Kubota 03-M-E3B / 03-M-DI-E3B / 03-M-E3BG Diesel Engine Workshop Manual

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Page 1

WORKSHOP MANUAL

KiSC issued 07, 2008 A

DIESEL ENGINE

03-M-E3B SERIES,

03-M-DI-E3B SERIES,

03-M-E3BG SERIES

Page 2

TO THE READER

KiSC issued 07, 2008 A

This Workshop Manual has been prepared to provide servicing personnel with information on the mechanism, service and maintenance of 03-M-E3B, 03-M-DI-E3B and 03-M-E3BG series. It is divided into three parts, “General”, “Mechanism” and “Servicing”.

Q General

Information on the engine identification, the general precautions, maintenance check list, check and maintenance and special tools ar e descr ib ed .

Q 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.

Q 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

Page 3

03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM

KiSC issued 07, 2008 A

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 instruct ions and safe ty regulations before y ou attempt to re p air 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.

Q IMPORTANT : Indicates that equipment or property damage could result if instructions are not

followed.

Q NOTE : Gives helpful information.

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.

Page 4

03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM

KiSC issued 07, 2008 A

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 influe nce 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 to re pair 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.

Page 5

03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM

KiSC issued 07, 2008 A

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 fir st and connect it last.

• Battery gas can explode. Keep sparks and open flame away from the top of battery, espe cially 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.

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.

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 regula tions when disp osing of oil, fuel, coolant, electrolyte and other harmful waste.

Page 6

03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM

KiSC issued 07, 2008 A

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.

Page 7

03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM

KiSC issued 07, 2008 A

SPECIFICATIONS

Model D1503-M D1703-M Number of Cylinders 3 Type Vertical, Water-cooled, 4 cycle diesel engine Bore × Stroke 83.0 X 92.4 mm (3.27 X 3.64 in.) 87.0 X 92.4 mm (3.43 X 3.64 in.) Total Displacement 1499 cm ISO Net Continuous 19.5 KW / 2800 min

(26.1 HP / 2800 min

ISO/SAE Net Intermittent 22.4 KW / 2800 min

(30.0 HP / 2800 min

SAE Gross Intermittent 23.8 KW / 2800 min

(31.9 HP / 2800min Maximum Bare Speed 3020 min Minimum Bare Idling Speed 750 to 850 min Combustion Chamber Spherical Type (E-TVCS) Fuel Injection Pump PFR 3M Type Mini Pump (DENSO) Governor Mechanical all speed governor Direction of Rotation Counter-clockwise (viewd from flywheel side) Injection Nozzle OPD Mini Nozzle (DENSO) Injection Timing 0.2662 rad (15.25 °) before T.D.C. 0.2836 rad (16.25 °) before T.D.C. Firing Order 1-2-3 Injection Pressure 13.73 MPa (140.0 kgf/cm Compression Ratio 22.8 : 1 22.0 : 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 Starting System Electric Starting with Starter Starting Motor 12 V, 1.2 kW Starting Support Device By glow plug in combustion chamber EGR NONE Battery 12 V, 60 AH equivalent Charging Alternator 12 V, 360 W Fuel Diesel Fuel No.2-D (ASTM D975) Lubricating Oil Class CF lubricating oil as per API classification is recommended.

Lubricating Oil Capacity

Oil Pan Depth 90 mm (3.5 in.)

Oil Pan Depth 124 mm (4.88 in.)

Weight (Dry) 148 kg (326 lbs)

* The specification described above is of the standard engine of each model. * Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW

(91.47 cu.in.) 1647 cm3 (100.5 cu.in.)

-1

(rpm)

-1

(rpm))

-1

(rpm)

-1

(rpm))

-1

(rpm)

-1

(rpm))

-1

(rpm)

21.2 KW / 2800 min

(28.4 HP / 2800 min

24.4 KW / 2800 min

(32.7 HP / 2800 min

26.1 KW / 2800 min

(35.0 HP / 2800 min

-1

(rpm)

, 1991 psi)

For details on recommended lubricating oils, see page G-7, 10

5.6 L (1.5 U.S.gals)

7.0 L (1.8 U.S.gals)

-1

(rpm)

-1

(rpm))

-1

(rpm)

-1

(rpm))

-1

(rpm)

-1

(rpm))

W10275180

Page 8

03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM

KiSC issued 07, 2008 A

Model D1803-M Number of Cylinders 3 Type Vertical, Water-cooled, 4 cycle diesel engine Bore × Stroke 87.0 X 102.4 mm (3.43 X 4.031 in.) Total Displacement 1826 cm ISO Net Continuous 22.8 KW / 2700 min

(30.6 HP / 2700 min

ISO/SAE Net Intermittent 26.3 KW / 2700 min

(35.3 HP / 2700 min

SAE Gross Intermittent 27.9 KW / 2700 min

(37.4 HP / 2700 min Maximum Bare Speed 3020 min Minimum Bare Idling Speed 750 to 850 min

(111.4 cu.in.)

-1

(rpm)

-1

(rpm)

(rpm))

(rpm)

(rpm))

(rpm)

(rpm))

Combustion Chamber Spherical Type (E-TVCS) Fuel Injection Pump PFR 3M Type Mini Pump (DENSO) Governor Mechanical all speed governor Direction of Rotation Counter-clockwise (viewd from flywheel side) Injection Nozzle OPD Mini Nozzle (DENSO) Injection Timing 0.2836 rad (16.25 °) before T.D.C. Firing Order 1-2-3 Injection Pressure 13.73 MPa (140.0 kgf/cm

, 1991 psi) Compression Ratio 24.3 : 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 Starting System Electric Starting with Starter Starting Motor 12 V, 2.0 kW Starting Support Device By glow plug in combustion chamber EGR NONE Battery 12 V, 92 AH equivalent Charging Alternator 12 V, 360 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-7, 10

Lubricating Oil Capacity

Oil Pan Depth 90 mm (3.5 in.)

Oil Pan Depth 124 mm (4.88 in.)

5.6 L (1.5 U.S.gals)

7.0 L (1.8 U.S.gals)

Weight (Dry) 151 kg (333 lbs)

* The specification described above is of the standard engine of each model. * Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW

SPECIFICATIONS

W10316200

Page 9

03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM

KiSC issued 07, 2008 A

SPECIFICATIONS

Model V2003-M V2203-M Number of Cylinders 4 Type Vertical, Water-cooled, 4 cycle diesel engine Bore × Stroke 83.0 X 92.4 mm (3.27 X 3.64 in.) 87.0 X 92.4 mm (3.43 X 3.64 in.) Total Displacement 1999 cm ISO Net Continuous 26.7 KW / 2800 min

(35.8 HP / 2800 min

ISO/SAE Net Intermittent 30.8 KW / 2800 min

(41.3 HP / 2800 min

SAE Gross Intermittent 32.6 KW / 2800 min

(43.7 HP / 2800 min Maximum Bare Speed 3020 min Minimum Bare Idling Speed 750 to 850 min

(122.0 cu.in.) 2197 cm3 (134.1 cu.in.)

-1

(rpm)

-1

(rpm))

-1

(rpm)

-1

(rpm))

-1

(rpm)

-1

(rpm))

-1

(rpm)

29.6 KW / 2800 min

(39.7 HP / 2800 min

34.1 KW / 2800 min

(45.7 HP / 2800 min

35.9 KW / 2800 min

(48.1 HP / 2800 min

-1

(rpm)

-1

(rpm))

-1

(rpm))

-1

(rpm))

(rpm)

Combustion Chamber Spherical Type (E-TVCS) Fuel Injection Pump PFR 4M Type Mini Pump (DENSO) Governor Mechanical all speed governor Direction of Rotation Counter-clockwise (viewd from flywheel side) Injection Nozzle OPD Mini Nozzle (DENSO) Injection Timing 0.2836 rad (16.25 °) before T.D.C. Firing Order 1-3-4-2 Injection Pressure 13.73 MPa (140.0 kgf/cm

, 1991 psi) Compression Ratio 22.8 : 1 22.0 : 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 Starting System Electric Starting with Starter Starting Motor 12 V, 1.4 kW Starting Support Device By glow plug in combustion chamber EGR NONE Battery 12 V, 88 AH equivalent Charging Alternator 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-7, 10

Lubricating Oil Capacity

Oil Pan Depth 90 mm (3.5 in.)

Oil Pan Depth 124 mm (4.88 in.)

7.6 L (2.0 U.S.gals)

9.5 L (2.5 U.S.gals)

Weight (Dry) 180 kg (397 lbs)

* The specification described above is of the standard engine of each model. * Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW

W10384770

Page 10

03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM

KiSC issued 07, 2008 A

SPECIFICATIONS

Model V2403-M V2403-M-T Number of Cylinders 4 Type Vertical, Water-cooled, 4 cycle diesel engine Bore × Stroke 87.0 X 102.4 mm (3.43 X 4.031 in.) Total Displacement 2434 cm ISO Net Continuous 30.2 KW / 2700 min

(40.5 HP / 2700 min

ISO/SAE Net Intermittent 34.8 KW / 2700 min

(46.7 HP / 2700 min

SAE Gross Intermittent 36.5 KW / 2700 min

(48.9 HP / 2700 min Maximum Bare Speed 3020 min Minimum Bare Idling Speed 750 to 850 min

-1

(rpm)

-1

(rpm))

-1

(rpm)

-1

(rpm))

-1

(rpm)

-1

(rpm))

-1

(rpm) 2950 min-1 (rpm)

-1

(rpm) 750 min-1 (rpm)

(148.5 cu.in.)

36.4 KW / 2700 min

(48.8 HP / 2700 min

41.9 KW / 2700 min

(56.2 HP / 2700 min

44.0 KW / 2700 min

(59.0 HP / 2700 min

-1

(rpm)

-1

(rpm))

-1

(rpm)

-1

(rpm))

-1

(rpm)

-1

(rpm))

Combustion Chamber Spherical Type (E-TVCS) Fuel Injection Pump PFR 4M Type Mini Pump (DENSO) Governor Mechanical all speed governor Direction of Rotation Counter-clockwise (viewd from flywheel side) Injection Nozzle OPD Mini Nozzle (DENSO) Injection Timing 0.2836 rad (16.25 °) before T.D.C. 0.14 rad (8.3 °) before T.D.C. Firing Order 1-3-4-2 Injection Pressure 13.73 MPa (140.0 kgf/cm

, 1991 psi) Compression Ratio 23.2 : 1 23.0 : 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 Starting System Electric Starting with Starter Starting Motor 12 V, 2.0 kW Starting Support Device By glow plug in combustion chamber EGR NONE Battery 12 V, 92 AH equivalent Charging Alternator 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-7, 10

Lubricating Oil Capacity

Oil Pan Depth 90 mm (3.5 in.)

Oil Pan Depth 124 mm (4.88 in.)

7.6 L (2.0 U.S.gals) –

9.5 L (2.5 U.S.gals)

Weight (Dry) 184 kg (406 lbs) 190 kg (419 lbs)

* The specification described above is of the standard engine of each model. * Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW

W10334350

Page 11

03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM

KiSC issued 07, 2008 A

Model D1803-M-DI Number of Cylinders 3 Type Vertical, Water-cooled, 4 cycle diesel engine Bore × Stroke 87.0 X 102.4 mm (3.43 X 4.031 in.) Total Displacement 1826 cm ISO Net Continuous 23.2 KW / 2700 min

(31.1 HP / 2700 min

ISO/SAE Net Intermittent 26.7 KW / 2700 min

(35.8 HP / 2700 min

SAE Gross Intermittent 27.9 KW / 2700 min

(37.4 HP / 2700 min Maximum Bare Speed 2920 min Minimum Bare Idling Speed 850 to 950 min

(111.4 cu.in.)

-1

(rpm)

-1

(rpm)

(rpm))

(rpm)

(rpm))

(rpm)

(rpm))

Combustion Chamber Reentrant Type (Direct Injection) Fuel Injection Pump Bosch “K” Type Mini Pump Governor Mechanical all speed governor Direction of Rotation Counter-clockwise (viewd from flywheel side) Injection Nozzle Bosch “P” Type Hole Nozzle Injection Timing 0.087 rad (5.0 °) before T.D.C. Firing Order 1-2-3 Injection

Pressure

1st stage 18.63 MPa (190.0 kgf/cm 2nd stage 22.56 MPa (230.0 kgf/cm

, 2702 psi)

, 3271 psi) Compression Ratio 20.5 : 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 Starting System Electric Starting with Starter Starting Motor 12 V, 1.4 kW Starting Support Device By glow plug in combustion chamber EGR NONE Battery 12 V, 88 AH equivalent Charging Alternator 12 V, 360 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-7, 10

Lubricating Oil Capacity

Oil Pan Depth 90 mm (3.5 in.)

Oil Pan Depth 124 mm (4.88 in.)

5.6 L (1.5 U.S.gals)

7.0 L (1.8 U.S.gals)

Weight (Dry) 151 kg (333 lbs)

* The specification described above is of the standard engine of each model. * Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW

SPECIFICATIONS

W10343470

Page 12

03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM

KiSC issued 07, 2008 A

SPECIFICATIONS

Model V2403-M-DI V2403-M-DI-T Number of Cylinders 4 Type Vertical, Water-cooled, 4 cycle diesel engine Bore × Stroke 87.0 X 102.4 mm (3.43 X 4.031 in.) Total Displacement 2434 cm ISO Net Continuous 30.5 KW / 2700 min

(40.9 HP / 2700 min

ISO/SAE Net Intermittent 35.1 KW / 2700 min

(47.1 HP / 2700 min

SAE Gross Intermittent 36.5 KW / 2700 min

(48.9 HP / 2700 min Maximum Bare Speed 2920 min Minimum Bare Idling Speed 850 to 950 min

-1

(rpm)

-1

(rpm))

-1

(rpm)

-1

(rpm))

-1

(rpm)

-1

(rpm))

-1

(rpm) 2450 min-1 (rpm)

-1

(rpm) 900 min-1 (rpm)

(148.5 cu.in.)

30.7 KW / 2400 min

(41.2 HP / 2400 min

35.3 KW / 2400 min

(47.3 HP / 2400 min

36.5 KW / 2400 min

(48.9 HP / 2400 min

-1

(rpm)

-1

(rpm))

-1

(rpm)

-1

(rpm))

-1

(rpm)

-1

(rpm))

Pressure

1st stage 18.63 MPa (190.0 kgf/cm 2nd stage 22.56 MPa (230.0 kgf/cm

, 2702 psi)

, 3271 psi) Compression Ratio 20.5 : 1 20.2 : 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 Starting System Electric Starting with Starter Starting Motor 12 V, 2.0 kW Starting Support Device By glow plug in combustion chamber EGR NONE Battery 12 V, 92 AH equivalent Charging Alternator 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-7, 10

Lubricating Oil Capacity

Oil Pan Depth 90 mm (3.5 in.)

Oil Pan Depth 124 mm (4.88 in.)

7.6 L (2.0 U.S.gals)

9.5 L (2.5 U.S.gals)

Weight (Dry) 184 kg (406 lbs) 190 kg (416 lbs)

* The specification described above is of the standard engine of each model. * Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW

W10452650

Page 13

03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM

KiSC issued 07, 2008 A

Model D1703-M-BG Number of Cylinders 3 Type Vertical, Water-cooled, 4 cycle diesel engine Bore × Stroke 87.0 X 92.4 mm (3.43 X 3.64 in.) Total Displacement 1647 cm ISO Net Continuous 14.0 KW / 1500 min

(18.8 HP / 1500 min

ISO/SAE Net Intermittent 16.1 KW / 1500 min

(21.6 HP / 1500 min

SAE Gross Intermittent 16.6 KW / 1500 min

(22.3 HP / 1500 min

-1

(rpm)

-1

(rpm))

-1

(rpm)

-1

(rpm))

-1

(rpm)

-1

(rpm)) Maximum Bare Speed 2120 min Minimum Bare Idling Speed 2120 min

(100.5 cu.in.)

-1

(rpm)

-1

(rpm)

16.9 KW / 1800 min

(22.7 HP / 1800 min

19.5 KW / 1800 min

(26.1 HP / 1800 min

20.2 KW / 1800 min

(27.1 HP / 1800 min

Combustion Chamber Spherical Type (E-TVCS) Fuel Injection Pump PFR 3M Type Mini Pump (DENSO) Governor Mechanical all speed governor + Electronic Governor Direction of Rotation Counter-clockwise (viewd from flywheel side) Injection Nozzle OPD Mini Nozzle (DENSO) Injection Timing 0.2487 rad (14.25 °) before T.D.C. Firing Order 1-2-3 Injection Pressure 13.73 MPa (140.0 kgf/cm

, 1991 psi) Compression Ratio 22.0 : 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 Starting System Electric Starting with Starter Starting Motor 12 V, 1.4 kW Starting Support Device By glow plug in combustion chamber EGR NONE Battery 12 V, 60 AH equivalent Charging Alternator 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-7, 10

Lubricating Oil Capacity

Oil Pan Depth 90 mm (3.5 in.)

Oil Pan Depth 124 mm (4.88 in.)

5.6 L (1.5 U.S.gals)

7.0 L (1.8 U.S.gals)

Weight (Dry) 164 kg (362 lbs)

* The specification described above is of the standard engine of each model. * Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW

SPECIFICATIONS

-1

(rpm)

-1

(rpm))

-1

(rpm)

-1

(rpm))

-1

(rpm)

-1

(rpm))

W10336120

Page 14

03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM

KiSC issued 07, 2008 A

Model V2003-M-BG Number of Cylinders 4 Type Vertical, Water-cooled, 4 cycle diesel engine Bore × Stroke 83.0 X 92.4 mm (3.27 X 3.64 in.) Total Displacement 1999 cm ISO Net Continuous 17.5 KW / 1500 min

(23.5 HP / 1500 min

ISO/SAE Net Intermittent 20.1 KW / 1500 min

(27.0 HP / 1500 min

SAE Gross Intermittent 20.6 KW / 1500 min

(27.6 HP / 1500 min

-1

(rpm)

-1

(rpm))

-1

(rpm)

-1

(rpm))

-1

(rpm)

-1

(rpm)) Maximum Bare Speed 2120 min Minimum Bare Idling Speed 2120 min

(122.0 cu.in.)

-1

(rpm)

-1

(rpm)

20.3 KW / 1800 min

(27.2 HP / 1800 min

23.4 KW / 1800 min

(31.4 HP / 1800 min

24.3 KW / 1800 min

(32.6 HP / 1800 min

Combustion Chamber Spherical Type (E-TVCS) Fuel Injection Pump PFR 4M Type Mini Pump (DENSO) Governor Mechanical all speed governor + Electronic Governor Direction of Rotation Counter-clockwise (viewd from flywheel side) Injection Nozzle OPD Mini Nozzle (DENSO) Injection Timing 0.2487 rad (14.25 °) before T.D.C. Firing Order 1-3-4-2 Injection Pressure 13.73 MPa (140.0 kgf/cm

, 1991 psi) Compression Ratio 22.8 : 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 Starting System Electric Starting with Starter Starting Motor 12 V, 1.4 kW Starting Support Device By glow plug in combustion chamber EGR NONE Battery 12 V, 88 AH equivalent Charging Alternator 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-7, 10

Lubricating Oil Capacity

Oil Pan Depth 90 mm (3.5 in.)

Oil Pan Depth 124 mm (4.88 in.)

7.6 L (2.0 U.S.gals)

9.5 L (2.5 U.S.gals)

Weight (Dry) 195 kg (430 lbs)

* The specification described above is of the standard engine of each model. * Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW

SPECIFICATIONS

-1

(rpm)

-1

(rpm))

-1

(rpm)

-1

(rpm))

-1

(rpm)

-1

(rpm))

W10389960

Page 15

03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM

KiSC issued 07, 2008 A

Model V2003-M-T-BG Number of Cylinders 4 Type Vertical, Water-cooled, 4 cycle diesel engine Bore × Stroke 83.0 X 92.4 mm (3.27 X 3.64 in.) Total Displacement 1999 cm ISO Net Continuous 22.3 KW / 1500 min

(29.9 HP / 1500 min

ISO/SAE Net Intermittent 25.7 KW / 1500 min

(34.5 HP / 1500 min

SAE Gross Intermittent 26.2 KW / 1500 min

(35.1 HP / 1500 min

-1

(rpm)

-1

(rpm))

-1

(rpm)

-1

(rpm))

-1

(rpm)

-1

(rpm)) Maximum Bare Speed 2120 min Minimum Bare Idling Speed 2120 min

(122.0 cu.in.)

-1

(rpm)

-1

(rpm)

25.7 KW / 1800 min

(34.5 HP / 1800 min

29.6 KW / 1800 min

(39.7 HP / 1800 min

30.6 KW / 1800 min

(41.0 HP / 1800 min

Combustion Chamber Spherical Type (E-TVCS) Fuel Injection Pump PFR 4M Type Mini Pump (DENSO) Governor Mechanical all speed governor + Electronic Governor Direction of Rotation Counter-clockwise (viewd from flywheel side) Injection Nozzle OPD Mini Nozzle (DENSO) Injection Timing 0.2662 rad (15.25 °) before T.D.C. Firing Order 1-3-4-2 Injection Pressure 13.73 MPa (140.0 kgf/cm

, 1991 psi) Compression Ratio 21.7 : 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 Starting System Electric Starting with Starter Starting Motor 12 V, 1.4 kW Starting Support Device By glow plug in combustion chamber EGR NONE Battery 12 V, 88 AH equivalent Charging Alternator 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-7, 10

Lubricating Oil Capacity

Oil Pan Depth 90 mm (3.5 in.)

Oil Pan Depth 124 mm (4.88 in.)

7.6 L (2.0 U.S.gals)

9.5 L (2.5 U.S.gals)

Weight (Dry) 208 kg (459 lbs)

* The specification described above is of the standard engine of each model. * Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW

SPECIFICATIONS

-1

(rpm)

-1

(rpm))

-1

(rpm)

-1

(rpm))

-1

(rpm)

-1

(rpm))

W10413710

Page 16

03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM

KiSC issued 07, 2008 A

Model V2203-M-BG Number of Cylinders 4 Type Vertical, Water-cooled, 4 cycle diesel engine Bore × Stroke 87.0 X 92.4 mm (3.43 X 3.64 in.) Total Displacement 2197 cm ISO Net Continuous 18.8 KW / 1500 min

(25.2 HP / 1500 min

ISO/SAE Net Intermittent 21.7 KW / 1500 min

(29.1 HP / 1500 min

SAE Gross Intermittent 22.2 KW / 1500 min

(29.8 HP / 1500 min

-1

(rpm)

-1

(rpm))

-1

(rpm)

-1

(rpm))

-1

(rpm)

-1

(rpm)) Maximum Bare Speed 2120 min Minimum Bare Idling Speed 2120 min

(134.1 cu.in.)

-1

(rpm)

-1

(rpm)

22.6 KW / 1800 min

(30.3 HP / 1800 min

26.0 KW / 1800 min

(34.9 HP / 1800 min

26.9 KW / 1800 min

(36.1 HP / 1800 min

, 1991 psi) Compression Ratio 22.0 : 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 Starting System Electric Starting with Starter Starting Motor 12 V, 1.4 kW Starting Support Device By glow plug in combustion chamber EGR NONE Battery 12 V, 88 AH equivalent Charging Alternator 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-7, 10

Lubricating Oil Capacity

Oil Pan Depth 90 mm (3.5 in.)

Oil Pan Depth 124 mm (4.88 in.)

7.6 L (2.0 U.S.gals)

9.5 L (2.5 U.S.gals)

Weight (Dry) 195 kg (430 lbs)

* The specification described above is of the standard engine of each model. * Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW

SPECIFICATIONS

-1

(rpm)

-1

(rpm))

-1

(rpm)

-1

(rpm))

-1

(rpm)

-1

(rpm))

W10419300

Page 17

03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM

KiSC issued 07, 2008 A

Model V2403-M-BG Number of Cylinders 4 Type Vertical, Water-cooled, 4 cycle diesel engine Bore × Stroke 87.0 X 102.4 mm (3.43 X 4.031 in.) Total Displacement 2434 cm ISO Net Continuous 21.5 KW / 1500 min

(28.8 HP / 1500 min

ISO/SAE Net Intermittent 24.8 KW / 1500 min

(33.3 HP / 1500 min

SAE Gross Intermittent 25.3 KW / 1500 min

(33.9 HP / 1500 min

-1

(rpm)

-1

(rpm))

-1

(rpm)

-1

(rpm))

-1

(rpm)

-1

(rpm)) Maximum Bare Speed 2120 min Minimum Bare Idling Speed 2120 min

(148.5 cu.in.)

-1

(rpm)

-1

(rpm)

25.1 KW / 1800 min

(33.7 HP / 1800 min

28.9 KW / 1800 min

(38.8 HP / 1800 min

29.8 KW / 1800 min

(40.0 HP / 1800 min

, 1991 psi) Compression Ratio 23.2 : 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 Starting System Electric Starting with Starter Starting Motor 12 V, 2.0 kW Starting Support Device By glow plug in combustion chamber EGR NONE Battery 12 V, 88 AH equivalent Charging Alternator 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-7, 10

Lubricating Oil Capacity

Oil Pan Depth 90 mm (3.5 in.)

Oil Pan Depth 124 mm (4.88 in.)

7.6 L (2.0 U.S.gals)

9.5 L (2.5 U.S.gals)

Weight (Dry) 190 kg (419 lbs)

* The specification described above is of the standard engine of each model. * Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW

SPECIFICATIONS

-1

(rpm)

-1

(rpm))

-1

(rpm)

-1

(rpm))

-1

(rpm)

-1

(rpm))

W10424850

Page 18

03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM

KiSC issued 07, 2008 A

DIMENSIONS

D1503-M D1703-M D1803-M A 567.0 mm (22.32 in.) 560.0 mm (22.05 in.) 560.0 mm (22.05 in.) B 512.0 mm (20.16 in.) 480.0 mm (18.90 in.) 480.0 mm (18.90 in.) C 643.0 mm (25.31 in.) 643.0 mm (25.31 in.) 648.0 mm (25.51 in.)

W1031045

Page 19

03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM

KiSC issued 07, 2008 A

DIMENSIONS

V2003-M V2203-M V2403-M V2403-M-T A 652.0 mm (25.67 in.) 652.0 mm (25.67 in.) 652.0 mm (25.67 in.) 667.1 mm (26.26 in.) B 480.0 mm (18.90 in.) 480.0 mm (18.90 in.) 480.0 mm (18.90 in.) 449.0 mm (17.68 in.)

C 643.0 mm (25.31 in.) 643.0 mm (25.31 in.) 648.0 mm (25.51 in.) 737.3 mm (29.03 in.)

W1028881

Page 20

03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM

KiSC issued 07, 2008 A

DIMENSIONS

D1803-M-DI A 560.0 mm (22.05 in.) B 492.0 mm (19.37 in.) C 636.0 mm (25.04 in.)

W1035766

Page 21

03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM

KiSC issued 07, 2008 A

DIMENSIONS

V2403-M-DI V2403-M-DI-T A 655.0 mm (25.79 in.) 667.1 mm (26.26 in.) B 492.0 mm (19.37 in.) 449.0 mm (17.68 in.)

C 636.0 mm (25.04 in.) 737.3 mm (29.03 in.)

W1035816

Page 22

03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM

KiSC issued 07, 2008 A

DIMENSIONS

D1703-M-BG A 605.6 mm (23.84 in.) B 505.0 mm (19.88 in.) C 642.8 mm (25.31 in.)

W1036026

Page 23

03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM

KiSC issued 07, 2008 A

DIMENSIONS

V2003-M-BG V2003-M-T-BG V2203-M-BG V2403-M-BG A 700.6 mm (27.58 in.) 700.6 mm (27.58 in.) 700.6 mm (27.58 in.) 700.6 mm (27.58 in.) B 505.0 mm (19.88 in.) 505.0 mm (19.88 in.) 505.0 mm (19.88 in.) 505.0 mm (19.88 in.)

C 633.3 mm (24.93 in.) 674.0 mm (26.54 in.) 633.3 mm (24.93 in.) 684.0 mm (26.93 in.)

W1035948

Page 24

WIRING DIAGRAM

KiSC issued 07, 2008 A

Start Relay

ECU (Electronic Control Unit)

Alternator

Starter

3.0

10 18

1.25

5 13 21

14 22

16 17 24 25

1.25

Solenoid

Slowdown(1200 min-1(rpm)) Speed Switch

(1800 min Manual Stop Switch

(Run/Stop)

-1

(rpm)/1500 min-1(rpm))

Engine Speed Sensor

3.03.0

0.85

Water Temp. Sensor

0.85

3.0

Oil Switch

3EEADAHFP001A

Battery

Slow Blow Fuse

( 50 A )

Key Switch

OFF

Glow

Start

30 AC

10A

Glow Relay

3.0

OP ALT

Glow

Water Temp. Switch

(Water Temperature) (Oil Pressure) (Alternator)

(Glow Plug)

Hour Meter

Glow Plug

Pilot Lamp

12V3.4W X 4

Page 25

GENERAL

KiSC issued 07, 2008 A

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........................................................................... G-8

[2] CHECK POINTS OF INITIAL 50 HOURS........................................... G-10

[3] CHECK POINTS OF EVERY 50 HOURS........................................... G-12

[4] CHECK POINTS OF EVERY 100 HOURS......................................... G-13

[5] CHECK POINTS OF EVERY 150 HOURS......................................... G-15

[6] CHECK POINTS OF EVERY 200 HOURS......................................... G-17

[7] CHECK POINTS OF EVERY 400 HOURS......................................... G-21

[8] CHECK POINTS OF EVERY 500 HOURS......................................... G-23

[9] CHECK POINTS OF EVERY 1 OR 2 MONTHS............................... G-25

[10]CHECK POINTS OF EVERY YEAR....................................................G-26

[11]CHECK POINTS OF EVERY 800 HOURS......................................... G-27

[12]CHECK POINTS OF EVERY 1500 HOURS....................................... G-28

[13]CHECK POINTS OF EVERY 3000 HOURS....................................... G-31

[14]CHECK POINTS OF EVERY 2 YEARS.............................................. G-34

5. SPECIAL TOOLS.......................................................................................... G-38

Page 26

03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM

KiSC issued 07, 2008 A

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.

Q Engine Serial Number

The engine serial number is an identified number for the engine.

It is marked after the engine model number.

It indicates month and year of manufacture as fo llows.

• Year of manufacture

Alphabet or

Number

1 2001 F 2015 2 2002 G 2016 3 2003 H 2017 4 2004 J 2018 5 2005 K 2019 6 2006 L 2020 7 2007 M 2021 8 2008 N 2022

9 2009 P 2023 A 2010 R 2024 B 2011 S 2025 C 2012 T 2026 D 2013 V 2027 E 2014

Year

Alphabet or

Number

G GENERAL

Year

(1) Engine Model Name and Serial

Number

W1010477

G-1

Page 27

03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM

KiSC issued 07, 2008 A

G GENERAL

• Month of manufacture

Month Engine Lot Number January A0001 ~ A9999 B0001 ~ BZ999 February C0001 ~ C9999 D0001 ~ DZ999 March E0001 ~ E9999 F0001 ~ FZ999 April G0001 ~ G9999 H0001 ~ HZ999 May J0001 ~ J9999 K0001 ~ KZ999 June L0001 ~ L9999 M0001 ~ MZ999 July N0001 ~ N9999 P0001 ~ PZ999 August Q0001 ~ Q9999 R0001 ~ RZ999 September S0001 ~ S9999 T0001 ~ TZ999 October U0001 ~ U9999 V0001 ~ VZ999 November W0001 ~ W9999 X0001 ~ XZ999 December Y0001 ~ Y9999 Z0001 ~ ZZ999

* Alphabetical letters “I” and “O” are not used. e.g. D1803

- 7 B A001

(a) (b)(c) (d)

(a) Engine Model Name : D1803 (b) Year : 7 indicates 2007 (c) Month : A or B indicates January (d) Lot number : (0001 ~ 9999 or A001 ~ Z999)

W1011076

G-2

Page 28

03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM

KiSC issued 07, 2008 A

G GENERAL

[2] E3B ENGINE

[Example : Engine Model Name D1803-M-E3B-XXXX or D1803-M-DI-E3B-XXXX]

The emission controls previously implemented in various countries to prevent air pollution will be stepped up as Non-Road Emission Standards continue to change. The timing or applicable da te 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).

When servicing or repairing ###-E3B series engines, use only replacement parts for that specific E3B engine, designated by the appropriate E3B Kubota Parts List and perform all maintenance services listed in the appropriate Kubota Operator's Manual or in the appropriate E3B Kubota Workshop Manual. Use of incorrect replacement parts or replacement parts from other emission level engines (for example: E2 B engines), may result in emission leve ls out of compliance with the original E3B design and EPA or other applica ble regulations.Please r efer to the emission label located on the engine head cover to identify Output classification and Emission Control Information. E3B engines are identified with "ET" at the end of the Model designation, on the US EPA label. Please note : E3B is not marked on the engine.

Category (1) Engine output classification EU regulation

K From 19 to less than 37 kW STAGE ΙΙΙA J From 37 to less than 75 kW STAGE ΙΙΙA

I From 75 to less than 130 kW STAGE ΙΙΙA

[3] CYLINDER NUMBER

Category (2) Engine output classification EPA regulation

Less than 19kW Tier 4

(1) EU regulation engine output classification category (2) “E3B” engines are identified with “ET” at the end of the Model designation, on

the US EPA label. “E3B” designates Tier 3 and some Interim Tier 4 / Tier 4 models, depending on engine output classification.

From 19 to less than 56 kW Interim Tier 4 From 56 to less than 75 kW Tier 3 From 75 to less than 130 kW Tier 3

W1031971

The cylinder numbers of KUBOTA diesel engine are designated

as shown in the figure.

The sequence of cylinder numbers is given as No.1, No.2, No.3

and No.4 starting from the gear case side.

W1011077

G-3

Page 29

03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM

KiSC issued 07, 2008 A

2. GENERAL PRECAUTIONS

• During disassembly, carefully arrange removed parts in a clean area to prevent confusion later. Screws, bolts and nuts should b e 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 provide d.

• Before disassembling or servicing live wires, make sure to always disconnect the grounding cable from the battery first.

• Remove oil and dirt from parts before measuring.

• Use only KUBOTA genuine parts for parts replacement to maintain engine performance and to ensure safety.

• Gaskets and O-rings must be replaced during reassembly. Apply grease to new O-rings or oil seals before assembling.

• When reassembling external or internal snap ring s, position them so that the sharp edge faces against the direction from which force is applied.

• Be sure to perform run-in the serviced or reassembled engine. Do not attempt to give heavy load at once, or serious damage may result to the engine.

(1) Grease (2) Force (3) Place the Sharp Edge against the

Direction of Force

G GENERAL

(A) External Snap Ring (B) Internal Snap Ring

W1011734

G-4

Page 30

03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM

KiSC issued 07, 2008 A

G GENERAL

3. MAINTENANCE CHECK LIST

To maintain long-lasting and safe engine performance, make it a rule to carry out regular inspections by following

the table below.

[D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M, V2403-M-T] [D1703-M-BG, V2003-M-BG, V2003-M-T-BG, V2203-M-BG, V2403- M-BG]

Service Interval

Item

* Checking fuel hoses and clamp bands ,

(1) Oil pan depth Changing engine oil (depending on the oil pan)

*Cleaning air cleaner element (replace the element after 6-times cleanings)

*Cleaning fuel filter (Element type) , Checking battery electrolyte level , Checking fan belt tension and damage ,

Replacing oil filter cartridge

Checking radiator hoses and clamp bands , * Checking intake air line , Replacing fuel filter cartridge , Cleaning water jacket and radiator interior , Replacing fan belt , Recharging battery , * Replacing air cleaner element , Checking valve clearance , * Checking injection nozzle condition , * Checking turbocharger , * Checking injection pump , * Replacing intake air line , Replacing battery , Replacing radiator hoses and clamp bands , * Replacing fuel hoses and clamps , Changing radiator coolant (L.L.C.) ,

(90 mm, 3.5 in.)

(2) Oil pan depth

(124 mm, 4.88 in.)

(1) Oil pan depth

(90 mm, 3.5 in.)

(2) Oil pan depth

(124 mm, 4.88 in.)

100

150

200

hrs

400 hrs

+ Change engine oil and replace oil filter cartridge after the first 50 hours of operation. * 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.

Every

500 hrs

1 or 2

months1 year

800

hrs

1500

hrs

3000

hrs2 years

W1029462

G-5

Page 31

03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM

KiSC issued 07, 2008 A

G GENERAL

[D1803-M-DI, V2403-M-DI, V2403-M-DI-T]

Service Interval

hrs

Every

1 or 2

months1 year

800 hrs

1500

hrs

3000

hrs2 years

Item

* Checking fuel hoses and clamp bands ,

(1) Oil pan depth Changing engine oil (depending on the oil pan)

*Cleaning air cleaner element (replace the element after 6-times cleanings)

*Cleaning fuel filter (Element type) , Checking battery electrolyte level , Checking fan belt tension and damage ,

Replacing oil filter cartridge

(90 mm, 3.5 in.)

(2) Oil pan depth

(124 mm, 4.88 in.)

(1) Oil pan depth

(90 mm, 3.5 in.)

(2) Oil pan depth

(124 mm, 4.88 in.)

100

200

400

hrs

500

+ Change engine oil and replace oil filter cartridge after the first 50 hours of operat ion. * 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.

W1032664

G-6

Page 32

03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM

KiSC issued 07, 2008 A

G GENERAL

CAUTION

• When changing or inspecting, be sure to level and stop the engine. Q NOTE Engine Oil :

• Refer to the following table for the suit ab le Ame r ic an Petroleum Institute (API) classification of engine oil

according to the engine type (with internal EGR, external EGR or non-EGR) and the Fuel Type Used : (Low Sulfur, Ultra Low Sulfur or High Sulfur Fuels).

Engine oil classification (API classification)

Fuel Type

High Sulfur Fuel [0.05 % (500 ppm) ≤ Sulfur Content <

0.50 % (5000 ppm)]

Engines with non-EGR Engines with internal EGR

(If the "CF-4, CG-4, CH-4, or CI-4" engine oil is used with a high-sulfur fuel, change the engine oil at shorter intervals. (approximately half))

Engines with external EGR

–

Low Sulfur Fuel [Sulfur Content <

0.05 % (500 ppm)] or Ultra Low Sulfur Fuel [Sulfur Content <

CF, CF-4, CG-4, CH-4 or CI-4

CF or CI-4

(Class CF-4, CG-4 and CH-4 engine oils cannot be used on EGR type engines.)

0.0015 % (15 ppm)]

EGR : Exhaust Gas Re-circulation

W1024941

• CJ-4 classification oil is intended for use in engines equipped with DPF (Diesel Particulate Filter) and is

Not Recommended for use in Kubota E3 specification engines.

• Oil used in the engine should have API classification and Proper SAE Engine Oil Viscosity according to

the ambient temperatures where the engine is operated.

• With strict emission control regulations now in effect, the CF-4 and CG-4 engine oils hav e been developed

for use with low sulfur fuels, for On-Highway vehicle engines. When a Non-Road engine runs on high sulfur fuel, it is advisable to use a "CF or better" classification engine oil with a high Total Base Number (a minimum TBN of 10 is recommended).

Fuel :

• Cetane Rating : The minimum recommended Fuel Cetane Rating is 45. A cetane rating greater than 50 is

preferred, especially for ambient temperatures below −20 °C (−4 °F) or elevations above 1500 m (5000 ft).

• Diesel Fuel Specification Type and Sulfur Content % (ppm) used, must be compliant with all applicable

emission regulations for the area in which the engine is operated.

• Use of diesel fuel with sulfur content less than 0.10 % (1000 ppm) is strongly recommended.

• If high-sulfur fuel (sulfur content 0.5 0 % (50 00 ppm) to 1.0 % ( 10 000 ppm) ) is used a s a diesel fu el, chan ge

the engine oil and oil filter at shorter intervals. (approximately half)

• DO NOT USE Fuels that have sulfur content greater than 1.0 % (10000 ppm).

• Diesel fuels specified to EN 590 or ASTM D975 are recommended.

• No.2-D is a distillate fuel of lower vo lati lity f or engine s in in dust rial and he avy mo bile se rvice . (SAE J31 3

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, whe n operated in US EPA regulated areas. Therefore, please use No.2- D S500 or S1 5 diesel fue l as an alternative t o No.2 -D, and use No.1-D S500 or S15 diesel fuel as an alternative to No.1-D for ambient temperatures below −10 °C (14 °F).

No.1-D or No.2-D, S15 : Ultra Low Sulfur Diesel (ULSD) 15 ppm or 0.0015 wt.%

1) SAE : Society of Automotive Engineers

2) EN : European Norm

3) ASTM : American Society of Testing and Materials

4) US EPA : United States Environmental Protection Agency

5) No.1-D or No.2-D, S500 : Low Sulfur Diesel (LSD) less than 500 ppm or 0.05 wt.%

G-7

Page 33

03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM

KiSC issued 07, 2008 A

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.

3. If the level is too low, add new oil to the specified level.

IMPORTANTQ

• When using an oil of different maker or viscosity from the previous, drain old oil. Never mix two different types of oil.

NOTEQ

• Be sure to inspect the engine, locating it on a horizontal place. If placed on gradients, accurately, oil quantity may not be measured.

• Be sure to keep the oil level between upper and lower limits of the dipstick. Too much oil may cause a drop in output or excessive blow-by gas. On the closed breather type engine in which mist is sucked through port, too much oil may caused oil hammer. While too little oil, may seize the engine’s rotating and sliding parts.

(1) Dipstick (a) Maximum

G GENERAL

(b) Minimum

W1016222

G-8

Page 34

03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM

KiSC issued 07, 2008 A

G GENERAL

Checking and Replenish Coolant

1. Without recovery tank : Remove the radiator cap (1) and check to see that the coolant level is just below the port. With recovery tank (2) : Check to see that the coolant level lies between FULL (A) and LOW (B).

2. If coolant level is too low, check the reason for decreasing coolant. (Case 1) If coolant is decreasing by evaporation, replenish only fresh, soft water. (Case 2) If coolant is decreasing by leak, replenish coolant of the same manufacture and type in the specified mixture ratio (fresh, soft water and L.L.C.). If the coolant brand cannot be identified, dr ain out all of the remaining coolant and refill with a totally new brand of coolant mix.

CAUTION

• Do not remove the radiator cap until coolant temperature is below its boiling point. Then loosen the cap slightly to relieve any excess pressure before removing the cap completely.

IMPORTANTQ

• During filling the coolant, air must be vented from the engine coolant passages. The air vents by jiggling the radiator upper and lower hoses.

• Be sure to close the radiator cap securely. If the cap is loose or improperly closed, coolant may leak out and the engine could overheat.

• Do not use an antifreeze and scale inhibitor at the same time.

• Never mix the different type or brand of L.L.C..

(1) Radiator Cap (2) Recovery Tank

A : FULL B : LOW

W1035779

G-9

Page 35

03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM

KiSC issued 07, 2008 A

[2] CHECK POINTS OF INITIAL 50 HOURS

Changing Engine Oil

CAUTION

• Be sure to stop engine before changing engine oil.

1. Start and warm up the engine for approx. 5 minutes.

2. Place an oil pan underneath the engine.

3. To drain the used oil, remove the drain plug (1) at the bottom of the engine and drain the oil completely.

4. Screw the drain plug (1).

5. Fill new oil up to upper line on the dipstick (2).

IMPORTANTQ

• When using an oil of different maker or viscosity from the previous one, remove all of the old oil.

• Never mix two different types of oil.

• Engine oil should have properties of API classification CF (See page G-7).

• Use the proper SAE Engine Oil according to ambient temperature.

Above 25 °C (77 °F)

0 °C to 25 °C (32 °F to 77 °F)

Below 0 °C (32 °F)

G GENERAL

SAE 30 or SAE 10W-30 SAE 10W-40

SAE 20 or SAE 10W-30 SAE 10W-40

SAE 10W or SAE 10W-30 SAE 10W-40

Models

D1503-M, D1703-M D1803-M, D1803-M-DI D1703-M-BG

V2003-M, V2203-M V2403-M, V2403-M-DI, V2403-M-DI-T V2003-M-BG, V2003-M-T-BG V2203-M-BG, V2403-M-BG

V2403-M-T

*90 mm (3.5 in.) oil pan depth is optional.

(1) Drain Plug (2) Dipstick

124 mm (4.88 in.) *90 mm (3.5 in.)

7.0 L

1.8 U.S.gals

9.5 L

2.5 U.S.gals

9.5 L

2.5 U.S.gals

Oil pan depth

5.6 L

1.5 U.S.gals

7.6 L

2.0 U.S.gals

–

W1016604

G-10

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G GENERAL

Replacing Oil Filter Cartridge

CAUTION

• Be sure to stop the engine before replacing filter cartridge.

1. Remove the oil filter cartridge (1) with the filter wrench.

2. Apply a slight coat of oil onto the new cartridge gasket.

3. To install the new cartridge, screw it in by hand. Over tightening may cause deformation of rubber gasket.

4. After the new cartridge has been replaced, the engine oil normally decrease a little. Thus see that the engine oil does not leak through the seal and be sure to read the oil level on the dipstick. Then, replenish the engine oil up to the specified level.

IMPORTANTQ

• 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

W1013487

G-11

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[3] CHECK POINTS OF EVERY 50 HOURS

Checking Fuel Hoses and Clamp Bands

1. If the clamp (2) is loose, apply oil to the threads and securely retighten it.

2. The fuel hose (1) is made of rubber and ages regardless of the period service. Change the fuel hose together with the clamp every two years.

3. However, if the fuel hose and clamp a re fo und to be d amaged or deteriorate earlier than two years, then cha nge or rem e dy .

4. After the fuel hose and the clamp have been changed, bleed th e fuel system.

CAUTION

• Stop the engine when attempting the check and change prescribed above.

(When bleeding fuel system)

1. Fill the tank with fuel and open the fuel cock (4). ([B] only.)

2. Loosen the air vent plug (3) of the fuel filter a few turns.

3. Screw back the plug when bubbles do not come up any more.

4. Open the air vent cock (5) on top of the fuel injection pump.

5. If equipped electrical fuel feed pump, turn the key to AC position and pump the fuel up for 10 to 15 seconds. If equipped mechanical fuel feed pump, set the stop lever on stop position and crank the engine for 10 to 15 seconds.

6. Close securely the air vent cock after air bleeding.

NOTEQ

• Always keep the air vent cock on the fuel injection pump closed except when air is vented, or it may c ause the engine to stop.

(1) Fuel Hose (2) Clamp (3) Air Vent Plug (4) Fuel Cock (5) Air Vent Cock

G GENERAL

[A] Cartridge Type [B] Element Type

W1035921

G-12

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[4] CHECK POINTS OF EVERY 100 HOURS

Cleaning Air Cleaner Element

1. Remove the air cleaner element.

2. Use clean dry compressed air on the inside of the element. Pressure of compressed air must be under 210 kPa (2.1 kgf/cm 30 psi). Maintain reasonable distance between the nozzle and the filter.

NOTEQ

• The air cleaner uses a dry element. Never apply oil to it.

• Do not run the engine with filter element removed.

• Change the element once a year or every 6th cleaning.

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. After cleaning, reassemble the fuel filter, keeping out dust and dirt.

5. Bleed the fuel system.

IMPORTANTQ

• If dust and dirt enter the fuel, the fuel injection pump and injection nozzle will wear quickly. To prevent this, be sure to clean the fuel filter cup (5) periodically.

(1) Cock Body (2) Air Vent Plug (3) Fuel Cock

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

(4) Filter Element (5) Filter Cup (6) Retaining Ring

G GENERAL

W1045746

W1046058

W1047154

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.

Deflection (A) Factory spec.

(A) Deflection

7.0 to 9.0 mm

0.28 to 0.35 in.

W1208957

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G GENERAL

Fan Belt Damage and Wear

1. Check the fan belt for damage.

2. If the fan belt is damaged, replace it.

3. Check if the fan belt is worn and sunk in the pulley groove.

4. If the fan belt is nearly worn out and deeply sunk in the pulley groove, replace it.

(A) Good (B) Bad

W1057475

G-14

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[5] CHECK POINTS OF EVERY 150 HOURS

Changing Engine Oil (for 90 mm (3.5 in.) Depth Oil Pan) [D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M]

[D1703-M-BG, V2003-M-BG, V2003-M-T-BG, V2203-M-BG, V2403-M-BG]

CAUTION

• Be sure to stop engine before changing engine oil.

1. Start and warm up the engine for approx. 5 minutes.

2. Place an oil pan underneath the engine.

3. To drain the used oil, remove the drain plug (1) at the bottom of the engine and drain the oil completely.

4. Screw the drain plug (1).

5. Fill new oil up to upper line on the dipstick (2).

IMPORTANTQ

• When using an oil of different maker or viscosity from the previous one, remove all of the old oil.

• Never mix two different types of oil.

• Engine oil should have properties of API classification CF (See page G-7).

• Use the proper SAE Engine Oil according to ambient temperature.

Above 25 °C (77 °F)

0 °C to 25 °C (32 °F to 77 °F)

Below 0 °C (32 °F)

G GENERAL

SAE 30 or SAE 10W-30 SAE 10W-40

SAE 20 or SAE 10W-30 SAE 10W-40

SAE 10W or SAE 10W-30 SAE 10W-40

Models

D1503-M D1703-M D1803-M D1703-M-BG

V2003-M V2203-M V2403-M V2003-M-BG V2003-M-T-BG V2203-M-BG V2403-M-BG

*90 mm (3.5 in.) oil pan depth is optional.

(1) Drain Plug (2) Dipstick

124 mm (4.88 in.) *90 mm (3.5 in.)

7.0 L

1.8 U.S.gals

9.5 L

2.5 U.S.gals

Oil pan depth

5.6 L

1.5 U.S.gals

7.6 L

2.0 U.S.gals

W1022029

G-15

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G GENERAL

Replacing Oil Filter Cartridge (for 90 mm (3.5 in.) Dept h Oil Pan) [D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M]

[D1703-M-BG, V2003-M-BG, V2003-M-T-BG, V2203-M-BG, V2403-M-BG]

CAUTION

• Be sure to stop the engine before replacing filter cartrid ge.

1. Remove the oil filter cartridge (1) with the filter wrench.

2. Apply a slight coat of oil onto the new cartridge gasket.

3. To install the new cartridge, screw it in by hand. Over tightening may cause deformation of rubber gasket.

IMPORTANTQ

• 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

W1022423

G-16

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[6] CHECK POINTS OF EVERY 200 HOURS

Changing Engine Oil (for 124 mm (4.88 in.) Depth Oil Pan) [D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M,

V2403-M-T] [D1703-M-BG, V2003-M-BG, V2003-M-T-BG, V2203-M-BG, V2403-M-BG]

CAUTION

• Be sure to stop engine before changing engine oil.

1. Start and warm up the engine for approx. 5 minutes.

2. Place an oil pan underneath the engine.

3. To drain the used oil, remove the drain plug (1) at the bottom of the engine and drain the oil completely.

4. Screw the drain plug (1).

5. Fill new oil up to upper line on the dipstick (2).

IMPORTANTQ

• When using an oil of different maker or viscosity from the previous one, remove all of the old oil.

• Never mix two different types of oil.

• Engine oil should have properties of API classification CF (See page G-7).

• Use the proper SAE Engine Oil according to ambient temperature.

Above 25 °C (77 °F)

0 °C to 25 °C (32 °F to 77 °F)

Below 0 °C (32 °F)

G GENERAL

SAE 30 or SAE 10W-30 SAE 10W-40

SAE 20 or SAE 10W-30 SAE 10W-40

SAE 10W or SAE 10W-30 SAE 10W-40

Models

D1503-M D1703-M D1803-M D1703-M-BG

V2003-M V2203-M V2403-M V2003-M-BG V2003-M-T-BG V2203-M-BG V2403-M-BG

V2403-M-T

*90 mm (3.5 in.) oil pan depth is optional.

(1) Drain Plug (2) Dipstick

124 mm (4.88 in.) *90 mm (3.5 in.)

7.0 L

1.8 U.S.gals

9.5 L

2.5 U.S.gals

9.5 L

2.5 U.S.gals

Oil pan depth

5.6 L

1.5 U.S.gals

7.6 L

2.0 U.S.gals

–

W1022765

G-17

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G GENERAL

Changing Engine Oil (for 90 mm (3.5 in.) Depth Oil Pan) [D1803-M-DI, V2403-M-DI, V2403-M-DI-T]

CAUTION

• Be sure to stop engine before changing engine oil.

1. Start and warm up the engine for approx. 5 minutes.

2. Place an oil pan underneath the engine.

3. To drain the used oil, remove the drain plug (1) at the bottom of the engine and drain the oil completely.

4. Screw the drain plug (1).

5. Fill new oil up to upper line on the dipstick (2).

IMPORTANTQ

• When using an oil of different maker or viscosity from the previous one, remove all of the old oil.

• Never mix two different types of oil.

• Engine oil should have properties of API classification CF (See page G-7).

• Use the proper SAE Engine Oil according to ambient temperature.

Above 25 °C (77 °F)

0 °C to 25 °C (32 °F to 77 °F)

Below 0 °C (32 °F)

SAE 30 or SAE 10W-30 SAE 10W-40

SAE 20 or SAE 10W-30 SAE 10W-40

SAE 10W or SAE 10W-30 SAE 10W-40

Models

D1803-M-DI V2403-M-DI

V2403-M-DI-T

*90 mm (3.5 in.) oil pan depth is optional.

(1) Drain Plug (2) Dipstick

124 mm (4.88 in.) *90 mm (3.5 in.)

7.0 L

1.8 U.S.gals

9.5 L

2.5 U.S.gals

Oil pan depth

5.6 L

1.5 U.S.gals

7.6 L

2.0 U.S.gals

W1034539

G-18

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G GENERAL

Replacing Oil Filter Cartridge (for 124 mm (4.88 in.) Depth Oil Pan)

[D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M, V2403-M-T] [D1703-M-BG, V2003-M-BG, V2003-M-T-BG, V2203-M-BG, V2403-M-BG]

CAUTION

• Be sure to stop the engine before replacing filter cartridge.

1. Remove the oil filter cartridge (1) with the filter wrench.

2. Apply a slight coat of oil onto the new cartridge gasket.

3. To install the new cartridge, screw it in by hand. Over tightening may cause deformation of rubber gasket.

IMPORTANTQ

• 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

W1023046

Replacing Oil Filter Cartridge (for 90 mm (3.5 in.) Depth Oil Pan) [D1803-M-DI, V2403-M-DI, V2403-M-DI-T]

CAUTION

• Be sure to stop the engine before replacing filter cartridge.

1. Remove the oil filter cartridge (1) with the filter wrench.

2. Apply a slight coat of oil onto the new cartridge gasket.

3. To install the new cartridge, screw it in by hand. Over tightening may cause deformation of rubber gasket.

IMPORTANTQ

• 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

W1035283

Checking Radiator Hoses and Clamp Bands

1. Check to see if the radiator hoses are properly fixed every 200 hours of operation or every six months, whichever comes first.

2. If the clamp is loose, apply oil to the threads and retighten it securely.

3. The water hose is made of rubber and tends to age. It must be replaced every two years. Also replace the clamp and tighten it securely.

(1) Upper Hose (2) Lower Hose

W1029518

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G GENERAL

Checking Intake Air Line

1. Check to see if the intake air hose(s) are properly fixed every 200 hours of operation.

2. If the clamp is loose, apply oil to the threads and retighten it securely.

3. The intake air hose(s) is made of rubber and tend s to age. It must be changed every two years. Also change the clamp and tighte n it securely.

IMPORTANTQ

• To prevent serious damage to the engine, keep out any dust inside the intake air line.

(1) Intake Air Hose (2) Clamp

W1029631

G-20

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[7] CHECK POINTS OF EVERY 400 HOURS

Changing Engine Oil (for 124 mm (4.88 in.) Depth Oil Pan) [D1803-M-DI, V2403-M-DI, V2403-M-DI-T]

CAUTION

• Be sure to stop engine before changing engine oil.

1. Start and warm up the engine for approx. 5 minutes.

2. Place an oil pan underneath the engine.

3. To drain the used oil, remove the drain plug (1) at the bottom of the engine and drain the oil completely.

4. Screw the drain plug (1).

5. Fill new oil up to upper line on the dipstick (2).

IMPORTANTQ

• When using an oil of different maker or viscosity from the previous one, remove all of the old oil.

• Never mix two different types of oil.

• Engine oil should have properties of API classification CF (See page G-7).

• Use the proper SAE Engine Oil according to ambient temperature.

Above 25 °C (77 °F)

0 °C to 25 °C (32 °F to 77 °F)

Below 0 °C (32 °F)

G GENERAL

SAE 30 or SAE 10W-30 SAE 10W-40

SAE 20 or SAE 10W-30 SAE 10W-40

SAE 10W or SAE 10W-30 SAE 10W-40

Models

D1803-M-DI V2403-M-DI

V2403-M-DI-T

*90 mm (3.5 in.) oil pan depth is optional.

(1) Drain Plug (2) Dipstick

124 mm (4.88 in.) *90 mm (3.5 in.)

7.0 L

1.8 U.S.gals

9.5 L

2.5 U.S.gals

Oil pan depth

5.6 L

1.5 U.S.gals

7.6 L

2.0 U.S.gals

W1035850

G-21

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G GENERAL

Replacing Oil Filter Cartridge (for 124 mm (4.88 in.) Depth Oil Pan)

[D1803-M-DI, V2403-M-DI, V2403-M-DI-T]

CAUTION

• Be sure to stop the engine before replacing filter cartrid ge.

1. Remove the oil filter cartridge (1) with the filter wrench.

2. Apply a slight coat of oil onto the new cartridge gasket.

3. To install the new cartridge, screw it in by hand. Over tightening may cause deformation of rubber gasket.

IMPORTANTQ

• 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

W1036519

Replacing Fuel Filter Cartridge (Cartridge Type)

Water and dust in fuel are collected in the filter cartridge. So,

change the filter cartridge every 400 hours service.

1. Remove the used filter cartridge with filter wrench.

2. Apply a thin film of fuel to the surface of new filter cartridge gasket before screwing on.

3. Then tighten enough by hand.

4. Loosen the air vent plug to let the air out.

5. Start engine and check for fuel leakage.

(1) Fuel Filter Cartridge

W1050548

Replacing Fuel Filter Element (Element Type)

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. Replace the filter element (4).

4. Reassemble the fuel filter, keeping out dust and dirt.

5. Bleed the fuel system.

(1) Cock Body (2) Air Vent Plug (3) Fuel Cock

(4) Filter Element (5) Filter Cup (6) Retaining Ring

W1050583

G-22

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[8] CHECK POINTS OF EVERY 500 HOURS

Cleaning Water Jacket and Radiator Interior

CAUTION

• Do not remove the radiator cap when the engine is hot. Then loosen cap slightly to the stop to relieve any excess pressure before removing cap completely.

1. Stop the engine and let cool down.

2. To drain the coolant, open the radiator drain plu g (2) and remove the radiator cap (1). Then radiator cap (1) must be removed to completely drain the coolant. And open the drain cock (3).

3. After all coolant is drained, close the drain plug.

4. Fill with clean water and cooling system cleaner.

5. Follow directions of the cleaner instruction.

6. After flushing, fill with clean water and anti-freeze until the coolant level is just below the port. Install the radiator cap (1) securely.

7. Fill with coolant up to “FULL” (A) mark on the recovery tank (4).

8. Start and operate the engine for few minutes.

9. Stop the engine and let cool. Check coolant level of radiator and recovery tank (4) and add coolant if necessary.

IMPORTANTQ

• Do not start engine without coolant.

• Use clean, fresh, soft water and anti-f reeze to fill the radiator and recovery tank.

• When the anti-freeze is mixed with fresh, soft wa ter, the antifreeze mixing ratio must be less than 50 %.

• Securely tighten radiator cap. If the cap is loose or improperly fitted, water may leak out and the engine could overheat.

(1) Radiator Cap (2) Drain Plug (3) Drain Cock (4) Recovery Tank

G GENERAL

A : Full B : Low

W1038102

G-23

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G GENERAL

Anti-Freeze

• There are two types of anti-freeze available: use the permanent type (PT) for this engine.

• Before adding anti-freeze for the first time, clean the radiator interior by pouring fresh, soft water and draining it a few times.

• The procedure for mixing water and anti-freeze differs a ccordin g to the make of the anti-freeze and the ambient temperature. Basically, it should be referred to SAE J1034 standard, more specifically also to SAE J814c.

• Mix the anti-freeze with fresh, soft water, and then fill into the radiator.

IMPORTANTQ

• When the anti-freeze is mixed with fresh, soft wat er, the antifreeze mixing ratio must be less than 50 %.

Vol %

anti-freeze

40 –24 –11 106 223 50 –37 –35 108 226

Freezing point Boiling point*

°C °F °C °F

* At 1.01 × 100000 Pa (760 mmHg) pressure (atmospheric). A

higher boiling point is obtained by using a radiator pressure cap which permits the development of pressure within the cooling system.

NOTEQ

• The above data represents industrial standards that necessitate a minimum glycol co ntent in the concentrated anti-freeze.

• When the coolant level drops due to evaporation, ad d fresh, soft water only to keep the anti-freeze mixing ratio less than 50 %. In case of leakage, add anti-freeze and fresh, soft water in the specified mixing ratio.

• Anti-freeze absorbs moisture. Keep unused anti-freeze in a tightly sealed container.

• Do not use radiator cleaning agents when anti-freeze has been added to the coolant. (Anti-freeze contains an anti-corrosive agent, which will react with the radiator cleaning agent forming sludge which will affect the engine parts.)

W1039218

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.

7.0 to 9.0 mm / 98 N

Deflection (A) Factory spec.

0.28 to 0.35 in. / 98 N (10 kgf, 22 lbf)

(1) Fan Belt (A) Deflection

W1052220

G-24

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[9] 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.

• When charging battery, remove battery vent plugs.

• When disconnecting the cable from the battery, start with the negative terminal first. When connecting the cable to the battery, start with the positive terminal first.

• Never check battery charge by placing a metal objec t across the posts. Use a voltmeter or hydrometer.

1) Slow Charging

1. Add distilled water if the electrolyte level is low. When charging, the amount of electrolyte should be slightly lower than the specified level to prevent overflow.

2. Connect the battery to the charging unit, following the manufacture’s instructions.

3. As the electrolyte generates gas while ch arging, rem ove all po rt caps.

4. The electrolyte temperature must not exceed 40 °C (104 °F) during charging. If it exceed 40 °C (104 °F), decrease the chargin g amperage or stop charging for a while.

5. When charging several batteries in series, charge at the rate of the smallest battery in the line.

2) Quick Charging

1. Determine the proper charging curren t and charging time with the tester attached to the quick charger.

2. Determine the proper charging current as 1/1 of the battery capacity. If the battery capacity exceeds 50 Ah, consider 50 A as the maximum.

Q Precaution for Operating a Quick Charger

• Operate with a quick charger differs according to the type. Consult the instruction manual and use accordingly.

G GENERAL

W1052658

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G GENERAL

Battery Specific Gravity

1. Check the specific gravity of the electrolyte in each cell with a hydrometer.

2. When the electrolyte temperature dif fers from that at which the hydrometer was calibrated, correct the specific gravity reading following the formula mentioned in (Reference).

3. If the specific gravity is less than 1.215 (after it is corrected for temperature), charge or replace the battery.

4. If the specific gravity differs between any two cells by more than

0.05, replace the battery.

NOTEQ

• Hold the hydrometer tube vertical without removing it from the electrolyte.

• Do not suck too much electrolyte into the tube.

• Allow the float to move freely and hold the hydromet er at eye level.

• The hydrometer reading must be taken at the highest electrolyte level.

(Reference)

• Specific gravity slightly varies with temperature. To be exact, the specific gravity decreases by 0. 0007 with an increase of 1 °C (0.0004 with an increase of 1 °F) in temperature, and increases by 0.0007 with a decreases of 1 °C (0.0004 with a decrease of 1 °F). Therefore, using 20 °C (68 °F) as a reference, the specific gravity reading must be corrected by the following formula :

- Specific gravity at 20 °C = Measured value + 0.0007 ×

(electrolyte temperature : 20 °C)

- Specific gravity at 68 °F = Measured value + 0.0004 ×

(electrolyte temperature : 68 °F)

Specific Gravity State of Charge

1.260 Sp. Gr. 100 % Charged

1.230 Sp. Gr. 75 % Charged

1.200 Sp. Gr. 50 % Charged

1.170 Sp. Gr. 25 % Charged

1.140 Sp. Gr. Very Little Useful Capacity

1.110 Sp. Gr. Dischar ged

At an electrolyte temperature of 20 °C (68 °F)

(a) Good (b) Bad

W1012763

[10] CHECK POINTS OF EVERY YEAR

Replacing Air Cleaner Element

1. Remove used air cleaner element.

2. Replace new air cleaner element.

NOTEQ

• The air cleaner uses a dry element. Never apply oil to it.

• Do not run the engine with filter element removed.

W1020554

G-26

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[11] CHECK POINTS OF EVERY 800 HOURS

Valve Clearance

IMPORTANTQ

• Valve clearance must be checked and adjusted when engine is cold.

1. Remove the head cover.

2. Align the “1TC” mark line (3) on the flywheel and projection (2) on the housing so that the No.1 piston comes to the compression or overlap top dead center.

3. Check the following valve clearance (1) marked with “,” using a feeler gauge.

4. If the clearance is not within the factory specifications, adjust with the adjusting screw.

Valve clearance Factory spec.

NOTEQ

• The “1TC” mark line on the flywheel is just for No. 1 cylinder. There is no “TC” marking for the other cylinders.

• No. 1 piston comes to the top dead center position when the “TC” marking is aligned with the projection (2) in the window on flywheel-housing. Turn the flywheel 0.26 rad (15 °) clockwise and counterclockwise to see if the piston is at the compression top dead center or the overlap position. Now referring to the table below, readjust the valve clearance ( 1). (The piston is at the top dead center when both the IN. and EX. valves do not move; it is at the overlap position when both the valves move.)

• Finally turn the flywheel 6.28 rad (360 °) and align the “1TC” mark line and the projection (2) perfectly. Adjust all the other valve clearance as required.

• After turning the flywheel counterclockwise twice or three times, recheck the valve clearance (1).

• After adjusting the valve clearance (1), firmly ti ghten the lock nut of the adjusting screw.

V alve arrangement

G GENERAL

0.18 to 0.22 mm

0.0071 to 0.0086 in.

3 Cylinder 4 Cylinder

Adjustable cylinder location of piston

When No. 1 piston is at compression top dead center

When No. 1 piston is at overlap position

(1) Valve Clearance (2) Projection

G-27

IN. EX. IN. EX.

No. 1 ,,,, No. 2 ,, No. 3 ,, No. 4 – – No. 1 No. 2 ,, No. 3 ,, No. 4 – – ,,

(3) 1TC Mark Line

W10113200

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G GENERAL

[12] CHECK POINTS OF EVERY 1500 HOURS

CAUTION

• Check the injection pressure and condition after c onfirming that there is nobody standing in the d irection the fume goes.

• If the fume from the nozzle directly contacts the human body, cells may be destro yed and blood poisoning may be caused.

Nozzle Spraying Condition [D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M,

V2403-M-T] [D1703-M-BG, V2003-M-BG, V2003-M-T-BG, V2203-M-BG, V2403-M-BG]

1. Set the injection nozzle to a nozzle tester, and check the nozzle spraying condition.

2. If the spraying condition is defective, replace the nozzle piece.

(a) Good (b) Bad

W10411400

[D1803-M-DI, V2403-M-DI, V2403-M-DI-T]

1. Set the injection nozzle to a nozzle tester, and check the nozzle spraying condition.

2. If the spraying condition is defective, replace the injection nozzle assembly.

(a) Good (b) Bad

W1037040

G-28

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G GENERAL

Fuel Injection Pressure [D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M,

V2403-M-T] [D1703-M-BG, V2003-M-BG, V2003-M-T-BG, V2203-M-BG, V2403-M-BG]

1. Set the injection nozzle to a nozzle tester.

2. Slowly move the tester handle to measure the pressure at which fuel begins jetting out from the nozzle.

3. If the measurement is not within the factory specifications, replace the adjusting washer (1) in the nozzle holder to adjust it.

(Reference)

• Pressure variation with 0.025 mm (0.00098 in.) difference of adjusting washer thickness. Approx. 590 kPa (6.0 kgf/cm

Fuel injection pressure Factory spec.

(1) Adjusting Washer

, 85 psi)

13.73 to 14.70 MPa

140.0 to 150.0 kgf/cm 1992 to 2133 psi

W10182100

[D1803-M-DI, V2403-M-DI, V2403-M-DI-T]

1. Set the injection nozzle to a nozzle tester.

2. Slowly move the tester handle to measure the pressure at which fuel begins jetting out from the nozzle.

3. If the measurement is not within the factory specifications, replace the injection nozzle assembly.

Fuel injection pressure (1st stage)

Factory spec.

18.64 to 20.10 MPa

190.0 to 205.0 kgf/cm 2703 to 2915 psi

W10408820

G-29

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G GENERAL

Valve Seat Tightness [D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M,

V2403-M-T] [D1703-M-BG, V2003-M-BG, V2003-M-T-BG, V2203-M-BG, V2403-M-BG]

1. Set the injection nozzle to a nozzle tester.

2. Raise the fuel pressure, and keep at 12.75 MPa (130.0 kgf/cm 1849 psi) for 10 seconds.

3. If any fuel leak is found, replace the nozzle piece.

No fuel leak at

Valve seat tightness Factory spec.

12.75 MPa

130.0 kgf/cm 1849 psi

W10412730

[D1803-M-DI, V2403-M-DI, V2403-M-DI-T]

1. Set the injection nozzle to a nozzle tester.

2. Raise the fuel pressure, and keep at 16.67 MPa (170.0 kgf/cm 2418 psi) for 10 seconds.

3. If any fuel leak is found, replace the injection nozzle assembly.

No fuel leak at

Valve seat tightness Factory spec.

16.67 MPa

170.0 kgf/cm 2418 psi

W1037135

Nozzle Holder [D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M,

V2403-M-T] [D1703-M-BG, V2003-M-BG, V2003-M-T-BG, V2203-M-BG, V2403-M-BG]

1. Secure the nozzle retaining nut (7) with a vise.

2. Remove the nozzle holder (1), and take out parts inside.

(When reassembling)

• Assemble the nozzle in clean fuel oil.

• Install the push rod (4), noting its direction.

• After assembling the nozzle, be sure to adjust the fuel injection pressure.

35 to 39 N·m

Tightening torque

(1) Nozzle Holder (2) Adjusting Washer (3) Nozzle Spring (4) Push Rod

Nozzle holder

Overflow pipe retaining nut

Nozzle holder assembly

(5) Distance Piece (6) Nozzle Piece (7) Nozzle Retaining Nut

3.5 to 4.0 kgf·m 26 to 28 lbf·ft

20 to 24 N·m

2.0 to 2.5 kgf·m 15 to 18 lbf·ft

49 to 68 N·m

5.0 to 7.0 kgf·m 37 to 50 lbf·ft

W1018491

G-30

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[13] CHECK POINTS OF EVERY 3000 HOURS

Checking Turbocharger (Turbine Side)

1. Check the exhaust port (2) and inlet port (3) side of turbine housing (1) to see if there is no exhaust gas leak.

2. If any gas leak is found, retighten the bolts and nuts or replace the gasket with new one.

(Compressor Side)

1. Check the inlet hose (4) of the compressor cover (5) to see if there is no air leak.

2. Check for loose connections or cracks in the suction side of the intake hose.

3. If any air leak is found, change the clamp (6) and / or inlet hoses.

(Radial Clearance)

1. If the wheel contact to the housing, replace the turbocharger assembly with new one.

(1) Turbine Housing (2) Exhaust Port (3) Inlet Port

G GENERAL

(4) Inlet Hose (5) Compressor Cover (6) Clamp

W1022082

G-31

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G GENERAL

Checking Injection Pump [D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M,

V2403-M-T] [D1703-M-BG, V2003-M-BG, V2003-M-T-BG, V2203-M-BG, V2403-M-BG] (Fuel Tightness of Pump Element)

1. Remove the solenoid.

2. Remove the injection pipes and glow plugs.

3. Install the injection pump pressure tester to the injection pump.

4. Install the injection nozzle (2) jetted with the proper injection pressure to the injection pump pressure tester (1). (Refer to the figure.)

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. Remove the solenoid.

2. Remove the injection pipes and glow plugs.

3. Set a pressure tester to the fuel injection pump.

4. Install the injection nozzle (2) jetted with the proper injection pressure to the injection pump pressure tester (1).

5. Run the starter to increase the pressure.

6. Stop the starter when the fuel jets from the injection nozzle. After that, turn the flywheel by the hand and raise the pressure to approx. 13.73 MPa (140.0 kgf/cm

, 1991 psi).

7. Now turn the flywheel back about half a turn (to keep the plunger free). Maintain the flywheel at this position and clock the time taken for the pressure to drop from 13.73 to 12.75 MPa (from

140.0 to 130.0 kgf/cm

8. Measure the time needed to decrease the pressure from 13.73 to

12.75 MPa (from 140.0 to 130.0 kgf/cm

, from 1991 to 1849 psi).

9. If the measurement is less than allowable limit, replace the pump with new one or repair with a Kubota-authorized pump service shop.

Fuel tightness of pump element

Fuel tightness of delivery valve

Allowable limit

Factory spec.

Allowable limit

13.73 MPa

140.0 kgf/cm 1991 psi

10 seconds

13.73 → 12.75 MPa

140.0 → 130.0 kgf/cm 1991 → 1849 psi

5 seconds

13.73 → 12.75 MPa

140.0 → 130.0 kgf/cm 1991 → 1849 psi

NOTEQ

• Never try to disassemble the injection pump assembly. For repairs, you are strongly requested to contact a Kubotaauthorized pump service shop.

(1) Injection Pump Pressure Tester (2) Injection Nozzle

(3) Protection Cover for Jetted Fuel

W1022357

G-32

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G GENERAL

Checking Injection Pump [D1803-M-DI, V2403-M-DI, V2403-M-DI-T]

(Fuel Tightness of Pump Element)

1. Remove the solenoid.

2. Remove the injection pipes and glow plugs.

3. Install the injection pump pressure tester to the injection pump.

4. Install the injection nozzle (2) jetted with the proper injection pressure to the injection pump pressure tester (1). (Refer to the figure.)

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. Remove the solenoid.

2. Remove the injection pipes and glow plugs.

3. Set a pressure tester to the fuel injection pump.

4. Install the injection nozzle (2) jetted with the proper injection pressure to the injection pump pressure tester (1).

5. Run the starter to increase the pressure.

6. Stop the starter when the fuel jets from the injection nozzle. After that, turn the flywheel by the hand and raise the pressure to approx. 18.63 MPa (190.0 kgf/cm

, 2702 psi).

7. Now turn the flywheel back about half a turn (to keep the plunger free). Maintain the flywheel at this position and clock the time taken for the pressure to drop from 18.63 to 17.65 MPa (from

190.0 to 180.0 kgf/cm

8. Measure the time needed to decrease the pressure from 18.63 to

17.65 MPa (from 190.0 to 180.0 kgf/cm

, from 2702 to 2560 psi).

9. If the measurement is less than allowable limit, replace the pump with new one or repair with a Kubota-authorized pump service shop.

Fuel tightness of pump element

Fuel tightness of delivery valve

Allowable limit

Factory spec.

Allowable limit

18.63 MPa

190.0 kgf/cm 2702 psi

10 seconds

18.63 → 17.65 MPa

190.0 → 180.0 kgf/cm 2702 → 2560 psi

5 seconds

18.63 → 17.65 MPa

190.0 → 180.0 kgf/cm 2702 → 2560 psi

NOTEQ

• Never try to disassemble the injection pump assembly. For repairs, you are strongly requested to contact a Kubotaauthorized pump service shop.

(1) Injection Pump Pressure Tester (2) Injection Nozzle

(3) Protection Cover for Jetted Fuel

W1037269

G-33

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[14] CHECK POINTS OF EVERY 2 YEARS

Replacing Intake Air Line

1. Loosen the clamp (2).

2. Remove the intake air hose (1) and clamp (2).

3. Replace new intake air hose (1) and new clamp (2).

4. Tighten the clamp (2).

NOTEQ

• To prevent serious damage to the engine, keep out any dust inside the intake air line.

(1) Intake Air Hose (2) Clamp

Replacing Battery

CAUTION

• When charging battery, remove battery vent plugs.

• When disconnecting the cable from the battery, start with the negative terminal first. When connecting the cable to th e battery, start with the positive terminal first.

• Never check battery charge by placing a me tal object across the posts.

1. Disconnect the negative terminal and positive terminal.

2. Remove the battery holder.

3. Remove the used battery.

4. Replace the new battery.

5. Tighten the battery holder.

6. Connect the positive terminal.

7. Connect the negative terminal.

Replacing Radiator Hoses and Clamp Bands

G GENERAL

W1023867

W1023996

CAUTION

• Do not remove the radiator cap when the engine is hot. The n loosen cap slightly to the stop to relieve any excess pressure before removing cap completely.

1. Drain the coolant.

2. Loosen the clamp bands.

3. Remove the upper hose (1) and lower hose (2).

4. Replace new upper / lower hose (1), (2) and clamp bands.

5. Tighten the clamp bands.

6. Fill with clean water and anti-freeze until the coolant level is just below the port. Install the radiator cap securely.

(1) Upper Hose (2) Lower Hose

W1024178

G-34

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G GENERAL

Replacing Fuel Hoses and Clamp Bands

1. Loosen the clamp (2) and remove the fuel hose (1).

2. Replace new fuel hose (1) and new clamp (2).

3. Tighten the clamp (2).

CAUTION

• Stop the engine when attempting the check and change prescribed above.

(When bleeding fuel system)

1. Fill the tank with fuel and open the cock (4). ([B] only.)

2. Loosen the air vent plug (3) of the fuel filter a few turns.

3. Screw back the plug when bubbles do not come up any more.

4. Open the air vent cock on top of the fuel injection pump.

6. Close securely the air vent cock after air bleeding.

NOTEQ

• Always keep the air vent cock on the fuel injection pump closed except when air is vented, or it may cause the engine to stop.

(1) Fuel Hose (2) Clamp (3) Air Vent Plug (4) Fuel Cock

[A] Cartridge Type [B] Element Type

W1024305

G-35

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G GENERAL

Changing Radiator Coolant (L.L.C.)

CAUTION

• Do not remove the radiator cap when the engine is hot. The n loosen cap slightly to the stop to relieve any excess pressure before removing cap completely.

1. Stop the engine and let cool down.

2. To drain the coolant, open the radiator drain plug (2) and remove the radiator cap (1). Then radiator cap (1) must be removed to completely drain the coolant. And open the drain cock of engine body.

3. After all coolant is drained, close the drain plug.

4. Fill with clean water and cooling system cleaner.

5. Follow directions of the cleaner instruction.

6. After flushing, fill with clean water and anti-freeze until the coolant level is just below the port. Install the radiator cap (1) securely.

7. Fill with coolant up to “FULL” (A) mark on the recovery tank (3).

8. Start and operate the engine for few minutes.

9. Stop the engine and let cool. Check coolant level of radiator and recovery tank (3) and add coolant if necessary.

IMPORTANTQ

• Do not start engine without coolant.

• Use clean, fresh, soft water and anti-freeze to fill the radiator and recovery tank.

• When the anti-freeze is mixed with fresh, soft wat er, the antifreeze mixing ratio must be less than 50 %.

• Securely tighten radiator cap. If the cap is loose or improperly fitted, water may leak out and the engine could overheat.

(1) Radiator Cap (2) Drain Plug (3) Recovery Tank

A : Full B : Low

W1024599

G-36

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G GENERAL

Changing Radiator Coolant (L.L.C.) (Continued) (Anti-freeze)

• There are two types of anti-freeze available: use the permanent type (PT) for this engine.

• Before adding anti-freeze for the first time, clean the radiator interior by pouring fresh, soft water and draining it a few times.

• The procedure for mixing water and anti-freeze differ s acco rd ing to the make of the anti-freeze and the ambient temperature. Basically, it should be referred to SAE J1034 standard, more specifically also to SAE J814c.

• Mix the anti-freeze with fresh, soft water, and then fill into the radiator.

IMPORTANTQ

• When the anti-freeze is mixed with fresh, soft wa ter, the antifreeze mixing ratio must be less than 50 %.

Vol %

anti-freeze

40 –24 –11 106 223 50 –37 –35 108 226

Freezing point Boiling point*

°C °F °C °F

* At 1.01 × 100000 Pa (760 mmHg) pres sure (atmospheric). A

higher boiling point is obtained by using a radiator pressure cap which permits the development of pressure within the cooling system.

NOTEQ

• The above data represents industrial standards that necessitate a minimum glycol content in the concentrated anti-freeze.

• When the coolant level drops due to evaporation, add fr esh, soft water only to keep the anti-freeze mixing ratio less than 50 %. In case of leakage, add anti-freeze and fresh, soft water in the specified mixing ratio.

• Anti-freeze absorbs moisture. Keep unused anti-freeze in a tightly sealed container.

W1024852

G-37

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5. SPECIAL TOOLS

G GENERAL

Diesel Engine Compression Tester [D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M,

V2403-M-T] [D1703-M-BG, V2003-M-BG, V2003-M-T-BG, V2203-M-BG, V2403-M-BG]

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.

(1) Gauge (2) L Joint (3) Adaptor A (4) Adaptor B (5) Adaptor C (6) Adaptor E

(7) Adaptor F (8) Adaptor G

(9) Adaptor H (10) Adaptor I (11) Adaptor J

W1024200

Diesel Engine Compression Tester (for Glow Plug) [D1803-M-DI, V2403-M-DI, V2403-M-DI-T]

Code No.: 07909-39081 (Assembly)

07909-31291 (K) 07909-31301 (L) 07909-31311 (M)

Application: Use to measure diesel engine compression and

diagnosis of need for major overhaul.

Adaptor: The adaptor K is required for 03-M-DI.

(1) Gauge (2) Hose Assembly (3) L Joint

(4) Adaptor K (5) Adaptor L (6) Adaptor M

W1206183

Oil Pressure Tester

Code No: 07916-32032 Application: Use to measure lubricating oil pressure.

(1) Gauge (2) Cable (3) Threaded Joint (4) Adaptor 1

(5) Adaptor 2 (6) Adaptor 3 (7) Adaptor 4 (8) Adaptor 5

W1024318

G-38

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NOTEQ

• 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

psi) BPF 1/2 C Copper gasket D Flange (Material : Steel) E Hex. nut 27 mm (1.1 in.) across the plat F Adhesive application G Fillet welding on the enter circumference H Retaining nut

I 17 mm dia. (0.67 in. dia.)

J 8 mm dia. (0.3 in. dia.) K 1.0 mm (0.039 in.) L 17 mm dia. (0.67 in. dia.) M 6.10 to 6.20 mm dia. (0.241 to 0.244 in. dia.) N 8 mm (0.3 in.) O 4 mm (0.2 in.) P 11.97 to 11.99 mm dia. (0.4713 to 0.4720 in. dia.) QPF 1/2 R 23 mm (0.91 in.) S 17 mm (0.67 in.) T 4 mm (0.2 in.) U 12.00 to 12.02 mm dia. (0.4725 to 0.4732 in. dia.) V 100 mm (3.94 in.)

W M12 × P1.5

X 5 mm (0.2 in.)

Valve Guide Replacing Tool

Application: Use to press out and press fit the valve guide.

A 225 mm (8.86 in.) B 70 mm (2.8 in.) C 45 mm (1.8 in.) D 20 mm dia. (0.79 in. dia.) E 12.7 to 12.9 mm dia. (0.500 to 0.507 in. dia.) F 7.50 to 7.60 mm dia. (0.296 to 0.299 in. dia.) G 25 mm dia. (0.98 in. dia.) H 7.70 to 8.00 mm dia. (0.304 to 0.314 in. dia.)

I 5 mm (0.2 in.)

J 20 mm dia. (0.79 in. dia.) K 13.5 to 13.8 mm dia. (0.532 to 0.543 in. dia.) L 8.90 to 9.10 mm (0.351 to 0.358 in.)

C1 Chamfer 1.0 mm (0.039 in.) C2 Chamfer 2.0 mm (0.079 in.)

C0.3 Chamfer 0.3 mm (0.01 in.)

G GENERAL

, 4267

W10252400

W1025017

G-39

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G GENERAL

Bushing Replacing Tools

Application: Use to press out and to press fit the bushing.

1. For small end bushing

A 162 mm (6.38 in.) B 35 mm (1.4 in.) C 27 mm (1.1 in.) D 35 mm dia. (1.4 in. dia.) E 27.90 to 27.95 mm dia. (1.099 to 1.100 in. dia.) F 25.00 to 25.01 mm dia. (0.9843 to 0.9846 in. dia.)

2. For idle gear bushing

A 175 mm (6.89 in.) B 40 mm (1.6 in.) C 38 mm (1.5 in.) D 45 mm dia. (1.8 in. dia.) E 41.90 to 41.95 mm dia. (1.650 to 1.651 in. dia.) F 37.950 to 37.970 mm dia. (1.4941 to 1.4948 in. dia.)

W1025500

Flywheel Stopper

Application: Use to loosen and tighten the flywheel screw.

A 20 mm (0.79 in.) B 15 mm (0.59 in.) C 10 mm dia. (0.39 in. dia.) D 30 mm (1.2 in.) E 8 mm (0.3 in.) F 200 mm (7.87 in.)

W10259480

Crankshaft Bearing 1 Replacing Tool

Application: Use to press out and press fit the crankshaft bearing 1.

1. Extracting tool

A 135 mm (5.31 in.) B 72 mm (2.8 in.) C 40 mm radius (1.6 in. radius) D 10 mm (0.39 in.) E 20 mm (0.79 in.) F 20 mm dia. (0.79 in. dia.)

G 64.80 to 64.90 mm dia. (2.552 to 2.555 in. dia.)

H 59.80 to 59.90 mm dia. (2.355 to 2.358 in. dia.)

2. Inserting tool

A 130 mm (5.12 in.) B 72 mm (2.8 in.) C 40 mm radius (1.6 in. radius) D 9 mm (0.4 in.) E 4 mm (0.2 in.) F 20 mm (0.79 in.)

G 20 mm dia. (0.79 in. dia.)

H 68 mm dia. (2.7 in. dia.)

I 59.80 to 59.90 mm dia. (2.355 to 2.358 in. dia.)

J 64.80 to 64.90 mm dia. (2.552 to 2.555 in. dia.)

W1026139

G-40

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G GENERAL

Socket Wrench for Crank Pulley Nut (46 mm Deep Socket Wrench)

Application: Use to loosen and tighten the fan drive pulley mounting

nut.

A 100 mm (3.94 in.) B 25.0 mm (0.984 in.) C 27.0 mm (1.06 in.) D 45.0 mm dia. (1.77 in. dia.) E 35.0 mm dia. (1.38 in. dia.) F 62.5 mm dia. (2.46 in. dia.) G 46.0 mm (1.81 in.)

W1044361

Auxiliary Socket for Fixing Crankshaft Sleeve

Application: Use to fix the crankshaft sleeve of the diesel engine.

A 80.0 mm (3.15 in.) B 60.10 to 60.30 mm (2.367 to 2.374 in.) C 80.0 mm dia. (3.15 in. dia.) D 85.0 mm dia. (3.35 in. dia.) E 60.10 to 60.30 mm dia. (2.367 to 2.374 in. dia.) F 26.30 to 26.40 mm (1.036 to 1.039 in.) G 25.85 to 25.90 mm (1.018 to 1.019 in.) H 15.0 mm (0.591 in.)

I 5.0 mm (0.20 in.)

(1) Stopper (2) Sleeve Guide

(3) Auxiliary Socket for Pushing

W1027695

G-41

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G GENERAL

Auxiliary Socket for Fixing Crankshaft Sleeve (Continued)

Application: Use to fix the crankshaft sleeve of the diesel engine.

J 42.0 mm (1.65 in.)

K 30.50 to 30.60 mm (1.201 to 1.204 in.)

L 23.0 mm (0.906 in.)

M 20.0 mm (0.787 in.)

N 2.0 mm (0.079 in.)

O 31.911 to 31.950 mm dia. (1.2564 to 1.2578 in. dia.)

P 30.0 mm dia. (1.18 in. dia.)

Q 5.0 mm dia. (0.20 in. dia.)

R 0.09 rad (5 °) S 25.0 mm dia. (0.984 in. dia.) T 60.0 mm dia. (2.36 in. dia.) U 79.80 to 79.85 mm dia. (3.142 to 3.143 in. dia.) V 10.0 mm (0.394 in.)

W 0.04 mm dia. (0.002 in. dia.)

X 140 mm (5.51 in.) Y 120 mm (4.72 in.) Z 110 mm (4.33 in.)

a 50.0 mm (1.97 in.) b 39.90 to 40.00 mm (1.571 to 1.574 in.) c 25.0 mm (0.984 in.) d 90.0 mm dia. (3.54 in. dia.) e 81.0 mm dia. (3.19 in. dia.)

f 80.10 to 80.15 mm dia. (3.154 to 3.155 in. dia.) g 30.0 mm dia. (1.18 in. dia.) h 5.0 mm dia. (0.20 in. dia.)

i 70.0 mm (2.76 in.)

j 50.0 mm (1.97 in.) k 40.0 mm dia. (1.57 in. dia.)

C1 Chamfer 1.0 mm (0.039 in.) C5 Chamfer 5.0 mm (0.20 in.)

C0.3 Chamfer 0.3 mm (0.01 in.)

R1 1.0 mm radius (0.039 in. radius) R2 2.0 mm radius (0.079 in. radius)

R10 10.0 mm radius (0.394 in. radius)

(2) Sleeve Guide (3) Auxiliary Socket for Pushing

W1027898

G-42

Page 68

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KiSC issued 07, 2008 A

Balancer Metal Replacing Tool (for Removing)

Application: Use to remove the metal bearing.

G GENERAL

A 41 mm (1.6 in.) L 41.934 to 41.950 mm dia. (1.6510 to 1.6515 in. dia.) B 32.5 mm (1.28 in.) M 24.959 to 24.980 mm dia. (0.98264 to 0.98346 in. dia.) C Chamfer 0.3 mm (0.01 in.) N 21.947 to 21.960 mm dia. (0.86406 to 0.86456 in. dia.) D 25 mm dia. (0.98 in. dia.) O 36 mm (1.4 in.) E 46.950 to 46.975 mm dia. (1.8485 to 1.8494 in. dia.) P 5 mm (0.2 in.) F 0.52 rad (30 °) Q 29.0 mm (1.14 in.) G 43.934 to 43.950 mm dia. (1.7297 to 1.7303 in. dia.) R 28.0 mm (1.10 in.) H 148.5 mm (5.846 in.) S 195.25 to 195.75 mm (7.6870 to 7.7066 in.)

I 10 mm (0.39 in.) T 145 mm (5.71 in.) J 46.50 to 46.75 mm dia. (1.831 to 1.840 in. dia.) U 384.75 to 385.25 mm (15.148 to 15.167 in.) K 44.950 to 44.975 mm dia. (1.7697 to 1.7706 in. dia.)

G-43

Page 69

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KiSC issued 07, 2008 A

Balancer Metal Replacing Tool (for Fitting)

Application: Use to press fit the metal bearing.

G GENERAL

A 182 mm (7.17 in.) O B 140 mm (5.51 in.) P C 37 mm (1.5 in.) Q 43.934 to 43.950 mm dia. (1.7297 to 1.7303 in. dia.)

D 35 mm dia. (1.4 in. dia.) R 140 mm (5.51 in.) E 60 mm dia. (2.4 in. dia.) S 36 mm (1.4 in.) F 10 mm (0.39 in.) T 60 mm dia. (2.4 in. dia.) G 0.52 rad (30 °) U 46.950 to 46.975 mm dia. (1.8485 to 1.8494 in. dia.) H 21.947 to 21.960 mm dia. (0.86406 to 0.86456 in. dia.) V 44.950 to 44.975 mm dia. (1.7697 to 1.7706 in. dia.)

I 24.959 to 24.980 mm dia. (0.98264 to 0.98346 in. dia.) W 41.934 to 41.950 mm dia. (1.6510 to 1.6515 in. dia.)

J Chamfer 0.3 mm (0.01 in.) X 145 mm (5.71 in.) K 8.8 to 9.2 mm (0.35 to 0.36 in.) Y 195.25 to 195.75 mm (7.6870 to 7.7066 in.) L 5 mm (0.2 in.) Z 29 mm (1.1 in.)

M 3.3 to 3.7 mm (0.13 to 0.14 in.) a 36 mm (1.4 in.) N

25 mm dia. (0.98 in. dia.)

60 mm dia. (2.4 in. dia.)

46.950 to 46.975 mm dia. (1.8485 to 1.8494 in. dia.)

G-44

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KiSC issued 07, 2008 A

G GENERAL

Idle Gear 2 Puller

Application: Use for remove the idle gear 2 from the shaft.

A 24 mm (0.94 in.) B 10 mm dia. (0.39 in. dia.) C 0.5 mm radius (0.02 in. radius) D M20 x Pitch 2.0 E 10 mm (0.39 in.) F 20 mm (0.79 in.) G 5 mm (0.2 in.) H 95 mm (3.7 in.)

I 125 mm (4.92 in.)

J 0.87 rad (50 °) K 5 mm (0.2 in.) L 60 mm radius (2.4 in. radius) M M20 x Pitch 2.0 N 30 mm (1.2 in.) O 10 mm (0.39 in.) P 10 mm (0.39 in.) Q 10 mm (0.39 in.) R 35.5 mm (1.40 in.) S 4.5 mm radius (0.18 in. radius) T 40 mm (1.6 in.) U 40 mm (1.6 in.) V 12 mm (0.47 in.)

W 120 mm (4.72 in.)

C2 Chamfer 2.0 mm (0.079 in.)

W1028521

G-45

Page 71

MECHANISM

KiSC issued 07, 2008 A

CONTENTS

1. ENGINE BODY ........................................ ... ... .... ... ... ... ... ................................. M-1

[1] PISTON......................................................................................................M-1

[2] BUILT-IN DYNAMIC BALANCER (BALANCER MODEL ONLY).......... M-2

[3] HALF-FLOATING HEAD COVER............................................................M-3

2. COOLING SYSTEM........................................................................................ M-4

[1] BOTTOM BYPASS SYSTEM...................................................................M-4

3. FUEL SYSTEM ...............................................................................................M-5

[1] GOVERNOR..............................................................................................M-5

4. TURBOCHARGER SYSTEM..........................................................................M-6

[1] BOOST COMPENSATOR .................... ... .... ... ...................................... .... M-6

Page 72

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KiSC issued 07, 2008 A

1. ENGINE BODY

[1] PISTON

DIESEL ENGINE

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 disulfide (1) serves as a solid lubricant, like a Graphite or Teflon. This material helps resist metal wears even with little lube oil.

(1) Molybdenum Disulfide [A] D1503-M, D1703-M

D1803-M, V2003-M V2203-M, V2403-M V2403-M-T D1703-M-BG, V2003-M-BG V2003-M-T-BG, V2203-M-BG V2403-M-BG

[B] D1803-M-DI, V2403-M-DI

V2403-M-DI-T

W1013114

M-1

Page 73

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KiSC issued 07, 2008 A

DIESEL ENGINE

[2] BUILT-IN DYNAMIC BALANCER (BALANCER MODEL ONLY)

Engine are sure to vibrate by piston’s reciprocation. Theoretically, three-cylinder engines are much less prone to cause vibration than four-cylinder ones (second inertia, etc.). However, any engine has many moving parts in addition to its pistons and cannot be completely free from vibration.

The four cylinders engine can be fitted with balance weight on crankcase to absorb the second inertia mentioned above and reduce vibration.

This engine is internally provide with two balancers (1), one at the suction side and the other at the exhaust side.

(1) Balancer [A] D1503-M, D1703-M

D1803-M, V2003-M V2203-M, V2403-M V2403-M-T

[B] D1803-M-DI, V2403-M-DI

V2403-M-DI-T

W1013221

M-2

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KiSC issued 07, 2008 A

[3] HALF-FLOATING HEAD COVER

DIESEL ENGINE

The rubber packing is fitted in to maintain the cylinder head cover 0.5 mm (0.02 in.) or so off the cylinder head. This arrangement helps reduce noise coming from the cylinder head.

(1) Cylinder Head Cover (2) Rubber Packing

W1013327

M-3

Page 75

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KiSC issued 07, 2008 A

2. COOLING SYSTEM

[1] BOTTOM BYPASS SYSTEM

DIESEL ENGINE

Bottom bypass system is introduced in 03-M Series

for improving the cooling performance of the radiator.

While the temperature of coolant in the engine is lo w, the thermostat (1) is held closed and the coolant is allowed to flow through the bypass pipe and to circulate in the engine.

When the temperature exceeds the thermostat valve opening level, the thermostat (1) fully opens itself to prevent the hot coolant from flowing through the bypass into the engine.

In this way, the radiator can increase its cooling performance.

(1) Thermostat (A) Bypass Opened

(B) Bypass Closed

W1013406

M-4

Page 76

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KiSC issued 07, 2008 A

3. FUEL SYSTEM

[1] GOVERNOR

DIESEL ENGINE

The governor serves to keep engine speed constant by automatically adjusting the amount of fuel supplied to the engine according to changes in the load. This engine employs an all-speed governor which controls the centrifugal force of the steel ball (1) weight, produced by rotation of the fuel camshaft (5), and the tension of the governor spring 1 (7) and 2 (8) are balanced.

(1) Steel Ball (2) Governor Sleeve (3) Steel Ball (4) Governor Ball Case (5) Fuel Camshaft (6) Governor Lever

(7) Governor Spring 1 (8) Governor Spring 2

(9) Fork Lever 2 (10) Fork Lever 1 (11) Fork Lever Shaft (12) Fork Lever Holder

W1017186

M-5

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KiSC issued 07, 2008 A

4. TURBOCHARGER SYSTEM

[1] BOOST COMPENSATOR

DIESEL ENGINE

(1) Injection Pump Assembly (2) Boost Compensator

Assembly (3) Actuator (4) Solenoid (5) Plunger (6) Solenoid Guide (7) Hi-Idling Body

W1014318

The higher the boost pressure rises, the more fuel is fed. In this way, the turbocharger proves itself for highpower performance.

W1014402

When the boost pressure drops, excess fuel is cut down, allowing much less black emission.

The system is tremendously efficient in cutting down on the emission; under low boost pressures at quick speed-up or start-up, in particular.

W1014432

M-6

Page 78

SERVICING

KiSC issued 07, 2008 A

CONTENTS

1. TROUBLESHOOTING......................................................................................S-1

[1] ENGINE BODY ..........................................................................................S-1

[2] ELECTRONIC GOVERNOR......................................................................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. CHECKING, DISASSEMBLING AND SERVICING......................................S-21

[1] CHECKING AND ADJUSTING ...............................................................S-21

(1) Engine Body........................... .... ... ... ... ....................................... .........S-21

(2) Lubricating System ................................. ... ... ... ... .... ... ... ......................S-24

(3) Cooling System............................. ... ... ....................................... ... ......S-24

(4) Fuel System........................................................................................S-27

(5) Electrical System ............................................................. ...................S-36

(6) Turbocharger ......................................................................................S-40

(7) Electronic Governor ............................................................................S-41

[2] DISASSEMBLING AND ASSEMBLING..................................................S-46

(1) Draining Oil and Coolant.....................................................................S-46

(2) External Components .........................................................................S-46

(3) Cylinder Head and Valves ..................................................................S-48

(4) Gear Case and Timing Gears .............................................................S-54

(5) Piston and Connecting Rod ................................................................S-63

(6) Flywheel and Crankshaft ....................................................................S-68

(7) Starter .................................................................................................S-71

(8) Alternator ............................................................................................S-72

[3] SERVICING ..............................................................................................S-73

(1) Cylinder Head and Valves ..................................................................S-73

(2) Timing Gears ...................................... .... ... ... ... ...................................S-81

(3) Piston and Connecting Rod ................................................................S-86

(4) Crankshaft...........................................................................................S-90

(5) Cylinder...............................................................................................S-95

(6) Oil Pump ............................. ....................................... ... ......................S-97

(7) Starter .................................................................................................S-97

(8) Alternator ..........................................................................................S-101

Page 79

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KiSC issued 07, 2008 A

1. TROUBLESHOOTING

[1] ENGINE BODY

DIESEL ENGINE

Symptom Probable Cause Solution

Engine Does Not Start

Starter Does Not Run Battery discharged Charge G-25, 26

No fuel Replenish fuel G-12 Air in the fuel system Vent air G-12 Water in the fuel system Change fuel and

repair or replace fuel

system Fuel hose clogged Clean or replace G-12 Fuel filter clogged Replace G-22 Excessively high viscosity of fuel or engine oil at

low temperature Fuel with low cetane number Use specified fuel 5 to 15 Fuel leak due to loose injection pipe retaining nut Tighten retaining nut S-48 Incorrect injection timing Adjust S-27, 28 Fuel camshaft worn Replace S-62 Injection nozzle clogged Clean or replace (IDI)

Injection pump malfunctioning Repair or replace S-29, 30,

Seizure of crankshaft, camshaft, piston, cylinder or bearing

Compression leak from cylinder Replace head

Improper valve timing Correct or replace

Piston ring and cylinder worn Replace S -21, 22,

Excessive valve clearance Adjust S-23 Solenoid malfunctioning Replace S-40, 54,

Starter malfunctioning Repair or replace S-38, 46,

Key switch malfunctioning Replace – Wiring disconnected Connect –

Use specified fuel or

engine oil

Repair or replace (DI)

Repair or replace S-61 to 67

gasket, tighten

cylinder head screw,

glow plug and nozzle

holder

timing gear

Reference Page

–

5 to 15,

G-10

S-33, 34,

35, 49

S-33, 34,

35, 49

31, 32, 54,

S-90 to 96

S-49, 50,

51, 52

S-60, 61

64 to 67,

88, 89, 95

71, 97

W1114419

S-1

Page 80

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KiSC issued 07, 2008 A

DIESEL ENGINE

Symptom Probable Cause Solution

Engine Revolution Is Not Smooth

Fuel filter clogged or dirty Replace G-22 Air cleaner clogged Clean or replace G-13, 20,

Fuel leak due to loose injection pipe ret aining nu t Tighten retaining nut S-48 Injection pump malfunctioning Repair or replace S-29, 30,

Incorrect nozzle opening pressure Adjust (IDI)

Repair or replace (DI) Injection nozzle stuck or clogged Repair or replace S-34, 49 Governor malfunctioning Repair S-56, 57,

Turbocharger bearing worn out Replace the

turbocharger

assembly Turbocharger shaft bent Replace the

turbocharger

assembly Turbocharger fin or other part damaged due to

foreign matters

Replace the

turbocharger

assembly

Either White or Blue Exhaust Gas Is Observed

Excessive engine oil Reduce to specified

level Piston ring and cylinder worn or stuck Repair or replace S-21, 22,

Incorrect injection timing Adjust S-27, 28

Oil Leak into Exhaust Pipe or Suction Pipe

Oil pipe clogged or deformed Repair or replace S-47 Turbocharger’s piston ring seal faulty Replace the

turbocharger

assembly

Either Black or Dark Gray Exhaust Gas Is Observed

Overload Reduce the load – Low grade fuel used Use specified fuel 5 to 15 Fuel filter clogged Replace G-22 Air cleaner clogged Clean or replace G-13, 20,

Deficient nozzle injection Repair or replace

nozzle

Reference Page

31, 32, 54,

S-34, 49 S-34, 49

S-47

G-8

64 to 67,

88, 89, 95

S-47

S-33, 34,

35, 49

W1011567

S-2

Page 81

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KiSC issued 07, 2008 A

DIESEL ENGINE

Symptom Probable Cause Solution

Reference Page

Deficient Output Incorrect injection timing Adjust S-27, 28

Engine’s moving parts seem to be seizing Repair or replace – Injection pump malfunctioning Repair or replace S-29, 30,

31, 32, 54,

Deficient nozzle injection Repair or replace

nozzle

Compression leak Check the

S-33, 34,

35, 49

S-21, 22 compression pressure and repair

Gas leak from exhaust system Repair or replace S-40, 47 Air leak from compressor discharge side Repair or replace S-40, 47 Air cleaner dirty or clogged Clean or replace G-13, 20,

Turbocharger compressor wheel turning heavily Replace the

S-47 turbocharger assembly

Excessive Lubricant Oil Consumption

Piston ring’s gap facing the same direction Shift ring gap

direction

S-64, 65

Oil ring worn or stuck Replace S-66, 67,

88, 89

Piston ring groove worn Replace piston S-66, 67,

89 Valve stem and valve guide worn Replace S-53, 76 Crankshaft bearing, and crank pin bearing worn Replace S-64, 65,

70, 91, 92,

93 Oil leaking due to defective seals or packing Replace –

Fuel Mixed into Lubricant Oil

Injection pump’s plunger worn Repair or replace S-29, 30,

31, 32, 54,

55 Deficient nozzle injection Repair or replace

nozzle

S-33, 34,

35, 49

Injection pump broken Replace S-54, 55

Water Mixed into Lubricant Oil

Head gasket defective Replace S-51, 52 Cylinder block or cylinder head flawed Replace S-51, 74

W1012032

S-3

Page 82

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KiSC issued 07, 2008 A

DIESEL ENGINE

Symptom Probable Cause Solution

Reference Page

Low Oil Pressure Engine oil insufficient Replenish G-8

Oil strainer clogged Clean S-63 Relief valve stuck with dirt Clean – Relief valve spring weaken or broken Replace – Excessive oil clearance of crankshaft bearing Replace S-70, 92,

Excessive oil clearance of crankpin bearing R eplace S-64, 65,

91 Excessive oil clearance of rocker arm Replace S-50, 80 Oil passage clogged Clean – Different type of oil Use specified type of

oil

5 to 15,

G-10

Oil pump defective Replace S-24, 62,

High Oil Pressure Different type of oil Use specified type of

oil

5 to 15,

G-10

Relief valve defective Replace –

Engine overheated Engine oil insufficient Replenish G-10

Fan belt broken or elongated Replace or adjust G-14, 24 Coolant insufficient Replenish G-9 Radiator net and radiator fin clogged with dust Clean – Inside of radiator corroded Clean or replace G-23 Coolant flow route corroded Clean or replace G-23, 24 Radiator cap defective Replace S-25 Overload running Reduce the load – Head gasket defective Replace S-51, 52 Incorrect injection timing Adjust S-27, 28 Unsuitable fuel used Use specified fuel 5 to 15

Battery Quickly Discharged

Battery electrolyte insufficient Replenish distilled

water and charge

Fan belt slips Adjust belt tension or

replace

G-13, 25

G-13, 14,

24 Wiring disconnected Connect – Rectifier defective Replace S-72, 102 Alternator defective Replace S-72, 101 Battery defective Replace –

W1012501

S-4

Page 83

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KiSC issued 07, 2008 A

DIESEL ENGINE

[2] ELECTRONIC GOVERNOR

IMPORTANTQ

• The engine trouble divides into an electronic governor, the main body of the engine, and the operating constancy. This manual describes it concerning the check of an electronic governor. Refer to WSM of engine and operator's manual if you cannot find trouble rela ted to an electronic governor by checking an electronic governor.

Engine will not start.

Cause Corrections Refer to Checking

Starter Operating but Not Cranking the Engine

Starter Does Not Operate Check emergency stop switch Emergency stop switch

Engine stopped automatically. Engine can be started again and stops again 10 seconds later.

Cause Corrections Refer to Checking

Trouble in the electronic governor composition parts

Check operation of the solenoid Solenoid Check harness of the solenoid Solenoid Check harness of the glow plug Glow plug

Check blinking pattern of the glow

Signal pattern sheet

lamp (1)

W1039573

(1) Glow Lamp

Engine speed cannot be controlled.

Cause Corrections Refer to Checking

Engine speed does not increase/ decrease

Check slow down switch Slow down switch Check speed switch Speed switch Check operation of the solenoid Solenoid Check harness of speed sensor Harness

Engine runs rough Check operation of the solenoid S olenoid

Check harness of speed sensor Harness

W1041393

W1041483

S-5

Page 84

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KiSC issued 07, 2008 A

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

DIESEL ENGINE

(1-Long and 4-Short) Coolant temperature is

Water temperature sensor

abnormal

(1-Long and 5-Short) Emergency stop switch

Emergency stop switch

operated

(2-Long and 1-Short) Abnormality of speed

Speed sensor

sensor

(2-Long and 2-Short) Solenoid malfunction Solenoid

(2-Long and 4-Short) Disconnection of water

Water temperature sensor

temperature sensor

(2-Long and 5-Short) Short circuit of water

Water temperature sensor

temperature sensor

(2-Long and 6-Short) Disconnection of alternator

Alternator L Terminal

L Terminal

W1042224

S-6

Page 85

03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM

KiSC issued 07, 2008 A

2. SERVICING SPECIFICATIONS

ENGINE BODY

Item Factory Specification Allowable Limit

Valve Clearance (When Cold) 0.18 to 0.22 mm

0.0071 to 0.0086 in.

Compression Pressure (When Cranking with Starting Motor)

[D1503-M], [D1703-M] [D1803-M], [V2003-M] [V2203-M], [V2403-M] [V2403-M-T] [D1703-M-BG], [V2003-M-BG] [V2003-M-T-BG], [V2203-M-BG] [V2403-M-BG]

Compression Pressure (When Cranking with Starting Motor)

[D1803-M-DI], [V2403-M-DI] [V2403-M-DI-T]

3.24 to 3.72 MPa /

-1

290 min

(rpm)

33.0 to 38.0 kgf/cm

-1

290 min

(rpm)

470 to 540 psi /

-1

290 min

(rpm)

2.95 to 3.23 MPa /

-1

290 min

(rpm)

30.0 to 33.0 kgf/cm

-1

290 min

(rpm)

427 to 469 psi /

-1

290 min

(rpm)

DIESEL ENGINE

–

2.55 MPa /

-1

26.0 kgf/cm

290 min

(rpm)

-1

(rpm)

370 psi /

-1

290 min

(rpm)

2.35 MPa /

-1

24.0 kgf/cm

290 min

(rpm)

-1

(rpm)

341 psi /

-1

290 min

(rpm)

Difference among Cylinders Top Clearance

[D1503-M], [D1703-M]

0.575 to 0.675 mm

0.0227 to 0.0265 in.

–

10 % or less

–

[D1803-M], [V2003-M] [V2203-M], [V2403-M] [V2403-M-T] [D1703-M-BG], [V2003-M-BG] [V2003-M-T-BG], [V2203-M-BG] [V2403-M-BG]

Top Clearance

[D1803-M-DI], [V2403-M-DI]

0.60 to 0.70 mm

0.024 to 0.027 in.

–

[V2403-M-DI-T]

Cylinder Head Surface Flatness – 0.05 mm / 500 mm

0.002 in. /

19.7 in.

Valve Recessing (Protrusion to Recessing)

Protrusion

0.05 mm

0.002 in.

–

[D1503-M], [D1703-M] [D1803-M], [V2003-M] [V2203-M], [V2403-M]

Recessing

0.15 mm

0.0059 in.

0.40 mm

0.016 in.

[V2403-M-T] [D1703-M-BG], [V2003-M-BG] [V2003-M-T-BG], [V2203-M-BG] [V2403-M-BG]

Valve Recessing

[D1803-M-DI], [V2403-M-DI]

Recessing 0.65 to 0.85 mm

0.026 to 0.033 in.

–

[V2403-M-DI-T]

W1116131

S-7

Page 86

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KiSC issued 07, 2008 A

ENGINE BODY (Continued)

Item Factory Specification Allowable Limit

Valve Stem to Valve Guide

Clearance

0.040 to 0.070 mm

0.0016 to 0.0027 in.

DIESEL ENGINE

0.10 mm

0.0039 in.

Valve Stem

Valve Guide

Valve Face

O.D.

I.D.

Angle (Intake)

[D1503-M], [D1703-M] [D1803-M], [V2003-M] [V2203-M], [V2403-M]

Angle (Exhaust)

[V2403-M-T] [D1703-M-BG], [V2003-M-BG] [V2003-M-T-BG], [V2203-M-BG] [V2403-M-BG]

Valve Face

Angle (Intake)

[D1803-M-DI], [V2403-M-DI] [V2403-M-DI-T]

Angle (Exhaust)

Valve Seat Width (Intake)

Width (Exhaust)

Valve Seat

Angle (Intake)

[D1503-M], [D1703-M] [D1803-M], [V2003-M] [V2203-M], [V2403-M]

Angle (Exhaust)

[V2403-M-T] [D1703-M-BG], [V2003-M-BG] [V2003-M-T-BG], [V2203-M-BG] [V2403-M-BG]

Valve Seat

Angle (Intake)

[D1803-M-DI], [V2403-M-DI] [V2403-M-DI-T]

Angle (Exhaust)

Valve Timing (Intake Valve)

Open

[D1503-M] [D1703-M-BG]

Valve Timing (Intake Valve)

Open

[D1703-M], [D1803-M] [V2003-M], [V2203-M] [V2403-M], [V2403-M-DI-T]

[V2003-M-BG], [V2203-M-BG] [V2403-M-BG]

7.960 to 7.975 mm

0.3134 to 0.3139 in.

8.015 to 8.030 mm

0.3156 to 0.3161 in.

1.0 rad 60 °

0.79 rad 45 °

2.12 mm

0.0835 in.

2.12 mm

0.0835 in.

1.0 rad 60 °

0.79 rad 45 °

0.1 rad (8 °)

before T.D.C.

0.35 rad (20 °) after B.D.C.

0.21 rad (12 °)

before T.D.C.

0.63 rad (36 °) after B.D.C.

–

W1014004

S-8

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KiSC issued 07, 2008 A

ENGINE BODY (Continued)

Item Factory Specification Allowable Limit

Valve Timing (Intake Valve)

[V2403-M-T] [V2003-M-T-BG]

Valve Timing (Intake Valve)

[D1803-M-DI] [V2403-M-DI]

Valve Timing (Exhaust Valve)

[D1503-M] [V2003-M]

Valve Timing (Exhaust Valve)

[D1703-M], [D1803-M] [V2203-M], [V2403-M] [V2403-M-BG]

Valve Timing (Exhaust Valve)

[V2403-M-T] [V2403-M-DI-T] [D1703-M-BG] [V2003-M-BG] [V2203-M-BG]

Valve Timing (Exhaust Valve)

[D1803-M-DI] [V2403-M-DI]

Valve Timing (Exhaust Valve)

[V2003-M-T-BG]

Open

0.35 rad (20 °) before T.D.C.

0.79 rad (45 °)

after B.D.C.

0.2 rad (9 °)

before T.D.C.

0.68 rad (39 °)

after B.D.C.

1.0 rad (60 °)

before B.D.C.

0.21 rad (12 °)

after T.D.C.

0.99 rad (57 °)

before B.D.C.

0.21 rad (12 °)

after T.D.C.

0.87 rad (50 °)

before B.D.C.

0 rad (0 °)

after T.D.C.

0.72 rad (41 °)

before B.D.C.

0.2 rad (9 °) after T.D.C.

0.96 rad (55 °) before B.D.C.

DIESEL ENGINE

–

Valve Spring Fr ee Len gth

Setting Load / Setting Length

Tilt

S-9

0.24 rad (14 °)

after T.D.C.

41.7 to 42.2 mm

1.65 to 1.66 in.

118 N / 35.0 mm

12.0 kgf / 35.0 mm

26.5 lbf / 1.38 in. –

–

41.2 mm

1.62 in.

100 N / 35.0 mm

10.2 kgf / 35.0 mm

22.5 lbf /1.38 in.

1.0 mm

0.039 in.

W1014959

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KiSC issued 07, 2008 A

ENGINE BODY (Continued)

Item Factory Specification Allowable Limit

Rocker Arm Shaft to Rocker Arm

Oil Clearance

0.016 to 0.045 mm

0.00063 to 0.0017 in.

DIESEL ENGINE

0.10 mm

0.0039 in.

Rocker Arm Shaft

O.D.

13.973 to 13.984 mm

–

0.55012 to 0.55055 in.

Rocker Arm

I.D.

14.000 to 14.018 mm

–

0.55119 to 0.55188 in.

Push Rod Alignment – 0.25 mm

0.0098 in.

Tappet to Tappet Guide

Tappet

Oil Clearance

O.D.

0.020 to 0.062 mm

0.00079 to 0.0024 in.

23.959 to 23.980 mm

0.07 mm

0.003 in. –

0.94327 to 0.94409 in.

Tappet Guide

I.D.

24.000 to 24.021 mm

–

0.94489 to 0.94570 in.

Timing Gear Crank Gear to Idle Gear

Idle Gear to Cam Gear

Idle Gear to Injection Pump Gear

Backlash

0.04150 to 0.1122 mm

0.001634 to 0.004417 in.

0.04150 to 0.1154 mm

0.001634 to 0.004543 in.

0.04150 to 0.1154 mm

0.001634 to 0.004543 in.

0.15 mm

0.0059 in.

0.15 mm

0.0059 in.

0.15 mm

0.0059 in.

Crank Gear to Oil Pump Gear

Backlash

0.04150 to 0.1090 mm

0.001634 to 0.004291 in.

Idle Gear to Balancer Gear (Balancer Model Only)

Cam Gear to Balancer Gear (Balancer Model Only)

Crank Gear to Idle Gear 2 (Side PTO Model Only)

Idle Gear 2 to Hydraulic Pump Drive Gear (Side PTO Model Only)

Backlash

0.03500 to 0.1160 mm

0.001378 to 0.004566 in.

0.03500 to 0.1160 mm

0.001378 to 0.004566 in.

0.04150 to 0.1154 mm

0.001634 to 0.004543 in.

0.03080 to 0.1062 mm

0.001213 to 0.004181 in.

Idle Gear Side Clearance 0.12 to 0.48 mm

0.0048 to 0.018 in.

Idle Gear Shaft to Idle Gear Bushing

Oil Clearance

0.025 to 0.066 mm

0.00099 to 0.0025 in.

Idle Gear Shaft

O.D.

37.959 to 37.975 mm

1.4945 to 1.4950 in.

Idle Gear Bushing

I.D.

38.000 to 38.025 mm

1.4961 to 1.4970 in.

0.15 mm

0.0059 in.

0.15 mm

0.0059 in.

0.15 mm

0.0059 in.

0.15 mm

0.0059 in.

0.15 mm

0.0059 in.

0.9 mm

0.04 in.

0.10 mm

0.0039 in. –

–

W1015276

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KiSC issued 07, 2008 A

DIESEL ENGINE

ENGINE BODY (Continued)

Item Factory Specification Allowable Limit

Camshaft Side Clearance 0.070 to 0.22 mm

0.0028 to 0.0086 in.

0.30 mm

0.012 in.

Camshaft Alignment – 0.01 mm

0.0004 in.

Cam (Intake)

[D1503-M] [D1703-M-BG]

Height

33.27 mm

1.310 in.

33.22 mm

1.308 in.

[V2003-M] [V2403-M-DI-T] [V2003-M-BG] [V2203-M-BG]

[D1703-M], [D1803-M] [V2203-M], [V2403-M] [V2403-M-T] [D1803-M-DI], [V2403-M-DI] [V2003-M-T-BG] [V2403-M-BG]

Cam (Exhaust)

[V2403-M-DI-T]

[V2403-M-T] [D1703-M-BG], [V2003-M-BG] [V2203-M-BG]

[D1503-M], [D2003-M] [V2003-M-T-BG]

[D1703-M], [D1803-M] [V2203-M], [V2403-M] [V1803-M-DI], [V2403-M-DI] [V2403-M-BG]

Camshaft Journal to Cylinder Block Bore

Height

Oil Clearance

33.47 mm

1.318 in.

33.90 mm

1.335 in.

33.00 mm

1.299 in.

33.27 mm

1.310 in.

33.47 mm

1.318 in.

33.90 mm

1.335 in.

0.050 to 0.091 mm

0.0020 to 0.0035 in.

33.42 mm

1.316 in.

33.85 mm

1.333 in.

33.95 mm

1.297 in.

33.22 mm

1.308 in.

33.42 mm

1.316 in.

33.85 mm

1.333 in.

0.15 mm

0.0059 in.

Camshaft Journal

Cylinder Block Bore

Balancer Shaft (Balancer Model Only)

O.D.

39.934 to 39.950 mm

–

1.5722 to 1.5728 in.

I.D.

40.000 to 40.025 mm

–

1.5748 to 1.5757 in.

Side Clearance 0.070 to 0.22 mm

0.0028 to 0.0086 in.

0.30 mm

0.012 in.

Alignment – 0.02 mm

0.0008 in.

W1117772

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KiSC issued 07, 2008 A

ENGINE BODY (Continued)

Item Factory Specification Allowable Limit

Balancer Shaft Journal 1 to Balancer Shaft Bearing 1 (Balancer Model Only)

Oil Clearance

0.0300 to 0.111 mm

0.00119 to 0.00437 in.

DIESEL ENGINE

0.20 mm

0.0079 in.

Balancer Shaft Journal 1

O.D.

43.934 to 43.950 mm

1.7297 to 1.7303 in.

Balancer Shaft Bearing 1

I.D.

43.980 to 44.045 mm

1.7315 to 1.7340 in.

Balancer Shaft Journal 2 to Balancer Shaft Bearing 2 (Balancer Model Only)

Balancer Shaft Journal 2

Oil Clearance

O.D.

0.0300 to 0.111 mm

0.00119 to 0.00437 in.

41.934 to 41.950 mm

1.6509 to 1.6515 in.

Balancer Shaft Bearing 2

I.D.

41.980 to 42.045 mm

1.6528 to 1.6553 in.

Balancer Shaft Journal 3 to Balancer Shaft Bearing 3 (Balancer Model Only)

Balancer Shaft Journal 3

Oil Clearance

O.D.

0.020 to 0.094 mm

0.00079 to 0.0037 in.

21.947 to 21.960 mm

0.86406 to 0.86456 in.

Balancer Shaft Bearing 3

I.D.

21.980 to 22.041 mm

0.86536 to 0.86775 in.

Piston Pin Bore I.D. 25.000 to 25.013 mm

0.98426 to 0.98476 in.

Top Ring to Ring Groove

[D1803-M-DI]

Clearance 0.050 to 0.090 mm

0.0020 to 0.0035 in.

[V2403-M-DI]

Second Ring to Ring Groove

[D1503-M], [D1703-M]

Clearance 0.0930 to 0.128 mm

0.00367 to 0.00503 in.

[D1803-M], [V2003-M] [V2203-M], [V2403-M] [V2403-M-T], [V2403-M-DI-T] [D1703-M-BG], [V2003-M-BG] [V2003-M-T-BG], [V2203-M-BG] [V2403-M-BG]

Second Ring to Ring Groove

[D1803-M-DI], [V2403-M-DI]

Oil Ring to Ring Groove

[D1503-M], [D1703-M]

Clearance 0.0780 to 0.110 mm

0.00307 to 0.00433 in.

Clearance 0.020 to 0.060 mm

0.00079 to 0.0023 in.

[D1803-M], [V2003-M] [V2203-M], [V2403-M] [V2403-M-T], [V2403-M-DI-T] [D1703-M-BG], [V2003-M-BG] [V2003-M-T-BG], [V2203-M-BG] [V2403-M-BG]

Oil Ring to Ring Groove

[D1803-M-DI], [V2403-M-DI]

Clearance 0.030 to 0.070 mm

0.0012 to 0.0027 in.

–

0.20 mm

0.0079 in. –

–

0.20 mm

0.0079 in. –

–

25.05 mm

0.9862 in.

0.20 mm

0.0079 in.

0.20 mm

0.0079 in.

0.20 mm

0.0079 in.

0.15 mm

0.0059 in.

0.15 mm

0.0059 in.

W1119370

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KiSC issued 07, 2008 A

DIESEL ENGINE

ENGINE BODY (Continued)

Item Factory Specification Allowable Limit

Top Ring

[D1503-M], [V2003-M], [V2403-M-T]

Ring Gap 0.20 to 0.35 mm

0.0079 to 0.013 in.

1.25 mm

0.0492 in.

[D1803-M-DI], [V2403-M-DI] [V2403-M-DI-T] [V2003-M-BG], [V2003-M-T-BG],

Top Ring

[D1703-M], [D1803-M]

Ring Gap 0.25 to 0.40 mm

0.0099 to 0.015 in.

1.25 mm

0.0492 in.

[V2203-M], [V2403-M] [D1703-M-BG], [V2203-M-BG] [V2403-M-BG]

Second Ring

[D1503-M], [D1703-M]

Ring Gap 0.30 to 0.45 mm

0.012 to 0.017 in.

1.25 mm

0.0492 in.

[D1803-M], [V2203-M] [V2403-M] [D1803-M-DI], [V2403-M-DI] [D1703-M-BG], [V2003-M-BG] [V2203-M-BG], [V2403-M-BG]

Second Ring [V2003-M], [V2403-M-T], [V2403-M-DI-T]

Ring Gap 0.40 to 0.55 mm

0.016 to 0.021 in.

1.25 mm

0.0492 in.

[V2003-M-T-BG]

Oil Ring

[D1503-M], [D1703-M]

Ring Gap 0.25 to 0.45 mm

0.0099 to 0.017 in.

1.25 mm

0.0492 in.

[D1803-M], [V2003-M] [V2203-M], [V2403-M], [V2403-M-T] [V2403-M-DI-T] [D1703-M-BG], [V2003-M-BG] [V2003-M-T-BG], [V2203-M-BG] [V2403-M-BG]

Oil Ring

[D1803-M-DI], [V2403-M-DI]

Ring Gap 0.20 to 0.40 mm

0.0079 to 0.015 in.

1.25 mm

0.0492 in.

Connecting Rod Alignment – 0.05 mm

0.002 in.

Piston Pin to Small End Bushing

Oil Clearance

0.014 to 0.036 mm

0.00056 to 0.0014 in.

0.15 mm

0.0059 in.

Piston Pin

O.D.

25.004 to 25.011 mm

–

0.98441 to 0.98468 in.

Small End Bushing

I.D.

25.025 to 25.040 mm

–

0.98524 to 0.98582 in.

Crankshaft Alignment – 0.02 mm

0.0008 in.

Crankshaft Journal to Crankshaft Bearing 1

Crankshaft Journal

Oil Clearance

O.D.

0.0400 to 0.118 mm

0.00158 to 0.00464 in.

59.921 to 59.940 mm

0.20 mm

0.0079 in. –

2.3591 to 2.3598 in.

Crankshaft Bearing 1

I.D.

59.980 to 60.039 mm

–

2.3615 to 2.3637 in.

W1086708

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KiSC issued 07, 2008 A

ENGINE BODY (Continued)

Item Factory Specification Allowable Limit

Crankshaft Journal to Crankshaft Bearing 2

Oil Clearance

0.0400 to 0.104 mm

0.00158 to 0.00409 in.

DIESEL ENGINE

0.20 mm

0.0079 in.

Crankshaft Journal

O.D.

59.921 to 59.940 mm

2.3591 to 2.3598 in.

Crankshaft Bearing 2

I.D.

59.980 to 60.025 mm

2.3615 to 2.3631 in.

Crankpin to Crankpin Bearing

Oil Clearance

0.025 to 0.087 mm

0.00099 to 0.0034 in.

Crankpin

O.D.

46.959 to 46.975 mm

1.8488 to 1.8494 in.

Crankpin Bearing

I.D.

47.000 to 47.046 mm

1.8504 to 1.8522 in.

Crankshaft Side Clearance 0.15 to 0.31 mm

0.0059 to 0.012 in.

Cylinder Bore (Standard)

[D1503-M], [V2003-M]

I.D. 83.000 to 83.022 mm

3.2678 to 3.2685 in.

[V2003-M-BG], [V2003-M-T-BG]

Cylinder Bore (Standard)

[D1703-M], [D1803-M]

I.D. 87.000 to 87.022 mm

3.4252 to 3.4260 in.

[V2203-M], [V2403-M], [V2403-M-T] [D1803-M-DI], [V2403-M-DI] [V2403-M-DI-T] [D1703-M-BG], [V2203-M-BG] [V2403-M-BG]

Cylinder Bore (Oversize)

[D1503-M], [V2003-M]

I.D. 83.250 to 83.272 mm

3.2776 to 3.2784 in.

[V2003-M-BG], [V2003-M-T-BG]

Cylinder Bore (Oversize)

[D1703-M], [D1803-M]

I.D. 87.250 to 87.272 mm

3.4351 to 3.4359 in.

[V2203-M], [V2403-M], [V2403-M-T] [D1803-M-DI], [V2403-M-DI] [V2403-M-DI-T] [D1703-M-BG], [V2203-M-BG] [V2403-M-BG]

Difference among Minimum Wear to

–0.15 mm

Maximum Wear

–

0.20 mm

0.0079 in. –

–

0.5 mm

0.02 in.

83.170 mm

3.2744 in.

87.170 mm

3.4319 in.

83.420 mm

3.2843 in.

87.420 mm

3.4417 in.

0.0059 in.

W1054843

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KiSC issued 07, 2008 A

LUBRICATING SYSTEM

Item Factory Specification Allowable Limit

Engine Oil Pressure At Idle Speed

More than 98 kPa

1.0 kgf/cm

14 psi

DIESEL ENGINE

50 kPa

0.5 kgf/cm

7 psi

At Rated Speed

300 to 440 kPa

3.0 to 4.5 kgf/cm 43 to 64 psi

Engine Oil Pressure Switch Working

Pressure

50 kPa

0.5 kgf/cm

7 psi

Inner Rotor to Outer Rotor Clearance 0.030 to 0.14 mm

0.0012 to 0.0055 in.

Outer Rotor to Pump Body Clearance 0.11 to 0.19 mm

0.0044 to 0.0074 in.

Inner Rotor to Cover Clearance 0.105 to 0.150 mm

0.00414 to 0.00590 in.

COOLING SYSTEM

Fan Belt Tension 7.0 to 9.0 mm (0.28 to

0.35 in.) deflection at

98 N (10 kgf, 22 lbf) of

force

Thermostat

[D1503-M], [D1703-M] [D1803-M], [V2003-M]

Valve Opening Temperature (At Beginning)

69.5 to 72.5 °C

157.1 to 162.5 °F

[V2203-M], [V2403-M] [V2403-M-T] [D1703-M-BG], [V2003-M-BG] [V2003-M-T-BG], [V2203-M-BG] [V2403-M-BG]

Thermostat

[D1803-M-DI], [V2403-M-DI] [V2403-M-DI-T]

Valve Opening Temperature (Opened Completely)

Valve Opening Temperature (At Beginning)

85 °C

185 °F

80.5 to 83.5 °C

176.9 to 182.3 °F

250 kPa

2.5 kgf/cm

36 psi

–

0.2 mm

0.008 in.

0.25 mm

0.0098 in.

0.20 mm

0.008 in.

W1120963

–

Valve Opening Temperature

95 °C

203 °F (Opened Completely)

Radiator Water Tightness No leak at

specified pressure

Radiator Cap Pressure Falling

Time

More than 10 seconds

for pressure fall

from 90 to 60 kPa

from 0.9 to 0.6 kgf/cm

from 10 to 9 psi

S-15

–

W1122456

Page 94

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KiSC issued 07, 2008 A

FUEL SYSTEM

Item Factory Specification Allowable Limit

Injection Pump

[D1503-M], [V2003-M-T-BG]

Injection Pump

[D1703-M], [D1803-M] [V2003-M], [V2203-M] [V2403-M]

Injection Pump

[V2403-M-T]

Injection Pump

[D1803-M-DI], [V2403-M-DI]

Injection Pump

[V2403-M-DI-T]

Injection Pump

[D1703-M-BG], [V2003-M-BG] [V2203-M-BG], [V2403-M-BG]

Pump Element

[D1503-M], [D1703-M] [D1803-M], [V2003-M] [V2203-M], [V2403-M] [V2403-M-T] [D1703-M-BG], [V2003-M-BG] [V2003-M-T-BG], [V2203-M-BG] [V2403-M-BG]

Pump Element

[D1803-M-DI], [V2403-M-DI] [V2403-M-DI-T]

Delivery Valve

[D1503-M], [D1703-M] [D1803-M], [V2003-M] [V2203-M], [V2403-M] [V2403-M-T] [D1703-M-BG], [V2003-M-BG] [V2003-M-T-BG], [V2203-M-BG] [V2403-M-BG]

Delivery Valve

[D1803-M-DI], [V2403-M-DI] [V2403-M-DI-T]

DIESEL ENGINE

Injection Timing 0.253 to 0.279 rad

–

(14.5 to 16.0 °) before

T.D.C.

Injection Timing 0.271 to 0.296 rad

–

(15.5 to 17.0 °) before

T.D.C.

Injection Timing 0.132 to 0.157 rad

–

(7.55 to 9.05 °) before

T.D.C.

Injection Timing 0.0742 to 0.100 rad

–

(4.25 to 5.75 °) before

T.D.C.

Injection Timing 0.0829 to 0.109 rad

–

(4.75 to 6.25 °) before

T.D.C.

Injection Timing 0.236 to 0.261 rad

–

(13.5 to 15.0 °) before

T.D.C.

Fuel Tightness – 13.73 MPa

140.0 kgf/cm 1991 psi

Fuel Tightness – 18.63 MPa

190.0 kgf/cm 2702 psi

Fuel Tightness 10 seconds

13.73 → 12.75 MPa

140.0 → 130.0 kgf/cm 1991 → 1849 psi

5 seconds

13.73 → 12.75 MPa

140.0 →

130.0 kgf/cm

1991 → 1849 psi

Fuel Tightness 10 seconds

18.63 → 17.65 MPa

190.0 → 180.0 kgf/cm 2702 → 2560 psi

5 seconds

18.63 → 17.65 MPa

190.0 →

180.0 kgf/cm

2702 → 2560 psi

W1123952

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KiSC issued 07, 2008 A

FUEL SYSTEM (Continued)

Item Factory Specification Allowable Limit

Injection Nozzle

[D1503-M], [D1703-M] [D1803-M], [V2003-M] [V2203-M], [V2403-M] [V2403-M-T] [D1703-M-BG], [V2003-M-BG] [V2003-M-T-BG], [V2203-M-BG] [V2403-M-BG]

Injection Nozzle

[D1803-M-DI], [V2403-M-DI] [V2403-M-DI-T]

Injection Nozzle V alve Seat

[D1503-M], [D1703-M] [D1803-M], [V2003-M] [V2203-M], [V2403-M] [V2403-M-T] [D1703-M-BG], [V2003-M-BG] [V2003-M-T-BG], [V2203-M-BG] [V2403-M-BG]

Injection Nozzle V alve Seat

[D1803-M-DI], [V2403-M-DI] [V2403-M-DI-T]

Injection Pressure 13.73 to 14.70 MPa

140.0 to 150.0 kgf/cm 1992 to 2133 psi

Injection Pressure (1st stage)

18.64 to 20.10 MPa

190.0 to 205.0 kgf/cm 2703 to 2915 psi

Valve Seat Tightness

When the pressure is

12.75 MPa

(130.0 kgf/cm

, 1849

psi), the valve seat must

be fuel tightness.

Valve Seat Tightness

When the pressure is

16.67 MPa

(170.0 kgf/cm

, 2418

psi), the valve seat must

be fuel tightness.

DIESEL ENGINE

–

W1041294

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Page 96

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KiSC issued 07, 2008 A

ELECTRICAL SYSTEM

Item Factory Specification Allowable Limit

Starter

Commutator

[D1503-M], [D1703-M] [V2003-M], [V2203-M] [D1803-M-DI] [D1703-M-BG], [V2003-M-BG] [V2003-M-T-BG], [V2203-M-BG]

O.D.

30.0 mm

1.18 in.

DIESEL ENGINE

29.0 mm

1.14 in.

Commutator

[D1803-M], [V2403-M] [V2403-M-DI], [V2403-M-T]

[V2403-M-DI-T]

[V2403-M-BG]

Mica

[D1503-M], [D1703-M] [D1803-M], [V2003-M] [V2203-M], [V2403-M] [V2403-M-T] [D1803-M-DI], [V2403-M-DI] [V2403-M-DI-T] [D1703-M-BG], [V2003-M-BG] [V2003-M-T-BG], [V2203-M-BG]

Mica

[V2403-M-BG]

Brush

[D1503-M], [D1703-M] [V2003-M], [V2203-M] [D1803-M-DI] [D1703-M-BG], [V2003-M-BG] [V2003-M-T-BG], [V2203-M-BG]

O.D.

Under Cut

Length

35.0 mm

1.38 in.

0.45 to 0.75 mm

0.018 to 0.029 in.

0.55 to 0.85 mm

0.022 to 0.033 in.

15.0 mm

0.591 in.

34.0 mm

1.34 in.

0.20 mm

0.0079 in.

0.20 mm

0.0079 in.

11.0 mm

0.433 in.

Brush

[D1803-M], [V2403-M] [V2403-M-DI], [V2403-M-T]

[V2403-M-DI-T]

Brush

[V2403-M-BG]

Brush Holder and Holder Support

Alternator

Stator Rotor Slip Ring

Brush

Glow Plug Resistance Approx. 0.9 Ω –

Length

Resistance No-load voltage

Resistance Resistance O.D.

Length

S-18

15.0 mm

0.591 in.

15.0 mm

0.591 in. Infinity

More than 13.5 V

Less than 1.0 Ω

2.9 Ω

14.4 mm

0.567 in.

10.5 mm

0.413 in.

9.0 mm

0.35 in.

12.0 mm

0.472 in. –

– – –

14.0 mm

0.551 in.

8.4 mm

0.33 in.

W1125417

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KiSC issued 07, 2008 A

DIESEL ENGINE

3. TIGHTENING TORQUES

Screws, bolts and nuts must be tightened to the specified torque using a torque wrench , several scre ws, 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.

Grade

Nominal Unit Diameter

M6 7.9 to 9.3 0.80 to 0.95 5.8 to 6.8 9.81 to 11.2 1.00 to 1.15 7.24 to 8.31

M8 18 to 20 1.8 to 2.1 13 to 15 24 to 27 2.4 to 2.8 18 to 20 M10 40 to 45 4.0 to 4.6 29 to 33 49 to 55 5.0 to 5.7 37 to 41 M12 63 to 72 6.4 to 7.4 47 to 53 78 to 90 7.9 to 9.2 58 to 66

Screw and bolt material grades are shown by numbers punched on the screw and bolt heads. Prior to tightening, be sure to check out the numbers as shown below.

Punched number Screw and bolt material grade

None or 4 Standard screw and bolt SS41, S20C

7 Special screw and bolt S43C, S48C (Refined)

Standard Screw and Bolt

N·m kgf·m lbf·ft N·m kgf·m lbf·ft

Special Screw and Bolt

W10371750

W1012705

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Page 98

03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM

KiSC issued 07, 2008 A

DIESEL ENGINE

[2] TIGHTENING TORQUES FOR SPECIAL USE SCREWS, BOLTS AND

NUTS

NOTEQ

• For “*” marked screws, bolts and nuts on the table, apply engine oil to their threads and seats before tightening.

• The letter “M” in Size x Pitch means that the screw, bolt or nut dimension stands for metric. The size is the nominal outside diameter in mm of the threads. The pitch is the nominal distance in mm between two threads.

Item Size x Pitch N·m kgf·m lbf·ft

Cylinder head cover screw M6 x 1.0 9.81 to 11.2 1.00 to 1.15 7.24 to 8.31 *Cylinder head screw M11 x 1.25 93.2 to 98.0 9.50 to 10.0 68.8 to 72.3 *Main bearing case screw 1 M9 x 1.25 46 to 50 4.7 to 5.2 34 to 37 *Main bearing case screw 2 M10 x 1.25 69 to 73 7.0 to 7.5 51 to 54 *Flywheel screw M12 x 1.25 98.1 to 107 10.0 to 11.0 72.4 to 79.5 *Connecting rod screw M8 x 1.0 45 to 49 4.5 to 5.0 33 to 36 *Rocker arm bracket screw M8 x 1.25 24 to 27 2.4 to 2.8 18 to 20 *Idle gear shaft screw M8 x 1.25 24 to 27 2.4 to 2.8 18 to 20 Fan drive pulley mounting nut M30 x 1.5 138 to 156 14.0 to 16.0 102 to 115 *Bearing case cover mounting screw M8 x 1.25 24 to 27 2.4 to 2.8 18 to 20 Glow plug M10 x 1.25 20 to 24 2.0 to 2.5 15 to 18 Nozzle holder assembly (IDI) M20 x 1.5 49 to 68 5.0 to 7.0 37 to 50 Nozzle holder (IDI) – 35 to 39 3.5 to 4.0 26 to 28 Nozzle holder clamp screw (DI) M10 x 1.25 26 to 29 2.6 to 3.0 19 to 21 Oil pressure switch R 1/8 15 to 19 1.5 to 2.0 11 to 14 Injection pipe retaining nut (IDI) M12 x 1.5 25 to 34 2.5 to 3.5 18 to 25 Injection pipe retaining nut (DI) M12 x 1.5 15 to 24 1.5 to 2.5 11 to 18 Overflow pipe assembly retaining nut

(IDI) Overflow pipe assembly retaining screw

(DI) Camshaft set screw M8 x 1.25 24 to 27 2.4 to 2.8 18 to 20 Hi-idling body M14 x 1.0 45 to 49 4.5 to 5.0 33 to 36 Balancer shaft set bolt

(Balancer model only) Alternator’s pulley nut – 58.4 to 78.9 5.95 to 8.05 43.1 to 58.2 Idle gear 2 stopper set screw

(Side PTO model only) Idle gear 2 shaft set screw

(Side PTO model only) Starter’s terminal B mounting nut M8 5.9 to 11 0.60 to 1.2 4.4 to 8.6

IDI :D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M, V2403-M-T D1703-M-BG, V2003-M-BG, V2003-M-T-BG, V2203-M-BG, V2403-M-BG DI :D1803-M-DI, V2403-M-DI, V2403-M-DI-T

M12 x 1.5 20 to 24 2.0 to 2.5 15 to 18

M6 x 1.0 9.81 to 11.2 1.00 to 1.15 7.24 to 8.31

M8 x 1.25 24 to 27 2.4 to 2.8 18 to 20

– 49 to 55 5.0 to 5.7 37 to 41

– 24 to 27 2.4 to 2.8 18 to 20

W1013236

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Page 99

03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM

KiSC issued 07, 2008 A

DIESEL ENGINE

4. CHECKING, DISASSEMBLING AND SERVICING

[1] CHECKING AND ADJUSTING

(1) Engine Body

Compression Pressure [D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M,

V2403-M-T] [D1703-M-BG, V2003-M-BG, V2003-M-T-BG, V2203-M-BG, V2403-M-BG]

1. Run the engine until it is warmed up.

2. Stop the engine and disconnect the 2P connector from the stop solenoid in order not to inject fuel.

3. Remove the air cleaner, the muffler and all injection nozzles.

4. Set a compression tester with the adaptor to the nozzle hole.

5. After making sure that the stop lever is set at the stop position (non-injection).

6. While cranking the engine with the starter, measure the compression pressure.

7. Repeat steps 4 through 6 for each cylinder.

8. If the measurement is below the allowable limit, apply a small amount of oil to the cylinder wall through the nozzle hole and measure the compression pressure again.

9. If the compression pressure is still less than the allowable limit, check the top clearance, valve and cylinder head.

10.If the compression pressure increases after applying oil, check the cylinder wall and piston rings.

NOTEQ

• Check the compression pressure with the specified valve clearance.

• Always use a fully charged battery for performing this test.

• Variances in cylinder compression values should be under 10 %.

Factory spec.

Compression pressure

Allowable limit

3.24 to 3.72 MPa

33.0 to 38.0 kgf/cm 470 to 540 psi

2.55 MPa

26.0 kgf/cm 370 psi

W1018639

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Page 100

03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM

KiSC issued 07, 2008 A

DIESEL ENGINE

Compression Pressure [D1803-M-DI, V2403-M-DI, V2403-M-DI-T]

1. Run the engine until it is warmed up.

2. Stop the engine and disconnect the 2P connector from the stop solenoid in order not to inject fuel.

3. Remove the air cleaner, the muffler and all glow plugs.

4. Set a compression tester (07909-39081) with the adaptor K (07909-31291) to the glow plug hole.

5. While cranking the engine with the starter, measure the compression pressure.

6. Repeat steps 4 through 5 for each cylinder.

NOTEQ

• Check the compression pressure with the specified valve clearance.

• Always use a fully charged battery for performing this test.

• Variances in cylinder compression values should be under 10 %.

Compression pressure

Factory spec.

Allowable limit

2.95 to 3.23 MPa

30.0 to 33.0 kgf/cm 427 to 469 psi

2.35 MPa

24.0 kgf/cm 341 psi

W1111297

S-22