Nanni N3.30 Workshop Manual
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Nanni N3.30 Workshop Manual

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WORK SHOP MANUAL
ENGINE BASE
N3.30
(Starting serial number: KTD08090423)
NANNI INDUSTRIES S.A.S – Zone Industrielle
11 avenue MARIOTTE
B.P.107 – 33260 LA TESTE - FRANCE
60300187

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  • Page 1 WORK SHOP MANUAL ENGINE BASE N3.30 (Starting serial number: KTD08090423) NANNI INDUSTRIES S.A.S – Zone Industrielle 11 avenue MARIOTTE B.P.107 – 33260 LA TESTE - FRANCE 60300187...
  • Page 2 TO THE READER This Workshop Manual has been prepared to provide servicing personnel with information on the mechanism, service and maintenance of 05-E3B. It is divided into three parts, “General”, “Mechanism” and “Servicing”. General Information on the engine identification, the general precautions, maintenance check list, check and maintenance and special tools are described.
  • Page 3 05-E3B, 05-E3BG, WSM SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS SAFETY FIRST This symbol, the industry’s “Safety Alert Symbol”, is used throughout this manual and on labels on the machine itself to warn of the possibility of personal injury. Read these instructions carefully. It is essential that you read the instructions and safety regulations before you attempt to repair or use this unit.
  • Page 4 05-E3B, 05-E3BG, 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 •...
  • Page 5 05-E3B, 05-E3BG, WSM SAFETY INSTRUCTIONS AVOID FIRES • Fuel is extremely flammable and explosive under certain conditions. Do not smoke or allow flames or sparks in your working area. • To avoid sparks from an accidental short circuit, always disconnect the battery negative cable first and connect it last.
  • Page 6 05-E3B, 05-E3BG, 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 your telephone. KiSC issued 12, 2007 A...

  • Page 7: Technical Data

    19/02/2009 TECHNICAL DATA ENGINE MODEL N3.30 (Since serial number KTD08090423) LUBRIFICATION ENGINE SPECIFICATION Oil pressure at idle RPM: 0.5 bar Number of cylinders: 3 Oil pressure at maximum load: Displacement: 1123 cc 2 to 4.5 bars Bore - Stroke: 78 X 78.4 mm...

  • Page 14: Table Of Contents

    GENERAL CONTENTS 1. ENGINE IDENTIFICATION ................G-1 [1] MODEL NAME AND ENGINE SERIAL NUMBER ........ G-1 [2] E3B ENGINE..................... G-3 [3] CYLINDER NUMBER ................G-3 2. GENERAL PRECAUTIONS ................G-4 3. MAINTENANCE CHECK LIST ............... G-5 4. CHECK AND MAINTENANCE ............... G-7 [1] DAILY CHECK POINTS................

  • Page 15: Engine Identification

    05-E3B, 05-E3BG, WSM G GENERAL 1. ENGINE IDENTIFICATION [1] MODEL NAME AND ENGINE SERIAL NUMBER When contacting the manufacture, always specify your engine model name and serial number. The engine model and its serial number need to be identified before the engine can be serviced or parts replaced. Engine Serial Number The engine serial number is an identified number for the engine.
  • Page 16 05-E3B, 05-E3BG, WSM G GENERAL • Month of manufacture Month Engine Lot Number January A0001 ~ A9999 B0001 ~ BZ999 February C0001 ~ C9999 D0001 ~ DZ999 March E0001 ~ E9999 F0001 ~ FZ999 April G0001 ~ G9999 H0001 ~ HZ999 J0001 ~ J9999 K0001 ~ KZ999 June...

  • Page 17: E3B Engine

    05-E3B, 05-E3BG, WSM G GENERAL [2] E3B ENGINE [Example : Engine Model Name D1105-E3B-XXXX] The emission controls previously implemented in various countries to prevent air pollution will be stepped up as Non-Road Emission Standards continue to change. The timing or applicable date of the specific Non-Road Emission regulations depends on the engine output classification.

  • Page 18: General Precautions

    05-E3B, 05-E3BG, WSM G GENERAL 2. GENERAL PRECAUTIONS • During disassembly, carefully arrange removed parts in a clean area to prevent confusion later. Screws, bolts and nuts should be replaced in their original position to prevent reassembly errors. • When special tools are required, use KUBOTA genuine special tools.

  • Page 19: Maintenance Check List

    05-E3B, 05-E3BG, WSM G GENERAL 3. MAINTENANCE CHECK LIST To maintain long-lasting and safe engine performance, make it a rule to carry out regular inspections by following the table below. Service Interval Every Item 1 or 2 1500 3000 months 1 year 2 years * Checking fuel hoses and clamp bands * Changing engine oil...
  • Page 20 05-E3B, 05-E3BG, WSM G GENERAL CAUTION • When changing or inspecting, be sure to level and stop the engine. NOTE Engine Oil : • Refer to the following table for the suitable American Petroleum Institute (API) classification of engine oil according to the engine type (with internal EGR, external EGR or non-EGR) and the Fuel Type Used : (Low Sulfur, Ultra Low Sulfur or High Sulfur Fuels).

  • Page 21: Check And Maintenance

    05-E3B, 05-E3BG, WSM G GENERAL 4. CHECK AND MAINTENANCE [1] DAILY CHECK POINTS Checking Engine Oil Level 1. Level the engine. 2. To check the oil level, draw out the dipstick (1), wipe it clean, reinsert it, and draw it out again. Check to see that the oil level lies (A) between the two notches.
  • Page 22 05-E3B, 05-E3BG, WSM G GENERAL Checking and Replenish Coolant 1. Without recovery tank : Remove the radiator cap (1) and check to see that the coolant level is just below the port. With recovery tank (2) : Check to see that the coolant level lies between FULL (A) and LOW (B).

  • Page 23: Check Points Of Initial 50 Hours

    05-E3B, 05-E3BG, WSM G GENERAL [2] CHECK POINTS OF INITIAL 50 HOURS Changing Engine Oil CAUTION • Be sure to stop engine before changing engine oil. 1. Start and warm up the engine for approx. 5 minutes. 2. Place an oil pan underneath the engine. 3.
  • Page 24 05-E3B, 05-E3BG, WSM G GENERAL Replacing Oil Filter Cartridge CAUTION • Be sure to stop the engine before changing filter cartridge. 1. Remove the oil filter cartridge with the filter wrench. 2. Apply a slight coat of oil onto the new cartridge gasket. 3.

  • Page 25: Check Points Of Every 50 Hours

    05-E3B, 05-E3BG, WSM G GENERAL [3] CHECK POINTS OF EVERY 50 HOURS Checking Fuel Hose 1. If the clamp (2) is loose, apply oil to the threads and securely retighten it. 2. The fuel hose (1) is made of rubber and ages regardless of the period service.

  • Page 26: Check Points Of Every 100 Hours

    05-E3B, 05-E3BG, WSM G GENERAL [4] CHECK POINTS OF EVERY 100 HOURS Cleaning Air Cleaner Element 1. Remove the air cleaner element. 2. Use clean dry compressed air on the inside of the element. Pressure of compressed air must be under 205 kPa (2.1 kgf/cm 30 psi).
  • Page 27 05-E3B, 05-E3BG, WSM G GENERAL Fan Belt Damage and Wear 1. Check the fan belt for damage. 2. If the fan belt is damaged, replace it. 3. Check if the fan belt is worn and sunk in the pulley groove. 4.

  • Page 28: Check Points Of Every 200 Hours

    05-E3B, 05-E3BG, WSM G GENERAL [5] CHECK POINTS OF EVERY 200 HOURS Changing Engine Oil CAUTION • Be sure to stop engine before changing engine oil. 1. Start and warm up the engine for approx. 5 minutes. 2. Place an oil pan underneath the engine. 3.
  • Page 29 05-E3B, 05-E3BG, WSM G GENERAL Replacing Oil Filter Cartridge CAUTION • Be sure to stop the engine before changing filter cartridge. 1. Remove the oil filter cartridge with the filter wrench. 2. Apply a slight coat of oil onto the new cartridge gasket. 3.

  • Page 30: Check Points Of Every 400 Hours

    05-E3B, 05-E3BG, WSM G GENERAL [6] CHECK POINTS OF EVERY 400 HOURS Replacing Fuel Filter Cartridge (Cartridge Type) Water and dust in fuel are collected in the filter cartridge. So, change the filter cartridge every 400 hours service. 1. Remove the used filter cartridge with filter wrench. 2.

  • Page 31: Check Points Of Every 500 Hours

    05-E3B, 05-E3BG, WSM G GENERAL [7] CHECK POINTS OF EVERY 500 HOURS 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 excess pressure before removing cap completely.
  • Page 32 05-E3B, 05-E3BG, WSM G GENERAL Anti-Freeze • There are two types of anti-freeze available: use the permanent type (PT) for this engine. • Before adding anti-freeze for the first time, clean the radiator interior by pouring fresh, soft water and draining it a few times. •...

  • Page 33: Check Points Of Every 1 Or 2 Months

    05-E3B, 05-E3BG, WSM G GENERAL [8] CHECK POINTS OF EVERY 1 OR 2 MONTHS Recharging CAUTION • When the battery is being activated, hydrogen and oxygen gases in the battery are extremely explosive. Keep open sparks and flames away from the battery at all times, especially when charging the battery.

  • Page 34: Check Points Of Every Year

    05-E3B, 05-E3BG, WSM G GENERAL Battery Specific Gravity 1. Check the specific gravity of the electrolyte in each cell with a hydrometer. 2. When the electrolyte temperature differs from that at which the hydrometer was calibrated, correct the specific gravity reading following the formula mentioned in (Reference).

  • Page 35: Check Points Of Every 800 Hours

    05-E3B, 05-E3BG, WSM G GENERAL [10] CHECK POINTS OF EVERY 800 HOURS Checking Valve Clearance IMPORTANT • Valve clearance must be checked and adjusted when engine is cold. 1. Remove the cylinder head cover and the glow plugs. 2. Align the “1TC” mark (1) on the flywheel and alignment mark (2) on the rear end plate so that the No.

  • Page 36: Check Points Of Every 1500 Hours

    05-E3B, 05-E3BG, WSM G GENERAL [11] 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.

  • Page 37: Check Points Of Every 3000 Hours

    05-E3B, 05-E3BG, WSM G GENERAL [12] CHECK POINTS OF EVERY 3000 HOURS Checking Turbocharger (Turbine Side) 1. Check the exhaust port (3) and inlet port (5) side of turbine housing (1) to see if there is no exhaust gas leak. 2.
  • Page 38 05-E3B, 05-E3BG, WSM G GENERAL Injection Timing 1. Remove the injection pipes. 2. Remove the engine stop solenoid. 3. Turn the flywheel counterclockwise (viewed from flywheel side) until the fuel fills up to the hole of the delivery valve holder (3) for No.
  • Page 39 05-E3B, 05-E3BG, 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 to the injection pump. 4. Install the injection nozzle (2) jetted with the proper injection pressure to the injection pump pressure tester (1).

  • Page 40: Check Points Of Every 2 Years

    05-E3B, 05-E3BG, WSM G GENERAL [13] CHECK POINTS OF EVERY 2 YEARS Replacing Intake Air Line 1. 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.
  • Page 41 05-E3B, 05-E3BG, WSM G GENERAL Replacing Fuel Hoses and Clamp Bands 1. Loosen the clamp (2) and remove the fuel hose (1). 2. Replace new fuel hose (1) and new clamp (2). 3. Tighten the clamp (2). CAUTION • Stop the engine when attempting the check and change prescribed above.
  • Page 42 05-E3B, 05-E3BG, WSM G GENERAL Changing 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 excess pressure before removing cap completely. 1. Stop the engine and let cool down. 2.
  • Page 43 05-E3B, 05-E3BG, 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. •...

  • Page 44: Special Tools

    05-E3B, 05-E3BG, WSM G GENERAL 5. SPECIAL TOOLS Diesel Engine Compression Tester (for Nozzle Hole) Code 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 and diagnosis of need for major overhaul.
  • Page 45 05-E3B, 05-E3BG, WSM G GENERAL 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. Pressure gauge full scale : More than 29.4 MPa (300 kgf/cm , 4267 psi) PF 1/2...
  • Page 46 05-E3B, 05-E3BG, WSM G GENERAL Bushing Replacing Tool Application: Use to press out and press in the bushing. 1. For small end bushing 157 mm (6.18 in.) 24 mm (0.94 in.) 120 mm (4.72 in.) 21.8 to 21.9 mm dia. (0.859 to 0.862 in. dia.) 24.8 to 24.9 mm dia.
  • Page 47 05-E3B, 05-E3BG, WSM G GENERAL Crankshaft Bearing 1 Replacing Tool Application: Use to press out and press in the crankshaft bearing 1. [Press Out] 135 mm (5.31 in.) 72 mm (2.8 in.) 40 mm radius (1.6 in. radius) 10 mm (0.39 in.) 24 mm (0.94 in.) 20 mm dia.
  • Page 48 05-E3B, 05-E3BG, WSM G GENERAL Crank Sleeve Setter Application: Use to fix the crankshaft sleeve. (1) Auxiliary Socket for Pushing 130 mm (5.12 in.) 112 mm (4.41 in.) 107 mm (4.21 in.) 82 mm (3.2 in.) 72 mm (2.8 in.) 67 mm (2.6 in.) 47 mm (1.8 in.) 36.00 to 36.20 mm (1.418 to 1.425 in.)
  • Page 49 MECHANISM CONTENTS 1. ENGINE BODY ....................M-1 [1] CLOSED BREATHER................M-1 [2] HALF-FLOATING HEAD COVER (D1305-E3B / E3BG) ......M-1 [3] GOVERNOR ....................M-2 [4] BOOST COMPENSATOR ................ M-4 KiSC issued 12, 2007 A...

  • Page 50: Engine Body

    05-E3B, 05-E3BG, WSM DIESEL ENGINE 1. ENGINE BODY [1] CLOSED BREATHER Closed breather system has been adopted to prevent the release of blow-by gas into the atmosphere. After its oil content is filtered by oil shield (4), the blow- by gas in fed back to the intake manifold through breather valve (3) to be used for re-combustion.

  • Page 51: Governor

    05-E3B, 05-E3BG, WSM DIESEL ENGINE [3] GOVERNOR Three Lever Type Fork Lever The governor system is a mechanical governor that used the flyweight (5). The flyweight (5) is mounted on the governor shaft that rotates at the same speed as the crankshaft. Because the feature of this mechanism takes out the engine speed directly as a centrifugal force of weight, the speed control that the change in the engine rotational...
  • Page 52 05-E3B, 05-E3BG, WSM DIESEL ENGINE (Overloaded Operation) The amount of the movement of the fork lever assembly is limited with the fuel limitation bolt (10) and can not be moved in the direction of the fuel increase. As overload reduces the centrifugal force of the governor weight, which is pressing the torque pin (8) into the floating lever (7), the floating lever pushes the fork lever 1 (6) in the way to increase the fuel supply with the...

  • Page 53: Boost Compensator

    05-E3B, 05-E3BG, WSM DIESEL ENGINE [4] BOOST COMPENSATOR (1) Boost Compensator Assembly (2) Actuator (3) Plate (4) Injection Pump Assembly (5) Guide (6) Stop Solenoid A : Fulcrum W1013537 Boost compensator is the device that reduces black smoke during the engine startup and acceleration. The rod of actuator (2) is pushed out by the rise of boost pressure, and the plate (3) moves in the direction of the fuel increase around the fulcrum (A).
  • Page 54 SERVICING CONTENTS 1. TROUBLESHOOTING ..................S-1 2. SERVICING SPECIFICATIONS ..............S-5 3. TIGHTENING TORQUES ................S-14 [1] TIGHTENING TORQUES FOR GENERAL USE SCREWS, BOLTS AND NUTS....................S-14 [2] TIGHTENING TORQUES FOR SPECIAL USE SCREWS, BOLTS AND NUTS....................S-15 4. CHECKING, DISASSEMBLING AND SERVICING........S-16 [1] CHECKING AND ADJUSTING ...............S-16 (1) Engine Body..................S-16 (2) Lubricating System ................S-18 (3) Cooling System...................S-18...

  • Page 55: Troubleshooting

    05-E3B, 05-E3BG, WSM DIESEL ENGINE 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Engine Does Not No fuel Replenish fuel G-11 Start Air in the fuel system Vent air G-11 Water in the fuel system Change fuel and – repair or replace fuel system Fuel pipe clogged Clean or replace...
  • Page 56 05-E3B, 05-E3BG, WSM DIESEL ENGINE Reference Symptom Probable Cause Solution Page Engine Revolution Is Fuel filter clogged or dirty Replace G-15, 16 Not Smooth Air cleaner clogged Clean or replace G-12, 15, Fuel leak due to loose injection pipe retaining nut Tighten retaining nut –...
  • Page 57 05-E3B, 05-E3BG, WSM DIESEL ENGINE Reference Symptom Probable Cause Solution Page Deficient Output Incorrect injection timing Adjust S-21 Engine’s moving parts seem to be seizing Repair or replace – Injection pump malfunctioning Repair or replace S-22, 39 Deficient nozzle injection Repair or replace S-23, 24 nozzle...
  • Page 58 05-E3B, 05-E3BG, WSM DIESEL ENGINE Reference Symptom Probable Cause Solution Page High Oil Pressure Different type of oil Use specified type of Relief valve defective Replace – Engine Overheated Engine oil insufficient Replenish Fan belt broken or elongated Replace or adjust G-12, 13 Coolant insufficient Replenish...

  • Page 59: Servicing Specifications

    05-E3B, 05-E3BG, WSM DIESEL ENGINE 2. SERVICING SPECIFICATIONS ENGINE BODY Item Factory Specification Allowable Limit Valve Clearance (Cold) 0.145 to 0.185 mm – 0.00571 to 0.00728 in. Compression Pressure D1005-E3B / E3BG 3.73 to 4.11 MPa 2.26 MPa D1105-E3B / E3BG 38.0 to 42.0 kgf/cm 23.0 kgf/cm D1305-E3B / E3BG...
  • Page 60 05-E3B, 05-E3BG, WSM DIESEL ENGINE ENGINE BODY (Continued) Item Factory Specification Allowable Limit Valve Spring Free Length 37.0 to 37.5 mm 36.5 mm 1.46 to 1.47 in. 1.44 in. Tilt – 1.0 mm 0.039 in. Setting Load 117.4 N / 31.0 mm 100.0 N / 31.0 mm 11.97 kgf / 31.0 mm 10.20 kgf / 31.0 mm...
  • Page 61 05-E3B, 05-E3BG, WSM DIESEL ENGINE ENGINE BODY (Continued) Item Factory Specification Allowable Limit Idle Gear Shaft to Gear Bushing Idle Gear 1 Clearance 0.020 to 0.054 mm 0.10 mm 0.00079 to 0.0021 in. 0.0039 in. Idle Gear Bushing I.D. 26.000 to 26.021 mm –...
  • Page 62 05-E3B, 05-E3BG, WSM DIESEL ENGINE ENGINE BODY (Continued) Item Factory Specification Allowable Limit Piston Ring Gap Top Ring 0.30 to 0.45 mm 1.25 mm [D1005-E3B / E3BG] 0.012 to 0.017 in. 0.0492 in. Second Ring 0.30 to 0.45 mm 1.25 mm 0.012 to 0.017 in.
  • Page 63 05-E3B, 05-E3BG, WSM DIESEL ENGINE Item Factory Specification Allowable Limit Crankshaft to Crankshaft Bearing 1 Oil Clearance 0.0340 to 0.114 mm 0.20 mm [D1005-E3B / E3BG], 0.00134 to 0.00448 in. 0.0079 in. [D1105-E3B / E3BG],[D1105-T-E3B], [V1505-E3B / E3BG], [V1505-T-E3B] Crankshaft O.D.
  • Page 64 05-E3B, 05-E3BG, WSM DIESEL ENGINE ENGINE BODY (Continued) Item Factory Specification Allowable Limit Crankshaft Side Clearance 0.15 to 0.31 mm 0.50 mm 0.0059 to 0.012 in. 0.020 in. Cylinder Liner I.D. D1005-E3B / E3BG 76.000 to 76.019 mm 76.15 mm 2.9922 to 2.9928 in.
  • Page 65 05-E3B, 05-E3BG, WSM DIESEL ENGINE COOLING SYSTEM Item Factory Specification Allowable Limit Fan Belt Tension 7.0 to 9.0 mm / 98 N – 0.28 to 0.35 in. / 98 N (10 kgf, 22 lbf) Thermostat Valve Opening 69.5 to 72.5 °C –...
  • Page 66 05-E3B, 05-E3BG, WSM DIESEL ENGINE FUEL SYSTEM Item Factory Specification Allowable Limit Injection Pump [D1005-E3B], [D1105-E3B], Injection Timing 0.3011 to 0.3272 rad – [D1305-E3B] (3000 min (rpm)) (17.25 to 18.75 °) before T.D.C. [D1105-T-E3B], [V1505-E3B], Injection Timing 0.2837 to 0.3097 rad –...
  • Page 67 05-E3B, 05-E3BG, WSM DIESEL ENGINE ELECTRICAL SYSTEM Item Factory Specification Allowable Limit Approx. 0.9 Ω Glow Plug Resistance – Starter (Gear Reduction Type) Commutator O.D. 30.0 mm 29.0 mm 1.18 in. 1.14 in. Difference O.D. Less than 0.02 mm 0.05 mm 0.0008 in.

  • Page 68: Tightening Torques

    05-E3B, 05-E3BG, WSM DIESEL ENGINE 3. TIGHTENING TORQUES Screws, bolts and nuts must be tightened to the specified torque using a torque wrench, several screws, bolts and nuts such as those used on the cylinder head must be tightened in proper sequence and the proper torque. [1] TIGHTENING TORQUES FOR GENERAL USE SCREWS, BOLTS AND NUTS When the tightening torques are not specified, tighten the screws, bolts and nuts according to the table below.

  • Page 69: Tightening Torques For Special Use Screws, Bolts And Nuts

    05-E3B, 05-E3BG, WSM DIESEL ENGINE [2] TIGHTENING TORQUES FOR SPECIAL USE SCREWS, BOLTS AND NUTS NOTE • For “ * ” marked screws, bolts and nuts on the table, apply engine oil to their threads and seats before tightening. • The letter “M” in Size x Pitch means that the screw, bolt or nut dimension stands for metric. The size is the nominal outside diameter in mm of the threads.

  • Page 70: Checking, Disassembling And Servicing

    05-E3B, 05-E3BG, WSM DIESEL ENGINE 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING (1) Engine Body Compression Pressure 1. Run the engine until it is warmed up. 2. Stop the engine. 3. Remove the air cleaner, the muffler and all glow plugs (or nozzles).
  • Page 71 05-E3B, 05-E3BG, WSM DIESEL ENGINE Valve Clearance IMPORTANT • Valve clearance must be checked and adjusted when engine is cold. 1. Remove the cylinder head cover and the glow plugs. 2. Align the “1TC” mark (1) on the flywheel and alignment mark (2) on the rear end plate so that the No.

  • Page 72: Cooling System

    05-E3B, 05-E3BG, WSM DIESEL ENGINE (2) Lubricating System Engine Oil Pressure 1. Remove the engine oil pressure switch, and set an oil pressure tester. 2. Start the engine. After warming up, measure the oil pressure of both idling and rated speeds. 3.
  • Page 73 05-E3B, 05-E3BG, WSM DIESEL ENGINE Fan Belt Damage and Wear 1. Check the fan belt for damage. 2. If the fan belt is damaged, replace it. 3. Check if the fan belt is worn and sunk in the pulley groove. 4.
  • Page 74 05-E3B, 05-E3BG, WSM DIESEL ENGINE 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 75 05-E3B, 05-E3BG, WSM DIESEL ENGINE (4) Fuel System Injection Timing 1. Remove the injection pipes. 2. Remove the engine stop solenoid. 3. Turn the flywheel counterclockwise (viewed from flywheel side) until the fuel fills up to the hole of the delivery valve holder (3) for No.
  • Page 76 05-E3B, 05-E3BG, WSM DIESEL ENGINE 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 to the injection pump. 4. Install the injection nozzle (2) jetted with the proper injection pressure to the injection pump pressure tester (1).
  • Page 77 05-E3B, 05-E3BG, WSM DIESEL ENGINE CAUTION • Check the nozzle 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.
  • Page 78 05-E3B, 05-E3BG, WSM DIESEL ENGINE Nozzle Holder 1. 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. •...
  • Page 79 05-E3B, 05-E3BG, WSM DIESEL ENGINE Battery Specific Gravity 1. Check the specific gravity of the electrolyte in each cell with a hydrometer. 2. When the electrolyte temperature differs from that at which the hydrometer was calibrated, correct the specific gravity reading following the formula mentioned in (Reference).
  • Page 80 05-E3B, 05-E3BG, WSM DIESEL 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.
  • Page 81 05-E3B, 05-E3BG, WSM DIESEL ENGINE Magnet Switch Continuity Test 1. Check the continuity across the C terminal (1) and the B terminal (2) with a circuit tester, pushing in the plunger. 2. If not continuous or if a certain value is indicated, replace the magnet switch.
  • Page 82 05-E3B, 05-E3BG, WSM DIESEL ENGINE Glow Plug Continuity 1. 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. Approx.

  • Page 83: Turbocharger

    05-E3B, 05-E3BG, WSM DIESEL ENGINE (6) Turbocharger Turbine Side 1. Check the exhaust port (3) and inlet port (5) side of turbine housing (1) to see if there is no exhaust gas leak. 2. If any gas leak is found, retighten the bolts and nuts or replace the gasket (2) / (4) / (6) with new one.

  • Page 84: Disassembling And Assembling

    05-E3B, 05-E3BG, WSM DIESEL ENGINE [2] DISASSEMBLING AND ASSEMBLING (1) Draining Oil and Coolant Draining Oil and Coolant CAUTION • Never remove radiator cap until coolant temperature is below its boiling point. Then loosen cap slightly to the stop to relieve any excess pressure before removing cap completely.

  • Page 85: Cylinder Head And Valve

    05-E3B, 05-E3BG, WSM DIESEL ENGINE (3) Cylinder Head and Valve Cylinder Head Cover 1. Disconnect the breather hose (1). 2. Remove the cylinder head cover screw (2). 3. Remove the cylinder head cover (3). (When reassembling) • Check to see if the cylinder head cover gasket is not defective. [D1005-E3B / E3BG, D1105-E3B / E3BG, D1105-T-E3B, V1505-E3B / E3BG, V1505-T-E3B] 7 to 8 N·m...
  • Page 86 05-E3B, 05-E3BG, WSM DIESEL ENGINE Nozzle Holder Assembly and Glow Plug 1. Remove the overflow pipe (1). 2. Remove the nozzle holder assemblies (4). 3. Remove the copper gasket (5) and heat seal (6). 4. Remove the lead (2) from the glow plugs (3). 5.
  • Page 87 05-E3B, 05-E3BG, WSM DIESEL ENGINE Rocker Arm and Push Rod 1. Remove the rocker arm bracket screws / nuts. 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 dimples.
  • Page 88 05-E3B, 05-E3BG, WSM DIESEL ENGINE Cylinder Head and Cylinder Head Gasket 1. Loosen the pipe clamps (1), and remove the water return pipe (2). 2. Remove the cylinder head screw in the order of (n or r) to (a) and remove the cylinder head.

  • Page 89: Gear Case And Timing Gears

    05-E3B, 05-E3BG, WSM DIESEL ENGINE 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 90 05-E3B, 05-E3BG, WSM DIESEL ENGINE Fan Drive Pulley 1. Secure the flywheel to keep it from turning. 2. Remove the fan drive pulley screw. 3. Draw out the fan drive pulley with a puller. (When reassembling) • Install the pulley to crankshaft, aligning the mark (1) on them (3- cylinder engine).
  • Page 91 05-E3B, 05-E3BG, WSM DIESEL ENGINE Gear Case 1. Remove the fuel feed pump. 2. Remove the gear case. (When reassembling) • Grease thinly to the oil seal, and install it, ensuring the lip does not come off. (1) Gear Case a : Bolt Length = 45 mm (1.8 in.) b : Bolt Length = 50 mm (2.0 in.) (A) Gear Case for Standard Oil Pan...
  • Page 92 05-E3B, 05-E3BG, WSM DIESEL ENGINE Boost Compensator (equipped with R24 Model) IMPORTANT • Use the stop solenoid mounting bolt (3) for the dropout prevention of boost compensator (2) and the damage prevention of the guide (6) when detach the boost compensator.
  • Page 93 05-E3B, 05-E3BG, WSM DIESEL ENGINE Injection Pump 1. Disconnect the start spring (4) on the thrust lever side (5). 2. Align the control rack pin (2) with the notch (1) on the crankcase, and remove the injection pump (3). 3. Remove the injection pump shims. 4.
  • Page 94 05-E3B, 05-E3BG, WSM DIESEL ENGINE Cam Gear, Idle Gear 1, 2 and Governor Gear 1. Remove the idle gear 2 (7) / idle gear 1 (4). 2. Remove the fuel camshaft stopper (8). 3. Draw out the fuel cam gear (1) with fuel camshaft (9). 4.

  • Page 95: Piston And Connecting Rod

    05-E3B, 05-E3BG, WSM DIESEL ENGINE (5) Piston and Connecting Rod Oil Pan and Oil Strainer (for Standard Oil Pan) 1. Remove the oil pan mounting screws (5). 2. Remove the oil pan (4). 3. Remove the oil strainer (3). (When reassembling) •...
  • Page 96 05-E3B, 05-E3BG, WSM DIESEL ENGINE 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.
  • Page 97 05-E3B, 05-E3BG, WSM DIESEL ENGINE Piston Ring and Connecting Rod 1. Remove the piston rings using a piston ring tool. 2. Remove the piston pin (7), and separate the connecting rod (6) from the piston (5). (When reassembling) • When installing the ring, assemble the rings so that the manufacturer’s mark (12) near the gap faces the top of the piston.

  • Page 98: Flywheel And Crankshaft

    05-E3B, 05-E3BG, WSM DIESEL ENGINE (6) Flywheel and Crankshaft Flywheel 1. Secure the flywheel to keep it from turning, using a flywheel stopper. 2. Remove all flywheel screws (1) and then remove the flywheel (2). (When reassembling) • Align the “1TC” mark (a) on the outer surface of the flywheel horizontally with the alignment mark (b) on the rear end plate.
  • Page 99 05-E3B, 05-E3BG, WSM DIESEL ENGINE Crankshaft Assembly (without D1305-E3B) 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.) (When reassembling) •...
  • Page 100 05-E3B, 05-E3BG, WSM DIESEL ENGINE Main Bearing Case Assembly 1. Remove the two main bearing case screws 1 (2) of each main bearing cases. 2. Remove the main bearing case from crankshaft. (When reassembling) • Clean the oil passage in the main bearing cases. •...

  • Page 101: Alternator

    05-E3B, 05-E3BG, WSM DIESEL ENGINE (7) Alternator (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 W1224079 1.

  • Page 102: Starter

    05-E3B, 05-E3BG, WSM DIESEL ENGINE (8) Starter Electromagnetic Drive Type (1) Solenoid Switch Mounting Nut (2) Starter Drive Housing (3) Drive Lever (4) Gasket (5) Solenoid Switch (6) B Terminal Nut (7) C Terminal Nut (8) Snap RIng (9) Overrunning Clutch (10) Armature (11) Brush Spring (12) Connecting Lead...
  • Page 103 05-E3B, 05-E3BG, WSM DIESEL ENGINE Gear Reduction Type (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 W1222714 1.

  • Page 104: Servicing

    05-E3B, 05-E3BG, WSM DIESEL ENGINE [3] SERVICING (1) Cylinder Head and Valves Top Clearance 1. Remove the cylinder head. (Do not attempt to remove the cylinder head gasket.) 2. Move the piston up and stick a strip of fuse [1.5 mm dia. (0.059 in.
  • Page 105 05-E3B, 05-E3BG, WSM DIESEL ENGINE Cylinder Head Flaw 1. Prepare an air spray red check. 2. Clean the surface of the cylinder head with detergent (2). 3. Spray the cylinder head surface with the red permeative liquid (1). Leave it five to ten minutes after spraying. 4.
  • Page 106 05-E3B, 05-E3BG, WSM DIESEL 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.
  • Page 107 05-E3B, 05-E3BG, WSM DIESEL ENGINE Correcting Valve and Valve Seat NOTE • Before correcting the valve and seat, check the valve stem and the I.D. of valve guide section, and repair them if necessary. • After correcting the valve seat, be sure to check the valve recessing.
  • Page 108 05-E3B, 05-E3BG, WSM DIESEL ENGINE Free Length and Tilt of Valve Spring 1. 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.
  • Page 109 05-E3B, 05-E3BG, WSM DIESEL ENGINE Push Rod Alignment 1. 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. 0.25 mm Push rod alignment Allowable limit 0.0098 in.

  • Page 110: Timing Gears, Camshaft And Governor Gear

    05-E3B, 05-E3BG, WSM DIESEL ENGINE (2) Timing Gears, Camshaft and Governor Gear 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 111 05-E3B, 05-E3BG, WSM DIESEL ENGINE Camshaft Side Clearance 1. 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.
  • Page 112 05-E3B, 05-E3BG, WSM DIESEL ENGINE Oil Clearance of Camshaft Journal 1. 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.

  • Page 113: Piston And Connecting Rod

    05-E3B, 05-E3BG, WSM DIESEL ENGINE (3) 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 114 05-E3B, 05-E3BG, WSM DIESEL ENGINE Connecting Rod Alignment NOTE • Since the I.D. of the connecting rod small end bushing is the basis of this check, check bushing for wear beforehand. 1. Install the piston pin into the connecting rod. 2.
  • Page 115 05-E3B, 05-E3BG, WSM DIESEL ENGINE Piston Ring Gap 1. Insert the piston ring into the lower part of the cylinder (the least worn out part) with a piston. 2. Measure the ring gap with a thickness gauge. 3. If the measurement exceeds the allowable limit, replace the piston ring.
  • Page 116 05-E3B, 05-E3BG, WSM DIESEL ENGINE Clearance between Piston ring and Piston Ring Groove 1. 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.

  • Page 117: Crankshaft

    05-E3B, 05-E3BG, WSM DIESEL ENGINE (4) Crankshaft Crankshaft Side Clearance 1. 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.
  • Page 118 05-E3B, 05-E3BG, WSM DIESEL ENGINE Oil Clearance between Crankpin and Crankpin Bearing 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.
  • Page 119 05-E3B, 05-E3BG, WSM DIESEL ENGINE 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 120 05-E3B, 05-E3BG, WSM DIESEL ENGINE Oil Clearance between Crankshaft Journal and Crankshaft Bearing 1 (Continued) D1305-E3B / E3BG 0.0340 to 0.119 mm Factory spec. Oil clearance between 0.00134 to 0.00468 in. crankshaft journal and 0.20 mm crankshaft bearing 1 Allowable limit 0.0079 in.
  • Page 121 05-E3B, 05-E3BG, WSM DIESEL ENGINE Oil Clearance between Crankshaft Journal and Crankshaft Bearing 2 (Crankshaft Bearing 3) 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.
  • Page 122 05-E3B, 05-E3BG, WSM DIESEL ENGINE Oil Clearance between Crankshaft Journal and Crankshaft Bearing 2 (Crankshaft Bearing 3) (Continued) D1305-E3B / E3BG 0.0340 to 0.103 mm Factory spec. Oil clearance between 0.00134 to 0.00405 in. crankshaft journal and 0.20 mm crankshaft bearing 2 Allowable limit 0.0079 in.

  • Page 123: Cylinder

    05-E3B, 05-E3BG, WSM DIESEL ENGINE (5) 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.

  • Page 124: Oil Pump

    05-E3B, 05-E3BG, WSM DIESEL ENGINE (6) Oil Pump Rotor Lobe Clearance 1. Measure the clearance between lobes of the inner rotor and the outer rotor with a feeler gauge. 2. If the clearance exceeds the factory specifications, replace the oil pump rotor assembly.
  • Page 125 05-E3B, 05-E3BG, WSM DIESEL ENGINE Commutator and Mica 1. 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.
  • Page 126 05-E3B, 05-E3BG, WSM DIESEL ENGINE Brush Holder 1. 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 Coil 1. Check the continuity across the commutator and armature coil core with resistance range of circuit tester.

  • Page 127: Alternator

    05-E3B, 05-E3BG, WSM DIESEL ENGINE (8) Alternator Bearing 1. Check the bearing for smooth rotation. 2. If it does not rotate smoothly, replace it. W1019790 Stator 1. Measure the resistance across each lead of the stator coil with resistance range of circuit tester. 2.
  • Page 128 05-E3B, 05-E3BG, WSM DIESEL ENGINE Rectifier 1. 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 Regulator 1.
  • Page 129 EDITOR : KUBOTA FARM & INDUSTRIAL MACHINERY SERVICE, LTD. 64, ISHIZU-KITAMACHI, SAKAI-KU, SAKAI-CITY, OSAKA, 590-0823, JAPAN PHONE : ( 81 ) 72-241-1129 : ( 81 ) 72-245-2484 E-mail : ksos-pub@kubota.co.jp Printed in Japan 2007. 12, S, EI, EI, e Code No.9Y111-00123 KUBOTA Corporation 2007.

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