250 μin.)

b 6.3 μm (250 μin.)

C1 Chamfer 1.0 mm (0.039 in.)

C2 Chamfer 2.0 mm (0.079 in.)

(1) Material : SS400

W1039429

G-31

Page 42

V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

G GENERAL

Valve Guide Replacing Tool

Application : Use to press out and press fit the valve guide.

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 11.7 to 11.9 mm dia. (0.461 to 0.468 in. dia.)

F 6.50 to 6.60 mm dia. (0.256 to 0.259 in. dia.)

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

H 6.70 to 7.00 mm dia. (0.264 to 0.275 in. dia.)

I 5.0 mm (0.20 in.)

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

K 12.5 to 12.8 mm dia. (0.493 to 0.503 in. dia.)

L 8.50 to 8.90 mm (0.335 to 0.350 in.)

C1 Chamfer 1.0 mm (0.039 in.)

C2 Chamfer 2.0 mm (0.079 in.)

C0.3 Chamfer 0.30 mm (0.012 in.)

(1) Material : SS400

W10250170

G-32

Page 43

V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

Front Cover Oil Seal Replacing Tool

Application : Use to press fit the front cover oil seal.

G GENERAL

A 120 mm (4.72 in.)

B 12.0 mm (0.472 in.)

C 2.90 to 3.00 mm (0.115 to 0.118 in.)

D 10.0 mm (0.394 in.)

E 80.0 mm (3.15 in.)

F 10.0 mm (0.394 in.)

G 95.0 mm dia. (3.74 in. dia.)

78.900 to 79.100 mm dia.

(3.1063 to 3.1141 in. dia.)

57.971 to 57.990 mm dia.

(2.2824 to 2.2830 in. dia.)

J 50.0 mm dia. (1.97 in. dia.)

K 15.0 mm dia. (0.591 in. dia.)

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

M 15.0 mm (0.591 in.)

N 90.0 mm (3.54 in.)

O 2.50 mm (0.0984 in.)

P 0.35 rad (20 °)

0.15 to 0.25 mm

(0.0059 to 0.0098 in.)

a Ra = 3.2 a

b Ra = 1.6 a

c 0.80 mm radius (0.031 in. radius)

d 1.5 mm radius (0.059 in. radius)

C0.5 Chamfer 0.50 mm (0.020 in.)

C1 Chamfer 1.0 mm (0.039 in.)

(1) Material : S43C-D

W1014589

G-33

Page 44

V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

Flywheel Housing Oil Seal Replacing Tool

Application : Use to press fit the flywheel housing oil seal.

G GENERAL

A 118 mm (4.65 in.)

B 12.0 mm (0.472 in.)

C 0.90 to 1.0 mm (0.036 to 0.039 in.)

D 10.0 mm (0.394 in.)

E 80.0 mm (3.15 in.)

F 10.0 mm (0.394 in.)

G 120 mm dia. (4.72 in. dia.)

100.90 to 101.10 mm dia.

(3.9725 to 3.9803 in. dia.)

86.966 to 86.988 mm dia.

(3.4239 to 3.4247 in. dia.)

J 79.0 mm dia. (3.11 in. dia.)

K 15.0 mm dia. (0.591 in. dia.)

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

M 13.0 mm (0.512 in.)

N 90.0 mm (3.54 in.)

O 2.50 mm (0.0984 in.)

P 0.35 rad (20 °)

0.15 to 0.25 mm

(0.0059 to 0.0098 in.)

a Ra = 3.2 a

b Ra = 1.6 a

c 0.80 mm radius (0.031 in. radius)

d 1.5 mm radius (0.059 in. radius)

e 0.20 mm radius (0.0079 in. radius)

C0.3 Chamfer 0.30 mm (0.012 in.)

C1 Chamfer 1.0 mm (0.039 in.)

(1) Material : S43C-D

W1015151

G-34

Page 45

V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

G GENERAL

Valve Bridge Shaft Replacing Tool

Application : Use to press fit the valve bridge shaft.

A 9.50 mm dia. (0.374 in. dia.) through hole

B 19.0 mm (0.748 in.)

C 23.2 mm (0.913 in.)

D 42.00 to 42.40 mm (1.654 to 1.669 in.)

E 12.5 mm dia. (0.492 in. dia.) through hole

F 61.0 mm (2.40 in.)

G 18.7 mm (0.736 in.)

H 30.90 to 31.70 mm (1.217 to 1.248 in.)

a 0.30 mm radius (0.012 in. radius)

C0.5 Chamfer 0.50 mm (0.020 in.)

C1 Chamfer 1.0 mm (0.039 in.)

C2 Chamfer 2.0 mm (0.079 in.)

(1) Material : SS400

W1015898

Camshaft Cover Replacing Tool

Application : Use to press fit the camshaft cover.

A 30.0 mm (1.18 in.)

B 30.0 mm dia., 20.0 mm depth (1.18 in. dia., 0.79 in. depth)

C 47.975 to 48.000 mm (1.8888 to 1.8897 in.)

D 52.0 mm (2.05 in.)

E 80.0 mm (3.15 in.)

F 16.5 to 16.6 mm (0.650 to 0.653 in.)

G 80.0 mm (3.15 in.)

H 10.0 mm (0.394 in.)

I 26.0 mm (1.02 in.)

J 100 mm (3.94 in.)

K 6.0 mm (0.24 in.)

L 132 mm (5.20 in.)

M 1.0 mm (0.039 in.)

a 1.0 mm radius (0.039 in. radius)

b 2.0 mm radius (0.079 in. radius)

c Ra = 3.2a

d 0.40 mm radius (0.016 in. radius)

C0.5 Chamfer 0.50 mm (0.020 in.)

C1z Chamfer 1.0 mm (0.039 in.)

(1) Material : S43C

W1014056

G-35

Page 46

V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

Crankshaft Sleeve Replacing Tool

Application : Use to fix the crankshaft sleeve of the diesel engine.

G GENERAL

A 1.50 mm (0.0591 in.) Q 33.0 mm (1.30 in.)

B 0.52 rad (30 °) R 115 mm depth (4.53 in. depth)

C 34.925 to 34.950 mm dia. (1.3750 to 1.3759 in. dia.) S 43.0 mm (1.69 in.)

D 22 mm dia. (0.8661 in. dia.) T 120 mm (4.72 in.)

E 81.980 to 81.985 mm dia. (3.2276 to 3.2277 in. dia.) U 163 mm (6.42 in.)

F 6.0 mm (0.24 in.) V 8.0 mm dia. (0.31 in. dia.)

G 23.5 mm (0.925 in.) W 33.475 to 33.525 mm (1.3180 to 1.3198 in.)

H 29.5 mm (1.16 in.) a Ra = 1.6 a

I 58.0 mm (2.28 in.) b 0.50 mm radius (0.020 in. radius)

J 95.0 mm (3.74 in.) c Ra = 3.2 a

K 98.0 mm dia. (3.86 in. dia.) d 1.50 mm radius (0.0591 in. radius)

L 0.52 rad (30 °) e 10.0 mm radius (0.394 in. radius)

M 82.100 to 82.200 mm dia. (3.2323 to 3.2362 in. dia.) C1 Chamfer 1.0 mm (0.039 in.)

N 1.50 mm (0.0591 in.) C3 Chamfer 3.0 mm (0.12 in.)

O 15.0 mm dia. (0.591 in. dia.) C5 Chamfer 5.0 mm (0.20 in.)

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

(1) Sleeve Guide Material : S43C (2) Shaft Material : S43C

G-36

Page 47

V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

G GENERAL

Engine Stand

Application : Use to support engine.

A 107 mm (4.21 in.)

B 246 mm (9.68 in.)

C 21 mm (0.83 in.)

D 204 mm (8.03 in.)

E 102 mm (4.02 in.)

F 15 mm (0.59 in.)

G 59 mm (2.3 in.)

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

I 80 mm radius (3.1 in. radius)

J 70 mm (2.8 in.)

K 460 mm (18.1 in.)

L 270 mm (10.6 in.)

M 6.0 mm (0.24 in.)

N 70 mm (2.8 in.)

C10 Chamfer 10 mm (0.39 in.)

(1) Material : S43C

W1033645

Crankcase Aligning Plate

Application : Use for aligning the crankcase 1 and 2.

A 126.6 mm (4.984 in.)

B 49.1 mm (1.93 in.)

C 37.5 mm (1.48 in.)

D 20 mm (0.79 in.)

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

F 14 mm dia. (0.55 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.)

(1) Material : S43C

W1047882

G-37

Page 48

V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

Flywheel Housing Guide

Application : Use to install the flywheel housing to the crankcase.

G GENERAL

A 70.0 mm (2.76 in.)

B 8.0 mm (0.31 in.)

C 22.0 mm (0.866 in.)

D 30.0 mm (1.18 in.)

E 87.0 mm dia. (3.43 in. dia.)

82.036 to 82.071 mm dia.

(3.2298 to 3.2311 in. dia.)

G 77.0 mm dia. (3.03 in. dia.)

H 57.0 mm dia. (2.24 in. dia.)

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

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

K 84.0 mm dia. (3.31 in. dia.)

L 3.5 mm (0.14 in.)

M 3.0 mm (0.12 in.)

N 6.60 to 6.80 mm (0.260 to 0.267 in.)

O 8.0 mm (0.31 in.)

P 67.0 mm dia. (2.64 in. dia.)

4.0 mm dia. (0.16 in. dia.)

through hole

a Ra = 1.6 a

b 1.5 mm radius (0.059 in. radius)

c Ra = 3.2 a

d 0.80 mm radius (0.031 in. radius)

C0.5 Chamfer 0.50 mm (0.020 in.)

C1 Chamfer 1.0 mm (0.039 in.)

(1) Material : SS400

W1017819

G-38

Page 49

V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

Injection Pump Gear Puller

Application : Use for remove the injection pump gear from governor shaft.

G GENERAL

M35 x P1.5, 6.0 mm depth

(0.24 in. depth)

35.0 mm dia., 12.0 mm depth

(1.38 in. dia., 0.472 in. depth)

30.0 mm dia., 27.5 mm depth

(1.18 in. dia., 1.08 in. depth)

40.00 to 40.20 mm dia.

(1.575 to 1.582 in. dia.)

35.90 to 36.10 mm dia.

(1.414 to 1.421 in. dia.)

F 2.09 rad (120 °)

G M8 x P1.25

H 9.0 mm dia. (0.35 in. dia.)

I 19.0 mm dia. (0.748 in. dia.)

J 12.0 mm (0.472 in.)

K 15.0 mm (0.591 in.)

L 27.5 mm (1.08 in.)

M 31.0 mm (1.22 in.)

N 57.5 mm (2.26 in.)

O 100 mm (3.94 in.)

13.75 to 14.00 mm

(0.5414 to 0.5511 in.)

Q 16.17 mm (0.6366 in.)

a 5.0 mm radius (0.20 in. radius)

b 0.40 mm radius (0.016 in. radius)

C0.2 Chamfer 0.20 mm (0.0079 in.)

C0.5 Chamfer 0.50 mm (0.020 in.)

(1) Material : SS400

W1018612

Fuel Camshaft Lock Screw (Socket Set Screw Dog Point Type)

Application : Use to fix the fuel camshaft.

A M8 × Pitch 1.25

B 0.79 rad (45 °)

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

D 4.0 mm (0.16 in.)

E 45 mm (1.8 in.)

F 10 mm (0.39 in.) : Conspicuously Painted

G 5.0 mm (0.20 in.)

(1) Material : SS400

W10461560

G-39

Page 50

V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

G GENERAL

Jig for Governor Connecting Rod

Application : Use for connecting the governor connecting rod to the rack pin of the fuel injection pump assembly.

A 0.50 mm (0.020 in.) O 5.0 mm (0.20 in.)

B 12.7 to 13.0 mm (0.500 to 0.511 in.) P 4.0 mm (0.16 in.)

C 8.70 to 9.00 mm (0.343 to 0.354 in.) Q 2.955 to 2.965 mm dia. (0.1164 to 0.1167 in. dia.)

D 39.0 mm (1.54 in.) R 3.020 to 3.030 mm dia. (0.1189 to 0.1192 in. dia.)

E 10.0 mm (0.394 in.) S Ra = 1.6 a

F 7.0 mm (0.28 in.) AA Governor housing side

G 6.0 mm (0.24 in.) BB Press in side

H 80.0 mm (3.15 in.) a 0.60 mm radius (0.024 in. radius)

I 27.95 to 28.05 mm (1.101 to 1.104 in.) b 1.0 mm radius (0.039 in. radius)

J 5.0 mm (0.20 in.) C0.2 Chamfer 0.20 mm (0.0079 in.)

3.000 to 3.010 mm dia., 6.0 mm depth

(0.1182 to 0.1185 in. dia., 0.24 in. depth)

L 9.0 mm (0.35 in.) C0.5 Chamfer 0.50 mm (0.020 in.)

M 5.0 mm (0.20 in.) C1 Chamfer 1.0 mm (0.039 in.)

N 14.45 to 14.55 mm (0.5689 to 0.5728 in.) C2 Chamfer 2.0 mm (0.079 in.)

(1) Material : S43C-D (2) Permanent Magnet :

8.0 mm dia. (0.31 in. dia.) Thickness : 3.0 mm (0.12 in.)

C0.4 Chamfer 0.40 mm (0.016 in.)

(3) Pin Material : SUM22

G-40

Page 51

MECHANISM

KiSC issued 01, 2009 A

CONTENTS

1. FEATURE ........................................................................................................ M-1

2. ENGINE BODY ............................................................................................... M-2

[1] CYLINDER BLOCK................................................................................... M-2

[2] COOLING JACKET................................................................................... M-3

[3] HALF-FLOATING HEAD COVER ............................................................ M-3

[4] CYLINDER HEAD ..................................................................................... M-4

[5] 4 SCREWS PER EACH CYLINDER ASSEMBLING STRUCTURE .... M-5

[6] CENTER DIRECT INJECTION SYSTEM (E-CDIS)............................... M-6

[7] GEAR TRAIN CONFIGURATION ............................................................ M-7

[8] PISTON...................................................................................................... M-7

[9] BUILT-IN DYNAMIC BALANCER (BALANCER MODEL ONLY) .......... M-7

3. LUBRICATING SYSTEM ................................................................................ M-8

[1] OIL COOLER ............................................................................................ M-8

4. COOLING SYSTEM........................................................................................ M-9

[1] THERMOSTAT .......................................................................................... M-9

[2] BOTTOM BYPASS SYSTEM................................................................. M-10

5. FUEL SYSTEM ............................................................................................. M-11

[1] GOVERNOR ............................................................................................ M-11

[2] 2 STAGE DI NOZZLE ........................................................................... M-14

[3] INJECTION PUMP WITH F.S.P............................................................ M-15

[4] CPV EQUIPPED DELIVERY VALVE.................................................... M-16

6. INTAKE AND EXHAUST SYSTEM ............................................................. M-17

[1] TURBOCHARGER................................................................................... M-17

Page 52

V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

1. FEATURE

ENGINE

The 07 series DI engine are the vertical type 4-cycle diesel engine featuring the advanced performances shown below.

This is a small sized, high power and environment conscious engine, which employs the four valve system, two inlet valves with double ports, and two exhaust valves with the new E-CDIS. The 07 series DI engine newly adopted ladder frame crankshaft support structure, gear train located at flywheel side and coolant evenness distribution type cooling jacket. Thus, this engine achieves high combustion efficiency and complies with various regulations of exhaust gas.

Based upon the conventional model, Kubota developed a unique governor system and various new mechanisms which reduces exhaust emission, noise and vibration and realize durability and high torque.

W1012645

M-1

Page 53

V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

2. ENGINE BODY

[1] CYLINDER BLOCK

ENGINE

The 07 series DI engine employs ladder frame structure type crankcases - the crankcase 1 (1) with combustion part and the crankcase 2 (2) which supports the crankcase 1 (1).

The following benefits are in the ladder frame structure.

1. Minimizing parts.

2. Noise reduction.

3. Reduction of loss and dispersion on friction thanks to

accuracy of axial concentricity.

The cylinder is a linerless type which enables good cooling operation, less strain and good abrasion resistance.

(1) Crankcase 1 (2) Crankcase 2

W1012790

M-2

Page 54

V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

[2] COOLING JACKET

[3] HALF-FLOATING HEAD COVER

ENGINE

The 07 series DI engine employs coolant evenness distribution type cooling jacket inside crankcase 1. The coolant is evenly supplied to each cylinder through the main gallery (3) in the jacket mold core (2).

(1) Coolant Passage between

Cylinder

(2) Jacket Mold Core (3) Main Gallery

W1013000

The rubber packing (2) is fitted in to maintain the head cover 0.5 mm (0.02 in.) or so off the cylinder head. This arrangement helps reduce noise coming from the cylinder head.

(1) Cylinder Head Cover (2) Rubber Packing

W1013327

M-3

Page 55

V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

[4] CYLINDER HEAD

ENGINE

This engine employs four valve system, the cylinder head is provided with double intake passage in order to ensure appropriate air suction and give an optimum swirl.

(1) Intake (2) Exhaust

W1013336

M-4

Page 56

V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

[5] 4 SCREWS PER EACH CYLINDER ASSEMBLING STRUCTURE

The 07 series DI engine employs 4 screws per each

cylinder assembling structure.

The cylinder head (2) and the crankcase 2 (4) are assembled from the top and bottom to the crankcase 1 (3) with each of 10 screws.

The following objectives are in the 4 screws per each cylinder assembling structure.

1. Reduce the load share rate of combustion pressure

on outer block surface wall.

2. Flexibility of cylinder head design.

(1) Cylinder Head Mounting

Screw

(2) Cylinder Head

(3) Crankcase 1 (4) Crankcase 2 (5) Crankcase 2 Mounting Screw

ENGINE

W1013265

M-5

Page 57

V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

[6] CENTER DIRECT INJECTION SYSTEM (E-CDIS)

The 07 series DI engine adopts the Center Direct Injection System (E-CDIS), in which the injection nozzle (3) is positioned upright at the center of the cylinder.

This system serves to inject fuel directly at the center of the cylinder. By so doing, injected fuel and suction air can be mixed more uniformly, leading to more stable, higher combustion performance. In other words, cleaner emission, higher power output, lower fuel consumption, lower operating noise and higher start-up performance have been achieved.

(1) Exhaust Valves (2) Piston

ENGINE

(3) Injection Nozzle (4) Intake Valves

W11094950

The 07 series DI engine has two intake valves and two exhaust valves per each cylinder.

The rocker arm (1) contacts a valve bridge arm (2) instead of the valves stem tip.

The valve bridge arm (2) then contacts both intake valves or both exhaust valves and causes two valves to open simultaneously.

(1) Rocker Arm (2) Valve Bridge Arm

W1014724

M-6

Page 58

V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

[7] GEAR TRAIN CONFIGURATION

[8] PISTON

ENGINE

The 07 series DI engine employs gear train located at flywheel side. The following benefits are in the rear gear train configuration.

1. Flexibility of auxiliary parts arrangement.

2. Reduction of gear chattering noise from crankshaft of

torsional and bending vibration.

(1) Rear Gear Train (2) Balancer Shaft 1 (Option)

(3) Balancer Shaft 2 (Option) (4) Flywheel

W1013611

Piston’s skirt is coated with molybdenum disulfide+, which reduces the piston slap noise and thus the entire operating noise.

+Molybdenum disulfide (MoS

The molybdenum disulfide (1) serves as a solid lubricant, like a Graphite or Teflon. This material helps resist metal wears even with little lube oil.

(1) Molybdenum Disulfide

[9] BUILT-IN DYNAMIC BALANCER (BALANCER MODEL ONLY)

Engines are sure to vibrate by piston’s reciprocation. Theoretically, three-cylinder engines are much less prone to cause vibration than four-cylinder ones (second inertia, etc.). However, any engine has many moving parts in addition to its pistons and cannot be completely free from vibration.

The four cylinder engine is fitted with balance weight on crankcase to absorb the second inertia mentioned above and reduce vibration.

(1) Balancer Shaft 1 (2) Balancer Shaft 2

W1015665

W1013617

M-7

Page 59

V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

3. LUBRICATING SYSTEM

[1] OIL COOLER

ENGINE

The 07 series engine has a coolant-cooled oil cooler that not only cools hot oil, but also warms the cool engine oil shortly after start up.

As shown in the figure, the oil flows inside the connected cooler plate, whereas coolant is kept circulating outside the cooler plate, thereby cooling down or warming the oil.

(A) Oil Inlet Port (B) Oil Outlet Port

(a) Coolant Inlet Port (b) Coolant Outlet Port

W10344770

M-8

Page 60

V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

4. COOLING SYSTEM

[1] THERMOSTAT

ENGINE

Conventional thermostatically-controlled valves (outlet water temperature control type) open against the flow of coolant. In this design, the pressure (steam pressure + water pump’s discharge pressure) affects the open/close performance of such valve. In other words, the valve may be delayed in opening at a preset opening temperature opening suddenly, above the preset temperature. This is called the overshoot phenomenon.

The overshoot problem invites the undershoot phenomenon too. Too much water cooled by the radiator flows through the water passage, which suddenly closes the valve below the thermostat’s preset valve closing temperature.

A repeated cycle of such overshoot (3) and undershoot phenomena is called the water temperature hunting. This hunting problem may adversely affect the cooling system parts, and also the engine and its related components.

To cope with this trouble, the 07 series engine is equipped with the flow control thermostat. The valve has a notch (4) to control the coolant flow-rate smoothly in small steps.

(1) Coolant Temperature (2) Time (3) Overshoot (4) Notch

(A) Valve Lift Versus Flow-rate (B) Flow-rate (C) At Short Valve Lift (D) At Medium Valve Lift (E) At High Valve Lift (F) Valve Lift

W1013684

M-9

Page 61

V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

[2] BOTTOM BYPASS SYSTEM

ENGINE

Bottom bypass system is introduced in the 07 series

for improving the cooling performance of the radiator.

While the temperature of coolant in the engine is low, the thermostat (1) is held closed and the coolant is allowed to flow through the bypass pipe and to circulate in the engine.

When the temperature exceeds the thermostat (1) valve opening level, the thermostat (1) fully opens itself to prevent the hot coolant from flowing through the bypass into the engine.

In this way, the radiator can increase its cooling performance.

(1) Thermostat (2) Radiator (3) Engine

(A) Bypass Opened (B) Bypass Closed

W1013406

M-10

Page 62

V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

5. FUEL SYSTEM

[1] GOVERNOR

ENGINE

The engine employs the separated fuel injection pump in combination with Kubota’s own small multifunction mechanical governor, which enables more dependability.

It also employs the torque limiting mechanism to control the maximum peak torque so that it complies with the regulations of exhaust gas.

This mechanism maintains engine speed at a constant level even under fluctuating loads, provides stable idling and regulates maximum engine speed by controlling the fuel injection rate.

This engine uses a mechanical governor that controls the fuel injection rate at all speed ranges (from idling to maximum speed) by utilizing the balance between the flyweight’s centrifugal force and spring tension.

A governor shaft for monitoring engine speed is independent of the injection pump shaft and rotates at twice the speed of conventional types, providing better response to load fluctuation and delivering greater engine output.

W1013830

Q At Start

The stop solenoid (energized-to-run type) is powered to release the stop lever.

As no centrifugal force is applied to flyweight (2), low tension of start spring (1) permits control rack to move the starting position, supplying the amount of fuel required to start the engine.

(1) Start Spring (2) Flyweight

W1013967

M-11

Page 63

V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

ENGINE

Q At Idling

Turn the speed control lever (2) clockwise to idle the engine. It tensions the governor spring (7) to pull the fork lever 2 (1).

When the fork lever 2 (1) is pulled, it moves the torque spring pin (3) and the fork lever 1 (5) in the direction of the arrow A to restrain the weight. In combination with the start spring tension, it is balanced with the centrifugal force of flywheel weight to keep idling.

(1) Fork Lever 2 (2) Speed Control Lever (3) Spring Pin (4) Start Spring

(5) Fork Lever 1 (6) Flyweight (7) Governor Spring

W1014034

Q At rated speed with full load and overload

As the speed control lever is changed from the middle speed to high speed, the governor spring tension increases to compress the torque spring and move the fork lever 1 in the direction of the arrow A.

The fork lever 2 moves until it reaches the output limiting bolt (2) to keep rated rotation and rated output.

When the engine is overloaded, the engine rotating speed decreases and the centrifugal force of flywheel weight decreases. Then the torque spring moves the fork lever 1 in the direction of arrow A.

The control rack moves in the direction that increases fuel supply to increase the output. It is balanced with the centrifugal force of the flywheel weight to produce lowspeed output (torque output).

(1) No-load Maximum Rotation (2) Output Limiting Bolt

(3) Torque Limiting Bolt

W1014276

M-12

Page 64

V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

ENGINE

Q To stop engine

When the stop solenoid (1) is turned off, the spring tension of the solenoid is released, the rod extrudes and the stop lever moves the control rack in the direction of the arrow B which stops the engine.

To stop the engine manually, move the external stop lever to the left.

(1) Stop Solenoid (2) Stop Lever Shaft

W1014393

M-13

Page 65

V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

[2] 2 STAGE DI NOZZLE

ENGINE

Exhaust and noise regulations are becoming increasingly strict, particularly in regard to the reduction of NOx (nitrogen oxides) and particulates.

The two-spring nozzle holder has been developed to reduce NOx (nitrogen oxides) and particulates from direct injection diesel engine exhaust.

Q Features

The two-spring nozzle holder limits needle valve lift at initial valve opening to throttle the injection quantity. Main injection occurs when the in-line pressure has increased sufficiently to move the needle valve through its full lift.

This gives the following features.

• Improved engine stability at low and intermediate speeds.

• Decreased engine hunting and surge.

• Decreased noise at idling.

• Decreased idling speed because of improved engine stability.

• Stabilized fuel injection characteristics from the injection pump and nozzle system, and easier matching of governor characteristics to engine demand.

(1) Nozzle Holder Body (2) 1st Stage Injection Pressure

Adjusting Shim (3) First Spring (4) Pressure Pin (5) Spring Seat (6) 2nd Stage Injection Pressure

Adjusting Shim

(7) Second Spring (8) Pre-lift Adjusting Spring Seat

(9) Chip-packing (10) Max-lift Adjusting Washer (11) Retaining Nut (12) Nozzle

W1014568

M-14

Page 66

V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

A-B : First Spring’s Set Force B-C-D : Combined Force of

First and Second Springs P1 : First Opening Pressure P2 : Second Opening Pressure

L : Full Needle Valve Lift l : Needle Valve Pre-lift

X1 : Cam Angle (°) Y1 : Injection Rate (mm3/°) X2 : Needle Valve Lift (mm) Y2 : In-line Pressure

ENGINE

W1014795

Q First opening pressure

The force of the high pressure fuel delivered by the injection pump acts to push the needle valve up. When this

force exceeds the set force of the first spring, the nozzle’s needle valve pushes the first pushrod up and the valve opens. (First opening pressure is represented by point E in the bottom left hand figure, and point A in the above figure.)

Q Second opening pressure

When the first pushrod has been lifted through the pre-lift, it contacts the second pushrod. As the set force of the second spring is acting on the second pushrod, the combined forces of both the first spring and the second spring then act on the needle valve, which will not lift unless these forces are overcome.

When the high pressure fuel (i.e., in-line pressure) overcomes the combined forces of the first and second springs, the needle valve is again lifted and main injection can begin. (Second opening pressure is represented by point F in the bottom left hand figure and B-C in the above figure.)

[3] INJECTION PUMP WITH F.S.P.

The fuel injection pump with F.S.P. (Fine Spill Port) mechanism is equipped with two functions: speed timer function and injection rate control function.

The former function works like this. As the rpm is low, the injection timing gets delayed. This helps cut down on NOx and operating noise.

The latter function serves to keep down the initial injection rate and keep up the later injection rate, which cuts down on NOx and PM as well.

(1) Fine Spill Port (F.S.P.) (2) Plunger Chamber (3) Main Port (4) Cylinder

(5) Plunger (6) F.S.P. Stroke (7) Leaking Fuel at Initial Fuel

Pressure-Feed Stage

W1014969

M-15

Page 67

V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

[4] CPV EQUIPPED DELIVERY VALVE

ENGINE

The Constant Pressure Valve (CPV) is a mechanism that maintains uniform residual pressure in the high pressure pipe. It stabilizes overall delivery quantity characteristics and especially delivery quantity characteristics at low speeds.

Q At high fuel pressure

The delivery valve (1), the steel ball (5) and the snapper valve (6) are moved up together. The delivery valve seat surface (2) opens when the fuel pressure becomes more than the delivery valve set pressure.

Q At after injection

The delivery valve (1), the steel ball (5) and the snapper valve (6) are moved down and the delivery valve seat surface (2) closes. The steel ball still opens on the way and the fuel returns to the injection pump side. The steel ball (5) closes when the fuel pressure becomes less than the snapper valve set pressure.

(1) Delivery Valve (2) Seat Surface (3) Valve Seat (4) Orifice (5) Steel Ball (6) Snapper Valve

(7) Snapper Valve Spring (8) Snapper Valve Seat

A : Current Delivery Valve B : CPV Equipped Delivery

Valve

W1015816

M-16

Page 68

V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

6. INTAKE AND EXHAUST SYSTEM

[1] TURBOCHARGER

ENGINE

(1) Lock Nut (2) Thrust Bearing (3) Snap Ring (4) O-ring (5) Thrust Sleeve (6) Piston Ring (7) Turbine Wheel (8) Turbine Housing

(9) Actuator (10) Compressor Wheel (11) Piston Ring (12) Oil Deflector (13) Bearing (14) Snap Ring

W10353780

A turbocharger consists basically of a centrifugal compressor mounted on a common shaft with a turbine driven by exhaust gas. The compressor is usually located between the air cleaner and the intake manifold (or intercooler; if equipped), while the turbine is located between the exhaust manifold and the muffler.

The prime job of the turbocharger is, by compressing the air, to force more air into the engine cylinders. This allows the engine to efficiently burn more fuel, thereby producing more horsepower.

In applications where the boost pressure is relatively low, the turbocharger is capable of reducing the smoke concentration, the concentration in the cylinder, fuel consumption, and deterioration in performance at elevated terrain by increasing the amount of air into the engine cylinders.

In applications where the boost pressure is high, the turbocharger is capable of providing a large increase in engine output by increasing the amount of air into the engine cylinders.

M-17

Page 69

SERVICING

KiSC issued 01, 2009 A

CONTENTS

1. TROUBLESHOOTING ......................................................................................S-1

2. SERVICING SPECIFICATIONS ......................................................................S-5

3. TIGHTENING TORQUES ..............................................................................S-12

[1] TIGHTENING TORQUES FOR GENERAL USE SCREWS, BOLTS

AND NUTS...............................................................................................S-12

[2] TIGHTENING TORQUES FOR SPECIAL USE SCREWS, BOLTS

AND NUTS...............................................................................................S-13

4. CHECKING, DISASSEMBLING AND SERVICING......................................S-15

[1] CHECKING AND ADJUSTING ...............................................................S-15

(1) Engine Body........................................................................................S-15

(2) Lubricating System .............................................................................S-17

(3) Cooling System ...................................................................................S-17

(4) Fuel System ........................................................................................S-20

(5) Electrical System ................................................................................S-23

(6) Turbocharger ......................................................................................S-27

[2] DISASSEMBLING AND ASSEMBLING..................................................S-28

(1) Draining Oil and Coolant .....................................................................S-28

(2) External Components .........................................................................S-28

(3) Cylinder Head and Valves ..................................................................S-31

(4) Thermostat ..........................................................................................S-35

(5) Injection Pump Unit .............................................................................S-36

(6) Water Pump and Oil Cooler ................................................................S-45

(7) Front Cover .........................................................................................S-46

(8) Flywheel and Timing Gears ................................................................S-47

(9) Piston and Connecting Rod ................................................................S-51

(10)Crankshaft and Crankcase .................................................................S-54

(11)Starter .................................................................................................S-56

(12)Alternator ............................................................................................S-56

[3] SERVICING ..............................................................................................S-59

(1) Cylinder Head and Valves ..................................................................S-59

(2) Timing Gears ......................................................................................S-65

(3) Piston and Connecting Rod ................................................................S-67

(4) Crankshaft...........................................................................................S-70

(5) Cylinder ...............................................................................................S-74

(6) Oil Pump .............................................................................................S-75

(7) Relief Valve .........................................................................................S-76

(8) Starter .................................................................................................S-76

(9) Alternator ............................................................................................S-78

Page 70

V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

1. TROUBLESHOOTING

ENGINE

Symptom Probable Cause Solution

Engine Does Not Start

Starter Does Not Run Battery discharged Charge G-18, 19

No fuel Replenish fuel G-11

Air in the fuel system Vent air G-11

Water in the fuel system Change fuel and

repair or replace fuel system

Fuel hose clogged Clean or replace G-11, 27

Fuel filter clogged Replace G-13, 15

Excessively high viscosity of fuel or engine oil at low temperature

Fuel with low cetane number Use specified fuel G-6

Fuel leak due to loose injection pipe retaining nut Tighten retaining nut S-31

Incorrect injection timing Adjust S-20

Fuel camshaft worn Replace S-41

Injection nozzle clogged Repair or replace S-22, 32

Injection pump malfunctioning Repair or replace S-21, 43

Seizure of crankshaft, camshaft, piston, cylinder or bearing

Compression leak from cylinder Replace head

Improper valve timing Correct or replace

Piston ring and cylinder worn Replace S-52, 53,

Excessive valve clearance Adjust S-16

Stop solenoid malfunctioning Replace S-26

Starter malfunctioning Repair or replace S-25, 56,

Key switch malfunctioning Replace –

Wiring disconnected Connect –

Use specified fuel or engine oil

Repair or replace –

gasket, tighten cylinder head screw, glow plug and nozzle holder

timing gear

Reference Page

–

G-6, 9

S-31 to 34

S-50

69, 74

W1034445

S-1

Page 71

V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

ENGINE

Symptom Probable Cause Solution

Engine Revolution Is Not Smooth

Fuel filter clogged or dirty Replace G-13, 15

Air cleaner clogged Clean or replace G-12, 24

Fuel leak due to loose injection pipe retaining nut Tighten retaining nut S-31

Injection pump malfunctioning Repair or replace S-21, 43

Incorrect nozzle opening pressure Repair or replace S-22, 32

Injection nozzle stuck or clogged Repair or replace S-22, 32

Governor malfunctioning Repair S-38, 39

Turbocharger bearing worn out Replace the

turbocharger assembly

Turbocharger shaft bent Replace the

turbocharger assembly

Turbocharger fin or other part damaged due to foreign matters

Replace the turbocharger assembly

Either White or Blue Exhaust Gas Is Observed

Excessive engine oil Reduce to specified

level

Piston ring and cylinder worn or stuck Repair or replace S-52, 53,

Incorrect injection timing Adjust S-20

Oil Leak into Exhaust Pipe or Suction Pipe

Waste oil pipe clogged or deformed Repair or replace S-29

Turbocharger’s piston ring seal faulty Replace the

turbocharger assembly

Either Black or Dark Gray Exhaust Gas Is Observed

Overload Reduce the load –

Low grade fuel used Use specified fuel G-6

Fuel filter clogged Replace G-13, 15

Air cleaner clogged Clean or replace G-12, 24

Deficient nozzle injection Repair or replace

nozzle

Reference Page

S-27, 29

G-7, 9

69, 74

S-29

S-22, 32

W1036076

S-2

Page 72

V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

ENGINE

Symptom Probable Cause Solution

Reference Page

Deficient Output Incorrect injection timing Adjust S-20

Engine’s moving parts seem to be seizing Repair or replace –

Injection pump malfunctioning Repair or replace S-21, 43

Deficient nozzle injection Repair or replace

S-22, 32

nozzle

Compression leak Check the

compression

S-15,

31 to 34

pressure and repair

Gas leak from exhaust system Repair or replace S-27, 29

Air leak from compressor discharge side Repair or replace S-27, 29

Air cleaner dirty or clogged Clean or replace G-12, 24

Compressor wheel turning heavily Replace the

S-27, 29 turbocharger assembly

Excessive Lubricant Oil Consumption

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

direction

S-52, 53

Oil ring worn or stuck Replace S-52, 53,

Piston ring groove worn Replace piston S-52, 53,

Valve stem and valve guide worn Replace S-35, 61

Crankshaft bearing and crank pin bearing worn Replace S-52, 53,

70 to 72

Oil leaking due to defective seals or packing Replace –

Fuel Mixed into Lubricant Oil

Injection pump’s plunger worn Repair or replace S-21, 43

Deficient nozzle injection Repair or replace

S-22, 32 nozzle

Injection pump broken Replace S-21, 43

Water Mixed into Lubricant Oil

Head gasket defective Replace S-33, 34

Cylinder block or cylinder head flawed Replace S-60

Low Oil Pressure Engine oil insufficient Replenish G-7, 9

Oil strainer clogged Clean S-51

Relief valve stuck with dirt Clean S-46, 76

Relief valve spring weaken or broken Replace S-46, 76

Excessive oil clearance of crankshaft bearing Replace S-54, 72

Excessive oil clearance of crankpin bearing Replace S-52, 71

Excessive oil clearance of rocker arm Replace S-32, 63

Oil passage clogged Clean –

Different type of oil Use specified type of

G-6, 9

oil

Oil pump defective Replace S-17, 75

W1037777

S-3

Page 73

V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

ENGINE

Symptom Probable Cause Solution

High Oil Pressure Different type of oil Use specified type of

Reference Page

G-6, 9

oil

Relief valve defective Replace S-46, 76

Engine Overheated Engine oil insufficient Replenish G-7, 9

Fan belt broken or elongated Replace or adjust G-12, 15

Coolant insufficient Replenish G-8, 15

Radiator net and radiator fin clogged with dust Clean –

Inside of radiator corroded Clean or replace G-15

Coolant flow route corroded Clean or replace G-15

Radiator cap defective Replace S-18

Overload running Reduce the load –

Head gasket defective Replace S-33, 34

Incorrect injection timing Adjust S-20

Unsuitable fuel used Use specified fuel G-6

Battery Quickly Discharged

Battery electrolyte insufficient Replenish distilled

water and charge

Fan belt slips Adjust belt tension or

G-18, 19

G-12, 15

replace

Wiring disconnected Connect –

Rectifier defective Replace S-26, 56

Alternator defective Replace S-26, 56

Battery defective Replace G-27,

S-23, 24

W1168623

S-4

Page 74

V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

2. SERVICING SPECIFICATIONS

ENGINE BODY

Item Factory Specification Allowable Limit

Compression Pressure 3.92 MPa /

−1

250 min

40.0 kgf/cm

250 min

(rpm)

−1

(rpm)

569 psi /

−1

250 min

(rpm)

Variance Among Cylinders – 10 % or less

Valve Clearance (Cold) 0.13 to 0.17 mm

0.0052 to 0.0068 in.

Top Clearance 0.60 to 0.80 mm

0.024 to 0.031 in.

Cylinder Head Surface Flatness – 0.05 mm

Valve Recessing (Intake and Exhaust) 0.65 to 0.85 mm

0.026 to 0.033 in.

Valve Stem to Valve Guide (Intake and Exhaust)

Clearance

0.055 to 0.085 mm

0.0022 to 0.0033 in.

2.90 MPa /

250 min

29.6 kgf/cm

250 min

421 psi /

250 min

–

0.002 in.

1.20 mm

0.0472 in.

0.10 mm

0.0039 in.

−1

ENGINE

(rpm)

Valve Stem

O.D.

6.960 to 6.975 mm

0.2741 to 0.2746 in.

Valve Guide

I.D.

7.030 to 7.045 mm

0.2768 to 0.2773 in.

Valve Face (Intake and Exhaust) Angle 0.79 rad

(45 °)

Valve Seat (Intake and Exhaust) Angle

0.79 rad (45 °)

Width

3.3 to 3.6 mm

0.13 to 0.14 in.

Intake Valve Timing Open

0.24 rad (14 °) before T.D.C.

0.70 rad (40 °)

after B.D.C.

Exhaust Valve Timing Open

0.87 rad (50 °)

before B.D.C.

0.24 rad (14 °)

after T.D.C.

Valve Spring (Intake and Exhaust) Tilt

–

1.0 mm

0.039 in.

Free Length

S-5

35.1 to 35.6 mm

1.39 to 1.40 in.

34.6 mm

1.36 in.

W1185533

Page 75

V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

ENGINE BODY (Continued)

Item Factory Specification Allowable Limit

Valve Spring (Intake and Exhaust) Setting Load /

Setting Length

Rocker Arm Shaft to Rocker Arm

Oil Clearance

63.5 N / 31.5 mm

6.48 kgf / 31.5 mm

14.3 lbf / 1.24 in.

0.016 to 0.045 mm

0.00063 to 0.0017 in.

ENGINE

45.9 N /

31.5 mm

4.68 kgf / 31.5 mm

10.3 lbf /

1.24 in.

0.15 mm

0.0059 in.

Rocker Arm Shaft

O.D.

14.973 to 14.984 mm

–

0.58949 to 0.58992 in.

Rocker Arm

I.D.

15.000 to 15.018 mm

–

0.59056 to 0.59125 in.

Valve Bridge Arm and Valve Bridge Shaft

Valve Bridge Shaft

Oil Clearance

O.D.

0.018 to 0.042 mm

0.00071 to 0.0016 in.

9.023 to 9.032 mm

0.15 mm

0.0059 in.

–

0.3553 to 0.3555 in.

Valve Bridge Arm

I.D.

9.050 to 9.065 mm

–

0.3563 to 0.3568 in.

Push Rod Alignment – 0.25 mm

0.0098 in.

Tappet to Tappet Bore

Tappet

Oil Clearance

O.D.

0.020 to 0.050 mm

0.00079 to 0.0019 in.

9.965 to 9.980 mm

0.07 mm

0.003 in.

–

0.3924 to 0.3929 in.

Tappet Bore

I.D.

10.000 to 10.015 mm

–

0.39370 to 0.39429 in.

Timing Gear

Crank Gear to Cam Gear

Backlash

0.0410 to 0.139 mm

0.00162 to 0.00547 in.

0.22 mm

0.0087 in.

Cam Gear to Idle Gear

Idle Gear to Injection Pump Gear

Idle Gear Side Clearance 0.15 to 0.25 mm

Idle Gear Shaft to Idle Gear Bushing

Idle Gear Shaft

Idle Gear Bushing

Backlash

Oil Clearance

O.D.

I.D.

S-6

0.0410 to 0.134 mm

0.00162 to 0.00527 in.

0.0410 to 0.134 mm

0.00162 to 0.00527 in.

0.0059 to 0.0098 in.

0.050 to 0.091 mm

0.0020 to 0.0036 in.

34.959 to 34.975 mm

1.3764 to 1.3769 in.

35.025 to 35.050 mm

1.3790 to 1.3799 in.

0.22 mm

0.0087 in.

0.22 mm

0.0087 in.

0.90 mm

0.035 in.

0.10 mm

0.0039 in.

–

W1041245

Page 76

V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

ENGINE BODY (Continued)

Item Factory Specification Allowable Limit

Camshaft Side Clearance – 0.10 mm

0.0039 in.

Camshaft Alignment – 0.01 mm

0.0004 in.

Cam Height Intake

37.50 mm

1.476 in.

37.00 mm

1.457 in.

ENGINE

Exhaust

37.90 mm

1.492 in.

Camshaft

Oil Clearance

0.050 to 0.091 mm

0.0020 to 0.0035 in.

Camshaft Journal 1

O.D.

34.934 to 34.950 mm

1.3754 to 1.3759 in.

Cylinder Block Bore 1

I.D.

35.000 to 35.025 mm

1.3780 to 1.3789 in.

Camshaft Journal 2

O.D.

43.934 to 43.950 mm

1.7297 to 1.7303 in.

Cylinder Block Bore 2

I.D.

44.000 to 44.025 mm

1.7323 to 1.7332 in.

Piston Pin Bore I.D. 28.000 to 28.013 mm

1.1024 to 1.1028 in.

Piston Pin to Small End Bushing

Oil Clearance

0.020 to 0.040 mm

0.00079 to 0.0015 in.

Piston Pin

O.D.

28.006 to 28.011 mm

1.1026 to 1.1027 in.

37.40 mm

1.472 in.

0.15 mm

0.0059 in.

–

28.05 mm

1.104 in.

0.15 mm

0.0059 in.

–

Small End Bushing

I.D.

28.031 to 28.046 mm

–

1.1036 to 1.1041 in.

Connecting Rod Alignment – 0.05 mm

0.002 in.

Piston Ring Gap Top Ring

Second Ring

Oil Ring

0.25 to 0.40 mm

0.0099 to 0.015 in.

0.30 to 0.45 mm

0.012 to 0.017 in.

0.25 to 0.45 mm

0.0099 to 0.017 in.

1.25 mm

0.0492 in.

1.25 mm

0.0492 in.

1.25 mm

0.0492 in.

W1042752

S-7

Page 77

V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

ENGINE BODY (Continued)

Piston Ring to Piston Ring Groove

Top Ring

ENGINE

Item Factory Specification Allowable Limit

Clearance

0.050 to 0.090 mm

0.0020 to 0.0035 in.

0.15 mm

0.0059 in.

Second Ring

Oil Ring

Clearance

Crankshaft Side Clearance 0.15 to 0.35 mm

0.090 to 0.12 mm

0.0035 to 0.0047 in.

0.020 to 0.060 mm

0.00079 to 0.0023 in.

0.0059 to 0.013 in.

0.20 mm

0.0079 in.

0.15 mm

0.0059 in.

0.50 mm

0.020 in.

Crankshaft Alignment – 0.02 mm

0.0008 in.

Crank Pin to Crank Pin Bearing

Crank Pin

Oil Clearance

O.D.

0.017 to 0.048 mm

0.00067 to 0.0018 in.

49.980 to 49.991 mm

0.20 mm

0.0079 in.

–

1.9678 to 1.9681 in.

Crankshaft Journal to Crankshaft Bearing

Crankshaft Journal

Oil Clearance

O.D.

0.030 to 0.073 mm

0.0012 to 0.0028 in.

79.977 to 79.990 mm

0.20 mm

0.0079 in.

–

3.1487 to 3.1492 in.

Cylinder Bore I.D. 94.000 to 94.022 mm

3.7008 to 3.7016 in.

Cylinder Bore (Oversize) I.D. 94.500 to 94.522 mm

3.7205 to 3.7213 in.

94.15 mm

3.707 in.

94.65 mm

3.726 in.

W10138740

S-8

Page 78

V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

LUBRICATING SYSTEM

Item Factory Specification Allowable Limit

Engine Oil Pressure At Idle Speed

ENGINE

–

49 kPa

0.50 kgf/cm

7.1 psi

At Rated Speed

197 to 392 kPa

2.00 to 4.00 kgf/cm

28.5 to 56.8 psi

Engine Oil Pressure Switch Working Pressure 40 to 58 kPa

0.40 to 0.60 kgf/cm

5.7 to 8.5 psi

Inner Rotor to Outer Rotor Clearance 0.030 to 0.090 mm

0.0012 to 0.0035 in.

Outer Rotor to Pump Body Clearance 0.100 to 0.184 mm

0.00394 to 0.00724 in.

Rotor to Cover Clearance 0.025 to 0.075 mm

0.00099 to 0.0029 in.

Relief Valve Spring Free

Length

Working Pressure

60.0 to 60.5 mm

2.37 to 2.38 in

294 kPa

3.00 kgf/cm

42.7 psi

COOLING SYSTEM

Fan Belt Tension 10.0 to 12.0 mm / 98 N

0.394 to 0.472 in. / 98 N (10 kgf, 22 lbf)

Radiator Cap Pressure Falling

Time

10 seconds or more

88 → 59 kPa

0.90 → 0.60 kgf/cm 13 → 8.5 psi

Radiator Water Leakage

Tes t P r e s su re

Thermostat Valve Opening

Temperature

No leak at specified

pressure

74.5 to 78.5 °C

166.1 to 173.3 °F

147 kPa

1.50 kgf/cm

21.3 psi

–

0.30 mm

0.012 in.

0.30 mm

0.012 in.

0.225 mm

0.00886 in.

55.0 mm

2.17 in.

–

W10139730

–

Valve Opening Temperature (Opened Completely)

S-9

90 °C

194 °F

–

W10135990

Page 79

V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

FUEL SYSTEM

Item Factory Specification Allowable Limit

Injection Timing V3307-DI-T-E2B 0.00436 rad before

–

T.D.C. to 0.0218 rad

after T.D.C.

(0.250 ° before T.D.C. to

1.25 ° after T.D.C.)

Pump Element Fuel Tightness – 18.63 MPa

190.0 kgf/cm 2702 psi

Delivery Valve Fuel Tightness 10 seconds

18.63 → 17.65 MPa

190.0 → 180.0 kgf/cm 2702 → 2560 psi

5 seconds

18.63 → 17.65 MPa

190.0 →

180.0 kgf/cm

2702 → 2560 psi

Fuel Injection Nozzle Injection Pressure

(1st stage)

18.64 to 19.61 MPa

190.0 to 200.0 kgf/cm

–

2703 to 2844 psi

ENGINE

Injection Pressure (2nd stage)

Valve Seat Tightness

22.56 to 23.53 MPa

230.0 to 240.0 kgf/cm

3272 to 3413 psi

When the pressure is

16.67 MPa

(170.0 kgf/cm

, 2418

psi), the valve seat must

be fuel tightness.

–

W10139730

S-10

Page 80

V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

ELECTRICAL SYSTEM

Item Factory Specification Allowable Limit

Glow Plug Resistance Approx. 0.95 Ω –

Starter

Commutator

O.D.

32.0 mm

31.4 mm

1.26 in.

ENGINE

1.24 in.

Mica

Brush

Brush Holder - Holder Support

Commutator - Armature Coil Core

Commutator - Segment

Field Coil Lead - Brush

Field Coil Brush - Yoke

Alternator

No-load Voltage

Stator

Rotor

Undercut

Length

Resistance

Output Voltage

Resistance

0.50 mm

0.020 in.

18.0 mm

0.709 in.

Infinity

0 Ω

Infinity

13.8 to 14.8 V at 25 °C (77 °F),

4000 min

-1

(rpm)

Less than 1.0 Ω

2.8 to 3.3 Ω

0.20 mm

0.0079 in.

11.0 mm

0.433 in.

–

Slip Ring

Brush

O.D.

Length

22.7 mm

0.894 in.

18.5 mm

0.728 in.

22.1 mm

0.870 in.

5.0 mm

0.20 in.

W1173869

S-11

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V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

ENGINE

3. TIGHTENING TORQUES

Screws, 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 AND

NUTS

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

Grade

Nominal Unit Diameter

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 8.31

M8 18 to 20 1.8 to 2.1 13 to 15 24 to 27 2.4 to 2.8 18 to 20

M10 40 to 45 4.0 to 4.6 29 to 33 49 to 55 5.0 to 5.7 37 to 41

M12 63 to 72 6.4 to 7.4 47 to 53 78 to 90 7.9 to 9.2 58 to 66

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

Punched number Screw and bolt material grade

None or 4 Standard screw and bolt SS41, S20C

7 Special screw and bolt S43C, S48C (Refined)

Standard Screw and Bolt

N·m kgf·m lbf·ft N·m kgf·m lbf·ft

Special Screw and Bolt

W10371750

W1012705

S-12

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V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

ENGINE

[2] TIGHTENING TORQUES FOR SPECIAL USE SCREWS, BOLTS AND

NUTS

NOTEQ

• For “*” marked screws, bolts and nuts on the table, apply engine oil to their threads and seats before tightening.

• The letter “M” in Size x Pitch means that the screw, bolt or nut dimension stands for metric. The size is the nominal outside diameter in mm of the threads. The pitch is the nominal distance in mm between two threads.

Item Size x Pitch N·m kgf·m lbf·ft

Glow lead mounting nut M4 x 0.7 0.98 to 1.7 0.10 to 0.18 0.73 to 1.3

Glow plug M8 x 1.0 7.7 to 9.3 0.78 to 0.95 5.7 to 6.8

Cylinder head cover screw M6 x 1.0 9.81 to 11.2 1.00 to 1.15 7.24 to 8.31

Injection pipe retaining nut M12 x 1.5 23 to 36 2.3 to 3.7 17 to 26

Oil switch taper screw R 1/8 15 to 19 1.5 to 2.0 11 to 14

Injection pump unit mounting nut M8 x 1.25 18 to 20 1.8 to 2.1 13 to 15

Drain plug M22 x 1.5 45 to 53 4.5 to 5.5 33 to 39

Oil pipe 1 mounting screw M10 x 1.25 16 to 19 1.6 to 2.0 12 to 14

Thermo valve R 3/8 30 to 39 3.0 to 4.0 22 to 28

Nozzle holder clamp screw M8 x 1.25 24 to 27 2.4 to 2.8 18 to 20

Overflow pipe assembly retaining screw M6 x 1.0 9.81 to 11.2 1.00 to 1.15 7.24 to 8.31

*Lubricating oil pipe mounting screw M10 x 1.25 16 to 19 1.6 to 2.0 12 to 14

Governor housing mounting screw M6 x 1.0 9.81 to 11.2 1.00 to 1.15 7.24 to 8.31

Lock nut M5 x 0.8 2.9 to 4.0 0.29 to 0.41 2.1 to 2.9

Injection pump assembly mounting screw M8 x 1.25 24 to 27 2.4 to 2.8 18 to 20

Injection pump assembly mounting nut M8 x 1.25 18 to 20 1.8 to 2.1 13 to 15

Governor weight mounting nut M12 x 1.25 63 to 72 6.4 to 7.4 47 to 53

Fuel camshaft stopper mounting screw M6 x 1.0 9.81 to 11.2 1.00 to 1.15 7.24 to 8.31

Fuel camshaft bearing stopper mounting screw

*Crankshaft screw M16 x 1.5 255 to 274 26.0 to 28.0 188 to 202

Relief valve retaining screw M22 x 1.5 69 to 78 7.0 to 8.0 51 to 57

*Flywheel screw M12 x 1.25 98.1 to 107 10.0 to 11.0 72.4 to 79.5

Camshaft set screw M8 x 1.25 24 to 27 2.4 to 2.8 18 to 20

Balancer shaft set screw M8 x 1.25 24 to 27 2.4 to 2.8 18 to 20

Starter’s terminal B mounting nut M8 x 1.25 9.8 to 11 1.0 to 1.2 7.3 to 8.6

Alternator pulley nut M24 58.4 to 78.9 5.95 to 8.05 43.1 to 58.2

Oil pump cover screw M6 7.9 to 9.3 0.80 to 0.95 5.8 to 6.8

M6 x 1.0 3.9 to 4.2 0.39 to 0.43 2.9 to 3.1

W1013236

S-13

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V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

ENGINE

Item Size x Pitch N·m kgf·m lbf·ft

Rocker arm bracket screw M10 x 1.25 49 to 55 5.0 to 5.7 37 to 41

*Cylinder head mounting screw M14 x 1.5 187 to 196 19.0 to 20.0 138 to 144

Injection pump gear mounting nut (left-handed screw)

M16 x 1.5 -LH 138 to 158 14.0 to 16.0 102 to 115

Oil cooler joint screw M20 x 1.5 40 to 44 4.0 to 4.5 29 to 32

Front cover mounting screw (7T) M8 x 1.25 24 to 27 2.4 to 2.8 18 to 20

Front cover mounting screw (10T) M8 x 1.25 30 to 34 3.0 to 3.5 22 to 25

Flywheel housing mounting screw (9T) M12 x 1.25 103 to 117 10.5 to 12.0 76.0 to 86.7

Idle gear mounting screw (10T) M8 x 1.25 30 to 34 3.0 to 3.5 22 to 25

*Connecting rod screw M9 x 1.0 69 to 73 7.0 to 7.5 51 to 54

*Crankcase 2 mounting screw M14 x 1.5 138 to 147 14.0 to 15.0 102 to 108

Crankcase 2 flange screw (9T) M10 x 1.25 59 to 63 6.0 to 6.7 44 to 47

W1335256

S-14

Page 84

V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

4. CHECKING, DISASSEMBLING AND SERVICING

[1] CHECKING AND ADJUSTING

(1) Engine Body

Compression Pressure

1. After warming up the engine, shut it down and remove the air cleaner, the muffler, breather tube, glow lead and all glow plugs.

2. Install a compression tester (1) (Code No: 07909-30208) and glow plug adaptor (2) to glow plug hole. (Refer to “5. SPECIAL TOOLS” at “GENERAL” Section.)

3. After making sure that the stop lever is set at the stop position (Non-injection), run the engine at 200 to 300 min starter.

4. Read the maximum pressure. Measure the pressure more than twice.

NOTEQ

• Check the compression pressure with the specified valve clearance.

• Always use a fully charged battery for performing this test.

• Variances in cylinder compression values should be under 10 %.

Compression pressure

Factory spec.

Allowable limit

3.92 MPa / 250 min

40.0 kgf/cm 569 psi / 250 min

2.90 MPa / 250 min

29.6 kgf/cm 421 psi / 250 min

/ 250 min-1 (rpm)

ENGINE

−1

(rpm) with the

-1

(rpm)

-1

(rpm)

-1

(rpm)

-1

(rpm)

Glow lead mounting nut

Tightening torque

Glow plug

(1) Compression Tester (2) Glow Plug Adaptor

0.98 to 1.7 N·m

0.10 to 0.18 kgf·m

0.73 to 1.3 lbf·ft

7.7 to 9.3 N·m

0.78 to 0.95 kgf·m

5.7 to 6.8 lbf·ft

W1048776

S-15

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V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

ENGINE

Valve Clearance

IMPORTANTQ

• Valve clearance must be checked and adjusted when engine is cold.

1. Remove the high pressure pipes, glow lead, glow plugs and the cylinder head cover.

2. Align the 1TC mark of flywheel and the convex of flywheel housing timing windows so that the first piston (front cover side) comes to the compression top dead center.

[Adjustable type of valve bridge arm]

3. Before adjusting the valve clearance, adjust the valve bridge arm evenly to the valve stem.

4. Loosen the lock nut (2) of adjusting screw (1) and adjust with screw.

5. Slightly push the rocker arm with your fingers and screw in the adjusting screw (1) slowly until you feel the screw touch the top of valve stem, then tighten the lock nut (2).

[Adjustment unnecessary type of valve bridge arm]

Valve clearance A Factory spec.

0.13 to 0.17 mm

0.0052 to 0.0066 in.

NOTEQ

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

Valve arrangement Adjustment cylinder Location of piston

When No.1 piston is at compression top dead center

When No.1 piston is at overlap position

Cylinder head cover screw

Tightening torque

Injection pipe retaining nut

(1) Adjusting Screw (2) Lock Nut (3) Adjusting Screw (4) Lock Nut

1st ,,

2nd ,

3rd ,

4th

1st

2nd ,

3rd ,

4th ,,

A : Valve Clearance

IN. EX.

9.81 to 11.2 N·m

1.00 to 1.15 kgf·m

7.24 to 8.31 lbf·ft

23 to 36 N·m

2.3 to 3.7 kgf·m 17 to 26 lbf·ft

W1197781

S-16

Page 86

V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

(2) Lubricating System

ENGINE

Engine Oil Pressure

1. Remove the oil switch and set a pressure tester (Code No. 07916-32032).

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.

49 kPa

0.50 kgf/cm

7.1 psi

197 to 392 kPa

2.00 to 4.00 kgf/cm

28.5 to 56.8 psi

147 kPa

1.50 kgf/cm

21.3 psi

Engine oil pressure

At idle speed

At rated speed

Allowable limit

Factory spec.

Allowable limit

(3) Cooling System

Tightening torque Oil switch taper screw

15 to 19 N·m

1.5 to 2.0 kgf·m 11 to 14 lbf·ft

W10349520

Fan Belt Tension

1. Measure the deflection (A), depressing the fan belt (2) 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, loosen the alternator mounting screws (1) and relocate the alternator to adjust.

Deflection (A) Factory spec.

(1) Alternator Mounting Screw (2) Fan Belt

(A) Deflection

10.0 to 12.0 mm

0.394 to 0.472 in.

W1082347

S-17

Page 87

V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

ENGINE

Fan Belt Damage and Wear

1. 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.

(A) Good (B) Bad

W1021108

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 Cap Air Leakage

1. Set a radiator tester (1) and an adaptor (2) on the radiator cap.

2. Apply the specified pressure of 88 kPa (0.90 kgf/cm

, 13 psi), and

measure the time for the pressure to fall to 59 kPa (0.60 kgf/cm

8.5 psi).

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

More than 10 seconds

Pressure falling time Factory spec.

(1) Radiator Tester (2) Adaptor

for pressure fall 88 → 59 kPa (0.90 → 0.60 kgf/cm 13 → 8.5 psi)

W1054156

Radiator Water Leakage

1. Pour a specified amount of water into the radiator.

2. Set a radiator tester (1) and an adaptor (2) 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 the radiator.

Radiator water leakage test pressure

Factory spec.

No leak at specified pressure

NOTEQ

• The pressure of the leak test is different from each radiator specification. Thus, do the leak test, refer to the test pressure of each radiator specification.

(1) Radiator Tester (2) Adaptor

W1016903

S-18

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V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

ENGINE

Thermostat Valve Opening Temperature

1. Push down the thermostat valve and insert a string between the valve and the valve seat.

2. Place the thermostat and a thermostat in a container with water and gradually heat the water.

3. Hold the string to suspend the thermostat in the water. When the water temperature rises, the thermostat valve will open, allowing it to fall down from the string. Read the temperature at this moment on the thermometer.

4. Continue heating the water and read the temperature when the valve has risen by about 8 mm (0.3 in.).

5. If the measurement is not acceptable, replace the thermostat.

Thermostat’s valve opening temperature

Temperature at which thermostat completely opens

Factory spec.

74.5 to 78.5 °C

166.1 to 173.3 °F

90 °C 194 °F

W1071639

S-19

Page 89

V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

(4) Fuel System

ENGINE

Injection Timing

1. Make sure of matching the injection timing align mark (1) of the injection pump unit and the flywheel housing, as shown in the illustration.

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 (3) for No.1 cylinder.

5. After the fuel fills up to the hole of the delivery valve holder (3) for No.1 cylinder, turn back (clockwise) the flywheel around 1.6 rad (90 °).

6. Turn the flywheel counterclockwise to set at around 0.17 rad (10 °) before T.D.C..

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

8. Check to see the degree on flywheel. The flywheel has mark “1TC” for the crank angle before the top dead center of No.1 piston.

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

IMPORTANTQ

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

0.00436 rad before T.D.C. to 0.0218 rad

Injection timing Factory spec.

after T.D.C. (0.250 ° before T.D.C. to

1.25 ° after T.D.C.)

Injection pipe retaining nut

Tightening torque

Injection pump unit mounting nut

(1) Injection Timing Align Mark (2) Injection Pump Unit Mounting Nut (3) Delivery Valve Holder

23 to 36 N·m

2.3 to 3.7 kgf·m 17 to 26 lbf·ft

18 to 20 N·m

1.8 to 2.1 kgf·m 13 to 15 lbf·ft

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

W1089274

S-20

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V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

ENGINE

Fuel Tightness of Pump Element

1. Remove the engine stop solenoid.

2. Remove the injection pipes.

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 the figure.)

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 pump service shop.

Fuel tightness of pump element

Allowable limit

18.63 MPa

190.0 kgf/cm 2702 psi

NOTEQ

• Never try to disassemble the injection pump assembly. For repairs, you are strongly requested to contact a Kubotaauthorized pump service shop.

(1) Injection Pump Pressure Tester (2) Injection Nozzle

(3) Protection Cover for Jetted Fuel

W1017430

Fuel Tightness of Delivery Valve

1. Remove the engine stop solenoid.

2. Remove the injection pipes.

3. Install 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 hand and raise the pressure to approx. 18.63 MPa (190.0 kgf/cm

, 2702 psi).

7. Now turn the flywheel back about half a turn (to keep the plunger free). Maintain the flywheel at this position and clock the time taken for the pressure to drop from 18.63 to 17.65 MPa (from

190.0 to 180.0 kgf/cm

8. Measure the time needed to decrease the pressure from 18.63 to

17.65 MPa (from 190.0 to 180.0 kgf/cm

, from 2702 to 2560 psi).

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

10 seconds

Factory spec.

Fuel tightness of delivery valve

Allowable limit

18.63 → 17.65 MPa

190.0 → 180.0 kgf/cm 2702 → 2560 psi

5 seconds

18.63 → 17.65 MPa

190.0 → 180.0 kgf/cm 2702 → 2560 psi

NOTEQ

• Never try to disassemble the injection pump assembly. For repairs, you are strongly requested to contact a Kubotaauthorized pump service shop.

(1) Injection Pump Pressure Tester (2) Injection Nozzle

(3) Protection Cover for Jetted Fuel

W1017786

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KiSC issued 01, 2009 A

ENGINE

CAUTION

• Check the nozzle injection pressure and condition after confirming that there is nobody standing in the direction the spray goes.

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

Nozzle Spraying Condition

1. Attach the injection nozzle to the nozzle tester, and check the nozzle spraying condition.

2. If the spraying condition is defective, replace the injection nozzle assembly or repair at Kubota-authorized nozzle service shop.

(a) Good (b) Bad

W10371670

Checking Nozzle Injection Pressure

1. Attach the injection nozzle to the 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 injection nozzle assembly or repair at Kubotaauthorized nozzle service shop.

NOTEQ

• Injection nozzle gasket must be replaced when the injection nozzle is removed for checking.

Injection pressure (1st stage)

Factory spec.

18.64 to 19.61 MPa

190.0 to 200.0 kgf/cm 2703 to 2844 psi

W1037280

Valve Seat Tightness

1. Attach the injection nozzle to the nozzle tester.

2. Raise the fuel pressure, and keep at 16.67 MPa (170.0 kgf/cm 2418 psi) for 10 seconds.

3. If any fuel leak is found, replace the injection nozzle assembly or repair at Kubota-authorized nozzle service shop.

No fuel leak at

Valve seat tightness Factory spec.

16.67 MPa

170.0 kgf/cm 2418 psi

W10374150

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V3307-DI-T-E2B, WSM

KiSC issued 01, 2009 A

ENGINE

(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.

IMPORTANTQ

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

Battery Voltage

1. 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.

Battery voltage Factory spec. More than 12 V

(1) Positive Terminal (2) Negative Terminal

W10125620

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KiSC issued 01, 2009 A

ENGINE

Battery Specific Gravity (for Refillable Battery’s only)

1. 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 reading following the formula mentioned in (Reference).

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

4. If the specific gravity differs between any two cells by more than

0.05, replace the battery.

NOTEQ

• Hold the hydrometer tube vertical without removing it from the 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 at 20 °C = Measured value + 0.0007 ×

(electrolyte temperature : 20 °C)

- Specific gravity at 68 °F = Measured value + 0.0004 ×

(electrolyte temperature : 68 °F)

Specific Gravity State of Charge

1.260 Sp. Gr. 100 % Charged

1.230 Sp. Gr. 75 % Charged

1.200 Sp. Gr. 50 % Charged

1.170 Sp. Gr. 25 % Charged

1.140 Sp. Gr. Very Little Useful Capacity

1.110 Sp. Gr. Discharged

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

(a) Good (b) Bad

W1019017

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KiSC issued 01, 2009 A

ENGINE

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.

NOTEQ

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

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

(1) C Ter m in a l (2) Positive Terminal

(3) Negative Terminal

W1019297

Magnetic Switch Test

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 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.

NOTEQ

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

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

(1) S Terminal (2) Positive Terminal

(3) Negative Terminal

0000010743E

Magnet Switch Continuity Test

1. 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.

(1) C Ter m in a l ( 2 ) B Terminal

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ENGINE

Alternator on Unit Test (Before testing)

• Before alternator on unit test, check the battery terminal connections, circuit connection, fan belt tension, charging indicator lamp, fuses on the circuit, and abnormal noise from the alternator.

• Prepare full charged battery for the test.

NOTEQ

• Be careful not to touch the rotating engine parts while engine 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 the specifications, disassemble the alternator and check the each component part for finding out the failure. See the “DISASSEMBLING AND ASSEMBLING” and “SERVICING” for alternator.

Regulating voltage at no load

Factory spec.

13.8 to 14.8 V at 25 °C (77 °F)

0000010745E

Glow Plug Continuity

1. Remove the glow plug (2).

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 (2) is faulty.

NOTEQ

• Adjust the direction of the ditch to the terminal side when the seal (1) is installed in the glow plug (2).

Resistance Factory spec. Approx. 0.95 Ω

(1) Seal (2) Glow Plug

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Engine Stop Solenoid

1. Remove the engine stop solenoid from the engine.

2. Connect the jumper leads from the pulling coil P terminal to the

switch (3), and from switch (3) to the battery positive terminal.

3. Connect the jumper leads from the holding coil H terminal to the

switch (4), and from switch (4) to the battery positive terminal.

4. Connect the jumper leads from the engine stop solenoid body to the battery negative terminal.

5. When switch (4) is turn on, the plunger pull into the solenoid body and then turn off the switch (4), the plunger comes out.

6. Turn on the switch (3) then turn on the switch (4), the plunger pull into the solenoid body and it keep in holding position after turn off the switch (4).

7. If the plunger is not attracted, the engine stop solenoid is faulty.

IMPORTANTQ

• Never apply the current for pulling coil more than two seconds when inspecting.

(1) Connector (2) Battery (3) Switch for Holding Coil (4) Switch for Pulling Coil

P : Terminal for Pulling Coil H : Terminal for Holding Coil

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(6) Turbocharger

ENGINE

Turbine Side

1. Check the exhaust port (2) and inlet port (4) side of turbine housing (3) to see if there is no exhaust gas leak.

2. If any gas leak is found, retighten the bolts and nuts or replace the gasket (1) / (5) with new one.

(1) Gasket (2) Exhaust Port (3) Turbine Housing

(4) Inlet Port (5) Gasket

W1076917

Compressor Side

1. Check the inlet hose (4) of the compressor cover (1) to see if there is no air leak.

2. Check for loose connections or cracks in the suction side of the intake hose (3).

3. If any air leak is found, change the clamp band (2) and / or intake hoses (3).

(1) Compressor Cover (2) Clamp Band

(3) Intake Hose (4) Inlet Hose

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Radial Clearance

1. If the wheel contact to the housing, replace the turbocharger assembly with new one.

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[2] DISASSEMBLING AND ASSEMBLING

(1) Draining Oil and Coolant

Draining Engine Oil

1. Start and warm up the engine for approx. 5 minutes.

2. Place an oil pan underneath the engine.

3. Remove the drain plug (1) to drain oil.

4. After draining, screw in the drain plug (1).

(When refilling)

• Fill the engine oil up to the upper line on the dipstick (2).

IMPORTANTQ

• Never mix two different types of oil.

• Use the proper SAE Engine Oil according to ambient temperature.

Tightening torque Drain plug

ENGINE

45 to 53 N·m

4.5 to 5.5 kgf·m 33 to 39 lbf·ft

(2) External Components

(1) Drain Plug (2) Dipstick

(a) Upper Line (b) Lower Line

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Draining Coolant

CAUTION

• Never remove radiator cap while operating or immediately after stopping. Otherwise, hot water will spout out from the radiator. Wait for more than ten minutes to cool the radiator, before opening the cap.

1. Open the radiator drain plug and remove the radiator cap.

2. Remove the radiator hose (1) from engine body.

(1) Radiator Hose

W1023496

Air Cleaner, Muffler and Others

1. Remove the air cleaner and muffler.

2. Remove the fan (6), fan belt (5), breather hose (4), fuel filter cartridge (3), fuel tubes (2), alternator (7) and starter (1).

(When reassembling)

• Check to see that there are no cracks on the belt surface.

• Mount the check valve with the ↓ mark toward the tank.

IMPORTANTQ

• After reassembling the fan belt (5), be sure to adjust the fan belt tension.

• Do not confuse the direction of the fan (6). Attach the fan (6) with its marking facing frontward (toward the radiator).

(1) Starter (2) Fuel Tube (3) Fuel Filter Cartridge (4) Breather Hose

(5) Fan Belt (6) Fan (7) Alternator

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ENGINE

CAUTION

• While the engine is running and or just after it stops, the turbocharger is hot, be careful not to touch the turbocharger.

NOTEQ

• When detaching and attaching the turbocharger assembly, be very careful not to allow dust, dirt and other foreign matter in the oil pipes.

• When the turbocharger assembly has been replace, pour fresh engine oil through the oil filler port of the turbocharger.

• Before starting the engine, make sure that air cleaner is in position.

Oil Pipe and Intake Hose

1. Remove the joint bolt (1), bolt (3) and clamp band (4).

2. Disconnect the oil pipe 1 (2) and oil pipe 2 (5).

3. Remove the intake hose (6).

(When reassembling)

• Pour fresh engine oil through the oil filler port of the turbocharger.

• Replace the gasket with new one.

• Be careful not to allow dust, dirt and other foreign matters in the oil pipes (2) / (5).

NOTEQ

• Tape or plug all openings to prevent foreign matters from damaging the oil cavities in the turbocharger.

(1) Joint Bolt (2) Oil Pipe 1 (3) Bolt

(4) Clamp Band (5) Oil Pipe 2 (6) Intake Hose

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ENGINE

Turbocharger Assembly and Exhaust Manifold

1. Remove the cover (1) and exhaust manifold mounting screws (3).

2. Take off the turbocharger assembly (4) with exhaust manifold (2).

3. Remove the oil pipe 1 (6) and oil pipe 2 (9). (If necessary)

4. Remove the exhaust port (5) and exhaust manifold (2). (If necessary)

(When reassembling)

• Replace the gasket (8) with new one.

NOTEQ

• Be careful not to damage the O-ring (10).

Tightening torque Oil pipe 1 mounting screw

16 to 19 N·m

1.6 to 2.0 kgf·m 12 to 14 lbf·ft

(1) Cover (2) Exhaust Manifold (3) Exhaust Manifold Mounting Screw (4) Turbocharger Assembly (5) Exhaust Port

(6) Oil Pipe 1 (7) Oil Pipe Gasket (8) Gasket (9) Oil Pipe 2

(10) O-ring

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(3) Cylinder Head and Valves

ENGINE

Cylinder Head Cover

1. Remove the glow lead (4) and the glow plugs (3).

2. Remove the injection pipes (1).

3. Remove the cylinder head cover (2).

(When reassembling)

• Check to see that the cylinder head cover gasket is not detective.

• Tighten the head cover mounting screws to specified torque.

• Check the position of the injection pipe clamps (5) to reduce the vibration of the injection pipes (1). (See the figure.)

• Adjust the direction of the ditch to the terminal side when the seal (6) is installed in the glow plug (3).

• After installing the glow plug (3), confirm that the seal (6) was set to the specified position.

9.81 to 11.2 N·m

1.00 to 1.15 kgf·m

7.24 to 8.31 lbf·ft

23 to 36 N·m

2.3 to 3.7 kgf·m 17 to 26 lbf·ft

7.7 to 9.3 N·m

0.78 to 0.95 kgf·m

5.7 to 6.8 lbf·ft

Tightening torque

Cylinder head cover screw

Injection pipe retaining nut

Glow plug

(1) Injection Pipe (2) Cylinder Head Cover (3) Glow Plug (4) Glow Lead

(5) Injection Pipe Clamp (6) Seal

(A) Good (B) Bad

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