Kubota WSM J Series Workshop Manual
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Kubota WSM J Series Workshop Manual

Kubota WSM J Series Workshop Manual

Diesel generator
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WORKSHOP MANUAL
DIESEL GENERATOR
J SERIES
KiSC issued 10, 2016 A

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Summary of Contents for Kubota WSM J Series

  • Page 1 WORKSHOP MANUAL DIESEL GENERATOR J SERIES KiSC issued 10, 2016 A...
  • Page 2 TO THE READER This Workshop Manual has been prepared to provide servicing personnel with information on the mechanism, service and maintenance of KUBOTA Generator J Series. It is divided into two parts, “Mechanism” and “Servicing”.  Mechanism Information on the construction and function are included. This part should be understood before proceeding with troubleshooting, disassembling and servicing.
  • Page 3 Record of Revisions For pdf, use search function {Search word} to find all the revised locations. Last digit Issue Reference of the Main Revised Point and Corrective Measures {Search word} month Page Code No. 2016.10 AVR circuit changed. M-10 to M-32 KiSC issued 10, 2016 A...
  • Page 4 SAFETY INSTRUCTIONS J SERIES, WSM SAFETY INSTRUCTIONS SAFETY FIRST This symbol, the industry’s “Safety Alert Symbol”, is used throughout this manual and decals on the generator 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.
  • Page 5 SAFETY INSTRUCTIONS J SERIES, WSM SAFETY STARTING • Do not start the engine by shorting across starter terminals. • Unauthorized modifications to the engine may impair the function and / or safety and affect engine life. SAFETY WORKING • Do not work on the generator while under the influence of alcohol, medication, or other substances or while fatigued.
  • Page 6 SAFETY INSTRUCTIONS J SERIES, WSM VENTILATE WORK AREA • If the generator must be running to do some work, make sure the area is well ventilated. Never run the engine in a closed area. The exhaust gas contains poisonous carbon monoxide. PREVENT ACID BURNS •...
  • Page 7 SAFETY INSTRUCTIONS J SERIES, WSM SAFETY DECALS  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 listed in the parts list. KiSC issued 10, 2016 A...
  • Page 8 SPECIFICATIONS J SERIES, WSM SPECIFICATIONS [50Hz] Model J106 J108 J112 J116 -STD -AUS -STD -AUS -STD -AUS -STD -AUS Type Revolving-field, brush type, separate and self - excitation system, AC generator Insulation Rotor coil: F Stator coil: B class Frequency 50 Hz Standby 6.0 kVA (6.0 kW)
  • Page 9 SPECIFICATIONS J SERIES, WSM Model J310 J315 J320 -STD -AUS -STD -AUS -STD -AUS Type Revolving-field, brush type, separate and self - excitation system, AC generator Insulation Rotor coil: F Stator coil: B class Frequency 50 Hz Standby 11 kVA (8.8 kW) 16.5 kVA (13.2 kW) 22 kVA (17.6 kW) output...
  • Page 10 SPECIFICATIONS J SERIES, WSM [60Hz] Model J107 J110 J114 J119 -STD -STD -STD -STD Type Revolving-field, brush type, separate and self - excitation system, AC generator Insulation Rotor coil: F Stator coil: B class Frequency 60 Hz Standby 7.1 kVA (7.1 kW) 11.0 kVA (11.0 kW) 15.4 kVA (15.4 kW) 20.6 kVA (20.6 kW)
  • Page 11 SPECIFICATIONS J SERIES, WSM Model J313 J318 J324 -STD -STD -STD Type Revolving-field, brush type, separate and self - excitation system, AC generator Insulation Rotor coil: F Stator coil: B class Frequency 60 Hz Standby 13.7 kVA (11 kW) 19.2 kVA (15.4 kW) 25.8 kVA (20.6 kW) output Prime output...
  • Page 12 DIMENSIONS J SERIES, WSM DIMENSIONS J108-STD, -AUS J112-STD, -AUS J116-STD, -AUS J106-STD, -AUS J110-STD, -SA J114-STD, -SA J119-STD, -SA Model J107-STD, -SA J310-STD, -AUS J315-STD, -AUS J320-STD, -AUS J313-STD J318-STD J324-STD Length mm (in.) 923 (36.4) 995 (39.2) 1215 (47.8) 1300 (51.1) Width mm (in.)

  • Page 13: Table Of Contents

    MECHANISM CONTENTS 1. GENERATOR ....................M-1 [1] STRUCTURE ..................... M-1 [2] AUTOMATIC VOLTAGE REGULATOR (A.V.R.)........M-2 [3] EMERGENCY RELAY CIRCUIT.............. M-4 (1) General ....................M-4 (2) Instructions................... M-5 (3) Flow Chart.................... M-7 [4] EARTH ....................... M-9 [5] WIRING DIAGRAM ................. M-10 KiSC issued 10, 2016 A...

  • Page 14: Generator

    GENERATOR J SERIES, WSM 1. GENERATOR [1] STRUCTURE (1) Rear Cover (5) Stator Assembly (9) Fan (Z482 only) (2) A.V.R. Assembly (6) Stator Housing (3) Brush Holder Assembly (7) Rotor Assembly (4) Rear Bracket (8) Fan 1. Stator Assembly The main coil and sub coil for power generation are wound in the slots provided in the core. The main coil generates the AC output and supplies A.V.R.

  • Page 15: Automatic Voltage Regulator (A.v.r

    GENERATOR J SERIES, WSM [2] AUTOMATIC VOLTAGE REGULATOR (A.V.R.) NOTE  • It is hazardous to proceed to any high voltage test on the alternator without having previously disconnected all connections to voltage regulator. Damages occurring to A.V.R. in such conditions will not be considered in a warranty claim. (1) A.V.R.
  • Page 16 GENERATOR J SERIES, WSM The block diagram of J Series A.V.R.’s is shown below. The A.V.R. consists basically of the components detector (12) through transistor (4). To run it for practical use, the other components separate excitation unit (14) through battery (16) are combined.

  • Page 17: Emergency Relay Circuit

    GENERATOR J SERIES, WSM come from the separate excitation unit (14). Let’s take an example of a car engine. The separate excitation unit (14) is equivalent to a fuel cut-off solenoid valve. With this unit running, the valve stays fully open. The rpm is controlled by a governor, to which the drive circuit (5) is equivalent.

  • Page 18: Instructions

    GENERATOR J SERIES, WSM (2) Instructions (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 W10132090 For Z482 and D722...
  • Page 19 GENERATOR J SERIES, WSM (1) Key Switch (2) Battery (3) Alternator L Terminal (4) Oil Switch (5) Water Temperature Switch (6) Delay Timer (7) Sensor Circuit (8) Emergency Stop Circuit (9) Built-in Relay (10) Drive circuit (11) Stop Solenoid W10138290 For D1005 and V1305 1.

  • Page 20: Flow Chart

    GENERATOR J SERIES, WSM (3) Flow Chart KiSC issued 10, 2016 A...
  • Page 21 GENERATOR J SERIES, WSM W1012333 KiSC issued 10, 2016 A...

  • Page 22: Earth

    Recommendations in the NEC, NFPA and OSHA regulations must be followed to assure compliance and safe operation. A grounding lug is provided on the KUBOTA generator frame for earth grounding depending on local, state, national or OSHA requirements. One possible connection method for construction site...

  • Page 23: Wiring Diagram

    GENERATOR J SERIES, WSM [5] WIRING DIAGRAM M-10 KiSC issued 10, 2016 A...
  • Page 24 GENERATOR J SERIES, WSM M-11 KiSC issued 10, 2016 A...
  • Page 25 GENERATOR J SERIES, WSM M-12 KiSC issued 10, 2016 A...
  • Page 26 GENERATOR J SERIES, WSM M-13 KiSC issued 10, 2016 A...
  • Page 27 GENERATOR J SERIES, WSM M-14 KiSC issued 10, 2016 A...
  • Page 28 GENERATOR J SERIES, WSM M-15 KiSC issued 10, 2016 A...
  • Page 29 GENERATOR J SERIES, WSM M-16 KiSC issued 10, 2016 A...
  • Page 30 GENERATOR J SERIES, WSM M-17 KiSC issued 10, 2016 A...
  • Page 31 GENERATOR J SERIES, WSM M-18 KiSC issued 10, 2016 A...
  • Page 32 GENERATOR J SERIES, WSM M-19 KiSC issued 10, 2016 A...
  • Page 33 GENERATOR J SERIES, WSM M-20 KiSC issued 10, 2016 A...
  • Page 34 GENERATOR J SERIES, WSM M-21 KiSC issued 10, 2016 A...
  • Page 35 GENERATOR J SERIES, WSM M-22 KiSC issued 10, 2016 A...
  • Page 36 GENERATOR J SERIES, WSM M-23 KiSC issued 10, 2016 A...
  • Page 37 GENERATOR J SERIES, WSM M-24 KiSC issued 10, 2016 A...
  • Page 38 GENERATOR J SERIES, WSM M-25 KiSC issued 10, 2016 A...
  • Page 39 GENERATOR J SERIES, WSM M-26 KiSC issued 10, 2016 A...
  • Page 40 GENERATOR J SERIES, WSM M-27 KiSC issued 10, 2016 A...
  • Page 41 GENERATOR J SERIES, WSM M-28 KiSC issued 10, 2016 A...
  • Page 42 GENERATOR J SERIES, WSM M-29 KiSC issued 10, 2016 A...
  • Page 43 GENERATOR J SERIES, WSM M-30 KiSC issued 10, 2016 A...
  • Page 44 GENERATOR J SERIES, WSM M-31 KiSC issued 10, 2016 A...
  • Page 45 GENERATOR J SERIES, WSM M-32 KiSC issued 10, 2016 A...
  • Page 46 SERVICING CONTENTS 1. GENERAL ......................S-1 [1] GENERAL IDENTIFICATION ..............S-1 [2] PRECAUTION.....................S-2 [3] LUBRICANTS, FUEL AND COOLANT .............S-3 [4] TROUBLESHOOTING ................S-4 (1) Generator....................S-4 (2) Engine....................S-15 [5] SERVICING SPECIFICATIONS ..............S-18 (1) Generator....................S-18 (2) Engine [Z482, D722] ................S-22 (3) Engine [D1005, V1305]...............S-28 [6] TIGHTENING TORQUES ................S-34 (1) Tightening Torques for Special Use Screws, Bolts and Nuts .....S-34 (2) Tightening Torques for General Use Screws, Bolts and Nuts ....S-35 [7] MAINTENANCE CHECK LIST..............S-36...

  • Page 47: General

    GENERAL J SERIES, WSM 1. GENERAL [1] GENERAL IDENTIFICATION When contacting your local KUBOTA distributor, always specify the model name and serial numbers of both engine and generator. (1) Generator Serial Number (3) Engine Model Name and Serial (2) Generator Model Name...

  • Page 48: Precaution

    Screws and nuts should be installed in their original position to prevent reassembly errors. • When special tools are required, use KUBOTA genuine special tools. Special tools which are not frequently used should be made according to the drawings provided.

  • Page 49: Lubricants, Fuel And Coolant

    GENERAL J SERIES, WSM [3] LUBRICANTS, FUEL AND COOLANT Item Model Capacity Grade 2.2 L J106-STD, -AUS (2.3 U.S.qts.) Higher than CD class (API) J107-STD, -SA (2.0 Imp.qts.) Above 25 C (77 F) J108-STD, -AUS SAE10W-30 3.4 L J110-STD, -SA SAE10W-30 (3.6 U.S.qts.) J310-STD, -AUS...

  • Page 50: Troubleshooting

    GENERAL J SERIES, WSM [4] TROUBLESHOOTING (1) Generator NOTE  • In order to replace the parts in safety, remove negative terminal of battery so as to prevent the battery and the parts from short-circuiting. • To avoid errors on delivery of spare parts, all information marked on nameplates should be supplied on parts orders, in particular model and serial number of the alternator.

  • Page 51: Engine

    GENERAL J SERIES, WSM (B) Voltage Faults (Single Phase) Measurement Trouble Checking Method Operating Possible Cause Countermeasure Condition Voltmeter Measure the voltage Output voltage Circuit breaker (NFB) is Set the circuit breaker to indicates at the output terminal is 0 V. OFF.
  • Page 52 GENERAL J SERIES, WSM (C) Voltage Faults (Three Phase) Measurement Trouble Checking Method Operating Possible Cause Countermeasure Condition Voltmeter Measure the voltage Output voltage Circuit breaker (NFB) is Set the circuit breaker to indicates at the output terminal is 0 V for all OFF.
  • Page 53 GENERAL J SERIES, WSM Measurement Trouble Checking Method Operating Possible Cause Countermeasure Condition Circuit Use a circuit tester Normal Abnormality in load Set the circuit breaker to breaker and measure the output circuit. ON after removing goes OFF. phase voltage voltages for abnormality (overlord, Open-phase overload or...
  • Page 54 GENERAL J SERIES, WSM (D) Engine Circuit Troubleshooting [Z482, D722] KiSC issued 10, 2016 A...
  • Page 55 GENERAL J SERIES, WSM KiSC issued 10, 2016 A...
  • Page 56 GENERAL J SERIES, WSM S-10 KiSC issued 10, 2016 A...
  • Page 57 GENERAL J SERIES, WSM S-11 KiSC issued 10, 2016 A...
  • Page 58 GENERAL J SERIES, WSM S-12 KiSC issued 10, 2016 A...
  • Page 59 GENERAL J SERIES, WSM (E) Engine Circuit Troubleshooting [D1005, V1305] S-13 KiSC issued 10, 2016 A...
  • Page 60 GENERAL J SERIES, WSM S-14 KiSC issued 10, 2016 A...
  • Page 61 GENERAL J SERIES, WSM (2) Engine Reference Symptom Probable Cause Solution Page Engine Does Not • No fuel Replenish fuel – Start. • Air in the fuel system Vent air – • Water in the fuel system Change fuel and –...
  • Page 62 GENERAL J SERIES, WSM Reference Symptom Probable Cause Solution Page Either White or Blue • Excessive engine oil Reduce to specified S-38 Exhaust Gas Is level Observed. • Low grade fuel used Use specified fuel • Piston ring and liner worn or stuck Repair or replace S-89, 99 •...
  • Page 63 GENERAL J SERIES, WSM Reference Symptom Probable Cause Solution Page Water Mixed into • Head gasket defective Replace S-62 Lubricant Oil • Cylinder block or cylinder head flawed Replace – Low Oil Pressure • Engine oil insufficient Replenish S-38 • Oil strainer clogged Clean –...

  • Page 64: Generator

    GENERAL J SERIES, WSM [5] SERVICING SPECIFICATIONS (1) Generator For General (50Hz) J106 J108 J112 J116 J310 J315 J320 Model Item -STD -STD -STD -STD -STD -STD -STD Frequency (Hz) Voltage (V) Current (A) 25.0 36.4 54.5 72.7 15.2 22.8 30.4 0.37 0.20...
  • Page 65 GENERAL J SERIES, WSM For Australia (50Hz) J106 J108 J112 J116 J310 J315 J320 Model Item -AUS -AUS -AUS -AUS -AUS -AUS -AUS Frequency (Hz) Voltage (V) 8.3+ 12.5+ Current (A) 22.9 33.3 50.0 66.7 13.9 8.3+ 20.9 12.5+ 27.8 12.5 0.41 0.26...
  • Page 66 GENERAL J SERIES, WSM For General (60Hz) J107 J110 J114 J119 J313 J318 J324 Model Item -STD -STD -STD -STD -STD -STD -STD Frequency (Hz) Voltage (V) 110 / 220 110 / 220 110 / 220 110 / 220 63.6+63.6 85.5+85.5 Current (A) 59.1 / 29.5...
  • Page 67 GENERAL J SERIES, WSM For Saudi Arabia (60Hz) J107 J110 J114 J119 Model Item Frequency (Hz) Voltage (V) 127 / 220 127 / 220 127 / 220 127 / 220 Current (A) 51.2 / 29.5 78.7 / 45.5 90.6 / 63.6 90.6 / 85.5 0.32 0.20...

  • Page 68: Engine [Z482, D722

    GENERAL J SERIES, WSM (2) Engine [Z482, D722] (A) Engine Body Item Factory Specification Allowable Limit Cylinder Head Surface Flatness 0.05 mm – 0.0020 in. Top Clearance 0.50 to 0.70 mm – 0.0197 to 0.0276 in. Compression Pressure 2.84 to 3.24 MPa 2.26 MPa 29.0 to 33.0 kgf/cm 23.0 kgf/cm...
  • Page 69 GENERAL J SERIES, WSM Engine Body (Continued) Item Factory Specification Allowable Limit Valve Spring Free Length 31.3 to 31.8 mm 28.4 mm 1.23 to 1.25 in. 1.12 in. Setting Load 64.7 N 54.9 N 6.6 kgf 5.6 kgf 14.6 lbs 12.3 lbs Setting Length 27.0 mm...
  • Page 70 GENERAL J SERIES, WSM Engine Body (Continued) Item Factory Specification Allowable Limit Timing Gear Crank Gear to Idle Gear Backlash 0.043 to 0.124 mm 0.15 mm 0.00169 to 0.00488 in. 0.0059 in. Idle Gear to Cam Gear Backlash 0.047 to 0.123 mm 0.15 mm 0.00185 to 0.00484 in.
  • Page 71 GENERAL J SERIES, WSM Engine Body (Continued) Item Factory Specification Allowable Limit Crankshaft Journal to Crankshaft Oil Clearance 0.034 to 0.106 mm 0.20 mm Bearing 1 0.00134 to 0.00417 in. 0.0079 in. Crankshaft Journal O.D. 39.934 to 39.950 mm – 1.57221 to 1.57284 in.
  • Page 72 GENERAL J SERIES, WSM (C) Cooling System Item Factory Specification Allowable Limit 69.5 to 72.5 C Thermostat Valve Opening – 157 to 163 F Temperature (At Begining) 85 C Valve Opening – 185 F Temperature (Opened Completely) Radiator Water Leakage No leaks at –...
  • Page 73 GENERAL J SERIES, WSM (E) Electrical System Starter Item Factory Specification Allowable Limit Commutator O.D. 28.0 mm 27.0 mm 1.10 in. 1.06 in. Mica Undercut 0.50 to 0.80 mm 0.20 mm 0.020 to 0.031 in. 0.0079 in. Brush Lenght 16.0 mm 10.5 mm 0.630 in.

  • Page 74: Engine [D1005, V1305

    GENERAL J SERIES, WSM (3) Engine [D1005, V1305] (A) Engine Body Item Factory Specification Allowable Limit Cylinder Head Surface Flatness – 0.05 mm. 0.0020 in. Top Clearance 0.55 to 0.70 mm – 0.0217 to 0.0276 in. Compression Pressure (When Cranking with Starting Motor) 2.84 to 3.24 MPa 2.26 MPa 29.0 to 33.0 kgf/cm...
  • Page 75 GENERAL J SERIES, WSM Engine Body (Continued) Item Factory Specification Allowable Limit Valve Spring Free Length 37.0 to 37.5 mm 36.5 mm 1.46 to 1.48 in. 1.44 in. Setting Load 118 N 100.0 N 12.0 kgf 10.2 kgf 26.4 lbs 22.5 lbs Setting Length 31.0 mm...
  • Page 76 GENERAL J SERIES, WSM Engine Body (Continued) Item Factory Specification Allowable Limit Timing Gear Crank Gear to Idle Gear Backlash 0.032 to 0.115 mm 0.15 mm 0.00120 to 0.00453 in. 0.0059 in. Idle Gear to Cam Gear Backlash 0.036 to 0.114 mm 0.15 mm 0.00142 to 0.00449 in.
  • Page 77 GENERAL J SERIES, WSM Engine Body (Continued) Item Factory Specification Allowable Limit Crankshaft Journal to Crankshaft Oil Clearance 0.034 to 0.114 mm 0.20 mm Bearing 1 0.00134 to 0.00449 in. 0.0079 in. O.D. 47.934 to 47.950 mm – Crankshaft Journal 1.88716 to 1.88779 in.
  • Page 78 GENERAL J SERIES, WSM (D) Fuel System Injection Pump Injection Timing 0.37 to 0.41 rad. – 21 to 23  before T.D.C. Pump Element Fuel Tightness – 14.7 MPa 150 kgf/cm 2130 psi Delivery Valve Fuel Tightness – 5 seconds 14.713.7 MPa 150140 kgf/cm 21301990 psi...
  • Page 79 GENERAL J SERIES, WSM Alternator Item Factory Specification Allowable Limit Output Characteristics 13.5 V, 30 A at – 83.3 s (5000 rpm) rpm Regulating Voltage 14.2 to 14.8 V – 19 s (1150 rpm) No-Load Characteristics – or less at 13.5 V 2.9 ...

  • Page 80: Tightening Torques

    GENERAL J SERIES, WSM [6] TIGHTENING TORQUES Screws, bolts and nuts must be tightened to the specified torque using a torque wrench, Several screws, bolts and nuts such as those used on the cylinder head must be tightened in proper sequence and at the proper torque. (1) Tightening Torques for Special Use Screws, Bolts and Nuts NOTE ...

  • Page 81: Tightening Torques For General Use Screws, Bolts And Nuts

    GENERAL J SERIES, WSM [D1005, V1305] Section Item N·m kgf·m ft-lbs Rear bracket mounting screw 24.5 to 34.3 2.5 to 3.5 18.1 to 25.3 Stator housing mounting screw 19.6 to 27.4 2.0 to 2.8 14.5 to 20.3 Generator Cooling fan mounting screw 19.6 to 27.4 2.0 to 2.8 14.5 to 20.3...

  • Page 82: Maintenance Check List

    GENERAL J SERIES, WSM [7] MAINTENANCE CHECK LIST Observe the following for service and maintenance. The lubricating oil change intervals listed in the table below are for classes CG, CE and CD lubricating oil of API classification with a low-sulfur fuel in use. If the CF-4 of CG-4 lubricating oil is used with a high-sulfur fuel, change the lubricating oil at shorter intervals than recommended in the table below depending on the operating condition.

  • Page 83: Checking And Maintenance (Generator

    GENERAL J SERIES, WSM [8] CHECKING AND MAINTENANCE (GENERATOR) (1) Generator (A) Check Points of Every 300 Hours Brush Wear 1. Check to see if the brush has worn to more than 1/2 below the standard dimensions. 2. If wear exceeds the allowable limit, replace. 15.0 mm Standard length 0.59 in.

  • Page 84: Engine

    GENERAL J SERIES, WSM (2) Engine (A) Check Points of Daily Checking Engine Oil Level CAUTION • Be sure to stop the engine before checking the engine oil level. 1. Level the engine and check the oil level on the gauge (1). 2.
  • Page 85  • To prevent serious damage to the engine, replacement oil filter cartridge must be highly efficient. Use only a genuine KUBOTA filter cartridge or its equivalent. (1) Engine Oil Filter Cartridge W12122640 (C) Check Points of Every 50 Hours...
  • Page 86 GENERAL J SERIES, WSM (D) Check points of Every 100 Hours Checking Air Cleaner Element 1. Remove the air cleaner element. 2. Use clean dry compressed air on the inside of the element. Air pressure at the nozzle must not exceed 690 kPa (7 kgf/cm , 100 psi).
  • Page 87 GENERAL J SERIES, WSM (E) Check Points of Every 200 Hours Checking Radiator Hose (Water Pipes) 1. Check to see if the radiator hoses (2) are properly fixed every 200 hours of operation or every six months, whichever comes first. 2.
  • Page 88 GENERAL J SERIES, WSM (J) Check Points of Every 2 Years Changing Fuel Line and Clamp CAUTION • Stop the engine when attempting to check the fuel line. • Never fail to check the fuel line periodically. The fuel line is subject to wear and aging, fuel may leak out onto the running engine, causing a fire.

  • Page 89: Special Tools

    GENERAL J SERIES, WSM SPECIAL TOOLS Valve Seat Cutter Set Code No: 07909-33102 Application: Use to reseat valves. Angle: 0.785 rad. (45) 0.262 rad. (15) Diameter: 28.6 mm (1.126 in.) 31.6 mm (1.244 in.) 35.0 mm (1.378 in.) 38.0 mm (1.496 in.) 41.3 mm (1.626 in.) 50.8 mm (2.000 in.) W12268050...
  • Page 90 GENERAL J SERIES, WSM Special-use Puller Set Code No: 07916-09032 Application: Use exclusively for pulling out bearings, gears and other parts with ease. W12285330 Connecting Rod Alignment Tool Code No: 07909-31661 Application: Use to check the connecting rod alignment. Applicable range: Connecting rod big end I.D. 30 to 75 mm (1.18 to 2.95 in.dia.) Connecting rod length.
  • Page 91 GENERAL J SERIES, WSM Radiator Tester Code No: 07909-31551 Application: Use to check of radiator cap pressure, and leaks from cooling system. Adapter: BANZAI Code No. RCT-2A-30S W1251713 NOTE  • The following special tools are not provided, so make them referring to the figure. Injection Pump Pressure Tester Application: Use to check fuel tightness of injection pumps.
  • Page 92 GENERAL J SERIES, WSM Valve Guide Replacing Tool Application: Use to press out and press fit the valve guide. [Z482, D722] 20 mm dia. (0.79 in. dia.) 9.96 to 9.98 mm dia. (0.3921 to 0.3929 in. dia.) 5.5 to 5.7 mm dia. (0.2165 to 0.2244 in.
  • Page 93 GENERAL J SERIES, WSM Idle Gear Bushing Replacing Tool Application: Use to press out and press fit the idle gear bushing. [Z482, D722] 150 mm (5.91 in.) 30 mm (1.18 in.) 20 mm (0.79 in.) 21.90 to 21.95 mm dia. (0.8622 to 0.8642 in.
  • Page 94 GENERAL J SERIES, WSM Crankshaft Bearing 1 Replacing Tool Application: Use to press out and press fit the crankshaft bearing 1. [Z482, D722] 130 mm (5.12 in.) 65 mm (2.56 in.) 1.57 rad. (40 ) 10 mm (0.39 in.) 22 mm (0.87 in.) 20 mm dia.

  • Page 95: Generator

    GENERATOR J SERIES, WSM 2. GENERATOR [1] DISASSEMBLING AND ASSEMBLING External Component Cover, Panel, Control Panel, Bonnet and Fuel Tank 1. Place the machine on firm and level surface. 2. Remove the both side cover (2). 3. Remove the negative wire from the battery and disconnect the lead wire from the stop solenoid, the glow plug, the water temperatur sensor, oil switch, the alternator (AC dynamo), the fuse box, and the earth.

  • Page 96: Generator

    GENERATOR J SERIES, WSM (2) Generator Rear Bracket 1. Remove the rear bracket mounting nuts. 2. Disconnect the wire harness and the carbon brushes,etc. 3. Lift up the generator. 4. Remove the rear bracket (1). (When reassembling) • Clean dirt from the bearing housing. •...
  • Page 97 GENERATOR J SERIES, WSM Rotor Assembly 1. Remove the cooling fan (2). 2. To avoid damage to the rotor assembly (1), suspend the rotor assembly (1) with a sling belt enough to keep it from lifting, and leave it suspended. 3.

  • Page 98: Servicing

    GENERATOR J SERIES, WSM [2] SERVICING Terminal Voltage for Each Part During Normal Periods (No-load Periods) Output Terminal 1. 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.

  • Page 99: Rotor Coil

    GENERATOR J SERIES, WSM Rotor Coil Main Field Winding (Rotor Coil) 1. Measure the coil resistance between each end of field coil. 2. If the resistance is not as specified, replace the rotor assembly or contact service station. Factory Rotor Resistance See page S-18, S-19 spec.

  • Page 100: Exciter Coil

    GENERATOR J SERIES, WSM Exciter Coil Exciter Field Winding (Sub Coil) 1. 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. Factory –...

  • Page 101: Emergency Relay Activates

    GENERATOR J SERIES, WSM Lamp Timer (for Glow Plug) [Z482, D722] 1. Remove the lamp timer from inside of the panel. 2. Connect the battery (4), lamp timer (1) and bulb (2) as shown in the figure. 3. The bulb (2) light up when contacting the lead wire 1 (3) with positive terminal of the battery (4) and goes off approximately 6 seconds late, the lamp relay is proper.
  • Page 102 GENERATOR J SERIES, WSM Oil Switch 1. 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. In normal state Infinity Resistance At pressure over...
  • Page 103 GENERATOR J SERIES, WSM Stop Solenoid [D1005, V1305] 1. Disconnect a lead wire (1) from ST terminal on starter. 2. Key switch turn to “ON” position, then the solenoid should operate strongly with an audible click, if not. 3. Remove the solenoid and check the continuity of pull-coil and hold-coil as well as checking plunger moving.

  • Page 104: Engine

    ENGINE J SERIES, WSM 3. ENGINE [1] ENGINE BODY (1) Checking and Adjusting Compression Pressure 1. After warming up the engine, stop it and remove the air cleaner, the muffler and all nozzle holders. 2. Install a compression tester (Code No: 07909-30207) for diesel engines to nozzle holder hole.
  • Page 105 ENGINE J SERIES, WSM Top Clearance 1. 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 grease so as to avoid the intake and exhaust valves and the combustion chamber ports.
  • Page 106 ENGINE J SERIES, WSM Valve Clearance IMPORTANT  • Valve clearance must be checked and adjusted when engine is cold. 1. Remove the head cover, the glow plugs and the timing window cover on the flywheel housing. 2. Align the 1TC mark line on the flywheel and center of timing window so that the No.

  • Page 107: Disassembling And Assembling

    ENGINE J SERIES, WSM (2) Disassembling and Assembling (A) Cylinder Head and Valves Cylinder Head Cover 1. Remove the head cover cap nuts. 2. Remove the cylinder head cover. (When reassembling) • Check to see if the cylinder head cover gasket is not defective. •...
  • Page 108 ENGINE J SERIES, WSM Rocker Arm Assembly and Push Rod 1. Remove the rocker arm bracket mounting nuts, and remove the rocker arm assembly (1). 2. Remove the push rods (2). (When reassembling) • Insert the push rods into the tappets securely. •...
  • Page 109 ENGINE J SERIES, WSM Valves 1. Remove the valve caps (2). 2. Remove the valve spring collet (3), pushing the valve spring retainer (4) by valve spring replacer (1). 3. Remove the valve spring retainer (4), valve spring (5) and valve stem seal (6).
  • Page 110 ENGINE J SERIES, WSM Fan Drive Pulley 1. Set the stopper to the flywheel. 2. Remove the fan drive pulley retaining screw. 3. Draw out the fan drive pulley with a puller. (When reassembling) • Install the pulley to the crankshaft, aligning the aligning marks (1) on them.
  • Page 111 ENGINE J SERIES, WSM Idle Gear and Camshaft 1. Remove the idle gear (3). 2. Align the round hole on the cam gear (5) with the camshaft stopper mounting screw position and remove the screws. 3. Remove the cam gear (5) with camshaft (6). IMPORTANT ...
  • Page 112 ENGINE J SERIES, WSM (C) Timing Gear, Camshaft and Fuel Camshaft [D1005, V1305] Fan Drive Pulley 1. Set the stopper to the flywheel. 2. Remove the fan drive pulley retaining screw (1). 3. Draw out the fan drive pulley (2) with a puller. (When reassembling) •...
  • Page 113 ENGINE J SERIES, WSM Gear Case 1. Remove the fuel feed pump. 2. Remove the gear case. 3. Remove the crankshaft collar and O-rings. (When reassembling) • Replace the gear case gasket with a new one. • Be sure to set four O-rings inside the gear case and the O-ring on the crankshaft.
  • Page 114 ENGINE J SERIES, WSM Injection Pump 1. Remove the injection pump mounting screws and nuts. 2. Align the control rack pin (2) with the notch (3) on the crankcase, then remove the injection pump (1). 3. Remove the injection pump timing shims. 4.
  • Page 115 ENGINE J SERIES, WSM Governor Shaft 1. Remove the external snap ring (1) from the governor shaft (2). 2. Pull out the governor shaft (2). (When reassembling) • Make sure assembling the external snap ring of the governor shaft. • Check the governor shaft for smooth rotation. IMPORTANT ...
  • Page 116 ENGINE J SERIES, WSM Fork Lever 1. Remove the start spring (7). 2. Remove the fork lever shaft cover (1). 3. Pull out the fork lever shaft (4), and remove the spacer (2), bearing (3), fork lever 1 (6) and fork lever 2 (5). (When reassembling) •...
  • Page 117 ENGINE J SERIES, WSM (D) Connecting Rod and Piston Oil Pan and Oil Strainer 1. Remove the oil pan mounting screws. 2. Remove the oil pan (4) by lightly tapping the rim of the pan with a wooden hammer. 3. Remove the oil strainer (3). (When reassembling) •...
  • Page 118 ENGINE J SERIES, WSM Pistons 1. Turn the flywheel and bring the piston to top dead center. 2. Draw out the piston upward by lightly tapping it from the bottom of the crankcase with the grip of a hammer. 3. Draw out the other piston in the same method as above. (When reassembling) •...
  • Page 119 ENGINE J SERIES, WSM Piston Ring and Connecting Rod 1. Remove the piston rings using a piston ring tool. 2. Remove the piston pin (1), and separate the connecting rod (7) from the piston (2). (When reassembling) • When installing the rings, assemble the rings so that the manufacturer’s mark (12) near the gap faces the top of the piston.
  • Page 120 ENGINE J SERIES, WSM (E) Crankshaft Flywheel 1. Fit the stopper to the flywheel. 2. At first, remove two pieces of the flywheel screws. 3. Insert two pieces of the flywheel guide screws in the holes. 4. Remove all flywheel screws. 5.
  • Page 121 ENGINE J SERIES, WSM Crankshaft Assembly 1. Remove the main bearing case screw 2 (1). 2. Pull out the crankshaft assembly. IMPORTANT  • Take care to protect crankshaft bearing 1 from scratches, caused by the crank gear, etc. (Wrap the gear in vinyl tape, etc.) (D1005 and V1305 only) (When reassembling) •...

  • Page 122: Servicing

    ENGINE J SERIES, WSM (3) Servicing (A) Cylinder Head and Valves Cylinder Head Surface Flatness 1. Clean the cylinder head surface. 2. Place a straightedge on the cylinder head’s four sides and two diagonal as shown in the figure. 3. Measure the clearance with a feeler gauge. 4.
  • Page 123 ENGINE J SERIES, WSM Valve Recessing 1. 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.
  • Page 124 ENGINE J SERIES, WSM Clearance between Valve Stem and Valve Guide 1. 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.
  • Page 125 ENGINE J SERIES, WSM Correcting Valve and Valve Seat NOTE  • Before correcting the valve and seat, check the valve stem and the I.D. of the valve guide section, and repair them if necessary. • After correcting the valve seat, be sure to check the valve recessing.
  • Page 126 ENGINE J SERIES, WSM Free Length and Tilt of Valve Spring 1. Measure the free length (A) of valve spring with venire 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.
  • Page 127 ENGINE J SERIES, WSM Oil Clearance between Rocker Arm and Rocker Arm Shaft 1. 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.
  • Page 128 ENGINE J SERIES, WSM Oil Clearance between Tappet and Tappet Guide Bore 1. 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.
  • Page 129 ENGINE J SERIES, WSM (B) Timing Gears, Camshaft and Fuel Camshaft Timing Gear Backlash 1. 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.
  • Page 130 ENGINE J SERIES, WSM Idle Gear Side Clearance 1. 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.
  • Page 131 ENGINE J SERIES, WSM Cam Height 1. 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. [Z482, D722] 26.88 mm Factory spec. 1.0583 in.
  • Page 132 ENGINE J SERIES, WSM Oil Clearance between Idle Gear Shaft and Idle Gear Bushing 1. 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.
  • Page 133 ENGINE J SERIES, WSM (C) Piston and Connecting Rod Piston 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.
  • Page 134 ENGINE J SERIES, WSM Replacing Small End Bushing (When removing) 1. Press out the used bushing using a small end bushing replacing tool. (When installing) 1. Clean a new small end bushing and bore, and apply engine oil to them. 2.
  • Page 135 ENGINE J SERIES, WSM Piston Ring Gap 1. Insert the piston ring into the lower part of the cylinder (the least worn out part) with a piston ring compressor and piston. 2. Measure the ring gap with a feeler gauge. 3.
  • Page 136 ENGINE J SERIES, WSM Connecting Rod Alignment NOTE  • Since the I.D. of the connecting rod small end bushing is the basis of this check, check the bushing for wear before hand. 1. Remove the crankpin bearing, and install the connecting rod cap. 2.
  • Page 137 ENGINE J SERIES, WSM Crankshaft Side Clearance (Continued) • Oversize dimensions of crankshaft journal [Z482, D722] Oversize 0.2 mm0.008 in. 0.4 mm0.016 in. 23.40 to 23.45 mm0.9134 to 23.80 to 23.85 mm Dimension A 0.9154 in. 0.9213 to 0.9232 in. 46.1 to 46.3 mm1.815 to 46.3 to 46.5 mm Dimension B...
  • Page 138 ENGINE J SERIES, WSM Oil Clearance between Crankpin and Crankpin Bearing 1. Clean the crankpin and crankpin bearing. 2. Put a strip of plastigage (Code No. 07909-30241) 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.
  • Page 139 ENGINE J SERIES, WSM Oil Clearance between Crankpin and Crankpin Bearing (Continued) (Reference) • Undersize crankpin bearing. [Z482, D722] Undersize Bearing Code Number Marking 0.2mm Crankpin bearing 02 15861-22971 020 US 0.008 in. 0.4mm Crankpin bearing 04 15861-22981 040 US 0.016 in.
  • Page 140 ENGINE J SERIES, WSM Oil Clearance between Crankshaft Journal and Crankshaft Bearing 1 1. Measure the O.D. of the crankshaft front journal with an outside micrometer. 2. Measure the I.D. of the crankshaft bearing 1 with an inside micrometer, and calculate the oil clearance. 3.
  • Page 141 ENGINE J SERIES, WSM Oil Clearance between Crankshaft Journal and Crankshaft Bearing 1 (Continued) (Reference) • Undersize crankshaft bearing 1 [Z482, D722] Undersize Bearing Code Number Marking 0.2 mm Crankshaft bearing 1 02 15861-23911 020 US 0.008 in. 0.4 mm Crankshaft bearing 1 04 15861-23921 040 US...
  • Page 142 ENGINE J SERIES, WSM Replacing Crankshaft Bearing 1 (When removing) 1. Press out the used crankshaft bearing 1 using a crankshaft bearing 1 replacing tool. (When installing) 1. Clean a new crankshaft bearing 1 and crankshaft journal bore, and apply engine oil to them. 2.
  • Page 143 ENGINE J SERIES, WSM Oil Clearance between Crankshaft Journal and Crankshaft Bearing 2 and Crankshaft Bearing 3 1. Put a strip of plastigage (Code No. 07909-30241) on the center of the journal. 2. Install the bearing case and tighten the bearing case screws 1 to the specified torque, and remove the bearing case again.
  • Page 144 ENGINE J SERIES, WSM Oil Clearance between Crankshaft Journal and Crankshaft Bearing 2 and Crankshaft Bearing 3 (Continued) (Reference) • Undersize crankshaft bearing 2 and 3 [Z482, D722] Undersize Bearing Code Number Marking Crankshaft bearing 2 15694-23931 020 US 0.2 mm 0.008 in.
  • Page 145 ENGINE J SERIES, WSM (E) Cylinder Cylinder Wear 1. 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.
  • Page 146 ENGINE J SERIES, WSM Correcting Cylinder 1. When the cylinder is worn beyond the allowable limit, bore and hone it to the specified dimension. [Z482, D722] 67.250 to 67.269 mm Factory spec. 2.64764 to 2.64839 in. Oversized cylinder liner I.D. 67.419 mm Allowable limit 2.65429 in.

  • Page 147: Checking

    ENGINE J SERIES, WSM [2] LUBRICATING SYSTEM (1) Checking Engine Oil Pressure 1. Remove the oil switch, and set a oil pressure tester (Code No. 07916-32032). 2. Start the engine. After warming up, measure the oil pressure of rated speeds. 3.
  • Page 148 ENGINE J SERIES, WSM Clearance between Outer Rotor and Pump Body 1. Measure the clearance between the outer rotor and the pump body with a feeler gauge. 2. If the clearance exceeds the factory specifications, replace the oil pump rotor assembly. Z482 0.07 to 0.15 mm Clearance between...

  • Page 149: Cooling System

    ENGINE J SERIES, WSM [3] COOLING SYSTEM (1) Checking and Adjusting Fan Belt Tension 1. Measure the deflection (A), depressing the belt halfway between the fan drive pulley and alternator at specified force (98 N, 10 kgf, 22 lbs). 2. If the measurement is not within the factory specifications, loosen the alternator mounting screws and relocate the alternator to adjust.
  • Page 150 ENGINE J SERIES, WSM Thermostat Valve Opening Temperature 1. 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.

  • Page 151: Checking And Adjusting

    ENGINE J SERIES, WSM [4] FUEL SYSTEM (1) Checking and Adjusting (A) Injection Pump Injection Timing 1. Remove the injection pipes. 2. Set the speed control lever to the maximum fuel discharge position. 3. Turn the flywheel counterclockwise (facing the flywheel) until fuel flows from the delivery valve holder.
  • Page 152 ENGINE J SERIES, WSM Fuel Tightness of Delivery Valve 1. Remove the injection pipes and glow plugs. 2. Set a pressure tester to the fuel injection pump. 3. Turn the flywheel and raise the pressure to approx. 14.7 MPa (150 kgf/cm , 2130 psi).

  • Page 153: Disassembling And Assembling

    ENGINE J SERIES, WSM Nozzle Spraying Condition 1. Set the injection nozzle to a nozzle tester (Code No. 07909- 31361), and check the nozzle spraying condition. 2. If the spraying condition is defective, replace the nozzle piece. (a) Good (b) Bad W10411400 Valve Seat Tightness 1.

  • Page 154: Electrical System

    ENGINE J SERIES, WSM [5] ELECTRICAL SYSTEM (1) Checking (A) Starter 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 and the leads from the starter B terminal.
  • Page 155 ENGINE J SERIES, WSM (C) Dynamo and Regulator [Z482, D722] Dynamo No-load voltage 1. Disconnect the lead wire from the dynamo. 2. Start the engine and measure the voltage generated by the dynamo. 3. Measure the output voltage with a voltmeter. If the measurement is not within the factory specifications, replace the dynamo.
  • Page 156 ENGINE J SERIES, WSM Regulating Voltage 1. Make the connections as shown in the figure, and turn on switch SW1. 2. Increase the alternator speed to 83.3 (5000 rpm). 3. Turn on switch SW2. Adjust load resistance R so that the ammeter shows 10 A.

  • Page 157: Disassembling And Assembling

    ENGINE J SERIES, WSM (2) Disassembling and Assembling (A) Starter [Z482, D722] (1) Solenoid Switch Mounting Nut (2) Starter Drive Housing (3) Drive Lever (4) Gasket (5) Solenoid Switch (6) Nut (7) Snap Ring (8) Overrunning Clutch (9) Armature (10) Brush Spring (11) Connecting Lead (12) Rear End Frame (13) Gasket...
  • Page 158 ENGINE J SERIES, WSM (B) Starter [D1005, V1305] Starter Motor 1. Disconnect the connecting lead. 2. Remove the mounting nuts. 3. Remove the magnet switch by sliding it up so that is disconnected from the driver lead. W1151715 Brush Holder 1.
  • Page 159 ENGINE J SERIES, WSM (C) Dynamo [Z482, D722] Stator 1. Remove the nut (3) and separate the stator comp (4). 2. Unscrew the screws (1) and remove the stator (2). (1) Screw (3) Nut (2) Stator (4) Stator Comp W1152409 Rotor 1.
  • Page 160 ENGINE J SERIES, WSM IC Regulator 1. Unscrew the three screws holding the IC regulator, and remove the IC regulator (1). (1) IC Regulator W1154950 Rectifier 1. Remove the four screws holding the rectifier and the stator lead wires. 2. Remove the rectifier (1). (1) Rectifier W1155083 Rear End Frame...

  • Page 161: Servicing

    ENGINE J SERIES, WSM Bearing on Drive End Side 1. Press out the bearing from drive end frame (3) with a press and jig (1). (1) Jig (3) Drive End Frame (2) Block W1155468 Bearing at Slip Ring Side 1. Lightly secure the rotor (1) with a vise to prevent damage, and remove the bearing (2) with a puller (3).
  • Page 162 ENGINE J SERIES, WSM Brush Wear 1. If the connect 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 than the allowable limit, replace the yoke assembly and brush holder.
  • Page 163 ENGINE J SERIES, WSM Overrunning Clutch 1. Inspect the pinion for wear or damage. 2. If there is any defect, replace the overrunning clutch assembly. 3. Check that the pinion turns freely and smoothly in the overrunning direction and dose not slip in the cranking directions. 4.
  • Page 164 ENGINE J SERIES, WSM (B) Dynamo [Z482, D722] Bearing 1. Check the bearing for smooth rotation. 2. If it dose not rotate smoothly, replace it. W1157349 (C) Alternator [D1005, V1305] Bearing 1. Check the bearing for smooth rotation. 2. If it dose not rotate smoothly, replace it. W1157436 Stator 1.
  • Page 165 ENGINE J SERIES, WSM Brush Wear 1. Measure the brush length with vernier caliper. 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. 10.0 mm Factory spec.
  • Page 166 : Farm and Industrial Machinery International Service Department Address 64, Ishizu-Kitamachi, Sakai-Ku, Sakai-City, Osaka, 590-0823, Japan Phone +81- 72-241-1129 +81- 72-245-2484 E-mail : ks_g.ksos-pub@kubota.com Printed in Japan 2016. 10, S, EI, EI, engusa Code No.9Y011-01945 2000. 10, S, EI, EI, engusa KUBOTA Corporation...

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