Manual de Servicio Motor

Engine Workshop Manual
Generator Set
DSKAA
DSKAB
DSKBA
English 05-2008 981-0548 (Issue 1)
California
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
WORKSHOP MANUAL
DIESEL ENGINE
03-M-E3B SERIES,
03-M-DI-E3B SERIES,
03-M-E3BG SERIES
KiSC issued 10, 2007 A
TO THE READER
This Workshop Manual has been prepared to provide servicing personnel with
information on the mechanism, service and maintenance of 03-M-E3B, 03-M-DI-E3B
and 03-M-E3BG series. It is divided into three parts, General, Mechanism and
Servicing.
General
Information on the engine identification, the general precautions, maintenance check
list, check and maintenance and special tools are described.
Mechanism
Information on the construction and function are included. This part should be
understood before proceeding with troubleshooting, disassembling and servicing.
Refer to Diesel Engine Mechanism Workshop Manual (Code No. 9Y021-01875) for
the one which has not been described to this workshop manual.
Servicing
Information on the troubleshooting, servicing specification lists, tightening torque,
checking and adjusting, disassembling and assembling, and servicing which cover
procedures, precautions, factory specifications and allowable limits.
All information illustrations and specifications contained in this manual are based on
the latest product information available at the time of publication.
The right is reserved to make changes in all information at any time without notice.
Due to covering many models of this manual, information or picture being used, have
not been specified as one model.
March 2007
KUBOTA Corporation 2007
1
03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM SAFETY INSTRUCTIONS
SAFETY INSTRUCTIONS
BEFORE SERVICING AND REPAIRING
Read all instructions and safety instructions in this
manual and on your engine safety decals.
Clean the work area and engine.
Park the machine on a firm and level ground.
Allow the engine to cool before proceeding.
Stop the engine, and remove the key.
Disconnect the battery negative cable.
Hang a DO NOT OPERATE tag in operator
station.
SAFETY FIRST
This symbol, the industrys Safety Alert Symbol, is used throughout this manual and on labels on
the machine itself to warn of the possibility of personal injury. Read these instructions carefully.
It is essential that you read the instructions and safety regulations before you attempt to repair or use
this unit.
DANGER : Indicates an imminently hazardous situation which, if not avoided, will result in
death or serious injury.
WARNING : Indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION : Indicates a potentially hazardous situation which, if not avoided, may result in
minor or moderate injury.
IMPORTANT : Indicates that equipment or property damage could result if instructions are not
followed.
NOTE : Gives helpful information.
2
SAFETY STARTING
Do not start the engine by shorting across starter
terminals or bypassing the safety start switch.
Unauthorized modifications to the engine may impair
the function and / or safety and affect engine life.
SAFETY WORKING
Do not work on the machine while under the influence
of alcohol, medication, or other substances or while
fatigued.
Wear close fitting clothing and safety equipment
appropriate to the job.
Use tools appropriate to the work. Makeshift tools,
parts, and procedures are not recommended.
When servicing is performed together by two or more
persons, take care to perform all work safely.
Do not touch the rotating or hot parts while the engine
is running.
Never remove the radiator cap while the engine is
running, or immediately after stopping. Otherwise, hot
water will spout out from radiator. Only remove
radiator cap when cool enough to touch with bare
hands. Slowly loosen the cap to first stop to relieve
pressure before removing completely.
Escaping fluid (fuel or hydraulic oil) under pressure
can penetrate the skin causing serious injury. Relieve
pressure before disconnecting hydraulic or fuel lines.
Tighten all connections before applying pressure.
Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable
or uncomfortable loud noises.
Do not open high-pressure fuel system.
High-pressure fluid remaining in fuel lines can cause
serious injury. Do not disconnect or attempt to repair
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.
3
AVOID FIRES
Fuel is extremely flammable and explosive under
certain conditions. Do not smoke or allow flames or
sparks in your working area.
To avoid sparks from an accidental short circuit,
always disconnect the battery negative cable first and
connect it last.
Battery gas can explode. Keep sparks and open
flame away from the top of battery, especially when
charging the battery.
Make sure that no fuel has been spilled on the engine.
VENTILATE WORK AREA
If the engine must be running to do some work, make
sure the area is well ventilated. Never run the engine
in a closed area. The exhaust gas contains poisonous
carbon monoxide.
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 regulations when disposing
of oil, fuel, coolant, electrolyte and other harmful
waste.
4
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.
5
03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM SPECIFICATIONS
SPECIFICATIONS
* The specification described above is of the standard engine of each model.
* Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW
W10275180
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
3
(91.47 cu.in.) 1647 cm
3
(100.5 cu.in.)
ISO Net Continuous 19.5 KW / 2800 min
-1
(rpm)
(26.1 HP / 2800 min
-1
(rpm))
21.2 KW / 2800 min
-1
(rpm)
(28.4 HP / 2800 min
-1
(rpm))
ISO/SAE Net Intermittent 22.4 KW / 2800 min
-1
(rpm)
(30.0 HP / 2800 min
-1
(rpm))
24.4 KW / 2800 min
-1
(rpm)
(32.7 HP / 2800 min
-1
(rpm))
SAE Gross Intermittent 23.8 KW / 2800 min
-1
(rpm)
(31.9 HP / 2800min
-1
(rpm))
26.1 KW / 2800 min
-1
(rpm)
(35.0 HP / 2800 min
-1
(rpm))
Maximum Bare Speed 3020 min
-1
(rpm)
Minimum Bare Idling Speed 750 to 850 min
-1
(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 0.2662 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
2
, 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, 1.2 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.
For details on recommended lubricating oils, see page G-7, 10
Lubricating Oil
Capacity
Oil Pan Depth
90 mm (3.5 in.)
5.6 L (1.5 U.S.gals)
Oil Pan Depth
124 mm (4.88 in.)
7.0 L (1.8 U.S.gals)
Weight (Dry) 148 kg (326 lbf)
6
W10316200
Model D1803-M
Bore Stroke 87.0 X 102.4 mm (3.43 X 4.031 in.)
3
(111.4 cu.in.)
-1
(rpm)
(30.6 HP / 2700 min
-1
(rpm))
-1
(rpm)
(35.3 HP / 2700 min
-1
(rpm))
-1
(rpm)
(37.4 HP / 2700 min
-1
(rpm))
-1
(rpm)
-1
(rpm)
Injection Timing 0.2836 rad (16.25 ) before T.D.C.
Firing Order 1-2-3
2
, 1991 psi)
Compression Ratio 24.3 : 1
EGR NONE
Lubricating Oil
Capacity
Oil Pan Depth
90 mm (3.5 in.)
5.6 L (1.5 U.S.gals)
Oil Pan Depth
124 mm (4.88 in.)
7.0 L (1.8 U.S.gals)
7
W10384770
Model V2003-M V2203-M
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.)
3
(122.0 cu.in.) 2197 cm
3
(134.1 cu.in.)
-1
(rpm)
(35.8 HP / 2800 min
-1
(rpm))
29.6 KW / 2800 min
-1
(rpm)
(39.7 HP / 2800 min
-1
(rpm))
-1
(rpm)
(41.3 HP / 2800 min
-1
(rpm))
34.1 KW / 2800 min
-1
(rpm)
(45.7 HP / 2800 min
-1
(rpm))
-1
(rpm)
(43.7 HP / 2800 min
-1
(rpm))
35.9 KW / 2800 min
-1
(rpm)
(48.1 HP / 2800 min
-1
(rpm))
-1
(rpm)
-1
(rpm)
Firing Order 1-3-4-2
2
, 1991 psi)
EGR NONE
Lubricating Oil
Capacity
Oil Pan Depth
90 mm (3.5 in.)
7.6 L (2.0 U.S.gals)
Oil Pan Depth
124 mm (4.88 in.)
9.5 L (2.5 U.S.gals)
8
W10334350
Model V2403-M V2403-M-T
3
(148.5 cu.in.)
-1
(rpm)
(40.5 HP / 2700 min
-1
(rpm))
36.4 KW / 2700 min
-1
(rpm)
(48.8 HP / 2700 min
-1
(rpm))
-1
(rpm)
(46.7 HP / 2700 min
-1
(rpm))
41.9 KW / 2700 min
-1
(rpm)
(56.2 HP / 2700 min
-1
(rpm))
-1
(rpm)
(48.9 HP / 2700 min
-1
(rpm))
44.0 KW / 2700 min
-1
(rpm)
(59.0 HP / 2700 min
-1
(rpm))
-1
(rpm) 2950 min
-1
(rpm)
-1
(rpm) 750 min
-1
(rpm)
2
, 1991 psi)
EGR NONE
Lubricating Oil
Capacity
Oil Pan Depth
90 mm (3.5 in.)
7.6 L (2.0 U.S.gals)
Oil Pan Depth
124 mm (4.88 in.)
9.5 L (2.5 U.S.gals)
Weight (Dry) 184 kg (406 lbf) 190 kg (419 lbf)
9
W10343470
Model D1803-M-DI
3
(111.4 cu.in.)
-1
(rpm)
(31.1 HP / 2700 min
-1
(rpm))
-1
(rpm)
(35.8 HP / 2700 min
-1
(rpm))
-1
(rpm)
(37.4 HP / 2700 min
-1
(rpm))
-1
(rpm)
-1
(rpm)
Combustion Chamber Reentrant Type (Direct Injection)
Fuel Injection Pump Bosch K Type Mini Pump
Injection Nozzle Bosch P Type Hole Nozzle
Firing Order 1-2-3
Injection
Pressure
1st stage 18.63 MPa (190.0 kgf/cm
2
, 2702 psi)
2nd stage 22.56 MPa (230.0 kgf/cm
2
, 3271 psi)
EGR NONE
Lubricating Oil
Capacity
Oil Pan Depth
90 mm (3.5 in.)
5.6 L (1.5 U.S.gals)
Oil Pan Depth
124 mm (4.88 in.)
7.0 L (1.8 U.S.gals)
10
W10452650
Model V2403-M-DI V2403-M-DI-T
3
(148.5 cu.in.)
-1
(rpm)
(40.9 HP / 2700 min
-1
(rpm))
30.7 KW / 2400 min
-1
(rpm)
(41.2 HP / 2400 min
-1
(rpm))
-1
(rpm)
(47.1 HP / 2700 min
-1
(rpm))
35.3 KW / 2400 min
-1
(rpm)
(47.3 HP / 2400 min
-1
(rpm))
-1
(rpm)
(48.9 HP / 2700 min
-1
(rpm))
36.5 KW / 2400 min
-1
(rpm)
(48.9 HP / 2400 min
-1
(rpm))
-1
(rpm) 2450 min
-1
(rpm)
-1
(rpm) 900 min
-1
(rpm)
Combustion Chamber Reentrant Type (Direct Injection)
Fuel Injection Pump Bosch K Type Mini Pump
Injection Nozzle Bosch P Type Hole Nozzle
Injection
Pressure
1st stage 18.63 MPa (190.0 kgf/cm
2
, 2702 psi)
2nd stage 22.56 MPa (230.0 kgf/cm
2
, 3271 psi)
EGR NONE
Lubricating Oil
Capacity
Oil Pan Depth
90 mm (3.5 in.)
7.6 L (2.0 U.S.gals)
Oil Pan Depth
124 mm (4.88 in.)
9.5 L (2.5 U.S.gals)
Weight (Dry) 184 kg (406 lbf) 190 kg (416 lbf)
11
W10336120
Model D1703-M-BG
3
(100.5 cu.in.)
-1
(rpm)
(18.8 HP / 1500 min
-1
(rpm))
16.9 KW / 1800 min
-1
(rpm)
(22.7 HP / 1800 min
-1
(rpm))
-1
(rpm)
(21.6 HP / 1500 min
-1
(rpm))
19.5 KW / 1800 min
-1
(rpm)
(26.1 HP / 1800 min
-1
(rpm))
-1
(rpm)
(22.3 HP / 1500 min
-1
(rpm))
20.2 KW / 1800 min
-1
(rpm)
(27.1 HP / 1800 min
-1
(rpm))
-1
(rpm)
Minimum Bare Idling Speed 2120 min
-1
(rpm)
Governor Mechanical all speed governor + Electronic Governor
Firing Order 1-2-3
2
, 1991 psi)
EGR NONE
Lubricating Oil
Capacity
Oil Pan Depth
90 mm (3.5 in.)
5.6 L (1.5 U.S.gals)
Oil Pan Depth
124 mm (4.88 in.)
7.0 L (1.8 U.S.gals)
12
W10389960
Model V2003-M-BG
3
(122.0 cu.in.)
-1
(rpm)
(23.5 HP / 1500 min
-1
(rpm))
20.3 KW / 1800 min
-1
(rpm)
(27.2 HP / 1800 min
-1
(rpm))
-1
(rpm)
(27.0 HP / 1500 min
-1
(rpm))
23.4 KW / 1800 min
-1
(rpm)
(31.4 HP / 1800 min
-1
(rpm))
-1
(rpm)
(27.6 HP / 1500 min
-1
(rpm))
24.3 KW / 1800 min
-1
(rpm)
(32.6 HP / 1800 min
-1
(rpm))
-1
(rpm)
-1
(rpm)
2
, 1991 psi)
EGR NONE
Lubricating Oil
Capacity
Oil Pan Depth
90 mm (3.5 in.)
7.6 L (2.0 U.S.gals)
Oil Pan Depth
124 mm (4.88 in.)
9.5 L (2.5 U.S.gals)
13
W10413710
Model V2003-M-T-BG
3
(122.0 cu.in.)
-1
(rpm)
(29.9 HP / 1500 min
-1
(rpm))
25.7 KW / 1800 min
-1
(rpm)
(34.5 HP / 1800 min
-1
(rpm))
-1
(rpm)
(34.5 HP / 1500 min
-1
(rpm))
29.6 KW / 1800 min
-1
(rpm)
(39.7 HP / 1800 min
-1
(rpm))
-1
(rpm)
(35.1 HP / 1500 min
-1
(rpm))
30.6 KW / 1800 min
-1
(rpm)
(41.0 HP / 1800 min
-1
(rpm))
-1
(rpm)
-1
(rpm)
2
, 1991 psi)
EGR NONE
Lubricating Oil
Capacity
Oil Pan Depth
90 mm (3.5 in.)
7.6 L (2.0 U.S.gals)
Oil Pan Depth
124 mm (4.88 in.)
9.5 L (2.5 U.S.gals)
14
W10419300
Model V2203-M-BG
3
(134.1 cu.in.)
-1
(rpm)
(25.2 HP / 1500 min
-1
(rpm))
22.6 KW / 1800 min
-1
(rpm)
(30.3 HP / 1800 min
-1
(rpm))
-1
(rpm)
(29.1 HP / 1500 min
-1
(rpm))
26.0 KW / 1800 min
-1
(rpm)
(34.9 HP / 1800 min
-1
(rpm))
-1
(rpm)
(29.8 HP / 1500 min
-1
(rpm))
26.9 KW / 1800 min
-1
(rpm)
(36.1 HP / 1800 min
-1
(rpm))
-1
(rpm)
-1
(rpm)
2
, 1991 psi)
EGR NONE
Lubricating Oil
Capacity
Oil Pan Depth
90 mm (3.5 in.)
7.6 L (2.0 U.S.gals)
Oil Pan Depth
124 mm (4.88 in.)
9.5 L (2.5 U.S.gals)
15
W10424850
Model V2403-M-BG
3
(148.5 cu.in.)
-1
(rpm)
(28.8 HP / 1500 min
-1
(rpm))
25.1 KW / 1800 min
-1
(rpm)
(33.7 HP / 1800 min
-1
(rpm))
-1
(rpm)
(33.3 HP / 1500 min
-1
(rpm))
28.9 KW / 1800 min
-1
(rpm)
(38.8 HP / 1800 min
-1
(rpm))
-1
(rpm)
(33.9 HP / 1500 min
-1
(rpm))
29.8 KW / 1800 min
-1
(rpm)
(40.0 HP / 1800 min
-1
(rpm))
-1
(rpm)
-1
(rpm)
2
, 1991 psi)
EGR NONE
Lubricating Oil
Capacity
Oil Pan Depth
90 mm (3.5 in.)
7.6 L (2.0 U.S.gals)
Oil Pan Depth
124 mm (4.88 in.)
9.5 L (2.5 U.S.gals)
16
03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIMENSIONS
DIMENSIONS
W1031045
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.)
17
W1028881
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.)
18
W1035766
D1803-M-DI
A 560.0 mm (22.05 in.)
B 492.0 mm (19.37 in.)
C 636.0 mm (25.04 in.)
19
W1035816
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.)
20
W1036026
D1703-M-BG
A 605.6 mm (23.84 in.)
B 505.0 mm (19.88 in.)
C 642.8 mm (25.31 in.)
21
W1035948
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.)
22
03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM
WIRING DIAGRAM
WIRING DIAGRAM
Key Switch
Solenoid
Water Temp. Switch
WT
OP
ALT
Pilot Lamp
12V3.4W 4
Glow Plug
3.0
Slow Blow Fuse
( 65 A )
3.0
1
0
A
Battery
Start Relay
Starter
Alternator
3.0
ECU (Electronic Control Unit)
3.0
Water Temp. Sensor
3.0
Oil Switch
Glow
(Water Temperature)
(Oil Pressure)
(Alternator)
(Glow Plug)
5
A
1.25
1.25
1.25
0.85
0
.
8
5
Engine Speed Sensor
3.0
Glow Relay
5
A
Manual Stop Switch
(Run/Stop)
0
.
8
5
Speed Switch
(1800 min
-1
(rpm)/1500 min
-1
(rpm))
Slowdown(1200 min
-1
(rpm))
B
ST
9 8 7 6 5 4 3 2
10 11 12 13 14 15 16 17
25 24 23 22 21 20 19 18
26 34
3 4
1 2
B
IG
L
Glow
ON
OFF
30 AC 50 19
Start
Hour Meter
2
1
4
3
1
5
A
1
0
A
3EEADAHFP001A
CONTENTS
GENERAL
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
[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
G-1
G 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.
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
W1010477
Alphabet or
Number
Year
Alphabet or
Number
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
(1) Engine Model Name and Serial
Number
G-2
G GENERAL
Month of manufacture
* Alphabetical letters I and O are not used.
e.g. D1803 - 7 B A001
(a) (b)(c) (d)
W1011076
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
(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)
G-3
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 date 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: E2B engines), may result in emission levels out
of compliance with the original E3B design and EPA or other applicable regulations.Please refer 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.
W1031971
[3] CYLINDER NUMBER
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
Category (1) Engine output classification EU regulation
K From 19 to less than 37 kW STAGE A
J From 37 to less than 75 kW STAGE A
I From 75 to less than 130 kW STAGE A
Category (2) Engine output classification EPA regulation
ET
Less than 19kW Tier 4
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
(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.
G-4
G GENERAL
2. GENERAL PRECAUTIONS
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.
W1011734
(1) Grease
(2) Force
(3) Place the Sharp Edge against the
Direction of Force
(A) External Snap Ring
(B) Internal Snap Ring
G-5
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]
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.
W1029462
Item
Service Interval
Every
50
hrs
100
hrs
150
hrs
200
hrs
400
hrs
500
hrs
1 or 2
months
1
year
800
hrs
1500
hrs
3000
hrs
2
years
* Checking fuel hoses and clamp bands
Changing engine oil
(depending on the oil pan)
(1) Oil pan depth
(90 mm, 3.5 in.)

(2) Oil pan depth
(124 mm, 4.88 in.)

*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
(1) Oil pan depth
(90 mm, 3.5 in.)

(2) Oil pan depth
(124 mm, 4.88 in.)

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.)
G-6
G GENERAL
[D1803-M-DI, V2403-M-DI, V2403-M-DI-T]
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.
W1032664
Item
Service Interval
Every
50
hrs
100
hrs
200
hrs
400
hrs
500
hrs
1 or 2
months
1
year
800
hrs
1500
hrs
3000
hrs
2
years
* Checking fuel hoses and clamp bands
Changing engine oil
(depending on the oil pan)
(1) Oil pan depth
(90 mm, 3.5 in.)

(2) Oil pan depth
(124 mm, 4.88 in.)

*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
(1) Oil pan depth
(90 mm, 3.5 in.)

(2) Oil pan depth
(124 mm, 4.88 in.)

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.)
G-7
G GENERAL
CAUTION
When changing or inspecting, be sure to level and stop the engine.
NOTE
Engine Oil :
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).
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 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).
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 0.50 % (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)
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 volatility for engines in industrial and heavy mobile service. (SAE J313
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, 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 C (14 F).
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.%
Fuel Type
Engine oil classification (API classification)
Engines with non-EGR
Engines with internal EGR
Engines with external EGR
High Sulfur Fuel
[0.05 % (500 ppm)
Sulfur Content <
0.50 % (5000 ppm)]
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))
Low Sulfur Fuel

[Sulfur Content <
0.05 % (500 ppm)] or
Ultra Low Sulfur Fuel
[Sulfur Content <
0.0015 % (15 ppm)]
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.)
G-8
G GENERAL
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.
IMPORTANT
When using an oil of different maker or viscosity from the
previous, drain old oil. Never mix two different types of oil.
NOTE
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
engines rotating and sliding parts.
W1016222
(1) Dipstick (a) Maximum
(b) Minimum
G-9
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, drain
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.
IMPORTANT
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..
W1035779
(1) Radiator Cap
(2) Recovery Tank
A : FULL
B : LOW
G-10
G GENERAL
[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).
IMPORTANT
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.
*90 mm (3.5 in.) oil pan depth is optional.
W1016604
Above 25 C (77 F)
SAE 30 or SAE 10W-30
SAE 10W-40
0 C to 25 C (32 F to 77 F)
SAE 10W-40
Below 0 C (32 F)
SAE 10W or SAE 10W-30
SAE 10W-40
Models
Oil pan depth
124 mm (4.88 in.) *90 mm (3.5 in.)
D1503-M, D1703-M
D1803-M, D1803-M-DI
D1703-M-BG
7.0 L
1.8 U.S.gals
5.6 L
1.5 U.S.gals
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
9.5 L
2.5 U.S.gals
7.6 L
2.0 U.S.gals
V2403-M-T
9.5 L
2.5 U.S.gals
(1) Drain Plug (2) Dipstick

G-11
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.
IMPORTANT
To prevent serious damage to the engine, replacement
element must be highly efficient. Use only a KUBOTA
genuine filter or its equivalent.
W1013487
(1) Engine Oil Filter Cartridge
G-12
G GENERAL
[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 are found to be damaged or
deteriorate earlier than two years, then change or remedy.
4. After the fuel hose and the clamp have been changed, bleed the
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.
NOTE
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.
W1035921
(1) Fuel Hose
(2) Clamp
(3) Air Vent Plug
(4) Fuel Cock
(5) Air Vent Cock
[A] Cartridge Type
[B] Element Type
G-13
G GENERAL
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
2
,
30 psi).
Maintain reasonable distance between the nozzle and the filter.
NOTE
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.
W1045746
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.
IMPORTANT
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.
W1046058
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.
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.
W1208957
(1) Cock Body
(2) Air Vent Plug
(3) Fuel Cock
(4) Filter Element
(5) Filter Cup
(6) Retaining Ring
(1) Upper Level Line (2) Lower Level Line
Deflection (A) Factory spec.
7.0 to 9.0 mm
0.28 to 0.35 in.
(A) Deflection
G-14
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.
W1057475
(A) Good (B) Bad
G-15
G GENERAL
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
IMPORTANT
(See page G-7).
temperature.
W1022029
Above 25 C (77 F)
SAE 10W-40
0 C to 25 C (32 F to 77 F)
SAE 10W-40
Below 0 C (32 F)
SAE 10W-40
Models
Oil pan depth
124 mm (4.88 in.) *90 mm (3.5 in.)
D1503-M
D1703-M
D1803-M
D1703-M-BG
7.0 L
1.8 U.S.gals
5.6 L
1.5 U.S.gals
V2003-M
V2203-M
V2403-M
V2003-M-BG
V2003-M-T-BG
V2203-M-BG
V2403-M-BG
9.5 L
2.5 U.S.gals
7.6 L
2.0 U.S.gals
G-16
G GENERAL
Replacing Oil Filter Cartridge (for 90 mm (3.5 in.) Depth Oil Pan)
[D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M]
V2403-M-BG]
CAUTION
IMPORTANT
W1022423
G-17
G GENERAL
[D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M,
V2403-M-T]
V2403-M-BG]
CAUTION
IMPORTANT
(See page G-7).
temperature.
W1022765
Above 25 C (77 F)
SAE 10W-40
0 C to 25 C (32 F to 77 F)
SAE 10W-40
Below 0 C (32 F)
SAE 10W-40
Models
Oil pan depth
124 mm (4.88 in.) *90 mm (3.5 in.)
D1503-M
D1703-M
D1803-M
D1703-M-BG
7.0 L
1.8 U.S.gals
5.6 L
1.5 U.S.gals
V2003-M
V2203-M
V2403-M
V2003-M-BG
V2003-M-T-BG
V2203-M-BG
V2403-M-BG
9.5 L
2.5 U.S.gals
7.6 L
2.0 U.S.gals
V2403-M-T
9.5 L
2.5 U.S.gals

G-18
G GENERAL
[D1803-M-DI, V2403-M-DI, V2403-M-DI-T]
CAUTION
IMPORTANT
(See page G-7).
temperature.
W1034539
Above 25 C (77 F)
SAE 10W-40
0 C to 25 C (32 F to 77 F)
SAE 10W-40
Below 0 C (32 F)
SAE 10W-40
Models
Oil pan depth
124 mm (4.88 in.) *90 mm (3.5 in.)
D1803-M-DI
7.0 L
1.8 U.S.gals
5.6 L
1.5 U.S.gals
V2403-M-DI
V2403-M-DI-T
9.5 L
2.5 U.S.gals
7.6 L
2.0 U.S.gals
G-19
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]
V2403-M-BG]
CAUTION
IMPORTANT
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
IMPORTANT
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.
W1029518
(1) Upper Hose (2) Lower Hose
G-20
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 tends to age. It must
be changed every two years. Also change the clamp and tighten
it securely.
IMPORTANT
To prevent serious damage to the engine, keep out any dust
inside the intake air line.
W1029631
(1) Intake Air Hose (2) Clamp
G-21
G GENERAL
[D1803-M-DI, V2403-M-DI, V2403-M-DI-T]
CAUTION
IMPORTANT
(See page G-7).
temperature.
W1035850
Above 25 C (77 F)
SAE 10W-40
0 C to 25 C (32 F to 77 F)
SAE 10W-40
Below 0 C (32 F)
SAE 10W-40
Models
Oil pan depth
124 mm (4.88 in.) *90 mm (3.5 in.)
D1803-M-DI
7.0 L
1.8 U.S.gals
5.6 L
1.5 U.S.gals
V2403-M-DI
V2403-M-DI-T
9.5 L
2.5 U.S.gals
7.6 L
2.0 U.S.gals
G-22
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
IMPORTANT
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.
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.
W1050583
(1) Fuel Filter Cartridge
(1) Cock Body
(2) Air Vent Plug
(3) Fuel Cock
(4) Filter Element
(5) Filter Cup
(6) Retaining Ring
G-23
G GENERAL
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 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 (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.
IMPORTANT
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 water, the anti-
freeze 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.
W1038102
(1) Radiator Cap
(2) Drain Plug
(3) Drain Cock
(4) Recovery Tank
A : Full
B : Low
G-24
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 according
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.
IMPORTANT
* 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.
NOTE
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 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.
W1052220
Vol %
anti-freeze
Freezing point Boiling point*
C F C F
40 24 11 106 223
50 37 35 108 226
7.0 to 9.0 mm / 98 N
0.28 to 0.35 in. / 98 N
(10 kgf, 22 lbf)
(1) Fan Belt (A) Deflection
G-25
G GENERAL
[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 object 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
manufactures instructions.
3. As the electrolyte generates gas while charging, remove all port
caps.
4. The electrolyte temperature must not exceed 40 C (104 F)
during charging.
If it exceed 40 C (104 F), decrease the charging 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 current 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.
Precaution for Operating a Quick Charger
Operate with a quick charger differs according to the type.
Consult the instruction manual and use accordingly.
W1052658
G-26
G GENERAL
Battery Specific Gravity
1. Check the specific gravity of the electrolyte in each cell with a
hydrometer.
2. When the electrolyte temperature differs 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.
NOTE
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 hydrometer 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)
At an electrolyte temperature of 20 C (68 F)
W1012763
[10] CHECK POINTS OF EVERY YEAR
Replacing Air Cleaner Element
1. Remove used air cleaner element.
2. Replace new air cleaner element.
NOTE
The air cleaner uses a dry element. Never apply oil to it.
Do not run the engine with filter element removed.
W1020554
Specific Gravity State of Charge
1.260 Sp. Gr. 100 % Charged
1.140 Sp. Gr. Very Little Useful Capacity
1.110 Sp. Gr. Discharged
(a) Good
(b) Bad
(c) Bad
G-27
G GENERAL
Valve Clearance
IMPORTANT
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.
NOTE
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 tighten the lock
nut of the adjusting screw.
W10113200
Valve clearance Factory spec.
0.18 to 0.22 mm
0.0071 to 0.0086 in.
Valve arrangement
Adjustable
cylinder
location of piston
3 Cylinder 4 Cylinder
IN. EX. IN. EX.
When No. 1 piston is
at compression top
dead center
No. 1
No. 2
No. 3
No. 4
at overlap position
No. 1
No. 2
No. 3
No. 4
(1) Valve Clearance
(2) Projection
(3) 1TC Mark Line
G-28
G GENERAL
CAUTION
Check the injection pressure and condition after confirming that there is nobody standing in the direction
the fume goes.
If the fume from the nozzle directly contacts the human body, cells may be destroyed and blood poisoning
may be caused.
Nozzle Spraying Condition
[D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M,
V2403-M-T]
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.
W10411400
[D1803-M-DI, V2403-M-DI, V2403-M-DI-T]
spraying condition.
2. If the spraying condition is defective, replace the injection nozzle
assembly.
W1037040
(a) Good (b) Bad
(a) Good (b) Bad
G-29
G GENERAL
Fuel Injection Pressure
[D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M,
V2403-M-T]
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
2
, 85 psi)
W10182100
[D1803-M-DI, V2403-M-DI, V2403-M-DI-T]
replace the injection nozzle assembly.
W10408820
Fuel injection pressure Factory spec.
13.73 to 14.70 MPa
140.0 to 150.0 kgf/cm
2
1992 to 2133 psi
(1) Adjusting Washer
Fuel injection pressure
(1st stage)
Factory spec.
18.64 to 20.10 MPa
190.0 to 205.0 kgf/cm
2
2703 to 2915 psi
G-30
G GENERAL
Valve Seat Tightness
[D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M,
V2403-M-T]
V2403-M-BG]
2. Raise the fuel pressure, and keep at 12.75 MPa (130.0 kgf/cm
2
,
1849 psi) for 10 seconds.
3. If any fuel leak is found, replace the nozzle piece.
W10412730
[D1803-M-DI, V2403-M-DI, V2403-M-DI-T]
2
,
3. If any fuel leak is found, replace the injection nozzle assembly.
W1037135
Nozzle Holder
[D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M,
V2403-M-T]
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.
W1018491
Valve seat tightness Factory spec.
No fuel leak at
12.75 MPa
130.0 kgf/cm
2
1849 psi
No fuel leak at
16.67 MPa
170.0 kgf/cm
2
2418 psi
Tightening torque
Nozzle holder
35 to 39 Nm
3.5 to 4.0 kgfm
26 to 28 lbfft
Overflow pipe retaining nut
20 to 24 Nm
2.0 to 2.5 kgfm
15 to 18 lbfft
Nozzle holder assembly
49 to 68 Nm
5.0 to 7.0 kgfm
37 to 50 lbfft
(1) Nozzle Holder
(3) Nozzle Spring
(4) Push Rod
(5) Distance Piece
(6) Nozzle Piece
(7) Nozzle Retaining Nut
G-31
G GENERAL
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.
W1022082
(1) Turbine Housing
(2) Exhaust Port
(3) Inlet Port
(4) Inlet Hose
(5) Compressor Cover
(6) Clamp
G-32
G GENERAL
Checking Injection Pump
[D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M,
V2403-M-T]
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)
3. Set a pressure tester to the fuel injection pump.
pressure to the injection pump pressure tester (1).
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
2
, 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
2
, from 1991 to 1849 psi).
8. Measure the time needed to decrease the pressure from 13.73 to
12.75 MPa (from 140.0 to 130.0 kgf/cm
2
, 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.
NOTE
Never try to disassemble the injection pump assembly. For
repairs, you are strongly requested to contact a Kubota-
authorized pump service shop.
W1022357
Fuel tightness of pump
element
Allowable limit
13.73 MPa
140.0 kgf/cm
2
1991 psi
Fuel tightness of
delivery valve
Factory spec.
10 seconds
13.73 12.75 MPa
140.0 130.0 kgf/cm
2
1991 1849 psi
Allowable limit
5 seconds
13.73 12.75 MPa
140.0 130.0 kgf/cm
2
1991 1849 psi
(1) Injection Pump Pressure Tester
(2) Injection Nozzle
(3) Protection Cover for Jetted Fuel
G-33
G GENERAL
Checking Injection Pump
[D1803-M-DI, V2403-M-DI, V2403-M-DI-T]
(Fuel Tightness of Pump Element)
figure.)
service shop.
(Fuel Tightness of Delivery Valve)
2
, 2702 psi).
taken for the pressure to drop from 18.63 to 17.65 MPa (from
190.0 to 180.0 kgf/cm
2
, from 2702 to 2560 psi).
17.65 MPa (from 190.0 to 180.0 kgf/cm
2
, from 2702 to 2560 psi).
shop.
NOTE
W1037269
element
Allowable limit
18.63 MPa
190.0 kgf/cm
2
2702 psi
Fuel tightness of
delivery valve
Factory spec.
10 seconds
18.63 17.65 MPa
190.0 180.0 kgf/cm
2
2702 2560 psi
Allowable limit
5 seconds
18.63 17.65 MPa
190.0 180.0 kgf/cm
2
2702 2560 psi
G-34
G GENERAL
[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).
NOTE
To prevent serious damage to the engine, keep out any dust
inside the intake air line.
W1023867
Replacing Battery
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 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.
W1023996
Replacing Radiator Hoses and Clamp Bands
CAUTION
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.
W1024178
(1) Intake Air Hose (2) Clamp
(1) Upper Hose (2) Lower Hose
G-35
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.
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.
NOTE
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.
W1024305
(1) Fuel Hose
(2) Clamp
(3) Air Vent Plug
(4) Fuel Cock
[A] Cartridge Type
[B] Element Type
G-36
G GENERAL
Changing Radiator Coolant (L.L.C.)
CAUTION
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.
IMPORTANT
Do not start engine without coolant.
Use clean, fresh, soft water and anti-freeze to fill the radiator
and recovery tank.
Securely tighten radiator cap. If the cap is loose or
improperly fitted, water may leak out and the engine could
overheat.
W1024599
(1) Radiator Cap
(2) Drain Plug
(3) Recovery Tank
A : Full
B : Low
G-37
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 differs according
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.
IMPORTANT
* 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.
NOTE
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 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.)
W1024852
Vol %
anti-freeze
Freezing point Boiling point*
C F C F
40 24 11 106 223
50 37 35 108 226
G-38
G GENERAL
5. SPECIAL TOOLS
Diesel Engine Compression Tester
[D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M,
V2403-M-T]
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.
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.
W1206183
Oil Pressure Tester
Code No: 07916-32032
Application: Use to measure lubricating oil pressure.
W1024318
(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
(1) Gauge
(2) Hose Assembly
(3) L Joint
(4) Adaptor K
(5) Adaptor L
(6) Adaptor M
(1) Gauge
(2) Cable
(3) Threaded Joint
(4) Adaptor 1
(5) Adaptor 2
(6) Adaptor 3
(7) Adaptor 4
(8) Adaptor 5
G-39
G GENERAL
NOTE
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.
W10252400
Valve Guide Replacing Tool
Application: Use to press out and press fit the valve guide.
W1025017
A
Pressure gauge full scale : More than 29.4 MPa (300 kgf/cm
2
, 4267
psi)
B PF 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.)
Q PF 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.)
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.)
C0.3 Chamfer 0.3 mm (0.01 in.)
G-40
G GENERAL
Bushing Replacing Tools
Application: Use to press out and to press fit the bushing.
1. For small end bushing
2. For idle gear bushing
W1025500
Flywheel Stopper
Application: Use to loosen and tighten the flywheel screw.
W10259480
Crankshaft Bearing 1 Replacing Tool
Application: Use to press out and press fit the crankshaft bearing 1.
1. Extracting tool
2. Inserting tool
W1026139
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.)
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.)
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.)
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.)
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.)
G-41
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.
W1044361
Auxiliary Socket for Fixing Crankshaft Sleeve
Application: Use to fix the crankshaft sleeve of the diesel engine.
W1027695
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.)
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.)
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
G-42
G GENERAL
Auxiliary Socket for Fixing Crankshaft Sleeve (Continued)
Application: Use to fix the crankshaft sleeve of the diesel engine.
W1027898
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.)
C0.3 Chamfer 0.3 mm (0.01 in.)
R1 1.0 mm radius (0.039 in. radius)
(2) Sleeve Guide (3) Auxiliary Socket for Pushing
G-43
G GENERAL
Balancer Metal Replacing Tool (for Removing)
Application: Use to remove the metal bearing.
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-44
G GENERAL
Balancer Metal Replacing Tool (for Fitting)
Application: Use to press fit the metal bearing.
A 182 mm (7.17 in.) O
60 mm dia. (2.4 in. dia.)
B 140 mm (5.51 in.) P
46.950 to 46.975 mm dia. (1.8485 to 1.8494 in. dia.)
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.)
G-45
G GENERAL
Idle Gear 2 Puller
Application: Use for remove the idle gear 2 from the shaft.
W1028521
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.)
CONTENTS
MECHANISM
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
M-1
DIESEL ENGINE
1. ENGINE BODY
[1] PISTON
Pistons skirt is coated with molybdenum
disulfide, which reduces the piston slap noise and
thus the entire operating noise.
Molybdenum disulfide (MoS2)
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.
W1013114
(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
M-2
DIESEL ENGINE
[2] BUILT-IN DYNAMIC BALANCER (BALANCER MODEL ONLY)
Engine are sure to vibrate by pistons 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.
W1013221
(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
M-3
DIESEL ENGINE
[3] HALF-FLOATING HEAD COVER
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.
W1013327
(1) Cylinder Head Cover (2) Rubber Packing
M-4
DIESEL ENGINE
2. COOLING SYSTEM
[1] BOTTOM BYPASS SYSTEM
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 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.
W1013406
(1) Thermostat (A) Bypass Opened
(B) Bypass Closed
M-5
DIESEL ENGINE
3. FUEL SYSTEM
[1] GOVERNOR
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.
W1017186
(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
M-6
DIESEL ENGINE
4. TURBOCHARGER SYSTEM
[1] BOOST COMPENSATOR
W1014318
The higher the boost pressure rises, the more fuel is
fed. In this way, the turbocharger proves itself for high-
power 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
(1) Injection Pump Assembly
(2) Boost Compensator
Assembly
(3) Actuator
(4) Solenoid
(5) Plunger
(6) Solenoid Guide
(7) Hi-Idling Body
CONTENTS
SERVICING
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
S-1
DIESEL ENGINE
1. TROUBLESHOOTING
[1] ENGINE BODY
W1114419
Symptom Probable Cause Solution
Reference
Page
Engine Does Not
Start
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
Use specified fuel or
engine oil
5 to 15,
G-10
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)
Repair or replace (DI)
S-33, 34,
35, 49
S-33, 34,
35, 49
Injection pump malfunctioning Repair or replace S-29, 30,
31, 32, 54,
55
Seizure of crankshaft, camshaft, piston, cylinder
or bearing
Repair or replace S-61 to 67
S-90 to 96
Compression leak from cylinder Replace head
gasket, tighten
cylinder head screw,
glow plug and nozzle
holder
S-49, 50,
51, 52
Improper valve timing Correct or replace
timing gear
S-60, 61
Piston ring and cylinder worn Replace S-21, 22,
64 to 67,
88, 89, 95
Excessive valve clearance Adjust S-23
Solenoid malfunctioning Replace S-40, 54,
55
Starter Does Not Run Battery discharged Charge G-25, 26
Starter malfunctioning Repair or replace S-38, 46,
71, 97
Key switch malfunctioning Replace
Wiring disconnected Connect
S-2
DIESEL ENGINE
W1011567
Reference
Page
Engine Revolution Is
Not Smooth
Fuel filter clogged or dirty Replace G-22
Air cleaner clogged Clean or replace G-13, 20,
26
Fuel leak due to loose injection pipe retaining nut Tighten retaining nut S-48
31, 32, 54,
55
Incorrect nozzle opening pressure Adjust (IDI)
Repair or replace (DI)
S-34, 49
S-34, 49
Injection nozzle stuck or clogged Repair or replace S-34, 49
Governor malfunctioning Repair S-56, 57,
62
Turbocharger bearing worn out Replace the
turbocharger
assembly
S-47
Turbocharger shaft bent Replace the
turbocharger
assembly
S-47
Turbocharger fin or other part damaged due to
foreign matters
Replace the
turbocharger
assembly
S-47
Either White or Blue
Exhaust Gas Is
Observed
Excessive engine oil Reduce to specified
level
G-8
Piston ring and cylinder worn or stuck Repair or replace S-21, 22,
64 to 67,
88, 89, 95
Oil Leak into Exhaust
Pipe or Suction Pipe
Oil pipe clogged or deformed Repair or replace S-47
Turbochargers piston ring seal faulty Replace the
turbocharger
assembly
S-47
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,
26
Deficient nozzle injection Repair or replace
nozzle
S-33, 34,
35, 49
S-3
DIESEL ENGINE
W1012032
Reference
Page
Deficient Output Incorrect injection timing Adjust S-27, 28
Engines moving parts seem to be seizing Repair or replace
31, 32, 54,
55
nozzle
S-33, 34,
35, 49
Compression leak Check the
compression
pressure and repair
S-21, 22
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,
26
Turbocharger compressor wheel turning heavily Replace the
turbocharger
assembly
S-47
Excessive Lubricant
Oil Consumption
Piston rings 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 pumps plunger worn Repair or replace S-29, 30,
31, 32, 54,
55
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
S-4
DIESEL ENGINE
W1012501
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,
93
Excessive oil clearance of crankpin bearing Replace 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,
97
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-23
Overload running Reduce the load
Head gasket defective Replace S-51, 52
Unsuitable fuel used Use specified fuel 5 to 15
Battery Quickly
Discharged
Battery electrolyte insufficient Replenish distilled
water and charge
G-13, 25
Fan belt slips Adjust belt tension or
replace
G-13, 14,
24
Wiring disconnected Connect
Rectifier defective Replace S-71, 102
Alternator defective Replace S-72, 101
Battery defective Replace
S-5
DIESEL ENGINE
[2] ELECTRONIC GOVERNOR
IMPORTANT
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 related to an electronic governor
by checking an electronic governor.
Engine will not start.
W1039573
Engine stopped automatically. Engine can be started again and stops again 10 seconds later.
W1041393
Engine speed cannot be controlled.
W1041483
Cause Corrections Refer to Checking
Starter Operating but Not Cranking
the Engine
Check operation of the solenoid Solenoid
Check harness of the solenoid Solenoid
Check harness of the glow plug Glow plug
Starter Does Not Operate Check emergency stop switch Emergency stop switch
Trouble in the electronic governor
composition parts
Check blinking pattern of the glow
lamp (1)
Signal pattern sheet
(1) Glow Lamp
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 Solenoid
Check harness of speed sensor Harness
S-6
DIESEL ENGINE
W1042224
Blinking Pattern of Glow Lamp Cause Refer to Checking
(1-Long and 1-Short) Overrunning (more than
115 %)
Solenoid
(1-Long and 2-Short) Low oil pressure Oil sensor
(1-Long and 3-Short) Defect of alternator Alternator
(1-Long and 4-Short) Coolant temperature is
abnormal
Water temperature sensor
(1-Long and 5-Short) Emergency stop switch
operated
Emergency stop switch
(2-Long and 1-Short) Abnormality of speed
sensor
Speed sensor
(2-Long and 2-Short) Solenoid malfunction Solenoid
(2-Long and 4-Short) Disconnection of water
temperature sensor
(2-Long and 5-Short) Short circuit of water
temperature sensor
(2-Long and 6-Short) Disconnection of alternator
L Terminal
Alternator L Terminal
S-7
DIESEL ENGINE
2. SERVICING SPECIFICATIONS
ENGINE BODY
W1116131
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]
3.24 to 3.72 MPa /
290 min
-1
(rpm)
33.0 to 38.0 kgf/cm
2
/
290 min
-1
(rpm)
470 to 540 psi /
290 min
-1
(rpm)
2.55 MPa /
290 min
-1
(rpm)
26.0 kgf/cm
2
/
290 min
-1
(rpm)
370 psi /
290 min
-1
(rpm)
(When Cranking with Starting Motor)
[D1803-M-DI], [V2403-M-DI]
[V2403-M-DI-T]
Difference among Cylinders
2.95 to 3.23 MPa /
290 min
-1
(rpm)
30.0 to 33.0 kgf/cm
2
/
290 min
-1
(rpm)
427 to 469 psi /
290 min
-1
(rpm)
2.35 MPa /
290 min
-1
(rpm)
24.0 kgf/cm
2
/
290 min
-1
(rpm)
341 psi /
290 min
-1
(rpm)
10 % or less
Top Clearance
[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]
0.575 to 0.675 mm
0.0227 to 0.0265 in.
Top Clearance
[D1803-M-DI], [V2403-M-DI]
[V2403-M-DI-T]
0.60 to 0.70 mm
0.024 to 0.027 in.
Cylinder Head Surface Flatness 0.05 mm / 500 mm

0.002 in. /
19.7 in.
Valve Recessing
(Protrusion to Recessing)
[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]
Protrusion
Recessing
0.05 mm
0.002 in.
0.15 mm
0.0059 in.
0.40 mm
0.016 in.
Valve Recessing
[D1803-M-DI], [V2403-M-DI]
[V2403-M-DI-T]
Recessing 0.65 to 0.85 mm
0.026 to 0.033 in.

S-8
DIESEL ENGINE
ENGINE BODY (Continued)
W1014004
Valve Stem to Valve Guide
Valve Stem
Valve Guide
Clearance
O.D.
I.D.
0.040 to 0.070 mm
0.0016 to 0.0027 in.
7.960 to 7.975 mm
0.3134 to 0.3139 in.
8.015 to 8.030 mm
0.3156 to 0.3161 in.
0.10 mm
0.0039 in.
Valve Face
[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]
Angle (Intake)
Angle (Exhaust)
1.0 rad
60
0.79 rad
45
Valve Face
[D1803-M-DI], [V2403-M-DI]
[V2403-M-DI-T]
Angle (Intake)
Angle (Exhaust)
0.79 rad
45
0.79 rad
45
Valve Seat Width (Intake)

Width (Exhaust)
2.12 mm
0.0835 in.
2.12 mm
0.0835 in.
Valve 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]
Angle (Intake)
Angle (Exhaust)
1.0 rad
60
0.79 rad
45
Valve Seat
[D1803-M-DI], [V2403-M-DI]
[V2403-M-DI-T]
Angle (Intake)
Angle (Exhaust)
0.79 rad
45
0.79 rad
45
Valve Timing (Intake Valve)

[D1503-M]
[D1703-M-BG]
Open
Close
0.1 rad (8 )
before T.D.C.
0.35 rad (20 )
after B.D.C.

[D1703-M], [D1803-M]
[V2003-M], [V2203-M]
[V2403-M], [V2403-M-DI-T]
[V2003-M-BG], [V2203-M-BG]
[V2403-M-BG]
Open
Close
0.21 rad (12 )
before T.D.C.
0.63 rad (36 )
after B.D.C.

S-9
DIESEL ENGINE
W1014959
[V2403-M-T]
[V2003-M-T-BG]
Open
Close
0.35 rad (20 )
before T.D.C.
0.79 rad (45 )
after B.D.C.

[D1803-M-DI]
[V2403-M-DI]
Open
Close
0.2 rad (9 )
before T.D.C.
0.68 rad (39 )
after B.D.C.
Valve Timing (Exhaust Valve)

[D1503-M]
[V2003-M]
Open
Close
1.0 rad (60 )
before B.D.C.
0.21 rad (12 )
after T.D.C.

[D1703-M], [D1803-M]
[V2203-M], [V2403-M]
[V2403-M-BG]
Open
Close
0.99 rad (57 )
before B.D.C.
0.21 rad (12 )
after T.D.C.

[V2403-M-T]
[V2403-M-DI-T]
[D1703-M-BG]
[V2003-M-BG]
[V2203-M-BG]
Open
Close
0.87 rad (50 )
before B.D.C.
0 rad (0 )
after T.D.C.

[D1803-M-DI]
[V2403-M-DI]
Open
Close
0.72 rad (41 )
before B.D.C.
0.2 rad (9 )
after T.D.C.

[V2003-M-T-BG]
Open
Close
0.96 rad (55 )
before B.D.C.
0.24 rad (14 )
after T.D.C.
Valve Spring Free Length

Setting Load /
Setting Length
Tilt
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.
S-10
DIESEL ENGINE
W1015276
Rocker Arm Shaft to Rocker Arm
Rocker Arm Shaft
Rocker Arm
Oil Clearance
O.D.
I.D.
0.016 to 0.045 mm
0.00063 to 0.0017 in.
13.973 to 13.984 mm
0.55012 to 0.55055 in.
14.000 to 14.018 mm
0.55119 to 0.55188 in.
0.10 mm
0.0039 in.
Push Rod Alignment 0.25 mm

0.0098 in.
Tappet to Tappet Guide
Tappet
Tappet Guide
Oil Clearance
O.D.
I.D.
0.020 to 0.062 mm
0.00079 to 0.0024 in.
23.959 to 23.980 mm
0.94327 to 0.94409 in.
24.000 to 24.021 mm
0.94489 to 0.94570 in.
0.07 mm
0.003 in.
Timing Gear
Crank Gear to Idle Gear
Idle Gear to Cam Gear
Idle Gear to Injection Pump Gear
Crank Gear to Oil Pump Gear
Idle Gear to Balancer Gear
(Balancer Model Only)
Cam Gear to Balancer Gear
Crank Gear to Idle Gear 2
(Side PTO Model Only)
Idle Gear 2 to Hydraulic Pump Drive Gear
(Side PTO Model Only)
Backlash
Backlash
Backlash
Backlash
Backlash
Backlash
Backlash
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.
0.04150 to 0.1090 mm
0.001634 to 0.004291 in.
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.
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.
0.15 mm
0.0059 in.
0.15 mm
0.0059 in.
0.15 mm
0.0059 in.
Idle Gear Side Clearance 0.12 to 0.48 mm
0.0048 to 0.018 in.
0.9 mm
0.04 in.
Idle Gear Shaft to Idle Gear Bushing
Idle Gear Shaft
Idle Gear Bushing
Oil Clearance
O.D.
I.D.
0.025 to 0.066 mm
0.00099 to 0.0025 in.
37.959 to 37.975 mm
1.4945 to 1.4950 in.
38.000 to 38.025 mm
1.4961 to 1.4970 in.
0.10 mm
0.0039 in.

S-11
DIESEL ENGINE
W1117772
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]
[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]
Height
33.27 mm
1.310 in.
33.47 mm
1.318 in.
33.90 mm
1.335 in.
33.22 mm
1.308 in.
33.42 mm
1.316 in.
33.85 mm
1.333 in.
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]
Height
33.00 mm
1.299 in.
33.27 mm
1.310 in.
33.47 mm
1.318 in.
33.90 mm
1.335 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.
Camshaft Journal to Cylinder Block Bore
Camshaft Journal
Cylinder Block Bore
Oil Clearance
O.D.
I.D.
0.050 to 0.091 mm
0.0020 to 0.0035 in.
39.934 to 39.950 mm
1.5722 to 1.5728 in.
40.000 to 40.025 mm
1.5748 to 1.5757 in.
0.15 mm
0.0059 in.
Balancer Shaft
Side Clearance 0.070 to 0.22 mm
0.0028 to 0.0086 in.
0.30 mm
0.012 in.
Balancer Shaft
Alignment 0.02 mm
0.0008 in.
S-12
DIESEL ENGINE
W1119370
Balancer Shaft Journal 1 to Balancer Shaft
Bearing 1 (Balancer Model Only)
Balancer Shaft Journal 1
Balancer Shaft Bearing 1
Oil Clearance
O.D.
I.D.
0.0300 to 0.111 mm
0.00119 to 0.00437 in.
43.934 to 43.950 mm
1.7297 to 1.7303 in.
43.980 to 44.045 mm
1.7315 to 1.7340 in.
0.20 mm
0.0079 in.

Oil Clearance
O.D.
I.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.
41.980 to 42.045 mm
1.6528 to 1.6553 in.
0.20 mm
0.0079 in.

Oil Clearance
O.D.
I.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.
21.980 to 22.041 mm
0.86536 to 0.86775 in.
0.20 mm
0.0079 in.
Piston Pin Bore I.D. 25.000 to 25.013 mm

0.98426 to 0.98476 in.
25.05 mm
0.9862 in.
Top Ring to Ring Groove
[D1803-M-DI]
[V2403-M-DI]
Clearance 0.050 to 0.090 mm
0.0020 to 0.0035 in.
0.20 mm
0.0079 in.
Second Ring to Ring Groove
[D1503-M], [D1703-M]
[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]
0.00367 to 0.00503 in.
0.20 mm
0.0079 in.
Second Ring to Ring Groove
[D1803-M-DI], [V2403-M-DI]
0.00307 to 0.00433 in.
0.20 mm
0.0079 in.
Oil Ring to Ring Groove
[D1503-M], [D1703-M]
[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]
0.00079 to 0.0023 in.
0.15 mm
0.0059 in.
Oil Ring to Ring Groove
[D1803-M-DI], [V2403-M-DI]
0.0012 to 0.0027 in.
0.15 mm
0.0059 in.
S-13
DIESEL ENGINE
W1086708
Top Ring
[D1503-M], [V2003-M], [V2403-M-T]
[D1803-M-DI], [V2403-M-DI]
[V2403-M-DI-T]
[V2003-M-BG], [V2003-M-T-BG],
Ring Gap 0.20 to 0.35 mm
0.0079 to 0.013 in.
1.25 mm
0.0492 in.
Top Ring
[D1703-M], [D1803-M]
[V2203-M], [V2403-M]
[D1703-M-BG], [V2203-M-BG]
[V2403-M-BG]
0.0099 to 0.015 in.
1.25 mm
0.0492 in.
Second Ring
[D1503-M], [D1703-M]
[D1803-M], [V2203-M]
[V2403-M]
[D1803-M-DI], [V2403-M-DI]
[D1703-M-BG], [V2003-M-BG]
[V2203-M-BG], [V2403-M-BG]
0.012 to 0.017 in.
1.25 mm
0.0492 in.
Second Ring
[V2003-M], [V2403-M-T], [V2403-M-DI-T]
[V2003-M-T-BG]
0.016 to 0.021 in.
1.25 mm
0.0492 in.
Oil Ring
[D1503-M], [D1703-M]
[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]
0.0099 to 0.017 in.
1.25 mm
0.0492 in.
Oil Ring
[D1803-M-DI], [V2403-M-DI]
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
Piston Pin
Small End Bushing
Oil Clearance
O.D.
I.D.
0.014 to 0.036 mm
0.00056 to 0.0014 in.
25.004 to 25.011 mm
0.98441 to 0.98468 in.
25.025 to 25.040 mm
0.98524 to 0.98582 in.
0.15 mm
0.0059 in.
Crankshaft Alignment 0.02 mm

0.0008 in.
Crankshaft Journal to Crankshaft Bearing
1
Crankshaft Journal
Crankshaft Bearing 1
Oil Clearance
O.D.
I.D.
0.0400 to 0.118 mm
0.00158 to 0.00464 in.
59.921 to 59.940 mm
2.3591 to 2.3598 in.
59.980 to 60.039 mm
2.3615 to 2.3637 in.
0.20 mm
0.0079 in.

S-14
DIESEL ENGINE
W1054843
Crankshaft Journal to Crankshaft Bearing
2
Crankshaft Journal
Crankshaft Bearing 2
Oil Clearance
O.D.
I.D.
0.0400 to 0.104 mm
0.00158 to 0.00409 in.
59.921 to 59.940 mm
2.3591 to 2.3598 in.
59.980 to 60.025 mm
2.3615 to 2.3631 in.
0.20 mm
0.0079 in.
Crankpin to Crankpin Bearing

Crankpin
Crankpin Bearing
Oil Clearance
O.D.
I.D.
0.025 to 0.087 mm
0.00099 to 0.0034 in.
46.959 to 46.975 mm
1.8488 to 1.8494 in.
47.000 to 47.046 mm
1.8504 to 1.8522 in.
0.20 mm
0.0079 in.
Crankshaft Side Clearance 0.15 to 0.31 mm

0.0059 to 0.012 in.
0.5 mm
0.02 in.
Cylinder Bore (Standard)
[D1503-M], [V2003-M]
[V2003-M-BG], [V2003-M-T-BG]
I.D. 83.000 to 83.022 mm
3.2678 to 3.2685 in.
83.170 mm
3.2744 in.
Cylinder Bore (Standard)
[D1703-M], [D1803-M]
[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]
I.D. 87.000 to 87.022 mm
3.4252 to 3.4260 in.
87.170 mm
3.4319 in.
Cylinder Bore (Oversize)
[D1503-M], [V2003-M]
[V2003-M-BG], [V2003-M-T-BG]
I.D. 83.250 to 83.272 mm
3.2776 to 3.2784 in.
83.420 mm
3.2843 in.
Cylinder Bore (Oversize)
[D1703-M], [D1803-M]
[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]
I.D. 87.250 to 87.272 mm
3.4351 to 3.4359 in.
87.420 mm
3.4417 in.
Difference among Minimum Wear to
Maximum Wear
0.15 mm
0.0059 in.
S-15
DIESEL ENGINE
LUBRICATING SYSTEM
W1120963
COOLING SYSTEM
W1122456
Engine Oil Pressure At Idle Speed
At Rated Speed
More than 98 kPa
1.0 kgf/cm
2
14 psi
300 to 440 kPa
3.0 to 4.5 kgf/cm
2
43 to 64 psi
50 kPa
0.5 kgf/cm
2
7 psi
250 kPa
2.5 kgf/cm
2
36 psi
Engine Oil Pressure Switch Working
Pressure
50 kPa
0.5 kgf/cm
2
7 psi
Inner Rotor to Outer Rotor Clearance 0.030 to 0.14 mm

0.0012 to 0.0055 in.
0.2 mm
0.008 in.
Outer Rotor to Pump Body Clearance 0.11 to 0.19 mm
0.0044 to 0.0074 in.
0.25 mm
0.0098 in.
Inner Rotor to Cover Clearance 0.105 to 0.150 mm
0.00414 to 0.00590 in.
0.20 mm
0.008 in.
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]
[V2203-M], [V2403-M]
[V2403-M-T]
[D1703-M-BG], [V2003-M-BG]
[V2003-M-T-BG], [V2203-M-BG]
[V2403-M-BG]
Valve Opening
Temperature
(At Beginning)
Valve Opening
Temperature
(Opened
Completely)
69.5 to 72.5 C
157.1 to 162.5 F
85 C
185 F
Thermostat
[D1803-M-DI], [V2403-M-DI]
[V2403-M-DI-T]
Valve Opening
Temperature
(At Beginning)
Valve Opening
Temperature
(Opened
Completely)
80.5 to 83.5 C
176.9 to 182.3 F
95 C
203 F
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
2
from 10 to 9 psi

S-16
DIESEL ENGINE
FUEL SYSTEM
W1123952
Injection Pump
[D1503-M], [V2003-M-T-BG]
Injection Timing 0.253 to 0.279 rad
(14.5 to 16.0 ) before
T.D.C.
Injection Pump
[D1703-M], [D1803-M]
[V2003-M], [V2203-M]
[V2403-M]
(15.5 to 17.0 ) before
T.D.C.
Injection Pump
[V2403-M-T]
(7.55 to 9.05 ) before
T.D.C.
Injection Pump
[D1803-M-DI], [V2403-M-DI]
(4.25 to 5.75 ) before
T.D.C.
Injection Pump
[V2403-M-DI-T]
(4.75 to 6.25 ) before
T.D.C.
Injection Pump
[D1703-M-BG], [V2003-M-BG]
[V2203-M-BG], [V2403-M-BG]
(13.5 to 15.0 ) before
T.D.C.
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]
Fuel Tightness 13.73 MPa
140.0 kgf/cm
2
1991 psi
Pump Element
[D1803-M-DI], [V2403-M-DI]
[V2403-M-DI-T]
Fuel Tightness 18.63 MPa
190.0 kgf/cm
2
2702 psi
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]
Fuel Tightness 10 seconds
13.73 12.75 MPa
140.0 130.0 kgf/cm
2
1991 1849 psi
5 seconds
13.73 12.75 MPa
140.0
130.0 kgf/cm
2
1991 1849 psi
Delivery Valve
[D1803-M-DI], [V2403-M-DI]
[V2403-M-DI-T]
Fuel Tightness 10 seconds
18.63 17.65 MPa
190.0 180.0 kgf/cm
2
2702 2560 psi
5 seconds
18.63 17.65 MPa
190.0
180.0 kgf/cm
2
2702 2560 psi
S-17
DIESEL ENGINE
FUEL SYSTEM (Continued)
W1041294
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 Pressure 13.73 to 14.70 MPa
140.0 to 150.0 kgf/cm
2
1992 to 2133 psi
Injection Nozzle
[D1803-M-DI], [V2403-M-DI]
[V2403-M-DI-T]
Injection Pressure
(1st stage)
18.64 to 20.10 MPa
190.0 to 205.0 kgf/cm
2
2703 to 2915 psi
Injection Nozzle Valve 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]
Valve Seat
Tightness
When the pressure is
12.75 MPa
(130.0 kgf/cm
2
, 1849
psi), the valve seat must
be fuel tightness.
Injection Nozzle Valve Seat

[D1803-M-DI], [V2403-M-DI]
[V2403-M-DI-T]
Valve Seat
Tightness
When the pressure is
16.67 MPa
(170.0 kgf/cm
2
, 2418
psi), the valve seat must
be fuel tightness.

S-18
DIESEL ENGINE
ELECTRICAL SYSTEM
W1125417
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]
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]
Brush
[D1803-M], [V2403-M]
[V2403-M-DI], [V2403-M-T]
[V2403-M-DI-T]
Brush
[V2403-M-BG]
Brush Holder and Holder Support
O.D.
O.D.
Under Cut
Under Cut
Length
Length
Length
Resistance
30.0 mm
1.18 in.
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.
15.0 mm
0.591 in.
15.0 mm
0.591 in.
Infinity
29.0 mm
1.14 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.
9.0 mm
0.35 in.
12.0 mm
0.472 in.
Alternator
Stator
Rotor
Slip Ring
Brush
No-load voltage
Resistance
Resistance
O.D.
Length
More than 13.5 V
Less than 1.0
2.9
14.4 mm
0.567 in.
10.5 mm
0.413 in.
14.0 mm
0.551 in.
8.4 mm
0.33 in.
Glow Plug Resistance Approx. 0.9
S-19
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 GENERAL USE SCREWS, BOLTS AND
NUTS
When the tightening torques are not specified, tighten the screws, bolts and nuts according to the table below.
W10371750
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.
W1012705
Grade
Nominal Unit
Diameter
Standard Screw and Bolt

Special Screw and Bolt
Nm kgfm lbfft Nm kgfm lbfft
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
Punched number Screw and bolt material grade
None or 4 Standard screw and bolt SS41, S20C
7 Special screw and bolt S43C, S48C (Refined)
S-20
DIESEL ENGINE
[2] TIGHTENING TORQUES FOR SPECIAL USE SCREWS, BOLTS AND
NUTS
NOTE
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.
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
W1013236
Item Size x Pitch Nm kgfm lbfft
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)
M12 x 1.5 20 to 24 2.0 to 2.5 15 to 18
Overflow pipe assembly retaining screw
(DI)
M6 x 1.0 9.81 to 11.2 1.00 to 1.15 7.24 to 8.31
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)
M8 x 1.25 24 to 27 2.4 to 2.8 18 to 20
Alternators 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)
49 to 55 5.0 to 5.7 37 to 41
Idle gear 2 shaft set screw
(Side PTO model only)
24 to 27 2.4 to 2.8 18 to 20
Starters terminal B mounting nut M8 5.9 to 11 0.60 to 1.2 4.4 to 8.6
S-21
DIESEL ENGINE
4. CHECKING, DISASSEMBLING AND SERVICING
[1] CHECKING AND ADJUSTING
(1) Engine Body
[D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M,
V2403-M-T]
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.
NOTE
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 %.
W1018639
Compression pressure
Factory spec.
3.24 to 3.72 MPa
33.0 to 38.0 kgf/cm
2
470 to 540 psi
Allowable limit
2.55 MPa
26.0 kgf/cm
2
370 psi
S-22
DIESEL ENGINE
[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.
NOTE
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 %.
W1111297
Compression pressure
Factory spec.
2.95 to 3.23 MPa
30.0 to 33.0 kgf/cm
2
427 to 469 psi
Allowable limit
2.35 MPa
24.0 kgf/cm
2
341 psi
S-23
DIESEL ENGINE
Valve Clearance
IMPORTANT
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.
NOTE
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 tighten the lock
nut of the adjusting screw.
W10379490
Valve clearance Factory spec.
0.18 to 0.22 mm
0.0071 to 0.0086 in.
Valve arrangement
Adjustable
cylinder
location of piston
3 Cylinder 4 Cylinder
IN. EX. IN. EX.
at compression top
dead center
No. 1
No. 2
No. 3
No. 4
at overlap position
No. 1
No. 2
No. 3
No. 4
(1) Valve Clearance
(2) Projection
(3) 1TC Mark Line
S-24
DIESEL ENGINE
(2) Lubricating System
Engine Oil Pressure
1. Remove the engine oil pressure switch, and set an oil pressure
tester (Code No.: 07916-32032). (Adaptor screw size : PT 1/8)
2. Start the engine. After warming up, measure the oil pressure of
both idling and rated speeds.
3. If the oil pressure is less than the allowable limit, check the
following.
Engine oil insufficient.
Oil pump defective
Oil strainer clogged
Oil filter cartridge clogged
Oil gallery clogged
Excessive oil clearance
Foreign matter in the relief valve
(When reassembling)
After checking the engine oil pressure, tighten the engine oil
pressure switch to the specified torque.
W1034952
(3) Cooling System
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.
W10356670
Engine oil pressure
At idle
speed
Factory
spec.
More than 98 kPa
1.0 kgf/cm
2
14 psi
Allowable
limit
50 kPa
0.5 kgf/cm
2
7 psi
At rated
speed
Factory
spec.
300 to 440 kPa
3.0 to 4.5 kgf/cm
2
43 to 64 psi
Allowable
limit
250 kPa
2.5 kgf/cm
2
36 psi
Tightening torque Oil pressure switch
15 to 19 Nm
1.5 to 2.0 kgfm
11 to 14 lbfft
7.0 to 9.0 mm
0.28 to 0.35 in.
(A) Deflection
S-25
DIESEL ENGINE
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.
W1020602
CAUTION
When removing the radiator cap, wait at least ten minutes after the engine has stopped and cooled down.
Otherwise, hot water may gush out, scalding nearby people.
Radiator Cap Air Leakage
1. Set a radiator tester and an adaptor on the radiator cap.
2. Apply the specified pressure 90 kPa (0.9 kgf/cm
2
, 10 psi), and
measure the time for the pressure to fall to 60 kPa (0.6 kgf/cm
2
,
9 psi).
3. If the measurement is less than the factory specification, replace
the radiator cap.
W10387530
Radiator Water Leakage
1. Pour a specified amount of water into the radiator.
2. Set a radiator tester and an adaptor and raise the water pressure
to the specified pressure.
3. Check the radiator for water leaks.
4. For water leak from the pinhole, replace the radiator or repair with
the radiator cement. When water leak is excessive, replace the
radiator.
NOTE
The pressure of the leak test is different from each radiator
specification.
Thus, do the leak test, refer to the test pressure of each
radiator specification.
W10389070
(A) Good (B) Bad
Pressure falling time Factory spec.
More than 10 seconds
for pressure fall from
90 to 60 kPa
(from 0.9 to 0.6 kgf/cm
2
,
from 10 to 9 psi)
Radiator water leakage
test pressure
Factory spec.
No leak at specified
pressure
S-26
DIESEL ENGINE
Thermostat Valve Opening Temperature
1. Suspend the thermostat in the water by a string with its end
inserted between the valve and seat.
2. Heating the water gradually, read the temperature when the
valve opens and leaves the string.
3. Continue heating and read the temperature when the valve
opens approx. 6 mm (0.2 in.).
replace the thermostat.
W1035849
Thermostats valve
opening temperature
Factory
spec.
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
69.5 to 72.5 C
157.1 to 162.5 F
D1803-M-DI
V2403-M-DI
V2403-M-DI-T
80.5 to 83.5 C
176.9 to 182.3 F
Temperature at
which thermostat
completely opens
Factory
spec.
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
85 C
185 F
D1803-M-DI
V2403-M-DI
V2403-M-DI-T
95 C
203 F
S-27
DIESEL ENGINE
(4) Fuel System
Injection Timing
[D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M,
V2403-M-T]
V2403-M-BG]
1. Remove the stop solenoid.
2. Remove the injection pipes and nozzle.
3. Set the speed control lever to maximum fuel discharge position.
(Reference)
Turn the flywheel with screwdriver.
4. Turn the flywheel counterclockwise (facing the flywheel) until the
fuel fills up to the hole of the delivery valve holder for 1st cylinder.
5. Turn the flywheel further and stop turning when the fuel begins to
flow over, to get the present injection timing.
6. (The flywheel has mark 1TC and four lines indicating every 0.09
rad (5 ) of crank angle from 0.17 rad (10 ) to 0.44 rad (25 )
before mark 1TC) Calculate the angle which the center of the
window points out. If the calculation differs from specified
injection timing, add or remove the shim to adjust.
(Injection Timing)
NOTE
The sealant is applied to both sides of the soft metal gasket
shim. The liquid gasket is not required for assembling.
Shims are available in thickness of 0.175 mm (6), 0.20 mm
(3), 0.25 mm (4) and 0.30 mm (5). Combine these shims for
adjustments.
The 0.175 mm thick shim is coated only on the lower face.
Therefore, do not use the 0.175 mm thick shim as the top
shim of the combination (injection pump side), because this
cause oil leakage.
Addition or reduction of shim (0.05 mm, 0.002 in.) delays or
advances the injection timing by approx. 0.009 rad (0.5 ).
In disassembling and replacing, be sure to use the same
number of new gasket shims with the same thickness.
W1036402
Model Injection timing
D1503-M
V2003-M-T-BG
0.253 to 0.279 rad (14.5 to 16.0 ) before T.D.C.
D1703-M, D1803-M
V2003-M, V2203-M
V2403-M
V2403-M-T 0.132 to 0.157 rad (7.55 to 9.05 ) before T.D.C.
D1703-M-BG
V2003-M-BG
V2203-M-BG
V2403-M-BG
(1) Delivery Valve Holder
(2) Timing Mark
(3) 2-Holes: 0.20 mm (Shim)
(4) 1-hole: 0.25 mm (Shim)
(5) Without hole: 0.30 mm (Shim)
(6) 2-Holes: 0.175 mm (Shim)
(A) 3 Cylinder
(B) 4 Cylinder
S-28
DIESEL ENGINE
Injection Timing
[D1803-M-DI, V2403-M-DI, V2403-M-DI-T]
1. Remove the stop solenoid.
2. Remove the injection pipes and nozzle.
3. Set the speed control lever to maximum fuel discharge position.
(Reference)
Turn the flywheel with screwdriver.
4. Turn the flywheel counterclockwise (facing the flywheel) until the
fuel fills up to the hole of the delivery valve holder for 1st cylinder.
5. Turn the flywheel further and stop turning when the fuel begins to
flow over, to get the present injection timing.
6. (The flywheel has mark 1TC and four lines indicating every 0.09
rad (5 ) of crank angle from 0.17 rad (10 ) to 0.44 rad (25 )
before mark 1TC) Calculate the angle which the center of the
window points out. If the calculation differs from specified
injection timing, add or remove the shim to adjust.
(Injection Timing)
NOTE
The sealant is applied to both sides of the soft metal gasket
shim. The liquid gasket is not required for assembling.
Shims are available in thickness of 0.175 mm (7), 0.20 mm
(3), 0.25 mm (4), 0.30 mm (5) and 0.35 mm (6). Combine these
shims for adjustments.
The 0.175 mm thick shim is coated only on the lower face.
Therefore, do not use the 0.175 mm thick shim as the top
shim of the combination (injection pump side), because this
cause oil leakage.
Addition or reduction of shim (0.05 mm, 0.002 in.) delays or
advances the injection timing by approx. 0.009rad (0.5 ).
In disassembling and replacing, be sure to use the same
number of new gasket shims with the same thickness.
W1047775
Model Injection Timing
D1803-M-DI
V2403-M-DI
V2403-M-DI-T 0.0829 to 0.109 rad (4.75 to 6.25 ) before T.D.C.
(1) Delivery Valve Holder
(2) Timing Mark
(4) 1-hole: 0.25 mm (Shim)
(5) Without hole: 0.30 mm (Shim)
(7) 2-Holes: 0.175 mm (Shim)
(A) 3 Cylinder
(B) 4 Cylinder
S-29
DIESEL ENGINE
Fuel Tightness of Pump Element
[D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M,
V2403-M-T]
V2403-M-BG]
figure.)
service shop.
NOTE
W1017430
element
Allowable limit
13.73 MPa
140.0 kgf/cm
2
1991 psi
S-30
DIESEL ENGINE
Fuel Tightness of Pump Element
[D1803-M-DI, V2403-M-DI, V2403-M-DI-T]
figure.)
service shop.
NOTE
W1104546
element
Allowable limit
18.63 MPa
190.0 kgf/cm
2
2702 psi
S-31
DIESEL ENGINE
Fuel Tightness of Delivery Valve
[D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M,
V2403-M-T]
V2403-M-BG]
2
, 1991 psi).
taken for the pressure to drop from 13.73 to 12.75 MPa (140.0 to
130.0 kgf/cm
2
, 1991 to 1849 psi).
12.75 MPa (140.0 to 130.0 kgf/cm
2
, 1991 to 1849 psi).
shop.
NOTE
W1017786
Fuel tightness of delivery
valve
Factory spec.
10 seconds
13.73 12.75 MPa
140.0 130.0 kgf/cm
2
1991 1849 psi
Allowable limit
5 seconds
13.73 12.75 MPa
140.0 130.0 kgf/cm
2
1991 1849 psi
S-32
DIESEL ENGINE
Fuel Tightness of Delivery Valve
[D1803-M-DI, V2403-M-DI, V2403-M-DI-T]
2
, 2702 psi).
taken for the pressure to drop from 18.63 to 17.65 MPa (190.0 to
180.0 kgf/cm
2
, 2702 to 2560 psi).
17.65 MPa (190.0 to 180.0 kgf/cm
2
, 2702 to 2560 psi).
shop.
NOTE
W1108296
Fuel tightness of delivery
valve
Factory spec.
10 seconds
18.63 17.65 MPa
190.0 180.0 kgf/cm
2
2702 2560 psi
Allowable limit
5 seconds
18.63 17.65 MPa
190.0 180.0 kgf/cm
2
2702 2560 psi
S-33
DIESEL ENGINE
CAUTION
Check the injection pressure and condition after confirming that there is nobody standing in the direction
the fume goes.
If the fume from the nozzle directly contacts the human body, cells may be destroyed and blood poisoning
may be caused.
Nozzle Spraying Condition
[D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M,
V2403-M-T]
V2403-M-BG]
spraying condition.
2. If the spraying condition is defective, replace the nozzle piece.
W10181310
[D1803-M-DI, V2403-M-DI, V2403-M-DI-T]
spraying condition.
2. If the spraying condition is defective, replace the injection nozzle
assembly.
W10226470
(a) Good (b) Bad
(a) Good (b) Bad
S-34
DIESEL ENGINE
Fuel Injection Pressure
[D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M,
V2403-M-T]
V2403-M-BG]
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
2
, 85 psi)
W10476390
[D1803-M-DI, V2403-M-DI, V2403-M-DI-T]
replace the injection nozzle assembly.
W10227280
Fuel injection pressure Factory spec.
13.73 to 14.70 MPa
140.0 to 150.0 kgf/cm
2
1992 to 2133 psi
Fuel injection pressure
(1st stage)
Factory spec.
18.64 to 20.10 MPa
190.0 to 205.0 kgf/cm
2
2703 to 2915 psi
S-35
DIESEL ENGINE
Valve Seat Tightness
[D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M,
V2403-M-T]
V2403-M-BG]
2
,
3. If any fuel leak is found, replace the nozzle piece.
W10183690
[D1803-M-DI, V2403-M-DI, V2403-M-DI-T]
2
,
3. If any fuel leak is found, replace the injection nozzle assembly.
W10228300
Nozzle Holder
[D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M,
V2403-M-T]
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.
W1018491
No fuel leak at
12.75 MPa
130.0 kgf/cm
2
1849 psi
No fuel leak at
16.67 MPa
170.0 kgf/cm
2
2418 psi
Tightening torque
Nozzle holder
35 to 39 Nm
3.5 to 4.0 kgfm
26 to 28 lbfft
Overflow pipe retaining nut
20 to 24 Nm
2.0 to 2.5 kgfm
15 to 18 lbfft
Nozzle holder assembly
49 to 68 Nm
5.0 to 7.0 kgfm
37 to 50 lbfft
(1) Nozzle Holder
(3) Nozzle Spring
(4) Push Rod
(5) Distance Piece
(6) Nozzle Piece
(7) Nozzle Retaining Nut
S-36
DIESEL ENGINE
(5) Electrical System
CAUTION
To avoid accidental short circuit, be sure to attach the positive cable to the positive terminal before the
negative cable is attached to the negative terminal.
Never remove the battery cap while the engine is running.
Keep electrolyte away from eyes, hands and clothes. If you are spattered with it, wash it away completely
with water immediately.
Keep open sparks and flames away from the battery at all times. Hydrogen gas mixed with oxygen
becomes very explosive.
IMPORTANT
If the machine is to be operated for a short time without battery (using a slave battery for starting), use
additional current (lights) while engine is running and insulate terminal of battery. If this advice is
disregarded, damage to alternator and regulator may result.
Battery Voltage
1. Stop the engine.
2. Measure the voltage with a circuit tester between the battery
terminals.
3. If the battery voltage is less than the factory specification, check
the battery specific gravity and recharge the battery.
W10125620
Battery voltage Factory spec. More than 12 V
(1) Positive Terminal (2) Negative Terminal
S-37
DIESEL ENGINE
Battery Specific Gravity
1. Check the specific gravity of the electrolyte in each cell with a
hydrometer.
2. When the electrolyte temperature differs 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.
NOTE
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 hydrometer 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)
At an electrolyte temperature of 20 C (68 F)
W1019017
Specific Gravity State of Charge
1.140 Sp. Gr. Very Little Useful Capacity
1.110 Sp. Gr. Discharged
(a) Good
(b) Bad
(c) Bad
S-38
DIESEL ENGINE
Motor Test
CAUTION
Secure the starter to prevent it from jumping up and down
while testing the motor.
1. Disconnect the battery negative cable from the battery.
2. Disconnect the battery positive cable from the battery.
3. Disconnect the leads from the starter B terminal.
4. Remove the starter from the engine.
5. Connect a jumper lead from the starter C terminal (1) to the
battery positive terminal (2).
6. Connect a jumper lead momentarily between the starters body
and the battery negative terminal (3).
7. If the motor does not run, starter is failure.
Repair or replace the starter.
NOTE
B terminal : It is the terminal which connects the cable from
the battery to the starter.
C terminal : It is the terminal which connects the cable from
the motor to the magnet switch.
W1019297
Magnetic Switch Test
1. Disconnect the battery negative cable from the battery.
2. Disconnect the battery positive cable from the battery.
3. Disconnect the leads from the starter B terminal.
4. Remove the starter from the engine.
5. Connect a jumper lead from the starter S terminal (1) to the
battery positive terminal (2).
6. Connect a jumper lead momentarily between the starters body
and the battery negative terminal (3).
7. If the pinion gear does not pop out, the magnetic switch is failure.
Repair or replace the starter.
NOTE
B terminal : It is the terminal which connects the cable from
the battery to the starter.
S terminal : It is the terminal which connects the cable from
the starter switch to the magnet switch.
0000010743E
Magnet Switch Continuity Test
1. Check the continuity across the C terminal (1) and the B terminal
(2) with a circuit tester, pushing in the plunger.
2. If not continuous or if a certain value is indicated, replace the
magnet switch.
0000010771E
(1) C Terminal
(2) Positive Terminal
(3) Negative Terminal
(1) S Terminal
(2) Positive Terminal
(3) Negative Terminal
(1) C Terminal (2) B Terminal
S-39
DIESEL ENGINE
Alternator on Unit Test
(Before testing)
Before alternator on unit test, check the battery terminal
connections, circuit connection, fan belt tension, charging
indicator lamp, fuses on the circuit, and abnormal noise from the
alternator.
Prepare full charged battery for the test.
NOTE
Be careful not to touch the rotating engine parts while
engine is running.
Keep safety distance from the engine rotating parts.
1. Start the engine.
2. When the engine is operating measure the voltage between two
battery terminals. If the voltage is between 13.8 V and 14.8 V,
the alternator is operating normally.
3. If the results of alternator on unit test are not within the
specifications, disassemble the alternator and check the each
component part for finding out the failure. See the
DISASSEMBLING AND ASSEMBLING and SERVICING for
alternator.
0000010745E
Glow Plug Lead Terminal Voltage
1. Turn the key switch to the GLOW (or PREHEAT) position, and
measure the voltage with a circuit tester between the lead
terminal and the engine body.
2. If the voltage differs from the battery voltage, the wiring harness
or main switch is faulty.
0000010725E
Glow Plug Continuity
1. Remove the glow plug.
2. Measure the resistance with a circuit tester between the glow
plug terminal and the glow plug housing.
3. If the factory specification is not indicated, glow plug is faulty.
0000010726E
Regulating voltage at no
load
Factory spec.
13.8 to 14.8 V at 25 C
(77 F)
Voltage
Main switch key at
GLOW
(or PREHEAT)
Approx. battery voltage
Resistance Factory spec. Approx. 0.9
S-40
DIESEL ENGINE
Engine Stop Solenoid
1. Remove the engine stop solenoid from the engine.
2. Connect the jumper leads from the pulling coil P terminal to the
switch (3), and from switch (3) to the battery positive terminal.
3. Connect the jumper leads from the holding coil H terminal to the
switch (4), and from switch (4) to the battery positive terminal.
4. Connect the jumper leads from the engine stop solenoid body to
the battery negative terminal.
5. When switch (4) is turn on, the plunger pull into the solenoid body
and then turn off the switch (4), the plunger comes out.
6. Turn on the switch (3) then turn on the switch (4), the plunger pull
into the solenoid body and it keep in holding position after turn off
the switch (4).
7. If the plunger is not attracted, the engine stop solenoid is faulty.
IMPORTANT
Never apply the current for pulling coil more than two
seconds when inspecting.
W1020600
(6) Turbocharger
Turbine Side
1. Check the exhaust port (2) and inlet port (3) side of the 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.
W1069824
Compressor Side
1. Check the inlet hose (1) of the compressor cover (2) 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 (3) and / or inlet hoses.
W1069939
Radial Clearance
1. If the wheel contact to the housing, replace the turbocharger
assembly with new one.
W1077353
(1) Connector
(2) Battery
(3) Switch for Holding Coil
(4) Switch for Pulling Coil
P : Terminal for Pulling Coil
H : Terminal for Holding Coil
(1) Turbine Housing
(2) Exhaust Port
(3) Inlet Port
(1) Inlet Hose
(2) Compressor Cover
(3) Clamp
S-41
DIESEL ENGINE
(7) Electronic Governor
Speed Sensor
1. Disconnect the speed sensor connector (2) (3P).
2. Check the state of the harness and if it is abnormal, please
replace it.
3. Turn the key switch to the ACC position.
4. Measure the voltage between the terminals of the connector (2)
(harness side).
5. When the measurements are the below table value.
The ECU is normal. The speed sensor (1) is failure, then please
replace it.
6. When the measurements are out of the below table value.
The ECU is failure, then please replace it.
W1058552
Water Temperature Sensor
1. Disconnect the water temperature sensor connector (2) (2P).
replace it.
4. Measure the voltage between the terminals of the connector (2)
(harness side).
The ECU is normal. The water temperature sensor (1) is failure,
then please replace it.
W1059499
Voltage
Terminal 1 - Terminal 3 12 V
Terminal 1 - Terminal 2 5 V
(1) Speed Sensor
(2) Speed Sensor Connector
(Harness Side)
(3) Terminal 3 (+)
(4) Terminal 2 (Signal)
(5) Terminal 1 (GND)
Voltage Terminal 1 - Terminal 2 5 V
(1) Water Temperature Sensor
(2) Water Temperature Sensor
Connector (Harness Side)
(3) Terminal 2 ()
(4) Terminal 1 (+)
S-42
DIESEL ENGINE
Oil Pressure Switch
1. Disconnect the connector of the oil pressure switch connector
(1P).
replace it.
3. Measure the resistance between the terminal of the connector
(harness side) and chassis.
The ECU is normal. The oil pressure switch (1) is failure, then
please replace it.
W1059711
Resistance Terminal 1 - Chassis Infinity
(1) Oil Pressure Switch
S-43
DIESEL ENGINE
Solenoid
1. Disconnect the connector of solenoid (2) (2P).
replace it.
4. Measure the voltage between the connector of solenoid (2)
(harness side).
The ECU is normal. Check the solenoid (1) according to the
procedure of confirming the solenoids movement.
(Reference)
The procedure of confirming the solenoids movement
1. Measure the resistance between the connector of solenoid (2).
The solenoid (1) is normal electrically. Check the solenoids
movement.
The solenoid (1) is failure, then please replace it.
4. Remove the solenoid (1) from the engine.
5. Supply the voltage (12 V) to the solenoid (1).
6. When the rod of the solenoid (1) moves smoothly.
The solenoid (1) is normal.
7. When the rod of the solenoid (1) does not move smoothly.
The solenoid (1) is failure, then please replace it.
CAUTION
Please note handling, the solenoid (1) becomes a high
temperature.
W1060938
Voltage Terminal 1 - Terminal 2 12 V
Resistance Terminal 1 - Terminal 2 2 to 4
(1) Solenoid
(2) Connector of Solenoid
(3) Terminal 2 ()
(4) Terminal 1 (+)
(A) Key Switch OFF Position
(B) Key Switch ON Position
S-44
DIESEL ENGINE
Glow Plug Harness
1. Disconnect the glow plug terminal (1).
replace it.
4. Measure the voltage between the glow pulg terminal (1) of the
connector (harness side) and chassis.
The ECU is normal. Some of the glow plugs are failure, then
please replace them.
W1061770
Alternator
1. Disconnect the terminal L (2) of the alternator (2P).
replace it.
3. Measure the resistance between the terminal L (2) of the
connector (harness side) and chassis.
The ECU is normal. The alternator is failure, then please replace
it.
W1063000
Speed Switch
replace it.
2. When the speed switch is turned ON and OFF, measure the
resistance between the speed switch (terminal side) (1) of it each
time.
The speed switch is normal. The ECU is failure, then please
replace it.
The speed switch is failure, then please replace it.
W1063856
Voltage Terminal - Chassis 12 V
(1) Glow Plug Terminal
Resistance Terminal L - Chassis Infinity
(1) Alternator (2) Terminal L (Harness Side)
Resistance
ON 0
OFF Infinity
(1) Speed Switch
(Terminal Side)
(A) Single Pole, Single Throw
(B) Single Pole, Double Throw
S-45
DIESEL ENGINE
Emergency Stop Switch
replace it.
2. When the emergency stop switch is turned ON and OFF,
measure the resistance between the emergency stop switch
(terminal side) (1) of it each time.
The emergency stop switch is normal. The ECU is failure, then
please replace it.
The emergency stop switch is failure, then please replace it.
W1066629
Slow Down Switch
replace it.
2. When the slow down switch is turned ON and OFF, measure the
resistance between the slow down switch (terminal side) (1) of it
each time.
The slow down switch is normal. The ECU is failure, then please
replace it.
The slow down switch is failure, then please replace it.
W1067200
Battery
1. Measure the voltage of the battery (1) with the engine stopped.
The battery is normal. The ECU is failure, then please replace it.
The battery is failure, then please replace it.
W1067456
Resistance
ON 0
OFF Infinity
(1) Emergency Stop Switch
(Terminal Side)
(A) Single Pole, Single Throw
Resistance
ON 0
OFF Infinity
(1) Slow Down Switch (Terminal Side) (A) Single Pole, Single Throw
Voltage + terminal - terminal 12 V
(1) Battery
S-46
DIESEL ENGINE
[2] DISASSEMBLING AND ASSEMBLING
(1) Draining Oil and Coolant
Draining Engine Oil
3. Remove the drain plug (1) to drain oil.
4. After draining, screw in the drain plug.
(When refilling)
Fill the engine oil up to the upper line on the dipstick (2).
IMPORTANT
temperature.
W1028998
Draining Coolant
CAUTION
Never remove radiator cap while operating or immediately
after stopping. Otherwise, hot water will spout out from the
radiator. Wait for more than ten minutes to cool the radiator,
before opening the cap.
1. Prepare a bucket. Open the coolant drain cock.
W1029172
(2) External Components
Air Cleaner, Muffler and Others
1. Remove the air cleaner and muffler.
2. Remove the fan (1), fan belt (4), alternator (2) and starter (3).
(When reassembling)
Check to see that there are no cracks on the belt surface.
IMPORTANT
After reassembling the fan belt, be sure to adjust the fan belt
tension.
Do not confuse the direction of the fan.
W1060302
(1) Coolant Drain Cock
(1) Fan
(2) Alternator
(3) Starter
(4) Fan Belt
S-47
DIESEL ENGINE
Turbocharger (equipped with Turbocharger Model)
CAUTION
While the engine is running and or just after it stops, the
turbocharger is hot, be careful not to touch the
turbocharger.
NOTE
When detaching and attaching the turbocharger assembly,
be very careful not to allow dust, dirt and other foreign
matters in the oil pipes.
When the turbocharger assembly has been replaced, pour
fresh engine oil through the oil filter port of the
turbocharger.
Before starting the engine, make sure that the air cleaner is
in position.
1. Disconnect the inlet hose (1).
2. Remove the joint bolt (2), (7) and take off the oil pipe 1 (8).
3. Remove the bolts 1 (3) and release the clamp (5).
4. Disconnect the oil pipe 2 (4) and pipe 3 (6).
5. Remove the bolts 2 (10).
6. Take off the turbocharger assembly (9).
(When reassembling)
Pour fresh engine oil through the oil filter port of the turbocharger.
Replace the gaskets with new one.
Be careful not to allow dust, dirt and other foreign matters in the
oil pipes.
NOTE
Tape or plug all opening to prevent foreign matters from
damaging the oil cavities in the turbocharger.
W1021474
(1) Inlet Hose
(2) Joint Bolt
(3) Bolt 1
(4) Oil Pipe 2
(5) Clamp
(6) Oil Pipe 3
(7) Joint Bolt
(8) Oil Pipe 1
(9) Turbocharger Assembly
(10) Bolt 2
S-48
DIESEL ENGINE
(3) Cylinder Head and Valves
Cylinder Head Cover
1. Remove the lead (4).
2. Remove the breather hose (1).
3. Remove the head cover screws (3).
4. Remove the cylinder head cover (2).
(When reassembling)
Check to see if the cylinder head cover gasket (5) is not
defective.
W1060460
Injection Pipes
1. Loosen the screws on the pipe clamps (2).
2. Detach the injection pipes (1).
(When reassembling)
Blow out dust inside the pipes.
W1060970
Tightening torque Cylinder head cover screw
9.81 to 11.2 Nm
1.00 to 1.15 kgfm
7.24 to 8.31 lbfft
(1) Breather Hose
(2) Cylinder Head Cover
(3) Head Cover Screw
(4) Lead
(5) Cylinder Head Cover Gasket
(6) Breather Valve
(7) Plate
Tightening torque
Injection pipe
retaining nut
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
25 to 34 Nm
2.5 to 3.5 kgfm
18 to 25 lbfft
D1803-M-DI
V2403-M-DI
V2403-M-DI-T
15 to 24 Nm
1.5 to 2.5 kgfm
11 to 18 lbfft
(1) Injection Pipe (2) Pipe Clamp
S-49
DIESEL ENGINE
Nozzle Holder Assembly and Glow Plug
[D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M,
V2403-M-T]
V2403-M-BG]
1. Remove the overflow pipe assembly (3).
2. Remove the nozzle holder assemblies (4) using a 21 mm deep
socket wrench.
3. Remove the copper gasket and heat seal (5).
4. Remove the glow plugs (2).
(When reassembling)
Replace the copper gasket and heat seal with new one.
W1020917
[D1803-M-DI, V2403-M-DI, V2403-M-DI-T]
1. Remove the overflow pipe assembly.
2. Remove the nozzle holder assemblies (2).
3. Remove the glow plugs (1).
(When reassembling)
Replace the copper gasket with new one.
W1111628
Tightening torque
Nozzle holder
assembly
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
49 to 68 Nm
5.0 to 7.0 kgfm
37 to 50 lbfft
Overflow pipe
assembly
retaining nut
20 to 24 Nm
2.0 to 2.5 kgfm
15 to 18 lbfft
Glow plug
20 to 24 Nm
2.0 to 2.5 kgfm
15 to 18 lbfft
(1) Lead
(2) Glow Plug
(3) Overflow Pipe Assembly
(4) Nozzle Holder Assembly
(5) Heat Seal
Tightening torque
Nozzle holder
clamp screw
D1803-M-DI
V2403-M-DI
V2403-M-DI-T
26 to 29 Nm
2.6 to 3.0 kgfm
19 to 21 lbfft
Overflow pipe
assembly
retaining screw
9.81 to 11.2 Nm
1.00 to 1.15 kgfm
7.24 to 8.31 lbfft
Glow plug
20 to 24 Nm
2.0 to 2.5 kgfm
15 to 18 lbfft
(1) Glow Plug (2) Nozzle Holder Assembly
S-50
DIESEL ENGINE
Nozzle Heat Seal Service Removal Procedure
[D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M,
V2403-M-T]
V2403-M-BG]
IMPORTANT
Use a plus (phillips head) screw driver (1) that has a
diameter which is bigger than the heat seal hole (Approx. 6
mm (1/4 in.)).
1. Drive screw driver (1) lightly into the heat seal hole.
2. Turn screw driver three or four times each way.
3. While turning the screw driver, slowly pull the heat seal (4) out
together with the injection nozzle gasket (3).
4. If the heat seal drops, repeat the above procedure.
(When reassembling)
Heat seal and injection nozzle gasket must be changed when the
injection nozzle is removed for cleaning or for service.
W1021255
Rocker Arm and Push Rod
1. Remove the rocker arm bracket screws.
2. Detach the rocker arm assembly (1).
3. Remove the push rods (2).
(When reassembling)
When putting the push rods (2) onto the tappets (3), check to see
if their ends are properly engaged with the grooves.
IMPORTANT
After installing the rocker arm, be sure to adjust the valve
clearance.
W1021437
(1) Plus Screw Driver
(3) Injection Nozzle Gasket
(4) Heat Seal
Tightening torque Rocker arm bracket screw
24 to 27 Nm
2.4 to 2.8 kgfm
18 to 20 lbfft
(1) Rocker Arm Assembly
(2) Push Rod
(3) Tappet
S-51
DIESEL ENGINE
Cylinder Head
1. Loosen the pipe clamp (2), and remove the water return pipe (1).
2. Remove the cylinder head screw in the order of (n or r) to (a).
3. Lift up the cylinder head (3) to detach.
4. Remove the cylinder head gasket (4).
(When reassembling)
Replace the cylinder head gasket (4) with a new one.
Tighten the cylinder head screws after applying sufficient oil.
Tighten the cylinder head screws in diagonal sequence starting
from the center in the order of (a) to (n or r).
Tighten them uniformly, or the head may deform in the long run.
IMPORTANT
To replace the cylinder head gasket (4), in advance make
sure the marking (5) of cylinder head gasket in the original
engine, and replace the same marking as the original
cylinder head gasket.
W1112015
Tightening torque Cylinder head screw
93.2 to 98.0 Nm
9.50 to 10.0 kgfm
68.8 to 72.3 lbfft
Gasket
Marking &
Code
Number
Model
D1503-M
D1703-M
D1803-M
D1803-M-DI
V2003-M
V2203-M
V2403-M
V2403-M-T
V2403-M-DI
V2403-M-DI-T
15 1G720-03600 1G750-03600 1G464-03600 1G790-03600
20 1G720-03310 1G750-03310 1G464-03310 1G790-03310
25 1G720-03610 1G750-03610 1G464-03610 1G790-03610
30 1G720-03620 1G750-03620 1G464-03620 1G790-03620
35 1G720-03630 1G750-03630 1G464-03630 1G790-03630
Gasket
Marking &
Code
Number
Model
D1703-M-BG V2003-M-BG V2003-M-T-BG
V2203-M-BG
V2403-M-BG
15 1G750-03600 1G464-03600 1G770-03600 1G790-03600
20 1G750-03310 1G464-03310 1G770-03310 1G790-03310
25 1G750-03610 1G464-03610 1G770-03610 1G790-03610
30 1G750-03620 1G464-03620 1G770-03620 1G790-03620
35 1G750-03630 1G464-03630 1G770-03630 1G790-03630
(1) Return Pipe
(2) Pipe Clamp
(3) Cylinder Head
(4) Cylinder Head Gasket
(5) Marking
(n or r) to (a) : To Loosen
(a) to (n or r) : To Tighten
(A) Gear Case Side
(B) Flywheel Side
S-52
DIESEL ENGINE
Cylinder Head (Continued)
IMPORTANT
When replacing piston, piston pin, small end bushing,
connecting rod, or crankpin bearings, measure piston
heads protrusion or recessing from the level of crankcase
cylinder face (average of all pistons) after installing the
pistons, and select the cylinder head gasket following the
below table.
Selecting the cylinder head gasket
1. Measure the piston heads protrusion or recessing from the
crankcase cylinder face 4 spots per each piston (average of all
pistons) using the dial gauge.
2. Select the suitable cylinder need gasket refer to the table below.
W1085632
Tappets
1. Remove the tappets (1) from the crankcase.
(When reassembling)
Visually check the contact between tappets and cams for proper
rotation. If defect is found, replace tappets.
Before installing the tappets, apply engine oil thinly around them.
IMPORTANT
Do not change the combination of tappet and tappet guide.
W1022001
Gasket Size (Number)
Piston Protrusion
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
D1803-M-DI
V2403-M-DI
V2403-M-DI-T
15
0.500 to 0.540 mm
0.0197 to 0.0212 in.
0.475 to 0.525 mm
0.0187 to 0.0206 in.
20
0.550 to 0.590 mm
0.0217 to 0.0232 in.
0.525 to 0.575 mm
0.0206 to 0.0227 in.
25
0.600 to 0.640 mm
0.0237 to 0.0251 in.
0.575 to 0.625 mm
0.0227 to 0.0246 in.
30
0.650 to 0.690 mm
0.0256 to 0.0271 in.
0.625 to 0.675 mm
0.0246 to 0.0266 in.
35
0.700 to 0.740 mm
0.0276 to 0.0291 in.
0.675 to 0.725 mm
0.0266 to 0.0285 in.
(6) Measuring Points [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
(1) Tappet
S-53
DIESEL ENGINE
Valves
1. Remove the valve caps (3).
2. Remove the valve spring collet (4), pushing the valve spring
retainer (5) by valve spring replacer (1).
3. Remove the valve spring retainer (5), valve spring (6) and valve
stem seal (2).
4. Remove the valve (7).
(When reassembling)
Wash the valve stem and valve guide hole, and apply engine oil
sufficiently.
After installing the valve spring collets (4), lightly tap the stem to
assure proper fit with a plastic hammer.
IMPORTANT
Do not change the combination of valve and valve guide.
W1022102
Thermostat Assembly
1. Remove the thermostat cover mounting screws, and remove the
thermostat cover (1).
2. Remove the thermostat assembly (3).
(When reassembling)
Replace the thermostat cover gasket (2) with new one.
Apply a liquid gasket (Three Bond 1215 or equivalent) to the
water flange 1 (4) and flange 2 (5)
W1105115
Water Pump Assembly (If necessary)
1. Remove the water pump assembly (1) from the gear case.
(When reassembling)
Replace the gasket (2) with new one.
W1051957
(1) Valve Spring Replacer
(2) Valve Stem Seal
(3) Valve Cap
(4) Valve Spring Collet
(5) Valve Spring Retainer
(6) Valve Spring
(7) Valve
(1) Thermostat Cover
(2) Thermostat Cover Gasket
(3) Thermostat Assembly
(4) Water Flange 1
(5) Water Flange 2
(1) Water Pump Assembly (2) Gasket
S-54
DIESEL ENGINE
(4) Gear Case and Timing Gears
Injection Pump (for Non Turbocharger Model)
1. Remove the solenoid (4) and hi-idling body (1).
2. Remove the engine stop lever (3) and solenoid guide (6).
3. Remove the fuel injection pump assembly (2).
IMPORTANT
Before removing the injection pump assembly (2), be sure to
remove the solenoid (4), hi-idling body (1), engine stop lever
(3) and solenoid guide (6).
(When reassembling)
Before attaching the solenoid (4), hi-idling body (1) and solenoid
guide (6), install the injection pump first into position.
Replace the hi-idling body gasket (5) with a new one.
Before fitting the stop lever (3) to the gear case, install the
solenoid guide (6) first into position. Then attach the stop lever
and use it to see if it functions well.
When installing the solenoid (4), be careful to keep the O-ring in
place.
Be sure to insert the push rod of the stop solenoid into the hole
at the center of the solenoid guide (6).
W1023686
Tightening torque Hi-idling body
45 to 49 Nm
4.5 to 5.0 kgfm
33 to 36 lbfft
(1) Hi-idling Body
(2) Injection Pump Assemply
(3) Stop Lever
(4) Slenoid
(5) Hi-idling Body Gasket
(6) Solenoid Guide
S-55
DIESEL ENGINE
Injection Pump (for Turbocharger Model)
1. Remove the boost compensator assembly (2).
2. Remove the hi-idling body (4).
3. Remove the solenoid (3).
4. Remove the solenoid guide (5).
5. Remove the injection pump assembly (1).
IMPORTANT
Before removing the injection pump assembly (1), be sure to
remove the boost compensator assembly (2), hi-idling body
(4), solenoid (3) and solenoid guide (5).
(When reassembling)
Before attaching the boost compensator assembly (2), hi-idling
body (4), solenoid (3) and solenoid guide (5), install the injection
pump first into position.
Replace the hi-idling body gasket with a new one.
Before fitting the boost compensator assembly (2) to the gear
case, make sure that the solenoid guide (5) is at the initial
position.
When installing the solenoid (3), be careful to keep the O-ring in
place.
Be sure to insert the push rod of the stop solenoid into the hole
at the center of the solenoid guide (5).
IMPORTANT
If you replace new boost compensator, it is necessary to
adjust it.
Get the adjustment procedure from KUBOTA.
W1032355
Tightening torque Hi-idling body
45 to 49 Nm
4.5 to 5.0 kgfm
33 to 36 lbfft
(1) Injection Pump Assembly
(2) Boost Compensator Assembly
(3) Solenoid
(4) Hi-idling Body
(5) Solenoid Guide
S-56
DIESEL ENGINE
Governor Springs and Speed Control Plate
NOTE
Specific tool (1) :
1.2 mm diameter hard wire with its end hooked, overall
length 200 mm (7.87 in.).
The tip of wire is bent like the hook to hang governor
springs.
1. Remove the injection pump cover.
2. Remove the speed control plate (6) mounting nuts and bolts.
3. Using the specific tool (1), undo the large governor spring (3)
from the fork lever (2).
4. Using the specific tool (1), undo the small governor spring (4)
from the fork lever (2).
5. Set the speed control lever (5) as shown in the figure.
6. Take out the speed control plate (6) with care not to let the large
(3) and small (4) governor springs come off this plate and fall in
to the gear case.
W1148604
(1) Specific Tool
(2) Fork Lever
(3) Large Governor Spring
(4) Small Governor Spring
(5) Speed Control Lever
(6) Speed Control Plate
S-57
DIESEL ENGINE
Governor Springs and Speed Control Plate (Continued)
(When reassembling)
Hook the small spring (4) first and then the large governor spring
(3) on the speed control plate (6).
Put the specific tool (1) from the injection pump side to catch the
large governor spring (3). Keep this spring slightly extended and
place the speed control plate (6) in its specified position.
Using the specific tool (1), hook the small governor spring (4)
onto the fork lever (2).
NOTE
Be careful not to stretch the small governor spring (4) too
long because otherwise it may get deformed permanently.
Using the specific tool (1), hook the large governor spring (3)
onto the fork lever (2).
Make sure both the governor springs (3), (4) are tight on the
fork lever (2).
Apply and tighten up the two bolts and two nuts on the
speed control plate (6).
Check that the speed control lever (5) positions low idle,
after assembling governor springs.
Check that the speed control lever (5) returns to the high idle
position rather than the low idle position, after moving the
lever to the maximum speed position.
Finally attach the injection pump cover in position.
W1152334
(1) Specific Tool
(2) Fork Lever
(3) Large Governor Spring
(4) Small Governor Spring
(5) Speed Control Lever
(6) Speed Control Plate
S-58
DIESEL ENGINE
Fan Drive Pulley
1. Lock the flywheel not to turn using the flywheel stopper.
2. Remove the fan drive pulley mounting nut (1) using 46 mm deep
socket wrench (3).
3. Remove the fan drive pulley (2) with gear puller (4).
4. Remove the feather key.
(When reassembling)
Apply grease to the splines of coupling.
W1024348
Tightening torque
Fan drive pulley mounting
nut
138 to 156 Nm
14.0 to 16.0 kgfm
102 to 115 lbfft
(1) Nut
(2) Fan Drive Pulley
(3) 46 mm Deep Socket Wrench
(4) Gear Puller
S-59
DIESEL ENGINE
Idle Gear 2 and Hydraulic Pump Base Assembly
(for Side PTO Model)
1. Remove the hour meter gear case (if equipped).
2. Remove the gear case cover (1).
3. Remove the hydraulic pump base assembly (2).
4. Remove the idle gear 2 stopper (3).
5. Remove the idle gear 2 (4) using the puller (5).
6. Remove the idle gear 2 shaft (7).
(When reassembling)
Replace the washer (6) and gear case cover gasket.
Replace the gear case cover gasket with new one.
W1034122
Tightening torque
Idle gear 2 shaft set screw
24 to 27 Nm
2.4 to 2.8 kgfm
18 to 20 lbfft
Idle gear 2 stopper set
screw
49 to 55 Nm
5.0 to 5.7 kgfm
37 to 41 lbfft
(1) Gear Case Cover
(2) Hydraulic Pump Base Assembly
(3) Idle Gear 2 Stopper
(4) Idle Gear 2
(5) Puller
(6) Washer
(7) Idle Gear 2 Shaft
(8) Idle Gear 2 Stopper Set Screw
(9) Idle Gear 2 Shaft Set Screw
S-60
DIESEL ENGINE
Gear Case (for Side PTO Model)
1. Remove the gear case (1).
2. Remove the O-rings (2).
(When reassembling)
Replace the gear case gasket and O-rings.
Check to see if there are four O-rings (2) inside the gear case (1).
Apply a thin film of engine oil to the oil seal, and install it, noting
the lip come off.
Before installing the gear case gasket, apply a non-drying
adhesive.
W1034671
Gear Case
1. Remove the hour meter gear case (if equipped).
2. Remove the gear case (1).
3. Remove the O-rings (2).
(When reassembling)
Replace the gear case gasket and O-rings (2).
Replace the hour meter gear case gasket with new one.
Check to see if there are four O-rings (2) inside the gear case (1).
Apply a thin film of engine oil to the oil seal (3), and install it,
noting the lip come off.
Before installing the gear case gasket, apply a non-drying
adhesive.
W1024531
Crankshaft Oil Slinger
1. Remove the crankshaft collar (3).
2. Remove the O-ring (2).
3. Detach the crankshaft oil slinger (1).
(When reassembling)
Insert the crankshaft collar (3) after install the gear case to
cylinder body.
W1024731
Idle Gear
1. Remove the external snap ring.
2. Detach the idle gear collar.
3. Detach the idle gear (2).
(When reassembling)
Check to see each gear is aligned with its aligning mark
- Idle gear (2) and crank gear (4)
- Idle gear (2) and cam gear (3)
- Idle gear (2) and injection pump gear (1)
W1024941
(1) Gear Case (2) O-rings
(1) Gear Case
(2) O-ring
(3) Oil Seal
(1) Crankshaft Oil Slinger
(2) O-ring
(3) Crankshaft Collar
(1) Injection Pump Gear
(2) Idle Gear
(3) Cam Gear
(4) Crank Gear
(5) Oil Pump Drive Gear
S-61
DIESEL ENGINE
Idle Gear (For Balancer Model)
1. Remove the external snap ring.
2. Detach the idle gear collar.
3. Detach the idle gear (2).
(When reassembling)
Check to see each gear is aligned with its aligning mark:
- Idle gear (2) and crank gear (6), cam gear (3) and balancer
gear (4)
- Cam gear (3) and idle gear (2)
- Idle gear (2) and injection pump gear (1)
- Idle gear (2) and balancer gear (7)
W1097988
Camshaft
1. Remove the camshaft set screws (1) and draw out the camshaft
(2).
(When reassembling)
When installing the idle gear, be sure to align the alignment
marks on gears.
W1025098
Camshaft and Balancer Shaft (For Balancer Model)
1. Remove the camshaft set screws and draw out the camshaft (1).
2. Remove the balancer shaft 1 (2) set bolts and draw out the
balancer shaft 1 (2).
3. Remove the balancer shaft 2 (3) set bolts and draw out the
balancer shaft 2 (3).
(When reassembling)
When install the balancer shaft 1 (2) and 2 (3), be sure to place
the 1st. and 4th. cylinders piston at the top dead center in
compression then, align all mating marks on each gear to
assemble the timing gears, set the idle gear last.
W1099079
(2) Idle Gear
(3) Cam Gear
(4) Balancer Gear
(6) Crank Gear
(7) Balancer Gear
Tightening torque Camshaft set screw
24 to 27 Nm
2.4 to 2.8 kgfm
18 to 20 lbfft
(1) Camshaft Set Screw (2) Camshaft
Tightening torque
Camshaft set screw
24 to 27 Nm
2.4 to 2.8 kgfm
18 to 20 lbfft
Balancer shaft set bolt
24 to 27 Nm
2.4 to 2.8 kgfm
18 to 20 lbfft
(1) Camshaft
(2) Balancer Shaft 1
(3) Balancer Shaft 2
S-62
DIESEL ENGINE
Fuel Camshaft and Fork Lever Assembly
1. Remove the fuel feed pump.
2. Detach the fuel camshaft stopper (1).
3. Remove the three fork lever holder mounting screws (2).
4. Draw out the fuel camshaft assembly (5), (6) and fork lever
assembly (3), (4), (7) at the same time.
(When reassembling)
After installation, check to see that the fork lever 1 (3) and lever
2 (4) are fixed to the fork lever shaft, and that they can turn
smoothly in the holder (7).
W1025309
Oil Pump
1. Remove the nut.
2. Draw out the oil pump drive gear (2) with gear puller (1).
3. Remove the four oil pump mounting screws. Detach the oil pump
(3).
W1025581
Crank Gear
1. Draw out the crank gear (2) with a puller (1).
2. Remove the feather key.
W1025476
(1) Fuel Camshaft Stopper
(2) Fork Lever Holder Mounting Screws
(3) Fork Lever 1
(4) Fork Lever 2
(6) Fuel Camshaft
(7) Fork Lever Holder
(1) Gear Puller
(3) Oil Pump
(1) Crank Puller (2) Crank Gear
S-63
DIESEL ENGINE
(5) Piston and Connecting Rod
Oil Pan and Oil Strainer
1. Remove the oil pan mounting screws.
2. Remove the oil pan (3) by lightly tapping the rim of the pan with
a wooden hammer.
3. Remove the oil pan gasket (2).
4. Remove the oil strainer (1) and O-ring (4).
(When reassembling)
After cleaning the oil strainer (1), check to see that the filter mesh
in clean, and install it.
Visually check the O-ring (4), apply engine oil, and install it.
Securely fit the O-ring (4) to the oil strainer (1).
Replace the oil pan gasket (2) with new one.
To avoid uneven tightening, tighten oil pan mounting screws in
diagonal order from the center.
W1025687
(1) Oil Strainer
(2) Oil Pan Gasket
(3) Oil Pan
(4) O-ring
S-64
DIESEL ENGINE
Pistons
[D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M,
V2403-M-T]
V2403-M-BG]
1. Completely clean carbon (1) in the cylinders.
2. Remove the connecting rod cap (3).
3. Turn the flywheel and bring the piston to top dead center.
4. Draw out the piston upward by lightly tapping it from the bottom
of the crankcase with the grip of a hammer.
5. Draw out the other piston in the same method as above.
(When reassembling)
Before inserting piston into the cylinder, apply enough engine oil
to the piston.
When inserting the piston into the cylinder, face the mark on the
connecting rod to the injection pump.
IMPORTANT
Do not change the combination of cylinder and piston. Make
sure of the position of each piston by marking. For example,
mark 1 on the No. 1 piston.
Place the piston rings with their gaps at 0.79 rad (45 ) from
the piston pins direction as shown in the figure.
Carefully insert the pistons using a piston ring compressor
(6).
When inserting the piston in place, be careful not to get the
molybdenum disulfide coating torn off its skirt. This coating
is useful in minimizing the clearance with the cylinder liner.
Just after the piston pin has been press-fitted, in particular,
the piston is still hot and the coating is easy to peel off. Wait
until the piston cools down.
W1026141
Tightening torque Connecting rod screw
45 to 49 Nm
4.5 to 5.0 kgfm
33 to 36 lbfft
(1) Carbon
(2) Connecting Rod Screw
(3) Connecting Rod Cap
(4) Connecting Rod
(5) Molybdenum Disulfide Coating in
Piston Skirt
(6) Piston Ring Compressor
(A) Top Ring Gap
(B) Second Ring Gap
(C) Oil Ring Gap
(D) Piston Pin Hole
(a) 0.79 rad (45 )
S-65
DIESEL ENGINE
Pistons
[D1803-M-DI, V2403-M-DI, V2403-M-DI-T]
1. Completely clean carbon (1) in the cylinders.
2. Remove the connecting rod cap (3).
3. Turn the flywheel and bring the piston to top dead center.
4. Draw out the piston upward by lightly tapping it from the bottom
of the crankcase with the grip of a hammer.
5. Draw out the other piston in the same method as above.
(When reassembling)
Before inserting piston into the cylinder, apply enough engine oil
to the piston.
When inserting the piston into the cylinder, face the mark on the
connecting rod to the injection pump.
IMPORTANT
Do not change the combination of cylinder and piston. Make
sure of the position of each piston by marking. For example,
mark 1 on the No. 1 piston.
Place the piston rings with their gaps at 2.09 rad (120 ) from
the piston pins direction as shown in the figure.
Carefully insert the pistons using a piston ring compressor
(7).
When inserting the piston in place, be careful not to get the
molybdenum disulfide coating torn off its skirt. This coating
is useful in minimizing the clearance with the cylinder liner.
Just after the piston pin has been press-fitted, in particular,
the piston is still hot and the coating is easy to peel off. Wait
until the piston cools down.
When replacing the piston, look at the code number (6)
marked on top of the piston. Use a replacement piston with
the same code number.
W1126904
Tightening torque Connecting rod screw
45 to 49 Nm
4.5 to 5.0 kgfm
33 to 36 lbfft
(1) Carbon
(2) Connecting Rod Screw
(3) Connecting Rod Cap
(4) Connecting Rod
(5) Molybdenum Disulfide Coating in
Piston Skirt
(6) Code Number
(7) Piston Ring Compressor
(A) Top Ring Gap
(B) Second Ring Gap
(C) Oil Ring Gap
(D) Piston Pin Hole
(a) 2.09 rad (120 )
S-66
DIESEL ENGINE
Piston Ring and Connecting Rod
[D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M,
V2403-M-T]
V2403-M-BG]
1. Remove the piston rings (1), (2), (3) using a piston ring tool.
2. Remove the piston pin (9), and separate the connecting rod (7)
from the piston (6).
(When reassembling)
When installing the rings, assemble the rings so that the
manufacturers mark (12) near the gap faces the top of the piston
(6).
When installing the oil ring (3) onto the piston (6), place the
expander joint (10) on the opposite side of the oil ring gap (11).
Apply engine oil to the piston pin (9).
When installing the connecting rod (7) to the piston (6), immerse
the piston (6) in 80 C (176 F) oil for 10 to 15 minutes and insert
the piston pin (9) to the piston (6).
When installing the connecting rod (7) to the piston (6), align the
mark (8) on the connecting rod (7) to the fan-shaped concave (5).
NOTE
Mark the same number on the connecting rod (7) and the
piston (6) so as not to change the combination.
W1026376
(1) Top Ring
(2) Second Ring
(3) Oil Ring
(4) Piston Pin Snap Ring
(5) Fan-Shaped Concave
(6) Piston
(7) Connecting Rod
(8) Mark
(9) Piston Pin
(10) Expander Joint
(11) Oil Ring Gap
(12) Manufacturers Mark
S-67
DIESEL ENGINE
Piston Ring and Connecting Rod
[D1803-M-DI, V2403-M-DI, V2403-M-DI-T]
1. Remove the piston rings (1), (2), (3) using a piston ring tool.
2. Remove the piston pin (8), and separate the connecting rod (6)
from the piston (5).
(When reassembling)
When installing the ring, assemble the rings so that the
manufacturers mark (12) near the gap faces the top of the piston
(5).
When installing the oil ring (3) onto the piston (5), place the
expander joint (10) on the opposite side of the oil ring gap (11).
Apply engine oil to the piston pin (8).
When installing the connecting rod (6) to the piston (5), immerse
the piston (5) in 80 C (176 F) oil for 10 to 15 minutes and insert
the piston pin (8) to the piston (5).
Assemble the piston (5) to the connecting rod (6) with the FW
mark (9) facing the flywheel side and the connecting rod mark (7)
facing the injection pump side.
NOTE
Mark the same number on the connecting rod (6) and the
piston (5) so as not to change the combination.
W1127943
(1) Top Ring
(2) Second Ring
(3) Oil Ring
(4) Piston Pin Snap Ring
(5) Piston
(6) Connecting Rod
(7) Mark
(8) Piston Pin
(9) FW Mark
(10) Expander Joint
(11) Oil Ring Gap
(12) Manufacturers Mark
S-68
DIESEL ENGINE
(6) Flywheel and Crankshaft
Flywheel
1. Fit the stopper to the flywheel (1).
2. At first, remove two pieces of the flywheel screws (2).
3. Insert two pieces of the flywheel guide screws (3) in the holes.
4. Remove the all flywheel screws (2).
5. Remove the flywheel (1) slowly along the flywheel guide screws
(3).
(When reassembling)
Insert two pieces of the flywheel guide screws (3).
Check to see that there are no metal particles left on the flywheel
mounting surfaces.
Apply engine oil to the threads and the undercut surface of the
flywheel bolt and fit the bolt.
W1026863
Bearing Case Cover
1. Remove the bearing case cover mounting screws. First, remove
inside screws (5) and then outside screws (3).
2. Screw two removed screws into the screw hole of bearing case
cover (6) to remove it.
IMPORTANT
The length of inside screws (5) and outside screws (3) are
different. Do not take a mistake using inside screws and
outside screws.
(When reassembling)
Fit the bearing case gasket (1) and the bearing case cover gasket
(2) with correct directions.
Install the bearing case cover (6) to position the casting mark
UP on it upward.
Apply engine oil to the oil seal lip and take care that it is not rolled
when installing.
Tighten the bearing case cover mounting screws with even force
on the diagonal line.
W10292140
Tightening torque Flywheel screw
98.1 to 107 Nm
10.0 to 11.0 kgfm
72.4 to 79.5 lbfft
(1) Flywheel
(2) Flywheel Screw
(3) Flywheel Guide Screws
Tightening torque
Bearing case cover
mounting screw
24 to 27 Nm
2.4 to 2.8 kgfm
18 to 20 lbfft
(1) Bearing Case Gasket
(2) Bearing Case Cover Gasket
(3) Bearing Case Cover Mounting Screw
(4) Oil Seal
(5) Bearing Case Cover Mounting Screw
(6) Bearing Case Cover
(a) Upside
S-69
DIESEL ENGINE
Crankshaft
NOTE
Before disassembling, check the side clearance of
crankshaft. Also check it during reassembling.
For D1503-M, D1703-M, V2003-M, V2203-M, D1703-M-BG,
V2003-M-BG, V2003-M-T-BG and V2203-M-BG
1. Remove the main bearing case screw 2 (1).
2. Pull out the crankshaft assembly, taking care not to damage the
crankshaft bearing 1 (3).
For D1803-M and D1803-M-DI
2. Turn the crankshaft to set the crank pin of the third cylinder to the
bottom dead center. Then draw out the crankshaft until the crank
pin of the second cylinder comes to the center of the third
cylinder.
3. Turn the crankshaft by 2.09 rad (120 ) counterclockwise to set
the crank pin of the second cylinder to the bottom dead center.
Draw out the crankshaft until the crank pin of the first cylinder
comes to the center of the third cylinder
4. Repeat the above steps to draw out all the crankshaft.
For V2403-M, V2403-M-DI, V2403-M-T, V2403-M-DI-T and V2403-
M-BG
2. Turn the crankshaft to set the crank pin of the 4th cylinder to the
horizontal directions (Right or Left). Then draw out all the
crankshaft, holding the crank pins to the horizontal directions
(Right or Left).
(When reassembling)
IMPORTANT
Install the crankshaft sub assembly, aligning the screw hole
of main bearing case 2 (2) with the screw hole of cylinder
block.
When tightening the main bearing case screw 2 (1), apply oil
to the screw and screw by hand before tightening the
specific torque.
If not smooth to screw by hand, align the screw holes
between the cylinder block and the main bearing case.
W1066311
Tightening torque Main bearing case screw 2
69 to 73 Nm
7.0 to 7.5 kgfm
51 to 54 lbfft
(1) Main Bearing Case Screw 2
(2) Main Bearing Case 2
(3) Crankshaft Bearing 1
(a) Cut place for removing and
installing the crankshaft
[A] D1803-M, D1803-M-DI
S-70
DIESEL ENGINE
Main Bearing Case Assembly
1. Remove the two main bearing case screws 1 (7), and remove the
main bearing case assembly being careful with thrust bearing
and crankshaft bearing.
2. Remove the main bearing case 1, 2 as above.
(When reassembling)
Clean the oil passage in the main bearing case.
Apply clean engine oil on the bearings.
Install the main bearing case assemblies in the original positions.
Since diameters of main bearing cases vary, install them in order
of makings (A, B for 3 cylinders and A, B, C for 4 cylinders) from
the gear case side.
Match the alignment numbers (1) and mark (2) on the main
bearing case.
When installing the main bearing case 1 and 2, face the mark
FLYWHEEL to the flywheel.
Install the thrust bearing with its oil groove (8) facing outward.
Confirm that the main bearing case moves smoothly after
tightening the main bearing case screw 1 (7) to the specified
torque.
W1027366
Tightening torque Main bearing case screw 1
46 to 50 Nm
4.7 to 5.2 kgfm
34 to 37 lbfft
(1) Alignment Number
(2) Alignment Mark
(3) A
(4) B
(5) C
(6) No Mark
(7) Main Bearing Case Screw 1
(8) Oil Groove
S-71
DIESEL ENGINE
(7) Starter
W1222714
1. Unscrew the C terminal nut (3), and disconnect the connecting lead.
2. Remove the two through bolts (1).
3. Detach the motor.
4. Remove the end frame (8).
5. Remove the brush from the brush holder while holding the spring up.
6. Remove the brush holder (9).
7. Draw out the armature (5) from the yoke (4).
8. Remove the housing (13).
9. Remove the idle gear (7) and the overrunning clutch (6).
10.Remove the magnet switch cover (10).
11.Remove the plunger (11).
NOTE
Do not damage to the brush and commutator.
(When reassembling)
Apply grease (DENSO No. 50 or equivalent) to the idle gear and overrunning clutch portions.
W1131675
(1) Through Bolt
(2) Brush
(3) C Terminal Nut
(4) Yoke
(5) Armature
(6) Overrunning Clutch
(7) Idle Gear
(8) End Frame
(9) Brush Holder
(10) Magnet Switch Cover
(11) Plunger
(12) B Terminal Nut
(13) Housing
Tightening torque B terminal nut
5.9 to 11 Nm
0.60 to 1.2 kgfm
4.4 to 8.6 lbfft
S-72
DIESEL ENGINE
(8) Alternator
W1224079
1. Remove the pulley (1).
2. Remove the rear end cover (12).
3. Remove the brush holder (11).
4. Remove the IC regulator (10).
5. Remove the four screws holding the stator lead wires.
6. Remove the rectifier (9).
7. Remove the rear end frame (8).
8. Press out the rotor (6) from drive end frame (2).
9. Remove the retainer plate (5).
10.Press out the bearing (4) from drive end frame (2) with a press and jig.
11.Lightly secure the rotor with a vise to prevent damage, and remove the bearing (7) with a puller.
(When reassembling)
W1224556
(1) Pulley
(2) Drive End Frame
(3) Stator
(4) Bearing
(5) Retainer Plate
(6) Rotor
(7) Bearing
(8) Rear End Frame
(9) Rectifier
(10) IC Regulator
(11) Brush Holder
(12) Rear End Cover
Tightening torque Pulley nut
58.4 to 78.9 Nm
5.95 to 8.05 kgfm
43.1 to 58.2 lbfft
S-73
DIESEL ENGINE
[3] SERVICING
(1) Cylinder Head and Valves
Top Clearance
1. Remove the cylinder head.
2. Move the piston up and stick a strip of fuse on the piston head at
three position with grease.
3. Lower the piston and install the cylinder head. (Use a new
cylinder head gasket and tighten with a specified tightening
torque.)
4. Turn the flywheel until the piston exceeds top dead center.
5. Remove the cylinder head and measure the thickness of the
fuses.
6. If the measurement is not within the factory specifications, check
the oil clearances between the crankpin and bearing and
between the piston pin and bushing.
NOTE
After checking the top clearance, be sure to assemble the
cylinder head with a new cylinder head gasket.
W1020190
Top clearance
Factory
spec.
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
0.575 to 0.675 mm
0.0227 to 0.0265 in.
D1803-M-DI
V2403-M-DI
V2403-M-DI-T
0.60 to 0.70 mm
0.024 to 0.027 in.
Tightening torque Cylinder head screws
93.2 to 98.0 Nm
9.50 to 10.0 kgfm
68.8 to 72.3 lbfft
(1) Piston
(2) Fuse
[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
S-74
DIESEL ENGINE
Cylinder Head Surface Flatness
1. Clean the cylinder head surface.
2. Place a straightedge on the cylinder heads four sides (A), (B),
(C) and (D) and two diagonal (E) and (F) as shown in the figure.
3. Measure the clearance with a feeler gauge.
4. If the measurement exceeds the allowable limit, correct it with a
surface grinder.
IMPORTANT
Do not place the straightedge on the combustion chamber.
Be sure to check the valve recessing after correcting.
W1027737
Cylinder Head Flaw
1. Prepare an air spray red check.
2. Clean the surface of the cylinder head with the detergent (2).
3. Spray the cylinder head surface with the red permeative liquid
(1). Leave it five to ten minutes after spraying.
4. Wash away the red permeative liquid on the cylinder head
surface with the detergent (2).
5. Spray the cylinder head surface with the white developer (3).
6. If flawed, it can be identified as red marks.
W1076542
Cylinder head surface
flatness
Allowable limit
0.05 mm
0.002 in.
(1) Red Permeative Liquid
(2) Detergent
(3) White Developer
S-75
DIESEL ENGINE
Valve Recessing
1. Clean the cylinder head surface, valve face and valve seat.
2. Insert the valve into the valve guide.
3. Measure the valve recessing with a depth gauge.
4. If the measurement exceeds the allowable limit, replace the
valve.
5. If it still exceeds the allowable limit after replacing the valve,
replace the cylinder head.
W10768800
Valve recessing
Factory
spec.
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
0.05 (protrusion) to
0.15 (recessing) mm
0.002 (protrusion) to
0.0059 (recessing) in.
D1803-M-DI
V2403-M-DI
V2403-M-DI-T
0.65 to 0.85 mm
0.026 to 0.033 in.
Allowable
limit
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
0.40 (recessing) mm
0.016 (recessing) in.
D1803-M-DI
V2403-M-DI
V2403-M-DI-T
(1) Cylinder Head Surface (A) Recessing

(B) Protrusion
S-76
DIESEL ENGINE
Clearance between Valve Stem and Valve Guide
1. Remove carbon from the valve guide section.
2. Measure the valve stem O.D. with an outside micrometer.
3. Measure the valve guide I.D. with a small hole gauge, and
calculate the clearance.
4. If the clearance exceeds the allowable limit, replace the valves.
If it still exceeds the allowable limit, replace the valve guide.
W10774950
Replacing Valve Guide
(When removing)
1. Press out the used valve guide using a valve guide replacing tool.
(See page SPECIAL TOOLS.)
(When installing)
1. Clean a new valve guide and valve guide bore, and apply engine
oil to them.
2. Press in a new valve guide using a valve guide replacing tool.
3. Ream precisely the I.D. of the valve guide to the specified
dimension.
IMPORTANT
Do not hit the valve guide with a hammer during
replacement.
W10278890
Clearance between
valve stem and valve
guide
Factory spec.
0.040 to 0.070 mm
0.0016 to 0.0027 in.
Allowable limit
0.10 mm
0.0039 in.
Valve stem O.D. Factory spec.
7.960 to 7.975 mm
0.3134 to 0.3139 in.
Valve guide I.D. Factory spec.
8.015 to 8.030 mm
0.3156 to 0.3161 in.
Valve guide I.D.
(Intake and exhaust)
Factory spec.
8.015 to 8.030 mm
0.3156 to 0.3161 in.
(A) When Removing (B) When Installing
S-77
DIESEL ENGINE
Valve Seating
1. Coat the valve face lightly with prussian blue and put the valve on
its seat to check the contact.
2. If the valve does not seat all the way around the valve seat or the
valve contact is less than 70 %, correct the valve seating as
follows.
3. If the valve contact does not comply with the reference value,
replace the valve or correct the contact of valve seating.
W10282190
Valve seat width Factory spec.
2.12 mm
0.0835 in.
(1) Correct
(2) Incorrect
(3) Incorrect
S-78
DIESEL ENGINE
Correcting Valve and Valve Seat
NOTE
Before correcting the valve and seat, check the valve stem
and the I.D. of valve guide section, and repair them if
necessary.
After correcting the valve seat, be sure to check the valve
recessing.
1) Correcting Valve
1. Correct the valve with a valve refacer.
[D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M,
V2403-M-T]
V2403-M-BG]
[D1803-M-DI, V2403-M-DI, V2403-M-DI-T]
2) Correcting Valve Seat
1. Slightly correct the seat surface with a 1.0 rad (60 ) or 0.79 rad
(45 ) valve seat cutter.
2. Resurface the seat surface with a 0.52 rad (30 ) valve seat cutter
or 0.26 rad (15 ) valve seat cutter to valve seat so that the width
is close to specified valve seat width (2.12 mm, 0.0835 in.).
3. After resurfacing the seat, inspect for even valve seating, apply a
thin film of compound between the valve face and valve seat, and
fit them with valve lapping tool.
4. Check the valve seating with prussian blue. The valve seating
surface should show good contact all the way around.
[D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M,
V2403-M-T]
V2403-M-BG]
[D1803-M-DI, V2403-M-DI, V2403-M-DI-T]
W10283500
Valve face angle
Factory
spec.
IN.
1.0 rad
60
EX.
0.79 rad
45
Valve face angle
Factory
spec.
IN.
0.79 rad
45
EX.
0.79 rad
45
Valve seat angle
Factory
spec.
IN.
1.0 rad
60
EX.
0.79 rad
45
Valve seat angle
Factory
spec.
IN.
0.79 rad
45
EX.
0.79 rad
45
(1) Valve Seat Width
(2) Identical Dimensions
(A) Check Contact
(B) Correct Seat Width
(C) Check Contact
(a) 0.26 rad (15 ) or 0.52 rad (30 )
(b) 0.79 rad (45 ) or 1.0 rad (60 )
(c) 0.52 rad (30 ) or 0.26 rad (15 )
S-79
DIESEL ENGINE
Valve Lapping
1. Apply compound evenly to the valve lapping surface.
2. Insert the valve into the valve guide. Lap the valve onto its seat
with a valve flapper or screwdriver.
3. After lapping the valve, wash the compound away and apply oil,
then repeat valve lapping with oil.
4. Apply prussian blue to the contact surface to check the seated
rate. If it is less than 70 %, repeat valve lapping again.
IMPORTANT
When valve lapping is performed, be sure to check the valve
recessing and adjust the valve clearance after assembling
the valve.
W10288140
Free Length and Tilt of Valve Spring
1. Measure the free length (B) of valve spring with vernier calipers.
If the measurement is less than the allowable limit, replace it.
2. Put the valve spring on a surface plate, place a square on the
side of the valve spring.
3. Check to see if the entire side is in contact with the square.
Rotate the valve spring and measure the maximum tilt (A).
If the measurement exceeds the allowable limit, replace it.
4. Check the entire surface of the valve spring for scratches.
If there is any defect, replace it.
W10289350
Valve Spring Setting Load
1. Place the valve spring on a tester and compress it to the same
length it is actually compressed in the engine.
2. Read the compression load on the gauge.
3. If the measurement is less than the allowable limit, replace it.
W10784360
Tilt (A) Allowable limit
1.0 mm
0.039 in.
Free length (B)
Factory spec.
41.7 to 42.2 mm
1.65 to 1.66 in.
Allowable limit
41.2 mm
1.62 in.
(A) Tilt (B) Free Length
Setting load /
Setting length
Factory spec.
118 N / 35.0 mm
12.0 kgf / 35.0 mm
26.5 lbf / 1.38 in.
Allowable limit
100 N / 35.0 mm
10.2 kgf / 35.0 mm
22.5 lbf / 1.38 in.
S-80
DIESEL ENGINE
Oil Clearance between Rocker Arm and Rocker Arm Shaft
1. Measure the rocker arm shaft O.D. with an outside micrometer.
2. Measure the rocker arm I.D. with an inside micrometer, and then
calculate the oil clearance.
3. If the oil clearance exceeds the allowable limit, replace the rocker
arm and measure the oil clearance again. If it still exceeds the
allowable limit, replace also the rocker arm shaft.
W1029150
Push Rod Alignment
1. Place the push rod on V blocks.
2. Measure the push rod alignment.
3. If the measurement exceeds the allowable limit, replace the push
rod.
W10292900
Oil Clearance between Tappet and Tappet Guide Bore
1. Measure the tappet O.D. with an outside micrometer.
2. Measure the I.D. of the tappet guide bore with a cylinder gauge,
and calculate the oil clearance.
3. If the oil clearance exceeds the allowable limit or the tappet is
damaged, replace the tappet.
W1029366
Oil clearance between
rocker arm and rocker
arm shaft
Factory spec.
0.016 to 0.045 mm
0.00063 to 0.0017 in.
Allowable limit
0.10 mm
0.0039 in.
Rocker arm shaft O.D. Factory spec.
13.973 to 13.984 mm
0.55012 to 0.55055 in.
Rocker arm I.D. Factory spec.
14.000 to 14.018 mm
0.55119 to 0.55188 in.
Push rod alignment Allowable limit
0.25 mm
0.0098 in.
Oil Clearance between
tappet and tappet guide
bore
Factory spec.
0.020 to 0.062 mm
0.00079 to 0.0024 in.
Allowable limit
0.07 mm
0.003 in.
Tappet O.D. Factory spec.
23.959 to 23.980 mm
0.94327 to 0.94409 in.
Tappet guide bore I.D. Factory spec.
24.000 to 24.021 mm
0.94489 to 0.94570 in.
S-81
DIESEL ENGINE
(2) Timing Gears
Timing Gear Backlash
1. Set a dial indicator (lever type) with its tip on the gear tooth.
2. Move the gear to measure the backlash, holding its mating gear.
3. If the backlash exceeds the allowable limit, check the oil
clearance of the shafts and the gear.
4. If the oil clearance is proper, replace the gear.
For Balancer Model Only
For Side PTO Model Only
W1029564
Idle Gear Side Clearance
1. Set a dial indicator with its tip on the idle gear.
2. Measure the side clearance by moving the idle gear to the front
and rear.
3. If the measurement exceeds the allowable limit, replace the idle
gear collar.
W1029843
Backlash between idle
gear and crank gear
Factory spec.
0.04150 to 0.1122 mm
0.001634 to 0.004417 in.
Allowable limit
0.15 mm
0.0059 in.
gear and cam gear
Factory spec.
0.04150 to 0.1154 mm
0.001634 to 0.004543 in.
Allowable limit
0.15 mm
0.0059 in.
gear and injection pump
gear
Factory spec.
0.04150 to 0.1154 mm
0.001634 to 0.004543 in.
Allowable limit
0.15 mm
0.0059 in.
Backlash between crank
gear and oil pump gear
Factory spec.
0.04150 to 0.1090 mm
0.001634 to 0.004291 in.
Allowable limit
0.15 mm
0.0059 in.
gear and balancer gear
(Intake side)
Factory spec.
0.03500 to 0.1160 mm
0.001378 to 0.004566 in.
Allowable limit
0.15 mm
0.0059 in.
Backlash between cam
gear and balancer gear
(Exhaust side)
Factory spec.
0.03500 to 0.1160 mm
0.001378 to 0.004566 in.
Allowable limit
0.15 mm
0.0059 in.
Backlash between crank
gear and idle gear 2
Factory spec.
0.04150 to 0.1154 mm
0.001634 to 0.004543 in.
Allowable limit
0.15 mm
0.0059 in.
gear 2 and hydraulic
pump drive gear
Factory spec.
0.03080 to 0.1062 mm
0.001213 to 0.004181 in.
Allowable limit
0.15 mm
0.0059 in.
Idle gear side clearance
Factory spec.
0.12 to 0.48 mm
0.0048 to 0.018 in.
Allowable limit
0.9 mm
0.04 in.
S-82
DIESEL ENGINE
Camshaft Side Clearance
1. Set a dial indicator with its tip on the camshaft.
2. Measure the side clearance by moving the cam gear to the front
to rear.
camshaft stopper.
W1030012
Camshaft Alignment
1. Support the camshaft with V blocks on the surface plate at both
end journals.
2. Set a dial indicator with its tip on the intermediate journal.
3. Measure the camshaft alignment.
camshaft.
W1031413
Camshaft side
clearance
Factory spec.
0.070 to 0.22 mm
0.0028 to 0.0086 in.
Allowable limit
0.30 mm
0.012 in.
Camshaft alignment Allowable limit
0.01 mm
0.0004 in.
S-83
DIESEL ENGINE
Cam Height
1. Measure the height of the cam at its highest point with an outside
micrometer.
2. If the measurement is less than the allowable limit, replace the
camshaft.
W1031532
Cam height of intake
Factory
spec.
D1503-M
D1703-M-BG
33.27 mm
1.310 in.
V2003-M
V2403-M-DI-T
V2003-M-BG
V2203-M-BG
33.47 mm
1.318 in.
D1703-M
D1803-M
V2203-M
V2403-M
V2403-M-T
D1803-M-DI
V2403-M-DI
V2003-M-T-BG
V2403-M-BG
33.90 mm
1.335 in.
Allowable
limit
D1503-M
D1703-M-BG
33.22 mm
1.308 in.
V2003-M
V2403-M-DI-T
V2003-M-BG
V2203-M-BG
33.42 mm
1.316 in.
D1703-M
D1803-M
V2203-M
V2403-M
V2403-M-T
D1803-M-DI
V2403-M-DI
V2003-M-T-BG
V2403-M-BG
33.85 mm
1.333 in.
S-84
DIESEL ENGINE
Cam Height (Continued)
1. Measure the height of the cam at its highest point with an outside
micrometer.
2. If the measurement is less than the allowable limit, replace the
camshaft.
W1111109
Oil Clearance of Camshaft Journal
1. Measure the camshaft journal O.D. with an outside micrometer.
2. Measure the cylinder block bore I.D. for camshaft with a cylinder
gauge, and calculate the oil clearance.
3. If the oil clearance exceeds the allowable limit, replace the
camshaft.
W1031662
Cam height of
exhaust
Factory
spec.
V2403-M-DI-T
33.00 mm
1.299 in.
V2403-M-T
D1703-M-BG
V2003-M-BG
V2203-M-BG
33.27 mm
1.310 in.
D1503-M
V2003-M
V2003-M-T-BG
33.47 mm
1.318 in.
D1703-M
D1803-M
V2203-M
V2403-M
D1803-M-DI
V2403-M-DI
V2403-M-BG
33.90 mm
1.335 in.
Allowable
limit
V2403-M-DI-T
32.95 mm
1.297 in.
V2403-M-T
D1703-M-BG
V2003-M-BG
V2203-M-BG
33.22 mm
1.308 in.
D1503-M
V2003-M
V2003-M-T-BG
33.42 mm
1.316 in.
D1703-M
D1803-M
V2203-M
V2403-M
D1803-M-DI
V2403-M-DI
V2403-M-BG
33.85 mm
1.333 in.
Oil clearance of
camshaft journal
Factory spec.
0.050 to 0.091 mm
0.0020 to 0.0035 in.
Allowable limit
0.15 mm
0.0059 in.
Camshaft journal O.D. Factory spec.
39.934 to 39.950 mm
1.5722 to 1.5728 in.
Cylinder block bore I.D. Factory spec.
40.000 to 40.025 mm
1.5748 to 1.5757 in.
S-85
DIESEL ENGINE
Oil Clearance between Idle Gear Shaft and Idle Gear Bushing
1. Measure the idle gear shaft O.D. with an outside micrometer.
2. Measure the idle gear bushing I.D. with an inside micrometer,
bushing.
If it still exceeds the allowable limit, replace the idle gear shaft.
W1030933
Replacing Idle Gear Bushing
(When removing)
1. Press out the used idle gear bushing using an idle gear bushing
replacing tool. (See page SPECIAL TOOLS.)
(When installing)
1. Clean a new idle gear bushing and idle gear bore, and apply
engine oil to them.
2. Press in a new bushing using an idle gear bushing replacing tool,
until it is flush with the end of the idle gear.
W1031083
Balancer Shaft Side Clearance (for Balancer Model Only)
1. Set a dial indicator with tip on the balancer shaft.
2. Measure the side clearance by moving the balancer shaft to the
front and rear.
balancer shaft.
W1030111
Balancer Shaft Alignment (for Balancer Model Only)
1. Support the balancer shaft with V blocks on the surface plate and
set a dial indicator with its tip on the intermediate journal at high
angle.
2. Rotate the balancer shaft on the V block and get the
misalignment (half of the measurement).
3. If the misalignment exceeds the allowable limit, replace the
balancer shaft.
W1042630
idle gear shaft and idle
gear bushing
Factory spec.
0.025 to 0.066 mm
0.00099 to 0.0025 in.
Allowable limit
0.10 mm
0.0039 in.
Idle gear shaft O.D. Factory spec.
37.959 to 37.975 mm
1.4945 to 1.4950 in.
Idle gear bushing I.D. Factory spec.
38.000 to 38.025 mm
1.4961 to 1.4970 in.
(A) When Removing (B) When Installing
Balancer shaft side
clearance
Factory spec.
0.070 to 0.22 mm
0.0028 to 0.0086 in.
Allowable limit
0.30 mm
0.012 in.
Balancer shaft
alignment
Allowable limit
0.02 mm
0.0008 in.
S-86
DIESEL ENGINE
Oil Clearance of Balancer Shaft Journal (for Balancer Model
Only)
1. Measure the balancer shaft journal O.D. with an outside
micrometer.
2. Measure the cylinder block bore I.D. for balancer shaft with an
inside micrometer or cylinder gauge.
3. If the clearance exceeds the allowable limit, replace the balancer
shaft.
W1030206
(3) Piston and Connecting Rod
Piston Pin Bore I.D.
1. Measure the piston pin bore I.D. in both the horizontal and
vertical directions with a cylinder gauge.
piston.
W1031817
Oil clearance of
balancer shaft journal 1
Factory spec.
0.0300 to 0.111 mm
0.00119 to 0.00437 in.
Allowable limit
0.20 mm
0.0079 in.
Balancer shaft journal 1
O.D.
Factory spec.
43.934 to 43.950 mm
1.7297 to 1.7303 in.
Balancer shaft bearing 1
I.D.
Factory spec.
43.980 to 44.045 mm
1.7315 to 1.7340 in.
Oil clearance of
Factory spec.
0.0300 to 0.111 mm
0.00119 to 0.00437 in.
Allowable limit
0.20 mm
0.0079 in.
O.D.
Factory spec.
41.934 to 41.950 mm
1.6509 to 1.6515 in.
I.D.
Factory spec.
41.980 to 42.045 mm
1.6528 to 1.6553 in.
Oil clearance of
Factory spec.
0.020 to 0.094 mm
0.00079 to 0.0037 in.
Allowable limit
0.20 mm
0.0079 in.
O.D.
Factory spec.
21.947 to 21.960 mm
0.86406 to 0.86456 in.
I.D.
Factory spec.
21.980 to 22.041 mm
0.86536 to 0.86775 in.
(1) Balancer Shaft Journal 3
Piston pin bore I.D.
Factory spec.
25.000 to 25.013 mm
0.98426 to 0.98476 in.
Allowable limit
25.05 mm
0.9862 in.
S-87
DIESEL ENGINE
Oil Clearance between Piston Pin and Small End Bushing
1. Measure the piston pin O.D. where it contacts the bushing with
an outside micrometer.
2. Measure the small end bushing I.D. with an inside micrometer,
bushing. If it still exceeds the allowable limit, replace the piston
pin.
W1031982
Replacing Connecting Rod Small End Bushing
(When removing)
1. Press out the used small end bushing using a small end bushing
replacing tool. (See page SPECIAL TOOLS.)
(When installing)
1. Clean a new small end bushing and bore, and apply engine oil to
them.
2. Using a small end bushing replacing tool, press in a new bushing
taking due care to see that the connecting rod oil hole matches
the bushing hole.
W1032140
Connecting Rod Alignment
NOTE
Since the I.D. of the connecting rod small end bushing is the
basis of this check, check bushing for wear beforehand.
1. Install the piston pin into the connecting rod.
2. Install the connecting rod on the connecting rod alignment tool.
3. Put a gauge over the piston pin, and move it against the face
plate.
4. If the gauge does not fit squarely against the face plate, measure
the space between the pin of the gauge and the face plate.
connecting rod.
W10314620
piston pin and small end
bushing
Factory spec.
0.014 to 0.036 mm
0.00056 to 0.0014 in.
Allowable limit
0.15 mm
0.0059 in.
Piston pin O.D. Factory spec.
25.004 to 25.011 mm
0.98441 to 0.98468 in.
Small end bushing I.D. Factory spec.
25.025 to 25.040 mm
0.98524 to 0.98582 in.
(A) When removing (B) When installing
Connecting rod
alignment
Allowable limit
0.05 mm
0.002 in.
S-88
DIESEL ENGINE
Piston Ring Gap
1. Insert the piston ring into the lower part of the liner (the least worn
out part) with the piston.
2. Measure the ring gap with a feeler gauge.
3. If the gap exceeds the allowable limit, replace the ring.
W1032246
Top ring
Factory
spec.
D1503-M
V2003-M
V2403-M-T
D1803-M-DI
V2403-M-DI
V2403-M-DI-T
V2003-M-BG
V2003-M-T-BG
0.20 to 0.35 mm
0.0079 to 0.013 in.
D1703-M
D1803-M
V2203-M
V2403-M
D1703-M-BG
V2203-M-BG
V2403-M-BG
0.25 to 0.40 mm
0.0099 to 0.015 in.
Allowable limit
1.25 mm
0.0492 in.
Second ring
Factory
spec.
D1503-M
D1703-M
D1803-M
V2203-M
V2403-M
D1803-M-DI
V2403-M-DI
D1703-M-BG
V2003-M-BG
V2203-M-BG
V2403-M-BG
0.30 to 0.45 mm
0.012 to 0.017 in.
V2003-M
V2403-M-T
V2403-M-DI-T
V2003-M-T-BG
0.40 to 0.55 mm
0.016 to 0.021 in.
Allowable limit
1.25 mm
0.0492 in.
Oil ring
Factory
spec.
D1503-M
D1703-M
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
0.25 to 0.45 mm
0.0099 to 0.017 in.
D1803-M-DI
V2403-M-DI
0.20 to 0.40 mm
0.0079 to 0.015 in.
Allowable limit
1.25 mm
0.0492 in.
S-89
DIESEL ENGINE
Clearance between Piston Ring and Groove
1. Clean the rings and the ring grooves, and install each ring in its
groove.
2. Measure the clearance between the ring and the groove with a
feeler gauge or depth gauge.
3. If the clearance exceeds the allowable limit, replace the piston
ring.
4. If the clearance still exceeds the allowable limit with new ring,
replace the piston.
W1032489
Top Ring
Factory
spec.
D1803-M-DI
V2403-M-DI
0.050 to 0.090 mm
0.0020 to 0.0035 in.
Allowable limit
0.20 mm
0.0079 in.
Second ring
Factory
spec.
D1503-M
D1703-M
D1803-M
V2003-M
V2203-M
V2403-M
V2403-M-T
V2403-M-ID-T
D1703-M-BG
V2003-M-BG
V2003-M-T-BG
V2203-M-BG
V2403-M-BG
0.0930 to 0.128 mm
0.00367 to 0.00503 in.
D1803-M-DI
V2403-M-DI
0.0780 to 0.110 mm
0.00307 to 0.00433 in.
Allowable limit
0.20 mm
0.0079 in.
Oil ring
Factory
spec.
D1503-M
D1703-M
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
0.020 to 0.060 mm
0.00079 to 0.0023 in.
D1803-M-DI
V2403-M-DI
0.030 to 0.070 mm
0.0012 to 0.0027 in.
Allowable limit
0.15 mm
0.0059 in.
(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
S-90
DIESEL ENGINE
(4) Crankshaft
Side Clearance of Crankshaft
1. Set a dial indicator with its tip on the end of the crankshaft.
2. Measure the side clearance by moving the crankshaft to the front
and rear.
thrust bearings.
4. If the same size bearing is useless because of the crankshaft
journal wear, replace it with an oversize one referring to the table
and figure.
(Reference)
Oversize dimensions of crankshaft journal
W1032880
Crankshaft Alignment
1. Support the crankshaft with V blocks on the surface plate at both
end journals.
2. Set a dial indicator with its tip on the intermediate journal.
3. Measure the crankshaft alignment.
crankshaft.
W1033001
Crankshaft side
clearance
Factory spec.
0.15 to 0.31 mm
0.0059 to 0.012 in.
Allowable limit
0.5 mm
0.02 in.
Oversize
0.2 mm
0.008 in.
0.4 mm
0.02 in.
Dimension A
54.50 to 54.70 mm
2.146 to 2.153 in.
54.60 to 54.80 mm
2.150 to 2.157 in.
Dimension B
26.20 to 26.25 mm
1.032 to 1.033 in.
26.40 to 26.45 mm
1.040 to 1.041 in.
Dimension C
2.8 to 3.2 mm radius
0.11 to 0.12 in. radius
(0.4S)
The crankshaft journal must be fine-finished to higher than
Crankshaft alignment Allowable limit
0.02 mm
0.0008 in.
S-91
DIESEL ENGINE
Oil Clearance between Crankpin and Crankpin Bearing
1. Clean the crankpin and crankpin bearing.
2. Put a strip of plastigage on the center of the crankpin.
3. Install the connecting rod cap and tighten the connecting rod
screws to the specified torque, and remove the cap again.
4. Measure the amount of the flattening with the scale, and get the
oil clearance.
crankpin bearing.
6. If the same size bearing is useless because of the crankpin wear,
replace it with an undersize one referring to the table and figure.
NOTE
Never insert the plastigage into the crankpin oil hole.
Be sure not to move the crankshaft while the connecting rod
screws are tightened.
(Reference)
Undersize dimensions of crankpin
W1033106
crankpin and crankpin
bearing
Factory spec.
0.025 to 0.087 mm
0.00099 to 0.0034 in.
Allowable limit
0.20 mm
0.0079 in.
Crankpin O.D. Factory spec.
46.959 to 46.975 mm
1.8488 to 1.8494 in.
Crankpin bearing I.D. Factory spec.
47.000 to 47.046 mm
1.8504 to 1.8522 in.
Undersize
0.2 mm
0.008 in.
0.4 mm
0.02 in.
Dimension A
*Dimension B
1.0 to 1.5 mm relief
0.040 to 0.059 in. relief
Dimension C
46.759 to 46.775 mm dia.
1.8409 to 1.8415 in. dia.
46.559 to 46.575 mm dia.
1.8331 to 1.8336 in. dia.
(0.4S)
The crankpin must be fine-finished to higher than
*Holes to be de-burred and edges rounded with 1.0 to 1.5 mm
(0.040 to 0.059 in.) relief.
S-92
DIESEL ENGINE
Oil Clearance between Crankshaft Journal and Crankshaft
Bearing 1
1. Measure the O.D. of the crankshaft journal with an outside
micrometer.
2. Measure the I.D. of the crankshaft bearing 1 with an inside
micrometer, and calculate oil clearance.
3. If the clearance exceeds the allowable limit, replace the
crankshaft bearing 1.
journal wear, replace it with an undersize one referring to the
table and figure.
(Reference)
Undersize dimensions of crankshaft journal
W1033717
Replacing Crankshaft Bearing 1
(When removing)
1. Press out the used crankshaft bearing 1 using a crankshaft
bearing 1 replacing tool. (See page SPECIAL TOOLS.)
(When installing)
1. Clean a new crankshaft bearing 1 and crankshaft journal bore,
and apply engine oil to them.
2. Using a crankshaft bearing 1 replacing tool, press in a new
bearing 1 (2) so that its seam (1) directs toward the exhaust
manifold side. (See figure.)
W1033946
crankshaft journal and
crankshaft bearing 1
Factory spec.
0.0400 to 0.118 mm
0.00158 to 0.00464 in.
Allowable limit
0.20 mm
0.0079 in.
Crankshaft journal O.D. Factory spec.
59.921 to 59.940 mm
2.3591 to 2.3598 in.
Crankshaft bearing 1
I.D.
Factory spec.
59.980 to 60.039 mm
2.3615 to 2.3637 in.
Undersize
0.2 mm
0.008 in.
0.4 mm
0.02 in.
Dimension A
*Dimension B
Dimension C
59.721 to 59.740 mm dia.
2.3513 to 2.3519 in. dia.
59.521 to 59.540 mm dia.
2.3434 to 2.3440 in. dia.
(0.4S)
(0.040 to 0.059 in.) relief.
Dimension (A) Factory spec.
4.20 to 4.50 mm
0.166 to 0.177 in.
(1) Seam
(2) Crankshaft Bearing 1
(3) Cylinder Block
(A) Dimension
S-93
DIESEL ENGINE
Oil Clearance between Crankshaft Journal and Crankshaft
Bearing 2
1. Put a strip of plastigage on the center of the journal.
2. Install the bearing case and tighten the baring case screws 1 to
the specified torque, and remove the bearing case again.
3. Measure the amount of the flattening with the scale and get the
oil clearance.
4. If the clearance exceeds the allowable limit, replace the
crankshaft bearing 2.
journal wear, replace it with an undersize one referring to the
table and figure.
NOTE
Be sure not to move the crankshaft while the bearing case
screws are tightened.
(Reference)
Undersize dimensions of crankshaft journal
W1083821
crankshaft and
crankshaft bearing 2
Factory spec.
0.0400 to 0.104 mm
0.00158 to 0.00409 in.
Allowable limit
0.20 mm
0.0079 in.
Crankshaft journal O.D. Factory spec.
59.921 to 59.940 mm
2.3591 to 2.3598 in.
Crankshaft bearing 2
I.D.
Factory spec.
59.980 to 60.025 mm
2.3615 to 2.3631 in.
Undersize
0.2 mm
0.008 in.
0.4 mm
0.02 in.
Dimension A
*Dimension B
Dimension C, D
59.721 to 59.740 mm dia.
2.3513 to 2.3519 in. dia.
59.521 to 59.540 mm dia.
2.3434 to 2.3440 in. dia.
(0.4S)
(0.040 to 0.059 in.) relief.
S-94
DIESEL ENGINE
Replacing Crankshaft Sleeve
1. Remove the used crankshaft sleeve (3).
2. Set the sleeve guide (2) to the crankshaft (5).
3. Set the stopper (1) to the crankshaft (5) as shown in figure.
4. Heat a new sleeve to a temperature between 150 and 200 C
(302 and 392 F), and fix the sleeve to the crankshaft (5) as
shown in figure.
5. Press fit the sleeve using the auxiliary socket for pushing (4).
(Refer to SPECIAL TOOLS.)
NOTE
Mount the sleeve with its largely chamfered surface facing
outward.
Should heating is not enough, a sleeve might stop halfway,
so careful.
W1033503
(1) Stopper
(2) Sleeve Guide
(3) Crankshaft Sleeve
(4) Auxiliary Socket for Pushing
(5) Crankshaft
S-95
DIESEL ENGINE
(5) Cylinder
Cylinder Wear
1. Measure the I.D. of the cylinder at the six positions (see figure)
with a cylinder gauge to find the maximum and minimum I.D.s.
2. Get the difference (Maximum wear) between the maximum and
the minimum I.D.s.
3. If the wear exceeds the allowable limit, bore and hone to the
oversize dimension. (Refer to Correcting Cylinder.)
4. Visually check the cylinder wall for scratches. If deep scratches
are found, the cylinder should be bored. (Refer to Correcting
Cylinder.)
W1034389
Cylinder I.D.
Factory
spec.
D1503-M
V2003-M
V2003-M-BG
V2003-M-T-BG
83.000 to 83.022 mm
3.2678 to 3.2685 in.
D1703-M
D1803-M
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
87.000 to 87.022 mm
3.4252 to 3.4260 in.
Allowable
limit
D1503-M
V2003-M
V2003-M-BG
V2003-M-T-BG
83.170 mm
3.2744 in.
D1703-M
D1803-M
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
87.170 mm
3.4319 in.
A : Top
B : Middle
C : Bottom (Skirt)
(a) Right-angled to Piston Pin
(b) Piston Pin Direction
S-96
DIESEL ENGINE
Correcting Cylinder (Oversize)
1. When the cylinder is worn beyond the allowable limit, bore and
hone it to the specified dimension.
2. Replace the piston and piston rings with oversize ones.
Oversize : 0.25 mm (0.0098 in.)
NOTE
When the oversize cylinder is worn beyond the allowable
limit, replace the cylinder block with a new one.
W1034448
Oversize cylinder
I.D.
Factory
spec.
D1503-M
V2003-M
V2003-M-BG
V2003-M-T-BG
83.250 to 83.272 mm
3.2776 to 3.2784 in.
D1703-M
D1803-M
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
87.250 to 87.272 mm
3.4351 to 3.4359 in.
Allowable
limit
D1503-M
V2003-M
V2003-M-BG
V2003-M-T-BG
83.420 mm
3.2843 in.
D1703-M
D1803-M
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
87.420 mm
3.4417 in.
Finishing
Hone to 2.2 to 3.0 mRz
(0.000087 to 0.000118 in.Rz)
.
(1) Cylinder I.D. (Before Correction) (2) Cylinder I.D. (Oversize)
S-97
DIESEL ENGINE
(6) Oil Pump
Rotor Lobe Clearance
1. Measure the clearance between lobes of the inner rotor and the
outer rotor with a feeler gauge.
2. Measure the clearance between the outer rotor and the pump
body with a feeler gauge.
3. If the clearance exceeds the factory specifications, replace the oil
pump rotor assembly.
W1035296
Clearance between Rotor and Cover
1. Put a strip of plastigage onto the rotor face with grease.
2. Install the cover and tighten the screws.
3. Remove the cover carefully, and measure the width of the press
gauge with a sheet of gauge.
4. If the clearance exceeds the factory specifications, replace oil
pump rotor assembly.
W1035444
(7) Starter
Overrunning Clutch
1. Check the pinion and if worn or damage, replace the clutch
assembly.
2. Check that the pinion turns freely and smoothly in the
overrunning direction and does not slip in the cranking direction.
3. If the pinion slips or does not turn in both directions, replace the
overrunning clutch assembly.
NOTE
Do not wash off the grease in the overrunning clutch with
the chemicals or oils.
W1156799
Clearance between
inner rotor and outer
rotor
Factory spec.
0.030 to 0.14 mm
0.0012 to 0.0055 in.
Allowable limit
0.2 mm
0.008 in.
Clearance between
outer rotor and pump
body
Factory spec.
0.11 to 0.19 mm
0.0044 to 0.0074 in.
Allowable limit
0.25 mm
0.0098 in.
Clearance between
inner rotor and cover
Factory spec.
0.105 to 0.150 mm
0.00414 to 0.00590 in.
Allowable limit
0.20 mm
0.008 in.
S-98
DIESEL ENGINE
Commutator and Mica
1. Check the contact of the commutator for wear, and grind the
commutator with emery paper if it is slightly worn.
2. Measure the commutator O.D. with an outside micrometer at
several points.
3. If the minimum O.D. is less than the allowable limit, replace the
armature.
4. If the difference of the O.D.'s exceeds the allowable limit, correct
the commutator on a lathe to the factory specification.
5. Measure the mica undercut.
6. If the undercut is less than the allowable limit, correct it with a saw
blade and chamfer the segment edges.
W1112444
Commutator O.D.
Factory
spec.
D1503-M
D1703-M
V2003-M
V2203-M
D1803-M-DI
D1703-M-BG
V2003-M-BG
V2003-M-T-BG
V2203-M-BG
30.0 mm
1.18 in.
D1803-M
V2403-M
V2403-M-T
V2403-M-DI
V2403-M-DI-T
V2403-M-BG
35.0 mm
1.38 in.
Allowable
limit
D1503-M
D1703-M
V2003-M
V2203-M
D1803-M-DI
D1703-M-BG
V2003-M-BG
V2003-M-T-BG
V2203-M-BG
29.0 mm
1.14 in.
D1803-M
V2403-M
V2403-M-T
V2403-M-DI
V2403-M-DI-T
V2403-M-BG
34.0 mm
1.34 in.
Difference of O.D.s
Factory spec.
Less than 0.02 mm
0.0008 in.
Allowable limit
0.05 mm
0.002 in.
(1) Segment
(2) Depth of Mica
(3) Mica
(a) Correct
(b) Incorrect
S-99
DIESEL ENGINE
Commutator and Mica (Continued)
1. Check the contact of the commutator for wear, and grind the
commutator with emery paper if it is slightly worn.
2. Measure the commutator O.D. with an outside micrometer at
several points.
3. If the minimum O.D. is less than the allowable limit, replace the
armature.
4. If the difference of the O.D.'s exceeds the allowable limit, correct
the commutator on a lathe to the factory specification.
5. Measure the mica undercut.
6. If the undercut is less than the allowable limit, correct it with a saw
blade and chamfer the segment edges.
W1155802
Brush Wear
1. If the contact face of the brush is dirty or dusty, clean it with emery
paper.
2. Measure the brush length (A) with vernier caliper.
3. If the length is less than the allowable limit, replace the yoke
assembly and brush holder.
W1156360
Mica under cut
Factory
spec.
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
0.45 to 0.75 mm
0.018 to 0.029 in.
V2403-M-BG
0.55 to 0.85 mm
0.022 to 0.033 in.
Allowable limit
0.20 mm
0.0079 in.
(1) Segment
(2) Depth of Mica
(3) Mica
(a) Correct
(b) Incorrect
Brush length (A)
Factory spec.
15.0 mm
0.591 in.
Allowable
limit
D1503-M
D1703-M
V2003-M
V2203-M
D1803-M-DI
D1703-M-BG
V2003-M-BG
V2003-M-T-BG
V2203-M-BG
11.0 mm
0.433 in.
D1803-M
V2403-M
V2403-M-T
V2403-M-DI
V2403-M-DI-T
9.0 mm
0.35 in.
V2403-M-BG
12.0 mm
0.472 in.
S-100
DIESEL ENGINE
Brush Holder
1. Check the continuity across the brush holder and the holder
support with a circuit tester.
2. If it conducts, replace the brush holder.
W1156895
Armature Coil
1. Check the continuity across the commutator and armature coil
core with resistance range of circuit tester.
2. If it conducts, replace the armature.
3. Check the continuity across the segments of the commutator with
resistance range of circuit tester.
4. If it does not conduct, replace the armature.
W1156507
Field Coil
1. Check the continuity across the lead (1) and brush (2) with a
circuit tester.
2. If it does not conduct, replace the yoke assembly.
3. Check the continuity across the brush (2) and yoke (3) with a
circuit tester.
4. If it conducts, replace the yoke assembly.
W1156968
(1) Lead
(2) Bush
(3) Yoke
S-101
DIESEL ENGINE
(8) Alternator
Bearing
1. Check the bearing for smooth rotation.
2. If it does not rotate smoothly, replace it.
W1019790
Stator
1. Measure the resistance across each lead of the stator coil with
2. If the measurement is not within factory specification, replace it.
3. Check the continuity across each stator coil lead and core with
4. If infinity is not indicated, replace it.
W1019964
Rotor
1. Measure the resistance across the slip rings.
2. If the resistance is not the factory specification, replace it.
3. Check the continuity across the slip ring and core with resistance
range of circuit tester.
4. If infinity is not indicated, replace it.
W1020094
Slip Ring
1. Check the slip ring for score.
2. If scored, correct with an emery paper or on a lathe.
3. Measure the O.D. of slip ring with vernier calipers.
4. If the measurement is less than the allowable limit, replace it.
W1020208
Brush Wear
1. Measure the brush length with vernier calipers.
2. If the measurement is less than allowable limit, replace it.
3. Make sure that the brush moves smoothly.
4. If the brush is defective, replace it.
W1020329
Resistance Factory spec. Less than 1.0
Resistance Factory spec. 2.9
Slip ring O.D.
Factory spec.
14.4 mm
0.567 in.
Allowable limit
14.0 mm
0.551 in.
Brush length
Factory spec.
10.5 mm
0.413 in.
Allowable limit
8.4 mm
0.33 in.
S-102
DIESEL ENGINE
Rectifier
1. Check the continuity across each diode of rectifier with resistance
range of circuit tester.
2. The rectifier is normal if the diode in the rectifier conducts in one
direction and does not conduct in the reverse direction.
W1020452
IC Regulator
1. Check the continuity across the B terminal (2) and the F terminal
(1) of IC regulator with resistance range of circuit tester.
2. The IC regulator is normal if the conducts in one direction and
does not conduct in the reverse direction.
W1020645
(1) F Terminal (2) B Terminal
EDITOR:
KUBOTA FARM & INDUSTRIAL MACHINERY SERVICE, LTD.
64, ISHIZU-KITAMACHI, SAKAI-KU, SAKAI-CITY, OSAKA, 590-0823, JAPAN
PHONE : (81)72-241-1129
FAX : (81)72-245-2484
E-mail : [email protected]
KUBOTA Corporation
Printed in Japan 2007. 10, S, EI, EI, e Code No.9Y111-00142
2007. 03, S, EI, EI, e
Cummins Power Generation
1400 73rd Ave. NE
Minneapolis, MN 55432 USA
Phone 1 763 574 5000
Toll-free 1 800 888 6626
Fax 1 763 574 5298
Email [email protected]
www.cumminspower.com
Cummins
R
, the C logo, and Our energy working for you.
are trademarks of Cummins Inc.
E2008 Cummins Power Generation, Inc. All rights reserved.

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Engine Workshop Manual

Low Sulfur Fuel

(1) Drain Plug (2) Dipstick

(1) Drain Plug (2) Dipstick

Fuel hose clogged Clean or replace G-12

Cylinder Head Surface Flatness 0.05 mm / 500 mm

KiSC issued 10, 2007 A

Valve Seat Width (Intake)

Valve Timing (Intake Valve)

Valve Timing (Intake Valve)

KiSC issued 10, 2007 A

Valve Timing (Intake Valve)

Valve Timing (Exhaust Valve)

Valve Timing (Exhaust Valve)

Valve Timing (Exhaust Valve)

Valve Timing (Exhaust Valve)

Valve Timing (Exhaust Valve)

Valve Spring Free Length

Push Rod Alignment 0.25 mm

KiSC issued 10, 2007 A

Balancer Shaft Journal 2 to Balancer Shaft

Balancer Shaft Journal 3 to Balancer Shaft

Piston Pin Bore I.D. 25.000 to 25.013 mm

Crankshaft Alignment 0.02 mm

KiSC issued 10, 2007 A

Crankpin to Crankpin Bearing

Crankshaft Side Clearance 0.15 to 0.31 mm

Inner Rotor to Outer Rotor Clearance 0.030 to 0.14 mm

Radiator Water Tightness No leak at

Radiator Cap Pressure Falling

KiSC issued 10, 2007 A

Injection Nozzle Valve Seat

Injection Nozzle Valve Seat

KiSC issued 10, 2007 A

(1) Cylinder Head Surface (A) Recessing

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