Kubota D1503-M-DI, D1503-M-DI-T, V2203-M-DI, V2403-M-DI, D1703-M-DI Workshop Manual
...
WORKSHOP MANUAL
KiSC issued 10, 2009 A
DIESEL ENGINES
03-M-DI SERIES
TO THE READER
KiSC issued 10, 2009 A
This Workshop Manual has been prepared to provide servicing personnel with
information on the mechanism, service and maintenance of KUBOTA Diesel Engine 03M-DI Series. It is divided into two parts, “Mechanism” and “Servicing” for each section.
Q Mechanism
Information on the Features and New Mechanisms are described. This information
should be understood before proceeding with troubleshooting, disassembling and
servicing.
Q Servicing
The heading “General” includes general precautions, check and maintenance and
special tools. There are troubleshooting, 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, illustration being used, have not been
specified as one model.
March 2002
© KUBOTA Corporation 2002
03-M-DI Series, WSM
KiSC issued 10, 2009 A
SAFETY INSTRUCTIONS
SAFETY INSTRUCTIONS
SAFETY FIRST
This symbol, the industry’s “Safety Alert Symbol”, is used throughout this manual and on labels on
the machine itself to warn of the possibility of personal injury. Read these instructions carefully.
It is essential that you read the instructions and safety regulations before you attempt to repair or use
this unit.
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.
1
03-M-DI Series, WSM
KiSC issued 10, 2009 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 influence
of alcohol, medication, or other substances or while
fatigued.
• Wear close fitting clothing and safety equipment
appropriate to the job.
• Use tools appropriate to the work. Makeshift tools,
parts, and procedures are not recommended.
• When servicing is performed together by two or more
persons, take care to perform all work safely.
• Do not touch the rotating or hot parts while the engine
is running.
• Never remove the radiator cap while the engine is
running, or immediately after stopping. Otherwise, hot
water will spout out from radiator. Only remove
radiator cap when cool enough to touch with bare
hands. Slowly loosen the cap to first stop to relieve
pressure before removing completely.
• Escaping fluid (fuel or hydraulic oil) under pressure
can penetrate the skin causing serious injury. Relieve
pressure before disconnecting hydraulic or fuel lines.
Tighten all connections before applying pressure.
• Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable
or uncomfortable loud noises.
AVOID FIRES
• Fuel is extremely flammable and explosive under
certain conditions. Do not smoke or allow flames or
sparks in your working area.
• To avoid sparks from an accidental short circuit,
always disconnect the battery negative cable first and
connect it last.
• Battery gas can explode. Keep sparks and open
flame away from the top of battery, especially when
charging the battery.
• Make sure that no fuel has been spilled on the engine.
2
03-M-DI Series, WSM
KiSC issued 10, 2009 A
SAFETY INSTRUCTIONS
VENTILATE WORK AREA
• If the engine must be running to do some work, make
sure the area is well ventilated. Never run the engine
in a closed area. The exhaust gas contains poisonous
carbon monoxide.
DISPOSE OF FLUIDS PROPERLY
• Do not pour fluids into the ground, down a drain, or
into a stream, pond, or lake. Observe relevant
environmental protection regulations when disposing
of oil, fuel, coolant, electrolyte and other harmful
waste.
PREVENT ACID BURNS
• Sulfuric acid in battery electrolyte is poisonous. It is
strong enough to burn skin, clothing and cause
blindness if splashed into eyes. Keep electrolyte
away from eyes, hands and clothing. If you spill
electrolyte on yourself, flush with water, and get
medical attention immediately.
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.
3
03-M-DI Series, WSM
KiSC issued 10, 2009 A
SPECIFICATIONS
SPECIFICATIONS
Model D1503-M-DI D1503-M-DI-T D1703-M-DI D1803-M-DI
Number of Cylinders 3
Type Vertical, Water-cooled, 4 cycle DI diesel engine
Bore × Stroke mm × mm
(in. × in.)
(HP/min
(HP/min
(HP/min
3
(cu.in.) 1499 (91.47) 1647 (100.51) 1826 (111.43)
-1
(rpm)
-1
(rpm))
-1
(rpm)
-1
(rpm))
-1
(rpm)
-1
(rpm))
-1
(rpm) 3000 2800
-1
(rpm) 750 to 850
20.1 / 2800
(27.0 / 2800)
23.5 / 2800
(31.5 / 2800)
24.8 / 2800
(33.2 / 2800)
Total Displacement cm
SAE Net Cont. kW/min
SAE Net Intermittent kW/min
SAE Gross Intermittent kW/min
Maximum Bare Speed min
Maximum Idling Speed min
Combustion Chamber Troiddal Type (Direct Injection)
Fuel Injection Pump Bosch “K” Type Mini Pump
Governor Centrifugal Ball Type, All Speed Mechanical Governor
Direction of Rotation Counter-Clockwise (viewed from flywheel side)
Injection Nozzle Bosch “P” Type Hole Nozzle
Injection Timing 0.201 rad (11.5 °) Before T.D.C. 0.175 rad (10 °) Before T.D.C.
Firing Order 1-2-3
Injection Pressure 1st. Stage 18.6 MPa (190 kgf/cm
2nd. Stage 22.6 MPa (230 kgf/cm
Compression Ratio 20 19 20
Lubricating System Forced Lubrication by Trochoid Pump
Cooling System Pressurized radiation, forced circulation with water pump
Starting System Electric Starting with Starter
Starting Support Device Pre-heating by Glow Plug in Combustion Chamber
Battery
12 V, 60 A (75D31R)
Charging Alternator 12 V, 360 W 12 V, 480 W
Fuel Diesel Fuel No.2-D or No.2-DLS
Lubricating Oil Better than CD class (API)
Lubricating Oil
Capacity
Oil Pan Depth
90 mm (3.54 in.)
Oil Pan Depth
124 mm (4.88 in.)
Weight (Dry) BB spec. kg (lbs) 148 (326) 152 (335) 148 (326) 151 (333)
* The specification described above is of the standard engine of each model.
* Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW
83 × 92.4
(3.26 × 3.64)
27.2 / 2800
(36.5 / 2800)
31.3 / 2800
(42.0 / 2800)
32.7 / 2800
(43.8 / 2800)
5.6 L (1.48 U.S.gals)
7.0 L (1.85 U.S.gals)
12 V, 1.4 kW
87 × 92.4
(3.43 × 3.64)
22.7 / 2800
(30.4 / 2800)
26.1 / 2800
(35.0 / 2800)
27.4 / 2800
(36.7 / 2800)
2
, 2702 psi)
2
, 3271 psi)
87 × 102.4
(3.43 × 4.04)
23.9 / 2600
(32.1 / 2600)
27.2 / 2600
(36.5 / 2600)
28.4 / 2600
(38.1 / 2600)
12 V, 88 A
(115E41R)
W10275180
4
03-M-DI Series, WSM
KiSC issued 10, 2009 A
SPECIFICATIONS
Model V2203-M-DI V2403-M-DI
Number of Cylinders 4
Type Vertical, Water-cooled, 4 cycle DI diesel engine
Bore × Stroke mm × mm
(in. × in.)
3
Total Displacement cm
SAE Net Cont. kW/min
(HP/min
SAE Net Intermittent kW/min
(HP/min
SAE Gross Intermittent kW/min
(HP/min
Maximum Bare Speed min
Maximum Idling Speed min
(cu.in.) 2197 (134.07) 2434 (148.53)
-1
(rpm)
-1
(rpm))
-1
(rpm)
-1
(rpm))
-1
(rpm)
-1
(rpm))
-1
(rpm) 3000 3000
-1
(rpm) 750 to 850
87 × 92.4
(3.43 × 3.64)
30.2 / 2800
(40.5 / 2800)
34.8 / 2800
(46.7 / 2800)
36.4 / 2800
(48.8 / 2800)
87 × 102.4
(3.43 × 4.04)
31.8 / 2600
(42.6 / 2600)
36.6 / 2600
(34.8 / 2800)
38.0 / 2600
(51.0 / 2600)
Combustion Chamber Troiddal Type (Direct Injection)
Fuel Injection Pump Bosch “K” Type Mini Pump
Governor Centrifugal Ball Type, All Speed Mechanical Governor
Direction of Rotation Counter-Clockwise (viewed from flywheel side)
Injection Nozzle Bosch “P” Type Hole Nozzle
Injection Timing 0.192 rad (11 °) Before T.D.C.
Firing Order 1-3-4-2
2
Injection Pressure 1st. Stage 18.6 MPa (190 kgf/cm
2nd. Stage 22.6 MPa (230 kgf/cm
, 2702 psi)
2
, 3271 psi)
Compression Ratio 20
Lubricating System Forced Lubrication by Trochoid Pump
Cooling System Pressurized radiation, forced circulation with water pump
Starting System Electric Starting with Starter
12 V, 1.4 kW 12 V, 2.0 kW
Starting Suport Device Pre-heating by Glow Plug in Combustion Chamber
Battery 12 V, 88 A (115E41R) 12 V, 92 A (130E41R)
Charging Alternator 12 V, 480 W
Fuel Diesel Fuel No.2-D or No.2-DLS
Lubricating Oil Better than CD class (API)
Lubricating Oil
Capacity
Oil Pan Depth
90 mm (3.54 in.)
Oil Pan Depth
124 mm (4.88 in.)
7.6 L (2.01 U.S.gals)
9.5 L (2.51 U.S.gals)
Weight (Dry) BB spec. kg (lbs) 180 (397) 184 (406)
* The specification described above is of the standard engine of each model.
* Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW
W10299960
5
03-M-DI Series, WSM
KiSC issued 10, 2009 A
DIMENSIONS
DIMENSIONS
D1503-M-DI D1503-M-DI-T D1703-M-DI D1803-M-DI
A 599.2 mm
(23.59 in.)
B 643.5 mm
(25.33 in.)
C 414.2 mm
(16.31 in.)
D 229.3 mm
(9.03 in.)
E 514.4 mm
(20.25 in.)
599.2 mm
(23.59 in.)
644.0 mm
(25.35 in.)
414.2 mm
(16.31 in.)
229.8 mm
(9.05 in.)
514.4 mm
(20.25 in.)
572.1 mm
(22.52 in.)
643.3 mm
(25.33 in.)
414.0 mm
(16.30 in.)
229.3 mm
(9.03 in.)
507.1 mm
(19.96 in.)
575.9 mm
(22.67 in.)
685.0 mm
(26.97 in.)
419.0 mm
(16.50 in.)
266.0 mm
(10.47 in.)
499.0 mm
(19.65 in.)
W1031045
6
03-M-DI Series, WSM
KiSC issued 10, 2009 A
DIMENSIONS
V2203-M-DI V2403-M-DI
A 667.1 mm
(26.26 in.)
B 635.0 mm
(25.00 in.)
C 414.0 mm
(16.30 in.)
D 221.0 mm
(8.70 in.)
E 507.1 mm
(19.96 in.)
670.9 mm
(26.41 in.)
684.5 mm
(26.95 in.)
419.0 mm
(16.50 in.)
265.5 mm
(10.45 in.)
499.0 mm
(19.65 in.)
W1031355
7
MECHANISM
KiSC issued 10, 2009 A
CONTENTS
1. ENGINE BODY ............................................................................................... M-1
[1] HOLLOW CORE ....................................................................................... M-1
[2] PISTON...................................................................................................... M-1
[3] BUILT-IN DYNAMIC BALANCER (BALANCER MODEL ONLY) ......... M-2
[4] HALF-FLOATING HEAD COVER ............................................................ M-2
2. COOLING SYSTEM........................................................................................ M-3
[1] BOTTOM BYPASS SYSTEM................................................................... M-3
3. FUEL SYSTEM ............................................................................................... M-4
[1] GOVERNOR .............................................................................................. M-4
4. ELECTRICAL SYSTEM .................................................................................. M-6
[1] STARTER AUTO REDUCTION UNIT..................................................... M-6
(1) General ................................................................................................ M-6
(2) Basic Circuit ......................................................................................... M-6
(3) Component .......................................................................................... M-7
(4) Function ............................................................................................... M-7
03-M-DI Series, WSM
KiSC issued 10, 2009 A
1. ENGINE BODY
[1] HOLLOW CORE
[2] PISTON
DIESEL ENGINE
The cylinder block has a hollow core (1) already cast
inside the cylinder-to-cylinder water jacket.
In this core, there is a pair of vertical cooling
passages (right and left) as well as multiple horizontal
cooling channels that interconnect these cooling
passages. This design allows smoother cooling water
flow through the cylinder block, which cools down a wider
range between the cylinders more effectively.
(1) Hollow Core
W1013048
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
2)
W1013114
M-1
03-M-DI Series, WSM
KiSC issued 10, 2009 A
DIESEL ENGINE
[3] 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 V2203 and V2403 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
W1013221
[4] HALF-FLOATING HEAD COVER
The rubber packing (2) is fitted in to maintain the
cylinder head cover (1) 0.5 mm 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-2
03-M-DI Series, WSM
KiSC issued 10, 2009 A
2. COOLING SYSTEM
[1] BOTTOM BYPASS SYSTEM
DIESEL ENGINE
Bottom bypass system is introduced in 03-M-DI
Series for improving the cooling performance of the
radiator.
While the temperature of coolant in the engine is low,
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-3
03-M-DI Series, WSM
KiSC issued 10, 2009 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
Q At Start
Flowing of the battery current into the engine stop
solenoid (16), the plunger (17) is actuated to arrow
direction.
Since the steel ball (1) have no centrifugal force, the
control rack (14) is pushed to the right by the start spring
(13). Accordingly, the control rack (14) moves to the
maximum injection position to assure easy starting.
(13) Start Spring
(14) Control Rack
(15) Injection Pump
(16) Engine Stop Solenoid
(17) Plunger
(18) Guide
(19) Idling Apparatus
W1017215
M-4
03-M-DI Series, WSM
KiSC issued 10, 2009 A
DIESEL ENGINE
Q At Idling
When the speed control lever is set at the idling
position after the engine starts, the governor spring 1 (7)
does not work at all and the governor spring 2 (8) does
only act slightly. The governor sleeve (2) is pushed
leftward by a centrifugal force of steel ball (1).
Therefore, the fork lever 1 (10) and control rack (14)
are moved to the left by the governor sleeve (2) and then
the start spring (13) is compressed by the control rack
(14). As a result, the control rack (14) is kept at a position
where a centrifugal force of steel ball (1) and forces of
start spring (13), governor spring 2 (8) are balanced,
providing stable idling.
(1) Steel Ball
(2) Governor Sleeve
(6) Governor Lever
(7) Governor Spring 1
(8) Governor Spring 2
(10) Fork Lever 1
(13) Start Spring
(14) Control Rack
W1017317
Q At High Speed Running with Overload
When an overload is applied to the engine running at
a high speed, the centrifugal force of steel ball (1)
becomes small as the engine speed is dropped, and fork
lever 2 (9) is pulled to the right by the governor springs 1
(7) and 2 (8), increasing fuel injection. Though, fork lever
2 (9) becomes ineffective in increasing fuel injection
when it is stopped by the adjusting screw (21).
After that, when the force of torque spring (20)
becomes greater than the centrifugal force of the steel
ball (1), fork lever 1 (10) moves rightward to increase fuel
injection, causing the engine to run continuously at a high
torque.
(1) Steel Ball
(7) Governor Spring 1
(8) Governor Spring 2
(9) Fork Lever 2
(10)Fork Lever 1
(19) Idling Apparatus
(20) Torque Spring
(21) Adjusting Screw
W1017384
Q To Stop Engine
When the battery current stops, the plunger (17) of
engine stop solenoid (16) is returned to the original
position, the spring (22) to keep the control rack (14) in
“No fuel injection” position.
(14) Control Rack
(16) Engine Stop Solenoid
(17) Plunger
(22) Spring
M-5
W1018007
03-M-DI Series, WSM
KiSC issued 10, 2009 A
DIESEL ENGINE
4. ELECTRICAL SYSTEM
[1] STARTER AUTO REDUCTION UNIT
(1) General
The starter auto reduction unit (7) is designed to start the machine equipped with engine more reliably. This unit
has the following function by integrating an alternator (1) that puts out rpm-proportional pulses.
1. Fail-Safe Functions
a) Preventing the starter pinion from getting in mesh while the engine is runnning.
With the engine running, pulses from the alternator terminal P are constantly detected. Even if key switch (2) is
wrongly operated or the wiring gets short-circuited, the starter (5) can stay off, the starter (5) and flywheel ring gear
are effectively protected.
b) Starter auto reduction at a start of the engine.
When the engine has got started and the alternator (1) has reached the specified rpm, the electical current to the
starter (5) is automatically cut off, even if the key switch (2) is at the START position.
c) Safety mechanism in case of engine stall.
If the engine stalls with the key switch (2) at AC or START position, the key must be set once to OFF position for added
safety. The starter (5) is thus kept from turning on unexpectedly.
2. Other Features and Functions
a) Simplified wiring with built-in power relay.
The unit is internally provided with a power relay to get simpler wiring than ever before. If the key switch terminal AC,
ground cable or any other parts is wrongly connected, the starter (5) stays off. This helps identify wrong wiring more
easily.
b) With the output terminal for confirming engine start (Relay drive possible).
The unit has an external output terminal in order to confirm an engine start. An external relay (6) may also be
connected to this terminal. (Output current : below 200 mA)
(2) Basic Circuit
(1) Alternator
(2) Key Switch
(3) Slow Blow Fuse
(4) Battery
(5) Starter
(6) External Relay
(7) Starter Auto Reduction Unit
W1014160
M-6
03-M-DI Series, WSM
KiSC issued 10, 2009 A
(3) Component
DIESEL ENGINE
(1) Key Switch
(2) Battery
(3) Alternator
(4) P terminal
(5) Detection High rpm (N2)
(6) Delay Curcuit
(7) Detection Low rpm (N1)
(8) Self Holding Circuit
(9) Self Holding Circuit
(10) External Relay
(11) Starter
W1014290
(4) Function
(A) Starter Auto Reduction
a) While Engine is Running
A : Key Switch AC Terminal
(Voltage)
B : Key Switch 50 Terminal
(Voltage)
C : Alternator Revolution
D : Starter ST Terminal
-1
(rpm))
(min
(Voltage)
W1014807
M-7
03-M-DI Series, WSM
KiSC issued 10, 2009 A
b) When Engine Starts Normally
DIESEL ENGINE
A : Key Switch AC Terminal
(Voltage)
B : Key Switch 50 Terminal
(Voltage)
C : Alternator Revolution
D : Starter ST Terminal
N1 :Detection Low rpm
N2 :Detection High rpm
-1
(rpm))
(min
(Voltage)
W1014965
c) When Engine Stalls
A : Key Switch AC Terminal
(Voltage)
B : Key Switch 50 Terminal
(Voltage)
C : Alternator Revolution
D : Starter ST Terminal
-1
(rpm))
(min
(Voltage)
W1015076
M-8
03-M-DI Series, WSM
KiSC issued 10, 2009 A
d) Output Terminal for Confirming Engine Start
DIESEL ENGINE
A : Key Switch AC Terminal
(Voltage)
B : Key Switch 50 Terminal
(Voltage)
C : Alternator Revolution
D : Starter ST Terminal
E : Output for Confirming
N1 :Detection Low rpm
N2 :Detection High rpm
-1
(rpm))
(min
(Voltage)
Engine Start (Voltage)
W1015212
M-9
SERVICING
KiSC issued 10, 2009 A
CONTENTS
1. GENERAL .........................................................................................................S-1
[1] ENGINE IDENTIFICATION ........................................................................S-1
(1) Model Name and Engine Serial Number ..............................................S-1
(2) Cylinder Number ...................................................................................S-2
[2] GENERAL PRECAUTION .........................................................................S-3
[3] TIGHTENING TORQUES ..........................................................................S-4
(1) Tightening Torques for Special Use Screws, Bolts and Nuts ...............S-4
(2) Tightening Torques for General Use Screws, Bolts and Nuts ..............S-4
[4] TROUBLESHOOTING ................................................................................S-5
[5] SERVICING SPECIFICATIONS ................................................................ S-8
[6] MAINTENANCE CHECK LIST ................................................................S-17
[7] CHECK AND MAINTENANCE ................................................................S-19
(1) Daily Check Points..............................................................................S-19
(2) Check Points of Every 50 Hours .........................................................S-20
(3) Check Points of Every 100 Hours .......................................................S-21
(4) Check Point of Every 200 Hours .........................................................S-23
(5) Check Points of Every 400 Hours .......................................................S-24
(6) Check Points of 500 Hours .................................................................S-26
(7) Check Points of Every 1 or 2 Months..................................................S-29
(8) Check Point of Every Year ..................................................................S-31
(9) Check Point of Every 800 Hours .........................................................S-31
(10)Check Points of Every 1500 Hours.....................................................S-32
(11)Check Point of Every 3000 Hours.......................................................S-33
(12)Check Points of Every 2 Years ...........................................................S-33
[8] SPECIAL TOOLS.....................................................................................S-34
2. ENGINE BODY ..............................................................................................S-42
[1] CHECKING AND ADJUSTING ...............................................................S-42
[2] DISASSEMBLING AND ASSEMBLING..................................................S-43
(1) Draining Coolant and Oil.....................................................................S-43
(2) External Components .........................................................................S-43
(3) Cylinder Head and Valves ..................................................................S-44
(4) Timing Gears, Camshaft and Fuel Camshaft......................................S-49
(5) Piston and Connecting Rod ................................................................S-55
(6) Crankshaft...........................................................................................S-58
[3] SERVICING ..............................................................................................S-61
(1) Cylinder Head and Valves ..................................................................S-61
(2) Timing Gears, Camshaft and Fuel Camshaft......................................S-66
(3) Piston and Connecting Rod ................................................................S-70
(4) Crankshaft...........................................................................................S-73
(5) Cylinder...............................................................................................S-79
3. LUBRICATING SYSTEM ...............................................................................S-81
[1] Checking ...................................................................................................S-81
[2] Servicing ...................................................................................................S-82
4. COOLING SYSTEM.......................................................................................S-83
[1] CHECKING AND ADJUSTING ...............................................................S-83
[2] DISASSEMBLING AND ASSEMBLING...................................................S-85
5. FUEL SYSTEM ..............................................................................................S-86
[1] CHECKING AND ADJUSTING ...............................................................S-86
(1) Injection Pump.................................................................................... S-86
KiSC issued 10, 2009 A
(2) Injection Nozzle .................................................................................. S-88
6. ELECTRICAL SYSTEM................................................................................. S-89
[1] CHECKING .............................................................................................. S-89
(1) Starter................................................................................................. S-89
(2) Alternator............................................................................................ S-90
(3) Glow Plug ........................................................................................... S-91
(4) Engine Stop Solenoid......................................................................... S-91
(5) Glow Lamp Relay ............................................................................... S-92
(6) Starter Auto Reduction Unit................................................................ S-92
[2] DISASSEMBLING AND ASSEMBLING ................................................. S-93
(1) Starter................................................................................................. S-93
(2) Alternator............................................................................................ S-93
[3] SERVICING.............................................................................................. S-96
(1) Starter................................................................................................. S-96
(2) Alternator............................................................................................ S-98
(3) Wiring Diagram................................................................................. S-100
7. TURBO CHARGER SYSTEM .................................................................... S-101
[1] CHECKING ............................................................................................ S-101
[2] DISASSEMBLING AND ASSEMBLING ............................................... S-102
03-M-DI Series, WSM
KiSC issued 10, 2009 A
1. GENERAL
[1] ENGINE IDENTIFICATION
(1) Model Name and Engine Serial Number
When contacting the manufacture, always specify your engine
model name and serial number.
The engine model and its serial number need to be identified
before the engine can be serviced or parts replaced.
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 follows.
• Year of manufacture
Alphabet or
Number
• Month of manufacture
January A0001 ~ A9999 B0001 ~
February C0001 ~ C9999 D0001 ~
March E0001 ~ E9999 F0001 ~
April G0001 ~ G9999 H0001 ~
May J0001 ~ J9999 K0001 ~
June L0001 ~ L9999 M0001 ~
July N0001 ~ N9999 P0001 ~
August Q0001 ~ Q9999 R0001 ~
September S0001 ~ S9999 T0001 ~
October U0001 ~ U9999 V0001 ~
November W0001 ~ W9999 X0001 ~
December Y0001 ~ Y9999 Z0001 ~
e.g. D1803-1A0001
“1” indicates 2001 and “A” indicates January.
So, 1A indicates that the engine was manufactured on January,
2001.
DIESEL ENGINE
Year
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
Month
0001 ~ 9999 10000 ~
Alphabet or
Number
Engine Serial Number
Yea r
W1010477
S-1
03-M-DI Series, WSM
KiSC issued 10, 2009 A
(2) Cylinder Number
DIESEL ENGINE
The cylinder numbers of 03-M-DI Series 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
S-2
03-M-DI Series, WSM
KiSC issued 10, 2009 A
[2] GENERAL PRECAUTION
DIESEL ENGINE
• During disassembly, carefully arrange removed parts in a clean
area to prevent confusion later. Screws, bolts and nuts should be
replaced in their original position to prevent reassembly errors.
• When special tools are required, use KUBOTA genuine special
tools. Special tools which are not frequently used should be
made according to the drawings provided.
• 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 rings, 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
(A) External Snap Ring
(B) Internal Snap Ring
W1011734
S-3
03-M-DI Series, WSM
KiSC issued 10, 2009 A
DIESEL ENGINE
[3] TIGHTENING TORQUES
Screws, bolts and nuts must be tightened to the specified torque using a torque wrench, several screws, bolts and
nuts such as those used on the cylinder head must be tightened in proper sequence and the proper torque.
(1) Tightening Torques for Special Use Screws, Bolts and Nuts
NOTEQ
• In removing and applying the screws, bolts and nuts marked with “*”, a pneumatic wrench or similar
pneumatic tool, if employed, must be used with enough care not to get them seized.
• 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 ft-lbs
Cylinder head cover screw
* Cylinder head screw
* Main bearing case screw 1
* Main bearing case screw 2
* Flywheel screw
* Connecting rod screw
* Rocker arm bracket screw
* Idle gear shaft screw
Fan drive pulley mounting nut
* Bearing case cover screw
Glow plug
Nozzle holder clamp screw
Oil Switch taper screw
Injection pipe retaining nut
Overflow pipe assembly retaining screw
Camshaft set screw
Hi-idling body
M6 × 1.0
M11 × 1.25
M9 × 1.25
M10 × 1.25
M12 × 1.25
M8 × 1.0
M8 × 1.25
M8 × 1.25
–
M8 × 1.25
M10 × 1.25
–
PT 1/8
M12 × 1.5
–
M8 × 1.25
–
6.9 to 11.3
93.1 to 98.0
46.1 to 50.9
68.6 to 73.5
98.0 to 107.8
44.1 to 49.0
23.5 to 27.5
23.5 to 27.5
137.3 to 156.9
23.5 to 27.5
19.6 to 24.5
25.5 to 29.4
14.7 to 19.6
14.7 to 24.5
9.8 to 11.3
23.5 to 27.5
44.1 to 49.0
0.7 to 1.15
9.5 to 10.0
4.7 to 5.2
7.0 to 7.5
10.0 to 11.0
4.5 to 5.0
2.4 to 2.8
2.4 to 2.8
14.0 to 16.0
2.4 to 2.8
2.0 to 2.5
2.6 to 3.0
1.5 to 2.0
1.5 to 2.5
1.0 to 1.15
2.4 to 2.8
4.5 to 5.0
5.1 to 8.32
68.7 to 72.3
34.0 to 37.6
50.6 to 54.2
72.3 to 79.5
32.5 to 36.2
17.4 to 20.3
17.4 to 20.3
101.3 to 115.7
17.4 to 20.3
14.5 to 18.1
18.8 to 21.7
10.8 to 14.5
10.8 to 18.1
7.2 to 8.3
17.4 to 20.3
32.6 to 36.3
W1013236
(2) Tightening Torques for General Use Screws, Bolts and Nuts
Grade
Nominal Unit
Diameter
M6 7.9 to 9.3 0.80 to 0.95 5.8 to 6.9 9.8 to 11.3 1.00 to 1.15 7.23 to 8.32
M8 17.7 to 20.6 1.8 to 2.1 13.0 to 15.2 23.5 to 27.5 2.4 to 2.8 17.4 to 20.3
M10 39.2 to 45.1 4.0 to 4.6 28.9 to 33.3 48.1 to 55.9 4.9 to 5.7 35.4 to 41.2
M12 62.8 to 72.6 6.4 to 7.4 46.3 to 53.5 77.5 to 90.2 7.9 to 9.2 57.1 to 66.5
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 SS400, S20C
7 Special screw and bolt S43C, S48C (Refined)
Standard Screw and Bolt
Special Screw and Bolt
N·m kgf·m ft-lbs N·m kgf·m ft-lbs
W10371750
W1012705
S-4
03-M-DI Series, WSM
KiSC issued 10, 2009 A
[4] TROUBLESHOOTING
DIESEL ENGINE
Symptom Probable Cause Solution
Engine Does Not
Start
• No fuel
• Air in the fuel system
• Water in the fuel system
Replenish fuel
Vent air
Change fuel and
repair or replace fuel
system
• Fuel pipe clogged
• Fuel filter clogged
• Excessively high viscosity of fuel or engine oil
at low temperature
• Fuel with low cetane number
• Fuel leak due to loose injection pipe retaining
Clean
Clean or change
Use specified fuel or
engine oil
Use specified fuel
Tighten retaining nut
nut
• Incorrect injection timing
• Fuel camshaft worn
• Injection nozzle clogged
• Injection pump malfunctioning
• Seizure of crankshaft, camshaft, piston,
Adjust
Replace
Replace
Replace
Repair or replace
cylinder or bearing
• Compression leak from cylinder
Replace head
gasket, tighten
cylinder head screw,
glow plug and nozzle
holder
• Improper valve timing
Correct or replace
timing gear
• Piston ring and cylinder worn
• Excessive valve clearance
Replace
Adjust
Reference
Page
–
S-20
S-20, 21,
25
S-20
S-21, 25
–
–
S-44
S-86
S-54
S-88
S-49
–
–
S-53
S-42, 56,
57, 71, 72,
79
S-31
(Starter Does Not
Run)
Engine Revolution Is
Not Smooth
• Battery discharged
• Starter malfunctioning
• Key switch malfunctioning
• Starter auto reduction unit defective
• Wiring disconnected
• Fuel filter clogged or dirty
• Air cleaner clogged
• Fuel leak due to loose injection pipe retaining
nut
• Injection pump malfunctioning
• Incorrect nozzle injection pressure
• Injection nozzle stuck or clogged
• Governor malfunctioning
• Bearing worn out
• Shaft bent
• Fin or other part damaged due to foreign
matters
Charge
Repair or replace
Repair or replace
Replace
Connect
Clean or change
Clean or change
Tighten retaining nut
Replace
Replace
Replace
Repair
Replace the
turbocharger
assembly
Replace the
turbocharger
assembly
Replace the
turbocharger
assembly
S-29
S-89, 93,
96
–
S-92, 100
S-100
S-21, 25
S-21
S-44
S-49
S-88
S-88
S-50, 54
S-101
S-101
S-101
W1014322
S-5
03-M-DI Series, WSM
KiSC issued 10, 2009 A
DIESEL ENGINE
Symptom Probable Cause Solution
Either White or Blue
Exhaust Gas Is
Observed
• Excessive engine oil
• Piston ring and liner worn or stuck
• Incorrect injection timing
• Deficient compression
Reduce to specified
level
Repair or replace
Adjust
Check the cylinder
compression
pressure and top
clearance
Oil Leak into Exhaust
Pipe or Suction Pipe
• Waste oil pipe clogged or deformed
• Piston ring seal faulty
Repair or replace
Replace the
turbocharger
assembly
Either Black or Dark
Gray Exhaust Gas Is
Observed
Deficient Output • Incorrect injection timing
• Overload
• Low grade fuel used
• Fuel filter clogged
• Air cleaner clogged
• Deficient nozzle injection
• Engine’s moving parts seem to be seizing
• Injection pump malfunctioning
• Deficient nozzle injection
• Compression leak
Lessen load
Use specified fuel
Clean or change
Clean or change
Replace nozzle
Adjust
Repair or replace
Replace
Replace nozzle
Check the
compression
pressure and repair
• Gas leak from exhaust system
• Air leak from compressor discharge side
• Air cleaner dirty or clogged
• Compressor wheel turning heavily
Repair or replace
Repair or replace
Clean or replace
Replace the
turbocharger
assembly
Excessive Lubricant
Oil Consumption
• Piston ring’s gap facing the same direction
• Oil ring worn or stuck
• Piston ring groove worn
• Valve stem and valve guide worn
• Crankshaft bearing, and crank pin bearing
Shift ring gap
direction
Replace
Replace piston
Replace
Replace
worn
Fuel Mixed into
Lubricant Oil
Water Mixed into
Lubricant Oil
• Oil leaking due to defective seals or packing
• Injection pump’s plunger worn
• Deficient nozzle injection
• Injection pump broken
• Head gasket defective
• Cylinder block or cylinder head flawed
Replace
Replace injection
pump
Replace nozzle
Replace
Replace
Replace
Reference
Page
S-19
S-42, 56,
57, 71, 72,
79
S-86
S-42
–
S-101
–
–
S-21, 25
S-21
S-88
S-86
–
S-49
S-88
S-42
S-101
S-101
S-24
S-101
S-56
S-56, 71,
72
S-56, 71,
72
S-48, 62,
63
–
–
S-49
S-88
S-49
S-46, 47
S-46, 61
W1014322
S-6
03-M-DI Series, WSM
KiSC issued 10, 2009 A
DIESEL ENGINE
Symptom Probable Cause Solution
Low Oil Pressure • Engine oil insufficient
• Oil strainer clogged
• Relief valve stuck with dirt
• Relief valve spring weaken or broken
• Excessive oil clearance of crankshaft bearing
• Excessive oil clearance of crankpin bearing
• Excessive oil clearance of rocker arm
• Oil passage clogged
• Different type of oil
Replenish
Clean
Clean
Replace
Replace
Replace
Replace
Clean
Use specified type of
oil
• Oil pump defective
High Oil Pressure • Different type of oil
Repair or replace
Use specified type of
oil
• Relief valve defective
Engine Overheated • Engine oil insufficient
• Fan belt broken or elongated
• Coolant insufficient
• Radiator net and radiator fin clogged with
Replace
Replenish
Replace or adjust
Replenish
Clean
dust
Battery Quickly
Discharge
• Inside of radiator corroded
• Coolant flow route corroded
• Radiator cap defective
• Overload running
• Head gasket defective
• Incorrect injection timing
• Unsuitable fuel used
• Battery electrolyte insufficient
• Fan belt slips
Clean or replace
Clean or replace
Replace
Loosen load
Replace
Adjust
Use specified fuel
Replenish distilled
water and charge
Adjust belt tension or
change
• Wiring disconnected
• Rectifier defective
• Alternator defective
Connect
Replace
Replace
Reference
Page
S-19
S-55
–
–
S-60, 75,
76, 77, 78
S-56, 74
S-45, 65
–
S-23
S-54, 81,
82
S-23
–
S-19
S-22, 28
S-19
–
S-26
–
S-84
–
S-46, 47
S-86
–
S-21, 29
S-22, 28
S-100
S-93, 99
S-93
• Battery defective
S-7
Change
–
W1014322
03-M-DI Series, WSM
KiSC issued 10, 2009 A
DIESEL ENGINE
[5] SERVICING SPECIFICATIONS
ENGINE BODY
Item Factory Specification Allowable Limit
Cylinder Head Surface Flatness – 0.05 mm / 500 mm
0.0020 in. /
19.69 in.
Compression Pressure
(When Cranking with Starting Motor)
2.94 to 3.24 MPa /
290 min
30 to 33 kgf/cm
290 min
427 to 469 psi /
290 min
-1
(rpm)
-1
(rpm)
-1
(rpm)
2
/
2.35 MPa /
290 min
24 kgf/cm
290 min
341 psi /
290 min
-1
(rpm)
-1
(rpm)
-1
(rpm)
2
/
Difference among Cylinders
–
Top Clearance 0.60 to 0.70 mm
0.0236 to 0.0276 in.
Valve Clearance (When Cold) 0.18 to 0.22 mm
0.0071 to 0.0087 in.
Valve Seat Width (Intake)
2.12 mm
0.0835 in.
Width (Exhaust)
2.12 mm
0.0835 in.
Valve Seat Angle (Intake)
1.047 rad
60 °
Angle (Exhaust)
0.785 rad
45 °
Valve Face Angle (Intake)
1.047 rad
60 °
Angle (Exhaust)
0.785 rad
45 °
Valve Stem to Valve Guide
Clearance
0.040 to 0.070 mm
0.0016 to 0.0028 in.
10 % or less
–
–
–
–
–
–
–
–
0.1 mm
0.0039 in.
Valve Stem
Valve Guide
Valve Recessing Protrusion
O.D.
I.D.
Recessing
S-8
7.960 to 7.975 mm
0.31339 to 0.31398 in.
8.015 to 8.030 mm
0.31555 to 0.31614 in.
0.65 mm
0.026 in.
to
0.85 mm
0.033 in.
–
–
–
1.20 mm
0.0472 in.
W1013874
03-M-DI Series, WSM
KiSC issued 10, 2009 A
ENGINE BODY (Continued)
Item Factory Specification Allowable Limit
Valve Timing (Intake Valve) Open
0.16 rad (9 °)
before T.D.C.
DIESEL ENGINE
–
Close
0.79 rad (45 °)
–
after B.D.C.
Valve Timing (Exhaust Valve) Open
0.87 rad (50 °)
–
before B.D.C.
Close
0.21 rad (12 °)
–
after T.D.C.
Valve Spring Free Length
Setting Load /
Setting Length
Tilt
41.7 to 42.2 mm
1.6417 to 1.6614 in.
117.6 N / 35.0 mm
12.0 kgf / 35.0 mm
26.4 lbs / 1.3780 in.
–
41.2 mm
1.6220 in.
100.0 N / 35.0 mm
10.2 kgf / 35.0 mm
22.5 lbs /1.3780 in.
1.0 mm
0.039 in.
Rocker Arm Shaft to Rocker Arm
Rocker Arm Shaft
Clearance
O.D.
0.016 to 0.045 mm
0.00063 to 0.00177 in.
13.973 to 13.984 mm
0.1 mm
0.0039 in.
–
0.55012 to 0.55055 in.
Rocker Arm
I.D.
14.000 to 14.018 mm
–
0.55118 to 0.55189 in.
Push Rod Alignment – 0.25 mm
0.0098 in.
Tappet to Tappet Guide
Clearance
0.020 to 0.062 mm
0.00079 to 0.00244 in.
0.07 mm
0.0028 in.
Tappet
Tappet Guide
O.D.
I.D.
S-9
23.959 to 23.980 mm
0.94327 to 0.94410 in.
24.000 to 24.021 mm
0.94488 to 0.94571 in.
–
–
W1013874
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