Cummins Onan DKHA HDKBA HDKBB HDKBC HDKAH HQDPC MDKBH MDKUB Generator Set Service Repair Manual INSTANT

Engine Workshop Manual Generator Set DKHA HDKBA HDKBB HDKBC HDKAH HQDPC MDKBH MDKUB English 5−2008 981−0550 (Issue 1)

California Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

SM-E3B SERIES WORKSHOP MANUAL DIESEL ENGINE KiSC issued 10, 2007 A

TO THE READER This Workshop Manual has been prepared to provide servicing personnel with information on the mechanism, service and maintenance of SM-E3B series. 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. ■ Mechanism Information on the construction and function are included. This part should be understood before proceeding with troubleshooting, disassembling and servicing. Refer to Diesel Engine Mechanism Workshop Manual (Code No. 9Y021-01875) for the one which has not been described to this workshop manual. ■ Servicing Information on the troubleshooting, servicing specification lists, tightening torque, checking and adjusting, disassembling and assembling, and servicing which cover procedures, precautions, factory specifications and allowable limits. All information illustrations and specifications contained in this manual are based on the latest product information available at the time of publication. The right is reserved to make changes in all information at any time without notice. Due to covering many models of this manual, information or picture being used have not been specified as one model. March 2007 © KUBOTA Corporation 2007 KiSC issued 10, 2007 A

1 SM-E3B SERIES WSM SAFETY INSTRUCTIONS BEFORE SERVICING AND REPAIRING • Read all instructions and safety instructions in this manual and on your engine safety decals. • Clean the work area and engine. • Park the machine on a firm and level ground. • Allow the engine to cool before proceeding. • Stop the engine, and remove the key. • Disconnect the battery negative cable. • Hang a “DO NOT OPERATE” tag in operator station. SAFETY FIRST This symbol, the industry’s “Safety Alert Symbol”, is used throughout this manual and on labels on the machine itself to warn of the possibility of personal injury. Read these instructions carefully. It is essential that you read the instructions and safety regulations before you attempt to repair or use this unit. DANGER : Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING : Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION : Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. ■ IMPORTANT : Indicates that equipment or property damage could result if instructions are not followed. ■ NOTE : Gives helpful information. KiSC issued 10, 2007 A

2 SM-E3B SERIES WSM SAFETY INSTRUCTIONS SAFETY STARTING • Do not start the engine by shorting across starter terminals or bypassing the safety start switch. • Unauthorized modifications to the engine may impair the function and / or safety and affect engine life. SAFETY WORKING • Do not work on the machine while under the influence of alcohol, medication, or other substances or while fatigued. • Wear close fitting clothing and safety equipment appropriate to the job. • Use tools appropriate to the work. Makeshift tools, parts, and procedures are not recommended. • When servicing is performed together by two or more persons, take care to perform all work safely. • Do not touch the rotating or hot parts while the engine is running. • Never remove the radiator cap while the engine is running, or immediately after stopping. Otherwise, hot water will spout out from radiator. Only remove radiator cap when cool enough to touch with bare hands. Slowly loosen the cap to first stop to relieve pressure before removing completely. • Escaping fluid (fuel or hydraulic oil) under pressure can penetrate the skin causing serious injury. Relieve pressure before disconnecting hydraulic or fuel lines. Tighten all connections before applying pressure. • Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises. • Do not open high-pressure fuel system. High-pressure fluid remaining in fuel lines can cause serious injury. Do not disconnect or attempt repair or fuel lines, sensors, or any other components between the high-pressure fuel pump and injectors on engines with high pressure common rail fuel system. • High voltage exceeding 100 V is generated in the ECU, and is applied to the injector. Pay sufficient caution to electric shock when performing work activities. KiSC issued 10, 2007 A

3 SM-E3B SERIES 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. • Battery gas can explode. Keep sparks and open flame away from the top of battery, especially when charging the battery. • Make sure that no fuel has been spilled on the engine. VENTILATE WORK AREA • If the engine must be running to do some work, make sure the area is well ventilated. Never run the engine in a closed area. The exhaust gas contains poisonous carbon monoxide. DISPOSE OF FLUIDS PROPERLY • Do not pour fluids into the ground, down a drain, or into a stream, pond, or lake. Observe relevant environmental protection regulations when disposing of oil, fuel, coolant, electrolyte and other harmful waste. PREVENT ACID BURNS • Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, clothing and cause blindness if splashed into eyes. Keep electrolyte away from eyes, hands and clothing. If you spill electrolyte on yourself, flush with water, and get medical attention immediately. KiSC issued 10, 2007 A

4 SM-E3B SERIES WSM SAFETY INSTRUCTIONS PREPARE FOR EMERGENCIES • Keep a first aid kit and fire extinguisher handy at all times. • Keep emergency numbers for doctors, ambulance service, hospital and fire department near your telephone. KiSC issued 10, 2007 A

5 SM-E3B SERIES WSM SPECIFICATIONS SPECIFICATIONS * The specification described above is of the standard engine of each model. * Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW W10336300 Model Z482-E3B Z602-E3B Number of Cylinders 2 Type Vertical, Water-cooled, 4 cycle IDI diesel engine Bore × Stroke 67.0 × 68.0 mm (2.64 × 2.68 in.) 72.0 × 73.6 mm (2.83 × 2.90 in.) Total Displacement 479.0 cm 3 (29.23 cu.in.) 599.0 cm 3 (36.55 cu.in.) ISO Net Continous 8.10 kW / 3600 min -1 (rpm) (10.9 HP / 3600 min -1 (rpm)) 10.1 kW / 3600 min -1 ( rpm) (13.5 HP / 3600 min -1 (rpm)) ISO / SAE Net Intermittent 9.30 kW / 3600 min -1 (rpm) (12.5 HP / 3600 min -1 (rpm)) 11.6 kW / 3600 min -1 ( rpm) (15.5 HP / 3600 min -1 (rpm)) SAE Gross Intermittent 9.90 kW / 3600 min -1 (rpm) (13.3 HP / 3600 min -1 (rpm)) 12.5 kW / 3600 min -1 ( rpm) (16.8 HP / 3600 min -1 (rpm)) Maximum Bare Speed 3800 min -1 (rpm) Minimum Bare Idling Speed 900 to 1000 min -1 (rpm) Combustion Chamber Spherical type (E-TVCS) Fuel Injection Pump Bosch MD type mini pump Governor All speed mechanical governor Direction of Rotation Counter-clockwise (viewed from flywheel side) Injection Nozzle Bosch “Throttle” type Injection Timing 0.37 rad (21 °) before T.D.C. 0.35 rad (20 °) before T.D.C. Firing Order 1-2 Injection Pressure 13.73 MPa (140.0 kgf/cm 2 , 1991 psi) Compression Ratio 23.5 : 1 24 : 1 Lubricating System Forced lubrication by trochoid pump Oil Pressure Indicating Electrical type switch Lubricating Filter Full flow paper filter (Cartridge type) Cooling System Pressurized radiator, forced circulation with water pump (not included in the basic engine) Starting System Electric Starting with Starter Starting Motor 12 V, 0.8 kW 12 V, 1.0 kW Starting Support Device By glow plug in combustion chamber EGR None Battery 12 V, 28 AH equivalent 12 V, 36 AH equivalent Charging Alternator 12 V, 150 W 12 V, 480 W Fuel Diesel Fuel No.2-D (ASTM D975) Lubricating Oil Class CF lubricating oil as per API classification is recommended. For details on recommended lubricating oils, see page G-6, 9 Lubricating Oil Capacity Oil Pan Depth 101 mm (3.98 in.) 2.1 L (0.55 U.S.gals) 2.5 L (0.66 U.S.gals) Oil Pan Depth 121 mm (4.76 in.) 2.5 L (0.66 U.S.gals) – Weight (Dry) kg (lbs) 53.1 (117) 60.0 (132) KiSC issued 10, 2007 A

6 SM-E3B SERIES WSM SPECIFICATIONS * The specification described above is of the standard engine of each model. * Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW W10304910 Model D722-E3B D782-E3B D902-E3B Number of Cylinders 3 Type Vertical, Water-cooled, 4 cycle IDI diesel engine Bore × Stroke 67.0 × 68.0 mm (2.64 × 2.68 in.) 67.0 × 73.6 mm (2.64 × 2.90 in.) 72.0 × 73.6 mm (2.83 × 2.90 in.) Total Displacement 719.0 cm 3 (43.88 cu.in.) 778.0 cm 3 (47.48 cu.in.) 898.0 cm 3 (54.80 cu.in.) ISO Net Continuous 12.0 kW / 3600 min -1 (rpm) (16.4 HP / 3600 min -1 (rpm)) 11.7 kW / 3200 min -1 (rpm) (15.7 HP / 3200 min -1 (rpm)) 15.2 kW / 3600 min -1 (rpm) (20.4 HP / 3600 min -1 (rpm)) ISO / SAE Net Intermittent 14.0 kW / 3600 min -1 (rpm) (18.8 HP / 3600 min -1 (rpm)) 13.5 kW / 3200 min -1 (rpm) (18.1 HP / 3200 min -1 (rpm)) 17.5 kW / 3600 min -1 (rpm) (23.5 HP / 3600 min -1 (rpm)) SAE Gross Intermittent 14.9 kW / 3600 min -1 (rpm) (20.0 HP / 3600 min -1 (rpm)) 14.1 kW / 3200 min -1 (rpm) (18.9 HP / 3200 min -1 (rpm)) 18.5 kW / 3600 min -1 (rpm) (24.8 HP / 3600 min -1 (rpm)) Maximum Bare Speed 3800 min -1 (rpm) 3450 min -1 (rpm) 3800 min -1 (rpm) Minimum Bare Idling Speed 900 to 1000 min -1 (rpm) Combustion Chamber Spherical type (E-TVCS) Fuel Injection Pump Bosch MD type mini pump Governor All speed mechanical governor Direction of Rotation Counter-clockwise (viewed from flywheel side) Injection Nozzle Bosch “Throttle” type Injection Timing 0.37 rad (21 °) before T.D.C. 0.30 rad (17 °) before T.D.C. 0.35 rad (20 °) before T.D.C. Firing Order 1-2-3 Injection Pressure 13.73 MPa (140.0 kgf/cm 2 , 1991 psi) Compression Ratio 23.5 : 1 24 : 1 Lubricating System Forced lubrication by trochoid pump Oil Pressure Indicating Electrical type switch Lubricating Filter Full flow paper filter (Cartridge type) Cooling System Pressurized radiator, forced circulation with water pump (not included in the basic engine) Starting System Electric Starting with Starter Starting Motor 12 V, 0.8 kW 12 V, 1.0 kW 12 V, 1.2 kW Starting Support Device By glow plug in combustion chamber EGR None Battery 12 V, 36 AH equivalent 12 V, 52 AH equivalent Charging Alternator 12 V, 150 W 12 V, 480 W Fuel Diesel Fuel No.2-D (ASTM D975) Lubricating Oil Class CF lubricating oil as per API classification is recommended. For details on recommended lubricating oils, see page G-6, 9 Lubricating Oil Capacity Oil Pan Depth 101 mm (3.98 in.) 3.2 L (0.85 U.S.gals) – 3.7 L (0.98 U.S.gals) Oil Pan Depth 121 mm (4.76 in.) 3.8 L (1.0 U.S.gals) 3.6 L (0.95 U.S.gals) – Weight (Dry) kg (lbs) 63.0 (139) 63.5 (140) 72.0 (159) KiSC issued 10, 2007 A

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Cummins Onan DKHA HDKBA HDKBB HDKBC HDKAH HQDPC MDKBH MDKUB Generator Set Service Repair Manual INSTANT

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