kj-x 50 hertz series (engusa)-9y011-01832 · 2019. 12. 15. · total displacement 2197 cm3 (134.1...
TRANSCRIPT
KJ-X 50 HERTZ SERIES
WORKSHOP MANUALDIESEL GENERATOR
KiSC issued 09, 2009 A
TO THE READER
This Workshop Manual has been prepared to provide servicing personnel withinformation on the mechanism, service and maintenance of KJ-X 50 Hz series. It isdivided into three parts, “General”, “Mechanism” and “Servicing”.
GeneralInformation on the engine identification, the general precautions, maintenance check
list, check and maintenance and special tools are described.
MechanismInformation on the construction and function are included. This part should be
understood before proceeding with troubleshooting, disassembling and servicing.Refer to Diesel Engine Mechanism Workshop Manual (Code No. 9Y021-01875) for
the one which has not been described to this workshop manual.
ServicingInformation on the troubleshooting, servicing specification lists, tightening torque,
checking and adjusting, disassembling and assembling, and servicing which coverprocedures, precautions, factory specifications and allowable limits.
All information illustrations and specifications contained in this manual are based onthe latest product information available at the time of publication.
The right is reserved to make changes in all information at any time without notice.Do to covering many models of this manual, information or picture being used have
not been specified as one model.
August 1999© KUBOTA Corporation 1999
KiSC issued 09, 2009 A
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KJ-X50 Hz SERIES, WSM SAFETY INSTRUCTIONS
SAFETY INSTRUCTIONS
BEFORE SERVICING AND REPAIRING• Read all instructions and safety instructions in this
manual and on your machine safety decals.• Clean the work area and generator unit.• Place the generator unit on a firm and level ground.• Allow the engine to cool before proceeding.• Stop the engine, and remove the key.• Disconnect the battery negative cable.• Hang a “DO NOT OPERATE” tag on the control
panel.
SAFETY FIRSTThis symbol, the industry’s “Safety Alert Symbol”, is used throughout this manual and on labels on
the machine itself to warn of the possibility of personal injury. Read these instructions carefully.It is essential that you read the instructions and safety regulations before you attempt to repair or use
this unit.
DANGER : Indicates an imminently hazardous situation which, if not avoided, will result indeath or serious injury.
WARNING : Indicates a potentially hazardous situation which, if not avoided, could result indeath or serious injury.
CAUTION : Indicates a potentially hazardous situation which, if not avoided, may result inminor or moderate injury.
IMPORTANT : Indicates that equipment or property damage could result if instructions are notfollowed.
NOTE : Gives helpful information.
KiSC issued 09, 2009 A
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KJ-X50 Hz SERIES, WSM 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 whilefatigued.
• Wear close fitting clothing and safety equipmentappropriate to the job.
• Use tools appropriate to the work. Makeshift tools,parts, and procedures are not recommended.
• When servicing is performed together by two or morepersons, take care to perform all work safely.
• Do not touch the rotating or hot parts while the engineis running.
• Never remove the radiator cap while the engine isrunning, or immediately after stopping. Otherwise, hotwater will spout out from radiator. Only removeradiator cap when cool enough to touch with barehands. Slowly loosen the cap to first stop to relievepressure before removing completely.
• Escaping fluid (fuel or hydraulic oil) under pressurecan penetrate the skin causing serious injury. Relievepressure before disconnecting hydraulic or fuel lines.Tighten all connections before applying pressure.
• Wear a suitable hearing protective device such asearmuffs or earplugs to protect against objectionableor uncomfortable loud noises.
• Do not open high-pressure fuel system.High-pressure fluid remaining in fuel lines can causeserious injury. Do not disconnect or attempt to repairfuel lines, sensors, or any other components betweenthe high-pressure fuel pump and injectors on engineswith high pressure common rail fuel system.
• High voltage exceeding 100 V is generated in theECU, and is applied to the injector.Pay sufficient caution to electric shock whenperforming work activities.
KiSC issued 09, 2009 A
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KJ-X50 Hz SERIES, WSM SAFETY INSTRUCTIONS
AVOID FIRES• Fuel is extremely flammable and explosive under
certain conditions. Do not smoke or allow flames orsparks in your working area.
• To avoid sparks from an accidental short circuit,always disconnect the battery negative cable first andconnect it last.
• Battery gas can explode. Keep sparks and openflame away from the top of battery, especially whencharging the battery.
• Make sure that no fuel has been spilled on the engine.
VENTILATE WORK AREA• If the engine must be running to do some work, make
sure the area is well ventilated. Never run the enginein a closed area. The exhaust gas contains poisonouscarbon monoxide.
PREVENT ACID BURNS• Sulfuric acid in battery electrolyte is poisonous. It is
strong enough to burn skin, clothing and causeblindness if splashed into eyes. Keep electrolyteaway from eyes, hands and clothing. If you spillelectrolyte on yourself, flush with water, and getmedical attention immediately.
DISPOSE OF FLUIDS PROPERLY• Do not pour fluids into the ground, down a drain, or
into a stream, pond, or lake. Observe relevantenvironmental protection regulations when disposingof oil, fuel, coolant, electrolyte and other harmfulwaste.
KiSC issued 09, 2009 A
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KJ-X50 Hz SERIES, WSM 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 yourtelephone.
KiSC issued 09, 2009 A
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KJ-X50 Hz SERIES, WSM SAFETY INSTRUCTIONS
The following safety decals are installed on the generator.If a decal becomes damaged, illegible or is not on the generator, replace it. The decal part number is listedin the parts list.
SAFETY DECALS
KiSC issued 09, 2009 A
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KJ-X50 Hz SERIES, WSM SAFETY INSTRUCTIONS
KiSC issued 09, 2009 A
7
KJ-X50 Hz SERIES, WSM SPECIFICATIONS
SPECIFICATIONS
* The specification described above is of the standard engine of each model.* Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW
W1014466
Model KJ-S130VX KJ-S170FXG
ener
ator
Type Revolving field, self-excited brushless AC generator
Insulation class H
Frequency 50 Hz
Output 12.5 kVA (12.5 kW) 17.0 kVA (17.0 kW)
Voltage (AC) 110 / 220 V 120 / 240 V 110 / 220 V 120 / 240 V
Current 56.8 A 52.1 A 77.3 A 70.8 A
Number of phases 1
Number of poles 4
Power factor 100%
Eng
ine
Model V2203-E/E2 F2803-E/E2
Type Vertical, water cooled, 4-cycle, diesel engine
Number of cylinders 4 5
Bore × Stroke 87.0 × 92.4 mm (3.43 × 3.64 in.)
Total displacement 2197 cm3 (134.1 cu.in.) 2746 cm3 (167.6 cu.in.)
Rated output 16.9 kW (23.0 PS) 21.1 kW (28.7 PS)
Speed 1500 min-1 (rpm)
Combustion system Spherical combustion chamber
Compression ratio 23 : 1
Cooling system Pressurized radiator, forced circulation with water pump
Lubricating system Forced lubrication by trochoid pump
Lubricating oil Class CF lubricating oil as per API classification is recommended.If this class of lubricating oil is not available, preferably use Class CD or CE lubricating oil.
For details on recommended lubricating oils, see page G-8, 11
Starting system Electric type
Battery 12 V x 80 AH
Fuel tank capacity 37 L (9.8 U.S.gals) 60 L (16 U.S.gals)
Coolant capacity 9.0 L (2.4 U.S.gals) 10.5 L (2.77 U.S.gals)
Engine oil capacity 7.6 L (2.0 U.S.gals) 10.5 L (2.77 U.S.gals)
Net weight 500 kg (1100 lbs) 610 kg (1340 lbs)
Emergency stop mechanism In case of abnormal oil pressure or water temperature
KiSC issued 09, 2009 A
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KJ-X50 Hz SERIES, WSM SPECIFICATIONS
* The specification described above is of the standard engine of each model.* Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW
W1031094
Model KJ-T130DX KJ-T180VX
Gen
erat
or
Type Revolving field, self-excited brushless AC generator
Insulation class H
Frequency 50 Hz
Output 12.5 kVA (10.0 kW) 18.0 kVA (14.4 kW)
Voltage (AC) 220, 380, 415 V
Current 32.8, 19.0, 17.4 A 47.2, 27.3, 25.0 A
Number of phases 3
Number of poles 4
Power factor 80%
Eng
ine
Model D1703-E/E2 V2203-E/E2
Type Vertical, water cooled, 4-cycle, diesel engine
Number of cylinders 3 4
Bore × Stroke 87.0 × 92.4 mm (3.43 × 3.64 in.)
Total displacement 1647 cm3 (100.5 cu.in.) 2197 cm3 (134.1 cu.in.)
Rated output 12.7 kW (17.3 PS) 16.9 kW (23.0 PS)
Speed 1500 min-1 (rpm)
Combustion system Spherical combustion chamber
Compression ratio 23 : 1
Cooling system Pressurized radiator, forced circulation with water pump
Lubricating system Forced lubrication by trochoid pump
Lubricating oil Class CF lubricating oil as per API classification is recommended.If this class of lubricating oil is not available, preferably use Class CD or CE lubricating oil.
For details on recommended lubricating oils, see page G-8, 11
Starting system Electric type
Battery 12 V x 80 AH
Fuel tank capacity 37 L (9.8 U.S.gals)
Coolant capacity 8.0 L (2.1 U.S.gals) 9.0 L (2.4 U.S.gals)
Engine oil capacity 5.6 L (1.5 U.S.gals) 7.6 L (2.0 U.S.gals)
Net weight 450 kg (992 lbs) 505 kg (1110 lbs)
Emergency stop mechanism In case of abnormal oil pressure or water temperature
KiSC issued 09, 2009 A
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KJ-X50 Hz SERIES, WSM SPECIFICATIONS
* The specification described above is of the standard engine of each model.* Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW
W1036208
Model KJ-T230FX KJ-T300
Gen
erat
orType Revolving field, self-excited brushless AC generator
Insulation class H
Frequency 50 Hz
Output 23.0 kVA (18.4 kW) 30.0 kVA (24.0 kW)
Voltage (AC) 220, 380, 415 V 380 V
Current 60.4, 34.9, 32.0 A 45.6 A
Number of phases 3
Number of poles 4
Power factor 80 %
Eng
ine
Model F2803-E/E2 V3300-E2BG
Type Vertical, water cooled, 4-cycle, diesel engine
Number of cylinders 5 4
Bore × Stroke 87.0 × 92.4 mm (3.43 × 3.64 in.) 98.0 × 110 mm (3.86 × 4.33 in.)
Total displacement 2746 cm3 (167.6 cu.in.) 3318 cm3 (202.5 cu.in.)
Rated output 21.1 kW (28.7 PS) 26.8 kW (36.4 PS)
Speed 1500 min-1 (rpm)
Combustion system Spherical combustion chamber
Compression ratio 23 : 1 22.6 : 1
Cooling system Pressurized radiator, forced circulation with water pump
Lubricating system Forced lubrication by trochoid pump
Lubricating oilClass CF lubricating oil as per API classification is recommended.
If this class of lubricating oil is not available, preferably use Class CD or CE lubricating oil.For details on recommended lubricating oils, see page G-8, 11
Starting system Electric type
Battery 12 V x 80 AH 12 V x 92 AH
Fuel tank capacity 60 L (16 U.S.gals) 60 L (16 U.S.gals)
Coolant capacity 10.5 L (2.77 U.S.gals) 9.5 L (2.5 U.S.gals)
Engine oil capacity 10.5 L (2.77 U.S.gals) 13.2 L (3.49 U.S.gals)
Net weight 615 kg (1360 lbs) 710 kg (1570 lbs)
Emergency stop mechanism In case of abnormal oil pressure or water temperature
KiSC issued 09, 2009 A
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KJ-X50 Hz SERIES, WSM SPECIFICATIONS
[For AUSTRALIA]
* The specification described above is of the standard engine of each model.* Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW
W1040045
Model KJ-S130VX-AUS KJ-S170FX-AUS
Gen
erat
or
Type Revolving field, self-excited brushless AC generator
Insulation class H
Frequency 50 Hz
Output 12.5 kVA (12.5 kW) 17.0 kVA (17.0 kW)
Voltage (AC) 240 V
Current 52.1 A 70.8 A
Number of phases 1
Number of poles 4
Power factor 100 %
Eng
ine
Model V2203-E/E2 F2803-E/E2
Type Vertical, water cooled, 4-cycle, diesel engine
Number of cylinders 4 5
Bore × Stroke 87.0 × 92.4 mm (3.43 × 3.64 in.)
Total displacement 2197 cm3 (134.1 cu.in.) 2746 cm3 (167.6 cu.in.)
Rated output 16.9 kW (23.0 PS) 21.1 kW (28.7 PS)
Speed 1500 min-1 (rpm)
Combustion system Spherical combustion chamber
Compression ratio 23 : 1
Cooling system Pressurized radiator, forced circulation with water pump
Lubricating system Forced lubrication by trochoid pump
Lubricating oilClass CF lubricating oil as per API classification is recommended.
If this class of lubricating oil is not available, preferably use Class CD or CE lubricating oil.For details on recommended lubricating oils, see page G-8, 11
Starting system Electric type
Battery 12 V x 80 AH
Fuel tank capacity 37 L (9.8 U.S.gals) 60 L (16 U.S.gals)
Coolant capacity 9.0 L (2.4 U.S.gals) 10.5 L (2.77 U.S.gals)
Engine oil capacity 7.6 L (2.0 U.S.gals) 10.5 L (2.77 U.S.gals)
Net weight 505 kg (1110 lbs) 615 kg (1360 lbs)
Emergency stop mechanism In case of abnormal oil pressure or water temperature
KiSC issued 09, 2009 A
11
KJ-X50 Hz SERIES, WSM SPECIFICATIONS
[For AUSTRALIA]
* The specification described above is of the standard engine of each model.* Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW
W1032024
Model KJ-T130DX-AUS KJ-T180VX-AUS KJ-T230FX-AUSG
ener
ator
Type Revolving field, self-excited brushless AC generator
Insulation class H
Frequency 50 Hz
Output 12.5 kVA (10.0 kW) 18.0 kVA (14.4 kW) 23.0 kVA (18.4 kW)
Voltage (AC) 240 / 415 V
Current 17.4 A 25.0 A 32.0 A
Number of phases 3
Number of poles 4
Power factor 80 %
Eng
ine
Model D1703-E/E2 V2203-E/E2 F2803-E/E2
Type Vertical, water cooled, 4-cycle, diesel engine
Number of cylinders 3 4 5
Bore × Stroke 87.0 × 92.4 mm (3.43 × 3.64 in.)
Total displacement 1647 cm3 (100.5 cu.in.) 2197 cm3 (134.1 cu.in.) 2746 cm3 (167.6 cu.in.)
Rated output 12.7 kW (17.3 PS) 16.9 kW (23.0 PS) 21.1 kW (28.7 PS)
Speed 1500 min-1 (rpm)
Combustion system Spherical combustion chamber
Compression ratio 23 : 1
Cooling system Pressurized radiator, forced circulation with water pump
Lubricating system Forced lubrication by trochoid pump
Lubricating oilClass CF lubricating oil as per API classification is recommended.
If this class of lubricating oil is not available, preferably use Class CD or CE lubricating oil.For details on recommended lubricating oils, see page G-8, 11
Starting system Electric type
Battery 12 V x 80 AH
Fuel tank capacity 37 L (9.8 U.S.gals) 60 L (16 U.S.gals)
Coolant capacity 8.0 L (2.1 U.S.gals) 9.0 L (2.4 U.S.gals) 10.5 L (2.77 U.S.gals)
Engine oil capacity 5.6 L (1.5 U.S.gals) 7.6 L (2.0 U.S.gals) 10.5 L (2.77 U.S.gals)
Net weight 455 kg (1000 lbs) 510 kg (1120 lbs) 620 kg (1370 lbs)
Emergency stop mechanism In case of abnormal oil pressure or water temperature
KiSC issued 09, 2009 A
12
KJ-X50 Hz SERIES, WSM SPECIFICATIONS
[For AUSTRALIA]
* The specification described above is of the standard engine of each model.* Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW
W1041583
Model KJ-S240-AUS KJ-T300-AUS
Gen
erat
or
Type Revolving field, self-excited brushless AC generator
Insulation class H
Frequency 50 Hz
Output 24.0 kVA (24.0 kW) 30.0 kVA (24.0 kW)
Voltage (AC) 240 V 240 / 415 V
Current 100.0 A 41.7 A
Number of phases 1 3
Number of poles 4
Power factor 100 % 80 %
Eng
ine
Model V3300-E2BG
Type Vertical, water cooled, 4-cycle, diesel engine
Number of cylinders 4
Bore × Stroke 98.0 × 110 mm (3.86 × 4.33 in.)
Total displacement 3318 cm3 (202.5 cu.in.)
Rated output 27.6 kW (37.5 PS)
Speed 1500 min-1 (rpm)
Combustion system Spherical combustion chamber
Compression ratio 22.6 : 1
Cooling system Pressurized radiator, forced circulation with water pump
Lubricating system Forced lubrication by trochoid pump
Lubricating oilClass CF lubricating oil as per API classification is recommended.
If this class of lubricating oil is not available, preferably use Class CD or CE lubricating oil.For details on recommended lubricating oils, see page G-8, 11
Starting system Electric type
Battery 12 V x 92 AH
Fuel tank capacity 60 L (16 U.S.gals)
Coolant capacity 9.5 L (2.5 U.S.gals)
Engine oil capacity 13.2 L (3.49 U.S.gals)
Net weight 735 kg (1620 lbs) 710 kg (1570 lbs)
Emergency stop mechanism In case of abnormal oil pressure or water temperature
KiSC issued 09, 2009 A
13
KJ-X50 Hz SERIES, WSM DIMENSIONS
DIMENSIONS
For General
W1015752
For AUS
W1034807
Model KJ-S130VX KJ-S170FX KJ-T130DX KJ-T180VX KJ-T230FX KJ-T300Length mm (in.) 1488 (58.58) 1610 (63.39) 1393 (54.84) 1488 (58.58) 1613 (63.50) 1717 (67.60)
Width mm (in.) 650 (25.6) 740 (29.1) 650 (25.6) 650 (25.6) 740 (29.1) 824 (32.4)
Height mm (in.) 971 (38.2) 996 (39.2) 971 (38.2) 971 (38.2) 996 (39.2) 1046 (41.18)
Model KJ-S130VX-AUS
KJ-S170FX-AUS
KJ-T130DX-AUS
KJ-T180VX-AUS
KJ-T230FX-AUS
KJ-S240-AUS
KJ-T300-AUS
Length mm (in.) 1518 (59.76) 1643 (64.68) 1423 (56.02) 1518 (59.76) 1643 (64.68) 1717 (67.60) 1717 (67.60)
Width mm (in.) 650 (25.6) 740 (29.1) 650 (25.6) 650 (25.6) 740 (29.1) 824 (32.4) 824 (32.4)
Height mm (in.) 971 (38.2) 996 (39.2) 971 (38.2) 971 (38.2) 996 (39.2) 1046 (41.18) 1046 (41.18)
KiSC issued 09, 2009 A
G GENERAL
KiSC issued 09, 2009 A
CONTENTS
GENERAL
1. GENERATOR IDENTIFICATION.................................................................... G-12. ENGINE IDENTIFICATION............................................................................. G-2
[1] MODEL NAME AND ENGINE SERIAL NUMBER ................................ G-2[2] E2B ENGINE............................................................................................. G-3[3] CYLINDER NUMBER ............................................................................... G-3
3. GENERAL PRECAUTIONS ............................................................................ G-44. LUBRICANTS, FUEL AND COOLANT ......................................................... G-55. TIGHTENING TORQUES ............................................................................... G-6
[1] TIGHTENING TORQUES FOR GENERAL USE SCREWS, BOLTSAND NUTS................................................................................................ G-6
6. MAINTENANCE CHECK LIST....................................................................... G-77. CHECK AND MAINTENANCE....................................................................... G-9
[1] DAILY CHECK .......................................................................................... G-9[2] CHECK POINTS OF INITIAL 50 HOURS ........................................... G-11[3] CHECK POINTS OF EVERY 100 HOURS......................................... G-12[4] CHECK POINTS OF EVERY 250 HOURS......................................... G-14[5] CHECK POINTS OF EVERY 500 HOURS......................................... G-16[6] CHECK POINTS OF EVERY 1000 HOURS....................................... G-17[7] CHECK POINTS OF EVERY 1500 HOURS....................................... G-21[8] CHECK POINTS OF EVERY 3000 HOURS....................................... G-23[9] CHECK POINTS OF EVERY 1 YEAR ................................................ G-26[10]CHECK POINTS OF EVERY 2 YEARS.............................................. G-27
8. SPECIAL TOOLS.......................................................................................... G-31[1] ALL MODELS.......................................................................................... G-31[2] D1703-E/E2, V2203-E/E2, F2803-E/E2 ................................................... G-32[3] V3300-E2BG............................................................................................ G-37
KiSC issued 09, 2009 A
G-1
KJ-X50 Hz SERIES, WSM G GENERAL
1. GENERATOR IDENTIFICATIONWhen contacting your local KUBOTA distributor, always specify
the model name and serial number of generator unit.
W1010481
(1) Model Name and Generator Unit Serial Number
[A] KJ-S130VX(-AUS)KJ-S170FX(-AUS)KJ-T130DX(-AUS)KJ-T180VX(-AUS)KJ-T230FX(-AUS)
[B] KJ-T300(-AUS)KJ-S240-AUS
KiSC issued 09, 2009 A
G-2
KJ-X50 Hz SERIES, WSM G GENERAL
2. ENGINE IDENTIFICATION[1] MODEL NAME AND ENGINE SERIAL NUMBER
When contacting the manufacture, always specify your enginemodel name and serial number.
The engine model and its serial number need to be identifiedbefore the engine can be serviced or parts replaced.
Engine Serial NumberThe engine serial number is an identified number for the engine.
It is marked after the engine model number.It indicates month and year of manufacture as follows.
• Year of manufacture
W1010477
Alphabet or Number Year Alphabet or
Number Year
1 2001 F 2015
2 2002 G 2016
3 2003 H 2017
4 2004 J 2018
5 2005 K 2019
6 2006 L 2020
7 2007 M 2021
8 2008 N 2022
9 2009 P 2023
A 2010 R 2024
B 2011 S 2025
C 2012 T 2026
D 2013 V 2027
E 2014
(1) Engine Model Name and Serial Number
[A] D1703-E/E2V2203-E/E2F2803-E/E2
[B] V3300-E2BG
KiSC issued 09, 2009 A
G-3
KJ-X50 Hz SERIES, WSM G GENERAL
• Month of manufacture
* Alphabetical letters “I” and “O” are not used.e.g. D1703 - 8 B A001
(a) (b)(c) (d)
W1011076
[2] E2B ENGINE[Example : Engine Model Name D1703-E2B-XXXX or V3300-E2BG-XXXX]The emission controls that have been put into effect in various countries to prevent air pollution will be stepped up.
The time to enforce the regulations differs depending on the engine output classifications.Kubota has been supplying the diesel engines conforming to the emission regulations in respective countries.
Exhaust emissions regulations shift to the second stage. Kubota executed the improvement of the engine accordingto this regulation.
In order to discriminate the engines conforming to Tier 1 / Phase 1 requirements and those conforming to Tier 2 /Phase 2 requirements, we have adopted E2B or E2BG as a new model name for the engines conforming Tier 2 /Phase 2 regulations.
In the after-sale services for E2B or E2BG engines, only use the dedicated parts for E2B or E2BG models and carryout the maintenance services accordingly.
[3] CYLINDER NUMBERThe cylinder numbers of KUBOTA diesel engine are designated
as shown in the figure.The sequence of cylinder numbers is given as No.1, No.2, No.3
and No.4 starting from the gear case side.W1011077
Month Engine Lot Number
January A0001 ~ A9999 B0001 ~ BZ999
February C0001 ~ C9999 D0001 ~ DZ999
March E0001 ~ E9999 F0001 ~ FZ999
April G0001 ~ G9999 H0001 ~ HZ999
May J0001 ~ J9999 K0001 ~ KZ999
June L0001 ~ L9999 M0001 ~ MZ999
July N0001 ~ N9999 P0001 ~ PZ999
August Q0001 ~ Q9999 R0001 ~ RZ999
September S0001 ~ S9999 T0001 ~ TZ999
October U0001 ~ U9999 V0001 ~ VZ999
November W0001 ~ W9999 X0001 ~ XZ999
December Y0001 ~ Y9999 Z0001 ~ ZZ999
(a) Engine Model Name : D1703(b) Year : 8 indicates 2008(c) Month : A or B indicates January(d) Lot number : (0001 ~ 9999 or A001 ~ Z999)
KiSC issued 09, 2009 A
G-4
KJ-X50 Hz SERIES, WSM G GENERAL
3. GENERAL PRECAUTIONS• During disassembly, carefully arrange removed parts in a clean
area to prevent confusion later. Screws, bolts and nuts should bereplaced in their original position to prevent reassembly errors.
• When special tools are required, use KUBOTA genuine specialtools. Special tools which are not frequently used should bemade according to the drawings provided.
• Before disassembling or servicing live wires, make sure toalways disconnect the grounding cable from the battery first.
• Remove oil and dirt from parts before measuring.• Use only KUBOTA genuine parts for parts replacement to
maintain engine performance and to ensure safety.• Gaskets and O-rings must be replaced during reassembly.
Apply grease to new O-rings or oil seals before assembling.• When reassembling external or internal snap rings, position them
so that the sharp edge faces against the direction from whichforce is applied.
• Be sure to perform run-in the serviced or reassembled engine.Do not attempt to give heavy load at once, or serious damagemay result to the engine.
W1011734
(1) Grease(2) Force(3) Place the Sharp Edge against the
Direction of Force
(A) External Snap Ring(B) Internal Snap Ring
KiSC issued 09, 2009 A
G-5
KJ-X50 Hz SERIES, WSM G GENERAL
4. LUBRICANTS, FUEL AND COOLANT
W1010720
Item Model Capacity Grade
Engine oil
KJ-T130DXKJ-T130DX-AUS
5.6 L1.5 U.S.gals
Class CF lubricating oil as per API classification is recommended.If this class of lubricating oil is not available, preferably use Class CD or CE lubricating oil.For details on recommended lubricating oils, see page G-8, 11.Above 25 °C (77 °F)
SAE 10W-30SAE 10W-40SAE 30
0 °C to 25 °C (32 °F to 77 °F) SAE 10W-30SAE 10W-40SAE 20
Below 0 °C (32 °F)SAE 10W-30SAE 10W-40SAE 10W
KJ-S130VXKJ-T180VX
KJ-S130VX-AUSKJ-T180VX-AUS
7.6 L2.0 U.S.gals
KJ-S170FXKJ-T230FX
KJ-S170FX-AUSKJ-T230FX-AUS
10.5 L2.77 U.S.gals
KJ-T300KJ-S240-AUSKJ-T300-AUS
13.2 L3.49 U.S.gals
Fuel
KJ-S130VXKJ-T130DXKJ-T180VX
KJ-S130VX-AUSKJ-T130DX-AUSKJ-T180VX-AUS
37 L9.8 U.S.gals
Diesel fuel No. 2-D (ASTM D975)KJ-S170FXKJ-T230FX
KJ-T300KJ-S170FX-AUSKJ-T230FX-AUS
KJ-S240-AUSKJ-T300-AUS
60 L16 U.S.gals
Coolant
KJ-T130DXKJ-T130DX-AUS
8.0 L2.1 U.S.gals
Clean water (Soft water)Use antifreeze 50 / 50
KJ-S130VXKJ-T180VX
KJ-S130VX-AUSKJ-T180VX-AUS
9.0 L2.4 U.S.gals
KJ-S170FXKJ-T230FX
KJ-S170FX-AUSKJ-T230FX-AUS
10.5 L2.77 U.S.gals
KJ-T300KJ-S240-AUSKJ-T300-AUS
9.5 L2.5 U.S.gals
KiSC issued 09, 2009 A
G-6
KJ-X50 Hz SERIES, WSM G GENERAL
5. TIGHTENING TORQUESScrews, bolts and nuts must be tightened to the specified torque using a torque wrench, several screws bolts and
nuts such as those used on the cylinder head must be tightened in proper sequence and the proper torque.
[1] TIGHTENING TORQUES FOR GENERAL USE SCREWS, BOLTS ANDNUTS
When the tightening torques are not specified, tighten the screws, bolts and nuts according to the table below.
W10371750
Screw and bolt material grades are shown by numbers punched on the screw and bolt heads. Prior totightening, be sure to check out the numbers as shown below.
W1012705
Grade
Nominal UnitDiameter
Standard Screw and Bolt
Special Screw and Bolt
N·m kgf·m lbf·ft N·m kgf·m lbf·ft
M6 7.9 to 9.3 0.80 to 0.95 5.8 to 6.8 9.81 to 11.2 1.00 to 1.15 7.24 to 8.31M8 18 to 20 1.8 to 2.1 13 to 15 24 to 27 2.4 to 2.8 18 to 20M10 40 to 45 4.0 to 4.6 29 to 33 49 to 55 5.0 to 5.7 37 to 41M12 63 to 72 6.4 to 7.4 47 to 53 78 to 90 7.9 to 9.2 58 to 66M14 108 to 125 11.0 to 12.8 79.6 to 92.5 124 to 147 12.6 to 15.0 91.2 to 108
Punched number Screw and bolt material gradeNone or 4 Standard screw and bolt SS41, S20C
7 Special screw and bolt S43C, S48C (Refined)
KiSC issued 09, 2009 A
G-7
KJ-X50 Hz SERIES, WSM G GENERAL
6. MAINTENANCE CHECK LISTTo maintain long-lasting and safe engine performance, make it a rule to carry out regular inspections by following
the table below.
* The items listed above (* marked) are registered as emission related critical parts by KUBOTA in the U.S. EPAnonroad emission regulation. As the engine owner, you are responsible for the performance of the requiredmaintenance on the engine according to the above instruction.
W1029462
Service interval
ItemDaily
Initial 50
hours
Every 100
hours
Every 250
hours
Every 500
hours
Every 1000 hours
Every 1500
hours
Every 3000
hours
Every 1
year
Every 2
year
Refe-rence Page
Engine oilChecking G-9
Changing G-11, 14
Oil filter cartridge Replacing G-12, 16
CoolantChecking G-10
Changing G-27
*Air cleaner element (replace the element after 6-times cleanings)
Clearing G-12
Replacing G-29
Fan beltChecking G-12,
15
Replacing G-17
*Fuel hoses and clamp bands
Checking G-13
Replacing G-29
*Intake air lineChecking G-15
Replacing G-29
BatteryChecking G-13
Replacing G-30
Radiator hoses and clamp bands
Checking G-15
Replacing G-30
*Fuel filter Replacing G-16
Water jacket and radiator interior Cleaning G-18
Valve clearance Checking G-19, 20
Electric wiring and loose connections Checking –
*Injection nozzle pressure Checking G-21,
22
*Injection pump Checking G-25
*Injection timing Checking G-23, 24
Generator side bearing Checking G-21
KiSC issued 09, 2009 A
G-8
KJ-X50 Hz SERIES, WSM G GENERAL
CAUTION• When changing or inspecting, be sure to level and stop the engine. NOTE
Lubricating OilWith the emission control now in effect, the CF-4 and CG-4 lubricating oils have been developed for use of a low-
sulfur fuel on-road vehicle engines. When an off-road vehicle engine runs on a high-sulfur fuel, it is advisable toemploy the CF, CD or CE lubricating oil with a high total base number. If the CF-4 or CG-4 lubricating oil is used witha high-sulfur fuel, change the lubricating oil at shorter intervals.• Lubricating oil recommended when a low-sulfur or high-sulfur fuel is employed.
: Recommendable X : Not recommendableW1035555
Fuel
Lubricatingoil class
Low sulfur(0.5 % ≥) High sulfur Remarks
CF TBN ≥ 10CF-4 XCG-4 X
KiSC issued 09, 2009 A
G-9
KJ-X50 Hz SERIES, WSM G GENERAL
7. CHECK AND MAINTENANCE[1] DAILY CHECK
Checking Engine Oil Level1. Level the engine.2. To check the oil level, draw out the dipstick (1), wipe it clean,
reinsert it, and draw it out again.Check to see that the oil level lies between the two notches.
3. If the level is too low, add new oil to the specified level.IMPORTANT
• When using an oil of different maker or viscosity from theprevious, drain old oil. Never mix two different types of oil.NOTE
• Be sure to inspect the engine, locating it on a horizontalplace. If placed on gradients, accurately, oil quantity maynot be measured.
• Be sure to keep the oil level between upper and lower limitsof the dipstick. Too much oil may cause a drop in output orexcessive blow-by gas. On the closed breather type enginein which mist is sucked through port, too much oil maycaused oil hammer. While too little oil, may seize theengine’s rotating and sliding parts.
W1056278
(1) Dipstick
(a) Maximum(b) Minimum
[A] KJ-S130VX(-AUS)KJ-S170FX(-AUS)KJ-T130DX(-AUS)KJ-T180VX(-AUS)KJ-T230FX(-AUS)
[B] KJ-T300(-AUS)KJ-S240-AUS
KiSC issued 09, 2009 A
G-10
KJ-X50 Hz SERIES, WSM G GENERAL
Checking and Replenish Coolant
CAUTION• Do not remove the radiator cap until coolant temperature is
below its boiling point. Then loosen the cap slightly torelieve any excess pressure before removing the capcompletely.
1. Remove the radiator cap and check to see that the coolant levelis just below the port.
2. Check to see that the coolant level lies between FULL (A) andLOW (B).
3. If coolant level is too low, check the reason for decreasingcoolant.(Case 1)If coolant is decreasing by evaporation, replenish only fresh, softwater.(Case 2)If coolant is decreasing by leak, replenish coolant of the samemanufacture and type in the specified mixture ratio (fresh, softwater and L.L.C.). If the coolant brand cannot be identified, drainout all of the remaining coolant and refill with a totally new brandof coolant mix.IMPORTANT
• During filling the coolant, air must be vented from the enginecoolant passages. The air vents by jiggling the radiatorupper and lower hoses.
• Be sure to close the radiator cap securely. If the cap is looseor improperly closed, coolant may leak out and the enginecould overheat.
• Do not use an antifreeze and scale inhibitor at the same time.• Never mix the different type or brand of L.L.C..
W1056506
(1) Recovery Tank
(A) FULL(B) LOW
[A] KJ-S130VX(-AUS)KJ-S170FX(-AUS)KJ-T130DX(-AUS)KJ-T180VX(-AUS)KJ-T230FX(-AUS)
[B] KJ-T300(-AUS)KJ-S240-AUS
KiSC issued 09, 2009 A
G-11
KJ-X50 Hz SERIES, WSM G GENERAL
[2] CHECK POINTS OF INITIAL 50 HOURSChanging Engine Oil
CAUTION• Be sure to stop engine before changing engine oil.
1. Start and warm up the engine for approx. 5 minutes.2. Place an oil pan underneath the engine.3. To drain the used oil, remove the drain plug (1) at the bottom of
the engine and drain the oil completely.4. Screw the drain plug (1).5. Fill new oil up to upper line on the dipstick (2).
IMPORTANT• When using an oil of different maker or viscosity from the
previous one, remove all of the old oil.• Never mix two different types of oil.• Engine oil should have properties of API classification CD/
CE/CF/CF-4/CG-4.• Use the proper SAE Engine Oil according to ambient
temperature.
W1056639
Above 25 °C (77 °F) SAE 30 or SAE 10W-30 SAE 10W-40
0 °C to 25 °C (32 °F to 77 °F) SAE 20 or SAE 10W-30 SAE 10W-40
Below 0 °C (32 °F) SAE 10W or SAE 10W-30 SAE 10W-40
Models Capacity
KJ-T130DX(-AUS) 5.6 L1.5 U.S.gals
KJ-S130VX(-AUS)KJ-T180VX(-AUS)
7.6 L2.0 U.S.gals
KJ-S170FX(-AUS)KJ-T230FX(-AUS)
10.5 L2.77 U.S.gals
KJ-T300(-AUS)KJ-S240-AUS
13.2 L3.49 U.S.gals
(1) Drain Plug(2) Dipstick
(a) Maximum(b) Minimum
[A] KJ-S130VX(-AUS)KJ-S170FX(-AUS)KJ-T130DX(-AUS)KJ-T180VX(-AUS)KJ-T230FX(-AUS)
[B] KJ-T300(-AUS)KJ-S240-AUS
KiSC issued 09, 2009 A
G-12
KJ-X50 Hz SERIES, WSM G GENERAL
Replacing Oil Filter Cartridge
CAUTION• Be sure to stop the engine before replacing filter cartridge.
1. Remove the oil filter cartridge (1) with the filter wrench.2. Apply a slight coat of oil onto the new cartridge gasket.3. To install the new cartridge, screw it in by hand. Over tightening
may cause deformation of rubber gasket.4. After the new cartridge has been replaced, the engine oil
normally decrease a little. Thus see that the engine oil does notleak through the seal and be sure to read the oil level on thedipstick. Then, replenish the engine oil up to the specified level.IMPORTANT
• To prevent serious damage to the engine, replacementelement must be highly efficient. Use only a KUBOTAgenuine filter or its equivalent.
W1056762
Checking Fan Belt Tension1. Measure the deflection (A), depressing the belt halfway between
the fan drive pulley and alternator pulley at specified force 98 N(10 kgf, 22 lbf).
2. If the measurement is not within the factory specifications, loosenthe alternator mounting screws and relocate the alternator toadjust.
W10356670
[3] CHECK POINTS OF EVERY 100 HOURSCleaning Air Cleaner Element1. Remove the air cleaner element.2. Use clean dry compressed air on the inside of the element.
Pressure of compressed air must be under 205 kPa (2.1 kgf/cm2,30 psi).Maintain reasonable distance between the nozzle and the filter.NOTE
• The air cleaner uses a dry element. Never apply oil to it.• Do not run the engine with filter element removed.• Change the element once a year or every 6th cleaning.
W1045746
(1) Engine Oil Filter Cartridge [A] KJ-S130VX(-AUS)KJ-S170FX(-AUS)KJ-T130DX(-AUS)KJ-T180VX(-AUS)KJ-T230FX(-AUS)
[B] KJ-T300(-AUS)KJ-S240-AUS
Deflection (A) Factory spec.
KJ-S130VX(-AUS)KJ-S170FX(-AUS)KJ-T130DX(-AUS)KJ-T180VX(-AUS)KJ-T230FX(-AUS)
7.0 to 9.0 mm0.28 to 0.35 in.
KJ-T300(-AUS)KJ-S240-AUS
10 to 12 mm0.40 to 0.47 in.
(A) Deflection
KiSC issued 09, 2009 A
G-13
KJ-X50 Hz SERIES, WSM G GENERAL
Checking Fuel Hoses and Clamp Bands1. If the clamp (1) is loose, apply oil to the threads and securely
retighten it.2. The fuel hose (3) is made of rubber and ages regardless of the
period service.Change the fuel hose together with the clamp every two years.
3. However, if the fuel hose and clamp are found to be damaged ordeteriorate earlier than two years, then change or remedy.
4. After the fuel hose and the clamp have been changed, bleed thefuel system.
CAUTION• Stop the engine when attempting the check and change
prescribed above.
(When bleeding fuel system)1. Loosen the air vent plug (4) of the fuel filter a few turns.2. Screw back the plug when bubbles do not come up any more.3. Open the air vent cock (2) on top of the fuel injection pump.4. If equipped electrical fuel feed pump, turn the key to AC position
and pump the fuel up for 10 to 15 seconds.If equipped mechanical fuel feed pump, set the stop lever on stopposition and crank the engine for 10 to 15 seconds.
5. Close securely the air vent cock after air bleeding.NOTE
• Always keep the air vent cock on the fuel injection pumpclosed except when air is vented, or it may cause the engineto stop.
W1057097
Checking Battery Electrolyte Level1. Check the battery electrolyte level.2. If the level is below than lower level line (2), and the distilled water
to pour level of each cell.
W1047154
(1) Clamp(2) Air Vent Cock(3) Fuel Hose(4) Air Vent Plug
[A] KJ-S130VX(-AUS)KJ-S170FX(-AUS)KJ-T130DX(-AUS)KJ-T180VX(-AUS)KJ-T230FX(-AUS)
[B] KJ-T300(-AUS)KJ-S240-AUS
(1) Upper Level Line (2) Lower Level Line
KiSC issued 09, 2009 A
G-14
KJ-X50 Hz SERIES, WSM G GENERAL
[4] CHECK POINTS OF EVERY 250 HOURSChanging Engine Oil
CAUTION• Be sure to stop engine before changing engine oil.
1. Start and warm up the engine for approx. 5 minutes.2. Place an oil pan underneath the engine.3. To drain the used oil, remove the drain plug (1) at the bottom of
the engine and drain the oil completely.4. Screw the drain plug (1).5. Fill new oil up to upper line on the dipstick (2).
IMPORTANT• When using an oil of different maker or viscosity from the
previous one, remove all of the old oil.• Never mix two different types of oil.• Engine oil should have properties of API classification CD/
CE/CF/CF-4/CG-4.• Use the proper SAE Engine Oil according to ambient
temperature.
W1021645
Above 25 °C (77 °F) SAE 30 or SAE 10W-30 SAE 10W-40
0 °C to 25 °C (32 °F to 77 °F) SAE 20 or SAE 10W-30 SAE 10W-40
Below 0 °C (32 °F) SAE 10W or SAE 10W-30 SAE 10W-40
Models Capacity
KJ-T130DX(-AUS) 5.6 L1.5 U.S.gals
KJ-S130VX(-AUS)KJ-T180VX(-AUS)
7.6 L2.0 U.S.gals
KJ-S170FX(-AUS)KJ-T230FX(-AUS)
10.5 L2.77 U.S.gals
KJ-T300(-AUS)KJ-S240-AUS
13.2 L3.49 U.S.gals
(1) Drain Plug(2) Dipstick
(a) Maximum(b) Minimum
[A] KJ-S130VX(-AUS)KJ-S170FX(-AUS)KJ-T130DX(-AUS)KJ-T180VX(-AUS)KJ-T230FX(-AUS)
[B] KJ-T300(-AUS)KJ-S240-AUS
KiSC issued 09, 2009 A
G-15
KJ-X50 Hz SERIES, WSM G GENERAL
Fan Belt Damage and Wear1. Check the fan belt for damage.2. If the fan belt is damaged, replace it.3. Check if the fan belt is worn and sunk in the pulley groove.4. If the fan belt is nearly worn out and deeply sunk in the pulley
groove, replace it.
W1057475
Checking Intake Air Line1. Check to see if the intake air hose(s) is properly fixed every 250
hours of operation.2. If the clamp is loose, apply oil to the threads and retighten it
securely.3. The intake air hose(s) is made of rubber and tends to age. It must
be changed every two years. Also change the clamp and tightenit securely.IMPORTANT
• To prevent serious damage to the engine, keep out any dustinside the intake air line.
W1029631
Checking Radiator Hoses and Clamp Bands1. Check to see if the radiator hoses are properly fixed every 250
hours of operation or every six months, whichever comes first.2. If the clamp (1) is loose, apply oil to the threads and retighten it
securely.3. The radiator hose (2) is made of rubber and tends to age. It must
be replaced every two years. Also replace the clamp and tightenit securely.
W1029518
(A) Good (B) Bad
(1) Intake Air Hose (2) Clamp
(1) Clamp(2) Radiator Hose
[A] KJ-S130VX(-AUS)KJ-S170FX(-AUS)KJ-T130DX(-AUS)KJ-T180VX(-AUS)KJ-T230FX(-AUS)
[B] KJ-T300(-AUS)KJ-S240-AUS
KiSC issued 09, 2009 A
G-16
KJ-X50 Hz SERIES, WSM G GENERAL
[5] CHECK POINTS OF EVERY 500 HOURSReplacing Oil Filter Cartridge
CAUTION• Be sure to stop the engine before replacing filter cartridge.
1. Remove the oil filter cartridge (1) with the filter wrench.2. Apply a slight coat of oil onto the new cartridge gasket.3. To install the new cartridge, screw it in by hand. Over tightening
may cause deformation of rubber gasket.4. After the new cartridge has been replaced, the engine oil
normally decrease a little. Thus see that the engine oil does notleak through the seal and be sure to read the oil level on thedipstick. Then, replenish the engine oil up to the specified level.IMPORTANT
• To prevent serious damage to the engine, replacementelement must be highly efficient. Use only a KUBOTAgenuine filter or its equivalent.
W1021505
Replacing Fuel Filter CartridgeWater and dust in fuel are collected in the filter cartridge. So,
change the filter cartridge every 500 hours service. 1. Remove the used filter cartridge with filter wrench.2. Apply a thin film of fuel to the surface of new filter cartridge gasket
before screwing on.3. Then tighten enough by hand.4. Loosen the air vent plug to let the air out.5. Start engine and check for fuel leakage.
W1057596
(1) Engine Oil Filter Cartridge [A] KJ-S130VX(-AUS)KJ-S170FX(-AUS)KJ-T130DX(-AUS)KJ-T180VX(-AUS)KJ-T230FX(-AUS)
[B] KJ-T300(-AUS)KJ-S240-AUS
(1) Fuel Filter Cartridge [A] KJ-S130VX(-AUS)KJ-S170FX(-AUS)KJ-T130DX(-AUS)KJ-T180VX(-AUS)KJ-T230FX(-AUS)
[B] KJ-T300(-AUS)KJ-S240-AUS
KiSC issued 09, 2009 A
G-17
KJ-X50 Hz SERIES, WSM G GENERAL
[6] CHECK POINTS OF EVERY 1000 HOURSReplacing Fan Belt1. Remove the alternator.2. Remove the fan belt (1).3. Replace new fan belt.4. Install the alternator.5. Check the fan belt tension.
W1052220
Deflection (A) Factory spec.
KJ-S130VX(-AUS)KJ-S170FX(-AUS)KJ-T130DX(-AUS)KJ-T180VX(-AUS)KJ-T230FX(-AUS)
7.0 to 9.0 mm / 98 N0.28 to 0.35 in. / 98 N(10 kgf, 22 lbf)
KJ-T300(-AUS)KJ-S240-AUS
10 to12 mm / 98 N0.40 to 0.47 in. / 98 N(10 kgf, 22 lbf)
(1) Fan Belt (A) Deflection
KiSC issued 09, 2009 A
G-18
KJ-X50 Hz SERIES, WSM G GENERAL
Cleaning Water Jacket and Radiator Interior
CAUTION• Do not remove the radiator cap when the engine is hot. Then
loosen cap slightly to the stop to relieve any excesspressure before removing cap completely.
1. Stop the engine and let cool down.2. To drain the coolant, open the radiator drain plug (2) and remove
the radiator cap (1). Then radiator cap (1) must be removed tocompletely drain the coolant. And open the drain cock (3). ([B]only.)
3. After all coolant is drained, close the drain plug.4. Fill with clean water and cooling system cleaner.5. Follow directions of the cleaner instruction.6. After flushing, fill with clean water and anti-freeze until the coolant
level is just below the port. Install the radiator cap (1) securely.7. Fill with coolant up to “FULL” (A) mark on the recovery tank (3).8. Start and operate the engine for few minutes.9. Stop the engine and let cool. Check coolant level of radiator and
recovery tank (3) and add coolant if necessary.IMPORTANT
• Do not start engine without coolant.• Use clean, fresh, soft water and anti-freeze to fill the radiator
and recovery tank.• When the anti-freeze is mixed with fresh, soft water, the anti-
freeze mixing ratio must be less than 50 %.• Securely tighten radiator cap. If the cap is loose or
improperly fitted, water may leak out and the engine couldoverheat.
W1038102
(1) Radiator Cap(2) Drain Plug(3) Drain Cock(4) Recovery TankA : FullB : Low
[A] KJ-S130VX(-AUS)KJ-S170FX(-AUS)KJ-T130DX(-AUS)KJ-T180VX(-AUS)KJ-T230FX(-AUS)
[B] KJ-T300(-AUS)KJ-S240-AUS
KiSC issued 09, 2009 A
G-19
KJ-X50 Hz SERIES, WSM G GENERAL
Checking Valve Clearance (To be continued)[D1703-E/E2, V2203-E/E2, F2803-E/E2]
IMPORTANT• Valve clearance must be checked and adjusted when engine
is cold.1. Remove the head cover.2. Align the “1TC” mark line (3) on the flywheel and projection (2)
on the housing so that the No.1 piston comes to the compressionor overlap top dead center.
3. Check the following valve clearance (1) marked with “ ” using afeeler gauge.
4. If the clearance is not within the factory specifications, adjust withthe adjusting screw.
NOTE• The “1TC” mark line on the flywheel is just for No. 1 cylinder.
There is no “TC” marking for the other cylinders.• No. 1 piston comes to the top dead center position when the
“TC” marking is aligned with the projection (2) in the windowon flywheel-housing. Turn the flywheel 0.26 rad (15 °)clockwise and counterclockwise to see if the piston is at thecompression top dead center or the overlap position. Nowreferring to the table below, readjust the valve clearance (1).(The piston is at the top dead center when both the IN. andEX. valves do not move; it is at the overlap position whenboth the valves move.)
• Finally turn the flywheel 6.28 rad (360 °) and align the “1TC”mark line and the projection (2) perfectly. Adjust all theother valve clearance as required.
• After turning the flywheel counterclockwise twice or threetimes, recheck the valve clearance (1).
• After adjusting the valve clearance (1), firmly tighten the locknut of the adjusting screw.
W10161700
Valve clearance Factory spec. 0.18 to 0.22 mm0.0071 to 0.0086 in.
Valve arrangementAdjustablecylinderlocation of piston
3 Cylinder 4 Cylinder 5 Cylinder
IN. EX. IN. EX. IN. EX.
When No. 1 piston is at compression top dead center
No. 1
No. 2
No. 3
No. 4 – –
No. 5 – – – –
When No. 1 piston is at overlap position
No. 1
No. 2
No. 3
No. 4 – –
No. 5 – – – –
(1) Valve Clearance(2) Projection
(3) 1TC Mark Line
KiSC issued 09, 2009 A
G-20
KJ-X50 Hz SERIES, WSM G GENERAL
Checking Valve Clearance (Continued)[V3300-E2BG]
IMPORTANT• Valve clearance must be checked and adjusted when engine
is cold.1. Remove the head cover.2. Align the 1TC mark of flywheel and the convex of flywheel
housing timing windows so that the first piston (gear case side)comes to the compression top dead center.
3. Before adjusting the valve clearance of intake valve, adjust thebridge evenly to the valves stem.
4. Loosen the lock nut (2) and adjust with screw (1).5. Slightly push the rocker arm (intake side) by your fingers and
screw in the adjusting screw slowly until you feel the screw touchthe top of valve stem, then tighten the lock nut.
6. Loosen the lock nut (4) of adjusting screw (3) (push rod side) andinsert the thickness gauge between the rocker arm and thebridge head. Set the adjusting screw to the specified value, thentighten the lock nut.
7. Adjust the clearance between the rocker arm (exhaust side) andthe exhaust valve to the specified value.
NOTE• After adjusting, tighten the lock nut (4) securely.
W1037215
Valve clearance Factory spec. 0.23 to 0.27 mm0.0091 to 0.0106 in.
Valve arrangementAdjustablecylinderlocation of piston
IN. EX
When No.1 piston is at compression top dead center
No. 1
No. 2
No. 3
No. 4
When No.1 piston is at overlap position
No. 1
No. 2
No. 3
No. 4
Tightening torque Cylinder head cover screw6.9 to 11.3 N·m0.7 to 1.15 kgf·m5.1 to 8.32 lbf·ft
(1) Adjusting Screw(2) Lock Nut
(3) Adjusting Screw(4) Lock Nut
KiSC issued 09, 2009 A
G-21
KJ-X50 Hz SERIES, WSM G GENERAL
Checking Ball Bearing1. Measure axial dislocation of the outer ring.2. If the axial dislocation exceeds the allowable limit, replace the
bearing.
3. Measure the I.D. of the bearing housing.4. If the wear exceeds the allowable limit, replace the end bracket.
W1022010
[7] CHECK POINTS OF EVERY 1500 HOURS
CAUTION• Check the injection pressure and condition after confirming that there is nobody standing in the direction
the fume goes.• If the fume from the nozzle directly contacts the human body, cells may be destroyed and blood poisoning
may be caused.Nozzle Spraying Condition1. Set the injection nozzle to a nozzle tester, and check the nozzle
spraying condition.2. If the spraying condition is defective, replace the nozzle piece.
W10443270
Axial dislocation Allowable limit 0.05 mm0.002 in.
Bearing housing I.D. Allowable limit 90.02 mm
3.544 in.
(a) Good (b) Bad
KiSC issued 09, 2009 A
G-22
KJ-X50 Hz SERIES, WSM G GENERAL
Fuel Injection Pressure1. Set the injection nozzle to a nozzle tester.2. Slowly move the tester handle to measure the pressure at which
fuel begins jetting out from the nozzle.3. If the measurement is not within the factory specifications,
replace the adjusting washer (1) in the nozzle holder to adjust it.(Reference)• Pressure variation with 0.025 mm (0.00098 in.) difference of
adjusting washer thickness.Approx. 590 kPa (6.0 kgf/cm2, 85 psi)
W10182100
Valve Seat Tightness1. Set the injection nozzle to a nozzle tester.2. Raise the fuel pressure, and keep at 12.75 MPa (130.0 kgf/cm2,
1849 psi) for 10 seconds.3. If any fuel leak is found, replace the nozzle piece.
W10444330
Fuel injection pressure Factory spec.13.73 to 14.70 MPa140.0 to 150.0 kgf/cm2
1992 to 2133 psi
(1) Adjusting Washer
Valve seat tightness Factory spec.
No fuel leak at12.75 MPa130.0 kgf/cm2
1849 psi
KiSC issued 09, 2009 A
G-23
KJ-X50 Hz SERIES, WSM G GENERAL
[8] CHECK POINTS OF EVERY 3000 HOURSInjection Timing (To be continued)[KJ-S130VX(-AUS), KJ-S170FX(-AUS), KJ-T130DX(-AUS), KJ-T180VX(-AUS), KJ-T230FX(-AUS)]1. Remove the injection pipes and nozzle.2. Set the speed control lever to maximum fuel discharge position.(Reference)• Turn the flywheel with screwdriver.
3. Turn the flywheel counterclockwise (facing the flywheel) until thefuel fills up to the hole of the delivery valve holder (1) for 1stcylinder.
4. Turn the flywheel further and stop turning when the fuel begins toflow over, to get the present injection timing.
5. (The flywheel has mark 1TC and four lines indicating every 0.09rad (5 °) of crank angle from 0.17 rad (10 °) to 0.44 rad (25 °)before mark 1TC.) Calculate the angle which the center of thewindow points out. If the calculation differs from specifiedinjection timing, add or remove the shim to adjust.
(Injection Timing)
NOTE• The sealant is applied to both sides of the soft metal gasket
shim. The liquid gasket is not required for assembling.• Shims are available in thickness of 0.175 mm (7), 0.20 mm
(4), 0.25 mm (5) and 0.30 mm (6). Combine these shims foradjustments.
• The 0.175 mm thick shim is coated only on the lower face.Therefore, do not use the 0.175 mm thick shim as the topshim of the combination (injection pump side), because thiscause oil leakage.
• Addition or reduction of shim (0.05 mm, 0.002 in.) delays oradvances the injection timing by approx. 0.009 rad (0.5 °).
• In disassembling and replacing, be sure to use the samenumber of new gasket shims with the same thickness.
W1023147
Model Injection timing
D1703-E, V2203-EV2203-E2, F2803-E2 0.27 to 0.29 rad (15 ° to 17 °) before T.D.C.
F2803-E 0.28 to 0.31 rad (16 ° to 18 °) before T.D.C.
D1703-E2 0.236 to 0.270 rad (13.5 ° to 15.5 °) before T.D.C.
(1) Delivery Valve Holder(2) Timing Mark(3) Shim (Soft Metal Gasket Shim)(4) 2-holes : 0.20 mm (0.0079 in.) Shim(5) 1-hole : 0.25 mm (0.0098 in.) Shim(6) Without hole : 0.30 mm (0.012 in.)
Shim(7) 2-holes : 0.175 mm (0.00689 in.)
Shim
(A) 3 Cylinder(B) 4 Cylinder
KiSC issued 09, 2009 A
G-24
KJ-X50 Hz SERIES, WSM G GENERAL
Injection Timing (Continued)[KJ-T300(-AUS), KJ-S240-AUS]1. Make sure of matching the injection timing align mark (1) of the
injection pump unit and the plate (gearcase), as shown in theillustration.
2. Remove the injection pipes.3. Remove the stop solenoid.4. Turn the flywheel counterclockwise (viewed from flywheel side)
until the fuel fills up to the hole of the delivery valve holder (2) forNo.1 cylinder.
5. After the fuel fills up to the hole of the delivery valve holder forNo.1 cylinder, turn back (clockwise) the flywheel around 1.57 rad(90 °).
6. Turn the flywheel counterclockwise to set at around 0.35 rad(20 °) before T.D.C..
7. Slowly turn the flywheel counterclockwise and stop turning whenthe fuel begins to come up, to get the present injection timing.
8. Check to see the degree on flywheel.The flywheel has mark “1TC”, “10” and “20” for the crank anglebefore the top dead center of No.1 piston.
9. If the injection timing is not within the specification, rotate theinjection pump unit to adjust the injection timing.IMPORTANT
• When installing the injection pump unit to the engine body,follow the correct procedure.See the “Injection Pump Unit”.
(Injection Timing)
W1072910
Model Injection timing
V3300-E2BG 0.14 to 0.17 rad (8.0 ° to 10 °) before T.D.C.
Tightening torque
Injection pipe retaining nut22.6 to 36.3 N·m2.3 to 3.7 kgf·m16.6 to 26.8 lbf·ft
Injection pump unit mounting nut
17.7 to 20.6 N·m1.8 to 2.1 kgf·m13.0 to 15.2 lbf·ft
(1) Injection Timing Align Mark(2) Delivery Valve Holder
(a) Injection Timing Advanced(b) Injection Timing Retarded
KiSC issued 09, 2009 A
G-25
KJ-X50 Hz SERIES, WSM G GENERAL
Checking Injection Pump(Fuel Tightness of Pump Element)1. Remove the engine stop solenoid.2. Remove the injection pipes and glow plugs.3. Install the injection pump pressure tester (1) to the injection
pump.4. Install the injection nozzle (2) jetted with the proper injection
pressure to the injection pump pressure tester (1). (Refer to thefigure.)
5. Set the speed control lever to the maximum speed position.6. Run the starter to increase the pressure.7. If the pressure can not reach the allowable limit, replace the
pump with new one or repair with a Kubota-authorized pumpservice shop.
(Fuel Tightness of Delivery Valve)1. Remove the engine stop solenoid.2. Remove the injection pipes and glow plugs.3. Set a pressure tester to the fuel injection pump.4. Install the injection nozzle (2) jetted with the proper injection
pressure to the injection pump pressure tester (1).5. Run the starter to increase the pressure.6. Stop the starter when the fuel jets from the injection nozzle. After
that, turn the flywheel by hand and raise the pressure to approx.13.73 MPa (140.0 kgf/cm2, 1991 psi).
7. Now turn the flywheel back about half a turn (to keep the plungerfree). Maintain the flywheel at this position and clock the timetaken for the pressure to drop from 13.73 to 12.75 MPa (140.0 to130.0 kgf/cm2, 1991 to 1849 psi).
8. Measure the time needed to decrease the pressure from 13.73 to12.75 MPa (140.0 to 130.0 kgf/cm2, 1991 to 1849 psi).
9. If the measurement is less than allowable limit, replace the pumpwith new one or repair with a Kubota-authorized pump serviceshop.
NOTE• Never try to disassemble the injection pump assembly. For
repairs, you are strongly requested to contact a Kubota-authorized pump service shop.
W1022357
Fuel tightness of pump element Allowable limit
13.73 MPa140.0 kgf/cm2
1991 psi
Fuel tightness of delivery valve
Factory spec.
10 seconds13.73 → 12.75 MPa140.0 → 130.0 kgf/cm2
1991 → 1849 psi
Allowable limit
5 seconds13.73 → 12.75 MPa140.0 → 130.0 kgf/cm2
1991 → 1849 psi
(1) Injection Pump Pressure Tester(2) Injection Nozzle(3) Protection Cover for Jetted Fuel
[A] D1703-E/E2V2203-E/E2F2803-E/E2
[B] V3300-E2BG
KiSC issued 09, 2009 A
G-26
KJ-X50 Hz SERIES, WSM G GENERAL
[9] CHECK POINTS OF EVERY 1 YEARReplacing Air Cleaner Element1. Remove used air cleaner element.2. Replace new air cleaner element.
NOTE• The air cleaner uses a dry element. Never apply oil to it.• Do not run the engine with filter element removed.
W1020554
KiSC issued 09, 2009 A
G-27
KJ-X50 Hz SERIES, WSM G GENERAL
[10] CHECK POINTS OF EVERY 2 YEARSChanging Radiator Coolant (L.L.C.)
CAUTION• Do not remove the radiator cap when the engine is hot. Then
loosen cap slightly to the stop to relieve any excesspressure before removing cap completely.
1. Stop the engine and let cool down.2. To drain the coolant, open the radiator drain plug (2) and remove
the radiator cap (1). Then radiator cap (1) must be removed tocompletely drain the coolant. And open the drain cock (3). ([B]only.)
3. After all coolant is drained, close the drain plug.4. Fill with clean water and cooling system cleaner.5. Follow directions of the cleaner instruction.6. After flushing, fill with clean water and anti-freeze until the coolant
level is just below the port. Install the radiator cap (1) securely.7. Fill with coolant up to “FULL” (A) mark on the recovery tank (3).8. Start and operate the engine for few minutes.9. Stop the engine and let cool. Check coolant level of radiator and
recovery tank (3) and add coolant if necessary.IMPORTANT
• Do not start engine without coolant.• Use clean, fresh, soft water and anti-freeze to fill the radiator
and recovery tank.• When the anti-freeze is mixed with fresh, soft water, the anti-
freeze mixing ratio must be less than 50 %.• Securely tighten radiator cap. If the cap is loose or
improperly fitted, water may leak out and the engine couldoverheat.
W1024599
(1) Radiator Cap(2) Drain Plug(3) Drain Cock(4) Recovery TankA : FullB : Low
[A] KJ-S130VX(-AUS)KJ-S170FX(-AUS)KJ-T130DX(-AUS)KJ-T180VX(-AUS)KJ-T230FX(-AUS)
[B] KJ-T300(-AUS)KJ-S240-AUS
KiSC issued 09, 2009 A
G-28
KJ-X50 Hz SERIES, WSM G GENERAL
Changing Radiator Coolant (L.L.C.) (Continued)(Anti-freeze)• There are two types of anti-freeze available: use the permanent
type (PT) for this engine.• Before adding anti-freeze for the first time, clean the radiator
interior by pouring fresh, soft water and draining it a few times.• The procedure for mixing water and anti-freeze differs according
to the make of the anti-freeze and the ambient temperature.Basically, it should be referred to SAE J1034 standard, morespecifically also to SAE J814c.
• Mix the anti-freeze with fresh, soft water, and then fill into theradiator.IMPORTANT
• When the anti-freeze is mixed with fresh, soft water, the anti-freeze mixing ratio must be less than 50 %.
* At 1.01 × 100000 Pa (760 mmHg) pressure (atmospheric). Ahigher boiling point is obtained by using a radiator pressure capwhich permits the development of pressure within the coolingsystem.
NOTE• The above data represents industrial standards that
necessitate a minimum glycol content in the concentratedanti-freeze.
• When the coolant level drops due to evaporation, add fresh,soft water only to keep the anti-freeze mixing ratio less than50 %. In case of leakage, add anti-freeze and fresh, softwater in the specified mixing ratio.
• Anti-freeze absorbs moisture. Keep unused anti-freeze in atightly sealed container.
• Do not use radiator cleaning agents when anti-freeze hasbeen added to the coolant.(Anti-freeze contains an anti-corrosive agent, which willreact with the radiator cleaning agent forming sludge whichwill affect the engine parts.)
W1024852
Vol %anti-freeze
Freezing point Boiling point*
°C °F °C °F
40 –24 –11 106 223
50 –37 –35 108 226
KiSC issued 09, 2009 A
G-29
KJ-X50 Hz SERIES, WSM G GENERAL
Replacing Fuel Hoses and Clamp Bands1. Loosen the clamp (1) and remove the fuel hose (3).2. Replace new fuel hose (3) and new clamp (1).3. Tighten the clamp (1).
CAUTION• Stop the engine when attempting the check and change
prescribed above.
(When bleeding fuel system)1. Loosen the air vent plug (4) of the fuel filter a few turns.2. Screw back the plug when bubbles do not come up any more.3. Open the air vent cock (2) on top of the fuel injection pump.4. If equipped electrical fuel feed pump, turn the key to AC position
and pump the fuel up for 10 to 15 seconds.If equipped mechanical fuel feed pump, set the stop lever on stopposition and crank the engine for 10 to 15 seconds.
5. Close securely the air vent cock after air bleeding.NOTE
• Always keep the air vent cock on the fuel injection pumpclosed except when air is vented, or it may cause the engineto stop.
W1057873
Replacing Intake Air Line1. Loosen the clamp (2).2. Remove the intake air hose (1) and clamp (2).3. Replace new intake air hose (1) and new clamp (2).4. Tighten the clamp (2).
NOTE• To prevent serious damage to the engine, keep out any dust
inside the intake air line.
W1023867
(1) Clamp(2) Air Vent Cock(3) Fuel Hose(4) Air Vent Plug
[A] KJ-S130VX(-AUS)KJ-S170FX(-AUS)KJ-T130DX(-AUS)KJ-T180VX(-AUS)KJ-T230FX(-AUS)
[B] KJ-T300(-AUS)KJ-S240-AUS
(1) Intake Air Hose (2) Clamp
KiSC issued 09, 2009 A
G-30
KJ-X50 Hz SERIES, WSM G GENERAL
Replacing Battery
CAUTION• When the battery is being activated, hydrogen and oxygen
gases in the battery are extremely explosive. Keep opensparks and flames away from the battery at all times,especially when charging the battery.
• When charging battery, remove battery vent plugs.• When disconnecting the cable from the battery, start with
the negative terminal first. When connecting the cable to thebattery, start with the positive terminal first.
• Never check battery charge by placing a metal object acrossthe posts.
1. Disconnect the negative terminal and positive terminal.2. Remove the battery holder.3. Remove the used battery.4. Replace the new battery.5. Tighten the battery holder.6. Connect the positive terminal.7. Connect the negative terminal.
W1023996
Replacing Radiator Hoses and Clamp Bands
CAUTION• Do not remove the radiator cap when the engine is hot. Then
loosen cap slightly to the stop to relieve any excesspressure before removing cap completely.
1. Drain the coolant.2. Loosen the clamp bands (1).3. Remove the upper hose (2) and lower hose (3).4. Replace new upper / lower hose (2), (3) and clamp bands (1).5. Tighten the clamp bands.6. Fill with clean water and anti-freeze until the coolant level is just
below the port. Install the radiator cap securely.
W1057988
(1) Clamp(2) Upper Hose(3) Lower Hose
[A] KJ-S130VX(-AUS)KJ-S170FX(-AUS)KJ-T130DX(-AUS)KJ-T180VX(-AUS)KJ-T230FX(-AUS)
[B] KJ-T300(-AUS)KJ-S240-AUS
KiSC issued 09, 2009 A
G-31
KJ-X50 Hz SERIES, WSM G GENERAL
8. SPECIAL TOOLS[1] ALL MODELS
Diesel Engine Compression TesterCode No: 07909-30208 (Assembly) 07909-31251 (G)
07909-30934 (A to F) 07909-31271 (I)07909-31211 (E and F) 07909-31281 (J)07909-31231 (H)
Application: Use to measure diesel engine compression anddiagnosis of need for major overhaul.
W1024200
Oil Pressure TesterCode No: 07916-32032Application: Use to measure lubricating oil pressure.
W1043073
(1) Gauge(2) L Joint(3) Adaptor A(4) Adaptor B(5) Adaptor C(6) Adaptor E
(7) Adaptor F(8) Adaptor G(9) Adaptor H
(10) Adaptor I(11) Adaptor J
(1) Gauge(2) Cable(3) Threaded Joint(4) Adaptor 1
(5) Adaptor 2(6) Adaptor 3(7) Adaptor 4(8) Adaptor 5
KiSC issued 09, 2009 A
G-32
KJ-X50 Hz SERIES, WSM G GENERAL
[2] D1703-E/E2, V2203-E/E2, F2803-E/E2NOTE
• The following special tools are not provided, so make them referring to the figure.Injection Pump Pressure TesterApplication: Use to check fuel tightness of injection pumps.
W10252400
Valve Guide Replacing ToolApplication: Use to press out and press fit the valve guide.
W1025017
A Pressure gauge full scale : More than 29.4 MPa (300 kgf/cm2, 4267 psi)
B PF 1/2
C Copper gasket
D Flange (Material : Steel)
E Hex. nut 27 mm (1.1 in.) across the plat
F Adhesive application
G Fillet welding on the enter circumference
H Retaining nut
I 17 mm dia. (0.67 in. dia.)
J 8 mm dia. (0.3 in. dia.)
K 1.0 mm (0.039 in.)
L 17 mm dia. (0.67 in. dia.)
M 6.10 to 6.20 mm dia. (0.241 to 0.244 in. dia.)
N 8 mm (0.3 in.)
O 4 mm (0.2 in.)
P 11.97 to 11.99 mm dia. (0.4713 to 0.4720 in. dia.)
Q PF 1/2
R 23 mm (0.91 in.)
S 17 mm (0.67 in.)
T 4 mm (0.2 in.)
U 12.00 to 12.02 mm dia. (0.4725 to 0.4732 in. dia.)
V 100 mm (3.94 in.)
W M12 × P1.5
X 5 mm (0.2 in.)
A 225 mm (8.86 in.)
B 70 mm (2.8 in.)
C 45 mm (1.8 in.)
D 20 mm dia. (0.79 in. dia.)
E 12.7 to 12.9 mm dia. (0.500 to 0.507 in. dia.)
F 7.50 to 7.60 mm dia. (0.296 to 0.299 in. dia.)
G 25 mm dia. (0.98 in. dia.)
H 7.70 to 8.00 mm dia. (0.304 to 0.314 in. dia.)
I 5 mm (0.2 in.)
J 20 mm dia. (0.79 in. dia.)
K 13.5 to 13.8 mm dia. (0.532 to 0.543 in. dia.)
L 8.90 to 9.10 mm (0.351 to 0.358 in.)
C1 Chamfer 1.0 mm (0.039 in.)
C2 Chamfer 2.0 mm (0.079 in.)
C0.3 Chamfer 0.3 mm (0.01 in.)
KiSC issued 09, 2009 A
G-33
KJ-X50 Hz SERIES, WSM G GENERAL
Bushing Replacing ToolsApplication: Use to press out and to press fit the bushing.1. For small end bushing
2. For idle gear bushing
W1025500
Flywheel StopperApplication: Use to loosen and tighten the flywheel screw.
W10259480
A 162 mm (6.38 in.)
B 35 mm (1.4 in.)
C 27 mm (1.1 in.)
D 35 mm dia. (1.4 in. dia.)
E 27.90 to 27.95 mm dia. (1.099 to 1.100 in. dia.)
F 25.00 to 25.01 mm dia. (0.9843 to 0.9846 in. dia.)
A 175 mm (6.89 in.)
B 40 mm (1.6 in.)
C 38 mm (1.5 in.)
D 45 mm dia. (1.8 in. dia.)
E 41.90 to 41.95 mm dia. (1.650 to 1.651 in. dia.)
F 37.950 to 37.970 mm dia. (1.4941 to 1.4948 in. dia.)
A 20 mm (0.79 in.)
B 15 mm (0.59 in.)
C 10 mm dia. (0.39 in. dia.)
D 30 mm (1.2 in.)
E 8 mm (0.3 in.)
F 200 mm (7.87 in.)
KiSC issued 09, 2009 A
G-34
KJ-X50 Hz SERIES, WSM G GENERAL
Crankshaft Bearing 1 Replacing Tool [D1703, V2203] (Serial No. : below 3R9999)[F2803]Application: Use to press out and press fit the crankshaft bearing 1.1. Extracting tool
2. Inserting tool
W1026139
Crankshaft Bearing 1 Replacing Tool[D1703, V2203] (Serial No. above 3S0001)Application: Use to press out and press fit the crankshaft bearing 1.1. Extracting tool
2. Inserting tool
W1025644
A 135 mm (5.31 in.)
B 72 mm (2.8 in.)
C 40 mm radius (1.6 in. radius)
D 10 mm (0.39 in.)
E 20 mm (0.79 in.)
F 20 mm dia. (0.79 in. dia.)
G 56.80 to 56.90 mm dia. (2.237 to 2.240 in. dia.)
H 51.80 to 51.90 mm dia. (2.040 to 2.043 in. dia.)
A 130 mm (5.12 in.)
B 72 mm (2.8 in.)
C 40 mm radius (1.6 in. radius)
D 9 mm (0.4 in.)
E 4 mm (0.2 in.)
F 20 mm (0.79 in.)
G 20 mm dia. (0.79 in. dia.)
H 68 mm dia. (2.7 in. dia.)
I 51.80 to 51.90 mm dia. (2.040 to 2.043 in. dia.)
J 56.80 to 56.90 mm dia. (2.237 to 2.240 in. dia.)
A 135 mm (5.31 in.)
B 72 mm (2.8 in.)
C 40 mm radius (1.6 in. radius)
D 10 mm (0.39 in.)
E 20 mm (0.79 in.)
F 20 mm dia. (0.79 in. dia.)
G 64.80 to 64.90 mm dia. (2.552 to 2.555 in. dia.)
H 59.80 to 59.90 mm dia. (2.355 to 2.358 in. dia.)
A 130 mm (5.12 in.)
B 72 mm (2.8 in.)
C 40 mm radius (1.6 in. radius)
D 9 mm (0.4 in.)
E 4 mm (0.2 in.)
F 20 mm (0.79 in.)
G 20 mm dia. (0.79 in. dia.)
H 68 mm dia. (2.7 in. dia.)
I 59.80 to 59.90 mm dia. (2.355 to 2.358 in. dia.)
J 64.80 to 64.90 mm dia. (2.552 to 2.555 in. dia.)
KiSC issued 09, 2009 A
G-35
KJ-X50 Hz SERIES, WSM G GENERAL
Socket Wrench for Crank Pulley Nut (46 mm Deep SocketWrench)Application: Use to loosen and tighten the fan drive pulley mounting
nut.
W1044361
Auxiliary Socket for Fixing Crankshaft Sleeve (To be continued)Application: Use to fix the crankshaft sleeve of the diesel engine.
W1027695
A 100 mm (3.94 in.)
B 25.0 mm (0.984 in.)
C 27.0 mm (1.06 in.)
D 45.0 mm dia. (1.77 in. dia.)
E 35.0 mm dia. (1.38 in. dia.)
F 62.5 mm dia. (2.46 in. dia.)
G 46.0 mm (1.81 in.)
A 80.0 mm (3.15 in.)
B
D1703, V2203(Serial No.: below 3R9999) /F2803
52.10 to 52.30 mm (2.052 to 2.059 in.)
D1703, V2203(Serial No. : above 3S0001)
60.10 to 60.30 mm (2.367 to 2.374 in.)
C 80.0 mm dia. (3.15 in. dia.)
D 85.0 mm dia. (3.35 in. dia.)
E
D1703, V2203(Serial No.: below 3R9999) /F2803
52.10 to 52.30 mm dia. (2.052 to 2.059 in. dia.)
D1703, V2203(Serial No. : above 3S0001)
60.10 to 60.30 mm dia. (2.367 to 2.374 in. dia.)
F 26.30 to 26.40 mm (1.036 to 1.039 in.)
G 25.85 to 25.90 mm (1.018 to 1.019 in.)
H 15.0 mm (0.591 in.)
I 5.0 mm (0.20 in.)
(1) Stopper(2) Sleeve Guide
(3) Auxiliary Socket for Pushing
KiSC issued 09, 2009 A
G-36
KJ-X50 Hz SERIES, WSM G GENERAL
Auxiliary Socket for Fixing Crankshaft Sleeve (Continued)Application: Use to fix the crankshaft sleeve of the diesel engine.
W1027898
J 42.0 mm (1.65 in.)
K 30.50 to 30.60 mm (1.201 to 1.204 in.)
L 23.0 mm (0.906 in.)
M 20.0 mm (0.787 in.)
N 2.0 mm (0.079 in.)
O 31.911 to 31.950 mm dia. (1.2564 to 1.2578 in. dia.)
P 30.0 mm dia. (1.18 in. dia.)
Q 5.0 mm dia. (0.20 in. dia.)
R 0.09 rad (5 °)
S 25.0 mm dia. (0.984 in. dia.)
T 60.0 mm dia. (2.36 in. dia.)
U 79.80 to 79.85 mm dia. (3.142 to 3.143 in. dia.)
V 10.0 mm (0.394 in.)
W 0.04 mm dia. (0.002 in. dia.)
X 140 mm (5.51 in.)
Y 120 mm (4.72 in.)
Z 110 mm (4.33 in.)
a 50.0 mm (1.97 in.)
b 39.90 to 40.00 mm (1.571 to 1.574 in.)
c 25.0 mm (0.984 in.)
d 90.0 mm dia. (3.54 in. dia.)
e 81.0 mm dia. (3.19 in. dia.)
f 80.10 to 80.15 mm dia. (3.154 to 3.155 in. dia.)
g 30.0 mm dia. (1.18 in. dia.)
h 5.0 mm dia. (0.20 in. dia.)
i 70.0 mm (2.76 in.)
j 50.0 mm (1.97 in.)
k 40.0 mm dia. (1.57 in. dia.)
C1 Chamfer 1.0 mm (0.039 in.)
C5 Chamfer 5.0 mm (0.20 in.)
C0.3 Chamfer 0.3 mm (0.01 in.)
R1 1.0 mm radius (0.039 in. radius)
R2 2.0 mm radius (0.079 in. radius)
R10 10.0 mm radius (0.394 in. radius)
(2) Sleeve Guide (3) Auxiliary Socket for Pushing
KiSC issued 09, 2009 A
G-37
KJ-X50 Hz SERIES, WSM G GENERAL
[3] V3300-E2BGNOTE
• The following special tools are not provided, so make them referring to the figure.Injection Pump Pressure TesterApplication: Use to check fuel tightness of injection pumps.
0
A Pressure gauge full scale : More than 29.4 MPa (300 kgf/cm2, 4267 psi)
B PF 1/2
C Copper gasket
D Flange (Material : Steel)
E Hex. nut 27 mm (1.1 in.) across the plat
F Adhesive application
G Fillet welding on the enter circumference
H Retaining nut
I 17 mm dia. (0.67 in. dia.)
J 8 mm dia. (0.3 in. dia.)
K 1.0 mm (0.039 in.)
L 17 mm dia. (0.67 in. dia.)
M 6.10 to 6.20 mm dia. (0.241 to 0.244 in. dia.)
N 8 mm (0.3 in.)
O 4 mm (0.2 in.)
P 11.97 to 11.99 mm dia. (0.4713 to 0.4720 in. dia.)
Q PF 1/2
R 23 mm (0.91 in.)
S 17 mm (0.67 in.)
T 4 mm (0.2 in.)
U 12.00 to 12.02 mm dia. (0.4725 to 0.4732 in. dia.)
V 100 mm (3.94 in.)
W M12 × P1.5
X 5 mm (0.2 in.)
KiSC issued 09, 2009 A
G-38
KJ-X50 Hz SERIES, WSM G GENERAL
Small End Bushing Replacing ToolApplication: Use to press out and to press fit the small end bushing.
[Press out]
[Press fit]
W1040702
Idle Gear Bushing Replacing ToolApplication: Use to press out and to press fit the bushing.
W1040289
A 157 mm (6.18 in.)
B 14.5 mm (0.571 in.)
C 120 mm (4.72 in.)
D 30.0 mm dia. (1.18 in. dia.)
E 32.95 mm dia. (1.297 in. dia.)
F 20 mm dia. (0.79 in. dia.)
a 6.3 μm (250 μin.)
b 6.3 μm (250 μin.)
C1 Chamfer 1.0 mm (0.039 in.)
C2 Chamfer 2.0 mm (0.079 in.)
A 157 mm (6.18 in.)
B 14.5 mm (0.571 in.)
C 120 mm (4.72 in.)
D 30.0 mm dia. (1.18 in. dia.)
E 42.00 mm dia. (1.654 in. dia.)
F 20 mm dia. (0.79 in. dia.)
a 6.3 μm (250 μin.)
b 6.3 μm (250 μin.)
C1 Chamfer 1.0 mm (0.039 in.)
C2 Chamfer 2.0 mm (0.079 in.)
A 196 mm (7.72 in.)
B 37.5 mm (1.48 in.)
C 150 mm (5.91 in.)
D 44.95 mm dia. (1.770 in. dia.)
E 48.075 to 48.100 mm dia. (1.8927 to 1.8937 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.)
KiSC issued 09, 2009 A
G-39
KJ-X50 Hz SERIES, WSM G GENERAL
Gear Case Oil Seal Replacing ToolApplication: Use to press fit the oil seal.
W1041529
A 148.8 mm (5.858 in.)
B 50 mm (2.0 in.)
C 18.8 mm (0.740 in.)
D 13.7 to 13.9 mm (0.540 to 0.547 in.)
E 11 mm (0.43 in.)
F 18 mm dia. (0.71 in. dia.)
G 38 mm dia. (1.5 in. dia.)
H 45 mm dia. (1.8 in. dia.)
I 57.90 to 58.10 mm dia. (2.280 to 2.287 in. dia.)
J 79.5 mm dia. (3.13 in. dia.)
K 87 mm dia. (3.4 in. dia.)
L 12 mm (0.47 in.)
M 40 mm (1.6 in.)
N 120 mm (4.72 in.)
KiSC issued 09, 2009 A
G-40
KJ-X50 Hz SERIES, WSM G GENERAL
Valve Guide Replacing ToolApplication: Use to press out and press fit the valve guide.
Intake valve guide
Exhaust valve guide
W1038887
A 225 mm (8.86 in.)
B 70 mm (2.8 in.)
C 45 mm (1.8 in.)
D 20 mm dia. (0.79 in dia.)
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 mm (0.2 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 8.90 to 9.10 mm (0.351 to 0.358 in.)
C1 Chamfer 1.0 mm (0.039 in.)
C2 Chamfer 2.0 mm (0.079 in.)
C0.3 Chamfer 0.3 mm (0.01 in.)
A 225 mm (8.86 in.)
B 80 mm (3.1 in.)
C 40 mm (1.6 in.)
D 20 mm dia. (0.79 in dia.)
E 12.96 to 12.98 mm dia. (0.5103 to 0.5110 in. dia.)
F 7.50 to 7.70 mm dia. (0.296 to 0.303 in. dia.)
G 14.5 to 15.5 mm dia. (0.571 to 0.610 in.dia.)
H 8.00 to 8.10 mm dia. (0.315 to 0.318 in. dia.)
I 5 mm (0.2 in.)
J 17.5 to 18.5 mm dia. (0.689 to 0.728 in. dia.)
K 13.1 to 13.2 mm dia. (0.516 to 0.519 in. dia.)
L 9.90 to 10.1 mm (0.390 to 0.397 in.)
C1 Chamfer 1.0 mm (0.039 in.)
C2 Chamfer 2.0 mm (0.079 in.)
C0.3 Chamfer 0.3 mm (0.01 in.)
KiSC issued 09, 2009 A
G-41
KJ-X50 Hz SERIES, WSM G GENERAL
Auxiliary Socket for Fixing Crankshaft SleeveApplication: Use to fix the crankshaft sleeve of the diesel engine.
W1041815
A Rmax = 12.5 S
B 94.5 to 95.0 mm dia. (3.72 to 3.74 in. dia.)
C 40 mm dia. (1.6 in. dia.)
D 30 mm dia. (1.2 in. dia.)
E 12 mm (0.47 in.)
F 7.90 to 8.10 mm (0.311 to 0.318 in.)
G 20 mm (0.79 in.)
H 130 mm dia. (5.12 in. dia.)
I 99.40 to 99.60 mm dia. (3.914 to 3.921 in. dia.)
J 95.05 to 95.20 mm dia. (3.743 to 3.748 in. dia.)
K 3 mm dia. (0.1 in.dia.)
L 15 mm (0.59 in.)
M 10 mm (0.39 in.)
N 90 mm (3.5 in.)
O 115 mm (4.53 in.)
P 16.9 to 17.1 mm (0.666 to 0.673 in.)
C1 Chamfer 1.0 mm (0.039 in.)
C3 Chamfer 3.0 mm (0.12 in.)
C5 Chamfer 5.0 mm (0.20 in.)
C0.2 Chamfer 0.2 mm (0.008 in.)
C0.3 Chamfer 0.3 mm (0.01 in.)
KiSC issued 09, 2009 A
G-42
KJ-X50 Hz SERIES, WSM G GENERAL
Injection Pump Gear PullerApplication: Use for remove the injection pump gear from governor
shaft.
W1042094
Engine StandApplication: Use to support engine.
W1033645
A 10 mm dia. (0.39 in.dia.)
B M16 × Pitch 1.5
C 19 mm (0.75 in.)
D 0.5 mm radius (0.02 in. radius)
E 0.87 rad (50 °)
F 10 mm (0.39 in.)
G 20 mm (0.79 in.)
H 5 mm (0.2 in.)
I 95 mm (3.7 in.)
J 125 mm (4.92 in.)
K 5 mm (0.2 in.)
L M16 × Pitch 1.5
M 30 mm (1.2 in.)
N 9.5 mm (0.37 in.)
O 11 mm (0.43 in.)
P 9.5 mm (0.37 in.)
Q 14.5 mm (0.571 in.)
R 5.5 mm radius (0.22 in. radius)
S 20 mm (0.79 in.)
T 20 mm (0.79 in.)
U 80 mm (3.1 in.)
W 12 mm (0.47 in.)
C2 Chamfer 2.0 mm (0.079 in.)
A 480 mm (18.9 in.)
B 50 mm (2.0 in.)
C 108.5 mm (4.272 in.)
D 262.5 mm (10.33 in.)
E 12.5 mm (0.492 in.)
F 237.5 mm (9.350 in.)
G 142.5 mm (5.610 in.)
H 95 mm (3.7 in.)
I 14 mm dia. (0.55 in. dia.)
J 40 mm radius (1.6 in. radius)
K 210 mm (8.27 in.)
L 190 mm (7.48 in.)
M 100 mm (3.94 in.)
N 6 mm (0.2 in.)
O 6 mm (0.2 in.)
P 25 mm dia. (0.98 in. dia.)
C10 Chamfer 10 mm (0.39 in.)
KiSC issued 09, 2009 A
G-43
KJ-X50 Hz SERIES, WSM G GENERAL
Flywheel StopperApplication: Use to loosen and tighten the flywheel screw.
W1042515
Tool for Aligning the Crankcase 1 and 2Application: Use for aligning the crankcase 1 and 2.
W1047882
A 140 mm (5.51 in.)
B 80 mm (3.1 in.)
C 49.3 mm (1.94 in.)
D 49.3 mm (1.94 in.)
E 23.8 mm (0.937 in.)
F 23.8 mm (0.937 in.)
G 11 mm dia. (0.43 in. dia.)
H 56.5 mm (2.22 in.)
I 56.5 mm (2.22 in.)
J 8 mm (0.3 in.)
A 115 mm (4.53 in.)
B 56 mm (2.2 in.)
C 17 mm (0.67 in.)
D 20 mm (0.79 in.)
E 14 mm dia. (0.55 in. dia.)
F 11 mm dia. (0.43 in. dia.)
G 14 mm dia. (0.55 in. dia.)
H 17.5 mm (0.689 in.)
I 17.5 mm (0.689 in.)
J 35 mm (1.4 in.)
K 19 mm (0.75 in.)
KiSC issued 09, 2009 A
G-44
KJ-X50 Hz SERIES, WSM G GENERAL
Jig for Governor Connecting RodApplication: Use for connecting the governor connecting rod to the
rack pin of the fuel injection pump assembly.
W1115114
A 1 mm radius (0.04 in. radius)
B Chamfer 0.2 mm (0.008 in.)
C Chamfer 2 mm (0.08 in.)
D 35 mm dia. (1.4 in. dia.)
E Chamfer 1 mm (0.04 in.)
F Chamfer 0.1 mm (0.004 in.)
G 1 mm radius (0.04 in. radius)
H Chamfer 0.2 mm (0.008 in.)
I 8 mm radius (0.3 in. radius)
J 1 mm radius (0.04 in. radius)
K 1 mm radius (0.04 in. radius)
L Chamfer 0.2 mm (0.008 in.)
M Chamfer 0.2 mm (0.008 in.)
N 29 mm (1.1 in.)
O 6 mm (0.2 in.)
P 10.7 mm (0.421 in.)
Q 35 mm (1.4 in.)
R 99.3 mm (3.91 in.)
S 45.65 to 45.75 mm (1.798 to 1.801 in.)
T 145 mm (5.71 in.)
U 16.15 to 16.35 mm (0.6359 to 0.6437 in.)
V 3 mm (0.1 in.)
W 10 mm (0.39 in.)
X 8 mm (0.3 in.)
(1) Material: S45C-D (2) Permanent Magnet: 8 mm dia. (0.3 in. dia.)Thickness: 3 mm (0.1 in.)
KiSC issued 09, 2009 A
1 ENGINE
KiSC issued 09, 2009 A
CONTENTS
SERVICING
1. TROUBLESHOOTING ......................................................................................S-1[1] D1703-E/E2, V2203-E/E2, F2803-E/E2 ......................................................S-1[2] V3300-E2BG...............................................................................................S-4
2. SERVICING SPECIFICATIONS ......................................................................S-7[1] D1703-E/E2, V2203-E/E2, F2803-E/E2 ......................................................S-7[2] V3300-E2BG.............................................................................................S-13
3. TIGHTENING TORQUES ..............................................................................S-19[1] TIGHTENING TORQUES FOR SPECIAL USE SCREWS, BOLTS
AND NUTS...............................................................................................S-19(1) D1703-E/E2, V2203-E/E2, F2803-E/E2..............................................S-19(2) V3300-E2BG.......................................................................................S-20
4. CHECKING, DISASSEMBLING AND SERVICING......................................S-21[1] CHECKING AND ADJUSTING ...............................................................S-21
(1) Engine Body........................................................................................S-21(2) Lubricating System .............................................................................S-24(3) Cooling System...................................................................................S-25(4) Fuel System ........................................................................................S-27(5) Electrical System ................................................................................S-32
[2] DISASSEMBLING AND ASSEMBLING..................................................S-37(1) D1703-E/E2, V2203-E/E2, F2803-E/E2..............................................S-37(2) V3300-E2BG.......................................................................................S-53(3) Starter .................................................................................................S-75(4) Alternator ............................................................................................S-77
[3] SERVICING ..............................................................................................S-78(1) Cylinder Head and Valves ..................................................................S-78(2) Timing Gears ......................................................................................S-86(3) Piston and Connecting Rod ................................................................S-90(4) Crankshaft...........................................................................................S-94(5) Cylinder.............................................................................................S-102(6) Oil Pump ...........................................................................................S-103(7) Starter ...............................................................................................S-104(8) Alternator ..........................................................................................S-107
KiSC issued 09, 2009 A
S-1
KJ-X50 Hz SERIES, WSM ENGINE
1. TROUBLESHOOTING[1] D1703-E/E2, V2203-E/E2, F2803-E/E2
W1217350
Symptom Probable Cause Solution Reference Page
Engine Does Not Start
No fuel Replenish fuel G-13Air in the fuel system Vent air G-13Water in the fuel system Change fuel and
repair or replace fuel system
–
Fuel hose clogged Clean or replace G-13Fuel filter clogged Replace G-16Excessively high viscosity of fuel or engine oil at low temperature
Use specified fuel or engine oil
7 to 12, G-5
Fuel with low cetane number Use specified fuel 7 to 12Fuel leak due to loose injection pipe retaining nut Tighten retaining nut S-38Incorrect injection timing Adjust S-27Fuel camshaft worn Replace S-45Injection nozzle clogged Clean or replace S-31, 32Injection pump malfunctioning Repair or replace S-29, 30,
42Seizure of crankshaft, camshaft, piston, cylinder or bearing
Repair or replace S-45 to 49S-94 to 101
Compression leak from cylinder Replace head gasket, tighten cylinder head screw, glow plug and nozzle holder
S-38, 39, 40
Improper valve timing Correct or replace timing gear
S-45
Piston ring and cylinder worn Replace S-47, 48, 49, 92, 93,102
Excessive valve clearance Adjust S-22Stop solenoid malfunctioning Replace –
Starter Does Not Run Battery discharged Charge –Starter malfunctioning Repair or replace S-104, 105,
106Key switch malfunctioning Replace –Wiring disconnected Connect –
KiSC issued 09, 2009 A
S-2
KJ-X50 Hz SERIES, WSM ENGINE
W1219251
Symptom Probable Cause Solution Reference Page
Engine Revolution Is Not Smooth
Fuel filter clogged or dirty Replace G-16Air cleaner clogged Clean or replace G-12Fuel leak due to loose injection pipe retaining nut Tighten retaining nut S-38Injection pump malfunctioning Repair or replace S-29, 30,
42Incorrect nozzle opening pressure Adjust S-31Injection nozzle stuck or clogged Repair or replace S-31, 32Governor malfunctioning Repair S-42, 43,
45Either White or Blue Exhaust Gas Is Observed
Excessive engine oil Reduce to specified level
G-9
Piston ring and cylinder worn or stuck Repair or replace S-47, 48, 49, 92, 93,
102Incorrect injection timing Adjust S-27
Either Black or Dark Gray Exhaust Gas Is Observed
Overload Reduce the load –Low grade fuel used Use specified fuel 7 to 12Fuel filter clogged Replace G-16Air cleaner clogged Clean or replace G-12Deficient nozzle injection Repair or replace
nozzleS-31, 32
Deficient Output Incorrect injection timing Adjust S-27Engine’s moving parts seem to be seizing Repair or replace –Injection pump malfunctioning Repair or replace S-29, 30,
42Deficient nozzle injection Repair or replace
nozzleS-31, 32
Compression leak Check the compression pressure and repair
S-21
Air cleaner dirty or clogged Clean or replace G-12Excessive Lubricant OIl Consumption
Piston ring’s gap facing the same direction Shift ring gap direction
S-48
Oil ring worn or stuck Replace S-47, 48, 49
Piston ring groove worn Replace piston S-47, 48, 49
Valve stem and valve guide worn Replace S-81, 82Crankshaft bearing and crank pin bearing worn Replace S-52, 95 to
99Oil leaking due to defective seals or packing Replace –
KiSC issued 09, 2009 A
S-3
KJ-X50 Hz SERIES, WSM ENGINE
W1211178
Symptom Probable Cause Solution Reference Page
Fuel Mixed into Lubricant Oil
Injection pump’s plunger worn Repair or replace S-29, 30, 42
Deficient nozzle injection Repair or replace nozzle
S-31, 32
Injection pump broken Replace S-42Water Mixed into Lubricant Oil
Head gasket defective Replace S-40Cylinder block or cylinder head flawed Replace S-40
Low Oil Pressure Engine oil insufficient Replenish G-9Oil strainer clogged Clean S-46Relief valve stuck with dirt Clean –Relief valve spring weaken or broken Replace –Excessive oil clearance of crankshaft bearing Replace S-51Excessive oil clearance of crankpin bearing Replace S-47, 48,
49Excessive oil clearance of rocker arm Replace S-39Oil passage clogged Clean –Different type of oil Use specified type of
oilG-5
Oil pump defective Replace S-46High Oil Pressure Different type of oil Use specified type of
oilG-5
Relief valve defective Replace –Engine overheated Engine oil insufficient Replenish G-9
Fan belt broken or elongated Replace or adjust S-25Coolant insufficient Replenish G-5Radiator net and radiator fin clogged with dust Clean –Inside of radiator corroded Clean or replace –Coolant flow route corroded Clean or replace –Radiator cap defective Replace S-26Overload running Reduce the load –Head gasket defective Replace S-40Incorrect injection timing Adjust S-27Unsuitable fuel used Use specified fuel 7 to 12
Battery Quickly Discharged
Battery electrolyte insufficient Replenish distilled water and charge
G-13
Fan belt slips Adjust belt tension or replace
G-12
Wiring disconnected Connect –Rectifier defective Replace S-108Alternator defective Replace S-35Battery defective Replace –
KiSC issued 09, 2009 A
S-4
KJ-X50 Hz SERIES, WSM ENGINE
[2] V3300-E2BG
W1213581
Symptom Probable Cause Solution Reference Page
Engine Does Not Start
No fuel Replenish fuel G-13Air in the fuel system Vent air G-13Water in the fuel system Change fuel and
repair or replace fuel system
–
Fuel hose clogged Clean or replace G-13Fuel filter clogged Replace G-16Excessively high viscosity of fuel or engine oil at low temperature
Use specified fuel or engine oil
7 to 12, G-5
Fuel with low cetane number Use specified fuel 7 to 12Fuel leak due to loose injection pipe retaining nut Tighten retaining nut S-53Incorrect injection timing Adjust S-28Fuel camshaft worn Replace S-63, 64Injection nozzle clogged Clean or replace S-31, 32Injection pump malfunctioning Repair or replace S-29, 30,
65, 66Seizure of crankshaft, camshaft, piston, cylinder or bearing
Repair or replace S-68 to 74S-94 to 101
Compression leak from cylinder Replace head gasket, tighten cylinder head screw, glow plug and nozzle holder
S-53, 54, 55, 56
Improper valve timing Correct or replace timing gear
S-68
Piston ring and cylinder worn Replace S-70, 71, 92, 93, 102
Excessive valve clearance Adjust S-23Stop solenoid malfunctioning Replace –
Starter Does Not Run Battery discharged Charge –Starter malfunctioning Repair or replace S-104, 105,
106Key switch malfunctioning Replace –Wiring disconnected Connect –
Engine Revolution Is Not Smooth
Fuel filter clogged or dirty Replace G-16Air cleaner clogged Clean or replace G-12Fuel leak due to loose injection pipe retaining nut Tighten retaining nut S-53Injection pump malfunctioning Repair or replace S-29, 30,
65, 66Incorrect nozzle opening pressure Adjust S-31Injection nozzle stuck or clogged Repair or replace S-31, 32Governor malfunctioning Repair S-60, 61
KiSC issued 09, 2009 A
S-5
KJ-X50 Hz SERIES, WSM ENGINE
W1215489
Symptom Probable Cause Solution Reference Page
Either White or Blue Exhaust Gas Is Observed
Excessive engine oil Reduce to specified level
G-9
Piston ring and cylinder worn or stuck Repair or replace S-70, 71, 92, 93, 102
Incorrect injection timing Adjust S-28Either Black or Dark Gray Exhaust Gas Is Observed
Overload Reduce the load –Low grade fuel used Use specified fuel 7 to 12Fuel filter clogged Replace G-16Air cleaner clogged Clean or replace G-12Deficient nozzle injection Repair or replace
nozzleS-31, 32
Deficient Output Incorrect injection timing Adjust S-28Engine’s moving parts seem to be seizing Repair or replace –Injection pump malfunctioning Repair or replace S-29, 30,
65, 66Deficient nozzle injection Repair or replace
nozzleS-31, 32
Compression leak Check the compression pressure and repair
S-21
Air cleaner dirty or clogged Clean or replace G-12Excessive Lubricant OIl Consumption
Piston ring’s gap facing the same direction Shift ring gap direction
S-70
Oil ring worn or stuck Replace S-70, 71Piston ring groove worn Replace piston S-70, 71Valve stem and valve guide worn Replace S-81, 82Crankshaft bearing and crank pin bearing worn Replace S-71, 74,
95, 99Oil leaking due to defective seals or packing Replace –
Fuel Mixed into Lubricant Oil
Injection pump’s plunger worn Repair or replace S-29, 30, 65, 66
Deficient nozzle injection Repair or replace nozzle
S-31, 32
Injection pump broken Replace S-65Water Mixed into Lubricant Oil
Head gasket defective Replace S-55, 56Cylinder block or cylinder head flawed Replace S-55, 56
KiSC issued 09, 2009 A
S-6
KJ-X50 Hz SERIES, WSM ENGINE
W1212776
Symptom Probable Cause Solution Reference Page
Low Oil Pressure Engine oil insufficient Replenish G-9Oil strainer clogged Clean S-69Relief valve stuck with dirt Clean –Relief valve spring weaken or broken Replace –Excessive oil clearance of crankshaft bearing Replace S-74Excessive oil clearance of crankpin bearing Replace S-70, 71Excessive oil clearance of rocker arm Replace S-54Oil passage clogged Clean –Different type of oil Use specified type of
oilG-5
Oil pump defective Replace S-103, 104High Oil Pressure Different type of oil Use specified type of
oilG-5
Relief valve defective Replace –Engine overheated Engine oil insufficient Replenish G-9
Fan belt broken or elongated Replace or adjust S-25Coolant insufficient Replenish G-5Radiator net and radiator fin clogged with dust Clean –Inside of radiator corroded Clean or replace –Coolant flow route corroded Clean or replace –Radiator cap defective Replace S-26Overload running Reduce the load –Head gasket defective Replace S-55, 56Incorrect injection timing Adjust S-28Unsuitable fuel used Use specified fuel 7 to 12
Battery Quickly Discharged
Battery electrolyte insufficient Replenish distilled water and charge
G-13
Fan belt slips Adjust belt tension or replace
G-12
Wiring disconnected Connect –Rectifier defective Replace S-108Alternator defective Replace S-35Battery defective Replace –
KiSC issued 09, 2009 A
S-7
KJ-X50 Hz SERIES, WSM ENGINE
2. SERVICING SPECIFICATIONS[1] D1703-E/E2, V2203-E/E2, F2803-E/E2ENGINE BODY
W1040597
Item Factory Specification Allowable LimitValve Clearance (When Cold) 0.18 to 0.22 mm
0.0071 to 0.0086 in.–
Compression Pressure(When Cranking with Starting Motor)
Difference among Cylinders
3.24 to 3.72 MPa / 290 min-1 (rpm)
33.0 to 38.0 kgf/cm2 / 290 min-1 (rpm)470 to 540 psi /290 min-1 (rpm)
–
2.55 MPa / 290 min-1 (rpm)26.0 kgf/cm2 /
290 min-1 (rpm)370 psi /
290 min-1 (rpm)
10 % or lessTop Clearance 0.55 to 0.70 mm
0.022 to 0.027 in.–
Cylinder Head Surface Flatness – 0.05 mm / 500 mm0.002 in. / 19.7 in.
Valve Recessing Protrusion
Recessing
0.05 mm0.002 in.
0.15 mm0.0059 in.
–
0.40 mm0.016 in.
Valve Stem to Valve Guide
Valve Stem
Valve Guide
Clearance
O.D.
I.D.
0.040 to 0.070 mm0.0016 to 0.0027 in.
7.960 to 7.975 mm0.3134 to 0.3139 in.
8.015 to 8.030 mm0.3156 to 0.3161 in.
0.10 mm0.0039 in.
–
–
Valve Face Angle (Intake)
Angle (Exhaust)
1.0 rad60 °
0.79 rad45 °
–
–
Valve Seat Angle (Intake)
Angle (Exhaust)
1.0 rad60 °
0.79 rad45 °
–
–
Valve Seat Width (Intake)
Width (Exhaust)
2.12 mm0.0835 in.
2.12 mm0.0835 in.
–
–
Valve Timing (Intake Valve) Open
Close
0.21 rad (12 °)before T.D.C.
0.63 rad (36 °)after B.D.C.
–
–
KiSC issued 09, 2009 A
S-8
KJ-X50 Hz SERIES, WSM ENGINE
ENGINE BODY (Continued)
W1041845
Item Factory Specification Allowable LimitValve Timing (Exhaust Valve) Open
Close
1.05 rad (60 °)before B.D.C.
0.21 rad (12 °)after T.D.C.
–
–
Valve Spring Free Length
Setting Load / Setting Length
Tilt
41.7 to 42.2 mm1.65 to 1.66 in.
118 N / 35.0 mm12.0 kgf / 35.0 mm26.5 lbf / 1.38 in.
–
41.2 mm1.62 in.
100 N / 35.0 mm10.2 kgf / 35.0 mm
22.5 lbf /1.38 in.
1.0 mm0.039 in.
Rocker Arm Shaft to Rocker Arm
Rocker Arm Shaft
Rocker Arm
Oil Clearance
O.D.
I.D.
0.016 to 0.045 mm0.00063 to 0.0017 in.
13.973 to 13.984 mm0.55012 to 0.55055 in.
14.000 to 14.018 mm0.55119 to 0.55188 in.
0.10 mm0.0039 in.
–
–
Push Rod Alignment – 0.25 mm0.0098 in.
Tappet to Tappet Guide
Tappet
Tappet Guide
Oil Clearance
O.D.
I.D.
0.020 to 0.062 mm0.00079 to 0.0024 in.
23.959 to 23.980 mm0.94327 to 0.94409 in.
24.000 to 24.021 mm0.94489 to 0.94570 in.
0.07 mm0.003 in.
–
–
Timing GearCrank Gear to Idle Gear
Idle Gear to Cam Gear
Idle Gear to Injection Pump Gear
Crank Gear to Oil Pump Gear
Backlash
Backlash
Backlash
Backlash
0.04150 to 0.1122 mm0.001634 to 0.004417
in.
0.04150 to 0.1154 mm0.001634 to 0.004543
in.
0.04150 to 0.1154 mm0.001634 to 0.004543
in.
0.04150 to 0.1090 mm0.001634 to 0.004291
in.
0.15 mm0.0059 in.
0.15 mm0.0059 in.
0.15 mm0.0059 in.
0.15 mm0.0059 in.
Idle Gear Side Clearance 0.12 to 0.48 mm0.0048 to 0.018 in.
0.9 mm0.04 in.
KiSC issued 09, 2009 A
S-9
KJ-X50 Hz SERIES, WSM ENGINE
ENGINE BODY (Continued)
W1043006
Item Factory Specification Allowable LimitIdle Gear Shaft to Idle Gear Bushing
Idle Gear Shaft
Idle Gear Bushing
Oil Clearance
O.D.
I.D.
0.025 to 0.066 mm0.00099 to 0.0025 in.
37.959 to 37.975 mm1.4945 to 1.4950 in.
38.000 to 38.025 mm1.4961 to 1.4970 in.
0.10 mm0.0039 in.
–
–
Camshaft Side Clearance 0.070 to 0.22 mm0.0028 to 0.0086 in.
0.30 mm0.012 in.
Camshaft Alignment – 0.01 mm0.0004 in.
Cam Height (Intake and Exhaust)
33.47 mm1.318 in.
33.42 mm1.316 in.
Camshaft Journal to Cylinder Block Bore
Camshaft Journal
Cylinder Block Bore
Oil Clearance
O.D.
I.D.
0.050 to 0.091 mm0.0020 to 0.0035 in.
39.934 to 39.950 mm1.5722 to 1.5728 in.
40.000 to 40.025 mm1.5748 to 1.5757 in.
0.15 mm0.0059 in.
–
–
Piston Pin Bore I.D. 25.000 to 25.013 mm0.98426 to 0.98476 in.
25.05 mm0.9862 in.
Second Ring to Ring Groove Clearance 0.0930 to 0.120 mm0.00367 to 0.00472 in.
0.20 mm0.0079 in.
Oil Ring to Ring Groove Clearance 0.020 to 0.052 mm0.00079 to 0.0020 in.
0.15 mm0.0059 in.
Top Ring Ring Gap 0.30 to 0.45 mm0.012 to 0.017 in.
1.25 mm0.0492 in.
Second Ring Ring Gap 0.30 to 0.45 mm0.012 to 0.017 in.
1.25 mm0.0492 in.
Oil Ring Ring Gap 0.25 to 0.45 mm0.0099 to 0.017 in.
1.25 mm0.0492 in.
Connecting Rod Alignment – 0.05 mm0.002 in.
Piston Pin to Small End Bushing
Piston Pin
Small End Bushing
Oil Clearance
O.D.
I.D.
0.014 to 0.036 mm0.00056 to 0.0014 in.
25.004 to 25.011 mm0.98441 to 0.98468 in.
25.025 to 25.040 mm0.98524 to 0.98582 in.
0.15 mm0.0059 in.
–
–
Crankshaft Alignment – 0.02 mm0.0008 in.
KiSC issued 09, 2009 A
S-10
KJ-X50 Hz SERIES, WSM ENGINE
ENGINE BODY (Continued)
W1044270
Item Factory Specification Allowable LimitCrankshaft Journal to Crankshaft Bearing 1[D1703, V2203](Serial No. : below 3R9999)[F2803]
Crankshaft Journal
Crankshaft Bearing 1
Oil Clearance
O.D.
I.D.
0.0400 to 0.118 mm0.00158 to 0.00464 in.
51.921 to 51.940 mm2.0442 to 2.0448 in.
51.980 to 52.039 mm2.0465 to 2.0487 in.
0.20 mm0.0079 in.
–
–
Crankshaft Journal to Crankshaft Bearing 1[D1703, V2203](Serial No. : above 3S0001)
Crankshaft Journal
Crankshaft Bearing 1
Oil Clearance
O.D.
I.D.
0.0400 to 0.118 mm0.00158 to 0.00464 in.
59.921 to 59.940 mm2.3591 to 2.3598 in.
59.980 to 60.039 mm2.3615 to 2.3637 in.
0.20 mm0.0079 in.
–
–
Crankshaft Journal to Crankshaft Bearing 2[D1703, V2203](Serial No. : below 3R9999)[F2803]
Crankshaft Journal
Crankshaft Bearing 2
Oil Clearance
O.D.
I.D.
0.0400 to 0.104 mm0.00158 to 0.00409 in.
51.921 to 51.940 mm2.0442 to 2.0448 in.
51.980 to 52.025 mm2.0465 to 2.0482 in.
0.20 mm0.0079 in.
–
–
Crankshaft Journal to Crankshaft Bearing 2[D1703, V2203](Serial No. : above 3S0001)
Crankshaft Journal
Crankshaft Bearing 2
Oil Clearance
O.D.
I.D.
0.0400 to 0.104 mm0.00158 to 0.00409 in.
59.921 to 59.940 mm2.3591 to 2.3598 in.
59.980 to 60.025 mm2.3615 to 2.3631 in.
0.20 mm0.0079 in.
–
–
Crankpin to Crankpin Bearing
Crankpin
Crankpin Bearing
Oil Clearance
O.D.
I.D.
0.025 to 0.087 mm0.00099 to 0.0034 in.
46.959 to 46.975 mm1.8488 to 1.8494 in.
47.000 to 47.046 mm1.8504 to 1.8522 in.
0.20 mm0.0079 in.
–
–
Crankshaft[D1703, V2203](Serial No. : below 3R9999)[F2803]
Side Clearance 0.15 to 0.35 mm0.0059 to 0.013 in.
0.5 mm0.02 in.
Crankshaft[D1703, V2203](Serial No. : above 3S0001)
Side Clearance 0.15 to 0.31 mm0.0059 to 0.012 in.
0.5 mm0.02 in.
KiSC issued 09, 2009 A
S-11
KJ-X50 Hz SERIES, WSM ENGINE
ENGINE BODY (Continued)
W1045485
LUBRICATING SYSTEM
W1051333
COOLING SYSTEM
W1046673
Item Factory Specification Allowable LimitCylinder Bore (Standard) I.D. 87.000 to 87.022 mm
3.4252 to 3.4260 in.87.150 mm3.4311 in.
Cylinder Bore (Oversize) I.D. 87.500 to 87.522 mm3.4449 to 3.4457 in.
87.650 mm3.4508 in.
Engine Oil Pressure At Idle Speed
At Rated Speed
More than 98 kPa1.0 kgf/cm2
14 psi
300 to 440 kPa3.0 to 4.5 kgf/cm2
43 to 64 psi
50 kPa0.5 kgf/cm2
7 psi
250 kPa2.5 kgf/cm2
36 psiEngine Oil Pressure Switch Working
Pressure50 kPa
0.5 kgf/cm2
7 psi
–
Inner Rotor to Outer Rotor Clearance 0.03 to 0.14 mm0.0012 to 0.0055 in.
0.2 mm0.008 in.
Outer Rotor to Pump Body Clearance 0.11 to 0.19 mm0.0044 to 0.0074 in.
0.25 mm0.0098 in.
Inner Rotor to Cover Clearance 0.105 to 0.150 mm0.00414 to 0.00590 in.
0.2 mm0.008 in.
Fan Belt Tension 7.0 to 9.0 mm (0.28 to 0.35 in.) deflection at
98 N (10 kgf, 22 lbf) of force
–
Thermostat Valve Opening Temperature(At Beginning)
Valve Opening Temperature (Opened Completely)
69.5 to 72.5 °C157.1 to 162.5 °F
85 °C185 °F
–
–
Radiator Water Tightness No leak at specified pressure
–
Radiator Cap Pressure Falling Time
More than 10 seconds for pressure fall
from 90 to 60 kPafrom 0.9 to 0.6 kgf/cm2
from 10 to 9 psi
–
KiSC issued 09, 2009 A
S-12
KJ-X50 Hz SERIES, WSM ENGINE
FUEL SYSTEM
W1050119
ELECTRICAL SYSTEM
W1124497
Item Factory Specification Allowable LimitInjection Pump[D1703-E, V2203-E, V2203-E2, F2803-E2]
Injection Timing 0.27 to 0.29 rad(15 to 17 °) before T.D.C.
–
Injection Pump[F2803-E]
Injection Timing 0.28 to 0.31 rad(16 to 18 °) before T.D.C.
–
Injection Pump[D1703-E2]
Injection Timing 0.236 to 0.270 rad(13.5 to 15.5 °) before T.D.C.
–
Pump Element Fuel Tightness – 13.73 MPa140.0 kgf/cm2
1991 psiDelivery Valve Fuel Tightness 10 seconds
13.73 → 12.75 MPa140.0 → 130.0 kgf/cm2
1991 → 1849 psi
5 seconds13.73 → 12.75 MPa
140.0 →130.0 kgf/cm2
1991 → 1849 psiInjection Nozzle Injection Pressure 13.73 to 14.70 MPa
140.0 to 150.0 kgf/cm2
1992 to 2133 psi
–
Injection Nozzle Valve Seat Valve Seat Tightness
When the pressure is 12.75 MPa
(130.0 kgf/cm2, 1849 psi), the valve seat must
be fuel tightness.
–
StarterCommutator
Mica
Brush
O.D.
Under Cut
Length
30.0 mm1.18 in.
0.45 to 0.75 mm0.018 to 0.029 in.
15.0 mm0.591 in.
29.0 mm1.14 in.
0.20 mm0.0079 in.
11.0 mm0.433 in.
Alternator
Stator
Rotor
Slip Ring
Brush
No-load voltage
Resistance
Resistance
O.D.
Length
More than 13.5 V
Less than 1.0 Ω
2.9 Ω
14.4 mm0.567 in.
10.5 mm0.413 in.
–
–
–
14.0 mm0.551 in.
8.4 mm0.33 in.
Glow Plug Resistance Approx. 0.9 Ω –
KiSC issued 09, 2009 A
S-13
KJ-X50 Hz SERIES, WSM ENGINE
[2] V3300-E2BGENGINE BODY
W11261120
Item Factory Specification Allowable LimitCylinder Head Surface Flatness – 0.05 mm
0.002 in.Top Clearance 0.72 to 0.90 mm
0.029 to 0.035 in. –
Compression Pressure 4.31 MPa /250 min−1 (rpm)44.0 kgf/cm2 /
250 min−1 (rpm)626 psi /
250 min−1 (rpm)
3.26 MPa / 250 min−1 (rpm)33.2 kgf/cm2 /
250 min−1 (rpm)472 psi /
250 min−1 (rpm)Variance Among Cylinders – 10 % or lessValve Seat Angle (Intake)
Angle (Exhaust)
Width
1.0 rad60 °
0.79 rad45 °
2.12 mm0.0835 in.
–
–
–
Valve Face Angle (Intake)
Angle (Exhaust)
1.0 rad60 °
0.79 rad45 °
–
–
Valve Recessing Intake
Exhaust
−0.20 to 0 mm−0.0078 to 0 in.
−0.050 to 0.15 mm−0.0020 to 0.0059 in.
−0.4 mm−0.02 in.
−0.4 mm−0.02 in.
Valve Stem to Valve Guide
Valve Stem
Valve Guide
Valve Stem to Valve Guide
Valve Stem
Valve Guide
Clearance (Intake)
O.D. (Intake)
I.D. (Intake)
Clearance (Exhaust)
O.D. (Exhaust)
I.D. (Exhaust)
0.055 to 0.085 mm0.0022 to 0.0033 in.
6.960 to 6.975 mm0.2741 to 0.2746 in.
7.030 to 7.045 mm0.2768 to 0.2773 in.
0.040 to 0.070 mm0.0016 to 0.0027 in.
7.960 to 7.975 mm0.3134 to 0.3139 in.
8.015 to 8.030 mm0.3156 to 0.3161 in.
0.1 mm0.004 in.
–
–
0.1 mm0.004 in.
–
–
Valve Clearance (Cold) 0.23 to 0.27 mm0.0091 to 0.010 in.
–
KiSC issued 09, 2009 A
S-14
KJ-X50 Hz SERIES, WSM ENGINE
ENGINE BODY (Continued)
W1127908
Item Factory Specification Allowable LimitIntake Valve Timing Open
Close
0.24 rad (14 °)before T.D.C.
0.63 rad (36 °)after B.D.C.
–
–
Exhaust Valve Timing Open
Close
0.79 rad (45 °)before B.D.C.
0.30 rad (17 °)after T.D.C.
–
–
Valve Spring Free Length (Intake)
Free Length(Exhaust)
Tilt
35.1 to 35.6 mm1.39 to 1.40 in.
41.7 to 42.2 mm1.65 to 1.66 in.
–
34.6 mm1.36 in.
41.2 mm1.62 in.
1.0 mm0.039 in.
Valve Spring Setting Load / Setting Length (Intake)
Setting Load / Setting Length (Exhaust)
63.5 N / 31.5 mm6.48 kgf / 31.5 mm14.3 lbf / 1.24 in.
118 N / 35.0 mm12.0 kgf / 35.0 mm26.5 lbf / 1.38 in.
45.9 N / 31.5 mm
4.68 kgf / 31.5 mm10.3 lbf /1.24 in.
100 N / 35.0 mm10.2 kgf / 35.0 mm22.5 lbf / 1.38 in.
Rocker Arm Shaft to Rocker Arm
Rocker Arm Shaft
Rocker Arm
Clearance
O.D.
I.D.
0.016 to 0.045 mm0.00063 to 0.0017 in.
15.973 to 15.984 mm0.62886 to 0.62929 in.
16.000 to 16.018 mm0.62993 to 0.63062 in.
0.15 mm0.0059 in.
–
–
Valve Arm Bridge and Valve Arm Bridge Shaft
Valve Arm Bridge
Valve Arm Bridge Shaft
Clearance
I.D.
O.D.
0.018 to 0.042 mm0.00071 to 0.0016 in.
9.050 to 9.065 mm0.3563 to 0.3568 in.
9.023 to 9.032 mm0.3553 to 0.3555 in.
0.15 mm0.0059 in.
–
–
Push Rod Alignment – 0.25 mm0.0098 in.
KiSC issued 09, 2009 A
S-15
KJ-X50 Hz SERIES, WSM ENGINE
ENGINE BODY (Continued)
W1129677
Item Factory Specification Allowable LimitTappet to Tappet Guide
Tappet Guide Bore
Tappet
Clearance
I.D.
O.D.
0.020 to 0.062 mm0.00079 to 0.0024 in.
24.000 to 24.021 mm0.94489 to 0.94570 in.
23.959 to 23.980 mm0.94327 to 0.94409 in.
0.07 mm0.003 in.
–
–
Camshaft Side Clearance
Alignment
0.070 to 0.22 mm0.0028 to 0.0086 in.
–
0.30 mm0.012 in.
0.01 mm0.0004 in.
Cam Height Intake
Exhaust
37.63 mm1.481 in.
38.96 mm1.534 in.
37.13 mm1.462 in.
38.46 mm1.514 in.
Camshaft
Camshaft Journal
Camshaft Bearing
Oil Clearance
O.D.
I.D.
0.050 to 0.091 mm0.0020 to 0.0035 in.
45.934 to 45.950 mm1.8085 to 1.8090 in.
46.000 to 46.025 mm1.8111 to 1.8120 in.
0.15 mm0.0059 in.
–
–
Timing GearIdle Gear 1 to Crank Gear
Idle Gear 1 to Cam Gear
Idle Gear 1 to Idle Gear 2
Idle Gear 2 to Injection Pump Gear
Backlash
Backlash
Backlash
Backlash
0.0490 to 0.193 mm0.00193 to 0.00759 in.
0.0490 to 0.189 mm0.00193 to 0.00744 in.
0.0440 to 0.185 mm0.00174 to 0.00728 in.
0.0440 to 0.177 mm0.00174 to 0.00696 in.
0.22 mm0.0087 in.
0.22 mm0.0087 in.
0.22 mm0.0087 in.
0.22 mm0.0087 in.
Idle Gear Shaft 1, 2 to Idle Gear 1, 2 Bushing
Idle Gear 1, 2 Bushing
Idle Gear 1, 2 Shaft
Oil Clearance
I.D.
O.D.
0.050 to 0.091 mm0.0020 to 0.0035 in.
45.025 to 45.050 mm1.7727 to 1.7736 in.
44.959 to 44.975 mm1.7701 to 1.7706 in.
0.10 mm0.0039 in.
–
–
Idle Gear Side Clearance 0.15 to 0.30 mm0.0059 to 0.011 in.
0.9 mm0.04 in.
Piston Pin Bore I.D. 30.000 to 30.013 mm1.1811 to 1.1816 in.
30.05 mm1.183 in.
KiSC issued 09, 2009 A
S-16
KJ-X50 Hz SERIES, WSM ENGINE
ENGINE BODY (Continued)
W11316590
Item Factory Specification Allowable LimitSecond Ring to Ring Groove Clearance 0.093 to 0.120 mm
0.00367 to 0.00472 in.0.20 mm0.0079 in.
Oil Ring to Ring Groove Clearance 0.020 to 0.060 mm0.00079 to 0.0023 in.
0.15 mm0.0059 in.
Piston Ring Gap Top Ring
Second Ring
Oil Ring
0.30 to 0.45 mm0.012 to 0.017 in.
0.30 to 0.45 mm0.012 to 0.017 in.
0.25 to 0.45 mm0.0099 to 0.017 in.
1.25 mm0.0492 in.
1.25 mm0.0492 in.
1.25 mm0.0492 in.
Connecting Rod Alignment – 0.05 mm0.002 in.
Piston Pin to Small End Bushing
Piston Pin
Small End Bushing
Clearance
O.D.
I.D.
0.020 to 0.040 mm0.00079 to 0.0015 in.
30.006 to 30.011 mm1.1814 to 1.1815 in.
30.031 to 30.046 mm1.1824 to 1.1829 in.
0.15 mm0.0059 in.
–
–
Crankshaft Side Clearance
Alignment
0.15 to 0.31 mm0.0059 to 0.012 in.
–
0.50 mm0.020 in.
0.02 mm0.0008 in.
Crankshaft Journal to Crankshaft Bearing
Crankshaft Journal
Oil Clearance
O.D.
0.018 to 0.062 mm0.00071 to 0.0024 in.
74.977 to 74.990 mm2.9519 to 2.9523 in.
0.20 mm0.0079 in.
–
Crank Pin to Pin Bearing
Crank Pin
Oil Clearance
O.D.
0.018 to 0.051 mm0.00071 to 0.0020 in.
52.977 to 52.990 mm2.0857 to 2.0862 in.
0.20 mm0.0079 in.
–
Cylinder Bore I.D. 98.000 to 98.022 mm3.8582 to 3.8591 in.
98.15 mm3.864 in.
Cylinder Bore (Oversize) I.D. 98.500 to 98.522 mm3.8780 to 3.8788 in.
98.65 mm3.884 in.
KiSC issued 09, 2009 A
S-17
KJ-X50 Hz SERIES, WSM ENGINE
LUBRICATING SYSTEM
W11335240
COOLING SYSTEM
W10135990
Item Factory Specification Allowable LimitEngine Oil Pressure At Idle Speed
At Rated Speed
–
200 to 390 kPa2.0 to 4.0 kgf/cm2
29 to 56 psi
50 kPa0.5 kgf/cm2
7 psi
150 kPa1.5 kgf/cm2
21 psiEngine Oil Pressure Switch Working Pressure 40 to 50 kPa
0.4 to 0.6 kgf/cm2
6 to 8 psi
–
Inner Rotor to Outer Rotor Clearance 0.040 to 0.16 mm0.0016 to 0.0062 in.
0.3 mm0.01 in.
Outer Rotor to Pump Body Clearance 0.100 to 0.184 mm0.00394 to 0.00724 in.
0.3 mm0.01 in.
Inner Rotor to Cover Clearance 0.025 to 0.075 mm0.00099 to 0.0029 in.
0.225 mm0.00886 in.
Relief Valve Working Pressure 887 kPa9.04 kgf/cm2
129 psi
–
Thermostat Valve Opening Temperature
Valve Opening Temperature(Opened Completely)
74.5 to 78.5 °C166.1 to 173.3 °F
90 °C194 °F
–
–
Radiator Water Tightness No leak at specified pressure
–
Radiator Cap Air Leakage 10 seconds or more 90 → 60 kPa
0.9 → 0.6 kgf/cm2
10 → 9 psi
–
Fan Belt Tension 10.0 to 12.0 mm / 98 N0.394 to 0.472 in. / 98 N
(10 kgf, 22 lbf)
–
KiSC issued 09, 2009 A
S-18
KJ-X50 Hz SERIES, WSM ENGINE
FUEL SYSTEM
W11353580
ELECTRICAL SYSTEM
W1137041
Item Factory Specification Allowable LimitInjection Timing 0.14 to 0.17 rad
(8.0 to 10 °)before T.D.C.
–
Pump Element Fuel Tightness – 13.73 MPa140.0 kgf/cm2
1991 psiDelivery Valve Fuel Tightness 10 seconds
13.73 → 12.75 MPa140.0 → 130.0 kgf/cm2
1991 → 1849 psi
5 seconds13.73 → 12.75 MPa
140.0 → 130.0 kgf/cm2
1991 → 1849 psiFuel Injection Nozzle Injection Pressure
Valve Seat Tightness
13.73 to 14.70 MPa140.0 to 150.0 kgf/cm2
1992 to 2133 psi
When the pressure is 12.75 MPa
(130.0 kgf/cm2, 1849 psi), the valve seat must
be fuel tightness.
–
–
Commutator O.D. 32 mm1.3 in.
31.4 mm1.24 in.
Mica Undercut 0.5 mm0.02 in.
0.2 mm0.008 in.
Brush (Starter) Length 18.0 mm0.709 in.
11.0 mm0.433 in.
Alternator No-load Voltage 14 V at 4000 min-1 (rpm)
–
Rotor Coil Resistance 2.8 to 3.3 Ω –Slip Ring O.D. 22.7 mm
0.894 in.22.1 mm0.870 in.
Brush (Alternator) Length 18.5 mm0.728 in.
5.0 mm0.20 in.
Glow Plug Resistance(at cold occasion)
Approx. 1.0 Ω –
KiSC issued 09, 2009 A
S-19
KJ-X50 Hz SERIES, WSM ENGINE
3. TIGHTENING TORQUESScrews, bolts and nuts must be tightened to the specified torque using a torque wrench, several screws, bolts and
nuts such as those used on the cylinder head must be tightened in proper sequence and at the proper torque.
[1] TIGHTENING TORQUES FOR SPECIAL USE SCREWS, BOLTS ANDNUTS
NOTE• In removing and applying the screws, bolts and nuts marked with "*", pneumatic wrench or similar
pneumatic tool, if employed, must be used with enough care not to get them seized.• For "*" marked screws, bolts and nuts on the table, apply engine oil to their threads and seats before
tightening.
(1) D1703-E/E2, V2203-E/E2, F2803-E/E2
W1091652
Section Item Size x Pitch N·m kgf·m lbf·ftEngine *Cylinder head cover screw M6 x 1.0 9.81 to 11.2 1.00 to 1.15 7.24 to 8.31
*Cylinder head cover cap nut M8 x 1.25 7 to 8 0.7 to 0.9 5 to 6*Cylinder head screw M11 x 1.25 93.2 to 98.0 9.50 to 10.0 68.8 to 72.3*Main bearing case screw 1 M9 x 1.25 46 to 50 4.7 to 5.2 34 to 37*Main bearing case screw 2 M10 x 1.25 69 to 73 7.0 to 7.5 51 to 54*Flywheel screw M12 x 1.25 98.1 to 107 10.0 to 11.0 72.4 to 79.5*Connecting rod screw M8 x 1.0 45 to 49 4.5 to 5.0 33 to 36*Rocker arm bracket screw M8 x 1.25 24 to 27 2.4 to 2.8 18 to 20*Rocker arm bracket nut M8 x 1.25 24 to 27 2.4 to 2.8 18 to 20*Idle gear shaft screw M8 x 1.25 24 to 27 2.4 to 2.8 18 to 20Fan drive pulley mounting nut M30 x 1.5 138 to 156 14.0 to 16.0 102 to 115Fan drive pulley screw M16 x 1.5 314 to 333 32.0 to 34.0 232 to 245*Bearing case cover mounting screw M8 x 1.25 24 to 27 2.4 to 2.8 18 to 20
Glow plug M10 x 1.25 20 to 24 2.0 to 2.5 15 to 18Nozzle holder assembly M20 x 1.5 49 to 68 5.0 to 7.0 37 to 50Nozzle holder – 35 to 39 3.5 to 4.0 26 to 28Oil pressure switch R 1/8 15 to 19 1.5 to 2.0 11 to 14Injection pipe retaining nut M12 x 1.5 25 to 34 2.5 to 3.5 18 to 25Overflow pipe assembly retaining nut M12 x 1.5 20 to 24 2.0 to 2.5 15 to 18
Camshaft set screw M8 x 1.25 24 to 27 2.4 to 2.8 18 to 20Alternator’s pulley nut – 58.4 to 78.9 5.95 to 8.05 43.1 to 58.2Starter’s terminal B mounting nut M8 5.9 to 11 0.60 to 1.2 4.4 to 8.6
KiSC issued 09, 2009 A
S-20
KJ-X50 Hz SERIES, WSM ENGINE
(2) V3300-E2BG
W1013236
Item Size x Pitch N·m kgf·m lbf·ftCylinder head cover screw – 6.87 to 11.2 0.700 to 1.15 5.07 to 8.31*Cylinder head screw M12 x 1.25 98.1 to 107 10.0 to 11.0 72.4 to 79.5*Connecting rod screw M10 x 1.25 79 to 83 8.0 to 8.5 58 to 61*Flywheel screw M12 x 1.25 98.1 to 107 10.0 to 11.0 72.4 to 79.5*Crankshaft screw M16 x 1.5 255 to 274 26.0 to 28.0 188 to 202*Main bearing case screw M14 x 1.5 138 to 147 14.0 to 15.0 102 to 108Rocker arm bracket screw M10 x 1.25 49 to 55 5.0 to 5.7 37 to 41Nozzle holder assembly M20 x 1.5 49 to 68 5.0 to 7.0 37 to 50Nozzle holder – 35 to 39 3.5 to 4.0 26 to 28Injection pipe retaining nut M12 x 1.5 23 to 36 2.3 to 3.7 17 to 26Overflow pipe assembly retaining nut M12 x 1.5 20 to 24 2.0 to 2.5 15 to 18Oil switch taper screw R 1/8 15 to 19 1.5 to 2.0 11 to 14Oil cooler joint screw – 40 to 44 4.0 to 4.5 29 to 32Oil pump cover screw – 7.9 to 9.3 0.80 to 0.95 5.8 to 6.8Glow plugs M10 x 1.25 20 to 24 2.0 to 2.5 15 to 18Starter’s terminal B mounting nut M8 x 1.25 9.8 to 11 1.0 to 1.2 7.3 to 8.6Injection pump gear mounting nut M14 x 1.5 74 to 83 7.5 to 8.5 55 to 61Injection pump unit mounting nut M8 x 1.25 18 to 20 1.8 to 2.1 13 to 15
Gear case coverM8 x 1.25 (7T) 24 to 27 2.4 to 2.8 18 to 20M8 x 1.25 (10T) 33 to 36 3.3 to 3.7 24 to 26
Relief valve retaining screw – 69 to 78 7.0 to 8.0 51 to 57Idle gear mounting screw M8 x 1.25 24 to 27 2.4 to 2.8 18 to 20Plate mounting screw M8 x 1.25 24 to 27 2.4 to 2.8 18 to 20Camshaft set screw M8 x 1.25 24 to 27 2.4 to 2.8 18 to 20Flywheel housing mounting screw M12 x 1.25 78 to 90 7.9 to 9.2 58 to 66Crankcase 2 mounting screw M10 x 1.25 49 to 55 5.0 to 5.7 37 to 41Injection pump mounting screw M8 x 1.25 24 to 27 2.4 to 2.8 18 to 20Injection pump mounting nut M8 x 1.25 18 to 20 1.8 to 2.1 13 to 15Governor weight mounting nut M12 x 1.25 63 to 72 6.4 to 7.4 47 to 53Fuel camshaft stopper mounting screw – 7.9 to 9.3 0.80 to 0.95 5.8 to 6.8Governor housing mounting screw M6 x 1.0 9.81 to 11.2 1.00 to 1.15 7.24 to 8.31Anti-rotation nut M5 x 0.8 2.9 to 4.0 0.29 to 0.41 2.1 to 2.9Bearing case cover mounting screw M8 x 1.25 24 to 27 2.4 to 2.8 18 to 20Alternator pulley nut – 58.4 to 78.9 5.95 to 8.05 43.1 to 58.2
KiSC issued 09, 2009 A
S-21
KJ-X50 Hz SERIES, WSM ENGINE
4. CHECKING, DISASSEMBLING AND SERVICING[1] CHECKING AND ADJUSTING(1) Engine Body
Compression Pressure1. Run the engine until it is warmed up.2. Stop the engine and disconnect the 2P connector from the stop
solenoid in order not to inject fuel.3. Remove the air cleaner, the muffler and all injection nozzles.4. Set a compression tester with the adaptor H to the nozzle hole.5. Keep the engine stop lever at “Stop Position”.6. While cranking the engine with the starter, measure the
compression pressure.7. Repeat steps 4 through 6 for each cylinder.8. If the measurement is below the allowable limit, apply a small
amount of oil to the cylinder wall through the nozzle hole andmeasure the compression pressure again.
9. If the compression pressure is still less than the allowable limit,check the top clearance, valve and cylinder head.
10.If the compression pressure increases after applying oil, checkthe cylinder wall and piston rings.NOTE
• Check the compression pressure with the specified valveclearance.
• Always use a fully charged battery for performing this test.• Variances in cylinder compression values should be under
10 %.
W1018639
Compression pressure
Factory spec.
D1703-E/E2V2203-E/E2F2803-E/E2
3.24 to 3.72 MPa33.0 to 38.0 kgf/cm2
470 to 540 psi
V3300-E2BG4.31 MPa44.0 kgf/cm2
626 psi
Allowable limit
D1703-E/E2V2203-E/E2F2803-E/E2
2.55 MPa26.0 kgf/cm2
370 psi
V3300-E2BG3.26 MPa33.2 kgf/cm2
472 psi
(A) D1703-E/E2V2203-E/E2F2803-E/E2
(B) V3300-E2BG
KiSC issued 09, 2009 A
S-22
KJ-X50 Hz SERIES, WSM ENGINE
Valve Clearance (To be continued)[D1703-E/E2, V2203-E/E2, F2803-E/E2]
IMPORTANT• Valve clearance must be checked and adjusted when engine
is cold.1. Remove the head cover.2. Align the “1TC” mark line (3) on the flywheel and projection (2)
on the housing so that the No.1 piston comes to the compressionor overlap top dead center.
3. Check the following valve clearance (1) marked with “ ” using afeeler gauge.
4. If the clearance is not within the factory specifications, adjust withthe adjusting screw.
NOTE• The “1TC” mark line on the flywheel is just for No. 1 cylinder.
There is no “TC” marking for the other cylinders.• No. 1 piston comes to the top dead center position when the
“TC” marking is aligned with the projection (2) in the windowon flywheel-housing. Turn the flywheel 0.26 rad (15 °)clockwise and counterclockwise to see if the piston is at thecompression top dead center or the overlap position. Nowreferring to the table below, readjust the valve clearance (1).(The piston is at the top dead center when both the IN. andEX. valves do not move; it is at the overlap position whenboth the valves move.)
• Finally turn the flywheel 6.28 rad (360 °) and align the “1TC”mark line and the projection (2) perfectly. Adjust all theother valve clearance as required.
• After turning the flywheel counterclockwise twice or threetimes, recheck the valve clearance (1).
• After adjusting the valve clearance (1), firmly tighten the locknut of the adjusting screw.
W10607180
Valve clearance Factory spec. 0.18 to 0.22 mm0.0071 to 0.0086 in.
Valve arrangementAdjustablecylinderlocation of piston
3 Cylinder 4 Cylinder 5 Cylinder
IN. EX. IN. EX. IN. EX.
When No. 1 piston is at compression top dead center
No. 1
No. 2
No. 3
No. 4 – –
No. 5 – – – –
When No. 1 piston is at overlap position
No. 1
No. 2
No. 3
No. 4 – –
No. 5 – – – –
(1) Valve Clearance(2) Projection
(3) 1TC Mark Line
KiSC issued 09, 2009 A
S-23
KJ-X50 Hz SERIES, WSM ENGINE
Checking Valve Clearance (Continued)[V3300-E2BG]
IMPORTANT• Valve clearance must be checked and adjusted when engine
is cold.1. Remove the head cover.2. Align the 1TC mark of flywheel and the convex of flywheel
housing timing windows so that the first piston (gear case side)comes to the compression top dead center.
3. Before adjusting the valve clearance of intake valve, adjust thebridge evenly to the valves stem.
4. Loosen the lock nut (2) and adjust with screw (1).5. Slightly push the rocker arm (intake side) by your fingers and
screw in the adjusting screw slowly until you feel the screw touchthe top of valve stem, then tighten the lock nut.
6. Loosen the lock nut (4) of adjusting screw (3) (push rod side) andinsert the thickness gauge between the rocker arm and thebridge head. Set the adjusting screw to the specified value, thentighten the lock nut.
7. Adjust the clearance between the rocker arm (exhaust side) andthe exhaust valve to the specified value.
NOTE• After adjusting, tighten the lock nut (4) securely.
W1091976
Valve clearance Factory spec. 0.23 to 0.27 mm0.0091 to 0.0106 in.
Valve arrangementAdjustablecylinderlocation of piston
IN. EX
When No.1 piston is at compression top dead center
No. 1
No. 2
No. 3
No. 4
When No.1 piston is at overlap position
No. 1
No. 2
No. 3
No. 4
Tightening torque Cylinder head cover screw6.9 to 11.3 N·m0.7 to 1.15 kgf·m5.1 to 8.32 lbf·ft
(1) Adjusting Screw(2) Lock Nut
(3) Adjusting Screw(4) Lock Nut
KiSC issued 09, 2009 A
S-24
KJ-X50 Hz SERIES, WSM ENGINE
(2) Lubricating SystemEngine Oil Pressure1. Remove the engine oil pressure switch, and set an oil pressure
tester (Code No.: 07916-32032). (Adaptor screw size : PT 1/8)2. Start the engine. After warming up, measure the oil pressure of
both idling and rated speeds.3. If the oil pressure is less than the allowable limit, check the
following.• Engine oil insufficient.• Oil pump defective• Oil strainer clogged• Oil filter cartridge clogged• Oil gallery clogged• Excessive oil clearance• Foreign matter in the relief valve
(When reassembling)• After checking the engine oil pressure, tighten the engine oil
pressure switch to the specified torque.
[D1703-E/E2, V2203-E/E2, F2803-E/E2]
[V3300-E2BG]
W1034952
Engine oil pressure
At idle speed
Factory spec.
More than 98 kPa 1.0 kgf/cm2
14 psi
Allowable limit
50 kPa0.5 kgf/cm2
7 psi
At rated speed
Factory spec.
300 to 440 kPa3.0 to 4.5 kgf/cm2
43 to 64 psi
Allowable limit
250 kPa2.5 kgf/cm2
36 psi
Engine oil pressure
At idle speed
Allowable limit
50 kPa0.5 kgf/cm2
7 psi
At rated speed
Factory spec.
200 to 390 kPa2.0 to 4.0 kgf/cm2
29 to 56 psi
Allowable limit
150 kPa1.5 kgf/cm2
21 psi
Tightening torque Oil pressure switch15 to 19 N·m1.5 to 2.0 kgf·m11 to 14 lbf·ft
(A) D1703-E/E2V2203-E/E2F2803-E/E2
(B) V3300-E2BG
KiSC issued 09, 2009 A
S-25
KJ-X50 Hz SERIES, WSM ENGINE
(3) Cooling SystemFan Belt Tension1. Measure the deflection (A), depressing the belt halfway between
the fan drive pulley and alternator pulley at specified force 98 N(10 kgf, 22 lbf).
2. If the measurement is not within the factory specifications, loosenthe alternator mounting screws and relocate the alternator toadjust.
W1059386
Fan Belt Damage and Wear1. Check the fan belt for damage.2. If the fan belt is damaged, replace it.3. Check if the fan belt is worn and sunk in the pulley groove.4. If the fan belt is nearly worn out and deeply sunk in the pulley
groove, replace it.
W1020602
CAUTION• When removing the radiator cap, wait at least ten minutes after the engine has stopped and cooled down.
Otherwise, hot water may gush out, scalding nearby people.Radiator Water Leakage 1. Pour a specified amount of water into the radiator.2. Set a radiator tester and an adaptor and raise the water pressure
to the specified pressure.3. Check the radiator for water leaks.4. For water leak from the pinhole, replace the radiator or repair with
the radiator cement. When water leak is excessive, replace theradiator.
NOTE• The pressure of the leak test is different from each radiator
specification.Thus, do the leak test, refer to the test pressure of eachradiator specification.
W10389070
Deflection (A) Factory spec.
D1703-E/E2V2203-E/E2F2803-E/E2
7.0 to 9.0 mm0.28 to 0.35 in.
V3300-E2BG 10 to 12 mm0.40 to 0.47 in.
(A) Deflection
(A) Good (B) Bad
Radiator water leakage test pressure Factory spec. No leak at specified
pressure
KiSC issued 09, 2009 A
S-26
KJ-X50 Hz SERIES, WSM ENGINE
Radiator Cap Air Leakage1. Set a radiator tester and an adaptor on the radiator cap.2. Apply the specified pressure 90 kPa (0.9 kgf/cm2, 10 psi), and
measure the time for the pressure to fall to 60 kPa (0.6 kgf/cm2,9 psi).
3. If the measurement is less than the factory specification, replacethe radiator cap.
W10387530
Thermostat Valve Opening Temperature1. Suspend the thermostat in the water by a string with its end
inserted between the valve and seat.2. Heating the water gradually, read the temperature when the
valve opens and leaves the string.3. Continue heating and read the temperature when the valve
opens approx. 6 mm (0.2 in.).4. If the measurement is not within the factory specifications,
replace the thermostat.
W1035849
Pressure falling time Factory spec.
More than 10 secondsfor pressure fall from90 to 60 kPa(from 0.9 to 0.6 kgf/cm2,from 10 to 9 psi)
Thermostat’s valve opening temperature
Factory spec.
D1703-E/E2V2203-E/E2F2803-E/E2
69.5 to 72.5 °C157.1 to 162.5 °F
V3300-E2BG 74.5 to 78.5 °C166.1 to 173.3 °F
Temperature at which thermostat completely opens
Factory spec.
D1703-E/E2V2203-E/E2F2803-E/E2
85 °C185 °F
V3300-E2BG 90 °C194 °F
KiSC issued 09, 2009 A
S-27
KJ-X50 Hz SERIES, WSM ENGINE
(4) Fuel SystemInjection Timing (To be continued)[D1703-E/E2, V2203-E/E2, F2803-E/E2]1. Remove the injection pipes and nozzle.2. Set the speed control lever to maximum fuel discharge position.(Reference)• Turn the flywheel with screwdriver.
3. Turn the flywheel counterclockwise (facing the flywheel) until thefuel fills up to the hole of the delivery valve holder (1) for 1stcylinder.
4. Turn the flywheel further and stop turning when the fuel begins toflow over, to get the present injection timing.
5. (The flywheel has mark 1TC and four lines indicating every 0.09rad (5 °) of crank angle from 0.17 rad (10 °) to 0.44 rad (25 °)before mark 1TC.) Calculate the angle which the center of thewindow points out. If the calculation differs from specifiedinjection timing, add or remove the shim to adjust.
(Injection Timing)
NOTE• The sealant is applied to both sides of the soft metal gasket
shim. The liquid gasket is not required for assembling.• Shims are available in thickness of 0.175 mm (7), 0.20 mm
(4), 0.25 mm (5) and 0.30 mm (6). Combine these shims foradjustments.
• The 0.175 mm thick shim is coated only on the lower face.Therefore, do not use the 0.175 mm thick shim as the topshim of the combination (injection pump side), because thiscause oil leakage.
• Addition or reduction of shim (0.05 mm, 0.002 in.) delays oradvances the injection timing by approx. 0.009 rad (0.5 °).
• In disassembling and replacing, be sure to use the samenumber of new gasket shims with the same thickness.
W1063324
Model Injection timing
D1703-E, V2203-EV2203-E2, F2803-E2 0.27 to 0.29 rad (15 to 17 °) before T.D.C.
F2803-E 0.28 to 0.31 rad (16 to 18 °) before T.D.C.
D1703-E2 0.236 to 0.270 rad (13.5 to 15.5 °) before T.D.C.
(1) Delivery Valve Holder(2) Timing Mark(3) Shim (Soft Metal Gasket Shim)(4) 2-holes : 0.20 mm (0.0079 in.) Shim(5) 1-hole : 0.25 mm (0.0098 in.) Shim(6) Without hole : 0.30 mm (0.012 in.)
Shim(7) 2-holes : 0.175 mm (0.00689 in.)
Shim
(A) 3 Cylinder(B) 4 Cylinder
KiSC issued 09, 2009 A
S-28
KJ-X50 Hz SERIES, WSM ENGINE
Injection Timing (Continued)[V3300-E2BG]1. Make sure of matching the injection timing align mark (1) of the
injection pump unit and the plate (gearcase), as shown in theillustration.
2. Remove the injection pipes.3. Remove the stop solenoid.4. Turn the flywheel counterclockwise (viewed from flywheel side)
until the fuel fills up to the hole of the delivery valve holder (2) forNo.1 cylinder.
5. After the fuel fills up to the hole of the delivery valve holder forNo.1 cylinder, turn back (clockwise) the flywheel around 1.57 rad(90 °).
6. Turn the flywheel counterclockwise to set at around 0.35 rad(20 °) before T.D.C..
7. Slowly turn the flywheel counterclockwise and stop turning whenthe fuel begins to come up, to get the present injection timing.
8. Check to see the degree on flywheel.The flywheel has mark “1TC”, “10” and “20” for the crank anglebefore the top dead center of No.1 piston.
9. If the injection timing is not within the specification, rotate theinjection pump unit to adjust the injection timing.IMPORTANT
• When installing the injection pump unit to the engine body,follow the correct procedure.See the “Injection Pump Unit”.
(Injection Timing)
W1095214
Model Injection timing
V3300-E2BG 0.14 to 0.17 rad (8.0 ° to 10 °) before T.D.C.
Tightening torque
Injection pipe retaining nut22.6 to 36.3 N·m2.3 to 3.7 kgf·m16.6 to 26.8 lbf·ft
Injection pump unit mounting nut
17.7 to 20.6 N·m1.8 to 2.1 kgf·m13.0 to 15.2 lbf·ft
(1) Injection Timing Align Mark(2) Delivery Valve Holder
(a) Injection Timing Advanced(b) Injection Timing Retarded
KiSC issued 09, 2009 A
S-29
KJ-X50 Hz SERIES, WSM ENGINE
Fuel Tightness of Pump Element1. Remove the engine stop solenoid.2. Remove the injection pipes and glow plugs.3. Install the injection pump pressure tester (1) to the injection
pump.4. Install the injection nozzle (2) jetted with the proper injection
pressure to the injection pump pressure tester (1). (Refer to thefigure.)
5. Set the speed control lever to the maximum speed position.6. Run the starter to increase the pressure.7. If the pressure can not reach the allowable limit, replace the
pump with new one or repair with a Kubota-authorized pumpservice shop.
NOTE• Never try to disassemble the injection pump assembly. For
repairs, you are strongly requested to contact a Kubota-authorized pump service shop.
W1017430
Fuel tightness of pump element Allowable limit
13.73 MPa140.0 kgf/cm2
1991 psi
(1) Injection Pump Pressure Tester(2) Injection Nozzle(3) Protection Cover for Jetted Fuel
[A] D1703-E/E2V2203-E/E2F2803-E/E2
[B] V3300-E2BG
KiSC issued 09, 2009 A
S-30
KJ-X50 Hz SERIES, WSM ENGINE
Fuel Tightness of Delivery Valve1. Remove the engine stop solenoid.2. Remove the injection pipes and glow plugs.3. Set a pressure tester to the fuel injection pump.4. Install the injection nozzle (2) jetted with the proper injection
pressure to the injection pump pressure tester (1).5. Run the starter to increase the pressure.6. Stop the starter when the fuel jets from the injection nozzle (2).
After that, turn the flywheel by the hands and raise the pressureto approx. 13.73 MPa (140.0 kgf/cm2, 1991 psi).
7. Now turn the flywheel back about half a turn (to keep the plungerfree). Maintain the flywheel at this position and clock the timetaken for the pressure to drop from 13.73 to 12.75 MPa (140.0 to130.0 kgf/cm2, 1991 to 1849 psi).
8. Measure the time needed to decrease the pressure from 13.73 to12.75 MPa (140.0 to 130.0 kgf/cm2, 1991 to 1849 psi).
9. If the measurement is less than allowable limit, replace the pumpwith new one or repair with a Kubota-authorized pump serviceshop.
NOTE• Never try to disassemble the injection pump assembly. For
repairs, you are strongly requested to contact a Kubota-authorized pump service shop.
W1017786
Fuel tightness of delivery valve
Factory spec.
10 seconds13.73 → 12.75 MPa140.0 → 130.0 kgf/cm2
1991 → 1849 psi
Allowable limit
5 seconds13.73 → 12.75 MPa140.0 → 130.0 kgf/cm2
1991 → 1849 psi
(1) Injection Pump Pressure Tester(2) Injection Nozzle(3) Protection Cover for Jetted Fuel
[A] D1703-E/E2V2203-E/E2F2803-E/E2
[B] V3300-E2BG
KiSC issued 09, 2009 A
S-31
KJ-X50 Hz SERIES, WSM ENGINE
CAUTION• Check the injection pressure and condition after confirming that there is nobody standing in the direction
the fume goes.• If the fume from the nozzle directly contacts the human body, cells may be destroyed and blood poisoning
may be caused.Nozzle Spraying Condition1. Set the injection nozzle to a nozzle tester, and check the nozzle
spraying condition.2. If the spraying condition is defective, replace the nozzle piece.
W10181310
Fuel Injection Pressure1. Set the injection nozzle to a nozzle tester.2. Slowly move the tester handle to measure the pressure at which
fuel begins jetting out from the nozzle.3. If the measurement is not within the factory specifications,
replace the adjusting washer (1) in the nozzle holder to adjust it.(Reference)• Pressure variation with 0.025 mm (0.00098 in.) difference of
adjusting washer thickness.Approx. 590 kPa (6.0 kgf/cm2, 85 psi)
W10972720
Valve Seat Tightness1. Set the injection nozzle to a nozzle tester.2. Raise the fuel pressure, and keep at 12.75 MPa (130.0 kgf/cm2,
1849 psi) for 10 seconds.3. If any fuel leak is found, replace the nozzle piece.
W10183690
(a) Good (b) Bad
Fuel injection pressure Factory spec.13.73 to 14.70 MPa140.0 to 150.0 kgf/cm2
1992 to 2133 psi
(1) Adjusting Washer
Valve seat tightness Factory spec.
No fuel leak at12.75 MPa130.0 kgf/cm2
1849 psi
KiSC issued 09, 2009 A
S-32
KJ-X50 Hz SERIES, WSM ENGINE
Nozzle Holder1. Secure the nozzle retaining nut (7) with a vise.2. Remove the nozzle holder (1), and take out parts inside.(When reassembling)• Assemble the nozzle in clean fuel oil.• Install the push rod (4), noting its direction.• After assembling the nozzle, be sure to adjust the fuel injection
pressure.
W1018491
(5) Electrical System
CAUTION• To avoid accidental short circuit, be sure to attach the positive cable to the positive terminal before the
negative cable is attached to the negative terminal.• Never remove the battery cap while the engine is running.• Keep electrolyte away from eyes, hands and clothes. If you are spattered with it, wash it away completely
with water immediately.• Keep open sparks and flames away from the battery at all times. Hydrogen gas mixed with oxygen
becomes very explosive.IMPORTANT
• If the machine is to be operated for a short time without battery (using a slave battery for starting), useadditional current (lights) while engine is running and insulate terminal of battery. If this advice isdisregarded, damage to alternator and regulator may result.
Battery Voltage1. Stop the engine.2. Measure the voltage with a circuit tester between the battery
terminals.3. If the battery voltage is less than the factory specification, check
the battery specific gravity and recharge the battery.
W10125620
Tightening torque
Nozzle holder35 to 39 N·m3.5 to 4.0 kgf·m26 to 28 lbf·ft
Overflow pipe assembly retaining nut
20 to 24 N·m2.0 to 2.5 kgf·m15 to 18 lbf·ft
Nozzle holder assembly49 to 68 N·m5.0 to 7.0 kgf·m37 to 50 lbf·ft
(1) Nozzle Holder(2) Adjusting Washer(3) Nozzle Spring(4) Push Rod
(5) Distance Piece(6) Nozzle Piece(7) Nozzle Retaining Nut
Battery voltage Factory spec. More than 12 V
(1) Positive Terminal (2) Negative Terminal
KiSC issued 09, 2009 A
S-33
KJ-X50 Hz SERIES, WSM ENGINE
Battery Specific Gravity1. Check the specific gravity of the electrolyte in each cell with a
hydrometer.2. When the electrolyte temperature differs from that at which the
hydrometer was calibrated, correct the specific gravity readingfollowing the formula mentioned in (Reference).
3. If the specific gravity is less than 1.215 (after it is corrected fortemperature), charge or replace the battery.
4. If the specific gravity differs between any two cells by more than0.05, replace the battery.NOTE
• Hold the hydrometer tube vertical without removing it fromthe electrolyte.
• Do not suck too much electrolyte into the tube.• Allow the float to move freely and hold the hydrometer at eye
level.• The hydrometer reading must be taken at the highest
electrolyte level.(Reference)• Specific gravity slightly varies with temperature. To be exact, the
specific gravity decreases by 0.0007 with an increase of 1 °C(0.0004 with an increase of 1 °F) in temperature, and increasesby 0.0007 with a decreases of 1 °C (0.0004 with a decrease of 1°F).Therefore, using 20 °C (68 °F) as a reference, the specific gravityreading must be corrected by the following formula :- Specific gravity at 20 °C = Measured value + 0.0007 ×
(electrolyte temperature – 20 °C)- Specific gravity at 68 °F = Measured value + 0.0004 ×
(electrolyte temperature – 68 °F)
At an electrolyte temperature of 20 °C (68 °F)
W1019017
Specific Gravity State of Charge
1.260 Sp. Gr. 100 % Charged
1.230 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
(a) Good(b) Bad
(c) Bad
KiSC issued 09, 2009 A
S-34
KJ-X50 Hz SERIES, WSM 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.NOTE
• B terminal : It is the terminal which connects the cable fromthe battery to the starter.
• C terminal : It is the terminal which connects the cable fromthe motor to the magnet switch.
W1019297
Magnetic Switch Test1. Disconnect the battery negative cable from the battery.2. Disconnect the battery positive cable from the battery.3. Disconnect the leads from the starter B terminal.4. Remove the starter from the engine.5. Connect a jumper lead from the starter S terminal (1) to the
battery positive terminal (2).6. Connect a jumper lead momentarily between the starter’s body
and the battery negative terminal (3).7. If the pinion gear does not pop out, the magnetic switch is failure.
Repair or replace the starter.NOTE
• B terminal : It is the terminal which connects the cable fromthe battery to the starter.
• S terminal : It is the terminal which connects the cable fromthe starter switch to the magnet switch.
0000010743E
(1) C Terminal(2) Positive Terminal(3) Negative Terminal
[A] D1703-E/E2V2203-E/E2F2803-E/E2
[B] V3300-E2BG
(1) S Terminal(2) Positive Terminal(3) Negative Terminal
[A] D1703-E/E2V2203-E/E2F2803-E/E2
[B] V3300-E2BG
KiSC issued 09, 2009 A
S-35
KJ-X50 Hz SERIES, WSM ENGINE
Magnet Switch Continuity Test1. Check the continuity across the C terminal (1) and the B terminal
(2) with a circuit tester, pushing in the plunger.2. If not continuous or if a certain value is indicated, replace the
magnet switch.
W1063967
Alternator on Unit Test(Before testing)• Before alternator on unit test, check the battery terminal
connections, circuit connection, fan belt tension, chargingindicator lamp, fuses on the circuit, and abnormal noise from thealternator.
• Prepare full charged battery for the test.NOTE
• Be careful not to touch the rotating engine parts whileengine is running.Keep safety distance from the engine rotating parts.
1. Start the engine.2. When the engine is operating measure the voltage between two
battery terminals. If the voltage is between 13.8 V and 14.8 V,the alternator is operating normally.
3. If the results of alternator on unit test are not within thespecifications, disassemble the alternator and check the eachcomponent part for finding out the failure. See the“DISASSEMBLING AND ASSEMBLING” and “SERVICING” foralternator.
0000010745E
(1) C Terminal(2) B Terminal
[A] D1703-E/E2V2203-E/E2F2803-E/E2
[B] V3300-E2BG
Regulating voltage at no load Factory spec. 13.8 to 14.8 V at 25 °C
(77 °F)
[A] KJ-S130VX(-AUS)KJ-S170FX(-AUS)KJ-T130DX(-AUS)KJ-T180VX(-AUS)KJ-T230FX(-AUS)
[B] KJ-T300(-AUS)KJ-S240-AUS
KiSC issued 09, 2009 A
S-36
KJ-X50 Hz SERIES, WSM ENGINE
Glow Plug Lead Terminal Voltage1. Turn the key switch to the “GLOW (or PREHEAT)” position, and
measure the voltage with a circuit tester between the leadterminal and the engine body.
2. If the voltage differs from the battery voltage, the wiring harnessor main switch is faulty.
0000010725E
Glow Plug Continuity1. Remove the glow plug.2. Measure the resistance with a circuit tester between the glow
plug terminal and the glow plug housing.3. If the factory specification is not indicated, glow plug is faulty.
0000010726E
VoltageMain switch key at GLOW (or PREHEAT)
Approx. battery voltage
Resistance Factory spec. Approx. 0.9 Ω
KiSC issued 09, 2009 A
S-37
KJ-X50 Hz SERIES, WSM ENGINE
[2] DISASSEMBLING AND ASSEMBLING(1) D1703-E/E2, V2203-E/E2, F2803-E/E21) Cylinder Head and Valves
Cylinder Head Cover1. Remove the lead (4).2. Remove the breather hose (1).3. [a] D1703-E2, V2203-E2
Remove the cylinder head cover screws (3).[b] D1703-E, V2203-E / [c] F2803-E, F2803-E2Remove the cylinder head cover cap nuts (8).
4. Remove the cylinder head cover (2).(When reassembling)• Check to see if the cylinder head cover gasket (5) is not
defective.
W1060460
Tightening torque
Cylinder head cover screw9.81 to 11.2 N·m1.00 to 1.15 kgf·m7.24 to 8.31 lbf·ft
Cylinder head cover cap nut
7 to 8 N·m0.7 to 0.9 kgf·m5 to 6 lbf·ft
(1) Breather Hose(2) Cylinder Head Cover(3) Cylinder Head Cover Screw(4) Lead(5) Cylinder Head Cover Gasket(6) Breather Valve(7) Plate(8) Cylinder Head Cover Cap Nut
[a] D1703-E2, V2203-E2[b] D1703-E, V2203-E, F2803-E[c] F2803-E2
KiSC issued 09, 2009 A
S-38
KJ-X50 Hz SERIES, WSM ENGINE
Injection Pipes1. Loosen the screws on the pipe clamps (1).2. Detach the injection pipes (2).(When reassembling)• Blow out dust inside the pipes.
W1060970
Nozzle Holder Assembly and Glow Plug1. Remove the overflow pipe assembly (3).2. Remove the nozzle holder assemblies (4) using a 21 mm deep
socket wrench.3. Remove the copper gasket and heat seal (5).4. Remove the glow plugs (2).(When reassembling)• Replace the copper gasket and heat seal with new one.
W1020917
Nozzle Heat Seal Service Removal ProcedureIMPORTANT
• Use a plus (phillips head) screw driver (1) that has adiameter which is bigger than the heat seal hole (Approx. 6mm (1/4 in.)).
1. Drive screw driver (1) lightly into the heat seal hole.2. Turn screw driver three or four times each way.3. While turning the screw driver, slowly pull the heat seal (4) out
together with the injection nozzle gasket (3).4. If the heat seal drops, repeat the above procedure.(When reassembling)• Heat seal and injection nozzle gasket must be changed when the
injection nozzle is removed for cleaning or for service.
W1021255
Tightening torque Injection pipe retaining nut25 to 34 N·m2.5 to 3.5 kgf·m18 to 25 lbf·ft
(1) Pipe Clamp (2) Injection Pipe
Tightening torque
Nozzle holder assembly49 to 68 N·m5.0 to 7.0 kgf·m37 to 50 lbf·ft
Overflow pipe assembly retaining nut
20 to 24 N·m2.0 to 2.5 kgf·m15 to 18 lbf·ft
Glow plug20 to 24 N·m2.0 to 2.5 kgf·m15 to 18 lbf·ft
(1) Lead(2) Glow Plug(3) Overflow Pipe Assembly
(4) Nozzle Holder Assembly(5) Heat Seal
(1) Plus Screw Driver(2) Injection Nozzle
(3) Injection Nozzle Gasket(4) Heat Seal
KiSC issued 09, 2009 A
S-39
KJ-X50 Hz SERIES, WSM ENGINE
Rocker Arm and Push Rod1. Remove the rocker arm bracket screws (D1703-E2, V2203-E2)
or nuts (D1703-E, V2203-E, F2803-E, F2803-E2).2. Detach the rocker arm assembly (1).3. Remove the push rods (2).(When reassembling)• When putting the push rods (2) onto the tappets (3), check to see
if their ends are properly engaged with the grooves.IMPORTANT
• After installing the rocker arm, be sure to adjust the valveclearance.
W1021437
Tightening torque
Rocker arm bracket screw24 to 27 N·m2.4 to 2.8 kgf·m18 to 20 lbf·ft
Rocker arm bracket nut24 to 27 N·m2.4 to 2.8 kgf·m18 to 20 lbf·ft
(1) Rocker Arm Assembly(2) Push Rod
(3) Tappet
KiSC issued 09, 2009 A
S-40
KJ-X50 Hz SERIES, WSM ENGINE
Cylinder Head1. Loosen the pipe clamp (2), and remove the water return pipe (1).2. Remove the cylinder head screw in the order of (v or r or n) to (a).3. Lift up the cylinder head (3) to detach.4. Remove the cylinder head gasket (4) and O-ring (5).(When reassembling)• Replace the cylinder head gasket (4) with a new one.• Securely fit the O-ring (5) to the pin pipe (6).• Tighten the cylinder head screws after applying sufficient oil.• Tighten the cylinder head screws in diagonal sequence starting
from the center in the order of (a) to (n or r or v).• Tighten them uniformly, or the head may deform in the long run.• Retighten the cylinder head screws after running the engine for
30 minutes.
W1021755
Tightening torque Cylinder head screw93.2 to 98.0 N·m9.50 to 10.0 kgf·m68.8 to 72.3 lbf·ft
(1) Return Pipe(2) Pipe Clamp(3) Cylinder Head(4) Cylinder Head Gasket(5) O-ring(6) Pin Pipe
(v or r or n) to (a): To Loosen(a) to (n or r or v): To Tighten(A) Gear Case Side(B) Flywheel Side
KiSC issued 09, 2009 A
S-41
KJ-X50 Hz SERIES, WSM ENGINE
Thermostat Assembly1. Remove the thermostat cover mounting screws, and remove the
thermostat cover (1).2. Remove the thermostat assembly (3).(When reassembling)• Replace the thermostat cover gasket (2) with new one.
W10363950
Tappets1. Remove the tappets (1) from the crankcase.(When reassembling)• Visually check the contact between tappets and cams for proper
rotation. If defect is found, replace tappets.• Before installing the tappets, apply engine oil thinly around them.
IMPORTANT• Do not change the combination of tappet and tappet guide.
W1022001
Valves1. Remove the valve caps (3).2. Remove the valve spring collet (4), pushing the valve spring
retainer (5) by valve spring replacer (1).3. Remove the valve spring retainer (5), valve spring (6) and valve
stem seal (2).4. Remove the valve (7).(When reassembling)• Wash the valve stem and valve guide hole, and apply engine oil
sufficiently.• After installing the valve spring collets (4), lightly tap the stem to
assure proper fit with a plastic hammer.IMPORTANT
• Do not change the combination of valve and valve guide.
W1022102
(1) Thermostat Cover(2) Thermostat Cover Gasket
(3) Thermostat Assembly
(1) Tappet
(1) Valve Spring Replacer(2) Valve Stem Seal(3) Valve Cap(4) Valve Spring Collet
(5) Valve Spring Retainer(6) Valve Spring(7) Valve
KiSC issued 09, 2009 A
S-42
KJ-X50 Hz SERIES, WSM ENGINE
2) Timing Gears and CamshaftInjection Pump1. Remove the injection pump cover (3) with the engine stop lever
(2).2. Remove the injection pump mounting screws and nuts.3. Align the control rack pin (4) with the groove (5) on the
crankcase, then remove the injection pump.4. Remove the injection pump timing shims (6).5. In principle, the injection pump should not be disassemble.(When reassembling)• Install the injection pump so that its control rack pin (4) engages
with the groove (5) of fork lever 1 (1).• Install the injection pump cover with the arm of engine stop lever
(2) at the right of the arm of fork lever 1 (1).• Replace the injection pump cover gasket with new one.• The sealant is applied to both sides of the shim (soft metal gasket
shim). The liquid gasket is not required for assembling.• The 0.175 mm thick shim is coated only on the lower face.
Therefore, do not use the 0.175 mm thick shim as the top shim ofthe combination (injection pump side), because this cause oilleakage.
• Addition or reduction of shims (0.05 mm, 0.002 in.) delays oradvances the injection timing by approx. 0.009 rad (0.5 °).
• In disassembling and replacing, be sure to use same number ofnew shims with the same thickness.
• Refer to figure left to check the thickness of the shims.
W1023637
Start Spring1. Remove the start spring (1) from the gear case.(When reassembling)• Be careful not to drop the start spring into the gear case.• Hook the start spring so that the longer hook is on the fork lever
side.
W1025252
(1) Fork Lever 1(2) Engine Stop Lever(3) Injection Pump Cover(4) Control Rack Pin(5) Groove(6) Shim(7) 2-holes : 0.20 mm (0.0079 in.) Shim
(8) 1-hole : 0.25 mm (0.0098 in.) Shim(9) Without hole : 0.30 mm (0.012 in.)
Shim(10) 2-holes : 0.175 mm (0.00689 in.)
Shim(A) 3 Cylinder(B) 4 Cylinder
(1) Start Spring
KiSC issued 09, 2009 A
S-43
KJ-X50 Hz SERIES, WSM ENGINE
Governor SpringNOTE
• Specific tool (1) :1.2 mm diameter hard wire with its end hooked, overalllength 200 mm (7.87 in.).The tip of wire is bent like the hook to hang governorsprings.
1. Disconnect the governor spring (3) from the fork lever (2).(When reassembling)• Fix the governor spring to the speed control lever, and pull the
spring or wire through the window of the injection pump, andspring will be able to be hooked on the governor fork with ease.Bend the end of the governor spring to prevent if from falling off.
W1148604
Speed Control Plate1. Remove the speed control plate (1) and governor spring (2).(When reassembling)• Be careful not to drop the governor spring (2) in the gear case.• Replace the speed control plate gasket with new one.
W1072059
(1) Specific Tool(2) Fork Lever
(3) Governor Spring
(1) Speed Control Plate (2) Governor Spring
KiSC issued 09, 2009 A
S-44
KJ-X50 Hz SERIES, WSM ENGINE
Fan Drive Pulley1. Lock the flywheel not to turn using the flywheel stopper.2. [D1703, V2203]
Remove the fan drive pulley mounting nut (1) using 46 mm deepsocket wrench (3).[F2803]Remove the fan drive pulley screws.
3. Remove the fan drive pulley (2) with gear puller (4).4. [D1703, V2203]
Remove the feather key.(When reassembling)• Apply grease to the splines of coupling.• [F2803]
Install the pulley to the crankshaft, aligning the marks (5) onthem.
• Tighten the fan drive pulley mounting nut or the fan drive pulleyscrew to the specified torque.
W1025370
Gear Case1. Remove the hour meter gear case (if equipped).2. Remove the gear case (1).3. Remove the O-rings (2).(When reassembling)• Replace the gear case gasket and O-rings (2).• Replace the hour meter gear case gasket with new one.• Check to see if there are four O-rings (2) inside the gear case (1).• Apply a thin film of engine oil to the oil seal (3), and install it,
noting the lip come off.• Before installing the gear case gasket, apply a non-drying
adhesive.
W1024531
Tightening torque
Fan drive pulley mounting nut
138 to 156 N·m14.0 to 16.0 kgf·m102 to 115 lbf·ft
Fan drive pulley screw314 to 333 N·m32.0 to 34.0 kgf·m232 to 245 lbf·ft
(1) Nut(2) Fan Drive Pulley(3) 46 mm Deep Socket Wrench(4) Gear Puller(5) Mark
(A) F2803
(1) Gear Case(2) O-ring
(3) Oil Seal
KiSC issued 09, 2009 A
S-45
KJ-X50 Hz SERIES, WSM ENGINE
Crankshaft Oil Slinger1. Remove the crankshaft collar (3).2. Remove the O-ring (2).3. Detach the crankshaft oil slinger (1).(When reassembling)• Insert the crankshaft collar (3) after install the gear case to
cylinder body.
W1024731
Idle Gear1. Remove the external snap ring.2. Detach the idle gear collar.3. Detach the idle gear (2).(When reassembling)• Check to see each gear is aligned with its aligning mark
- Idle gear (2) and crank gear (4)- Idle gear (2) and cam gear (3)- Idle gear (2) and injection pump gear (1)
W1024941
Camshaft1. Remove the camshaft set screw (1) and draw out the camshaft
(2).(When reassembling)• When installing the idle gear, be sure to align the alignment
marks on gears.
W1025098
Fuel Camshaft and Fork Lever Assembly1. Remove the fuel feed pump.2. Detach the fuel camshaft stopper (1).3. Remove the three fork lever holder mounting screws (2).4. Draw out the fuel camshaft assembly (5), (6) and fork lever
assembly (3), (4), (7) at the same time.(When reassembling)• After installation, check to see that the fork lever 1 (3) and lever
2 (4) are fixed to the fork lever shaft, and that they can turnsmoothly in the holder (7).
W1025309
(1) Crankshaft Oil Slinger(2) O-ring
(3) Crankshaft Collar
(1) Injection Pump Gear(2) Idle Gear(3) Cam Gear
(4) Crank Gear(5) Oil Pump Drive Gear
Tightening torque Camshaft set screw24 to 27 N·m2.4 to 2.8 kgf·m18 to 20 lbf·ft
(1) Camshaft Set Screw (2) Camshaft
(1) Fuel Camshaft Stopper(2) Fork Lever Holder Mounting Screw(3) Fork Lever 1(4) Fork Lever 2
(5) Injection Pump Gear(6) Fuel Camshaft(7) Fork Lever Holder
KiSC issued 09, 2009 A
S-46
KJ-X50 Hz SERIES, WSM ENGINE
Oil Pump1. Remove the nut.2. Draw out the oil pump drive gear (2) with gear puller (1).3. Remove the four oil pump mounting screws. Detach the oil pump
(3).
W1025581
Crank Gear1. Draw out the crank gear (2) with a puller (1).2. Remove the feather key.
W1076123
3) Connecting Rod and PistonOil Pan and Oil Strainer1. Remove the oil pan mounting screws.2. Remove the oil pan (3) by lightly tapping the rim of the pan with
a wooden hammer.3. Remove the oil pan gasket (2).4. Remove the oil strainer (1) and O-ring (4).(When reassembling)• After cleaning the oil strainer (1), check to see that the filter mesh
in clean, and install it.• Visually check the O-ring (4), apply engine oil, and install it.• Securely fit the O-ring (4) to the oil strainer (1).• Replace the oil pan gasket (2) with new one.• To avoid uneven tightening, tighten oil pan mounting screws in
diagonal order from the center.
W1025687
(1) Gear Puller(2) Oil Pump Drive Gear
(3) Oil Pump
(1) Crank Puller (2) Crank Gear
(1) Oil Strainer(2) Oil Pan Gasket
(3) Oil Pan(4) O-ring
KiSC issued 09, 2009 A
S-47
KJ-X50 Hz SERIES, WSM ENGINE
Pistons (To be continued)1. Completely clean carbon (1) in the cylinders.2. Remove the connecting rod cap (3).3. Turn the flywheel and bring the piston to top dead center.4. Draw out the piston upward by lightly tapping it from the bottom
of the crankcase with the grip of a hammer.5. Draw out the other piston in the same method as above.
W1026909
(1) Carbon(2) Connecting Rod Screw
(3) Connecting Rod Cap(4) Connecting Rod
KiSC issued 09, 2009 A
S-48
KJ-X50 Hz SERIES, WSM ENGINE
Pistons (Continued)(When reassembling)• Before inserting piston into the cylinder, apply enough engine oil
to the piston.• When inserting the piston into the cylinder, face the mark on the
connecting rod to the injection pump.IMPORTANT
• Do not change the combination of cylinder and piston. Makesure of the position of each piston by marking. For example,mark “1” on the No. 1 piston.
• Place the piston rings with their gaps at 0.79 rad (45 °) fromthe piston pin’s direction as shown in the figure.
• Carefully insert the pistons using a piston ring compressor(1).
W1027404
Piston Ring and Connecting Rod (To be continued)1. Remove the piston rings (1), (2), (3) using a piston ring tool.2. Remove the piston pin (9), and separate the connecting rod (7)
from the piston (6).
W1026376
Tightening torque Connecting rod screw45 to 49 N·m4.5 to 5.0 kgf·m33 to 36 lbf·ft
(1) Piston Ring Compressor
(A) Top Ring Gap(B) Second Ring Gap
(C) Oil Ring Gap(D) Piston Pin Hole
(a) 0.79 rad (45 °)
(1) Top Ring(2) Second Ring(3) Oil Ring(4) Piston Pin Snap Ring(5) Fan-Shaped Concave(6) Piston
(7) Connecting Rod(8) Mark(9) Piston Pin
(A) Serial No. : below 4P9999(B) Serial No. : above 4Q0001
KiSC issued 09, 2009 A
S-49
KJ-X50 Hz SERIES, WSM ENGINE
Piston Ring and Connecting Rod (Continued)(When reassembling)• When installing the rings, assemble the rings so that the
manufacturer’s mark (9) near the gap faces the top of the piston(3).
• When installing the oil ring (8) onto the piston (3), place theexpander joint (6) on the opposite side of the oil ring gap (7).
• Apply engine oil to the piston pin (4).• When installing the connecting rod (2) to the piston (3), immerse
the piston (3) in 80 °C (176 °F) oil for 10 to 15 minutes and insertthe piston pin (4) to the piston (3).
• When installing the connecting rod (2) to the piston (3), align themark (1) on the connecting rod (2) to the fan-shaped concave (5).NOTE
• Mark the same number on the connecting rod (2) and thepiston (3) so as not to change the combination.
W1076292
(1) Mark(2) Connecting Rod(3) Piston(4) Piston Pin(5) Fan-Shaped Concave
(6) Expander Joint(7) Oil Ring Gap(8) Oil Ring(9) Manufacturer’s Mark
KiSC issued 09, 2009 A
S-50
KJ-X50 Hz SERIES, WSM ENGINE
4) CrankshaftFlywheel1. Fit the stopper to the flywheel (1).2. At first, remove two pieces of the flywheel screws (2).3. Insert two pieces of the flywheel guide screws (3) in the holes.4. Remove the all flywheel screws (2).5. Remove the flywheel (1) slowly along the flywheel guide screws
(3).(When reassembling)• Insert two pieces of the flywheel guide screws (3).• Check to see that there are no metal particles left on the flywheel
mounting surfaces.• Apply engine oil to the threads and the undercut surface of the
flywheel bolt and fit the bolt.
W1026863
Bearing Case Cover1. Remove the bearing case cover mounting screws. First, remove
inside screws (5) and then outside screws (3).2. Screw two removed screws into the screw hole of bearing case
cover (6) to remove it.IMPORTANT
• The length of inside screws (5) and outside screws (3) aredifferent. Do not take a mistake using inside screws andoutside screws.
(When reassembling)• Fit the bearing case gasket (1) and the bearing case cover gasket
(2) with correct directions.• Install the bearing case cover (6) to position the casting mark
“UP” on it upward.• Apply engine oil to the oil seal lip and take care that it is not rolled
when installing.• Tighten the bearing case cover mounting screws with even force
on the diagonal line.
W10292140
Tightening torque Flywheel screw98.1 to 107 N·m10.0 to 11.0 kgf·m72.4 to 79.5 lbf·ft
(1) Flywheel(2) Flywheel Screw
(3) Flywheel Guide Screw
Tightening torque Bearing case cover mounting screw
24 to 27 N·m2.4 to 2.8 kgf·m18 to 20 lbf·ft
(1) Bearing Case Gasket(2) Bearing Case Cover Gasket(3) Bearing Case Cover Mounting Screw(4) Oil Seal
(5) Bearing Case Cover Mounting Screw(6) Bearing Case Cover
(a) Upside
KiSC issued 09, 2009 A
S-51
KJ-X50 Hz SERIES, WSM ENGINE
CrankshaftNOTE
• Before disassembling, check the side clearance ofcrankshaft. Also check it during reassembling.
1. Remove the main bearing case screw 2 (1).2. Pull out the crankshaft assembly (4), taking care not to damage
the crankshaft bearing 1 (3).(When reassembling)
IMPORTANT• Install the crankshaft sub assembly (4), aligning the screw
hole of main bearing case 2 (2) with the screw hole ofcylinder block.
• When tightening the main bearing case screw 2 (1), apply oilto the screw and screw by hand before tightening thespecific torque.If not smooth to screw by hand, align the screw holesbetween the cylinder block and the main bearing case.
W1066311
Tightening torque Main bearing case screw 269 to 73 N·m7.0 to 7.5 kgf·m51 to 54 lbf·ft
(1) Main Bearing Case Screw 2(2) Main Bearing Case 2
(3) Crankshaft Bearing 1(4) Crankshaft Assembly
KiSC issued 09, 2009 A
S-52
KJ-X50 Hz SERIES, WSM ENGINE
Main Bearing Case Assembly1. Remove the two main bearing case screws 1 (8), and remove the
main bearing case assembly being careful with thrust bearingand crankshaft bearing.
2. Remove the main bearing case 1, 2 as above.(When reassembling)• Clean the oil passage in the main bearing case.• Apply clean engine oil on the bearings.• Install the main bearing case assemblies in the original positions.
Since diameters of main bearing cases vary, install them in orderof makings (A, B for 3 cylinders, A, B, C for 4 cylinders and A, B,C, D for 5 cylinders) from the gear case side.
• Match the alignment numbers (1) and mark (2) on the mainbearing case.
• When installing the main bearing case 1 and 2, face the mark“FLYWHEEL” to the flywheel.
• Install the thrust bearing with its oil groove (9) facing outward.• Confirm that the main bearing case moves smoothly after
tightening the main bearing case screw 1 (8) to the specifiedtorque.
W1027366
Tightening torque Main bearing case screw 146 to 50 N·m4.7 to 5.2 kgf·m34 to 37 lbf·ft
(1) Alignment Number(2) Alignment Mark(3) A(4) B(5) C
(6) D(7) No Mark(8) Main Bearing Case Screw 1(9) Oil Groove
KiSC issued 09, 2009 A
S-53
KJ-X50 Hz SERIES, WSM ENGINE
(2) V3300-E2BG1) Cylinder Head and Valves
Cylinder Head Cover and Nozzle Holder1. Remove the injection pipes (3) and overflow pipes (2).2. Remove the glow plugs (1).3. Remove the nozzle holder assembly (4) and copper gaskets (5).4. Remove the heat seal (6).5. Remove the head cover (7).(When reassembling)• Check to see that the cylinder head cover gasket is not defective.• Be sure to place the heat seal.• Tighten the head cover mounting bolts to specified torque.• Mount the check valve with the ↓ mark toward the tank.
W1049737
Nozzle Heat Seal Service Removal ProcedureIMPORTANT
• Use a plus (phillips head) screw driver (1) that has adiameter which is bigger than the heat seal hole (Approx. 6mm (1/4 in.)).
1. Drive screw driver (1) lightly into the heat seal hole.2. Turn screw driver three or four times each way.3. While turning the screw driver, slowly pull the heat seal (4) out
together with the injection nozzle gasket (3).4. If the heat seal drops, repeat the above procedure.(When reassembling)• Heat seal and injection nozzle gasket must be changed when the
injection nozzle is removed for cleaning or for service.
W1139845
Tightening torque
Cylinder head cover screw6.87 to 11.2 N·m0.700 to 1.15 kgf·m5.07 to 8.31 lbf·ft
Injection pipe retaining nut23 to 36 N·m2.3 to 3.7 kgf·m17 to 26 lbf·ft
Nozzle holder assembly49 to 68 N·m5.0 to 7.0 kgf·m37 to 50 lbf·ft
Overflow pipe assembly retaining nut
20 to 24 N·m2.0 to 2.5 kgf·m15 to 18 lbf·ft
Glow plug20 to 24 N·m2.0 to 2.5 kgf·m15 to 18 lbf·ft
(1) Glow Plug (2) Overflow Pipe(3) Injection Pipe(4) Nozzle Holder Assembly
(5) Copper Gasket(6) Heat Seal(7) Head Cover
(1) Plus Screw Driver(2) Injection Nozzle
(3) Injection Nozzle Gasket(4) Heat Seal
KiSC issued 09, 2009 A
S-54
KJ-X50 Hz SERIES, WSM ENGINE
Rocker Arm and Push Rod1. Remove the rocker arm (3) as a unit.2. Remove the push rods (1).3. Remove the bridge arm (4).(When reassembling)• When putting the push rods onto the tappets (2), check to see if
their ends are properly engaged with the grooves.IMPORTANT
• After reassembling the rocker arm, be sure to adjust thevalve clearance.
W1050212
Tightening torque Rocker arm bracket screw49 to 55 N·m5.0 to 5.7 kgf·m37 to 41 lbf·ft
(1) Push Rod(2) Tappet
(3) Rocker Arm (4) Bridge Arm
KiSC issued 09, 2009 A
S-55
KJ-X50 Hz SERIES, WSM ENGINE
Cylinder Head and Tappet1. Loosen the pipe band, and remove the water return pipe (1).2. Disconnect the fuel pipe (2) first and then the fuel filter (3).3. Remove the IN. / EX. Manifold.4. Remove the cylinder head screw in the order of (18) to (1), and
remove the cylinder head.5. Remove the cylinder head gasket.6. Remove the tappets (4) from the crank case.(When reassembling)• Replace the head gasket with a new one.• Before installing the tappets (4), apply engine oil thinly around
them.• When mounting the gasket, set it to the knock pin hole. Take
care not to mount it reversely.• The cylinder head should be free of scratches and dust.• Take care for handling the gasket not to damage it.• Install the cylinder head.• Tighten the cylinder head screw gradually in the order of (1) to
(18) after applying engine oil.• Be sure to adjust the valve clearance. See the “Valve
Clearance”.• It is not necessary to retighten the cylinder head screw after
running the engine for 30 minutes.IMPORTANT
• When replace the piston, piston pin bush, connecting rod orcrankpin bearing, select the cylinder head gasket thicknessto meet with the top clearance refer to the “SelectingCylinder Head Gasket”.NOTE
• Mark the cylinder number to the tappets to preventinterchanging.
W1170923
Tightening torque Cylinder head mounting screw
98.1 to 107 N·m10.0 to 11.0 kgf·m72.4 to 79.5 lbf·ft
(1) Return Pipe(2) Fuel Pipe(3) Fuel Filter(4) Tappet
A : Gear Case SideB : Flywheel Side
KiSC issued 09, 2009 A
S-56
KJ-X50 Hz SERIES, WSM ENGINE
Selecting Cylinder Head Gasket Replacing the Cylinder Head Gasket
1. Make sure the notch mark (a), (b) or (c) of cylinder head gasket(1) in advance.
2. Replace the same notch mark (a), (b) or (c) as the originalcylinder head gasket (1).
Selecting the Cylinder Head Gasket• Select the cylinder head gasket (1) thickness to meet with the top
clearance when replacing the piston, piston pin bush, connectingrod or crankpin bearing.
1. Measure the piston head’s protrusion or recessing from thecrankcase cylinder face (4 spots per each piston and average offour pistons) using the dial gauge as shown in figure.
2. Select the suitable cylinder head gasket refer to the table below.
W1022965
Valve1. Remove the valve cap (3) and the valve spring collets (1)
compressing the valve spring (5) with the valve spring retainer(4).
(When reassembling)• Install the intake valve spring with its small-pitch end downward
(at the head side).• Wash the valve stem and valve guide hole, and apply engine oil
sufficiently.• After installing the valve spring collets, lightly tap the stem to
assure proper fit with a plastic hammer.
W1053044
Notch Mark of Cylinder Head Gasket
Thickness of cylinder head gasket
Part Code
Piston Head’s protrusion or recessing from the level of Crankcase cylinder face.(average of 4 pistons)
Before tightening
After tightening
2 notches (a)
0.90 mm0.035 in.
0.80 mm0.031 in.
1C020-03310
-0.070 to +0.049 mm-0.0027 to +0.0019 in.
1 notch (b) 1.00 mm0.0394 in.
0.90 mm0.035 in.
1C020-03600
+0.0500 to +0.149 mm+0.00197 to +0.00586 in.
Without notch (c)
1.05 mm0.0413 in.
0.95 mm0.037 in.
1C020-03610
+0.150 to +0.200 mm+0.00591 to +0.00787 in.
(1) Cylinder Head Gasket(2) Measuring Point(A) Gear Case Side(B) Flywheel Side
(a) 2 Notches(b) 1 Notch(c) Without Notch
(1) Valve Spring Collet(2) Arm Bridge (3) Valve Cap(4) Valve spring Retainer (5) Valve Spring(6) Valve Stem Seal
(7) Valve(8) Large Pitch(9) Smaller Pitch
(10) Install the spring with its smaller-pitch end downward (at the head side)
KiSC issued 09, 2009 A
S-57
KJ-X50 Hz SERIES, WSM ENGINE
2) ThermostatThermostat Assembly1. Remove the thermostat cover mounting screws, and remove the
thermostat cover (1).2. Remove the thermostat assembly (3).(When reassembling)• Apply a liquid gasket (Three Bond 1215 or equivalent) only at the
thermostat cover side of the gasket (2).• Attach the thermostat with its hole facing toward the air suction
side.
W1072747
3) Injection NozzleNozzle Holder1. Secure the nozzle retaining nut (7) with a vise.2. Remove the nozzle holder (1), and take out parts inside.(When reassembling)• Assemble the nozzle in clean fuel oil.• Install the push rod (4), noting its direction.• After assembling the nozzle, be sure to adjust the fuel injection
pressure.
W1089102
(1) Thermostat Cover(2) Thermostat Cover Gasket
(3) Thermostat Assembly(4) Hole
Tightening torque
Nozzle holder35 to 39 N·m3.5 to 4.0 kgf·m26 to 28 lbf·ft
Overflow pipe nut20 to 24 N·m2.0 to 2.5 kgf·m15 to 18 lbf·ft
Nozzle holder assembly49 to 68 N·m5.0 to 7.0 kgf·m37 to 50 lbf·ft
(1) Nozzle Holder(2) Adjusting Washer(3) Nozzle Spring(4) Push Rod
(5) Distance Piece(6) Nozzle Piece(7) Nozzle Retaining Nut
KiSC issued 09, 2009 A
S-58
KJ-X50 Hz SERIES, WSM ENGINE
4) Injection Pump UnitInjection Pump Unit (To be continued)(Removing the fuel injection pump unit)1. Detach the gear cover for the fuel injection pump unit from the
gearcase.2. Place the piston of the 4th cylinder at the top dead center in the
compression stroke. Fix the flywheel with the flywheel stopper.IMPORTANT
• Look for the align mark on the idle gear 2. Using a whitemarking pen or the like, put an align mark on the engagedtooth of the idle gear. This helps to reassemble these gearsin mesh later.NOTE
• When the already existing align marks align with each other,there is no need to put another align mark.
3. Unscrew the two plugs (3) of the injection pump unit.4. Tighten the upper fuel cam shaft lock screw (5) until it comes into
contact with the fuel cam shaft. Make sure the cam shaft doesnot move any longer.
5. Tighten the lower fuel cam shaft lock screw (5) until it comes intocontact with the fuel cam shaft.NOTE
• Never overtighten the lock screws when they have come intocontact with the cam shaft. Otherwise the injection pumpitself may get damaged.
• Use of a socket set screw (dog point type) in recommendedfor best results. Such screw can be constructed as shownin figure (a).
6. Loosen the injection pump gear mounting nut. Using the specificgear puller, take out the gear (6).NOTE
• Be careful not to drop the key.7. Disconnect the lubricating oil pipe (4).8. Loosen the three injection pump unit mounting nut (2).9. Remove the injection pump unit support (1) and take out the
injection pump unit.
W1175054
A M8 × Pitch 1.25
B 5.0 mm dia. (0.20 in. dia.)
C 4.0 mm (0.16 in.)
D 45 mm (1.8 in.)
E 10 mm (0.39 in.) : Conspicuously Painted
(1) Injection Pump Unit Support(2) Injection Pump Unit Mounting Nut(3) Plug(4) Lubricating Oil Pipe
(5) Fuel Cam Shaft Lock Screw(Socket Set Screw Dog Point Type)
(6) Injection Pump Gear
KiSC issued 09, 2009 A
S-59
KJ-X50 Hz SERIES, WSM ENGINE
Injection Pump Unit (Continued)(Reassembling the fuel injection pump unit)1. Place the piston of the 4th cylinder at the top dead center in the
compression stroke. Fix the flywheel with the flywheel stopper.2. Place the injection pump gear (1) back into the gear case
position. Make sure of aligning the align marks of the injectionpump gear (1) and the idle gear 2 (3).
3. Install the injection pump unit to the injection pump gear (1).NOTE
• When installing the injection pump unit to the injectionpump gear, make sure that the key is fit in the keyway ofinjection pump gear.
4. Temporarily tighten the injection pump gear mounting nut byhand.
5. Fix the injection pump unit and tighten the injection pump gearmounting nut to the specified torque.
6. Take off the fuel cam shaft lock screws (4) and tighten the plugs(5) for plugging.
7. Loose the injection pump unit mounting nuts (7) for aligning theinjection timing.
8. Moving the injection pump unit clockwise (viewed from gear caseside), align the injection timing marks (6) on the injection pumpunit and on the gear case.
9. Tighten the injection pump unit mounting nut (7) to the specifiedtorque.
10.Reconnect the lubricating oil pipe (8) and place the injectionpump unit support and the gear cover of the injection pump unit.
11.Remove the flywheel stopper.12.Check the injection timing. (See the “Injection Timing”.)13.If the injection timing is not within the specification, repeat (7) to
(12) again.
W1176586
Tightening torque
Injection pump gear mounting nut
74 to 83 N·m7.5 to 8.5 kgf·m55 to 61 lbf·ft
Injection pump unit mounting nut
18 to 20 N·m1.8 to 2.1 kgf·m13 to 15 lbf·ft
(1) Injection Pump Gear(2) Align mark of the Injection Gear(3) Idle Gear 2(4) Fuel Cam Shaft Lock Screw
(Socket Set Screw Dog Point Type)
(5) Plug(6) Align Mark(7) Injection Pump Unit Mounting Nut(8) Lubricating Oil Pipe
KiSC issued 09, 2009 A
S-60
KJ-X50 Hz SERIES, WSM ENGINE
Governor Housing Assembly1. Remove the injection pump unit from the engine. (See the
“Injection Pump Unit”.)2. Remove the governor lubricating pipe (3).3. Remove the stop solenoid (1).4. Detach the sight cover (2) from the injection pump unit.5. Unhook the start spring (7) from the rack pin (6) of injection pump
assembly.6. Remove the nut (5).
NOTE• Be careful not to drop the nut inside.
7. Slide off the governor connecting rod (4) from the rack pin ofinjection pump assembly.
8. For convenient sake, temporarily hook the start spring on therack pin hole of the governor connecting rod.
9. Remove the governor housing mounting screws.10.Detach the governor housing assembly (8) from the injection
pump unit.(When reassembling)• When reassembling the inside parts, put the oil on each inside
part slightly.• After sliding on the governor connecting rod to the rack pin,
tighten the nut with the specified torque with using the jig forkeeping the governor connecting rod horizontal. (See theReplacing Injection Pump Assembly.)
• After tightening the nut, hook the start spring on the rack pin.• Check the movement of control rack of injection pump assembly
by the stop lever.NOTE
• When installing the governor housing assembly to theinjection pump unit, be careful not to damage O-ring (9).
• When linking the governor connecting rod to the rack pin ofinjection pump, use the jig for keeping the governorconnecting rod horizontal. Otherwise the control rack maybe stuck, and causes to be difficult to start the engine orhunting of governor. (See the Replacing Injection PumpAssembly.)
W1137126
Tightening torque
Governor housing mounting screw
9.81 to 11.2 N·m1.00 to 1.15 kgf·m7.24 to 8.31 lbf·ft
Anti-rotation nut2.9 to 4.0 N·m0.29 to 0.41 kgf·m2.1 to 2.9 lbf·ft
(1) Stop Solenoid(2) Sight Cover(3) Governor Lubricating Pipe(4) Governor Connecting Rod(5) Anti-Rotation Nut
(6) Rack Pin(7) Start Spring(8) Governor Housing Assembly(9) O-ring
KiSC issued 09, 2009 A
S-61
KJ-X50 Hz SERIES, WSM ENGINE
Governor Fork Lever Assembly1. Pull off the governor fork lever shaft (1) with the extra bolt (Dia :
4 mm, Pitch : 0.7 mm, Length : more than 25 mm) (2).2. Unhook the governor spring (3) at the governor fork lever (4)
side.3. Remove the governor fork lever assembly from the governor
housing (5).(When reassembling)• After reassembling the governor housing assembly, check the
movement of the governor fork lever assembly, the speed controllever and the stop lever.NOTE
• When assembling the inside parts, put the oil on each insidepart slightly.
• Be careful not to deform the start spring.
W1139749
(1) Governor Fork Lever Shaft(2) Extra Bolt
(Dia : 4 mm, Pitch : 0.7 mm, Length : more than 25 mm)
(3) Governor Spring(4) Governor Fork Lever(5) Governor Housing
KiSC issued 09, 2009 A
S-62
KJ-X50 Hz SERIES, WSM ENGINE
Governor Lever1. Remove the speed control lever (1) and the return spring (2).2. Remove the governor lever assembly (4) from the governor
housing.3. Remove the start spring (5) and the stop spring (3).
W1142375
Stop Lever1. Remove the stop lever (1) and the return spring (2).2. Remove the stop lever shaft (3).
W1143531
(1) Speed Control Lever(2) Return Spring(3) Stop Spring
(4) Governor Lever Assembly(5) Start Spring
(1) Stop Lever(2) Return Spring
(3) Stop Lever Shaft
KiSC issued 09, 2009 A
S-63
KJ-X50 Hz SERIES, WSM ENGINE
Fuel Camshaft and Governor Weight (To be continued)1. Separate the governor housing assembly from the injection
pump unit. (See the “Injection Pump Unit”.)2. Remove the governor sleeve (1).3. Remove the injection pump assembly (2).4. Remove the cover (3).5. Remove the fuel camshaft lock screws.6. Fix the fuel camshaft with open end wrench (4), and remove the
governor weight mounting nut and the governor weight (5).7. Loosen the fuel camshaft stopper mounting screws and remove
the fuel camshaft stopper (6).8. Pull out the fuel camshaft (9) and bearings (7) together.9. After removing the bearing’s cir-clip (8), press out the bearings.
NOTE• Do not use the fuel camshaft lock screws, when removing
the governor weight mounting nut. Otherwise, the lock boltsor injection pump housing might get damage.
(When reassembling)• Press the bearings into the fuel camshaft.• Set the cir-clip at the gear side’s bearing.• Install the fuel camshaft and bearings to the injection pump
housing.• Attach the fuel camshaft stopper and tighten the fuel camshaft
stopper mounting screws with the specified torque.• Attach the governor weight to the fuel camshaft and tighten the
governor weight mounting nut with specified torque.
W1144178
Tightening torque
Injection pump mounting screw
24 to 27 N·m2.4 to 2.8 kgf·m18 to 20 lbf·ft
Injection pump mounting nut
18 to 20 N·m1.8 to 2.1 kgf·m13 to 15 lbf·ft
(1) Governor Sleeve(2) Injection Pump Assembly(3) Cover(4) Open End Wrench (24 mm)(5) Governor Weight
(6) Fuel Camshaft Stopper(7) Bearing(8) Cir-clip (9) Fuel Camshaft
(10) Key Way of Fuel Camshaft
KiSC issued 09, 2009 A
S-64
KJ-X50 Hz SERIES, WSM ENGINE
Fuel Camshaft and Governor Weight (Continued)(When reassembling)• Fix the fuel camshaft with lock bolts as the key way of fuel
camshaft (10) is upward.• Install the injection pump assembly to the injection pump
housing.• Attach the O-ring and the cover and tighten the cover mounting
screws.• Install the governor sleeve to the fuel camshaft.• Check the movement of the governor sleeve.
NOTE• Be careful not to damage the O-ring.• Be careful the direction of the governor sleeve.• When reassembling the inside parts, put the oil on each
inside part slightly.
W1146489
Tightening torque
Fuel camshaft stopper mounting screw
7.9 to 9.3 N·m0.80 to 0.95 kgf·m5.8 to 6.8 lbf·ft
Governor weight mounting nut
63 to 72 N·m6.4 to 7.4 kgf·m47 to 53 lbf·ft
(1) Governor Sleeve(2) Injection Pump Assembly(3) Cover(4) Open End Wrench (24 mm)(5) Governor Weight
(6) Fuel Camshaft Stopper(7) Bearing(8) Cir-clip (9) Fuel Camshaft
(10) Key Way of Fuel Camshaft
KiSC issued 09, 2009 A
S-65
KJ-X50 Hz SERIES, WSM ENGINE
Replacing Injection Pump Assembly (If necessary)• The injection pump can be replaced with the crankshaft in
whatever position.1. Disconnect all injection pipes (1).2. Disconnect the fuel pipe (6) and fuel overflow pipe (4).3. Disconnect the connector (2) from the stop solenoid. Then
remove the stop solenoid (3).4. Detach the sight cover (7) from the injection pump unit.5. Unhook the start spring (10), and remove the anti-rotation nut (9).6. Slide off the governor connecting rod (8) from the rack pin of
injection pump assembly.7. Remove the injection pump mounting screws and nuts, and take
out the injection pump assembly (5).NOTE
• Be careful not to drop the anti-rotation nut (9).• Be careful not to deform the start spring.• When taking out the injection pump assembly, be careful not
to hit it against the governor connecting rod.(When reassembling)• Install the new injection pump according to the installing
procedure.
W1182379
(1) Injection Pipe(2) Connector(3) Stop Solenoid(4) Fuel Overflow Pipe(5) Injection Pump Assembly
(6) Fuel Pipe(7) Sight Cover (8) Governor Connecting Rod(9) Anti-Rotation Nut
(10) Start Spring
KiSC issued 09, 2009 A
S-66
KJ-X50 Hz SERIES, WSM ENGINE
Installing Procedure of Injection Pump Assembly (To becontinued)1. Install the fuel injection pump assembly (1) in its unit (2), and
hook the governor connecting rod to the rack pin of the fuelinjection pump assembly.
2. Place the service jig (3) in the stop solenoid mounting hole of thefuel injection pump unit.
3. Make sure the permanent magnet at the tip of the service jig isattracted to the governor connecting rod (4). To do this, turn thejig a little clockwise and counterclockwise and look into the fuelinjection pump unit sight hole to see if the governor connectingrod (4) moves right and left accordingly.
4. Slightly tighten the anti-rotation nut of the governor connectingrod.
5. Holding down the service jig (3) by hand, tighten up the anti-rotation nut (5) to the specified torque.
6. Hook the start spring (6) to the rack pin (7).
W1069371
(1) Fuel Injection Pump Assembly(2) Fuel Injection Pump Unit(3) Service Jig(4) Governor Connecting Rod
(5) Anti-rotation Nut(6) Start Spring(7) Rack Pin
KiSC issued 09, 2009 A
S-67
KJ-X50 Hz SERIES, WSM ENGINE
Installing Procedure of Injection Pump Assembly (Continued)1. Move the stop lever (1) and visually check to see if the fuel
injection pump control rack comes smoothly back to the startposition by the counter force of the start spring.
2. If the control rack fails to move back smoothly, remove the startspring and the anti-rotation nut, take the above steps from 2 ofthe former page again.
3. Finally fit the sight cover and the stop solenoid back into place.
W1069772
Fan Drive Pulley1. Set the stopper to the flywheel.2. Remove the crankshaft screw (2).3. Draw out the fan drive pulley (1).(When reassembling)
W1185033
5) Water PumpWater Pump1. Remove the pipe band and the water pipe (1).2. Remove the water pump (2).(When reassembling)• When mounting the water pump, take care not to forget mounting
the O-ring and not to let it out of position.
W1187742
Tightening torque
Anti-rotation nut2.9 to 4.0 N·m0.29 to 0.41 kgf·m2.1 to 2.9 lbf·ft
Injection pump mounting screw
24 to 27 N·m2.4 to 2.8 kgf·m18 to 20 lbf·ft
Injection pump mounting nut
18 to 20 N·m1.8 to 2.1 kgf·m13 to 15 lbf·ft
(1) Stop Lever (2) Sliding Point between Governor Fork Lever and Governor Connecting Rod
Tightening torque Crankshaft screw255 to 274 N·m26.0 to 28.0 kgf·m188 to 202 lbf·ft
(1) Fan Drive Pulley (2) Crankshaft Screw
(1) Water Pipe (2) Water Pump
KiSC issued 09, 2009 A
S-68
KJ-X50 Hz SERIES, WSM ENGINE
6) Gear Case and Timing GearsGear Case Cover1. Remove the gear case cover.(When reassembling)• Confirm that the liquid gasket coating surface is free of water,
dust and oil in order to maintain sealing effect.• Carefully apply the adhesive evenly. (Refer to the figure on the
left.)NOTE
• When mounting the adhesive-applied parts, take care to fitthem to the mating parts.
• Assemble the adhesive-applied parts within ten minutes.• Apply a liquid gasket (Three Bond 1217D) to the gear case
cover.
W1189218
Relief Valve1. Remove the relief valve retaining screw (1).2. Remove the relief valve (2), the spring (3) and the packing (4).
W1081251
Idle Gear and Camshaft1. Remove three set screws of the idle gear and draw out the idle
gear 1, 2.2. Remove two set screws of the camshaft stopper and draw out the
camshaft.(When reassembling)• Set the crankshaft at the top dead center of No. 1 and 4 cylinder
and the camshaft key to the top position and align the marks ofidle gear 1 (3) and idle gear 2 (2) to assemble them. (Refer to thefigure on the left.)
• Mount the injection pump gear (1) after installing the gear case.
W1189797
Tightening torque
Gear case cover mounting screw (7T)
24 to 27 N·m2.4 to 2.8 kgf·m18 to 20 lbf·ft
Gear case cover mounting screw (10T)
30 to 36 N·m3.3 to 3.7 kgf·m24 to 26 lbf·ft
(1) Liquid Gasket
Tightening torque Relief valve retaining screw
69 to 78 N·m7.0 to 8.0 kgf·m51 to 57 lbf·ft
(1) Relief Valve Retaining Screw(2) Relief Valve
(3) Spring(4) Packing
Tightening torque
Camshaft set screw24 to 27 N·m2.4 to 2.8 kgf·m18 to 20 lbf·ft
Idle gear mounting screw24 to 27 N·m2.4 to 2.8 kgf·m18 to 20 lbf·ft
(1) Injection Pump Gear(2) Idle Gear 2(3) Idle Gear 1
(4) Cam Gear(5) Crank Gear
KiSC issued 09, 2009 A
S-69
KJ-X50 Hz SERIES, WSM ENGINE
Plate (Gear Case)1. Remove the three plate mounting screws (1). Detach the plate
(2).(When reassembling)• Apply Three Bond 1217D adhesive or equivalent over the
shaded zones on both sides of the gasket that will be sandwichedbetween the crankcase and plate.
• Be sure to fix the O-rings (3).
W1057656
7) Piston and Connecting RodOil Pan and Oil Strainer1. Unscrew the oil pan mounting screws and remove the oil pan (1).2. Unscrew the oil strainer mounting screw, and remove the oil
strainer (2).(When reassembling)• Install the oil strainer, using care not to damage the O-ring.• Apply liquid gasket (Three Bond 1217D) to the oil pan as shown
in the figure.• Confirm that the liquid gasket coating surface is free of water,
dust and oil in order to maintain sealing effect.• Carefully apply the adhesive evenly.
NOTE• When mounting the adhesive-applied parts, take care to fit
them to the mating parts.• Assemble the adhesive-applied parts within ten minutes.• To avoid uneven tightening, tighten mounting screws in
diagonal order from the center.• After cleaning the oil strainer, install it.• Attach the oil pan with its central drain plug facing toward
the air suction side.
W1057949
Tightening torque Plate mounting screw24 to 27 N·m2.4 to 2.8 kgf·m18 to 20 lbf·ft
(1) Plate Mounting Screw(2) Plate(3) O-ring
(4) Gasket(5) Liquid Gasket
(1) Oil Pan(2) Oil Strainer
(3) Liquid Gasket
KiSC issued 09, 2009 A
S-70
KJ-X50 Hz SERIES, WSM ENGINE
Connecting Rod Cap1. Remove the connecting rod screws (1) from connecting rod cap.2. Remove the connecting rod caps.(When reassembling)• Align the marks (a) with each other. (Face the marks toward the
injection pump.)• Apply engine oil to the connecting rod screws and lightly screw it
in by hand, then tighten it to the specified torque.If the connecting rod screw won’t be screwed in smoothly, cleanthe threads.If the connecting rod screw is still hard to screw in, replace it.
• When using the existing crank pin metal again, put tally marks onthe crank pin metal and the connecting rod in order to keep theirpositioning.
• Fit the crank pin metal in place : its centrally groove side towardthe connecting rod, and the non-grooved side toward the cap.
W1058252
Piston1. Turn the flywheel and set a piston to the top dead center.2. Pull out the piston upward by lightly tapping it from the bottom of
the crankcase with the grip of a hammer.(When reassembling)• Before inserting the piston into the cylinder, apply enough engine
oil to the cylinder.• When inserting the piston into the cylinder, face the mark on the
connecting rod to the injection pump.IMPORTANT
• Do not change the combination of cylinder and piston.Make sure of the position of each piston by marking. Forexample, mark “1” on the No. 1 position.
• When inserting the piston into the cylinder, place the gap ofthe top ring on the opposite side of the combustion chamberand stagger the gaps of the second ring and oil ring markinga right angle from the gap of the top ring.
• Carefully insert the pistons using a piston ring compressor(1). Otherwise, their chrome-plated section may bescratched, causing trouble inside the liner.
W1058433
Tightening torque Connecting rod screw79 to 83 N·m8.0 to 8.5 kgf·m58 to 61 lbf·ft
(1) Connecting Rod Screw (a) Mark
(1) Piston Ring Compressor
(a) 0.79 rad (45 °)
(A) Top Ring Gap(B) Second Ring Gap(C) Oil Ring Gap(D) Piston Pin Hole
KiSC issued 09, 2009 A
S-71
KJ-X50 Hz SERIES, WSM ENGINE
Piston Ring and Connecting Rod1. Remove the piston rings using a piston ring tool.2. Put the fan shaped concave (8) on the piston as shown in figure.3. Remove the piston pin (7), and separate the connecting rod (6)
from the piston (5).(When reassembling)• Be sure to fix the crankpin bearing and the connecting rod are
same I.D. colors.• When installing the ring, assemble the rings so that the
manufacture’s mark (12) near the gap faces the top of the piston.• When installing the oil ring onto the piston, place the expander
joint (10) on the opposite side of the oil ring gap (11).• Apply engine oil to the piston pin.• When installing the piston pin, immerse the piston in 80 °C (176
°F) oil for 10 to 15 minutes and insert the piston pin to the piston.• Assemble the piston to the connecting rod with the aligning the
direction of the fan shaped concave (8) of piston head and themark (9) of connecting rod.
• The end faces of the oil ring are plated with hard chrome. Inputting the piston into the cylinder, be careful not to get the oil ringscratched by the cylinder. Use the piston ring fitter to tighten upthe oil ring. If the ring’s planting is scratched, it may get stuck onthe cylinder wall, causing a serious trouble.IMPORTANT
• Mark the same number on the connecting rod and the pistonso as not to change the combination.
W1059589
(1) Top Ring(2) Second Ring(3) Oil Ring(4) Piston Pin Snap Ring(5) Piston(6) Connecting Rod(7) Piston Pin(8) Fan Shaped Concave(9) Mark
(10) Expander Joint
(11) Oil Ring Gap(12) Manufacture’s Mark
(A) Connecting Rod ID Color : Blue or Yellow (without Color)
(B) Crankpin Bearing ID Color : Blue or Yellow (without Color)
KiSC issued 09, 2009 A
S-72
KJ-X50 Hz SERIES, WSM ENGINE
8) Flywheel and CrankshaftFlywheel1. Install the stopper to the flywheel so that the flywheel does not
turn.NOTE
• Do not use an impact wrench. Serious damage will occur.2. Detach the flywheel screws.3. Remove the flywheel.(When reassembling)• Apply engine oil to the flywheel screws.• Before fitting the flywheel and the crankshaft together, wipe oil,
dust and other foreign substances off their mating faces.• The flywheel and the crankshaft are fitting together in just one
position. Make sure they are tightly fit and drive the bolts.
W1060354
Bearing Case CoverNOTE
• Before disassembling, check the side clearance ofcrankshaft. Also check it during reassembly.
1. Remove the bearing case over mounting screws.2. Screw two removed screws into the screw hole (2) of bearing
case cover to remove it.(When reassembling)
IMPORTANT• In case of replacing the oil seal, use caution when installing
the seal in the bearing case cover as not to install it tilted.The seal should be flush with the cover.
• Confirm that the liquid gasket coating surface is free ofwater, dust and oil in order to maintain sealing effect.
• Apply liquid gasket (Three Bond 1217D) to the bearing casecover as shown in the figure.
• Before installing the bearing case cover / oil seal assembly,lube the seal, be careful not to damage the seal whileinstalling the assembly.Install the bearing case cover / oil seal assembly to positionthe casting mark “UP” on it upward.
• Tighten the bearing case cover mounting screws with evenforce on the diagonal line.NOTE
• When mounting the adhesive-applied parts, take care to fitthem to the mating parts.
• Assemble the adhesive-applied parts within ten minutes.
W1060482
Tightening torque Flywheel screw98.1 to 107 N·m10.0 to 11.0 kgf·m72.4 to 79.5 lbf·ft
Tightening torque Bearing case cover mounting screw
24 to 27 N·m2.4 to 2.8 kgf·m18 to 20 lbf·ft
(1) Top Mark “UP”(2) Screw Hole
(3) Liquid Gasket
KiSC issued 09, 2009 A
S-73
KJ-X50 Hz SERIES, WSM ENGINE
Flywheel Housing1. Remove the flywheel housing.(When reassembling)• Tighten the flywheel housing mounting screws with even force on
the diagonal line.• Make sure the crank cases 1 and 2 are clean. Install them in
position, referring to the flywheel housing’s contoured face.
W1060705
Crankcase 21. Remove the crankcase 2 (1).(When reassembling)
IMPORTANT• Make sure the crankcase 1 and 2 are clean.• Apply liquid gasket (Three Bond 1217D) to the crankcase 2
as shown in the figure.• Tighten the crankcase 2 mounting screws with even force on
the diagonal line.• Confirm that the liquid gasket coating surface is free of
water, dust and oil in order to maintain sealing effect.• Carefully apply the adhesive evenly.
NOTE• When mounting the adhesive-applied parts, take care to fit
them to the mating parts.• Assemble the adhesive-applied parts within ten minutes.
W1060825
Crankcase 1 and Crankcase 2(When reassembling)• Match the crankcase 1 and 2, referring to the flywheel housing’s
contoured face.• Tighten the crankcase 2 mounting screws loosely.• Tighten up the jig to the specified torque same as the flywheel
housing screw. This helps to minimize the level differencebetween the crankcase 1 and the crankcase 2 (at the flywheelside). Possible gap must be 0.05 mm (0.002 in.) or smaller.
W1111351
Tightening torque Flywheel housing mounting screw
78 to 90 N·m7.9 to 9.2 kgf·m58 to 66 lbf·ft
(1) Flywheel Housing
Tightening torque Crankcase 2 mounting screw
49 to 55 N·m5.0 to 5.7 kgf·m37 to 41 lbf·ft
(1) Crankcase 2 (2) Liquid Gasket
Tightening torque
Crankcase 2 mounting screw
49 to 55 N·m5.0 to 5.7 kgf·m37 to 41 lbf·ft
Flywheel housing mounting screw
78 to 90 N·m7.9 to 9.2 kgf·m58 to 66 lbf·ft
(1) Crankcase 1(2) Gap to be smaller than 0.05 mm
(0.0020 in.)
(3) Flywheel Housing(4) Crankcase 2(5) Jig
KiSC issued 09, 2009 A
S-74
KJ-X50 Hz SERIES, WSM ENGINE
Crankshaft1. Remove the main bearing case.2. Remove the crankshaft.(When reassembling)• Reassemble the main bearing case having the same number as
the one engraved on the crankcase, and set the casting mark “F/ W SIDE” on the main bearing case facing towards the flywheelside.
• Reassemble the thrust bearing (2), with the oil groove facingoutside, into both side of the fourth main bearing case (1).
• Apply oil to the bearing case screws and tighten them to thespecified torque.
W1061157
Tightening torque Main bearing case screw138 to 147 N·m14.0 to 15.0 kgf·m102 to 108 lbf·ft
(1) 4th Main Bearing Case(2) Thrust Bearing
(3) F / W SIDE Mark
KiSC issued 09, 2009 A
S-75
KJ-X50 Hz SERIES, WSM ENGINE
(3) Starter1) D1703-E/E2, V2203-E/E2, F2803-E/E2
W1222714
1. Unscrew the C terminal nut (3), and disconnect the connecting lead.2. Remove the two through bolts (1).3. Detach the motor.4. Remove the end frame (8).5. Remove the brush from the brush holder while holding the spring up.6. Remove the brush holder (9).7. Draw out the armature (5) from the yoke (4).8. Remove the housing (13).9. Remove the idle gear (7) and the overrunning clutch (6).10.Remove the magnet switch cover (10).11.Remove the plunger (11).
NOTE• Do not damage to the brush and commutator.
(When reassembling)• Apply grease (DENSO No. 50 or equivalent) to the idle gear and overrunning clutch portions.
W1059634
(1) Through Bolt(2) Brush(3) C Terminal Nut(4) Yoke(5) Armature(6) Overrunning Clutch(7) Idle Gear(8) End Frame(9) Brush Holder
(10) Magnet Switch Cover(11) Plunger(12) B Terminal Nut(13) Housing
Tightening torque B terminal nut5.9 to 11 N·m0.60 to 1.2 kgf·m4.4 to 8.6 lbf·ft
KiSC issued 09, 2009 A
S-76
KJ-X50 Hz SERIES, WSM ENGINE
2) V3300-E2BG
W1260607
Disassembling Motor1. Disconnect the solenoid switch (3).2. Remove the 2 through bolts (11) and the 2 brush holder lock bolts. Take out the rear bracket (15) and the brush
holder.3. Disconnect the armature (12) and the yoke (13). Remove also the ball (9) from the tip of the armature.4. Remove the set of packings (10), the 4 planetary gears (8) and another packing.5. Take out the shaft assembly (7). Take note of the position of the lever (5).
IMPORTANT• Before disconnecting the yoke, put tally marks on the yoke and the front bracket.• Take note of the positions of the set of packings and the setup bolt.• Apply grease to the gears, bearings, shaft’s sliding part and ball.
NOTE• Do not damage to the brush and commutator.
(When reassembling)• Apply grease (NIPPONDENSO No. 50 or equivalent) to the parts indicated in the figure.
W1124225
(1) Gear(2) Front Bracket(3) Solenoid Switch(4) Overrunning Clutch(5) Drive Lever(6) Internal Gear(7) Shaft Assembly(8) Planetary Gear(9) Ball
(10) Set of Packings(11) Through Bolt(12) Armature(13) Yoke(14) Brush Holder(15) Rear Bracket
Tightening torque B terminal nut9.8 to 11 N·m1.0 to 1.2 kgf·m7.3 to 8.6 lbf·ft
KiSC issued 09, 2009 A
S-77
KJ-X50 Hz SERIES, WSM ENGINE
(4) Alternator
W1224079
1. Remove the pulley (1).2. Remove the rear end cover (12).3. Remove the brush holder (11).4. Remove the IC regulator (10).5. Remove the four screws holding the stator lead wires.6. Remove the rectifier (9).7. Remove the rear end frame (8).8. Press out the rotor (6) from drive end frame (2).9. Remove the retainer plate (5).10.Press out the bearing (4) from drive end frame (2) with a press and jig.11.Lightly secure the rotor with a vise to prevent damage, and remove the bearing (7) with a puller.(When reassembling)
W1224556
(1) Pulley(2) Drive End Frame(3) Stator(4) Bearing(5) Retainer Plate(6) Rotor(7) Bearing(8) Rear End Frame(9) Rectifier
(10) IC Regulator(11) Brush Holder(12) Rear End Cover
Tightening torque Pulley nut58.4 to 78.9 N·m5.95 to 8.05 kgf·m43.1 to 58.2 lbf·ft
KiSC issued 09, 2009 A
S-78
KJ-X50 Hz SERIES, WSM ENGINE
[3] SERVICING(1) Cylinder Head and Valves
Top Clearance1. Remove the cylinder head (remove the cylinder head gasket
completely).2. Bring the piston to its top dead center fasten 1.5 mm dia. 5 to 7
mm long fuse wires to 3 to 4 spots on the piston top with greaseso as to avoid the intake and exhaust valves and the combustionchamber ports.
3. Bring the piston to its middle position, install the cylinder head,and tighten the cylinder head screws to specification. (Headgasket must be changed to new one.)
4. Turn the crank shaft until the piston exceeds its top dead center.5. Remove the cylinder head, and measure squeezed fuse wires for
thickness.6. If the measurement is not within the specified value, check the oil
clearance of the crankpin journal and the piston pin.NOTE
• After checking the top clearance, be sure to assemble thecylinder head with a new cylinder head gasket.
W1020190
Top Clearance Factory spec.
D1703-E/E2V2203-E/E2F2803-E/E2
0.55 to 0.70 mm0.022 to 0.027 in.
V3300-E2BG 0.72 to 0.90 mm0.029 to 0.035 in.
Tightening torque
Cylinder head screws
D1703-E/E2V2203-E/E2F2803-E/E2
93.2 to 98.0 N·m9.50 to 10.0 kgf·m68.8 to 72.3 lbf·ft
V3300-E2BG98.1 to 107 N·m10.0 to 11.0 kgf·m72.4 to 79.5 lbf·ft
(1) Piston(2) Fuse
[A] D1703-E/E2V2203-E/E2F2803-E/E2
[B] V3300-E2BG
KiSC issued 09, 2009 A
S-79
KJ-X50 Hz SERIES, WSM ENGINE
Cylinder Head Surface Flatness1. Clean the cylinder head surface.2. Place a straightedge on the cylinder head’s four sides (A), (B),
(C) and (D) and two diagonal (E) and (F) as shown in the figure.3. Measure the clearance with a feeler gauge.4. If the measurement exceeds the allowable limit, correct it with a
surface grinder.IMPORTANT
• Do not place the straightedge on the combustion chamber.• Be sure to check the valve recessing after correcting.
W1027737
Cylinder Head Flaw1. Prepare an air spray red check.2. Clean the surface of the cylinder head with the detergent (2).3. Spray the cylinder head surface with the red permeative liquid
(1). Leave it five to ten minutes after spraying.4. Wash away the read permeative liquid on the cylinder head
surface with the detergent (2).5. Spray the cylinder head surface with the white developer (3).6. If flawed, it can be identified as red marks.
W1076542
Cylinder head surface flatness Allowable limit 0.05 mm
0.002 in.
[A] D1703-E/E2V2203-E/E2F2803-E/E2
[B] V3300-E2BG
(1) Red Permeative Liquid(2) Detergent
(3) White Developer
KiSC issued 09, 2009 A
S-80
KJ-X50 Hz SERIES, WSM ENGINE
Valve Recessing1. Clean the cylinder head surface, valve face and valve seat.2. Insert the valve into the valve guide.3. Measure the valve recessing with a depth gauge.4. If the measurement exceeds the allowable limit, replace the
valve.5. If it still exceeds the allowable limit after replacing the valve,
replace the cylinder head.
[D1703-E/E2, V2203-E/E2, F2803-E/E2]
[V3300-E2BG]
W10768800
Valve recessing
Factory spec.
Intake and exhaust valve
(Protrusion)0.050 mm (0.0020 in.)
to(Recessing)0.15 mm (0.0059 in.)
Allowable limit (Recessing)0.4 mm (0.02 in.)
Valve recessing
Factory spec.
Intake valve
(Protrusion)0 mm (0 in.)
to(Recessing)0.20 mm (0.0078 in.)
Exhaust valve
(Protrusion)0.15 mm (0.0059 in.)
to(Recessing)0.050 mm (0.0020 in.)
Allowable limit (Recessing)0.4 mm (0.02 in.)
(1) Cylinder Head Surface
(A) Recessing(B) Protrusion
[A] D1703-E/E2V2203-E/E2F2803-E/E2
[B] V3300-E2BG
KiSC issued 09, 2009 A
S-81
KJ-X50 Hz SERIES, WSM ENGINE
Clearance between Valve Stem and Valve Guide1. Remove carbon from the valve guide section.2. Measure the valve stem O.D. with an outside micrometer.3. Measure the valve guide I.D. with a small hole gauge, and
calculate the clearance.4. If the clearance exceeds the allowable limit, replace the valves.
If it still exceeds the allowable limit, replace the valve guide.
[D1703-E/E2, V2203-E/E2, F2803-E/E2]
[V3300-E2BG]
W10774950
Clearance between valve stem and valve guide
Factory spec. 0.040 to 0.070 mm0.0016 to 0.0027 in.
Allowable limit 0.10 mm0.0039 in.
Valve stem O.D. Factory spec. 7.960 to 7.975 mm0.3134 to 0.3139 in.
Valve guide I.D. Factory spec. 8.015 to 8.030 mm0.3156 to 0.3161 in.
Clearance between valve stem and valve guide
Factory spec.
Intake valve
0.055 to 0.085 mm0.0022 to 0.0033 in.
Exhaust valve
0.040 to 0.070 mm0.0016 to 0.0027 in.
Allowable limit 0.1 mm0.004 in.
Valve stem O.D. Factory spec.
Intake valve
6.960 to 6.975 mm0.2741 to 0.2746 in.
Exhaust valve
7.960 to 7.975 mm0.3134 to 0.3139 in.
Valve guide I.D. Factory spec.
Intake valve
7.030 to 7.045 mm0.2768 to 0.2773 in.
Exhaust valve
8.015 to 8.030 mm0.3156 to 0.3161 in.
KiSC issued 09, 2009 A
S-82
KJ-X50 Hz SERIES, WSM ENGINE
Replacing Valve Guide(When removing)1. Press out the used valve guide using a valve guide replacing tool.
(See page “SPECIAL TOOLS”.)(When installing)1. Clean a new valve guide and valve guide bore, and apply engine
oil to them.2. Press in a new valve guide using a valve guide replacing tool.3. Ream precisely the I.D. of the valve guide to the specified
dimension.
[D1703-E/E2, V2203-E/E2, F2803-E/E2]
[V3300-E2BG]
IMPORTANT• Do not hit the valve guide with a hammer during
replacement.
W10278890
Valve Seating1. Coat the valve face lightly with prussian blue and put the valve on
its seat to check the contact.2. If the valve does not seat all the way around the valve seat or the
valve contact is less than 70 %, correct the valve seating asfollows.
3. If the valve contact does not comply with the reference value,replace the valve or correct the contact of valve seating.
W10282190
Valve guide I.D.(Intake and exhaust) Factory spec. 8.015 to 8.030 mm
0.3156 to 0.3161 in.
Valve guide I.D. Factory spec.
Intake valve
7.030 to 7.045 mm0.2768 to 0.2773 in.
Exhaust valve
8.015 to 8.030 mm0.3156 to 0.3161 in.
(A) When Removing (B) When Installing
Valve seat width Factory spec. 2.12 mm0.0835 in.
(1) Correct(2) Incorrect
(3) Incorrect
KiSC issued 09, 2009 A
S-83
KJ-X50 Hz SERIES, WSM ENGINE
Valve Lapping1. Apply compound evenly to the valve lapping surface.2. Insert the valve into the valve guide. Lap the valve onto its seat
with a valve flapper or screwdriver.3. After lapping the valve, wash the compound away and apply oil,
then repeat valve lapping with oil.4. Apply prussian blue to the contact surface to check the seated
rate. If it is less than 70 %, repeat valve lapping again.IMPORTANT
• When valve lapping is performed, be sure to check the valverecessing and adjust the valve clearance after assemblingthe valve.
W10288140
Correcting Valve and Valve SeatNOTE
• Before correcting the valve and seat, check the valve stemand the I.D. of valve guide section, and repair them ifnecessary.
• After correcting the valve seat, be sure to check the valverecessing.
1) Correcting Valve1. Correct the valve with a valve refacer.
2) Correcting Valve Seat1. Slightly correct the seat surface with a 1.0 rad (60 °) (intake
valve) or 0.79 rad (45 °) (exhaust valve) valve seat cutter.2. Resurface the seat surface with a 0.52 rad (30 °) valve seat cutter
to intake valve seat and with a 0.26 rad (15 °) valve seat cutter toexhaust valve seat so that the width is close to specified valveseat width (2.12 mm, 0.0835 in.).
3. After resurfacing the seat, inspect for even valve seating, apply athin film of compound between the valve face and valve seat, andfit them with valve lapping tool.
4. Check the valve seating with prussian blue. The valve seatingsurface should show good contact all the way around.
W10283500
Valve face angle Factory spec.
IN. 1.0 rad60 °
EX. 0.79 rad45 °
Valve seat angle Factory spec.
IN. 1.0 rad60 °
EX. 0.79 rad45 °
(1) Valve Seat Width(2) Identical Dimensions
(A) Check Contact(B) Correct Seat Width(C) Check Contact(a) 0.26 rad (15 °) or 0.52 rad (30 °)(b) 0.79 rad (45 °) or 1.0 rad (60 °)(c) 0.52 rad (30 °) or 0.26 rad (15 °)
KiSC issued 09, 2009 A
S-84
KJ-X50 Hz SERIES, WSM ENGINE
Free Length and Tilt of Valve Spring1. Measure the free length (B) of valve spring with vernier calipers.
If the measurement is less than the allowable limit, replace it.2. Put the valve spring on a surface plate, place a square on the
side of the valve spring.3. Check to see if the entire side is in contact with the square.
Rotate the valve spring and measure the maximum tilt (A).If the measurement exceeds the allowable limit, replace it.
4. Check the entire surface of the valve spring for scratches.If there is any defect, replace it.
[D1703-E/E2, V2203-E/E2, F2803-E/E2]
[V3300-E2BG]
W10289350
Valve Spring Setting Load1. Place the valve spring on a tester and compress it to the same
length it is actually compressed in the engine.2. Read the compression load on the gauge.3. If the measurement is less than the allowable limit, replace it.
[D1703-E/E2, V2203-E/E2, F2803-E/E2]
[V3300-E2BG]
W10784360
Tilt (A) Allowable limit 1.0 mm0.039 in.
Free length (B)
Factory spec.
Intake and exhaust valve
41.7 to 42.2 mm1.65 to 1.66 in.
Allowable limit
41.2 mm1.62 in.
Tilt (A) Allowable limit 1.0 mm0.039 in.
Free length (B)
Factory spec.
Intake valve
35.1 to 35.6 mm1.39 to 1.40 in.
Exhaust valve
41.7 to 42.2 mm1.65 to 1.66 in.
Allowable limit
Intake valve
34.6 mm1.36 in.
Exhaust valve
41.2 mm1.62 in.
(A) Tilt (B) Free Length
Setting load / setting length
Factory spec. Intake
and exhaust valve
118 N / 35.0 mm12.0 kgf / 35.0 mm26.5 lbf / 1.38 in.
Allowable limit
100 N / 35.0 mm10.2 kgf / 35.0 mm22.5 lbf / 1.38 in.
Setting load / setting length
Factory spec.
Intake valve
63.5 N / 31.5 mm6.48 kgf / 31.5 mm14.3 lbf / 1.24 in.
Exhaust valve
120 N / 35.0 mm12.0 kgf / 35.0 mm26.5 lbf / 1.38 in.
Allowable limit
Intake valve
45.9 N / 31.5 mm4.68 kgf / 31.5 mm10.3 lbf / 1.24 in.
Exhaust valve
100 N / 35.0 mm10.2 kgf / 35.0 mm22.5 lbf / 1.38 in.
KiSC issued 09, 2009 A
S-85
KJ-X50 Hz SERIES, WSM ENGINE
Oil Clearance between Rocker Arm and Rocker Arm Shaft1. Measure the rocker arm shaft O.D. with an outside micrometer.2. Measure the rocker arm I.D. with an inside micrometer, and then
calculate the oil clearance.3. If the oil clearance exceeds the allowable limit, replace the rocker
arm and measure the oil clearance again. If it still exceeds theallowable limit, replace also the rocker arm shaft.
[D1703-E/E2, V2203-E/E2, F2803-E/E2]
[V3300-E2BG]
W1029150
Push Rod Alignment1. Place the push rod on V blocks.2. Measure the push rod alignment.3. If the measurement exceeds the allowable limit, replace the push
rod.
W10292900
Oil Clearance between Tappet and Tappet Guide Bore1. Measure the tappet O.D. with an outside micrometer.2. Measure the I.D. of the tappet guide bore with a cylinder gauge,
and calculate the oil clearance.3. If the oil clearance exceeds the allowable limit or the tappet is
damaged, replace the tappet.
W1029366
Oil clearance of rocker arm shaft and bearing
Factory spec. 0.016 to 0.045 mm0.00063 to 0.0017 in.
Allowable limit 0.10 mm0.0039 in.
Rocker arm shaft O.D. Factory spec. 13.973 to 13.984 mm0.55012 to 0.55055 in.
Rocker arm I.D. for shaft Factory spec. 14.000 to 14.018 mm0.55119 to 0.55188 in.
Oil clearance of rocker arm shaft and bearing
Factory spec. 0.016 to 0.045 mm0.00063 to 0.0017 in.
Allowable limit 0.15 mm0.0059 in.
Rocker arm shaft O.D. Factory spec. 15.973 to 15.984 mm0.62886 to 0.62929 in.
Rocker arm I.D. for shaft Factory spec. 16.000 to 16.018 mm0.62993 to 0.63062 in.
Push rod alignment Allowable limit 0.25 mm0.0098 in.
Oil Clearance between tappet and tappet guide bore
Factory spec. 0.020 to 0.062 mm0.00079 to 0.0024 in.
Allowable limit 0.07 mm0.003 in.
Tappet O.D. Factory spec. 23.959 to 23.980 mm0.94327 to 0.94409 in.
Tappet guide bore I.D. Factory spec. 24.000 to 24.021 mm0.94489 to 0.94570 in.
KiSC issued 09, 2009 A
S-86
KJ-X50 Hz SERIES, WSM ENGINE
(2) Timing GearsTiming Gear Backlash1. Set a dial indicator (lever type) with its tip on the gear tooth.2. Move the gear to measure the backlash, holding its mating gear.3. If the backlash exceeds the allowable limit, check the oil
clearance of the shafts and the gear.4. If the oil clearance is proper, replace the gear.
[D1703-E/E2, V2203-E/E2, F2803-E/E2]
[V3300-E2BG]
W1029564
Backlash between crank gear and idle gear
Factory spec. 0.04150 to 0.1122 mm0.001634 to 0.004417 in.
Allowable limit 0.15 mm0.0059 in.
Backlash between idle gear and cam gear
Factory spec. 0.04150 to 01154 mm0.001634 to 0.004543 in.
Allowable limit 0.15 mm0.0059 in.
Backlash between idle gear and injection pump gear
Factory spec. 0.04150 to 0.1154 mm0.001634 to 0.004543 in.
Allowable limit 0.15 mm0.0059 in.
Backlash between crank gear and oil pump gear
Factory spec. 0.04150 to 0.1090 mm0.001634 to 0.004291 in.
Allowable limit 0.15 mm0.0059 in.
Backlash between crank gear and idle gear 1
Factory spec.
0.0490 to 0.193 mm0.00193 to 0.00759 in.
Backlash between idle gear 1 and cam gear
0.0490 to 0.189 mm0.00193 to 0.00744 in.
Backlash between idle gear 1 and idle gear 2
0.0440 to 0.185 mm0.00174 to 0.00728 in.
Backlash between idle gear 2 and injection pump gear
0.0440 to 0.177 mm0.00174 to 0.00696 in.
[A] D1703-E/E2V2203-E/E2F2803-E/E2
[B] V3300-E2BG
KiSC issued 09, 2009 A
S-87
KJ-X50 Hz SERIES, WSM ENGINE
Idle Gear Side Clearance1. Set a dial indicator with its tip on the idle gear.2. Measure the side clearance by moving the idle gear to the front
and rear.3. If the measurement exceeds the allowable limit, replace the idle
gear collar.
W1029843
Camshaft Side Clearance1. Set a dial indicator with its tip on the camshaft.2. Measure the side clearance by moving the cam gear to the front
to rear.3. If the measurement exceeds the allowable limit, replace the
camshaft stopper.
W1030012
Camshaft Alignment1. Support the camshaft with V blocks on the surface plate at both
end journals.2. Set a dial indicator with its tip on the intermediate journal.3. Measure the camshaft alignment.4. If the measurement exceeds the allowable limit, replace the
camshaft.
W1031413
Idle gear side clearance
Factory spec.
D1703-E/E2V2203-E/E2F2803-E/E2
0.12 to 0.48 mm0.0048 to 0.018 in.
V3300-E2BG 0.15 to 0.30 mm0.0059 to 0.011 in.
Allowable limit 0.90 mm0.04 in.
[A] D1703-E/E2V2203-E/E2F2803-E/E2
[B] V3300-E2BG
Camshaft side clearance
Factory spec. 0.070 to 0.22 mm0.0028 to 0.0086 in.
Allowable limit 0.30 mm0.012 in.
[A] D1703-E/E2V2203-E/E2F2803-E/E2
[B] V3300-E2BG
Camshaft alignment Allowable limit 0.01 mm0.0004 in.
KiSC issued 09, 2009 A
S-88
KJ-X50 Hz SERIES, WSM ENGINE
Cam Height1. Measure the height of the cam at its highest point with an outside
micrometer.2. If the measurement is less than the allowable limit, replace the
camshaft.
[D1703-E/E2, V2203-E/E2, F2803-E/E2]
[V3300-E2BG]
W1031532
Oil Clearance of Camshaft Journal1. Measure the camshaft journal O.D. with an outside micrometer.2. Measure the cylinder block bore I.D. for camshaft with a cylinder
gauge, and calculate the oil clearance.3. If the oil clearance exceeds the allowable limit, replace the
camshaft.
[D1703-E/E2, V2203-E/E2, F2803-E/E2]
[V3300-E2BG]
W10299330
Intake and exhaust cam height
Factory spec. 33.47 mm1.318 in.
Allowable limit 33.42 mm1.316 in.
Intake and exhaust cam height
Factory spec.
Intake valve
37.64 mm1.481 in.
Exhaust valve
38.96 mm1.534 in.
Allowable limit
Intake valve
37.13 mm1.462 in.
Exhaust valve
38.46 mm1.514 in.
Oil clearance of camshaft journal
Factory spec. 0.050 to 0.091 mm0.0020 to 0.0035 in.
Allowable limit 0.15 mm0.0059 in.
Camshaft journal O.D. Factory spec. 39.934 to 39.950 mm1.5722 to 1.5728 in.
Camshaft bearing I.D. Factory spec. 40.000 to 40.025 mm1.5748 to 1.5757 in.
Camshaft journal O.D. Factory spec. 45.934 to 45.950 mm1.8085 to 1.8090 in.
Camshaft bearing I.D. Factory spec. 46.000 to 46.025 mm1.8111 to 1.8120 in.
KiSC issued 09, 2009 A
S-89
KJ-X50 Hz SERIES, WSM ENGINE
Oil Clearance between Idle Gear Shaft and Idle Gear Bushing1. Measure the idle gear shaft O.D. with an outside micrometer.2. Measure the idle gear bushing I.D. with an inside micrometer,
and calculate the oil clearance.3. If the oil clearance exceeds the allowable limit, replace the
bushing.If it still exceeds the allowable limit, replace the idle gear shaft.
[D1703-E/E2, V2203-E/E2, F2803-E/E2]
[V3300-E2BG]
W1030933
Replacing Idle Gear Bushing(When removing)1. Press out the used idle gear bushing using an idle gear bushing
replacing tool. (See page “SPECIAL TOOLS”.)(When installing)1. Clean a new idle gear bushing and idle gear bore, and apply
engine oil to them.2. Press in a new bushing using an idle gear bushing replacing tool,
until it is flush with the end of the idle gear.
W1031083
Clearance between idle gear shaft and idle gear bushing
Factory spec.
D1703-E/E2V2203-E/E2F2803-E/E2
0.025 to 0.066 mm0.00099 to 0.0025 in.
V3300-E2BG 0.050 to 0.091 mm0.0020 to 0.0035 in.
Allowable limit 0.10 mm0.0039 in.
Idle gear bushing I.D. Factory spec. 38.000 to 38.025 mm1.4961 to 1.4970 in.
Idle gear shaft O.D. Factory spec. 37.959 to 37.975 mm1.4945 to 1.4950 in.
Idle gear 1, 2 bushing I.D. Factory spec. 45.025 to 45.050 mm
1.7727 to 1.7736 in.
Idle gear 1, 2 shaft O.D. Factory spec. 44.959 to 44.975 mm1.7701 to 1.7706 in.
[A] D1703-E/E2V2203-E/E2F2803-E/E2
[B] V3300-E2BG
(A) When Removing (B) When Installing
KiSC issued 09, 2009 A
S-90
KJ-X50 Hz SERIES, WSM ENGINE
(3) Piston and Connecting RodPiston Pin Bore I.D.1. Measure the piston pin bore I.D. in both the horizontal and
vertical directions with a cylinder gauge.2. If the measurement exceeds the allowable limit, replace the
piston.
W1031817
Oil Clearance between Piston Pin and Small End Bushing1. Measure the piston pin O.D. where it contacts the bushing with
an outside micrometer.2. Measure the small end bushing I.D. with an inside micrometer,
and calculate the oil clearance.3. If the oil clearance exceeds the allowable limit, replace the
bushing. If it still exceeds the allowable limit, replace the pistonpin.
[D1703-E/E2, V2203-E/E2, F2803-E/E2]
[V3300-E2BG]
W1031982
Piston pin bore I.D.
Factory spec.
D1703-E/E2V2203-E/E2F2803-E/E2
25.000 to 25.013 mm0.98426 to 0.98476 in.
V3300-E2BG 30.000 to 30.013 mm1.1811 to 1.1816 in.
Allowable limit
D1703-E/E2V2203-E/E2F2803-E/E2
25.05 mm0.9862 in.
V3300-E2BG 30.05 mm1.183 in.
Oil clearance between piston pin and small end bushing
Factory spec.
D1703-E/E2V2203-E/E2F2803-E/E2
0.014 to 0.036 mm0.00056 to 0.0014 in.
V3300-E2BG 0.020 to 0.040 mm0.00079 to 0.0015 in.
Allowable limit 0.15 mm0.0059 in.
Piston pin O.D. Factory spec. 25.004 to 25.011 mm0.98441 to 0.98468 in.
Small end bushing I.D. Factory spec. 25.025 to 25.040 mm0.98524 to 0.98582 in.
Piston pin O.D. Factory spec. 30.006 to 30.011 mm1.1814 to 1.1815 in.
Small end bushing I.D. Factory spec. 30.031 to 30.046 mm1.1824 to 1.1829 in.
KiSC issued 09, 2009 A
S-91
KJ-X50 Hz SERIES, WSM ENGINE
Replacing Connecting Rod Small End Bushing(When removing)1. Press out the used small end bushing using a small end bushing
replacing tool. (See page “SPECIAL TOOLS”.)(When installing)1. Clean a new small end bushing and bore, and apply engine oil to
them.[D1703-E/E2, V2203-E/E2, F2803-E/E2]2. Using a small end bushing replacing tool, press in a new bushing
taking due care to see that the position of the connecting rod oilhole matches the bushing hole.
[V3300-E2BG]2. Insert a new bushing onto the tool and press-fit it with a press so
that the seam (1) of bushing positions as shown in the figure, untilit is flash with the connecting rod.
W1032140
Connecting Rod AlignmentNOTE
• Since the I.D. of the connecting rod small end bushing is thebasis of this check, check bushing for wear beforehand.
1. Install the piston pin into the connecting rod.2. Install the connecting rod on the connecting rod alignment tool.3. Put a gauge over the piston pin, and move it against the face
plate.4. If the gauge does not fit squarely against the face plate, measure
the space between the pin of the gauge and the face plate.5. If the measurement exceeds the allowable limit, replace the
connecting rod.
W10314620
(1) Seam(A) When removing(B) When installing(C) 0.26 rad (15 °)
[A] V3300-E2BG
Connecting rod alignment Allowable limit 0.05 mm
0.002 in.
KiSC issued 09, 2009 A
S-92
KJ-X50 Hz SERIES, WSM ENGINE
Piston Ring Gap1. Insert the piston ring into the lower part of the liner (the least worn
out part) with the piston.2. Measure the ring gap with a feeler gauge.3. If the gap exceeds the allowable limit, replace the ring.
[D1703-E/E2, V2203-E/E2, F2803-E/E2]
[V3300-E2BG]
W1032246
Top ringFactory spec. 0.30 to 0.45 mm
0.012 to 0.017 in.
Allowable limit 1.25 mm0.0492 in.
Second ringFactory spec. 0.30 to 0.45 mm
0.012 to 0.017 in.
Allowable limit 1.25 mm0.0492 in.
Oil ringFactory spec. 0.25 to 0.45 mm
0.0099 to 0.017 in.
Allowable limit 1.25 mm0.0492 in.
Top ring and Second ring
Factory spec. 0.30 to 0.45 mm0.012 to 0.017 in.
Allowable limit 1.25 mm0.0492 in.
Oil ringFactory spec. 0.25 to 0.45 mm
0.0099 to 0.017 in.
Allowable limit 1.25 mm0.0492 in.
KiSC issued 09, 2009 A
S-93
KJ-X50 Hz SERIES, WSM ENGINE
Clearance between Piston Ring and Groove1. Clean the rings and the ring grooves, and install each ring in its
groove.2. Measure the clearance between the ring and the groove with a
feeler gauge or depth gauge.3. If the clearance exceeds the allowable limit, replace the piston
ring.4. If the clearance still exceeds the allowable limit with new ring,
replace the piston.
[D1703-E/E2, V2203-E/E2, F2803-E/E2]
[V3300-E2BG]
W1032489
Second ringFactory spec. 0.0930 to 0.120 mm
0.00367 to 0.00472 in.
Allowable limit 0.20 mm0.0079 in.
Oil ringFactory spec. 0.020 to 0.052 mm
0.00079 to 0.0020 in.
Allowable limit 0.15 mm0.0059 in.
Top ring : a
Factory spec.
More than 0.2 mm 0.008 in.
Second ring 0.0930 to 0.120 mm0.00367 to 0.00472 in.
Oil ring 0.020 to 0.060 mm0.00079 to 0.0023 in.
Second ringAllowable limit
0.20 mm0.0079 in.
Oil ring 0.15 mm0.0059 in.
(A) Top Ring (Key Stone Type) (B) Second ring, Oil Ring
KiSC issued 09, 2009 A
S-94
KJ-X50 Hz SERIES, WSM ENGINE
(4) CrankshaftSide Clearance of Crankshaft1. Set a dial indicator with its tip on the end of the crankshaft.2. Measure the side clearance by moving the crankshaft to the front
and rear.3. If the measurement exceeds the allowable limit, replace the
thrust bearings.4. If the same size bearing is useless because of the crankshaft
journal wear, replace it with an oversize one referring to the tableand figure.
[D1703, V2203] (Serial No. : below 3R9999)[F2803]
[D1703, V2203] (Serial No. : above 3S0001)[V3300-E2BG]
(Reference)[D1703-E/E2, V2203-E/E2, F2803-E/E2]• Oversize dimensions of crankshaft journal
[V3300-E2BG]• Oversize dimensions of crankshaft journal.
W1032880
Crankshaft side clearance
Factory spec. 0.15 to 0.35 mm0.0059 to 0.013 in.
Allowable limit 0.5 mm0.02 in.
Crankshaft side clearance
Factory spec. 0.15 to 0.31 mm0.0059 to 0.012 in.
Allowable limit 0.5 mm0.02 in.
Oversize 0.2 mm0.008 in.
0.4 mm0.02 in.
Dimension A 54.50 to 54.70 mm2.146 to 2.153 in.
54.60 to 54.80 mm2.150 to 2.157 in.
Dimension B 26.20 to 26.25 mm1.032 to 1.033 in.
26.40 to 26.45 mm1.040 to 1.041 in.
Dimension C 2.8 to 3.2 mm radius0.11 to 0.12 in. radius
2.8 to 3.2 mm radius0.11 to 0.12 in. radius
(0.4 S)The crankshaft journal must be fine-finished to higher than ∇∇∇∇.
Oversize 0.2 mm0.008 in.
0.4 mm0.02 in.
Dimension A 169.10 to 169.15 mm6.6575 to 6.6594 in.
169.20 to 169.25 mm6.6615 to 6.6633 in.
Dimension B 29.20 to 29.25 mm1.150 to 1.151 in.
29.40 to 29.45 mm1.158 to 1.159 in.
Dimension C 2.8 to 3.2 mm radius0.11 to 0.12 in. radius
2.8 to 3.2 mm radius0.11 to 0.12 in. radius
(0.8 S)The crankshaft journal must be fine-finished to higher than ∇∇∇∇.
[A] D1703-E/E2V2203-E/E2F2803-E/E2
[B] V3300-E2BG
KiSC issued 09, 2009 A
S-95
KJ-X50 Hz SERIES, WSM ENGINE
Crankshaft Alignment1. Support the crankshaft with V blocks on the surface plate at both
end journals.2. Set a dial indicator with its tip on the intermediate journal.3. Measure the crankshaft alignment.4. If the measurement exceeds the allowable limit, replace the
crankshaft.
W1033001
Oil Clearance between Crankpin and Crankpin Bearing (To beContinued)1. Clean the crankpin and crankpin bearing.2. Put a strip of plastigage on the center of the crankpin.3. Install the connecting rod cap and tighten the connecting rod
screws to the specified torque, and remove the cap again.4. Measure the amount of the flattening with the scale, and get the
oil clearance.5. If the oil clearance exceeds the allowable limit, replace the
crankpin bearing.6. If the same size bearing is useless because of the crankpin wear,
replace it with an undersize one referring to the table and figure.NOTE
• Never insert the plastigage into the crankpin oil hole.• Be sure not to move the crankshaft while the connecting rod
screws are tightened.
[D1703-E/E2, V2203-E/E2, F2803-E/E2]
(Reference)• Undersize dimensions of crankpin
W1033106
Crankshaft alignment Allowable limit 0.02 mm0.0008 in.
Oil clearance between crankpin and crankpin bearing
Factory spec. 0.025 to 0.087 mm0.00099 to 0.0034 in.
Allowable limit 0.20 mm0.0079 in.
Crankpin O.D. Factory spec. 46.959 to 46.975 mm1.8488 to 1.8494 in.
Crankpin bearing I.D. Factory spec. 47.000 to 47.046 mm1.8504 to 1.8522 in.
Undersize 0.2 mm0.008 in.
0.4 mm0.02 in.
Dimension A 3.3 to 3.7 mm radius0.13 to 0.14 in. radius
3.3 to 3.7 mm radius0.13 to 0.14 in. radius
*Dimension B 1.0 to 1.5 mm relief0.040 to 0.059 in. relief
1.0 to 1.5 mm relief0.040 to 0.059 in. relief
Dimension C 46.759 to 46.775 mm dia.1.8409 to 1.8415 in. dia.
46.559 to 46.575 mm dia.1.8331 to 1.8336 in. dia.
(0.4 S)The crankpin must be fine-finished to higher than ∇∇∇∇.*Holes to be de-burred and edges rounded with 1.0 to 1.5 mm (0.040 to 0.059 in.) relief.
KiSC issued 09, 2009 A
S-96
KJ-X50 Hz SERIES, WSM ENGINE
Oil Clearance between Crankpin and Crankpin Bearing(Continued)
[V3300-E2BG]
IMPORTANT• STD size crankpin bearing.
To replace it with a specific STD service part, make sure thecrankpin bearing has the same ID color as the connectingrod.
(Reference)• Undersize dimensions of crankshaft journal
W1106119
Crankpin O.D. Factory spec. 52.977 to 52.990 mm2.0857 to 2.0862 in.
Oil clearance between crankpin and crankpin bearing
Factory spec. 0.018 to 0.051 mm0.00071 to 0.0020 in.
Allowable limit 0.20 mm0.0079 in.
ID Color
Connecting rod Crankpin bearing
Large-end in. dia. Class Part code Center wall thick
Blue 56.010 to 56.020 mm2.2052 to 2.2055 in. L 1C020-22311 1.496 to 1.501 mm
0.05890 to 0.05909 in.
Yellow or
without color
56.000 to 56.010 mm2.2048 to 2.2051 in. S 1C020-22331 1.491 to 1.496 mm
0.05870 to 0.05889 in.
Undersize 0.2 mm0.008 in.
0.4 mm0.02 in.
Dimension A 2.8 to 3.2 mm radius0.11 to 0.12 in. radius
2.8 to 3.2 mm radius0.11 to 0.12 in. radius
*Dimension B 1.0 to 1.5 mm relief0.040 to 0.059 in. relief
1.0 to 1.5 mm relief0.040 to 0.059 in. relief
Dimension C 52.777 to 52.790 mm dia.2.0779 to 2.0783 in. dia.
52.577 to 52.590 mm dia.2.0700 to 2.0704 in. dia.
(0.8 S)The crankshaft journal must be fine-finished to higher than ∇∇∇∇.*Holes to be de-burred and edges rounded with 1.0 to 1.5 mm (0.040 to 0.059 in.) relief.
(1) ID Color(2) Crankpin Bearing
(3) Center Wall Thick
KiSC issued 09, 2009 A
S-97
KJ-X50 Hz SERIES, WSM ENGINE
Oil Clearance between Crankshaft Journal and CrankshaftBearing 1 (D1703-E/E2, V2203-E/E2, F2803-E/E2)1. Measure the O.D. of the crankshaft journal with an outside
micrometer.2. Measure the I.D. of the crankshaft bearing 1 with an inside
micrometer, and calculate oil clearance.3. If the clearance exceeds the allowable limit, replace the
crankshaft bearing 1.4. If the same size bearing is useless because of the crankshaft
journal wear, replace it with an undersize one referring to thetable and figure.
[D1703, V2203] (Serial No. : above 3S0001)
[D1703, V2203] (Serial No. : below 3R9999)[F2803]
(Reference)• Undersize dimensions of crankshaft journal
W1033717
Oil clearance between crankshaft journal and crankshaft bearing 1
Factory spec. 0.0400 to 0.118 mm0.00158 to 0.00464 in.
Allowable limit 0.20 mm0.0079 in.
Crankshaft journal O.D. Factory spec. 59.921 to 59.940 mm2.3591 to 2.3598 in.
Crankshaft bearing 1 I.D. Factory spec. 59.980 to 60.039 mm
2.3615 to 2.3637 in.
Crankshaft journal O.D. Factory spec. 51.921 to 51.940 mm2.0442 to 2.0448 in.
Crankshaft bearing 1 I.D. Factory spec. 51.980 to 52.039 mm
2.0465 to 2.0487 in.
Undersize 0.2 mm0.008 in.
0.4 mm0.02 in.
Dimension A 2.8 to 3.2 mm radius0.11 to 0.12 in. radius
2.8 to 3.2 mm radius0.11 to 0.12 in. radius
*Dimension B 1.0 to 1.5 mm relief0.040 to 0.059 in. relief
1.0 to 1.5 mm relief0.040 to 0.059 in. relief
Dimension C
D1703, V2203(Serial No. : above 3S0001)
59.721 to 59.740 mm dia.
2.3513 to 2.3519 in. dia.
59.521 to 59.540 mm dia.
2.3434 to 2.3440 in. dia.
D1703, V2203 (Serial No. : below 3R9999) / F2803
51.721 to 51.740 mm dia.
2.0363 to 2.0370 in. dia.
51.521 to 51.540 mm dia.
2.0284 to 2.0291 in. dia.
(0.4 S)The crankshaft journal must be fine-finished to higher than ∇∇∇∇.*Holes to be de-burred and edges rounded with 1.0 to 1.5 mm (0.040 to 0.059 in.) relief.
KiSC issued 09, 2009 A
S-98
KJ-X50 Hz SERIES, WSM ENGINE
Replacing Crankshaft Bearing 1 (D1703-E/E2, V2203-E/E2,F2803-E/E2)(When removing)1. Press out the used crankshaft bearing 1 using a crankshaft
bearing 1 replacing tool. (See page “SPECIAL TOOLS”.)(When installing)1. Clean a new crankshaft bearing 1 and crankshaft journal bore,
and apply engine oil to them.2. Using a crankshaft bearing 1 replacing tool, press in a new
bearing 1 (2) so that its seam (1) directs toward the exhaustmanifold side. (See figure.)
W1033946
Dimension (A) Factory spec. 4.20 to 4.50 mm0.166 to 0.177 in.
(1) Seam(2) Crankshaft Bearing 1
(3) Cylinder Block(A) Dimension
KiSC issued 09, 2009 A
S-99
KJ-X50 Hz SERIES, WSM ENGINE
Oil Clearance between Crankshaft Journal and CrankshaftBearing 2 (D1703-E/E2, V2203-E/E2, F2803-E/E2)1. Put a strip of plastigage on the center of the journal.2. Install the bearing case and tighten the baring case screws 1 to
the specified torque, and remove the bearing case again.3. Measure the amount of the flattening with the scale and get the
oil clearance.4. If the clearance exceeds the allowable limit, replace the
crankshaft bearing 2.5. If the same size bearing is useless because of the crankshaft
journal wear, replace it with an undersize one referring to thetable and figure.NOTE
• Be sure not to move the crankshaft while the bearing casescrews are tightened.
[D1703, V2203] (Serial No. : above 3S0001)
[D1703, V2203] (Serial No. : below 3R9999)[F2803]
(Reference)• Undersize dimensions of crankshaft journal
W1083821
Oil clearance between crankshaft and crankshaft bearing 2
Factory spec. 0.0400 to 0.104 mm0.00158 to 0.00409 in.
Allowable limit 0.20 mm0.0079 in.
Crankshaft journal O.D. Factory spec. 59.921 to 59.940 mm2.3591 to 2.3598 in.
Crankshaft bearing 2 I.D. Factory spec. 59.980 to 60.025 mm
2.3615 to 2.3631 in.
Crankshaft journal O.D. Factory spec. 51.921 to 51.940 mm2.0442 to 2.0448 in.
Crankshaft bearing 2 I.D. Factory spec. 51.980 to 52.025 mm
2.0465 to 2.0482 in.
Undersize 0.2 mm0.008 in.
0.4 mm0.02 in.
Dimension A 2.8 to 3.2 mm radius0.11 to 0.12 in. radius
2.8 to 3.2 mm radius0.11 to 0.12 in. radius
*Dimension B 1.0 to 1.5 mm relief0.040 to 0.059 in. relief
1.0 to 1.5 mm relief0.040 to 0.059 in. relief
Dimension C
D1703, V2203(Serial No. : above 3S0001)
59.721 to 59.740 mm dia.
2.3513 to 2.3519 in. dia.
59.521 to 59.540 mm dia.
2.3434 to 2.3440 in. dia.
D1703, V2203 (Serial No. : below 3R9999) / F2803
51.721 to 51.740 mm dia.
2.0363 to 2.0370 in. dia.
51.521 to 51.540 mm dia.
2.0284 to 2.0291 in. dia.
(0.4 S)The crankshaft journal must be fine-finished to higher than ∇∇∇∇.*Holes to be de-burred and edges rounded with 1.0 to 1.5 mm (0.040 to 0.059 in.) relief.
KiSC issued 09, 2009 A
S-100
KJ-X50 Hz SERIES, WSM ENGINE
Oil Clearance between Crankshaft Journal and CrankshaftBearing (V3300-E2BG)1. Clean the crankshaft journal and crankshaft bearing.2. Put a strip of plastigage gauge (Code No.: 07909-30241) on the
center of the journal.IMPORTANT
• Never insert the press gauge into the oil hole of the journal.3. Install the main bearing case and tighten the screws to the
specified torque, and remove the cases again.4. Measure the amount of the flattening with the scale and get the
oil clearance.5. If the clearance exceeds the allowable limit, replace the
crankshaft bearing.
(Reference)• Undersize crankshaft bearing
• Undersize dimensions of crankshaft journal
W1110110
Crankshaft journal O.D. Factory spec. 74.977 to 74.990 mm2.9519 to 2.9523 in.
Oil clearance between crankshaft journal and crankshaft bearing
Factory spec. 0.018 to 0.062 mm0.00071 to 0.0024 in.
Allowable limit 0.20 mm0.0079 in.
Undersize Bearing Code Number Marking
0.2 mm0.008 in. Crankshaft bearing 02 1C020-23910 020 US
0.4 mm0.02 in. Crankshaft bearing 04 1C020-23920 040 US
Undersize
Dimension
0.2 mm0.008 in.
0.4 mm0.02 in.
A 2.8 to 3.2 mm radius0.11 to 0.12 in. radius
2.8 to 3.2 mm radius0.11 to 0.12 in. radius
*B 1.0 to 1.5 mm relief0.040 to 0.059 in. relief
1.0 to 1.5 mm relief0.040 to 0.059 in. relief
C 74.777 to 74.790 mm dia.2.9440 to 2.9444 in. dia.
74.577 to 74.590 mm dia.2.9361 to 2.9366 in. dia.
(0.8 S)The crankshaft journal must be fine-finished to higher than ∇∇∇∇.*Holes to be de-burred and edges rounded with 1.0 to 1.5 mm (0.040 to 0.059 in.) relief.
KiSC issued 09, 2009 A
S-101
KJ-X50 Hz SERIES, WSM ENGINE
Replacing Crankshaft Sleeve1. Remove the used crankshaft sleeve (3).2. Set the sleeve guide (2) to the crankshaft (5).3. Set the stopper (1) to the crankshaft (5) as shown in figure.
(D1703, V2203, F2803)4. Heat a new sleeve to a temperature between 150 and 200 °C
(302 and 392 °F), and fix the sleeve to the crankshaft (5) asshown in figure.
5. Press fit the sleeve using the auxiliary socket for pushing (4).(Refer to “SPECIAL TOOLS”.)NOTE
• Mount the sleeve with its largely chamfered surface facingoutward.
• Should heating is not enough, a sleeve might stop halfway,so careful.
W1033503
(1) Stopper(2) Sleeve Guide(3) Crankshaft Sleeve(4) Auxiliary Socket for Pushing(5) Crankshaft
[A] D1703-E/E2V2203-E/E2F2803-E/E2
[B] V3300-E2BG
KiSC issued 09, 2009 A
S-102
KJ-X50 Hz SERIES, WSM ENGINE
(5) CylinderCylinder Wear1. Measure the I.D. of the cylinder at the six positions (see figure)
with a cylinder gauge to find the maximum and minimum I.D.’s.2. Get the difference (Maximum wear) between the maximum and
the minimum I.D.’s.3. If the wear exceeds the allowable limit, bore and hone to the
oversize dimension. (Refer to “Correcting Cylinder”.)4. Visually check the cylinder wall for scratches. If deep scratches
are found, the cylinder should be bored. (Refer to “CorrectingCylinder”.)
W1034389
Correcting Cylinder (Oversize)1. When the cylinder is worn beyond the allowable limit, bore and
hone it to the specified dimension.
2. Replace the piston and piston rings with oversize ones.Oversize : 0.50 mm (0.020 in.)NOTE
• When the oversize cylinder is worn beyond the allowablelimit, replace the cylinder block with a new one.
W1034448
Cylinder I.D.
Factory spec.
D1703-E/E2V2203-E/E2F2803-E/E2
87.000 to 87.022 mm3.4252 to 3.4260 in.
V3300-E2BG 98.000 to 98.022 mm3.8583 to 3.8591 in.
Allowable limit
D1703-E/E2V2203-E/E2F2803-E/E2
87.150 mm3.4311 in.
V3300-E2BG 98.150 mm3.8642 in.
Variance among cylinder Allowable limit 10 % or less
(A) Top(B) Middle(C) Bottom (Skirt)
(a) Right-angled to Piston Pin(b) Piston Pin Direction
Oversize cylinder I.D.
Factory spec.
D1703-E/E2V2203-E/E2F2803-E/E2
87.500 to 87.522 mm3.4449 to 3.4457 in.
V3300-E2BG 98.500 to 98.522 mm3.8780 to 3.8788 in.
Allowable limit
D1703-E/E2V2203-E/E2F2803-E/E2
87.650 mm3.4508 in.
V3300-E2BG 98.650 mm3.8839 in.
FinishingHone to 2.2 to 3.0 μmRz
∇∇∇(0.000087 to 0.000118 in.R max.)
(1) Cylinder I.D. (Before Correction) (2) Cylinder I.D. (Oversize)
KiSC issued 09, 2009 A
S-103
KJ-X50 Hz SERIES, WSM ENGINE
(6) Oil Pump1) D1703-E/E2, V2203-E/E2, F2803-E/E2
Rotor Lobe Clearance1. Measure the clearance between lobes of the inner rotor and the
outer rotor with a feeler gauge.2. Measure the clearance between the outer rotor and the pump
body with a feeler gauge.3. If the clearance exceeds the factory specifications, replace the oil
pump rotor assembly.
W1035296
Clearance between Rotor and Cover1. Put a strip of plastigage onto the rotor face with grease.2. Install the cover and tighten the screws.3. Remove the cover carefully, and measure the width of the press
gauge with a sheet of gauge.4. If the clearance exceeds the factory specifications, replace oil
pump rotor assembly.
W1035444
2) V3300-E2BGRotor Lobe Clearance1. Measure the clearance between lobes of the inner rotor and the
outer rotor with a feeler gauge.2. If the clearance exceeds the allowable limit, replace the oil pump
rotor assembly.
W1071254
Clearance between inner rotor and outer rotor
Factory spec. 0.030 to 0.14 mm0.0012 to 0.0055 in.
Allowable limit 0.2 mm0.008 in.
Clearance between outer rotor and pump body
Factory spec. 0.11 to 0.19 mm0.0044 to 0.0074 in.
Allowable limit 0.25 mm0.0098 in.
Clearance between inner rotor and cover
Factory spec. 0.105 to 0.150 mm0.00414 to 0.00590 in.
Allowable limit 0.2 mm0.008 in.
Clearance between inner rotor and outer rotor
Factory spec. 0.040 to 0.16 mm0.0016 to 0.0062 in.
Allowable limit 0.3 mm0.01 in.
KiSC issued 09, 2009 A
S-104
KJ-X50 Hz SERIES, WSM ENGINE
Clearance between Outer Rotor and Pump Body1. Measure the clearance between the outer rotor and the pump
body with a feeler gauge.2. If the clearance exceeds the allowable limit, replace the oil pump
rotor assembly.
W1071334
Clearance between Rotor and Cover1. Put a strip of plastigage onto the rotor face with grease.2. Install the cover and tighten the screws with the specified torque.3. Remove the cover carefully, and measure the amount of the
flattening with the scale and get the clearance.4. If the clearance exceeds the allowable limit, replace oil pump
rotor assembly and the cover.
W1148218
(7) StarterCommutator and Mica1. Check the contact of the commutator for wear, and grind the
commutator with emery paper if it is slightly worn.2. Measure the commutator O.D. with an outside micrometer at
several points.3. If the minimum O.D. is less than the allowable limit, replace the
armature.4. If the difference of the O.D.'s exceeds the allowable limit, correct
the commutator on a lathe to the factory specification.5. Measure the mica undercut.6. If the undercut is less than the allowable limit, correct it with a saw
blade and chamfer the segment edges.
Clearance between outer rotor and pump body
Factory spec. 0.100 to 0.184 mm0.00394 to 0.00724 in.
Allowable limit 0.3 mm0.01 in.
Clearance between rotor and cover
Factory spec. 0.025 to 0.075 mm0.00099 to 0.0029 in.
Allowable limit 0.225 mm0.00886 in.
Commutator O.D.
Factory spec.
D1703-E/E2V2203-E/E2F2803-E/E2
30.0 mm1.18 in.
V3300-E2BG 32.0 mm1.26 in.
Allowable limit
D1703-E/E2V2203-E/E2F2803-E/E2
29.0 mm1.14 in.
V3300-E2BG 31.4 mm1.24 in.
Mica under cut
Factory spec.
D1703-E/E2V2203-E/E2F2803-E/E2
0.45 to 0.75 mm0.018 to 0.029 in.
V3300-E2BG 0.50 mm0.020 in.
Allowable limit 0.20 mm0.0079 in.
(1) Segment(2) Depth of Mica(3) Mica
(a) Correct(b) Incorrect
KiSC issued 09, 2009 A
S-105
KJ-X50 Hz SERIES, WSM ENGINE
W1155802
Brush Wear1. If the contact face of the brush is dirty or dusty, clean it with emery
paper.2. Measure the brush length (A) with vernier caliper.3. If the length is less than the allowable limit, replace the yoke
assembly and brush holder.
W1156360
Brush Holder1. Check the continuity across the brush holder and the holder
support with a circuit tester.2. If it conducts, replace the brush holder.
W1156895
Armature Coil1. Check the continuity across the commutator and armature coil
core with resistance range of circuit tester.2. If it conducts, replace the armature.3. Check the continuity across the segments of the commutator with
resistance range of circuit tester.4. If it dose not conduct, replace the armature.
W1156507
Brush length (A)
Factory spec.
D1703-E/E2V2203-E/E2F2803-E/E2
15.0 mm0.591 in.
V3300-E2BG 18.0 mm0.709 in.
Allowable limit 11.0 mm0.433 in.
KiSC issued 09, 2009 A
S-106
KJ-X50 Hz SERIES, WSM ENGINE
Field Coil1. Check the continuity across the lead (1) and brush (2) with a
circuit tester.2. If it dose not conduct, replace the yoke assembly.3. Check the continuity across the brush (2) and yoke (3) with a
circuit tester.4. If it conducts, replace the yoke assembly.
W1156968
(1) Lead(2) Bush
(3) Yoke
KiSC issued 09, 2009 A
S-107
KJ-X50 Hz SERIES, WSM ENGINE
(8) AlternatorBearing1. Check the bearing for smooth rotation.2. If it does not rotate smoothly, replace it.
W1019790
Stator1. Measure the resistance across each lead of the stator coil with
resistance range of circuit tester.2. If the measurement is not within factory specification, replace it.3. Check the continuity across each stator coil lead and core with
resistance range of circuit tester.4. If infinity is not indicated, replace it.
W1019964
Rotor1. Measure the resistance across the slip rings.2. If the resistance is not the factory specification, replace it.3. Check the continuity across the slip ring and core with resistance
range of circuit tester.4. If infinity is not indicated, replace it.
W1020094
Slip Ring1. Check the slip ring for score.2. If scored, correct with an emery paper or on a lathe.3. Measure the O.D. of slip ring with vernier calipers.4. If the measurement is less than the allowable limit, replace it.
W1020208
Resistance Factory spec. Less than 1.0 Ω
Resistance Factory spec. 2.9 Ω
Slip ring O.D.
D1703-E/E2V2203-E/E2F2803-E/E2
Factory spec.
14.4 mm0.567 in.
Allowable limit
14.0 mm0.551 in.
V3300-E2BG
Factory spec.
22.7 mm0.894 in.
Allowable limit
22.1 mm0.870 in.
KiSC issued 09, 2009 A
S-108
KJ-X50 Hz SERIES, WSM ENGINE
Brush Wear1. Measure the brush length with vernier calipers.2. If the measurement is less than allowable limit, replace it.3. Make sure that the brush moves smoothly.4. If the brush is defective, replace it.
W1020329
Rectifier1. Check the continuity across each diode of rectifier with resistance
range of circuit tester.2. The rectifier is normal if the diode in the rectifier conducts in one
direction and does not conduct in the reverse direction.W1020452
IC Regulator1. Check the continuity across the B terminal (2) and the F terminal
(1) of IC regulator with resistance range of circuit tester.2. The IC regulator is normal if the conducts in one direction and
does not conduct in the reverse direction.
W1020645
Brush length
D1703-E/E2V2203-E/E2F2803-E/E2
Factory spec.
10.5 mm0.413 in.
Allowable limit
8.4 mm0.33 in.
V3300-E2BG
Factory spec.
18.5 mm0.728 in.
Allowable limit
5.0 mm0.20 in.
(1) F Terminal (2) B Terminal
KiSC issued 09, 2009 A
2 GENERATOR
KiSC issued 09, 2009 A
CONTENTS
MECHANISM
1. GENERATING METHOD.............................................................................. 2-M1[1] GENERAL PRINCIPLE........................................................................... 2-M1[2] PRINCIPLE OF OPERATION................................................................ 2-M2
2. STRUCTURE ................................................................................................. 2-M3[1] STATOR................................................................................................... 2-M3[2] EXCITER.................................................................................................. 2-M4[3] ROTOR .................................................................................................... 2-M4[4] AVR (Automatic Voltage Regulator)......................................................... 2-M4
3. AUTOMATIC VOLTAGE REGULATOR (AVR) ........................................... 2-M5[1] AVR CONNECTION DIAGRAM............................................................. 2-M5[2] GENERAL................................................................................................ 2-M6[3] CONSTANT-VOLTAGE CHARACTERISTICS ....................................... 2-M6[4] V/Hz CHARACTERISTICS ..................................................................... 2-M6[5] ADJUSTMENT......................................................................................... 2-M6[6] VOLTAGE ADJUSTMENT (VR1)........................................................... 2-M6[7] STABILITY ADJUSTMENT (VR2).......................................................... 2-M7[8] VOLT PER HERTZ ADJUSTER ........................................................... 2-M7[9] INITIAL EXCITATION ............................................................................. 2-M7
4. STATOR COIL WINDING ............................................................................ 2-M8[1] STATOR COIL CONNECTION WAYS AND OUTPUT TERMINAL
CONNECTION......................................................................................... 2-M85. EMERGENCY RELAY CIRCUIT.................................................................. 2-M9
[1] GENERAL................................................................................................ 2-M9[2] INSTRUCTIONS .................................................................................... 2-M10[3] FLOW CHART ...................................................................................... 2-M11
6. EARTH ......................................................................................................... 2-M127. WIRING DIAGRAM ..................................................................................... 2-M13
[1] GENERATOR DIAGRAM...................................................................... 2-M13[2] ENGINE CIRCUIT DIAGRAM.............................................................. 2-M22
(1) D1703-E/E2, V2203-E/E2, F2803-E/E2........................................... 2-M22(2) V3300-E2BG.................................................................................... 2-M23
KiSC issued 09, 2009 A
2-M1
KJ-X50 Hz SERIES, WSM GENERATOR
1. GENERATING METHOD[1] GENERAL PRINCIPLE
W10346150
When the coil rotates in the field, an alternating electromotive force occurs, although the details of the principle arenot described here.
The KJ-X60 Hz series diesel generators use a brushless rotating field coil system in which the armature coils (1),(6) in the figure are fixes and the field coil rotate to generate an electromotive force.
Direct current from the automatic voltage regulator (AVR) (7) flows through the exciter field coil (5) to generate acurrent in the exciter armature coil (4). Diodes (3) rectify this current to provide the energizing current for poles of thefield coil (2).
In this case, the part, which is same as an armature, including the conductor coil is known as a stator because itis fixed. On the other hand, the field pole is known as a rotor as it rotates.
When the rotor of the P pole rotates n times a minute, the frequency f is as follows.
f = (P / 2) x (n / 60) (Hz) ∴ n = (120 x f) / P min-1(rpm)
P = 4 poles in KJ-X Seriesn = 1500 min-1(rpm)
f = (4 / 2) x (1500 / 60) = 50 (Hz)
Thus the number of rotations is provided by the frequency and the poles number.This number of rotations is known as synchronous speed. Also, generator rotating at this speed is known as a
synchronous generator.The electromotive force generated per single line of magnetic flux is proportional to the value given in the below
formula wherein n is the number of rotor revolutions min-1(rpm), P the number of pole and φ (wb) the number ofmagnetic lines of flux.
e = φ / { (1 / P) x (60 / n)} = (n / 60) x P x φ
If there are two serial conductors, the total electromotive power is shown here.
E = P x (n / 60) x 2 x φ
E : Voltagen : Rotation Speedφ : Field Current
(1) Armature Coil(2) Field Coil(3) Diode(4) Exciter Armature Coil(5) Exciter Field Coil(6) Armature Coil(7) AVR(8) F-(9) F+
(10) Exciter Field Current
KiSC issued 09, 2009 A
2-M2
KJ-X50 Hz SERIES, WSM GENERATOR
[2] PRINCIPLE OF OPERATIONThe AVR is fed by auxiliary winding (4) located in the stator. The winding (4) with shunt characteristic (delivering
a voltage proportional to the generator’s output voltage).When starting the residual magnetism creates a current in the exciter armature (1). This current is rectified by the
rotating diodes (2) and feeds the main field (3).The induced voltage in the auxiliary winding (4) is then used to increase the excitation power via the AVR (6) to the
exciter field (7) to ensure a rapid and smooth build up of output voltage in the main stator winding (5).The voltage sensing for the AVR (6) is taken from the output leads (phase V-W).
W1021040
(1) Exciter Armature Coil(2) Rotating Diodes
(3) Main Field Coil(4) Auxiliary Winding
(5) Main Stator Winding (Armature Coil)
(6) AVR(7) Exciter Field Coil
KiSC issued 09, 2009 A
2-M3
KJ-X50 Hz SERIES, WSM GENERATOR
2. STRUCTURE
[1] STATORThe armature coil (2) is wound around the core slot
(3) where generating AC voltage.Beside the armature coils, the stator is wrapped with
auxiliary winding which function as the AVR powersource.
W1016322
(1) End Cover(2) Stator Core(3) Frame
(4) Exciter Armature Coil(5) Core Rotor(6) Fan
(7) Cover(8) Exciter Field Coil
(9) Bearing(10) Diode Stack
(1) Core(2) Armature Coil
(3) Slot
KiSC issued 09, 2009 A
2-M4
KJ-X50 Hz SERIES, WSM GENERATOR
[2] EXCITERThough composed of a stator and rotor, these parts
differ from the output stator / rotor combination, in thatthe stator has the field winding (F+, F-) and the rotor thearmature winding. A diode and Surge-absorber areconnected to the rotor. The diode converts the ACsupply generated by the armature winding into DC, andsends this DC to the output rotor (field winding).
W1016445
[3] ROTORThe main field coil (3), exciter armature coil (1),
bearing, and cooling fan are all mounted on the sameshaft.
The silicon diode stack and Surge-absorber arelocated exciter armature core. The silicon diode stackrectifies the exciter armature coil output to produce thecurrent which energizes the poles of the field coil,inducing electrical current in the rotor armature coil.
When the current flows in the coil, the temperature ofthe coil increases by joule heat.
The fan (2) cools the coil in order to keep thetemperature down to at least the regulated one.
W1016374
[4] AVR (Automatic Voltage Regulator)AVR works so that the current for field coil comply
with load condition.Functioning is controlled using auxiliary winding and
the voltage detected on the output side (V phase-Wphase).
W1016606
(1) Exciter Armature Coil(2) Cooling Fan
(3) Rotor Field Coil
KiSC issued 09, 2009 A
2-M5
KJ-X50 Hz SERIES, WSM GENERATOR
3. AUTOMATIC VOLTAGE REGULATOR (AVR)[1] AVR CONNECTION DIAGRAM
NOTE• The AVR is optimally adjusted upon shipment from the factory and does not require adjustment under
ordinary circumstances. Do not touch adjustment parts.
W1017183
SYMBOL NAME OF PARTS SYMBOL NAME OF PARTSG GENERATOR EX EXCITERF1 GENERATOR FIELD F2 EXCITER FIELDS SURGE ABSORBER AVR AUTO. VOLT. REGULATORSi SILICON RECTIFIER F FUSE (2A)
KiSC issued 09, 2009 A
2-M6
KJ-X50 Hz SERIES, WSM GENERATOR
[2] GENERALNOTE
• It is hazardous to proceed to any high voltage test on the alternator without having previouslydisconnected all connections to voltage regulator.Damages occurring to AVR in such conditions will not be considered in a warranty claim.
[3] CONSTANT-VOLTAGE CHARACTERISTICSThe output (magnetic field exciting current) is controlled in order to keep the generator terminal voltage nearly at a
constant level even when the load or the frequency fluctuates. In a frequency range below the V/Hz working point(around 90 % of rated frequency for normal operation), however, the V/Hz characteristics are applied.
[4] V/Hz CHARACTERISTICSWhen the frequency drops with the generator voltage
at a constant level, the exciting current increases to getthe generator over-excited. If continuously over-excited,the generator may overheat itself and burn out in theworst case. To cope with this problem, the generator isgiven the V/Hz characteristics, as shown in figure, inwhich the generator voltage drops as the frequencydecreases. When the load is turned on, therefore, thevoltage is suppressed until the specified frequency isreached again. This also helps improve the drive’s loadhandling capacity.
W1014019
[5] ADJUSTMENTThe AVR (Automatic Voltage Regulator) has been factory-adjusted to optimum settings. In case of readjustment,
pay enough attention to the voltage, frequency, load and other factors.
[6] VOLTAGE ADJUSTMENT (VR1)To adjust the voltage, slowly turn the VOLT. ADJ. (VR1) control. Clockwise turn increases the voltage, and
counterclockwise turn decreases it. When an external voltage regulator (HT) is used, set its control to the centerposition first and then turn the VR1 control to the rated voltage.
(A) Terminal Voltage (B) Frequency
KiSC issued 09, 2009 A
2-M7
KJ-X50 Hz SERIES, WSM GENERATOR
[7] STABILITY ADJUSTMENT (VR2)Use the STAB. ADJ. (VR2) control to adjust the voltage stability. Clockwise turn increases the damping factor, and
counterclockwise turn decreases it.The higher the damping factor is, the slowly the response is, but the better the stability is. The lower the damping
factor, on the other hand, the higher the response but the worse the stability.
[8] VOLT PER HERTZ ADJUSTERVolt per hertz adjuster is optimally adjusted upon shipment from the factory and does not require adjustment under
ordinary circumstance.
[9] INITIAL EXCITATIONA 12 V or 24 V battery is used for initial excitation. Stop the generator, disconnect the AVR cable, and connect the
battery’s positive and negative cables to the generator’s F+ and F– terminals, respectively, for just 2 or 3 seconds.(Connect and run the generator.)
If the residual voltage is not yet high enough, take the following steps to obtain higher one. Add a 25 W / 1 kΩ orso variable resistor in series with the generator’s F+ and F- terminals. Make a short-circuit with the variable resistorto give initial excitation. Then gradually increase the resistance and disconnect the variable resistor.
KiSC issued 09, 2009 A
2-M8
KJ-X50 Hz SERIES, WSM GENERATOR
4. STATOR COIL WINDING[1] STATOR COIL CONNECTION WAYS AND OUTPUT TERMINAL
CONNECTION
W1022919
Connection code Voltage (V) Factory connectionThree phase
AVR terminals : E3-200 (V-W)
Three phase
AVR terminals : E3-200 (CV-CW)
Single phase
AVR terminals : E3-200 (U-V)
KiSC issued 09, 2009 A
2-M9
KJ-X50 Hz SERIES, WSM GENERATOR
5. EMERGENCY RELAY CIRCUIT[1] GENERAL
This is an automatic engine stopping device. Thisdevice senses any abnormal situation on engine andrelated parts, such as oil pressure, or water temperature,occurring during engine operation, and activates the stopsolenoid to cut off fuel to the fuel injection pump and stopthe engine.
This relay has two independent timer functions, astart relay and a stop relay.
The start relay does not activate this relay for aspecified time period after the engine has started.
IMPORTANT• When this device stops the engine, it may be that
some minor damages to the engine has occurred.To limit engine damage as mush as possible,please do not make the faulty assumption that itis a perfectly safety device.
W1014496
(1) Emergency Relay
KiSC issued 09, 2009 A
2-M10
KJ-X50 Hz SERIES, WSM GENERATOR
[2] INSTRUCTIONS
W1014579
1. Circuit configurationAs shown in the block diagram above, Emergency Relay-1 (EG-1) comprises a delay timer for preventing the startof fault detection till the rise of oil pressure: a sensor input circuit for checking the oil pressure and the watertemperature: a drive timer for energizing a stop solenoid (11) for a given time period in case of a fault input from asensor: a drive circuit for a relay: and a relay for energizing the stop solenoid (11).
2. Details of the circuit - Delay timer circuit
Sets the delay time between the disengagement of the starter and the start of sensing. The timer operates onvoltage from terminal 50 of the key switch (1).
- Sensor input circuit (9)Monitors the oil switch (4) and the water temperature switch (3). When either of these switches is grounded forabout 4 ms or more, the circuit will decide that sensor trouble has occurred, and provide output to the drive timer.
- Drive timer circuitSets the time for which to operate the stop solenoid (11). Upon receipt of an output from the sensor input circuit(9), the timer will start to operate.
- Drive circuit (7)Drives the relay circuit (8) for a given delay time upon receipt of an output from the drive timer.Consists of a power transistor, and a diode to remove surge volts from the relay.
- Relay circuit (8)Provides output to the stop solenoid (11) through a power relay. A varistor is incorporated to prevent surgevoltage that would be otherwise generated when current to the stop solenoid (11) is cut off.
3. Operating principle EG-1 controls so that:- While an attempt was made to start the engine with the key switch (1) in the start position (50), the oil switch (4)
and water temperature switch (3) do not operate for fault detection.- When the key switch (1) is returned to the ON position (AC), from the position mentioned in step above, a state
will occur where fault detection is possible after an elapse of 9±3 seconds (at starter starting voltage and 20°C(68°F)).
- When the key switch (1) is turned to OFF after the start of the engine, or the water temperature switch (3) or oilswitch (4) detects a fault, the stop solenoid (11) will be energized for 10±3 seconds (at 12 V and 20°C (68°F)),and then disenergized.
(1) Key Switch (2) Battery (12 V) (3) Water Temperature Switch(4) Oil Switch(5) Emergency Relay
(6) Timer Circuit (Start Delay Circuit) (7) Drive Circuit(8) Relay Circuit
(9) Sensor Input Circuit(10) Timer Circuit (Stop Relay Circuit)(11) Stop Solenoid
KiSC issued 09, 2009 A
2-M11
KJ-X50 Hz SERIES, WSM GENERATOR
[3] FLOW CHART
KiSC issued 09, 2009 A
2-M12
KJ-X50 Hz SERIES, WSM GENERATOR
6. EARTH NOTE• To avoid electric shock, connect a grounding
cable to the ground terminal and ground it asshown in the figure. Use a 3 mm2 or larger coppergrounding cable whose grounding resistance isbelow 10Ω.
Ground the generator as much as possible.The end user, equipment owner or operator must
contact his local, state, county or municipal electric codedepartment to determine the approved generatorgrounding method to be used in his application orlocation.
Recommendations in the NEC, NFPA and OSHAregulations must be followed to assure compliance andsafe operation.
A grounding lug is provided on the KUBOTAgenerator frame for earth grounding depending on local,state, national or OSHA requirements.
One possible connection method for construction siteuse is as follows :
W1015027
(1) Generator Ground Terminal(2) #6 AWG Flexible Copper Ground connection(3) Metal Ground rod or Building Cold Water Pipe system Per
N.E.C. Cord
KiSC issued 09, 2009 A
KJ-S130VX (110 / 220 V, 120 / 240 V), KJ-S170FX (110 / 200 V, 120 / 240 V)
[1] GENERATOR DIAGRAM
2-M13
KJ-X50 HZ SERIES, WSM GENERATOR
7. WIRING DIAGRAM
3EJADABGP001A
KJ-S170FX-50KJ-S130VX-50KJ-S170FX-50KJ-S130VX-50
17
5012.51712.5
70.952.177.356.8
KiSC issued 09, 2009 A
KJ-T130DX (127 / 220 V), KJ-T180VX (127 / 220 V), KJ-T230FX (127 / 220 V)
2-M14
KJ-X50 HZ SERIES, WSM GENERATOR
3EJADABGP002A
KJ-T230FX-50KJ-T180VX-50KJ-T130DX-50
2318 5012.5
60.447.232.8
KiSC issued 09, 2009 A
KJ-T130DX (220 / 380 V), KJ-T180VX (220 / 380 V), KJ-T230FX (220 / 380 V)
2-M15
KJ-X50 HZ SERIES, WSM GENERATOR
3EJADABGP003A
KJ-T230FX-50KJ-T180VX-50KJ-T130DX-50
2318 5012.5
34.927.319.0
KiSC issued 09, 2009 A
KJ-T130DX (240 / 415 V), KJ-T180VX (240 / 415 V), KJ-T230FX (240 / 415 V)
2-M16
KJ-X50 HZ SERIES, WSM GENERATOR
3EJADABGP004A
KJ-T230FX-50KJ-T180VX-50KJ-T130DX-50
2318 50 240/415
12.5
32.025.017.4
KiSC issued 09, 2009 A
KJ-S130VX-AUS (240 V), KJ-S170FX-AUS (240 V)
2-M17
KJ-X50 HZ SERIES, WSM GENERATOR
3EJADABGP005A
1) Marked tube Nos. indicated as circled numbers.2) Cable color indicated as alphabet inside boxes.3) MLFC5.5 require vinyl cap U : Red, V : White, W : Blue, O : Black4) Unspecified lines are for MLFC 1.25.
RWL
REDWHITEBLUE
BYG
BLACKYELLOWGREEN
V3 U4 V4 U5 V5U2 V2 U3
A N
F
A N
F
A N
F
A N
F
A N
F
A N
F
A N
F
A N
F
U20
U30
U40
U50
V20
U21
V21
U31
V31
U41
V41
U51
V51
V30
V40
V50
KiSC issued 09, 2009 A
KJ-T130DX-AUS (240 / 415 V), KJ-T180VX-AUS (240 / 415 V), KJ-T230FX-AUS (240 / 415 V),
2-M18
KJ-X50 HZ SERIES, WSM GENERATOR
3EJADABGP006A
1) Marked tube Nos. indicated as circled numbers.2) Cable color indicated as alphabet inside boxes.3) MLFC5.5 require vinyl cap U : Red, V : White, W : Blue, O : Black4) Unspecified lines are for MLFC 1.25
Circuit Breaker (NFB) Capacity KJ-T130DX-AUS ...... 20A KJ-T180VX-AUS ...... 30A KJ-T230FX-AUS ...... 40A
0 0 U1 V1 W1U V W
U
CU
V
CV
W
CW
0
0
A N
F
A N
F
A N
F
A N
F
A N
F
A N
FNL1
L2
L3
E
RWL
REDWHITEBLUE
BYG
BLACKYELLOWGREENKJ-T230FX-AUS-50
KJ-T180VX-AUS-50KJ-T130DX-AUS-50
2318 50 240/415
12.5
32.025.017.4
03
05
04
U12
V12
W12
KiSC issued 09, 2009 A
KJ-T300 (380 V)
2-M19
KJ-X50 HZ SERIES, WSM GENERATOR
3EJADABGP007A
007
E3
006
200
CU
F+ F-
Aux.winding
E3WBR R L
200 7 6V Y GY OR
F+4 3 F-
U
T1
T7
T2
T10
T4
T5
T8
T3
T9
T11
T6
T12
CVV
WCWOO
Ulk
GRAYRED GYR
VL
VIOLETBLUE ORANGE
WHITEWOR
Code
4
BRCode
7
E3200
6
3
Wiring colorBROWN
3
12
VR
F+F-
FUSE
Wiring colorYELLOWY
LKCT
E
OFF
OFF
LK
k l
57 3 1
S
R
T
7 35 1
T-R
S-T
R-S
OFF
OFF
AS 68 4 2 VS 8 46 2
NFB
V
W
O
Wiring of the Engine Circuit.To Terminals
Wiring of the Engine Circuit.To Terminals
PLF
AV R
[ G E N E R AT O R ] [ C O N T R O L PA N E L ]
VA
KiSC issued 09, 2009 A
KJ-S240-AUS (240 V)
2-M20
KJ-X50 HZ SERIES, WSM GENERATOR
Wiring of the Engine Circuit to Terminals
Wiring of the Engine Circuit, to Terminals
Function
Neutral
Earth
Active
Wiring color
Light Blue
Green Yellow
BROWN
Code
LB
GY
BR
E
V
UFUSE
VR
3
12
200
E3
006
7
6007
OR
67E3
L GYBR WYVR
F-3F+4200
E3
200
3
4
F+
F-
Wiring of the Engine Circuit to fuse 10A
9897531
642
NFB
N
CTLK
lk
CTLK
lk
U
V
F-F+
Aux.winding
V1U1
V2U2
VN
U
AV R
[ G E N E R AT O R ] [ C O N T R O L PA N E L ]
PLVFA
9Y0210183ELT001US
KiSC issued 09, 2009 A
KJ-T300-AUS (240 / 415 V)
2-M21
KJ-X50 HZ SERIES, WSM GENERATOR
9Y0210183ELT002US
[ G E N E R AT O R ] [ C O N T R O L PA N E L ]
AV R
LB
3331
3432
U
V
W
23211311AS
OFF
N24221412
RELAYTHERMAL
Wiring of the Engine Circuit to fuse 10A
97986 4 2
5 3 1
l
L
k
KCT
O
W
E
V
U
246OFF
VS
T-R
S-T
8
135
NFB
R-S
OFF
l
LCT
l
L
k
K
k
K
7
VR
21
3
CT
O
W
CW
V
U
CU
CV
O
Wiring of the Engine Circuit
T6
T12
T11
T9
T3
T8
T5
T10
T4
T2
T7
T1
4
200
4
F+
3
200
F-
007
006E3
6
7
E3
3 F-47 6 F+
WORGYYVL
200E3
BR R
Function
Neutral
Earth
Active
Wiring color
Light Blue
Green Yellow
BROWN
Code
LB
GY
BR
Wiring of the Engine Circuit, To Terminals
F-F+
1U
W V
74
28511
129
6
10
3
Aux.winding FUSE
A V F PL
KiSC issued 09, 2009 A
(1) D1703-E/E2, V2203-E/E2, F2803-E/E2
[2] ENGINE CIRCUIT DIAGRAM
2-M22
KJ-X50 HZ SERIES, WSM GENERATOR
3EJADABGP008A
*
KiSC issued 09, 2009 A
(2) V3300-E2BG
2-M23
KJ-X50 HZ SERIES, WSM GENERATOR
3EJADABGP009A
Main switch
3R
1.25
GR
1.25
WY1.25B2B
Wiring not requiredCN7-1 and CN7-2(Panel side)
8 1096 731 2 4 5
Starter
Alternator
L
M6
IG
Fuse(F2)
BatterySide of engine
Slow blow fuse
3L
5.5RM8B
ST
60
5.5R
1.25WY2G
5.5R
CN7-1
TB3
5.5R
60
3L
3R3L
3Y
46
51
321.25WY
3L
1.25L1.25W
2G1.25B3L1
2
1.25W1.25L
2G
45
63
Base
3LWiring of the Thermal relay
10A
14
3L
3L
125
3
Oil switch
Water temp. switch
Glow plug
Electric fuel feed pump
Pull
Hold
Solenoid
3ATB11.25Y
1.25GL
3R3R3R
1.25W
1.25L
87
910 10
87
9
CN7-2
11
1.25B
1.25B
1.25Y1.25GL
223
45
43
52Y
78
67
68
1.25WR1.25Y
2B
3Y
991010
1.25B
Starter relay
1.25
G
(F3)Fuse
1.25
B
1.25
GL
1.25L
3A
Fuse(F1)
2Y
1.25GL
1.25G50
RS1RS2
1.25GLB
1.25L1.25W
AC30OSWS
O1.25B
1.25Y1.25R1.25B
19EU
1.25B
Wiring of the AVR terminals
Wiring of the generator terminals
50
3L1.
25L2R
2G 2G
30AC
TB2
1.25B19
3L
302G
Hour meter
AC50
2R2L 19
1.25B
1.25
GW
ON GLOFF 0
321
ST
3R
53 1
2 1.25
R 3Y
5 2
3Y
53 1
2
3 1
1.25
WR
1.25
WG
Connection tableTerminalKey position
Emergency relay (EG-20)
123
0ONHEATSTART
OFF30 AC 19 50
ACEGO NB50
LLSWSOS
1.25
WR
1.25
L
Glow relay Solenoid relay
1.25BR1.25WB
1.25
L1.
25W
1.25
B1.
25W
R1.
25G
1.25
WG
1.25
Y
1.25
GL
1.25
WR
1.25
L1.
25G
1.25
G
1.25B
GCharge
Cover open
YYB
Glow
WGWBBY
RBRL
BY
YYB
BRWB
Monitor lamp
Oil pressure
Water temp
L
RW
RS2SH
GL1 GL2PP RS1
Relay unit
1.25
GW
RG2
RST1
2G
RG1
LS1950
AC
1.25
GR
1.25
R2R
EGO
NBRS
T2L
1.25
WY
1.25
B1.
25G
1.25
B
KiSC issued 09, 2009 A
CONTENTS
SERVICING
1. TROUBLESHOOTING ....................................................................................2-S1[1] EVIDENT PHYSICAL DEFECTS (OVERHEATING, NOISE,
VIBRATIONS ...) .......................................................................................2-S1[2] VOLTAGE FAULTS .................................................................................2-S2[3] ENGINE CIRCUIT TROUBLESHOOTING..............................................2-S4
2. SERVICING SPECIFICATIONS ....................................................................2-S63. TIGHTENING TORQUES ..............................................................................2-S8
[1] TIGHTENING TORQUES FOR SPECIAL USE SCREWS, BOLTSAND NUTS...............................................................................................2-S8
4. CHECKING, DISASSEMBLING AND SERVICING......................................2-S9[1] CHECKING AND ADJUSTING ...............................................................2-S9
(1) Initial Excitation Method ......................................................................2-S9(2) Control Panel ......................................................................................2-S9(3) Emergency Relay Activates ..............................................................2-S11
[2] DISASSEMBLING AND ASSEMBLING................................................2-S13(1) External Component .........................................................................2-S13(2) Generator..........................................................................................2-S13
[3] SERVICING ............................................................................................2-S16(1) Terminal Voltage for Each Part During Normal Periods (No-load
Periods).............................................................................................2-S16(2) Stator Coil .........................................................................................2-S16(3) Rotor Coil ..........................................................................................2-S17(4) Exciter Coil ........................................................................................2-S18
KiSC issued 09, 2009 A
2-S1
KJ-X50 Hz SERIES, WSM GENERATOR
1. TROUBLESHOOTINGNOTE
• In order to replace the parts in safety, remove negative terminal of battery so as to prevent the battery andthe parts from short-circuiting.
• To avoid errors on delivery of spare parts, all information marked on nameplates should be supplied onparts orders, in particular model and serial number of the alternator. Also give the parts numbers from theparts list.
[1] EVIDENT PHYSICAL DEFECTS (OVERHEATING, NOISE, VIBRATIONS...)
W1011938
Fault Action Origin of fault
A
Excessive overheating of bearing (temp. of bearing over 80 °C) (With or without abnormal bearing noise)
Replace bearing • If the bearing has turned blue or if the grease has turned black, change the bearing.
• Bearing race badly locked (moving in its housing).
• Bracket misalignment.
B
Excessive overheating of alternator frame (temperature 30 °C (86 °F) above ambient)
Check• Air inlets and outlets of
alternator• Measuring equipment
(voltmeter-Ammeter)• Ambient temperature
• Air flow (inlet-outlet) partially clogged or hot air is being recycled either from alternator or prime mover.
• Alternator overloaded.• Fan belt slips.
C
Excessive vibration and humming noise coming from the alternator
Stop the gen-set and check the installation and others
• Three phase alternator is single phase loaded in excess of acceptable level.
Start up with no-load: if humming persists …
• Short-circuit in the alternator stator.
D
Alternator damaged by a significant impact which is followed by humming and vibration
Stop the gen-set immediately
• Short-circuit in external circuit.• Break or deterioration in the coupling.• Break or twist in shaft extension.• Shifting or short-circuit of the main field
winding.• Bursting or unlocking of the fan.• Diode burnt, regulator, rectifier bridge
damaged.
E
Smoke, sparks, of flames issuing from the alternator
Stop the gen-set immediately
• Short-circuit in external circuit (including wiring between alternator and control board).
• Object fallen into the machine.• Short-circuit or flash in stator winding.
KiSC issued 09, 2009 A
2-S2
KJ-X50 Hz SERIES, WSM GENERATOR
[2] VOLTAGE FAULTS
W1012329
Defect Action Measure Origin of fault
F
No voltage at no load or start up
Disconnect lead wires F+ and F– from AVR.Connect a battery of 12 or 24 volts for two or three seconds to disconnected lead wires F+ and F– on the AVR
• The alternator builds up and voltage is correct after battery removal
• Lack of residual magnetism.• Check voltage between F– and F+ of
the AVR (correct value about 15 V).• V < 10 V exciter faulty.• Fault in rotating diodes.
• The alternator builds up but voltage does not reach nominal value after battery removal
• Check the connection of the auxiliary leads to the AVR.
• Readjust the voltage adjuster (VR) voltage.
• The alternator builds up but voltage collapses after battery removal
• AVR failure.
• The alternator builds up but no voltage and no frequency
• Check the connection of the sensing leads to the AVR (2 A Fuse).
• Exciter windings shorted or open circuit (check winding).
• Rotating diodes burnt (check diodes).• Main field winding open circuit (check
resistance).
G
Voltage too high
Adjust potentiometer voltage
• No adjustment of voltage, measure voltage between F+ and F– on AVR
• Defecting circuit (200 and E3) open.• AVR faulty.
H
Voltage oscillation
SetVR2Stab. ADJ
• If no result • Check speed for possible cycle irregularity.
• Check out put connections.• Faulty AVR.• Speed below nominal on load.• A rotating diode is open circuit.• Auxiliary winding is open circuit (check
resistance values).• Short-circuit on main field (check
resistance).• Exciter armature winding faulty (check
resistance).• Engine’s speed is not steady.
I
Voltage correct on no-load, too low on load
Run on no-load and check voltage between F+ and F–
• Voltage between F– and F+ is < 12 V (D.C.)
• Check speed.
• Voltage between F– and F+ is < 10 V (D.C.)
• Fault in rotating diodes.• Short-circuit in main field, check
resistance.• Exciter armature field faulty (check
values).
KiSC issued 09, 2009 A
2-S3
KJ-X50 Hz SERIES, WSM GENERATOR
W1012878
Defect Action Measure Origin of fault
J
Voltage collapses during normal operation
Check the regulator, the surge suppressor, the rotating diodes and replace any defective part
• The output voltage does not return the nominal value
• Exciter winding faulty (check values).• Main field faulty (check values).• Faulty exciter armature.
KiSC issued 09, 2009 A
2-S4
KJ-X50 Hz SERIES, WSM GENERATOR
[3] ENGINE CIRCUIT TROUBLESHOOTING Engine Circuit Troubleshooting Sequence Chart
KiSC issued 09, 2009 A
2-S5
KJ-X50 Hz SERIES, WSM GENERATOR
KiSC issued 09, 2009 A
2-S6
KJ-X50 Hz SERIES, WSM GENERATOR
2. SERVICING SPECIFICATIONSGENERATING UNIT (To be continued)
W1020122
ModelItem KJ-S130VX KJ-S170FX KJ-T130DX KJ-T180VX KJ-T230FX KJ-T300
Frequency (Hz) 50Generator Type PX-316 KU1 PX-319 KU1 PX-312 KU3 PX-316 KU3 PX-319 KU3 PX-322 KE3Voltage (V) 110 /
220120 / 240
110 / 220
120 / 240 220, 380, 415 380
Current (A)56.8 52.1 77.3 70.8
32.819.017.4
47.227.325.0
60.434.932.0
45.6
Exciter field (Ω) 31.2 34.7 41.1 45.8 48.3Exciter armature (Ω) 0.553 0.605 0.553 0.605 0.581Stator coil (U-V) (Ω)
0.170 0.140
(220 V)0.197
(380 V, 415 V)0.789
(220 V)0.132
(380 V, 415 V)0.529
(220 V)0.104
(380 V, 415 V)0.415
(380 V)0.324
Auxiliary winding (Ω) 1.33 1.25 1.36 1.16 1.08 0.97Rotor field coil (Ω) 2.9 3.51 2.54 2.90 3.51 3.64
Air gapmm (in.)
Main stator Side 1.4 (0.055)
Exciter side 0.8 (0.03)Bearing 6308ZZRegulated voltage value (%) ±3.5
Circuit breaker capacity (A)
60 100 75
(220 V)40
(380 V, 415 V)
20
(220 V)50
(380 V, 415 V)
30
(220 V)75
(380 V, 415 V)
40
50
KiSC issued 09, 2009 A
2-S7
KJ-X50 Hz SERIES, WSM GENERATOR
GENERATING UNIT (Continued)
W1017763
Model
Item
KJ-S130VX-
AUS
KJ-S170FX-
AUS
KJ-T130DX-
AUS
KJ-T180VX-
AUS
KJ-T230FX-
AUS
KJ-S240-AUS
KJ-T300-AUS
Frequency (Hz) 50Generator Type PX-316
KU1PX-319
KU1PX-312
KU3PX-316
KU3PX-319
KU3PX-322
KE1PX-322
KE3Voltage (V) 110 /
220120 / 240
110 / 220
120 / 240 220, 380, 415 240 240 / 415
Current (A)56.8 52.1 77.3 70.8
32.819.017.4
47.227.325.0
60.434.932.0
100.0 41.7
Exciter field (Ω) 31.2 34.7 41.1 45.8 36.1 48.3Exciter armature (Ω) 0.553 0.605 0.553 0.605 0.575 0.581Stator coil (U-V) (Ω)
0.170 0.140
(220 V)0.197
(380 V, 415 V)0.789
(220 V)0.132
(380 V, 415 V)0.529
(220 V)0.104
(380 V, 415 V)0.415
0.1155 0.324
Auxiliary winding (Ω) 1.33 1.25 1.36 1.16 1.08 1.11 0.97Rotor field coil (Ω) 2.9 3.51 2.54 2.90 3.51 3.64
Air gapmm (in.)
Main stator Side 1.4 (0.055)
Exciter side 0.8 (0.03)
Bearing 6308ZZRegulated voltage value (%) ±3.5
Circuit breaker capacity (A)
60 100 75
(220 V)40
(380 V, 415 V)
20
(220 V)50
(380 V, 415 V)
30
(220 V)75
(380 V, 415 V)
40
100 50
KiSC issued 09, 2009 A
2-S8
KJ-X50 Hz SERIES, WSM GENERATOR
3. TIGHTENING TORQUESScrews, bolts and nuts must be tightened to the specified torque using a torque wrench, several screws, bolts and
nuts such as those used on the cylinder head must be tightened in proper sequence and at the proper torque.
[1] TIGHTENING TORQUES FOR SPECIAL USE SCREWS, BOLTS ANDNUTS
NOTE• In removing and applying the screws, bolts and nuts marked with "*", pneumatic wrench or similar
pneumatic tool, if employed, must be used with enough care not to get them seized.• For "*" marked screws, bolts and nuts on the table, apply engine oil to their threads and seats before
tightening.
W1091652
Section Item Size x Pitch N·m kgf·m lbf·ftGenerator Rotor mounting screw M8 18 to 21 1.8 to 2.2 13 to 15
Stator mounting screw – 20 to 27 2.0 to 2.8 15 to 20End bracket mounting screw M10 20 to 27 2.0 to 2.8 15 to 20Adapter mounting screw M10 36 to 43 3.6 to 4.4 26 to 31
KiSC issued 09, 2009 A
2-S9
KJ-X50 Hz SERIES, WSM GENERATOR
4. CHECKING, DISASSEMBLING AND SERVICING[1] CHECKING AND ADJUSTING(1) Initial Excitation Method
Flashing the FieldThe alternator is self exciting from the residual magnetism of the
magnetic circuit of the exciter. When first tested (at the factory) thismagnetic circuit is magnetized but after a breakdown it may benecessary to remagnetize.
IMPORTANT• If the connection has the wrong polarity or different position
(such as F+ and F- side) magnetization is reversely reduced.W1071816
(2) Control PanelCircuit Breaker (CB)1. Test for continuity between the each upper and lower breaker
terminals with an ohmmeter.2. Confirm that there is continuity when the breaker switch in “ON”.3. If there is no continuity, it indicates that the contacts are faulty.
Replace the breaker.NOTE
• When there is a short-circuit in the wiring, the circuit breakertrips off. If this happens, eliminate the cause, then reset thecircuit breaker. If the circuit breaker holds, test the load forfaults.* In the switchable type, a sub-breaker turns OFF first andmain breaker doesn’t.
• When there is an over-current, the thermal relay operates theshunt trip on the main circuit breaker. If this happens,remove the load then turn the circuit breaker ON again(Reset the breaker.).* The thermal relay does not work if the battery voltage fallsbelow 70 to 80 % prescribed level. Be aware of good batterycare.
W1019844
AC Ammeter1. Test for continuity between the ammeter terminals with an
ohmmeter.2. Replace the ammeter if there is no continuity.
W1072360
KiSC issued 09, 2009 A
2-S10
KJ-X50 Hz SERIES, WSM GENERATOR
Voltage Adjuster (Potentiometer)1. Measure the resistance of the 1-2 connection with an ohmmeter.2. Place an ohmmeter on the 1-3 connection and check the
variation in resistance while turning the knob.3. If the factory specification is not indicated, replace the adjuster.
W1072462
Current Transformer CT1 and CT2 (CT for Ammeter)1. Disconnect the lead wires from one side of the transformer.2. Test for continuity between the transformer terminals with an
ohmmeter.3. Replace the transformer if there is no continuity.
W1072713
Lamp Timer (for Glow Plug)1. Remove the lamp timer (1) from inside of the panel.2. Connect the battery (4), lamp timer (1) and bulb (2) as shown in
the figure3. The bulb (2) light up when contacting the lead wire 1 (3) with
positive terminal of the battery (4) and goes off approximately 6seconds late, the lamp relay is proper.
W1121405
Resistance Factory spec.
1-2 0 Ω
1-3 Vary smoothly from 0 to 1 kΩ
(1) Potentiometer (2) Hole
(1) Lamp Timer(2) Bulb
(3) Lead Wire 1(4) Battery (12 V)
KiSC issued 09, 2009 A
2-S11
KJ-X50 Hz SERIES, WSM GENERATOR
(3) Emergency Relay ActivatesNOTE
• When emergency relay activates and engine has stopped, check the cause and repair it.Stop Solenoid Circuit1. Disconnect the stop solenoid connector (1). Connect the
voltmeter (+) side to the connector (2) opposite to the stopsolenoid, and the voltmeter (−) side to an unpainted portion of theengine frame (Ground). The voltmeter’s range mustaccommodate DC 50 V. Turn the key switch to “ON”, and thento “OFF” in this situation.
2. Normally, the battery voltage will appear (DC 12 V) when the keyswitch is “ON” and after 10 ±3 sec., it will go to 0 V.
W1121855
Emergency Relay Circuit1. When the engine is running at rated rpm’s connect the lead wires
to the terminal of the oil switch (1) or the water temperaturesensor.
2. Also ground the other end of the lead wires to an unpaintedportion of the engine frame.
(In normal operation)• The stop solenoid activates and the engine stops automatically.• As the stop solenoid is activated again after 10 ± 3 seconds of its
first engagement, a ‘tick’ sound can be heard.
W1072817
Oil Switch1. The oil switch (1) has continuity when the engine is stopped and
has no continuity while the engine is running.2. Replace the oil switch (1) if it is defective.
W1074063
Water Temperature Sensor1. Insert the water temperature sensor (1) in the engine oil, and
continue the circuit when the oil temperature rises to 112 to 118°C (234 to 244 °F).
2. Check that the resistance is 0 ohm in case water temperaturesensor is defective.
IMPORTANT• Be careful when handling the water temperature sensor so
that you do not drop it.• When assembling the sensor, apply sealing agent to the
threads, and then screw it in firmly.• Make a test run after installation, to check for any water
leaks.
W1074271
(1) Stop Solenoid Connector (2) Connector
(1) Oil Switch
Resistance (Switch terminal -Chassis)
In normal state Infinity
At pressure over approx. 98 kPa (1.0 kgf/cm2, 14 psi)
0 Ω
(1) Oil Switch
Water temperature sensor Factory spec.
Water temperature above than 112 to 118 °C (234 to 244 °F). Contact ON.
(1) Water Temperature Sensor
KiSC issued 09, 2009 A
2-S12
KJ-X50 Hz SERIES, WSM GENERATOR
Engine Stop Solenoid Test1. Disconnect the 1P connector from the engine stop solenoid.2. Remove the engine stop solenoid from the engine.3. Connect the jumper leads from the battery positive terminal (2) to
the 1P connector, and from the battery negative terminal (1) tothe engine stop solenoid body.
4. If the solenoid plunger is not attracted, the engine stop solenoidis faulty.
W1075754
(1) Negative Terminal (2) Positive Terminal
KiSC issued 09, 2009 A
2-S13
KJ-X50 Hz SERIES, WSM GENERATOR
[2] DISASSEMBLING AND ASSEMBLING(1) External Component
NOTE• The below procedure is given for model KJ-T160DX. Procedure will vary according to model.
Cover, Panel, Control Panel and Bonnet1. Place the generator unit on firm and level surface.2. Remove the inspection cover 2 (4), 1 (5), and open the drain cock
to drain coolant.3. Remove the drain plug and drain engine oil. 4. Disconnect the battery negative cable.5. Close the fuel cock and disconnect the fuel hose from the fuel
filter.6. Disconnect the fuel return hose from the injection nozzle.7. Remove the air cleaner (11).8. Remove the rear inspection cover.9. Disconnect the battery positive cable.10.Remove the battery inspection cover and remove the battery
(10).11.Remove the inspection cover for AVR and disconnect the output
cable (u.v.w) and AVR controlled wirings at the each terminal.12.Disconnect the wiring connectors between the control panel (7)
and generator unit.13.Remove the control panel (7).14.Remove the each side cover.15.Remove the exhaust muffler cap (3).16.Remove the bonnet cover (2).17.Remove the control panel bracket.18.Remove the radiator (8) with bracket.
W1068967
(2) GeneratorEnd Bracket1. Loosen the mounting screws for the frame and the end bracket
evenly.2. Hook the gear puller until it clicks onto the rear cover’s
outerfearence, and then pull off the cover.(When reassembling)• Check the rubber O-ring and spring washer are in place.• Clean dirt from the bearing housing when assembling.
Also apply oil to the outer surfaces of the bearing housing.• Keeping the bracket level with the bearing’s outer race, press the
bearing and bearing housing together (perform by hand).Check the bearing has fit inside the housing, then while holdingthe housing still, tap the bearing into place with a wooden mallet.
W1069197
(1) Handling Hook(2) Bonnet Cover(3) Muffler and Cap(4) Inspection Cover 2(5) Inspection Cover 1(6) Front Cover
(7) Control Panel(8) Radiator(9) Fuel Tank
(10) Battery(11) Air Cleaner(12) Side Panel
Tightening torque End bracket mounting screw
20 to 24 N·m2.0 to 2.5 kgf·m15 to 18 lbf·ft
KiSC issued 09, 2009 A
2-S14
KJ-X50 Hz SERIES, WSM GENERATOR
Checking Ball Bearing1. Measure axial dislocation of the outer ring.2. If the axial dislocation exceeds the allowable limit, replace the
bearing.
3. Measure the I.D.of the bearing housing.4. If the wear exceeds the allowable limit, replace the end bracket.
W1116881
Stator Assembly1. Remove the spread-proof rubber (1) mounting nut.2. Hoist up the engine and the generator, keeping them level (above
than spread-proof rubber).3. Set a base (2) under the engine (not under the oil pan).4. When removing the engine, support it on a base or stands.5. Remove the bracket and stator mounting screws.6. Remove the bracket, then stator and check for any damage to the
winding.(When reassembling)• Handle the generator so as not to damage the winding.
Also be careful when putting it down.• Clean all fitting parts of the engine and frame when assembling.
W1069357
Axial dislocation Allowable limit 0.05 mm0.002 in.
Bearing housing I.D. Allowable limit 90.02 mm
3.544 in.
Tightening torque Stator mounting screw20 to 24 N·m2.0 to 2.5 kgf·m15 to 18 lbf·ft
(1) Spread-proof Rubber (2) Base
KiSC issued 09, 2009 A
2-S15
KJ-X50 Hz SERIES, WSM GENERATOR
Rotor Assembly1. To avoid damage to the rotor, suspend the rotor with a sling
enough to keep it from lifting, and leave it suspended.2. Remove the rotor mounting screws (6).3. Remove the rotor assembly (1), take care not to damage the
winding.(When reassembling)• Clean any oil and dirt from the mounting surfaces of the rotor and
flywheel. If this is not done correctly, it will result in damage ofrotor and stator caused by loose fittings.
• Handle carefully to avoid damaging the winding.
W1069561
Tightening torque
Rotor mounting screw18 to 21 N·m1.8 to 2.2 kgf·m13 to 15 lbf·ft
Adapter mounting screw36 to 43 N·m3.6 to 4.4 kgf·m26 to 31 lbf·ft
(1) Rotor Assembly(2) Flywheel(3) Flywheel Housing
(4) Adaptor(5) Adapter Mounting Screw(6) Rotor Mounting Screw
KiSC issued 09, 2009 A
2-S16
KJ-X50 Hz SERIES, WSM GENERATOR
[3] SERVICINGIMPORTANT
• The resistance described hereafter are the value based on corresponded to the temperature of 20 °C (68°F).The resistance measured outside t1 °C can be converted into that at 20 °C (68 °F) with the following formula: R = {(273 + 20) / (273 + t1)}x R1
Where t1 is the temperature when the resistance is measured and R1 is the resistance measured at t1.Example : If the resistance measured at a temperature of 30 °C (86 °F) is 10 Ω.t1 = 30 °C R1 = 10 Ω R = {(273 + 20) / (273 + 30)} x 10 = 9.67 Ω
*The resistance should be 9.67 Ω at a temperature of 20 °C (68 °F)
(1) Terminal Voltage for Each Part During Normal Periods (No-load Periods)Output Terminal1. With the NFB in the “ON” position, measure the voltage in each
phase and each line.2. If the factory specification is not indicated, inspect the output
circuit or the wiring harness. (Refer to wiring diagram.)
W1070126
(2) Stator CoilMain Armature Winding1. Test for continuity between coil leads with a mΩ meter. Many
kind of wiring have been arranged in the stator depending on thevoltage variation.
2. If the resistance is not as specified, replace the stator coil orcontact service station.
* Measurement is not possible with a regular tester.W1070258
Auxiliary Winding1. Measure the coil resistance between each auxiliary winding 3-4.2. If the factory specification is not indicated, replace the stator coil
or contact service station.
W1070378
Output voltage Factory spec. Rated voltage 5 %
Resistance Factory spec. Refer to “SERVICING, SPECIFICATIONS”
Resistance Factory spec. Refer to “SERVICING, SPECIFICATIONS”
KiSC issued 09, 2009 A
2-S17
KJ-X50 Hz SERIES, WSM GENERATOR
Grounding of Stator Coil1. Measure the insulation resistance between each stator winding
and lamination with a MΩ meter.2. Reading should be more than 1 MΩ at 500 V.3. If continuous, replace the stator coil or contact service station.
W1070462
(3) Rotor CoilThere are two kinds of winding in the rotor assembly, the one is rotor field coil and the other is exciter armature coil.
Main Field Winding and Exciter Armature Winding1. Remove the field coil end at the diode stack board.2. Measure the coil resistance between each end of field coil.3. If the resistance is not as specified, replace the rotor assembly or
contact service station.
W1070562
Grounding of Rotor Coil1. Connect leads of a megaohmmeter between each lead (1) and
exciter rotor laminations (2).2. Reading should be more than 1 MΩ at 500 V.3. If continuous, replace the rotor assembly or contact service
station.
W1070811
Silicon Diodes Stack and Surge-absorber1. Disconnect the exciter armature coil at the connection terminal
on diode board.2. Loosen the two mounting bolts for the diode stack and remove it.3. Check the polarity of diode stack leads carefully. It is a good idea
to tag them (+, -, ~) during disassembly.4. A diode in a good condition enables the current to flow in only one
direction from anode to cathode.W1070905
Resistance Factory spec.
Rotor field coil
Refer to “SERVICING SPECIFICATIONS”Exciter
armature coil
(1) Rotor Field Coil (2) Exciter Armature Coil
(1) Lead (2) Lamination
KiSC issued 09, 2009 A
2-S18
KJ-X50 Hz SERIES, WSM GENERATOR
(4) Exciter CoilExciter Field Winding1. Measure the coil resistance between each lead with a miliohm
meter.2. If the resistance is not as specified, replace the exciter coil
assembly or contact service station.
W1071549
Grounding of Exciter Field Coil1. Measure the insulation resistance between each lead and the
laminations with a megaohmmeter.2. A reading should be more than 1 MΩ at 500 V.3. If continuous, replace the exciter coil assembly or contact service
station.W1071657
Resistance Factory spec. F– - F+ Refer to “SERVICING
SPECIFICATIONS”
KiSC issued 09, 2009 A
Editor : Farm and Industrial Machinery International Service DepartmentAddress : 64, Ishizu-Kitamachi, Sakai-Ku, Sakai-City, Osaka, 590-0823, JapanPhone : +81-72-241-1129Fax : +81-72-245-2484E-mail : [email protected]
KUBOTA CorporationPrinted in Japan 2009. 09, S, EI, EI, engusa
1999. 08, S, EI, EI, engusa Code No.9Y011-01832