Kubota V3600-E3 Shop Manual
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Kubota V3600-E3 Shop Manual

Diesel engine
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KUBOTA SHOP MANUAL
V3600-E3 · V3600-T-E3 ·
MODELS
V3800-DI-T-E3 · V3300-E3BG ·
V3600-T-E3BG

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Summary of Contents for Kubota V3600-E3

  • Page 1 KUBOTA SHOP MANUAL V3600-E3 · V3600-T-E3 · MODELS V3800-DI-T-E3 · V3300-E3BG · V3600-T-E3BG...
  • Page 2 The right is reserved to make changes in all information at any time without notice. Due to covering many models of this manual, information or picture being used have not been specified as one model. October 2007 © KUBOTA Corporation 2007...
  • Page 3 SAFETY INSTRUCTIONS V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM 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 SAFETY INSTRUCTIONS V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM 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 SAFETY INSTRUCTIONS V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM 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 SAFETY INSTRUCTIONS V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM 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.

  • Page 7: Specifications

    SPECIFICATIONS V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM SPECIFICATIONS V3600-T- V3800DI-T- V3800DI-T- Model V3600-E3B V3600-E3CB V3600-T-E3B E3CB E3CB Number of Cylinder Type Vertical, water-cooled, 4-cycle diesel engine Bore × Stroke 98 × 120 mm (3.86 × 4.72 in.) 100 × 120 mm (3.94 × 4.72 in.) Total Displacement 3620 cm (220.9 cu.in.)
  • Page 8 SPECIFICATIONS V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Model V3300-E3BG V3600-T-E3BG V3800DI-T-E3BG Number of Cylinders Type Vertical, Water-cooled, 4 cycle diesel engine Bore × Stroke 98 x 110 mm (3.86 x 4.33 in.) 98 x 120 mm (3.86 x 4.72 in.) 100 x 120 mm (3.94 x 4.72 in.) Total Displacement 3318 cm...

  • Page 9: Performance Curves

    PERFORMANCE CURVES V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM PERFORMANCE CURVES (1) Brake Horse Power (2) Engine Speed (3) B.S.F.C. (4) Torque...
  • Page 10 DIMENSIONS V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM DIMENSIONS...
  • Page 11 DIMENSIONS V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM...

  • Page 12: 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-8 [1] DAILY CHECK POINTS................

  • Page 13: Engine Identification

    G GENERAL V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM 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.
  • Page 14 G GENERAL V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM • 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...

  • Page 15: E3B Engine

    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. Over the past several years, Kubota has been supplying diesel engines that comply with regulations in the respective countries affected by Non-Road Emission regulations. For Kubota Engines, E3B will be the designation that identifies engine models affected by the next emission phase (See the table below).

  • Page 16: General Precautions

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

  • Page 17: Maintenance Check List

    *Replacing intake air line Replacing battery * The items listed above (* marked) are registered as emission related critical parts by KUBOTA in the U.S.EPA nonroad emission regulation. As the engine owner, you are responsible for the performance of the required maintenance on the engine according to the above instruction.
  • Page 18 *Replacing intake air line Replacing battery * The items listed above (* marked) are registered as emission related critical parts by KUBOTA in the U.S.EPA nonroad emission regulation. As the engine owner, you are responsible for the performance of the required maintenance on the engine according to the above instruction.
  • Page 19 JUN87) • Since KUBOTA diesel engines of less than 56 kW (75 hp) utilize EPA Tier 4 and Interim Tier 4 standards, the use of low sulfur fuel or ultra low sulfur fuel is mandatory for these engines, when operated in US EPA regulated areas.

  • Page 20: Check And Maintenance

    G GENERAL V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM 4. CHECK AND MAINTENANCE [1] DAILY CHECK POINTS Checking Engine Oil Level 1. Level the engine. 2. To check the oil level, draw out the dipstick (1), wipe it clean, reinsert it, and draw it out again. Check to see that the oil level lies between the two notches.
  • Page 21 G GENERAL V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM 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 22: Check Points Of Initial 50 Hours

    Then, replenish the engine oil up to the specified level. IMPORTANT • To prevent serious damage to the engine, replacement element must be highly efficient. Use only a KUBOTA genuine filter or its equivalent. (1) Engine Oil Filter Cartridge W1017137...

  • Page 23: Check Point Of Every 50 Hours

    G GENERAL V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Fan Belt Tension 1. 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, loosen the alternator mounting screws and relocate the alternator to adjust.

  • Page 24: Check Points Of Every 250 Hours

    G GENERAL V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM [4] CHECK POINTS OF EVERY 250 HOURS Fan Belt Tension 1. 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).
  • Page 25 G GENERAL V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Cleaning Fuel Filter (Element Type only) 1. Close the fuel cock (3). 2. Unscrew the retaining ring (6) and remove the filter cup (5), and rinse the inside with kerosene. 3. Take out the element (4) and dip it in the kerosene to rinse. 4.

  • Page 26: Check Points Of Every 500 Hours

    G GENERAL V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Checking Battery Electrolyte Level 1. Check the battery electrolyte level. 2. If the level is below than lower level line (2), and the distilled water to pour level of each cell. (1) Upper Level Line (2) Lower Level Line W1047154...
  • Page 27 Then, replenish the engine oil up to the specified level. IMPORTANT • To prevent serious damage to the engine, replacement element must be highly efficient. Use only a KUBOTA genuine filter or its equivalent. (1) Engine Oil Filter Cartridge W1015117 Replacing Fuel Filter Cartridge (Cartridge Type) Water and dust in fuel are collected in the filter cartridge.
  • Page 28 G GENERAL V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Replacing Fan Belt 1. Remove the alternator. 2. Remove the fan belt (1). 3. Replace new fan belt. 4. Install the alternator. 5. Check the fan belt tension. 10 to 12 mm / 98 N Deflection (A) Factory spec.
  • Page 29 G GENERAL V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM 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 30: Check Point Of Every 1000 Hours

    G GENERAL V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM [6] CHECK POINT OF EVERY 1000 HOURS Checking Valve Clearance IMPORTANT • Valve clearance must be checked and adjusted when engine is cold. 1. Remove the injection pipes. (V3800DI-T-E3B, V3800DI-T-E3CB, V3800DI-T-E3BG only) 2.

  • Page 31: Check Points Of Every 1 Or 2 Months

    G GENERAL V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM [7] CHECK POINTS OF EVERY 1 OR 2 MONTHS Recharging CAUTION • When the battery is being activated, hydrogen and oxygen gases in the battery are extremely explosive. Keep open sparks and flames away from the battery at all times, especially when charging the battery.
  • Page 32 G GENERAL V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM 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 33: Check Points Of Every 1500 Hours

    G GENERAL V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM [8] 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 34 G GENERAL V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM [V3800DI-T-E3B, V3800DI-T-E3CB, V3800DI-T-E3BG] 1. Set the injection nozzle to the nozzle tester. 2. Slowly move the tester handle to measure the pressure at which fuel begins jetting out from the nozzle. 3.

  • Page 35: Check Points Of Every 3000 Hours

    G GENERAL V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM [9] CHECK POINTS OF EVERY 3000 HOURS Checking Turbocharger [V3600-T-E3B, V3600-T-E3CB, V3800DI-T-E3B, V3800DI-T-E3CB, V3800DI-T-E3BG] (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 36 G GENERAL V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Injection Timing 1. Remove the timer gear lubricating pipe (1). (V3600-E3B, V3600-E3CB, V3800DI-T-E3B, V3800DI-T-E3CB, V3800DI-T- E3BG only) 2. Remove the gear case cover (2). (V3600-E3B, V3600-E3CB, V3800DI-T-E3B, V3800DI-T-E3CB, V3800DI-T-E3BG only) 3. Set the timer 0 ° restoring jig (4) to the timer gear(3). (V3600-E3B, V3600-E3CB, V3800DI-T-E3B, V3800DI-T-E3CB, V3800DI-T-E3BG only) 4.
  • Page 37 G GENERAL V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Injection Timing (Continued) 7. Turn the flywheel counterclockwise (viewed from flywheel side) until the fuel fills up to the hole of the delivery valve holder (6) for No.1 cylinder. 8. After the fuel fills up to the hole of the delivery valve holder for No.1 cylinder, turn back (clockwise) the flywheel around 1.6 rad (90 °).
  • Page 38 5. Set the speed control lever to the maximum speed position. 6. Run the starter to increase the pressure. 7. If the pressure can not reach the allowable limit, replace the pump with new one or repair with a Kubota-authorized pump service shop. (Fuel Tightness of Delivery Valve) 1.
  • Page 39 18.63 → 17.65 MPa V3800DI-T-E3CB 190.0 → 180.0 kgf/cm V3800DI-T-E3BG 2702 → 2560 psi NOTE • Never try to disassemble the injection pump assembly. For repairs, you are strongly requested to contact a Kubota- authorized pump service shop. W1068099 G-27...

  • Page 40: Check Points Of Every 1 Year

    G GENERAL V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM [10] CHECK POINTS OF EVERY 1 YEAR Changing Engine Oil (All model) CAUTION • Be sure to stop engine before changing engine oil. 1. Start and warm up the engine for approx. 5 minutes. 2.

  • Page 41: Check Points Of Every 2 Years

    G GENERAL V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM [11] CHECK POINTS OF EVERY 2 YEARS Replacing Fan Belt 1. Remove the alternator. 2. Remove the fan belt (1). 3. Replace new fan belt. 4. Install the alternator. 5. Check the fan belt tension. 10 to 12 mm / 98 N Deflection (A) Factory spec.
  • Page 42 G GENERAL V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM 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 43 G GENERAL V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Replacing Fuel Hose and Clamp Bands 1. Loosen the clamp (2) and remove the fuel hose (3). 2. Replace new fuel hose (3) and new clamp (2). 3. Tighten the clamp (2). CAUTION •...

  • Page 44: Special Tools

    G GENERAL V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM 5. SPECIAL TOOLS Diesel Engine Compression Tester (for Injection 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 G GENERAL V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM 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 , 4270 psi) PF 1/2...
  • Page 46 G GENERAL V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Small End Bushing Replacing Tool Application: Use to press out and to press fit the small end bushing. [Press out] 157 mm (6.18 in.) 14.5 mm (0.571 in.) 120 mm (4.72 in.) 30.0 mm dia.
  • Page 47 G GENERAL V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Gear Case Oil Seal Replacing Tool Application: Use to press fit the oil seal. 148.8 mm (5.858 in.) 50 mm (2.0 in.) 18.8 mm (0.740 in.) 13.7 to 13.9 mm (0.540 to 0.547 in.) 11 mm (0.43 in.) 18 mm dia.
  • Page 48 G GENERAL V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Valve Guide Replacing Tool Application: Use to press out and press fit the valve guide. Intake valve guide (V3600-E3B, V3600-T-E3B, V3600-E3CB, V3600-T-E3CB, V3300-E3BG, V3600-T-E3BG) and Intake / Exhaust valve guide (V3800DI-T-E3B, V3800DI-T-E3CB, V3800DI-T-E3BG) 225 mm (8.86 in.)
  • Page 49 G GENERAL V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Auxiliary Socket for Fixing Crankshaft Sleeve Application: Use to fix the crankshaft sleeve of the diesel engine. Rmax = 12.5 S 94.5 to 95.0 mm dia. (3.72 to 3.74 in. dia.) 40 mm dia.
  • Page 50 G GENERAL V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Balancer Bushing Replacing Tool 1 Components Parts 1) Shaft 498 mm (19.6 in.) 318.80 to 319.20 mm (12.552 to 12.566 in.) 102.8 to 103.2 mm (4.048 to 4.062 in.) 60 mm (2.4 in.) 8 mm (0.3 in.) 5 mm (0.2 in.) 30 mm dia.
  • Page 51 G GENERAL V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM 3) Piece 2 Chamfer 0.1 mm (0.004 in.) 1 mm (0.04 in.) Chamfer 1 mm (0.04 in.) 54.30 to 54.40 mm dia. (2.138 to 2.141 in. dia.) 34.025 to 34.050 mm dia. (1.3396 to 1.3405 in. dia.) 48.5 mm dia.
  • Page 52 G GENERAL V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Balancer Replacing Tools 3, 4, 5 Application: Use to press fit the bushing. NOTE • This special tool is not provided, so make it referring to the figure. Name of Part Q’ty.
  • Page 53 G GENERAL V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM 2) Shaft 44 mm dia. (1.7 in. dia.) 12 mm (0.47 in.) Chamfer 1 mm (0.04 in.) 3 mm (0.1 in.) 3 mm (0.1 in.) 30 mm (1.2 in.) 38 mm (1.5 in.) 35 mm (1.4 in.) M12 ×...
  • Page 54 G GENERAL V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM 4) Joint 1 M12 × P1.25 Chamfer 1 mm (0.04 in.) 30 mm dia. (1.2 in. dia.) 13 mm dia. (0.51 in. dia.) Chamfer 3 mm (0.1 in.) 3 mm (0.1 in.) 45 mm (1.8 in.) 75 mm (3.0 in.) 57 mm (2.2 in.)
  • Page 55 G GENERAL V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM 7) Piece 3 26 mm (1.0 in.) 18 mm (0.71 in.) 16.5 to 17.0 mm (0.650 to 0.669 in.) 1.5 mm (0.059 in.) 53.00 to 53.20 mm dia. (2.087 to 2.094 in dia.) 49.55 to 49.75 mm dia.
  • Page 56 G GENERAL V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Timer Gear Puller (V3600-E3B, V3800DI-T-E3B, V3600-E3CB, V3800DI-T-E3CB, V3800DI-T-E3BG) Application: Use for removing the timer gear from governor shaft. 27 mm (1.1 in.) 130 mm (5.12 in.) 15 mm (0.59 in.) 115 mm (4.53 in.) 26 mm dia.
  • Page 57 G GENERAL V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Flywheel Stopper (for SAE Flywheel and Housing) Application: Use to loosen and tighten the flywheel screw. 140 mm (5.51 in.) 80 mm (3.1 in.) 49.3 mm (1.94 in.) 49.3 mm (1.94 in.) 23.8 mm (0.937 in.) 23.8 mm (0.937 in.) 11 mm dia.
  • Page 58 G GENERAL V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Jig for Governor Connecting Rod Application: Use for connecting the governor connecting rod to the rack pin of the fuel injection pump assembly. 1 mm radius (0.04 in. radius) Chamfer 0.2 mm (0.008 in.) Chamfer 2 mm (0.08 in.) 35 mm dia.
  • Page 59 G GENERAL V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Nozzle Adaptor for Measuring Cylinder Compression Pressure (V3800DI-T-E3B, V3800DI-T-E3CB, V3800DI-T- E3BG) Application: Use for measuring diesel engine compression pressure. 5 mm (0.2 in.) 3.0 mm dia., 44.5 to 45.0 mm depth (0.12 in.
  • Page 60 MECHANISM CONTENTS 1. FEATURE ......................M-1 2. ENGINE BODY ....................M-3 [1] CYLINDER BLOCK................... M-3 [2] GEAR TRAIN .................... M-4 [3] HALF-FLOATING HEAD COVER ............M-4 [4] CYLINDER HEAD ..................M-5 [5] E-TVCS (V3600-E3B, V3600-T-E3B, V3600-E3CB, V3600-T-E3CB, V3300-E3BG, V3600-T-E3BG) ..............M-6 [6] CENTER DIRECT INJECTION SYSTEM (E-CDIS) (V3800DI-T-E3B, V3800DI-T-E3CB, V3800DI-T-E3BG)............
  • Page 61 (2) External / Mechanical EGR (V3800DI-T-E3B, V3800DI-T-E3CB, V3800DI-T-E3BG) ................M-27...

  • Page 62: Feature

    E-TVCS VERSION-II. Thus, this engine achieves high combustion efficiency and complies with various regulations of exhaust gas. Based upon the conventional model, Kubota developed a unique governor system and various new mechanisms which reduces exhaust emission, noise and vibration and realize durability and high torque.
  • Page 63 E-CDIS. Thus, this engine achieves high combustion efficiency and complies with various regulations of exhaust gas. Based upon the conventional model, Kubota developed a unique governor system and various new mechanisms which reduces exhaust emission, noise and vibration and realize durability and high torque.

  • Page 64: Engine Body

    DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM 2. ENGINE BODY [1] CYLINDER BLOCK This engine employs separate type crankcases - the crankcase 1 (1) with combustion part and the crankcase 2 (2) which supports the crankcase 1 (1) and reduces noise.

  • Page 65: Gear Train

    DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM [2] GEAR TRAIN V3 series engine has 2 types of gear train. Standard type has 2 idle gears. Optional type has 1 idle gear. If the engine is optional 1 idle gear type, the engine model name has “C”.

  • Page 66: Cylinder Head

    - two inlet valves and double ports, and one exhaust valve which produce good inlet inertia to improve combustion efficiency and volumetric efficiency. It also employs Kubota’s unique combustion chamber with multiple injection grooves. Besides the conventional cross port system, it...

  • Page 67: E-Tvcs (V3600-E3B, V3600-T-E3B, V3600-E3Cb, V3600-T-E3Cb, V3300-E3Bg, V3600-T-E3Bg

    V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM [5] E-TVCS (V3600-E3B, V3600-T-E3B, V3600-E3CB, V3600-T-E3CB, V3300-E3BG, V3600-T-E3BG) The combustion chamber (2) is of Kubota’s exclusive E-TVCS combustion chamber type. Suction air is whirled to be mixed effectively with fuel, prompting combustion and reducing fuel consumption.

  • Page 68: Center Direct Injection System (E-Cdis)

    DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM [6] CENTER DIRECT INJECTION SYSTEM (E-CDIS) (V3800DI-T-E3B, V3800DI-T-E3CB, V3800DI-T-E3BG) V3 series DI engine adopts the Center Direct Injection System (E-CDIS), in which the injection nozzle is positioned upright at the center of the cylinder. This system serves to inject fuel directly at the center of the cylinder.

  • Page 69: Piston (Except V3300-E3Bg

    DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM [7] PISTON (EXCEPT V3300-E3BG) Piston’s skirt is coated with molybdenum disulfide , which reduces the piston slap noise and thus the entire operating noise. Molybdenum disulfide (MoS The molybdenum disulfied serves as a solid lubricant, like a Graphite or Teflon.

  • Page 70: Lubricating System

    DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM 3. LUBRICATING SYSTEM [1] OIL COOLER V3 series engine has a water-cooled oil cooler that not only cools hot oil, but also warms the cool engine oil shortly after start up. As shown in the figure, the oil flows inside the connected cooler plate, whereas coolant is kept circulating outside the cooler plate, thereby cooling down...

  • Page 71: Cooling System

    DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM 4. COOLING SYSTEM [1] THERMOSTAT Conventional thermostatically-controlled valves (outlet water temperature control type) open against the flow of coolant. In this design, the pressure (steam pressure + water pump’s discharge pressure) affects the open/close performance of such valve.

  • Page 72: Bottom Bypass System

    DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM [2] BOTTOM BYPASS SYSTEM Bottom bypass system is introduced in V3 series for improving the cooling performance of the radiator. While the temperature of coolant in the engine is low, the thermostat is held closed and the coolant is allowed to flow through the bypass pipe and to circulate in the engine.

  • Page 73: Fuel System

    V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM 5. FUEL SYSTEM [1] GOVERNOR (STANDARD MECHANICAL TYPE) The engine employs the separated fuel injection pump in combination with Kubota’s own small multi- function mechanical governor, which enable more dependability. It also employs the torque limiting mechanism to control the maximum peak torque so that it complies with the regulations of exhaust gas.
  • Page 74 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM At Idling Turn the speed control lever (6) clockwise to idle the engine. It tensions the governor spring (3) to pull the fork lever 2 (1). When the fork lever 2 is pulled, it moves the torque spring pin (7) and the fork lever 1 (5) in the direction of the arrow A to restrain the weight.

  • Page 75: Electronic Governor (Factory Option For V3300- E3Bg, V3600-T-E3Bg, Standard For V3800Di-T-E3Bg

    DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM To stop engine When the stop solenoid is turned off, the spring tension of the solenoid is released, the rod extrudes and the stop lever moves the control rack in the direction of the arrow B which stops the engine.

  • Page 76: Construction

    DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM (2) Construction (1) Injection Pump (3) Proportional Solenoid (5) Engine Speed (7) Governor Spring (8) Governor Weight (2) Control Rack (4) ECU (6) Accelerate Lever (fixed at maximum speed) (3) Controlling mechanism (1) Quantity Reduction (3) Fuel Quantity (5) Mechanical Governor Fuel...

  • Page 77: Emergency Engine Stop Function

    DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM (4) Emergency Engine Stop Function (1) Battery (4) Oil Pressure Switch (6) Option (8) ECU (2) Key Switch (5) Water Temperature Switch (7) Engine Speed Sensor (9) Proportional Solenoid (3) Alternator L Terminal 1.
  • Page 78 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Emergency stop by sensor activation 1. A specified time after the key switch has been returned from the ST to ON position, the system gets ready to detect an error. 2. The oil pressure switch stays out of function while the engine is at a stop.

  • Page 79: Main Components

    DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM (5) Main Components It processes the speed signal received from the speed sensor and compares it to a reference speed set with Calibration Program. The output of the control unit is a pulse width modulated signal to the proportional solenoid.

  • Page 80: Wiring Diagram

    DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM (6) Wiring Diagram (1) Actuator (6) Speed Sensor (11) Hour Meter (16) Key Switch (2) Speed Switch (7) Water Temperature Sensor (12) Control Unit (17) Slow Blow Fuse (3) Slow Down Switch (8) Oil Switch (13) Glow Plug or Intake Air Heater (18) Alternator...

  • Page 81: Mechanical Timer With Cold Start Advance Function (V3600-E3B, V3800Di-T-E3Bg

    DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM [3] MECHANICAL TIMER WITH COLD START ADVANCE FUNCTION (V3600-E3B, V3800DI-T-E3B, V3600-E3CB, V3800DI-T-E3CB, V3800DI-T- E3BG) This device makes the fuel injection timing advanced by engine oil temperature and engine rpm in order to improve the engine cold start-ability and reduce the blue white smoke.
  • Page 82 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Speed control (Except V3800DI-T-E3BG) If the engine rpm is higher than a certain rpm, the fuel injection timing advance by engine oil temperature does not work. At that time, the quantity of advance timing is variably changed by centrifugal force of the timer flyweights which meets engine rpm.

  • Page 83: Throttle Nozzle (V3600-E3B, V3600-T-E3B, V3600-E3Cb, V3600-T-E3Cb, V3300-E3Bg, V3600-T-E3Bg

    DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM [4] THROTTLE NOZZLE (V3600-E3B, V3600-T-E3B, V3600-E3CB, V3600-T-E3CB, V3300-E3BG, V3600-T-E3BG) The small-size DENSO made OPD mini nozzle is of a flat-cut-provided double throttle type. This type of nozzle is designed to control the injection quantity when the lift rate is low at start of injection, and to cut down on the knocking sound caused by excessive fuel injection by giving the needle valve section more...

  • Page 84: Stage Di Nozzle (V3800Di-T-E3B, V3800Di-T-E3Cb, V3800Di- T-E3Bg

    DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM [5] 2 STAGE DI NOZZLE (V3800DI-T-E3B, V3800DI-T-E3CB, V3800DI-T- E3BG) Exhaust and noise regulations are becoming increasingly strict, particularly in regard to the reduction of NOx (nitrogen oxides) and particulates. The two-spring nozzle holder has been developed to reduce NOx (nitrogen oxides) and particulates from direct injection diesel engine exhaust.

  • Page 85: Injection Pump With F.s.p. (V3800Di-T-E3B, V3800Di-T-E3Cb, V3800Di-T-E3Bg

    DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM [6] INJECTION PUMP WITH F.S.P. (V3800DI-T-E3B, V3800DI-T-E3CB, V3800DI-T-E3BG) The fuel injection pump with F.S.P. (Fine Spill Port) mechanism is equipped with two functions: speed timer function and injection rate control function. The former function works like this.

  • Page 86: Turbocharger System

    DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM 6. TURBOCHARGER SYSTEM [1] BOOST COMPENSATOR (OPTION FOR TURBOCHARGED MODEL) The boost compensator is controlled by the boost pressure of the control mechanism which controls transient smoke caused by oversupply of fuel when the engine starts and accelerates.

  • Page 87: General

    [1] GENERAL In order to meet with the strict emission regulations, Kubota has adopted the EGR on the V3600-T and V3800DI-T. The nitrogen oxide (NOx) which is a hazardous component in exhaust gas is generated by oxidation of nitrogen in the air, due to rise of the combustion temperature in cylinders.
  • Page 88 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM (2) External / Mechanical EGR (V3800DI-T-E3B, V3800DI-T-E3CB, V3800DI-T-E3BG) (1) Thermo Valve (4) Intake Manifold (a) Boost Pressure (f) Cooled EGR Gas Merges (2) Mechanical EGR Valve (5) Exhaust Manifold (b) Coolant Temperature with Fresh Air (3) Reed Valve (6) EGR Cooler...
  • Page 89 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM (A) EGR Cooler The EGR (Exhaust Gas Recirculation) cooler is used to lower combustion temperature and efficiently cool EGR gas, with the aim of reducing the NOx that is in the exhaust gas of diesel engine.
  • Page 90 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM (C) Mechanical EGR Valve Mechanical EGR valve controls the flow of cooled EGR gas to the intake manifold. If the boost pressure is low, EGR valve is closed, so cooled EGR gas does not flow to the intake manifold. If the boost pressure is getting higher, EGR valve is opening and cooled EGR gas is flowing to the intake manifold.
  • Page 91 SERVICING CONTENTS 1. TROUBLESHOOTING ..................S-1 [1] ENGINE BODY ..................S-1 [2] ELECTRONIC GOVERNOR (FACTORY OPTION FOR V3300- E3BG, V3600-T-E3BG / STANDARD FOR V3800DI-T-E3BG) .....S-5 2. SERVICING SPECIFICATIONS ..............S-7 3. TIGHTENING TORQUES ................S-19 [1] TIGHTENING TORQUES FOR GENERAL USE SCREWS, BOLTS AND NUTS....................S-19 [2] TIGHTENING TORQUES FOR SPECIAL USE SCREWS, BOLTS AND NUTS....................S-20 4.
  • Page 92 (8) Alternator..................S-110...

  • Page 93: Troubleshooting

    DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM 1. TROUBLESHOOTING [1] ENGINE BODY Reference Symptom Probable Cause Solution Page Engine Does Not Start No fuel Replenish fuel G-11 Air in the fuel system Vent air G-11 Water in the fuel system Change fuel and G-11, 13, 15 repair or replace fuel...
  • Page 94 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Reference Symptom Probable Cause Solution Page Starter Does Not Run Battery discharged Charge G-19, 20, S-34 Starter malfunctioning Repair or replace S-36, 83, Key switch malfunctioning Replace – Wiring disconnected Connect –...
  • Page 95 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Reference Symptom Probable Cause Solution Page Either Black or Dark Overload Reduce the load – Gray Exhaust Gas Is Low grade fuel used Use specified fuel 5, 6, G-7 Observed Fuel filter clogged Replace G-13, 15 Air cleaner clogged...
  • Page 96 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Reference Symptom Probable Cause Solution Page Low Oil Pressure Engine oil insufficient Replenish G-10 Oil strainer clogged Clean S-75 Relief valve stuck with dirt Clean S-73 Relief valve spring weaken or broken Replace S-73 Excessive oil clearance of crankshaft bearing...

  • Page 97: Electronic Governor (Factory Option For V3300- E3Bg, V3600-T-E3Bg / Standard For V3800Di-T-E3Bg

    DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM [2] ELECTRONIC GOVERNOR (FACTORY OPTION FOR V3300-E3BG, V3600-T-E3BG / STANDARD FOR V3800DI-T-E3BG) IMPORTANT • The engine trouble divides into an electronic governor, the main body of the engine, and the operating constancy.
  • Page 98 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Blinking Pattern of Glow Lamp Cause Refer to Checking (1-Long and 1-Short) Overrunning (more than Solenoid 115 %) (1-Long and 2-Short) Low oil pressure Oil sensor (1-Long and 3-Short) Defect of alternator Alternator (1-Long and 4-Short) Coolant temperature is...

  • Page 99: Servicing Specifications

    DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM 2. SERVICING SPECIFICATIONS ENGINE BODY Item Factory Specification Allowable Limit Cylinder Head Surface Flatness – 0.05 mm 0.002 in. Top Clearance [V3600-E3B, V3600-T-E3B, V3600-E3CB, 1.05 to 1.27 mm – V3600-T-E3CB, V3600-T-E3BG] 0.0414 to 0.0500 in.
  • Page 100 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM ENGINE BODY (Continued) Item Factory Specification Allowable Limit Valve Seat [V3600-E3B, V3600-T-E3B, Angle (Intake) 1.0 rad – V3600-E3CB, V3600-T-E3CB, 60 ° V3300-E3BG, V3600-T-E3BG] Angle (Exhaust) 0.79 rad – 45 ° Width 2.12 mm –...
  • Page 101 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Item Factory Specification Allowable Limit Valve Stem to Valve Guide [V3600-E3B, V3600-T-E3B, Clearance (Intake) 0.055 to 0.085 mm 0.1 mm V3600-E3CB, V3600-T-E3CB, 0.0022 to 0.0033 in. 0.004 in. V3300-E3BG, V3600-T-E3BG] (Exhaust) 0.040 to 0.070 mm 0.1 mm 0.0016 to 0.0027 in.
  • Page 102 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM ENGINE BODY (Continued) Item Factory Specification Allowable Limit Valve Clearance (Cold) 0.23 to 0.27 mm – 0.0091 to 0.010 in. Intake Valve Timing 0.17 rad (10 °) [V3600-E3B, V3600-E3CB] Open – before T.D.C.
  • Page 103 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM ENGINE BODY (Continued) Item Factory Specification Allowable Limit Valve Spring [V3600-E3B, V3600-T-E3B, Free Length 35.1 to 35.6 mm 34.6 mm V3600-E3CB, V3600-T-E3CB, (Intake) 1.39 to 1.40 in. 1.36 in. V3300-E3BG, V3600-T-E3BG] Free Length 41.7 to 42.2 mm 41.2 mm...
  • Page 104 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM ENGINE BODY (Continued) Item Factory Specification Allowable Limit Push Rod Alignment – 0.25 mm 0.0098 in. Tappet to Tappet Guide Clearance 0.020 to 0.062 mm 0.07 mm 0.00079 to 0.0024 in. 0.003 in.
  • Page 105 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM ENGINE BODY (Continued) Item Factory Specification Allowable Limit Timing Gear (Standard Gear Train) [V3600-E3B, V3600-T-E3B, V3800DI-T-E3B, V3300-E3BG, V3600-T-E3BG, V3800DI-T-E3BG] Idle Gear 1 to Crank Gear Backlash 0.0490 to 0.193 mm 0.22 mm 0.00193 to 0.00759 in.
  • Page 106 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM ENGINE BODY (Continued) Item Factory Specification Allowable Limit Balancer Shaft (Balancer Model Only) Side Clearance 0.070 to 0.22 mm 0.3 mm 0.0028 to 0.0086 in. 0.01 in. Balancer Shaft (Balancer Model Only) Alignment –...
  • Page 107 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM 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. Alignment – 0.02 mm 0.0008 in. Crankshaft Journal to Crankshaft Bearing Oil Clearance 0.018 to 0.062 mm 0.20 mm...
  • Page 108 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM LUBRICATING SYSTEM Item Factory Specification Allowable Limit Engine Oil Pressure At Idle Speed – 50 kPa 0.5 kgf/cm 7 psi At Rated Speed 200 to 390 kPa 150 kPa 2.0 to 4.0 kgf/cm 1.5 kgf/cm 29 to 56 psi 21 psi...
  • Page 109 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM FUEL SYSTEM Item Factory Specification Allowable Limit Injection Timing [V3600-E3B, V3600-E3CB] 0.127 to 0.152 rad – (7.25 to 8.75 °) before T.D.C. [V3600-T-E3B, V3600-T-E3CB, V3600-T-E3BG] 0.0568 to 0.0829 rad – (3.25 to 4.75 °) before T.D.C.
  • Page 110 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM FUEL SYSTEM (Continued) Item Factory Specification Allowable Limit Fuel Injection Nozzle Injection Pressure 13.73 to 14.71 MPa – [V3600-E3B, V3600-E3CB 140.0 to 150.0 kgf/cm V3600-T-E3B, V3600-T-E3CB, 1992 to 2133 psi V3300-E3BG, V3600-T-E3BG] Valve Seat When the pressure is –...

  • Page 111: Tightening Torques

    DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM 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 112: Tightening Torques For Special Use Screws, Bolts And Nuts

    DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM [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.
  • Page 113 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Item Size x Pitch N·m kgf·m lbf·ft Injection pump gear mounting nut (V3600-T-E3B, V3600-T-E3CB, M14 x 1.5 74 to 83 7.5 to 8.5 55 to 61 V3300-E3BG, V3600-T-E3BG) Timer gear mounting nut (V3600-E3B, V3800DI-T-E3B, –...

  • Page 114: Checking, Disassembling And Servicing

    DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING (1) Engine Body Compression Pressure [V3600-E3B, V3600-T-E3B, V3600-E3CB, V3600-T-E3CB, V3300-E3BG, V3600-T-E3BG] 1. After warming up the engine, stop it and remove the air cleaner, the muffler and all nozzle holders / all glow plugs.
  • Page 115 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM [V3800DI-T-E3B, V3800DI-T-E3CB, V3800DI-T-E3BG] 1. After warming up the engine, stop it and remove the air cleaner, the muffler, high pressure pipes, cylinder head cover, overflow pipe, all nozzle holders and all nozzle gaskets. 2.
  • Page 116 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Checking Valve Clearance IMPORTANT • Valve clearance must be checked and adjusted when engine is cold. 1. Remove the injection pipes. (V3800DI-T-E3B, V3800DI-T-E3CB, V3800DI-T-E3BG only) 2. Remove the head cover. 3. Set the No.1 piston at the compression top dead center. 4.

  • Page 117: Lubricating System

    DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM (2) Lubricating System Engine Oil Pressure 1. Remove the oil switch and set a pressure tester (Code No. 07916-32032). 2. Start the engine. After warming up, measure the oil pressure of both idling and rated speeds.
  • Page 118 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM 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 119 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Thermostat Valve Opening Temperature 1. Push down the thermostat valve and insert a string between the valve and the valve seat. 2. Place the thermostat and a thermostat in a container with water and gradually heat the water.

  • Page 120: Fuel System

    DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM (4) Fuel System Injection Timing 1. Remove the timer gear lubricating pipe (1). (V3600-E3B, V3600-E3CB, V3800DI-T-E3B, V3800DI-T-E3CB, V3800DI-T- E3BG only) 2. Remove the gear case cover (2). (V3600-E3B, V3600-E3CB, V3800DI-T-E3B, V3800DI-T-E3CB, V3800DI-T-E3BG only) 3.
  • Page 121 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Injection Timing (Continued) 7. Turn the flywheel counterclockwise (viewed from flywheel side) until the fuel fills up to the hole of the delivery valve holder (6) for No.1 cylinder. 8. After the fuel fills up to the hole of the delivery valve holder for No.1 cylinder, turn back (clockwise) the flywheel around 1.6 rad (90 °).

  • Page 122: V3600-E3Cb, 140.0 Kgf/Cm

    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 at a Kubota-authorized pump service shop. V3600-E3B, V3600-T-E3B, 13.73 MPa...
  • Page 123 1849 psi)), (DI : 18.63 to 17.65 MPa, (190.0 to 180.0 kgf/cm 2702 to 2560 psi)). 9. If the measurement is less than allowable limit, replace the pump with new one or repair at a Kubota-authorized pump service shop. V3600-E3B...

  • Page 124: Washer

    DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM 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 125 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM [V3800DI-T-E3B, V3800DI-T-E3CB, V3800DI-T-E3BG] 1. Set the injection nozzle to the nozzle tester. 2. Slowly move the tester handle to measure the pressure at which fuel begins jetting out from the nozzle. 3.

  • Page 126: Electrical System

    DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Nozzle Holder [V3600-E3B, V3600-T-E3B, V3600-E3CB, V3600-T-E3CB, V3300-E3BG, V3600-T-E3BG] 1. Secure the nozzle retaining nut (7) with a vise. 2. Remove the nozzle holder (1), and take out parts inside. (When reassembling) •...
  • Page 127 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM 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 128 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM 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 129 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Alternator on Unit Test (Before testing) • Before alternator on unit test, check the battery terminal connections, circuit connection, fan belt tension, charging indicator lamp, fuses on the circuit, and abnormal noise from the alternator.

  • Page 130: Turbocharger

    DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Intake Air Heater [V3800DI-T-E3B, V3800DI-T-E3CB, V3800DI-T-E3BG] 1. Disconnect the lead. 2. Measure the resistance between each + terminal (1) / (2) and intake air heater body (3). 3. If the resistance is infinity, the intake air heater is faulty. Approx.

  • Page 131: Electronic Governor (Factory Option For V3300-E3Bg, V3600-T- E3Bg / Standard For V3800Di-T-E3Bg

    DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Radial Clearance 1. If the wheel contact to the housing, replace the turbocharger assembly with new one. W1077353 (7) Electronic Governor (Factory Option for V3300-E3BG, V3600-T-E3BG / Standard for V3800DI-T-E3BG) Speed Sensor 1.
  • Page 132 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Oil Pressure Switch 1. Disconnect the connector of the oil pressure switch connector (1P). 2. Check the state of the harness and if it is abnormal, please replace it. 3. Measure the resistance between the terminal of the connector (harness side) and chassis.
  • Page 133 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Solenoid 1. Disconnect the connector of solenoid (2) (2P). 2. Check the state of the harness and if it is abnormal, please replace it. 3. Turn the key switch to the ACC position. 4.
  • Page 134 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Glow Plug / Intake Air Heater Harness 1. Disconnect the glow plug / intake air heater terminal (1). 2. Check the state of the harness and if it is abnormal, please replace it.
  • Page 135 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Emergency Stop Switch 1. Check the state of the harness and if it is abnormal, please replace it. 2. When the emergency stop switch is turned ON and OFF, measure the resistance between the emergency stop switch (terminal side) (1) of it each time.

  • Page 136: Egr System

    DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM [2] EGR SYSTEM (1) Checking the function of EGR system (V3800DI-T-E3B, V3800DI-T-E3CB, V3800DI-T- E3BG only) 1. Check the coolant temperature and monitor the coolant temperature while checking 1) and 2). 2. If the coolant temperature is already 55 °C (131 °F), cool down the engine.
  • Page 137 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM 2) If the coolant temperature is over 70 °C (158 °F), the surface temperature of EGR pipe must be over 100 °C (212 °F). S-45...

  • Page 138: Disassembling And Assembling

    DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM [3] DISASSEMBLING AND ASSEMBLING (1) Draining Oil and Coolant Draining Engine Oil 1. Start and warm up the engine for approx. 5 minutes. 2. Place an oil pan underneath the engine. 3.

  • Page 139: External Components

    DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM (2) External Components Air Cleaner, Muffler and Others (All models) 1. Remove the air cleaner and muffler. 2. Remove the fan, fan belt, alternator and starter. (When reassembling) • Check to see that there are no cracks on the belt surface. IMPORTANT •...

  • Page 140: Turbocharger(V3600-T-E3B, V3800Di-T-E3B, V3600-T- E3Cb, V3800Di-T-E3Cb, V3600-T-E3Bg, V3800Di-T-E3Bg

    DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM (3) TURBOCHARGER (V3600-T-E3B, V3800DI-T-E3B, V3600-T-E3CB, V3800DI-T-E3CB, V3600-T-E3BG, V3800DI-T-E3BG) CAUTION • While the engine is running and or just after it stops, the turbocharger is hot, be careful not to touch the turbocharger.

  • Page 141: Exhaust Gas Recirculation (Egr) (V3800Di-T-E3B, V3800Di-T- E3Cb, V3800Di-T-E3Bg

    DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM (4) Exhaust Gas Recirculation (EGR) (V3800DI-T-E3B, V3800DI-T-E3CB, V3800DI-T-E3BG) EGR Pipe 1. Remove the EGR pipe (1). (When reassembling) • Replace the gaskets with new ones. (1) EGR Pipe W1184151 EGR Cooler 1.
  • Page 142 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Thermo Valve (If necessary) 1. Disconnect hoses (1), (2). 2. Remove the thermo valve (3). NOTE • If you drop the thermo valve (3), replace the thermo valve (3) with new one. (When reassembling) •...

  • Page 143: Cylinder Head And Valves

    DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM (5) Cylinder Head and Valves Cylinder Head Cover and Nozzle Holder [V3600-E3B, V3600-T-E3B, V3600-E3CB, V3600-T-E3CB, V3300-E3BG, V3600-T-E3BG] 1. Remove the injection pipes (3) and overflow pipes (2). 2. Remove the glow plugs (1). 3.
  • Page 144 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Nozzle Heat Seal Service Removal Procedure [V3600-E3B, V3600-T-E3B, V3600-E3CB, V3600-T-E3CB, V3300-E3BG, V3600-T-E3BG] IMPORTANT • Use a plus (phillips head) screw driver (1) that has a diameter which is bigger than the heat seal hole (Approx. 6 mm (1/4 in.)).
  • Page 145 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Cylinder Head Cover and Nozzle Holder [V3800DI-T-E3B, V3800DI-T-E3CB, V3800DI-T-E3BG] 1. Remove the injection pipes (2). 2. Remove the cylinder head cover (1). 3. Remove the over flow pipe (3). 4. Remove the nozzle holder clamps (4), nozzle holder assembly (5) and nozzle gaskets.
  • Page 146 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Rocker Arm and Push Rod 1. 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.
  • Page 147 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Cylinder Head and Tappet 1. 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.
  • Page 148 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM 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. If you do not replace piston, piston pin bush, connecting rod, crankpin bearings, or crank journal bearings, replace the same notch mark (a), (b) or (c) as the original cylinder head gasket (1).

  • Page 149: Thermostat

    DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Valve 1. Remove the valve caps (3) (V3600-E3B, V3600-T-E3B, V3600-E3CB, V3600-T-E3CB, V3300-E3BG, V3600-T-E3BG only). 2. Remove the valve spring collet (1), pushing the valve spring retainer (4) by valve spring replacer. 3.

  • Page 150: Injection Nozzle

    DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM (7) Injection Nozzle Nozzle Holder [V3600-E3B, V3600-T-E3B, V3600-E3CB, V3600-T-E3CB, V3300-E3BG, V3600-T-E3BG] 1. Secure the nozzle retaining nut (7) with a vise. 2. Remove the nozzle holder (1), and take out parts inside. (When reassembling) •...
  • Page 151 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Injection Pump Unit (Removing) 1. Removing the timer lubricating pipe (1). (V3600-E3B, V3800DI-T-E3B, V3600-E3CB, V3800DI-T-E3CB, V3800DI-T-E3BG only) 2. Remove the injection pump gear cover (2). 3. Set the timer 0 ° restoring jig (4) to the timer gear (3). (V3600-E3B, V3800DI-T-E3B, V3600-E3CB, V3800DI-T-E3CB, V3800DI-T-E3BG only) 4.
  • Page 152 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Injection Pump Unit (Continued) 9. Remove the plugs (1). NOTE • When you tighten the fuel camshaft lock screw, the tightening order (upper / lower) is different in the engine model. •...
  • Page 153 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Injection Pump Unit (Continued) 15.Disconnect the governor lubricating pipe (6). (V3600-E3B, V3600-T-E3B, V3800DI-T-E3B, V3300-E3BG, V3600-T-E3BG, V3800DI-T-E3BG) Remove the governor lubricating pipe joint screw (8). (V3600-E3CB, V3600-T-E3CB, V3800DI-T-E3CB) 16.Remove the injection pump unit support (7). 17.Hold the injection pump unit not to drop.
  • Page 154 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Injection Pump Unit (Continued) (Reassembling) 1. Make sure that No.4 piston is at compression top dead center. 2. Set the timer 0 ° restoring jig (5) to the timer gear (4). (V3600-E3B, V3600-E3CB, V3800DI-T-E3B, V3800DI-T-E3CB, V3800DI-T-E3BG) 3.
  • Page 155 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Governor Housing Assembly 1. Remove the injection pump unit from the engine. (See the “Injection Pump Unit”.) 2. Remove the governor lubricating pipe (3). 3. Remove the solenoid (1). 4. Detach the sight cover (2) from the injection pump unit. 5.

  • Page 156: Shaft

    DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Governor Fork Lever Assembly 1. Pull out the governor fork lever shaft (1) with the M4 extra bolt (Dia : 4 mm, Pitch : 0.7 mm, Length : more than 25 mm) (2). 2.
  • Page 157 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Governor Lever 1. 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). (1) Speed Control Lever (4) Governor Lever Assembly (2) Return Spring...
  • Page 158 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Fuel Camshaft and Governor Weight 1. Separate the governor housing assembly from the injection pump unit. (See the “Governor Housing Assembly”.) 2. Remove the governor sleeve (1). 3. Remove the injection pump assembly (2). 4.
  • Page 159 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Fuel Camshaft and Governor Weight (Continued) NOTE • Use a shock driver to remove the fuel camshaft bearing stopper (6). 7. Remove the fuel camshaft bearing stopper (6). 8. Pull out the fuel camshaft and bearings (7) together from the injection pump housing.
  • Page 160 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Replacing Injection Pump Assembly NOTE • You can remove the injection pump assembly at any crankshaft angle. 1. Remove the all injection pipes (1). 2. Disconnect the fuel hoses (6) and air bleeding hose (4) from the injection pump unit.
  • Page 161 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Installing Procedure of Injection Pump Assembly 1. Install the fuel injection pump assembly (1) in the injection pump unit (2) not to damage governor connecting rod. 2. Slide the governor connecting rod (4) into the rack pin (7) of the injection pump assembly (1).
  • Page 162 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Installing Procedure of Injection Pump Assembly (Continued) 8. Take out the service jig (1). 9. Move the stop lever (6) and visually check to see if the fuel injection pump control rack comes smoothly back to the start position by the counter force of the start spring.

  • Page 163: Water Pump And Oil Cooler

    DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Fan Drive Pulley 1. Set the stopper to the flywheel. 2. Remove the crankshaft screw (2). 3. Draw out the fan drive pulley (1). (When reassembling) 255 to 274 N·m Tightening torque Crankshaft screw 26.0 to 28.0 kgf·m 188 to 202 lbf·ft...

  • Page 164: Gear Case And Timing Gears

    DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM (9) Gear Case and Timing Gears Gear Case Cover 1. Remove the gear case cover (1). (When reassembling) • Confirm that the liquid gasket coating surface is free of water, dust and oil in order to maintain sealing effect. •...
  • Page 165 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Relief Valve 1. Remove the relief valve retaining screw (1). 2. Remove the relief valve (2), the spring (3) and the packing (4). 69 to 78 N·m Relief valve retaining Tightening torque 7.0 to 8.0 kgf·m screw 51 to 57 lbf·ft...
  • Page 166 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Idle Gear 1 and Idle Gear 2 (for Balancer Model) 1. Remove the idle gear mounting screw (1). 2. Draw out the idle gear (2) and (3). (When reassembling) • When install the idle gear (2) and (3), be sure to place the 4th cylinder piston at the top dead center in compression then, align all mating marks on each gear to assemble the timing gears, set the idle gear last.

  • Page 167: Piston And Connecting Rod

    DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Plate (Gear Case) (Except V3600-E3CB, V3600-T-E3CB, V3800DI-T-E3CB) 1. Remove the three plate mounting screws (1). 2. Remove the plate (2). (When reassembling) • Apply Three Bond 1217D adhesive or equivalent on the crankcase like a figure.
  • Page 168 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Connecting Rod Cap 1. 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.) •...
  • Page 169 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Piston 1. Clean carbon in each cylinder completely. 2. Remove a connecting rod cap. 3. Turn the flywheel to set a piston at the top dead center. 4. Push a connecting rod from the bottom side of crankcase with grip of a hammer to remove a piston.
  • Page 170 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM 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) •...

  • Page 171: Flywheel And Crankshaft

    DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM (11) Flywheel and Crankshaft Flywheel 1. Set the flywheel stopper not to turn the flywheel. NOTE • Do not use an impact wrench. Serious damage will occur. 2. Remove the flywheel screws. 3.
  • Page 172 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Flywheel Housing 1. Remove the flywheel housing. (When reassembling) • Make sure the surface of the crank cases 1, 2 are clean and alignment between crankcase 1 and 2 is correct. •...
  • Page 173 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Aligning Crankcase 1 and Crankcase 2 1. Set the crankcase 2 on the crankcase 1. 2. Tighten the crankcase 2 mounting screws loosely. 3. Set the jig or flywheel housing to the specified torque of the flywheel housing screw to align the crankcase 1 and the crankcase 2 (at the flywheel side).
  • Page 174 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Crankshaft 1. Remove the main bearing case. 2. Remove the crankshaft. (When reassembling) • Match the numbering marks (“1”, “2”, “3”, “4”, “5”) between main bearing case and crankcase set the casting mark “F / W SIDE” on the main bearing case facing towards the flywheel side.

  • Page 175: Intake Air Heater

    DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM (12) Intake Air Heater [V3800DI-T-E3B, V3800DI-T-E3CB, V3800DI-T-E3BG] Intake Air Heater 1. Remove the inlet hose. 2. Disconnect the lead. 3. Remove the flange (1). 4. Remove the intake air heater (2). (1) Flange (2) Intake air heater W1043265...
  • Page 176 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Pulley 1. Hold the rotor (base of the claw) in a vise. 2. Loosen the lock nut using a M24 box wrench. 58.4 to 78.9 N·m Tightening torque Pulley nut 5.95 to 8.05 kgf·m 43.1 to 58.2 lbf·ft W1074849 Rotor...
  • Page 177 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Reassembling the Brush 1. Fit the brush with its sliding face in the clockwise direction when viewed from front. IMPORTANT • Be sure to keep the 2 brushes deep in the brush holder. Otherwise the rotor and the rear section can not be fitted into the position.

  • Page 178: Servicing

    DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM [4] SERVICING (1) Cylinder Head 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 179 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Cylinder Head Surface Flatness 1. 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 to measure each clearance with feeler gauge.
  • Page 180 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Valve Recessing 1. Clean the cylinder head, the valve face and 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 181 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Valve Lapping 1. Apply compound evenly to the valve seat. 2. Insert the valve into the valve guide. 3. Lap the valve onto its seat with a valve flapper or screwdriver. 4.
  • Page 182 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Clearance between Valve Stem and Valve Guide 1. Clean carbon from the valve guide and valve stem. 2. Measure the valve stem O.D. with an outside micrometer. 3. Measure the valve guide I.D. of the cylinder head at the most wear part as shown in the figure below with a small hole gauge.
  • Page 183 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Replacing Valve Guide (When removing) 1. Press out the used valve guide with valve guide replacing tool. (When installing) 1. Clean a new valve guide. 2. Apply engine oil to a new valve guide. 3.
  • Page 184 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM 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 185 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Free Length and Tilt of Valve Spring 1. Measure the free length (B) with vernier calipers. 2. If the measurement is less than the allowable limit, replace the spring. 3. Put the spring on a surface plate. 4.
  • Page 186 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Valve Spring Setting Load 1. Place the valve spring on a tester. 2. Compress it to the same length it is actually compressed in the engine. 3. Read the compression load on the gauge. 4.
  • Page 187 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM 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 188: Timing Gears

    DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM (2) Timing Gears 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 189 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG 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.
  • Page 190 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Camshaft Alignment 1. Support the camshaft with V block on the surface plate. 2. Set a dial indicator with its tip on the intermediate journal at right angle. 3. Rotate the camshaft on the V blocks to get the misalignment (half of the measurement).
  • Page 191 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM 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 an inside micrometer. 3. Calculate the oil clearance. 4.
  • Page 192 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Replacing Idle Gear Bushing (When removing) 1. Press out the used bushing with idle gear bushing replacing tool. (When installing) 1. Clean a new idle gear bushing and idle gear bore. 2.

  • Page 193: Piston And Connecting Rod

    DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM (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 194 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG 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 beforehand. 1. Remove the piston pin from the piston. 2.
  • Page 195 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Clearance between Piston Ring and Groove 1. Remove carbon from the ring grooves. 2. Measure the clearance between the ring and the groove with a feeler gauge or depth gauge. 3. If the clearance exceeds allowable limit, replace the ring. 4.

  • Page 196: Crankshaft

    DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM (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.
  • Page 197 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM 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. 4.
  • Page 198 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Oil Clearance between Crankshaft Journal and Crankshaft Bearing 1. Clean the crankshaft journal and crankshaft bearing. 2. Put a strip of press gauge on the center of the journal. IMPORTANT • Never insert the press gauge into the oil hole of the journal. 3.

  • Page 199: Cylinder

    DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM (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 200: Oil Pump

    DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM (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 allowable limit, replace the oil pump rotor assembly.
  • Page 201 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Commutator and Mica 1. Check the contact face 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.
  • Page 202 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Armature Coil 1. Check the continuity across the commutator and armature coil core with an ohmmeter. 2. If it conducts, replace the armature. 3. Check the continuity across the segments of the commutator with an ohmmeter.
  • Page 203 DIESEL ENGINE V3-E3B SERIES, V3-E3CB SERIES, V3-E3BG SERIES, WSM Rotor 1. Measure the resistance across the slip rings with an ohmmeter. 2. If the resistance is not the factory specification, replace it. 3. Check the continuity across the slip and core with an ohmmeter. 4.

This manual is also suitable for:

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