Kubota WG1605-G-E3 Instruction manual

WORKSHOP MANUAL
GASOLINE,LPG ENGINE
WG1605-G-E3,WG1605-L-E3,
WG1605-GL-E3
KiSC issued 01, 2012 A

TO THE READER
This Workshop Manual tells the servicing personnel about the mechanism, servicing and
maintenance of the WG1605-G-E3, WG1605-L-E3 and WG1605-GL-E3. It contains 4 parts:
"Information", "General", "Mechanism" and "Servicing".
Information
This section contains information below.
• Safety First
• Specification
• Important Items of Exhaust Emission Regulation
• Performance Curve
• Dimension
• Wiring Diagram
General
This section contains information below.
• Engine Identification
• General Precautions
• Maintenance Check List
• Check and Maintenance
• Special Tools
Mechanism
This section contains information on the structure and the function of the unit. Before you continue
with the subsequent sections, make sure that you read this section.
Servicing
This section contains information below.
• Troubleshooting
• Servicing Specifications
• Tightening Torques
• Checking, Disassembling and Servicing
All illustrations, photographs and specifications contained in this manual are of the newest
information available at the time of publication.
KUBOTA reserves the right to change all information at any time without notice.
Since this manual includes many models, information or illustrations and photographs can show
more than one model.
January, 2012
© KUBOTA Corporation 2012
KiSC issued 01, 2012 A

I INFORMATION
KiSC issued 01, 2012 A

CONTENTS
1. SAFETY FIRST .............................................................................................................................. I-1
2. SPECIFICATIONS.......................................................................................................................... I-4
3. IMPORTANT ITEMS OF EXHAUST EMISSION REGULATION.................................................... I-6
[1] THREE-WAY CATALYST ........................................................................................................ I-7
[2] VAPORIZER AND LOCK OFF VALVE
(WG1605-L-E3, WG1605-GL-E3) ............................................................................................ I-7
[3] LENGTH OF THE VAPOR HOSE
(WG1605-L-E3, WG1605-GL-E3) ........................................................................................... I-7
[4] IMPORTANT NOTICE.............................................................................................................. I-7
[5] EMISSION-RELATED INSTALLATION INSTRUCTIONS........................................................ I-7
(1) Exhaust System.................................................................................................................. I-7
(2) Intake System..................................................................................................................... I-7
(3) Crankcase Ventilation Connections.................................................................................... I-7
(4) Gasoline Fuel System ........................................................................................................ I-7
(5) Gaseous Fuel System ........................................................................................................ I-7
(6) Engine Control Unit (ECU) ................................................................................................. I-8
(7) Vehicle Interface Connectors ............................................................................................. I-8
(8) Malfunction Indicator Light (MIL) ........................................................................................ I-8
4. PERFORMANCE CURVES............................................................................................................I-9
5. DIMENSIONS ............................................................................................................................... I-10
6. WIRING DIAGRAM....................................................................................................................... I-12
INFORMATION
KiSC issued 01, 2012 A

INFORMATION
WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, WSM
I-1
1. SAFETY FIRST
WSM000001INI0001US1
BEFORE YOU START SERVICE
• 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 stable and level ground.
• Let the temperature of the engine decrease before
you start a job.
• Stop the engine, then remove the key.
• Disconnect the battery negative cable.
• Hang a "DO NOT OPERATE" tag in the operator
station.
WSM000001INI0002US0
START SAFELY
• Do not do the procedures below when you start the
engine.
– short across starter terminals
– bypass the safety start switch
• Do not make unauthorized modifications to the
engine. This can cause damage and decrease the
engine life.
WSM000001INI0003US0
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 01, 2012 A

INFORMATION
WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, WSM
I-2
OPERATE SAFELY
• Do not use the machine after you consume alcohol
or medication or when you are tired.
• Put on applicable clothing and safety equipment.
• Use applicable tools only. Do not use alternative
tools or parts.
• When 2 or more persons do servicing, make sure
that you do it safely.
• Do not touch the hot parts or parts that turn when the
engine operates.
• Do not remove the radiator cap when the engine
operates, or immediately after it stops. If not, hot
water can spout out from the radiator. Only remove
the radiator cap when it is at a sufficiently low
temperature to touch with bare hands. Slowly loosen
the cap to release the pressure before you remove it
fully.
• Released fluid (fuel or hydraulic oil) under pressure
can cause damage to the skin and cause serious
injury. Release the pressure before you disconnect
hydraulic or fuel lines. Tighten all connections before
you apply the pressure.
• Do not open a fuel system under high pressure.
The fluid under high pressure that stays in fuel lines
can cause serious injury. Do not disconnect or repair
the fuel lines, sensors, or any other components
between the fuel pump and injectors on engines with
a common rail fuel system under high pressure.
• Put on an applicable ear protective device (earmuffs
or earplugs) to prevent injury against loud noises.
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PREVENT A FIRE
• Fuel is very flammable and explosive under some
conditions. Do not smoke or let flames or sparks in
your work area.
• To prevent sparks from an accidental short circuit,
always disconnect the battery negative cable first
and connect it last.
• The battery gas can cause an explosion. Keep the
sparks and open flame away from the top of battery,
especially when you charge the battery.
• Make sure that you do not spill fuel on the engine.
WSM000001INI0005US1
KEEP A GOOD AIRFLOW IN THE WORK AREA
• If the engine is in operation, make sure that the area
has good airflow. Do not operate the engine in a
closed area. The exhaust gas contains poisonous
carbon monoxide.
WSM000001INI0006US1
KiSC issued 01, 2012 A

INFORMATION
WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, WSM
I-3
DISCARD FLUIDS CORRECTLY
• Do not discard fluids on the ground, down the drain,
into a stream, pond, or lake. Obey related
environmental protection regulations when you
discard oil, fuel, coolant, electrolyte and other
dangerous waste.
WSM000001INI0007US1
PREVENT ACID BURNS
• Keep electrolyte away from your eyes, hands and
clothing. Sulfuric acid in battery electrolyte is
poisonous and it can burn your skin and clothing and
cause blindness. If you spill electrolyte on yourself,
clean yourself with water, and get medical aid
immediately.
WSM000001INI0008US1
PREPARE FOR EMERGENCIES
• Keep a first aid kit and fire extinguisher ready at all
times.
• Keep the emergency contact telephone numbers
near your telephone at all times.
WSM000001INI0009US1
KiSC issued 01, 2012 A

INFORMATION
WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, WSM
I-4
2. SPECIFICATIONS
*The specification described above is of the standard engine of each model.
*Conversion Formula: HP = 0.746 kW, PS = 0.7355 kW
*KUBOTA RECOMMENDED LPG FUEL SPECIFICATIONS
• Commercial Propane gas only.
• Equivalent to Propanes H-D-5 of GPA* standards.
(vol %)
*GPA means Gas Processors Association (U.S.A.)
Model WG1605-G-E3 WG1605-L-E3
Gasoline fuel LPG fuel
Number of Cylinder 4
Type Vertical, water cooled,
4-cycle Gasoline engine
Vertical, water cooled,
4-cycle LPG engine
Bore × Stroke 79.0 × 78.4 mm (3.11 × 3.09 in.)
Total Displacement 1.537 L (93.79 cu.in.)
SAE Gross Intermittent 42.5 kW (57.0 HP) / 3600 min-1 (rpm)
37.0 kW (49.6 HP) / 3000 min-1 (rpm)
41.0 kW (55.0 HP) / 3600 min-1 (rpm)
36.0 kW (48.3 HP) / 3000 min-1 (rpm)
ISO / SAE Net Intermittent 38.5 kW (51.6 HP) / 3600 min-1 (rpm)
33.5 kW (44.9 HP) / 3000 min-1 (rpm)
37.1 kW (49.8 HP) / 3600 min-1 (rpm)
32.5 kW (43.6 HP) / 3000 min-1 (rpm)
ISO Net Continuous 30.8 kW (41.3 HP) / 3600 min-1 (rpm)
26.8 kW (35.9 HP) / 3000 min-1 (rpm)
29.7 kW (39.8 HP) / 3600 min-1 (rpm)
26.1 kW (35.0 HP) / 3000 min-1 (rpm)
Maximum Bare Speed 3575 to 3625 min-1 (rpm)
2975 to 3025 min-1 (rpm)
Minimum Bare Idling Speed 725 to 775 min-1 (rpm)
Cylinder Head Overhead-Valve
Ignition System Full Transistor Battery Ignition Type
Governor Electronic Governor
Direction of Rotation Counter-Clockwise (Viewed from Flywheel Side)
Spark Plug Type / Spark Plug Gap NGK IFR6F8DN 0.70 to 0.80 mm (0.028 to 0.031 in.)
Ignition Timing
0.45 rad (26 °) before T.D.C. /
3000 min-1 (rpm), 3600 min-1 (rpm)
0.17 rad (10 °) before T.D.C. /
750 min-1 (rpm), 800 min-1 (rpm)
0.35 rad (20 °) before T.D.C. /
3000 min-1 (rpm), 3600 min-1 (rpm)
0.17 rad (10 °) before T.D.C. /
750 min-1 (rpm), 800 min-1 (rpm)
Firing Order 1-3-4-2
Compression Ratio 9.1: 1
Lubricating System Forced Lubrication by Trochoid Pump
Oil Pressure Indication Electrical Type Switch
Lubricating Filter Full Flow Paper Filter (Cartridge Type)
Cooling System Pressurized Radiator, Forced Circulation with Water Pump
Starting System Electric Starting with Starter
Starting Motor 12 V, 1.0 kW
Battery 12 V, 52 AH or Equivalent
Charging Alternator 12 V, 480 W, 720 W
Fuel *Unleaded Automobile Gasoline Commercial LPG
Lubricating Oil Better than SL Class (API) SAE 10W-30
Lubricating Oil Capacity 6.0 L (1.6 U.S.gals)
Catalytic Muffler / Converter Three Way Catalyst
Weight (Dry) 119 kg (262 lbs) 120 kg (265 lbs)
Application General Power Source
C3H8C3H6C4H10 Others
≥90 % ≤5 % ≤2.5 % −
KiSC issued 01, 2012 A

INFORMATION
WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, WSM
I-5
*The specification described above is of the standard engine of each model.
*Conversion Formula: HP = 0.746 kW, PS = 0.7355 kW
*KUBOTA RECOMMENDED LPG FUEL SPECIFICATIONS
• Commercial Propane gas only.
• Equivalent to Propanes H-D-5 of GPA* standards.
(vol %)
*GPA means Gas Processors Association (U.S.A.)
9Y1210661INI0001US0
Model WG1605-GL-E3
Gasoline fuel LPG fuel
Number of Cylinder 4
Type Vertical, water cooled, 4-cycle Dual Fuel (Gasoline / LPG) engine
Bore × Stroke 79.0 × 78.4 mm (3.11 × 3.09 in.)
Total Displacement 1.537 L (93.79 cu.in.)
SAE Gross Intermittent 42.5 kW (57.0 HP) / 3600 min-1 (rpm)
37.0 kW (49.6 HP) / 3000 min-1 (rpm)
41.0 kW (55.0 HP) / 3600 min-1 (rpm)
36.0 kW (48.3 HP) / 3000 min-1 (rpm)
ISO / SAE Net Intermittent 38.5 kW (51.6 HP) / 3600 min-1 (rpm)
33.5 kW (44.9 HP) / 3000 min-1 (rpm)
37.1 kW (49.8 HP) / 3600 min-1 (rpm)
32.5 kW (43.6 HP) / 3000 min-1 (rpm)
ISO Net Continuous 30.8 kW (41.3 HP) / 3600 min-1 (rpm)
26.8 kW (35.9 HP) / 3000 min-1 (rpm)
29.7 kW (39.8 HP) / 3600 min-1 (rpm)
26.1 kW (35.0 HP) / 3000 min-1 (rpm)
Maximum Bare Speed 3575 to 3625 min-1 (rpm)
2975 to 3025 min-1 (rpm)
Minimum Bare Idling Speed 725 to 775 min-1 (rpm)
Cylinder Head Overhead-Valve
Ignition System Full Transistor Battery Ignition Type
Governor Electronic Governor
Direction of Rotation Counter-Clockwise (Viewed from Flywheel Side)
Spark Plug Type / Spark Plug Gap NGK IFR6F8DN 0.70 to 0.80 mm (0.028 to 0.031 in.)
Ignition Timing
0.45 rad (26 °) before T.D.C. /
3000 min-1 (rpm), 3600 min-1 (rpm)
0.17 rad (10 °) before T.D.C. /
750 min-1 (rpm), 800 min-1 (rpm)
0.35 rad (20 °) before T.D.C. /
3000 min-1 (rpm), 3600 min-1 (rpm)
0.17 rad (10 °) before T.D.C. /
750 min-1 (rpm), 800 min-1 (rpm)
Firing Order 1-3-4-2
Compression Ratio 9.1: 1
Lubricating System Forced Lubrication by Trochoid Pump
Oil Pressure Indication Electrical Type Switch
Lubricating Filter Full Flow Paper Filter (Cartridge Type)
Cooling System Pressurized Radiator, Forced Circulation with Water Pump
Starting System Electric Starting with Starter
Starting Motor 12 V, 1.0 kW
Battery 12 V, 52 AH or Equivalent
Charging Alternator 12 V, 480 W, 720 W
Fuel *Unleaded Automobile Gasoline Commercial LPG
Lubricating Oil Better than SL Class (API) SAE 10W-30
Lubricating Oil Capacity 6.0 L (1.6 U.S.gals)
Catalytic Muffler / Converter Three Way Catalyst
Weight (Dry) 121 kg (267 lbs)
Application General Power Source
C3H8C3H6C4H10 Others
≥90 % ≤5 % ≤2.5 % −
KiSC issued 01, 2012 A

INFORMATION
WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, WSM
I-6
3. IMPORTANT ITEMS OF EXHAUST EMISSION
REGULATION
WG1605 is available and unavailable in those countries.
Current and future emission regulations.
HC+NOx/CO (g/kWh)
• *: with evaporative emission regulation
• **: See figure below
9Y1210661INI0002US0
9Y1210661INI0017US0
kW, Disp. Model Type North
America Europe Japan
19 < P, 1.0 < L WG1605-G-E3, WG1605-L-E3,
WG1605-GL-E3 E3 Available Available Non-available
Countries kW, disp. 2009 2010 2011 2012 2013 2014 2015 2016
USA
CARB 19 < P < 560
1.0 < L 2.7/4.4* ** 0.8/20.6*
EPA 19 < P ≤560
1.0 < L 2.7/4.4* **
Canada 19 < P None
Japan 19 ≤P < 560 HC/0.6 g/kWh, NOx/0.6 g/kWh, CO/20 g/kWh
EU 19 < P None
KiSC issued 01, 2012 A

INFORMATION
WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, WSM
I-7
[1] THREE-WAY CATALYST
A three-way catalyst is a catalyst that oxidizes HC to CO2and H2O and also CO to CO2respectively and at the
same time reduces NOx to N2near the stoichiometric ratio.
The main basic component of an exhaust gas purification system that uses a three-way catalyst is feedback
control of air-fuel ratio by means of an O2sensor for the purpose of maximizing the emission purification efficiency
characteristic with reference to the intake air-fuel ratio of the three-way catalyst.
9Y1210661INI0004US0
[2] VAPORIZER AND LOCK OFF VALVE
(WG1605-L-E3, WG1605-GL-E3)
Vaporizer requires a normally-closed electrically controlled fuel lock off valve that is close coupled to the vaporizer
and off when ignition switch is off or when the engine is not running normally (supplied from Kubota). In operation
without a lock off upstream the vaporizer will flow fuel with the engine off. The vaporizer is not a fuel shut-off safety
device.
9Y1210661INI0016US0
[3] LENGTH OF THE VAPOR HOSE
(WG1605-L-E3, WG1605-GL-E3)
Vapor hose length must not exceed 700 mm (27.6 in), shorter is generally considered better. Care should be
taken with hose routing and length to minimize the affect on vaporizer vibration isolation. The metal reinforced hose
should not be used.
9Y1210661INI0007US0
[4] IMPORTANT NOTICE
These instructions are provided to the Final Engine Assemblers (FEA) who must ensure the engine, exhaust
system (catalyst), fuel system etc, are installed correctly in the engine's certified configuration.
Please confirm whether emission-related items are certain on application review.
(for EPA only)
Failing to follow these instructions when installing a certified engine in a piece of nonroad equipment violates
federal law (40 CFR 1068.105(b)), subject to fines or other penalties as described in the Clean Air Act.
The contractual agreement contract is necessary before mass-production.
9Y1210661INI0018US0
[5] EMISSION-RELATED INSTALLATION INSTRUCTIONS
(1) Exhaust System
Kubota supplies a certified catalyst. FEA must use a Kubota certified catalyst and assemble the exhaust system
parts according to the instructions.
No other catalyst is certified for use with WG1605 Engine. No Other Catalyst can be used.
FEA may only install the exhaust system parts confirmed at application review.
9Y1210661INI0019US0
(2) Intake System
To prevent decreases of engine output performance, intake resistance must be kept below a certain point.
9Y1210661INI0020US0
(3) Crankcase Ventilation Connections
Crankcase emissions may not be discharged directly into the ambient atmosphere throughout its useful life.
(40 CFR 1048.115 (a))
9Y1210661INI0021US0
(4) Gasoline Fuel System
If your equipment uses a volatile liquid fuel (such as gasoline), they must meet the evaporative emission
standards of 40 CFR 1048.
9Y1210661INI0022US0
(5) Gaseous Fuel System
FEA must use only the vaporizer and the lock off valve Kubota offers and assemble the LPG fuel system parts
according to the instructions.
9Y1210661INI0023US0
KiSC issued 01, 2012 A

INFORMATION
WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, WSM
I-8
(6) Engine Control Unit (ECU)
Installation must utilize all 4 of the vibration mounts.
ECU header pins must be horizontal or point downward.
9Y1210661INI0024US0
(7) Vehicle Interface Connectors
Vehicle interface connectors shall be connected with your wire harness.
9Y1210661INI0025US0
(8) Malfunction Indicator Light (MIL)
When the MIL goes on, it must display "Check Engine", "Service Engine Soon", or a similar message that EPA
approve. (40 CFR 1048.110 (b))
9Y1210661INI0026US0
KiSC issued 01, 2012 A

INFORMATION
WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, WSM
I-9
4. PERFORMANCE CURVES
WG1605-G/L/GL-E3
9Y1210661INI0005US0
(1) Brake Horsepower
(2) Engine Speed
(3) Specific Fuel Consumption
(4) Torque
(5) Gross Intermittent Torque
(6) Gross Intermittent Brake
Horsepower
(7) Gross Intermittent Specific
Fuel Consumption
a: Gasoline Use
b: LP Gas Use
KiSC issued 01, 2012 A

INFORMATION
WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, WSM
I-10
5. DIMENSIONS
WG1605-G-E3
9Y1210661INI0009US0
WG1605-L-E3
9Y1210661INI0010US0
KiSC issued 01, 2012 A

INFORMATION
WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, WSM
I-11
WG1605-GL-E3
9Y1210661INI0011US0
KiSC issued 01, 2012 A

INFORMATION
WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, WSM
I-12
6. WIRING DIAGRAM
WG1605-G-E3
KiSC issued 01, 2012 A

INFORMATION
WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, WSM
I-13
WG1605-L-E3
KiSC issued 01, 2012 A

INFORMATION
WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, WSM
I-14
WG1605-GL-E3
KiSC issued 01, 2012 A

G GENERAL
KiSC issued 01, 2012 A

CONTENTS
1. Engine IDENTIFICATION ............................................................................................................. G-1
[1] ENGINE MODEL NAME, CODE NUMBER AND ENGINE SERIAL NUMBER ...................... G-1
[2] E3 ENGINE ............................................................................................................................ G-3
[3] CYLINDER NUMBER ............................................................................................................. G-3
[4] CATALYTIC CONVERTER .................................................................................................... G-4
2. GENERAL PRECAUTIONS.......................................................................................................... G-5
3. MAINTENANCE CHECK LIST ..................................................................................................... G-6
4. CHECK AND MAINTENANCE ..................................................................................................... G-7
[1] DAILY CHECK POINTS ......................................................................................................... G-7
[2] CHECK POINTS OF INTIAL 50 HOURS ............................................................................. G-10
[3] CHECK POINTS OF EVERY 50 HOURS ............................................................................ G-11
[4] CHECK POINTS OF EVERY 100 HOURS .......................................................................... G-12
[5] CHECK POINTS OF EVERY 200 HOURS .......................................................................... G-14
[6] CHECK POINTS OF EVERY 1000 HOURS ........................................................................ G-15
[7] CHECK POINTS OF EVERY 2000 HOURS ........................................................................ G-17
[8] CHECK POINTS OF EVERY 1 YEAR.................................................................................. G-17
[9] CHECK POINTS OF EVERY 2 YEARS ............................................................................... G-20
5. SPECIAL TOOLS ....................................................................................................................... G-24
GENERAL
KiSC issued 01, 2012 A