Karcher HDS13-80 User Manual [en, de, es, fr, it]
Kubota Diesel Engine
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5.963-388.0 05/09
CONTENTS
SAFE OPERATION .................................................................................................. 1
SERVICING OF THE ENGINE .................................................................................... 1
NAMES OF PARTS .....................................................................................................2
PRE-OPERATION CHECK .......................................................................................... 3
BREAK-IN.................................................................................................................3
DAILY CHECK..........................................................................................................3
OPERATING THE ENGINE ......................................................................................... 4
STARTING THE ENGINE(NORMAL) .......................................................................4
COLD WEATHER STARTING ................................................................................. 5
STOPPING THE ENGINE ........................................................................................ 6
CHECKS DURING OPERATION .............................................................................6
Radiator Cooling water(Coolant) ...................................................................................... 6
Oil pressure lamp ............................................................................................................. 6
Fuel .................................................................................................................................. 7
Color of exhaust ............................................................................................................... 7
Immediately stop the engine if;......................................................................................... 7
REVERSED ENGINE REVOLUTION AND REMEDIES ..........................................7
How to tell when the engine starts running backwards .................................................... 7
Remedies ......................................................................................................................... 7
MAINTENANCE ...........................................................................................................8
SERVICE INTERVALS .............................................................................................9
PERIODIC SERVICE ................................................................................................. 12
FUEL ...................................................................................................................... 12
Fuel level check and refueling ........................................................................................ 12
Air bleeding the fuel system ........................................................................................... 13
Checking the fuel pipes .................................................................................................. 14
Cleaning the fuel filter pot............................................................................................... 14
Fuel filter cartridge replacement ..................................................................................... 15
ENGINE OIL ...........................................................................................................15
Checking oil level and adding engine oil ........................................................................ 15
Changing engine oil........................................................................................................ 16
Replacing the oil filter cartridge ...................................................................................... 17
RADIATOR .............................................................................................................17
Checking coolant level, adding coolant .......................................................................... 18
Changing coolant ........................................................................................................... 19
Remedies for quick decrease of coolant ........................................................................ 19
Checking radiator hoses and clamp bands .................................................................... 19
Precaution at overheating .............................................................................................. 19
Cleaning radiator core(outside) ...................................................................................... 19
Anti-freeze ...................................................................................................................... 20
Radiator cement ............................................................................................................. 20
AIR CLEANER........................................................................................................21
Evacuator valve.............................................................................................................. 21
For the air cleaner with a dust cup (optional) ................................................................. 21
Dust indicator (optional) ................................................................................................. 22
BATTERY ...............................................................................................................22
Battery charging ............................................................................................................. 22
ENGLISH
ENGLISH
CONTENTS
Direction for long term storage ....................................................................................... 23
ELECTRIC WIRING ............................................................................................... 23
FAN BELT ..............................................................................................................24
Adjusting Fan Belt Tension ............................................................................................ 24
CARRIAGE AND STORAGE .....................................................................................25
CARRIAGE ............................................................................................................. 25
STORAGE ..............................................................................................................25
TROUBLESHOOTING ............................................................................................... 26
SPECIFICATIONS ..................................................................................................... 28
WIRING DIAGRAMS.................................................................................................. 31
FOREWORD
You are now the proud owner of a KUBOTA Engine. This engine is a
product of KUBOTA quality engineering and manufacturing. It is made
of fine materials and under a rigid quality control system. It will give
you long, satisfactory service. To obtain the best use of your engine,
please read this manual carefully. It will help you become familiar with
the operation of the engine and contains many helpful hints about
engine maintenance. It is KUBOTA's policy to utilize as quickly as
possible every advance in our research. The immediate use of new
techniques in the manufacture of products may cause some small
parts of this manual to be outdated. KUBOTA distributors and dealers
will have the most up-to-date information. Please do not hesitate to
consult with them.
ENGLISH
3
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 assemble or use this unit.
DANGER : Indicates an imminently hazardous situation which,
3
WARNING : Indicates a potentially hazardous situation which,
3
CAUTION : Indicates a potentially hazardous situation which,
3
IMPORTANT : Indicates that equipment or property damage
NOTE : Gives helpful information.
SAFETY FIRST
if not avoided, will result in death or serious
injury.
if not avoided, could result in death or serious
injury.
if not avoided, may result in minor or moderate
injury.
could result if instructions are not followed.
ENGLISH
SAFE OPERATION
1SAFE OPERATION
Careful operation is your best assurance against an accident. Read and understand this
section carefully before operating the engine. All operators, no matter how much
experience they may have, should read this and other related manuals before operating
the engine or any equipment attached to it. It is the owner's obligation to provide all
operators with this information and instruct them on safe operation.
Be sure to observe the following for safe operation.
OBSERVE SAFETY INSTRUCTIONS
1.
A Read and understand carefully this "OPERATOR'S
MANUAL" and "LABELS ON THE ENGINE" before
attempting to start and operate the engine.
A Learn how to operate and work safely. Know your
equipment and its limitations. Always keep the engine in
good condition.
A Before allowing other people to use your engine, explain
how to operate and have them read this manual before
operation.
A DO NOT modify the engine. UNAUTHORIZED
MODIFICATIONS to the engine may impair the function
and/or safety and affect engine life. If the engine does not
perform properly, consult your local Kubota Engine
Distributor first.
2. WEAR SAFE CLOTHING AND PERSONAL PROTECTIVE EQUIPMENT (PPE)
A DO NOT wear loose, torn or bulky clothing around the
machine that may catch on working controls and
projections or into fans, pulleys and other moving parts
causing personal injury.
A Use additional safety items-PPE, e.g. hard hat, safety
protection, safety goggles, gloves, etc., as appropriate or
required.
A DO NOT operate the machine or any equipment attached
to it while under the influence of alcohol, medication, or
other drugs, or while fatigued.
A DO NOT wear radio or music headphones while
operating the engine.
ENGLISH
SAFE OPERATION2
3. CHECK BEFORE STARTING & OPERATING THE ENGINE
ENGLISH
A Be sure to inspect the engine before operation. Do not
operate the engine if there is something wrong with it.
Repair it immediately.
A Ensure all guards and shields are in place before
operating the engine. Replace any that are damaged or
missing.
A Check to see that you and others are a safe distance
from the engine before starting.
A Always keep the engine at least 3 feet (1 meter) away
from buildings and other facilities.
A DO NOT allow children or livestock to approach the
machine while the engine is running.
A DO NOT start the engine by shorting across starter
terminals. The machine may start in gear and move. Do
not bypass or defeat any safety devices.
4. KEEP THE ENGINE AND SURROUNDINGS CLEAN
A Be sure to stop the engine before cleaning.
A Keep the engine clean and free of accumulated dirt,
grease and trash to avoid a fire. Store flammable fluids in
proper containers and cabinets away from sparks and
heat.
A Check for and repair leaks immediately.
A DO NOT stop the engine without idling; Allow the engine
to cool down, first. Keep the engine idling for about 5
minutes before stopping unless there is a safety problem
that requires immediate shut down.
5. SAFE HANDLING OF FUEL AND LUBRICANTS -KEEP AWAY FROM FIRE
A Always stop the engine before refueling and/or
lubricating.
A DO NOT smoke or allow flames or sparks in your work
area. Fuel is extremely flammable and explosive under
certain conditions.
A Refuel at a well ventilated and open place. When fuel
and/or lubricants are spilled, refuel after letting the
engine cool down.
A DO NOT mix gasoline or alcohol with diesel fuel. The
mixture can cause a fire or severe engine damage.
A Do not use unapproved containers e.g. buckets, bottles,
jars. Use approved fuel storage containers and
dispensers.
3SAFE OPERATION
6. EXHAUST GASES & FIRE PREVENTION
A Engine exhaust fumes can be very harmful if allowed to
accumulate. Be sure to run the engine in a well ventilated
location and where there are no people or livestock near
the engine.
A The exhaust gas from the muffler is very hot. To prevent
a fire, do not expose dry grass, mowed grass, oil or any
other combustible materials to exhaust gas. Keep the
engine and muffler clean at all times.
A To avoid a fire, be alert for leaks of flammable
substances from hoses and lines. Be sure to check for
leaks from hoses or pipes, such as fuel and hydraulic
fluid by following the maintenance check list.
A To avoid a fire, do not short across power cables and
wires. Check to see that all power cables and wirings are
in good condition. Keep all electrical connections clean.
Bare wire or frayed insulation can cause a dangerous
electrical shock and personal injury.
7. ESCAPING FLUID
A Relieve all pressure in the air, the oil and the cooling
systems before disconnecting any lines, fittings or
related items.
A Be cautious of possible pressure relief when
disconnecting any device from a pressurized system that
utilizes pressure. DO NOT check for pressure leaks with
your hand. High pressure oil or fuel can cause personal
injury.
A Escaping fluid under pressure has sufficient force to
penetrate skin causing serious personal injury.
A Fluid escaping from pinholes may be invisible. Use a
piece of cardboard or wood to search for suspected
leaks: do not use hands and body. Use safety goggles or
other eye protection when checking for leaks.
A If injured by escaping fluid, see a medical doctor
immediately. This fluid can produce gangrene or severe
allergic reaction.
ENGLISH
SAFE OPERATION4
8. CAUTIONS AGAINST BURNS & BATTERY EXPLOSION
ENGLISH
A To avoid burns, be cautious of hot components, e.g.
muffler, muffler cover, radiator, hoses, engine body,
coolants, engine oil, etc. during operation and after the
engine has been shut off.
A DO NOT remove the radiator cap while the engine is
running or immediately after stopping. Otherwise hot
water will spout out from the radiator. Wait until the
radiator is completely cool to the touch before removing
the cap. Wear safety goggles.
A Be sure to close the coolant drain valve, secure the
pressure cap, and fasten the pipe band before operating.
If these parts are taken off, or loosened, it will result in
serious personal injury.
A The battery presents an explosive hazard. When the
battery is being charged, hydrogen and oxygen gases
are extremely explosive.
A DO NOT use or charge the battery if its fluid level is below
the LOWER mark.
Otherwise, the component parts may deteriorate earlier
than expected, which may shorten the service life or
cause an explosion. Immediately, add distilled water until
the fluid level is between the UPPER and LOWER marks.
A Keep sparks and open flames away from the battery,
especially during charging. DO NOT strike a match near
the battery.
A DO NOT check the battery charge by placing a metal
object across the terminals. Use a voltmeter or
hydrometer.
A DO NOT charge a frozen battery. There is a risk of
explosion. When frozen, warm the battery up to at least
16 C (61 F).
9. KEEP HANDS AND BODY AWAY FROM ROTATING PARTS
A Be sure to stop the engine before checking or adjusting
the belt tension and cooling fan.
A Keep your hands and body away from rotating parts,
such as the cooling fan, V-belt, fan drive V-belt, pulley or
flywheel. Contact with rotating parts can cause severe
personal injury.
A DO NOT run the engine without safety guards. Install
safety guards securely before operation.
5SAFE OPERATION
10. ANTI-FREEZE & DISPOSAL OF FLUIDS
A Anti-freeze contains poison. Wear rubber gloves to avoid
personal injury. In case of contact with skin, wash it off
immediately.
A DO NOT mix different types of Anti-freeze. The mixture
can produce a chemical reaction causing harmful
substances. Use approved or genuine KUBOTA Antifreeze.
A Be mindful of the environment and the ecology. Before
draining any fluids, determine the correct way to dispose
of them. Observe the relevant environmental protection
regulations when disposing of oil, fuel, coolant, brake
fluid, filters and batteries.
A When draining fluids from the engine, place a suitable
container underneath the engine body.
A DO NOT pour waste onto the ground, down a drain, or
into any water source. Dispose of waste fluids according
to environmental regulations.
ENGLISH
SAFE OPERATION6
11. CONDUCTING SAFETY CHECKS & MAINTENANCE
ENGLISH
A When inspecting the engine or servicing, place the
engine on a large flat surface. DO NOT work on anything
that is supported ONLY by lift jacks or a hoist. Always use
blocks or the correct stands to support the engine before
servicing.
A Disconnect the battery from the engine before
conducting service. Put a "DO NOT OPERATE!" tag on
the key switch to avoid accidental starting.
A To avoid sparks from an accidental short circuit always
disconnect the battery's ground cable (-) first and
reconnect it last.
A Be sure to stop the engine and remove the key when
conducting daily and periodic maintenance, service and
cleaning.
A Check or conduct maintenance after the engine, coolant,
muffler, or muffler cover have cooled off completely.
A Always use the appropriate tools and fixtures. Verify that
they are in good condition before performing any service
work. Make sure you understand how to use them before
service.
A Use ONLY correct engine barring techniques for
manually rotating the engine. DO NOT attempt to rotate
the engine by pulling or prying on the cooling fan and Vbelt. This practice can cause serious personal injury or
premature damage to the cooling fan and belt.
A Replace fuel pipes and lubricant pipes with their hose
clamps every 2 years or earlier whether they are
damaged or not. They are made of rubber and age
gradually.
A When servicing is performed together by two or more
persons, take care to perform all work safely.
A Keep a first aid kit and fire extinguisher handy at all times.
7SAFE OPERATION
12. WARNING AND CAUTION LABELS
Part No.19077-8724-1 or 16667-8724-1
(55mm in diameter) (37mm in diameter)
Part No.TA040-4957-1
Do not get your hands close
to engine fan and fan belt.
13. CARE OF WARNING AND CAUTION LABELS
1. Keep warning and caution labels clean and free from obstructing material.
2. Clean warning and caution labels with soap and water, dry with a soft cloth.
3. Replace damaged or missing warning and caution labels with new labels from your local
KUBOTA dealer.
4. If a component with warning and caution label(s) affixed is replaced with a new part, make
sure the new label(s) is (are) attached in the same location(s) as the replaced component.
5. Mount new warning and caution labels by applying to a clean dry surface and pressing any
bubbles to the outside edge.
ENGLISH
8 SAFE OPERATION
ENGLISH
SERVICING OF THE ENGINE
1SERVICING OF THE ENGINE
Your dealer is interested in your new engine and has the
desire to help you get the most value from it. After reading
this manual thoroughly, you will find that you can do some
of the regular maintenance yourself.
However, when in need of parts or major service, be sure
to see your KUBOTA dealer.
For service, contact the KUBOTA Dealership from which
you purchased your engine or your local KUBOTA dealer.
When in need of parts, be prepared to give your dealer
the engine serial number.
Locate the serial number now and record them in the
space provided.
Type Serial No.
Engine
Date of Purchase
Name of Dealer
(To be filled in by purchaser)
ENGLISH
(1) Engine serial number
2 NAMES OF PARTS
NAMES OF PARTS
ENGLISH
(1) Intake manifold
(2) Speed control lever
(3) Engine stop lever
(4) Injection pump
(5) Fuel feed pump
(6) Cooling fan
(7) Fan drive pulley
(8) Oil filter cartridge
(9) Water drain cock
(10) Oil filler plug
(11) Exhaust manifold
(12) Alternator
(13) Starter
(14) Oil level gauge
(15) Oil pressure switch
(16) Flywheel
(17) Oil drain plug
(18) Oil pan
(19) Engine hook
PRE-OPERATION CHECK
BREAK-IN
During the engine break-in period, observe the following by all means:
1. Change engine oil and oil filter cartridge after the first 50 hours of operation. (See "ENGINE OIL" in "PERIODIC
SERVICE" section.)
2. When ambient temperature is low, operate the machine after the engine has been completely warmed up.
DAILY CHECK
To prevent trouble from occurring, it is important to know the conditions of the engine well. Check it before starting.
To avoid personal injury:
A Be sure to install shields and safeguards attached to the engine when operating.
A Stop the engine at a flat and wide space when checking.
A Keep dust or fuel away from the battery, wiring, muffler and engine to prevent a fire.
Check and clear them before operating everyday. Pay attention to the heat of the
exhaust pipe or exhaust gas so that it can not ignite trash.
Item Ref. page
1. Parts which had trouble in previous operation -
2. By walking around the machine (1) Oil or water leaks 15 to 20
(2) Engine oil level and contamination 15,16
(3) Amount of fuel 12
(4) Amount of coolant 18 to 20
(5) Dust in air cleaner dust cup 21
(6) Damaged parts and loosened bolts and nuts -
3. By inserting the key into the starter
switch
4. By starting the engine (1) Color of exhaust fumes 7
(1) Proper functions of meters and pilot lamps; no stains on
these parts
(2) Proper function of glow lamp timer -
(2) Unusual engine noise 7
(3) Engine start-up condition 5
(4) Slow-down and acceleration behavior 7
-
3PRE-OPERATION CHECK
ENGLISH
4 OPERATING THE ENGINE
OPERATING THE ENGINE
ENGLISH
STARTING THE ENGINE(NORMAL)
To avoid personal injury:
A Do not allow children to approach the
machine while the engine is running.
A Be sure to install the machine on
which the engine is installed, on a flat
place.
A Do not run the engine on gradients.
A Do not run the engine in an enclosed
area. Exhaust gas can cause air
pollution and exhaust gas poisoning.
A Keep your hands away from rotating
parts (such as fan, pulley, belt,
flywheel etc.) during operation.
A Do not operate the machine while
under the influence of alcohol or
drugs.
A Do not wear loose, torn or bulky
clothing around the machine. It may
catch on moving parts or controls,
leading to the risk of accident. Use
additional safety items, e.g. hard hat,
safety boots or shoes, eye and
hearing protection, gloves, etc., as
appropriate or required.
A Do not wear radio or music
headphones while operating engine.
A Check to see if it is safe around the
engine before starting.
A Reinstall safeguards and shields
securely and clear all maintenance
tools when starting the engine after
maintenance.
A Do not use ether or any starting fluid for starting the
engine, or a severe damage will occur.
A When starting the engine after a long storage (of more
than 3 months), first set the stop lever to the "STOP"
position and then activate the starter for about 10
seconds to allow oil to reach every engine part.
1. Set the fuel lever to the "ON" position.
(1) Fuel lever (A) "ON"
2. Place the engine stop lever to the
"START" position.
3. Place the speed control lever at more
than half "OPERATION".
(1) Engine stop lever
(2) Speed Control lever
(B) "OFF"
(A) "STOP"
(B) "START"
(C) "IDLING"
(D) "OPERATION"
5OPERATING THE ENGINE
4. Insert the key into the key switch and
turn it to the "OPERATION" position.
(A) "OFF" SWITCHED OFF
(B) "ON" OPERATION
(C) "GL" PREHEATING
(D) "ST" STARTING
(A) "GL" PREHEATING
(B) "OFF" SWITCHED OFF
(C) "ON" OPERATION
(D) "ST" STARTING
5. Turn the starter switch to the
"PREHEATING" position to allow the
glow lamp to redden.
(with lamp timer in use)
A The glow lamp goes out in about 5 seconds when the
lamp timer is up. Refer to this for pre-heating.
Even with the glow lamp off, the glow plug can be preheated by turning the starter switch to the
"PREHEATING" position.
6. Turn the key to the "STARTING"
position and the engine should start.
Release the key immediately when the
engine starts.
7. Check to see that the oil pressure lamp
and charge lamp are off. If the lamps
are still on, immediately stop the
engine, and determine the cause.
(See "CHECKS DURING OPERATION" in
"OPERATING THE ENGINE" section.)
A If the oil pressure lamp should be still on, immediately
stop the engine and check;
- if there is enough engine oil.
- if the engine oil has dirt in it.
- if the wiring is faulty.
8. Warm up the engine at medium speed
without load.
A If the glow lamp should redden too quickly or too
slowly, immediately ask your KUBOTA dealer to
check and repair it.
A If the engine does not catch or start at 10 seconds
after the starter switch is set at "STARTING" position,
wait for another 30 seconds and then begin the engine
starting sequence again. Do not allow the starter
motor to run continuously for more than 20 seconds.
COLD WEATHER STARTING
If the ambient temperature is below -5 C(23 F)* and the
engine is very cold, start it in the following manner:
Take steps (1) through (4) above.
5. Turn the key to the "PREHEATING"
position and keep it there for a certain
period mentioned below.
A Shown below are the standard preheating times for
various temperatures. This operation, however, is not
required, when the engine is warmed up.
Ambient temperature Preheating time
Above 10 C (50 F) NO NEED
10 C (50 F) to -5 C (23 F)
*Below -5 C (23 F)
Limit of continuous use
6. Turn the key to the "STARTING"
position and the engine should start.
(If the engine fails to start after 10 seconds, turn off
the key for 5 to 30 seconds. Then repeat steps (5)
and (6).)
A Do not allow the starter motor to run continuously for
more than 20 seconds.
A Be sure to warm up the engine, not only in winter, but
also in warmer seasons. An insufficiently warmed-up
engine can shorten its service life.
A When there is fear of temperature dropping below
-15 C (5 F) detach the battery from the machine, and
keep it indoors in a safe area, to be reinstalled just
before the next operation.
Approx. 5 seconds
Approx. 10 seconds
20 seconds
ENGLISH
OPERATING THE ENGINE6
STOPPING THE ENGINE
1. Return the speed control lever to low
ENGLISH
idle, and run the engine under idling
conditions.
2. Set the engine stop lever to the "STOP"
position.
3. With the starter switch placed to the
"SWITCHED OFF" position, remove the
key. (Be sure to return the engine stop
lever to the "START" position to be
ready for the next start.)
(1) Engine stop lever
(2) Speed control lever
A If equipped with a turbo-charger, allow the engine to
idle for 5 minutes before shutting it off after a full load
operation.
Failure to do so may lead to turbo-charger trouble.
(A) "STOP"
(B) "START"
(C) "IDLING"
(D) "OPERATION"
CHECKS DURING OPERATION
While running, make the following checks to see that all
parts are working correctly.
BRadiator Cooling water(Coolant)
To avoid personal injury:
A Do not remove radiator cap until
coolant temperature is well below its
boiling point. Then loosen cap
slightly to the stop position, to
relieve any pressure, before
removing cap completely.
When the engine overheats and hot coolant overflows
through the radiator and hoses, stop the engine
immediately and make the following checks to determine
the cause of trouble:
Check item
1. Check to see if there is any coolant leak;
2. Check to see if there is any obstacle around the
cooling air inlet or outlet;
3. Check to see if there is any dirt or dust between
radiator fins and tube;
4. Check to see if the fan belt is too loose;
5. Check to see if radiator water pipe is clogged; and
6. Check to see if anti-freeze is mixed to a 50/50% mix of
water and anti-freeze.
BOil pressure lamp
The lamp lights up to warn the operator that the engine oil
pressure has dropped below the prescribed level. If this
should happen during operation or should not go off even
after the engine is accelerated more than 1000rpm,
immediately stop the engine and check the following:
1. Engine oil level (See "ENGINE OIL" in "PERIODIC
SERVICE" section.)
2. Lubricant system (See "ENGINE OIL" in "PERIODIC
SERVICE" section.)
7OPERATING THE ENGINE
BFuel
To avoid personal injury:
A Fluid escaping from pinholes may be
invisible. Do not use hands to search
for suspected leaks; Use a piece of
cardboard or wood, instead. If
injured by escaping fluid, see a
medical doctor at once. This fluid can
produce gangrene or a severe
allergic reaction.
A Check any leaks from fuel pipes or
fuel injection pipes. Use eye
protection when checking for leaks.
Be careful not to empty the fuel tank. Otherwise air may
enter the fuel system, requiring fuel system bleeding.
(See "FUEL" in "PERIODIC SERVICE" section.)
BColor of exhaust
While the engine is run within the rated output range:
A The color of exhaust remains colorless.
A If the output slightly exceeds the rated level, exhaust
may become a little colored with the output level kept
constant.
A If the engine is run continuously with dark exhaust
emission, it may lead to trouble with the engine.
BImmediately stop the engine if;
A The engine suddenly slows down or accelerates.
A Unusual noises are suddenly heard.
A Exhaust fumes suddenly become very dark.
A The oil pressure lamp or the water temperature alarm
lamp lights up.
REVERSED ENGINE REVOLUTION AND REMEDIES
ENGLISH
To avoid personal injury:
A Reversed engine operation can make
the machine reverse and run it
backwards. It may lead to serious
trouble.
A Reversed engine operation may
make exhaust gas gush out into the
intake side and ignite the air cleaner;
It could catch fire.
Reversed engine revolution must be stopped immediately
since engine oil circulation is cut quickly, leading to
serious trouble.
BHow to tell when the engine starts running
backwards
1. Lubricating oil pressure drops sharply. Oil pressure
warning light, if used, will light.
2. Since the intake and exhaust sides are reversed, the
sound of the engine changes, and exhaust gas will
come out of the air cleaner.
3. A louder knocking sound will be heard when the
engine starts running backwards.
BRemedies
1. Immediately set the engine stop lever to the "STOP"
position to stop the engine.
2. After stopping the engine, check the air cleaner, intake
rubber tube and other parts, and then replace parts as
needed.
8 MAINTENANCE
MAINTENANCE
ENGLISH
To avoid personal injury:
A Be sure to conduct daily checks,
periodic maintenance, refueling or
cleaning on a level surface with the
engine shut off and remove the key.
A Before allowing other people to use
your engine, explain how to operate,
and have them read this manual
before operation.
A When cleaning any parts, do not use
gasoline but use regular cleanser.
A Always use proper tools, that are in
good condition. Make sure you
understand how to use them, before
performing any service work.
A When installing, be sure to tighten all
bolts lest they should be loose.
Tighten the bolts by the specified
torque.
A Do not put any tools on the battery,
or battery terminals may short out.
Severe burns or fire could result.
Detach the battery from the engine
before maintenance.
A Do not touch muffler or exhaust
pipes while they are hot; Severe
burns could result.
SERVICE INTERVALS
Observe the following for service and maintenance.
The lubricating oil change intervals listed in the table below are for Class CF lubricating oil of API classification with a lowsulfur fuel in use. If the CF-4, CG-4, CH-4 or CI-4 lubricating oil is used with a high-sulfur fuel, change the lubricating oil
at shorter intervals than recommended in the table below depending on the operating condition. (approximately half)
Interval Item
Every 50 hours Check of fuel pipes and clamp bands 14 @
See NOTE Change of engine oil (depending on the oil pan) 15 to 17
Cleaning of air cleaner element 21 *1 @
Cleaning of fuel filter 14
Every 100 hours
Check of battery electrolyte level 22,23
Check of fan belt tightness 24
Draining water separator -
Check of radiator hoses and clamp bands 19
Every 200 hours
Replacement of oil filter cartridge (depending on the
oil pan)
Check of intake air line - @
Every 400 hours
Replacement of fuel filter cartridge 15 @
Cleaning of water separator -
Removal of sediment in fuel tank -
Every 500 hours
Cleaning of water jacket (radiator interior) 18 to 20
Replacement of fan belt 24
Every one or two
months
Recharging of battery 22,23
Every year Replacement of air cleaner element 21 *2 @
Every 800 hours Check of valve clearance 26
Every 1500 hours Check of fuel injection nozzle injection pressure - *3 @
Every 3000 hours
Check of turbo charger - *3 @
Check of injection pump - *3 @
Change of radiator coolant (L.L.C.) 18 to 20
Replacement of battery 22,23
Every two years
Replacement of radiator hoses and clamp bands 19
Replacement of fuel pipes and clamp bands 14 *3 @
Replacement of intake air line - *4 @
Ref.
page
17
9MAINTENANCE
ENGLISH
10 MAINTENANCE
A The jobs indicated by must be done after the first 50 hours of operation.
*1 Air cleaner should be cleaned more often in dusty conditions than in normal conditions.
*2 After 6 times of cleaning.
ENGLISH
*3 Consult your local KUBOTA Dealer for this service.
*4 Replace only if necessary.
A When the battery is used for less than 100 hours in a year, check its electrolyte yearly. (for refillable battery's only)
A 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.
Please see the Warranty Statement in detail.
A Changing interval of engine oil
Models
D1503-M-E3
D1703-M-E3
D1803-M-E3
V2003-M-E3
V2203-M-E3
V2403-M-E3
V2403-M-T-E3
124 mm (4.88 in.) *90 mm (3.54 in.)
Initial
* 90 mm (3.54 in.) oil pan depth is optional.
**Standard replacement interval
A American Petroleum Institute (API) classification: above CF
A Ambient temperature: below 35 C (95 F)
Lubricating oil
With strict emission control regulations now in effect, the CF-4 and CG-4 engine oils have 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).
A Lubricating oil recommended when a low-sulfur or high-sulfur fuel is employed.
: Recommendable X : Not recommendable
Lubricating
oil classification
CF *TBN 10
CF-4 X
CG-4 X
CH-4 X
CI-4 X
Low-sulfur High-sulfur
* TBN: Total Base Number
**Fuel
A 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.
A Use of diesel fuel with sulfur content less than 0.10 % (1000 ppm) is strongly recommended.
A If high-sulfur fuel (sulfur content 0.50 % (5000 ppm) to 1.0 % (10000 ppm)) is used as a diesel fuel, change the engine
oil and oil filter at shorter intervals. (approximately half).
A DO NOT USE Fuels that have sulfur content greater than 1.0 % (10000 ppm).
A Since KUBOTA diesel engines of less than 56 kW (75 hp) utilize EPA Tier 4 and Interim Tier 4 standards, the use of
low sulfur fuel or ultra low sulfur fuel is mandatory for these engines, when operated in US EPA regulated areas.
Therefore, please use No.2-D S500 or S15 diesel fuel as an alternative to 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 (14 ).
1) No.1-D or No.2-D, S500 : Low Sulfur Diesel (LSD) less than 500 ppm or 0.05 wt.%
No.1-D or No.2-D, S15 : Ultra Low Sulfur Diesel (ULSD) 15 ppm or 0.0015 wt.%
A 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 pan depth
200 Hrs 150 Hrs
50 Hrs
**Fuel
Remarks
11MAINTENANCE
A Oil used in the engine should have API classification and Proper SAE Engine Oil according to the ambient
temperatures as shown below:
Above 25 (77 ) SAE30, SAE10W-30 or 15W-40
0 to 25 (32 to 77 ) SAE20, SAE10W-30 or 15W-40
Below 0 (32 ) SAE10W, SAE10W-30 or 15W-40
A Recommended API classification
Refer to the following table for the suitable American 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)]
Low Sulfur Fuel
[Sulfur Content <
0.05 % (500 ppm)] or
Ultra Low Sulfur Fuel
[Sulfur Content <
0.0015 % (15 ppm)]
EGR: Exhaust Gas Re-circulation
CF
(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))
CF, CF-4, CG-4, CH-4 or CI-4
Engines with non-EGR
Engines with internal EGR
Engines with external EGR
---
CF or CI-4
(Class CF-4, CG-4 and CH-4 engine, oils
cannot be used on EGR type engines.)
ENGLISH
12 PERIODIC SERVICE
PERIODIC SERVICE
ENGLISH
FUEL
Fuel is flammable and can be dangerous. You should
handle fuel with care.
To avoid personal injury:
A Do not mix gasoline or alcohol with
diesel fuel. This mixture can cause
an explosion.
A Be careful not to spill fuel during
refueling. If fuel should spill, wipe it
off at once, or it may cause a fire.
A Do not fail to stop the engine before
refueling. Keep the engine away from
the fire.
A Be sure to stop the engine while
refueling or bleeding and when
cleaning or changing fuel filter or fuel
pipes. Do not smoke when working
around the battery or when refueling.
A Check the fuel systems at a well
ventilated and wide place.
A When fuel and lubricant are spilled,
refuel after letting the engine cool off.
A Always keep spilled fuel and
lubricant away from engine.
BFuel level check and refueling
1. Check to see that the fuel level is above the lower limit
of the fuel level gauge.
2. If the fuel is too low, add fuel to the upper limit. Do not
overfill.
Carbon
Residue on,
10 percent
Residuum,
%
Viscosity
Kinematic
cSt or
mm /s at
40
1.9 4.1 32.6 40.1
Ash,
weight
%
Viscosity
Saybolt,
SUS at
37.8(100)
()
90%
Point
Water and
Sediment,
volume
%
0.05 0.35 0.01
338
(640)
Flash Point,
()
Min Max Max Max
52
(125)
Distillation
Temperatures,
Min Max Min Max Min Max
282
(540)
Sulfur,
weight
%
Max Max Min
0.50 No. 3 40
A Cetane Rating : The minimum recommended Fuel
Cetane Rating is 45. A cetane rating greater than 50
is preferred, especially for ambient temperatures
below -20 (-4 ) or elevations above 1500 m (5000
ft).
A 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.
A Use of diesel fuel with sulfur content less than 0.10 %
(1000 ppm) is strongly recommended.
A If high-sulfur fuel (sulfur content 0.50 % (5000 ppm) to
1.0 % (10000 ppm)) is used as a diesel fuel, change
the engine oil and oil filter at shorter intervals.
(approximately half).
A DO NOT USE Fuels that have sulfur content greater
than 1.0 % (10000 ppm).
A Diesel fuels specified to EN 590 or ASTM D975 are
recommended.
A No.2-D is a distillate fuel of lower volatility for engines
in industrial and heavy mobile service.
(SAE J313 JUN87)
A Since KUBOTA diesel engines of less than 56 kW (75
hp) utilize EPA Tier 4 and Interim Tier 4 standards, the
use of low sulfur fuel or ultra low sulfur fuel is
mandatory for these engines, when operated in US
EPA regulated areas. Therefore, please use No.2-D
S500 or S15 diesel fuel as an alternative to 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 (14 ).
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.%
No.1-D or No.2-D, S15 : Ultra Low Sulfur Diesel
(ULSD) 15 ppm or 0.0015 wt.%
Copper
Strip
Corrosion
Cetane
Number
13PERIODIC SERVICE
A Be sure to use a strainer when filling the fuel tank, or
dirt or sand in the fuel may cause trouble in the fuel
injection pump.
A For fuel, always use diesel fuel. You are required not
to use alternative fuel, because its quality is unknown
or it may be inferior in quality. Kerosene, which is very
low in cetane rating, adversely affects the engine.
Diesel fuel differs in grades depending on the
temperature.
A Be careful not to let the fuel tank become empty, or air
can enter the fuel system, necessitating bleeding
before next engine start.
BAir bleeding the fuel system
To avoid personal injury;
A Do not bleed a hot engine as this
could cause fuel to spill onto a hot
exhaust manifold creating a danger
of fire.
Air bleeding of the fuel system is required if;
A after the fuel filter and pipes have been detached and
refitted;
A after the fuel tank has become empty; or
A before the engine is to be used after a long storage.
[PROCEDURE ] (gravity feed fuel tanks only)
1. Fill the fuel tank to the fullest extent. Open the fuel
filter lever.
2. Open the air vent cock on top of the fuel injection
pump.
3. Turn the engine, continue it for about 10 seconds,
then stop it, or move the fuel feed pump lever by hand
(optional).
4. Close the air vent cock on top of the fuel injection
pump.
[GRAVITY FEED SYSTEM]
(1) Air vent cock
(2) Fuel feed pump
[PROCEDURE ] (fuel tanks lower than injection
pump)
1. For fuel tanks that are lower than the injection pump.
The fuel system must be pressurized by the fuel
system electric fuel pump.
2. If an electric fuel pump is not used, you must manually
actuate the pump by lever to bleed.
3. The primary fuel filter must be on the pressure side of
the pump if the fuel tank is lower than the injection
pump.
4. To bleed, follow (2) through (4) above.
A Tighten air vent plug of the fuel injection pump except
when bleeding, or it may stop the engine suddenly.
[TANK BELOW INJECTION PUMP SYSTEM]
ENGLISH
A 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 tank below injection pump
(2) Pre-filter
(3) Electric or Mechanical pump
(4) Main Filter
(5) Injection pump
PERIODIC SERVICE14
BChecking the fuel pipes
ENGLISH
To avoid personal injury;
A Check or replace the fuel pipes after
stopping the engine. Broken fuel
pipes can cause fires.
Check the fuel pipes every 50 hours of operation. When if;
1. If the clamp band is loose, apply oil to the screw of the
band, and tighten the band securely.
2. If the fuel pipes, made of rubber, become worn out,
replace them and clamp bands every 2 years.
3. If the fuel pipes and clamp bands are found worn or
damaged before 2 years' pass, replace or repair them
at once.
4. After replacement of the pipes and bands, air-bleed
the fuel system.
A When the fuel pipes are not installed, plug them at
both ends with clean cloth or paper to prevent dirt from
entering. Dirt in the pipes can cause fuel injection
pump malfunction.
BCleaning the fuel filter pot
Every 100 hours of operation, clean the fuel filter in a
clean place to prevent dust intrusion.
1. Close the fuel filter lever.
(1) Fuel filter lever
(2) Fuel filter pot
2. Remove the top cap, and rinse the inside with diesel
fuel.
3. Take out the element, and rinse it with diesel fuel.
4. After cleaning, reinstall the fuel filter, keeping out of
dust and dirt.
5. Air-bleed the injection pump.
A Entrance of dust and dirt can cause a malfunction of
the fuel injection pump and the injection nozzle. Wash
the fuel filter cup periodically.
(A) "OFF"
(B) "ON"
(1) Clamp band
(2) Fuel pipe
(1) O ring
(2) Filter element
(3) Spring
(4) Filter bowl
(5) Screw ring
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