Kubota D1503-M Workshop Manual Download Page 158

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S-80

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

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.

KiSC issued 07, 2008 A

Summary of Contents for D1503-M

Page 1: ...WORKSHOP MANUAL DIESEL ENGINE 03 M E3B SERIES 03 M DI E3B SERIES 03 M E3BG SERIES KiSC issued 07 2008 A ...

Page 2: ...to Diesel Engine Mechanism Workshop Manual Code No 9Y021 01875 for the one which has not been described to this workshop manual Q Servicing Information on the troubleshooting servicing specification lists tightening torque checking and adjusting disassembling and assembling and servicing which cover procedures precautions factory specifications and allowable limits All information illustrations an...

Page 3: ...ual 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 w...

Page 4: ...ng 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 applyin...

Page 5: ... 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 y...

Page 6: ... WSM SAFETY INSTRUCTIONS PREPARE FOR EMERGENCIES Keep a first aid kit and fire extinguisher handy at all times Keep emergency numbers for doctors ambulance service hospital and fire department near your telephone KiSC issued 07 2008 A ...

Page 7: ...e 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 cm2 1991 psi Compression Ratio 22 8 1 22 0 1 Lubricating System Forced Lubrication by Trochoid Pump Oil ...

Page 8: ... clockwise viewd from flywheel side Injection Nozzle OPD Mini Nozzle DENSO Injection Timing 0 2836 rad 16 25 before T D C Firing Order 1 2 3 Injection Pressure 13 73 MPa 140 0 kgf cm2 1991 psi Compression Ratio 24 3 1 Lubricating System Forced Lubrication by Trochoid Pump Oil Pressure Indicating Electrical type switch Lubricating Filter Full flow paper filter cartridge type Cooling System Pressuri...

Page 9: ... 4M Type Mini Pump DENSO Governor Mechanical all speed governor Direction of Rotation Counter clockwise viewd from flywheel side Injection Nozzle OPD Mini Nozzle DENSO Injection Timing 0 2836 rad 16 25 before T D C Firing Order 1 3 4 2 Injection Pressure 13 73 MPa 140 0 kgf cm2 1991 psi Compression Ratio 22 8 1 22 0 1 Lubricating System Forced Lubrication by Trochoid Pump Oil Pressure Indicating E...

Page 10: ...rnor Mechanical all speed governor Direction of Rotation Counter clockwise viewd from flywheel side Injection Nozzle OPD Mini Nozzle DENSO Injection Timing 0 2836 rad 16 25 before T D C 0 14 rad 8 3 before T D C Firing Order 1 3 4 2 Injection Pressure 13 73 MPa 140 0 kgf cm2 1991 psi Compression Ratio 23 2 1 23 0 1 Lubricating System Forced Lubrication by Trochoid Pump Oil Pressure Indicating Elec...

Page 11: ...flywheel side Injection Nozzle Bosch P Type Hole Nozzle Injection Timing 0 087 rad 5 0 before T D C Firing Order 1 2 3 Injection Pressure 1st stage 18 63 MPa 190 0 kgf cm2 2702 psi 2nd stage 22 56 MPa 230 0 kgf cm2 3271 psi Compression Ratio 20 5 1 Lubricating System Forced Lubrication by Trochoid Pump Oil Pressure Indicating Electrical type switch Lubricating Filter Full flow paper filter cartrid...

Page 12: ...peed governor Direction of Rotation Counter clockwise viewd from flywheel side Injection Nozzle Bosch P Type Hole Nozzle Injection Timing 0 087 rad 5 0 before T D C 0 096 rad 5 5 before T D C Firing Order 1 3 4 2 Injection Pressure 1st stage 18 63 MPa 190 0 kgf cm2 2702 psi 2nd stage 22 56 MPa 230 0 kgf cm2 3271 psi Compression Ratio 20 5 1 20 2 1 Lubricating System Forced Lubrication by Trochoid ...

Page 13: ...chanical all speed governor Electronic Governor Direction of Rotation Counter clockwise viewd from flywheel side Injection Nozzle OPD Mini Nozzle DENSO Injection Timing 0 2487 rad 14 25 before T D C Firing Order 1 2 3 Injection Pressure 13 73 MPa 140 0 kgf cm2 1991 psi Compression Ratio 22 0 1 Lubricating System Forced Lubrication by Trochoid Pump Oil Pressure Indicating Electrical type switch Lub...

Page 14: ...hanical all speed governor Electronic Governor Direction of Rotation Counter clockwise viewd from flywheel side Injection Nozzle OPD Mini Nozzle DENSO Injection Timing 0 2487 rad 14 25 before T D C Firing Order 1 3 4 2 Injection Pressure 13 73 MPa 140 0 kgf cm2 1991 psi Compression Ratio 22 8 1 Lubricating System Forced Lubrication by Trochoid Pump Oil Pressure Indicating Electrical type switch Lu...

Page 15: ...chanical all speed governor Electronic Governor Direction of Rotation Counter clockwise viewd from flywheel side Injection Nozzle OPD Mini Nozzle DENSO Injection Timing 0 2662 rad 15 25 before T D C Firing Order 1 3 4 2 Injection Pressure 13 73 MPa 140 0 kgf cm2 1991 psi Compression Ratio 21 7 1 Lubricating System Forced Lubrication by Trochoid Pump Oil Pressure Indicating Electrical type switch L...

Page 16: ...hanical all speed governor Electronic Governor Direction of Rotation Counter clockwise viewd from flywheel side Injection Nozzle OPD Mini Nozzle DENSO Injection Timing 0 2487 rad 14 25 before T D C Firing Order 1 3 4 2 Injection Pressure 13 73 MPa 140 0 kgf cm2 1991 psi Compression Ratio 22 0 1 Lubricating System Forced Lubrication by Trochoid Pump Oil Pressure Indicating Electrical type switch Lu...

Page 17: ...chanical all speed governor Electronic Governor Direction of Rotation Counter clockwise viewd from flywheel side Injection Nozzle OPD Mini Nozzle DENSO Injection Timing 0 2487 rad 14 25 before T D C Firing Order 1 3 4 2 Injection Pressure 13 73 MPa 140 0 kgf cm2 1991 psi Compression Ratio 23 2 1 Lubricating System Forced Lubrication by Trochoid Pump Oil Pressure Indicating Electrical type switch L...

Page 18: ...MENSIONS 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 KiSC issued 07 2008 A ...

Page 19: ...2203 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 KiSC issued 07 2008 A ...

Page 20: ...18 03 M E3B 03 M DI E3B 03 M E3BG WSM DIMENSIONS 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 KiSC issued 07 2008 A ...

Page 21: ...E3B 03 M DI E3B 03 M E3BG WSM DIMENSIONS 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 KiSC issued 07 2008 A ...

Page 22: ...20 03 M E3B 03 M DI E3B 03 M E3BG WSM DIMENSIONS 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 KiSC issued 07 2008 A ...

Page 23: ...3 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 KiSC issued 07 2008 A ...

Page 24: ...Glow Water Temperature Oil Pressure Alternator Glow Plug Engine Speed Sensor Water Temp Sensor Oil Switch Water Temp Switch Slowdown 1200 min 1 rpm Speed Switch 1800 min 1 rpm 1500 min 1 rpm Manual Stop Switch Run Stop Solenoid ECU Electronic Control Unit Start Relay 2 4 1 3 1 25 1 25 0 85 3 0 3 0 5A 5A 5A 10A 10A 3 0 0 85 0 85 3 0 B IG L 1 25 26 18 10 1 2 11 19 3 4 5 12 13 14 20 21 22 6 7 8 9 15 ...

Page 25: ...VERY 50 HOURS G 12 4 CHECK POINTS OF EVERY 100 HOURS G 13 5 CHECK POINTS OF EVERY 150 HOURS G 15 6 CHECK POINTS OF EVERY 200 HOURS G 17 7 CHECK POINTS OF EVERY 400 HOURS G 21 8 CHECK POINTS OF EVERY 500 HOURS G 23 9 CHECK POINTS OF EVERY 1 OR 2 MONTHS G 25 10 CHECK POINTS OF EVERY YEAR G 26 11 CHECK POINTS OF EVERY 800 HOURS G 27 12 CHECK POINTS OF EVERY 1500 HOURS G 28 13 CHECK POINTS OF EVERY 30...

Page 26: ...d Q Engine Serial Number The engine serial number is an identified number for the engine It is marked after the engine model number It indicates month and year of manufacture as follows Year of manufacture 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 20...

Page 27: ... 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 ...

Page 28: ...vel 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 no...

Page 29: ...rom 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 directi...

Page 30: ...0 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 filte...

Page 31: ...ding 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 i...

Page 32: ...00 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 industr...

Page 33: ...ker or viscosity from the previous drain old oil Never mix two different types of oil NOTE Q 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...

Page 34: ...e 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 Q During filling the coolant air must be vented from the engine coolant pass...

Page 35: ...ll 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 20 or SAE 10W 30 SAE 10W 40 Below 0 C 32 F SAE 10W or SAE 10W 30 SAE 10W 40 Models Oi...

Page 36: ...nd 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 Q To prevent serious damage to the engine replacement element must be highly eff...

Page 37: ...bove 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 mechanica...

Page 38: ...le the fuel filter keeping out dust and dirt 5 Bleed the fuel system IMPORTANT Q 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...

Page 39: ...d 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 KiSC issued 07 2008 A ...

Page 40: ...tick 2 IMPORTANT Q When using an oil of different maker or viscosity from the previous one remove all of the old oil Never mix two different types of oil Engine oil should have properties of API classification CF See page G 7 Use the proper SAE Engine Oil according to ambient temperature 90 mm 3 5 in oil pan depth is optional W1022029 Above 25 C 77 F SAE 30 or SAE 10W 30 SAE 10W 40 0 C to 25 C 32 ...

Page 41: ...ew 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 Q To prevent...

Page 42: ...MPORTANT Q When using an oil of different maker or viscosity from the previous one remove all of the old oil Never mix two different types of oil Engine oil should have properties of API classification CF See page G 7 Use the proper SAE Engine Oil according to ambient temperature 90 mm 3 5 in oil pan depth is optional W1022765 Above 25 C 77 F SAE 30 or SAE 10W 30 SAE 10W 40 0 C to 25 C 32 F to 77 ...

Page 43: ...Q When using an oil of different maker or viscosity from the previous one remove all of the old oil Never mix two different types of oil Engine oil should have properties of API classification CF See page G 7 Use the proper SAE Engine Oil according to ambient temperature 90 mm 3 5 in oil pan depth is optional W1034539 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 20 ...

Page 44: ... DI V2403 M DI T CAUTION Be sure to stop the engine before replacing filter cartridge 1 Remove the oil filter cartridge 1 with the filter wrench 2 Apply a slight coat of oil onto the new cartridge gasket 3 To install the new cartridge screw it in by hand Over tightening may cause deformation of rubber gasket 4 After the new cartridge has been replaced the engine oil normally decrease a little Thus...

Page 45: ...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 Q To prevent serious damage to the engine keep out any dust inside the intake air line W1029631 1 Intake Air Hose 2 Clamp KiSC issued 07 2008 A ...

Page 46: ...stick 2 IMPORTANT Q When using an oil of different maker or viscosity from the previous one remove all of the old oil Never mix two different types of oil Engine oil should have properties of API classification CF See page G 7 Use the proper SAE Engine Oil according to ambient temperature 90 mm 3 5 in oil pan depth is optional W1035850 Above 25 C 77 F SAE 30 or SAE 10W 30 SAE 10W 40 0 C to 25 C 32...

Page 47: ...t must be highly efficient Use only a KUBOTA genuine filter or its equivalent 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 T...

Page 48: ...e 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 Q Do not s...

Page 49: ...n the cooling system NOTE Q 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 ...

Page 50: ...lyte should be slightly lower than the specified level to prevent overflow 2 Connect the battery to the charging unit following the manufacture s instructions 3 As the electrolyte generates gas while 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 chargi...

Page 51: ...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 electr...

Page 52: ...kwise 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 pe...

Page 53: ...ing Condition D1503 M D1703 M D1803 M V2003 M V2203 M V2403 M V2403 M T D1703 M BG V2003 M BG V2003 M T BG V2203 M BG V2403 M BG 1 Set the injection nozzle to a nozzle tester and check the nozzle spraying condition 2 If the spraying condition is defective replace the nozzle piece W10411400 D1803 M DI V2403 M DI V2403 M DI T 1 Set the injection nozzle to a nozzle tester and check the nozzle sprayin...

Page 54: ...rence Pressure variation with 0 025 mm 0 00098 in difference of adjusting washer thickness Approx 590 kPa 6 0 kgf cm2 85 psi W10182100 D1803 M DI V2403 M DI V2403 M DI T 1 Set the injection nozzle to a nozzle tester 2 Slowly move the tester handle to measure the pressure at which fuel begins jetting out from the nozzle 3 If the measurement is not within the factory specifications replace the injec...

Page 55: ...3 M V2403 M T D1703 M BG V2003 M BG V2003 M T BG V2203 M BG V2403 M BG 1 Secure the nozzle retaining nut 7 with a vise 2 Remove the nozzle holder 1 and take out parts inside When reassembling Assemble the nozzle in clean fuel oil Install the push rod 4 noting its direction After assembling the nozzle be sure to adjust the fuel injection pressure W1018491 Valve seat tightness Factory spec No fuel l...

Page 56: ...eplace 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 Housin...

Page 57: ...increase the pressure 6 Stop the starter when the fuel jets from the injection nozzle After that turn the flywheel by the hand and raise the pressure to approx 13 73 MPa 140 0 kgf cm2 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 kg...

Page 58: ... when the fuel jets from the injection nozzle After that turn the flywheel by the hand and raise the pressure to approx 18 63 MPa 190 0 kgf cm2 2702 psi 7 Now turn the flywheel back about half a turn to keep the plunger free Maintain the flywheel at this position and clock the time taken for the pressure to drop from 18 63 to 17 65 MPa from 190 0 to 180 0 kgf cm2 from 2702 to 2560 psi 8 Measure th...

Page 59: ...o 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 Ban...

Page 60: ...k 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 Q Always...

Page 61: ...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 Q Do not start engin...

Page 62: ...0 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 Q 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 mix...

Page 63: ... 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 A...

Page 64: ... 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...

Page 65: ...9843 to 0 9846 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 E 41 90 to 41 95 mm dia 1 650 to 1 651 in dia F 37 950 to 37 970 mm dia 1 4941 to 1 4948 in dia 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 ...

Page 66: ... 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 E 60 10 to 60 30 mm dia 2 367 to 2 374 in dia F 26 30 to 26 40 mm 1 036 to 1 039 in G 25 85 to 25 90 mm 1 018 to 1 019 in H 15 0 mm ...

Page 67: ...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 ...

Page 68: ...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 ...

Page 69: ... 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...

Page 70: ...radius D M20 x Pitch 2 0 E 10 mm 0 39 in F 20 mm 0 79 in G 5 mm 0 2 in H 95 mm 3 7 in I 125 mm 4 92 in J 0 87 rad 50 K 5 mm 0 2 in L 60 mm radius 2 4 in radius M M20 x Pitch 2 0 N 30 mm 1 2 in O 10 mm 0 39 in P 10 mm 0 39 in Q 10 mm 0 39 in R 35 5 mm 1 40 in S 4 5 mm radius 0 18 in radius T 40 mm 1 6 in U 40 mm 1 6 in V 12 mm 0 47 in W 120 mm 4 72 in C2 Chamfer 2 0 mm 0 079 in KiSC issued 07 2008 ...

Page 71: ...TON 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 KiSC issued 07 2008 A ...

Page 72: ...ting 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 KiSC issued 07 2008 A ...

Page 73: ...gine 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 V20...

Page 74: ...OATING 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 KiSC issued 07 2008 A ...

Page 75: ...e 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 O...

Page 76: ... 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...

Page 77: ...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 KiSC issued...

Page 78: ... 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 Cyli...

Page 79: ...on 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 glo...

Page 80: ...rger 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 Incorrect injection timing Adjust S 27 28 Oil Leak into Exhaust P...

Page 81: ...ocharger compressor wheel turning heavily Replace the turbocharger assembly S 47 Excessive Lubricant Oil Consumption Piston ring s gap facing the same direction Shift ring gap direction S 64 65 Oil ring worn or stuck Replace S 66 67 88 89 Piston ring groove worn Replace piston S 66 67 89 Valve stem and valve guide worn Replace S 53 76 Crankshaft bearing and crank pin bearing worn Replace S 64 65 7...

Page 82: ...o 15 G 10 Relief valve defective Replace Engine overheated Engine oil insufficient Replenish G 10 Fan belt broken or elongated Replace or adjust G 14 24 Coolant insufficient Replenish G 9 Radiator net and radiator fin clogged with dust Clean Inside of radiator corroded Clean or replace G 23 Coolant flow route corroded Clean or replace G 23 24 Radiator cap defective Replace S 25 Overload running Re...

Page 83: ...ause 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 Cause Corrections Refer to Checking Trouble in the electronic governor composition parts Check blinking pattern of the glow...

Page 84: ...perature 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 Water temperature sensor 2 Long and 5 Short Short circuit of water temperature sensor Water temperature sensor 2...

Page 85: ...ng Cylinders 2 95 to 3 23 MPa 290 min 1 rpm 30 0 to 33 0 kgf cm2 290 min 1 rpm 427 to 469 psi 290 min 1 rpm 2 35 MPa 290 min 1 rpm 24 0 kgf cm2 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 ...

Page 86: ... 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 Exhaus...

Page 87: ...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 Valve Timing Exhaust Valve 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 Valve Timing Exhaust Valve D1803 M DI V2403 M DI Open Close 0 72 rad 41 before B D C 0 2 rad 9 after T D C Valve Timing Exhaust Valve V2003 M T BG Open Close 0 96 rad...

Page 88: ...ank 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 i...

Page 89: ...ust 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 ...

Page 90: ... 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 ...

Page 91: ... 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 Ring Gap 0 25 to 0 45 mm 0 0099 to 0 017 in 1 25 mm 0 0492 in Oil Ring D1803 M DI V2403 M DI Ring Gap 0 20 to 0 40 mm 0 0079 to 0 015 in 1 25 mm 0 0492 in Connecting Rod Alignment 0 05 mm 0 002 in Piston Pin to Small End Bushing Piston...

Page 92: ...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 Bo...

Page 93: ... 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 ...

Page 94: ...2003 M BG V2203 M BG V2403 M BG Injection Timing 0 236 to 0 261 rad 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 cm2 1991 psi Pump Element D1803 M DI V2403 M DI V2403 M DI T Fuel Tightness 18 63 MPa 190 0 kgf cm2 2702 psi Delivery Valve D1503 M D1703 M D18...

Page 95: ... V2403 M DI V2403 M DI T Injection Pressure 1st stage 18 64 to 20 10 MPa 190 0 to 205 0 kgf cm2 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 cm2 1849 psi the valve seat must be fuel tightness Injection Nozzle Valve Seat D18...

Page 96: ...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 ...

Page 97: ...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 N m kgf m lbf ft N m kgf m lbf ft 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 2...

Page 98: ...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 ...

Page 99: ...gine 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 compres...

Page 100: ... 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 Q 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 pre...

Page 101: ...rclockwise 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 a...

Page 102: ...ghten 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 Engi...

Page 103: ...kgf cm2 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 c...

Page 104: ... not within the factory specifications replace the thermostat W1035849 Thermostat s 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 D...

Page 105: ...he 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 thi...

Page 106: ...ction Timing NOTE Q 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 ...

Page 107: ...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 NOTE Q Never try to disassemble the injection pump assembly For repairs you are strongly requested to contact a Kubota ...

Page 108: ...re 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 NOTE Q Never try to disassemble the injection pump assembly For repairs you are strongly requested to contact a Kubota authorized pump service shop W1104546 Fu...

Page 109: ...alf 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 140 0 to 130 0 kgf cm2 1991 to 1849 psi 8 Measure the time needed to decrease the pressure from 13 73 to 12 75 MPa 140 0 to 130 0 kgf cm2 1991 to 1849 psi 9 If the measurement is less than allowable limit replace the pump with new one or repair with a...

Page 110: ...tain the flywheel at this position and clock the time taken for the pressure to drop from 18 63 to 17 65 MPa 190 0 to 180 0 kgf cm2 2702 to 2560 psi 8 Measure the time needed to decrease the pressure from 18 63 to 17 65 MPa 190 0 to 180 0 kgf cm2 2702 to 2560 psi 9 If the measurement is less than allowable limit replace the pump with new one or repair with a Kubota authorized pump service shop NOT...

Page 111: ...03 M D1703 M D1803 M V2003 M V2203 M V2403 M V2403 M T D1703 M BG V2003 M BG V2003 M T BG V2203 M BG V2403 M BG 1 Set the injection nozzle to a nozzle tester and check the nozzle spraying condition 2 If the spraying condition is defective replace the nozzle piece W10181310 D1803 M DI V2403 M DI V2403 M DI T 1 Set the injection nozzle to a nozzle tester and check the nozzle spraying condition 2 If ...

Page 112: ...ference Pressure variation with 0 025 mm 0 00098 in difference of adjusting washer thickness Approx 590 kPa 6 0 kgf cm2 85 psi W10476390 D1803 M DI V2403 M DI V2403 M DI T 1 Set the injection nozzle to a nozzle tester 2 Slowly move the tester handle to measure the pressure at which fuel begins jetting out from the nozzle 3 If the measurement is not within the factory specifications replace the inj...

Page 113: ...2403 M V2403 M T D1703 M BG V2003 M BG V2003 M T BG V2203 M BG V2403 M BG 1 Secure the nozzle retaining nut 7 with a vise 2 Remove the nozzle holder 1 and take out parts inside When reassembling Assemble the nozzle in clean fuel oil Install the push rod 4 noting its direction After assembling the nozzle be sure to adjust the fuel injection pressure W1018491 Valve seat tightness Factory spec No fue...

Page 114: ...times Hydrogen gas mixed with oxygen becomes very explosive IMPORTANT Q 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 c...

Page 115: ...d 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 referenc...

Page 116: ...y 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 starter s body and the battery negative terminal 3 7 If the pinion gear does not pop...

Page 117: ...in 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...

Page 118: ...d the engine stop solenoid is faulty IMPORTANT Q 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 Chec...

Page 119: ...e water temperature sensor connector 2 2P 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 water temperature sensor 1 is failure then please replace it 6 When the measurements are out of...

Page 120: ...e it 3 Measure the resistance between the terminal of the connector harness side and chassis 4 When the measurements are the below table value The ECU is normal The oil pressure switch 1 is failure then please replace it 5 When the measurements are out of the below table value The ECU is failure then please replace it W1059711 Resistance Terminal 1 Chassis Infinity 1 Oil Pressure Switch KiSC issue...

Page 121: ...resistance between the connector of solenoid 2 2 When the measurements are the below table value The solenoid 1 is normal electrically Check the solenoid s movement 3 When the measurements are out of the below table value 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 smooth...

Page 122: ...harness side and chassis 4 When the measurements are the below table value The ECU is normal The alternator is failure then please replace it 5 When the measurements are out of the below table value The ECU is failure then please replace it W1063000 Speed Switch 1 Check the state of the harness and if it is abnormal please replace it 2 When the speed switch is turned ON and OFF measure the resista...

Page 123: ...e between the slow down switch terminal side 1 of it each time 3 When the measurements are the below table value The slow down switch is normal The ECU is failure then please replace it 4 When the measurements are out of the below table value The slow down switch is failure then please replace it W1067200 Battery 1 Measure the voltage of the battery 1 with the engine stopped 2 When the measurement...

Page 124: ...TION 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 st...

Page 125: ...e 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 carefu...

Page 126: ...ssembling Blow out dust inside the pipes W1060970 Tightening torque Cylinder head cover screw 9 81 to 11 2 N m 1 00 to 1 15 kgf m 7 24 to 8 31 lbf ft 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...

Page 127: ...sembling 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 N m 5 0 to 7 0 kgf m 37 to 50 lbf ft Overflow pipe assembly retaining nut 20 to 24 N m 2 0 to 2 5 kgf m 15 to 18 lbf ft Glow plug 20 to 24 N m 2 0 to 2 5 kgf m 15 to 18 lbf ft 1 ...

Page 128: ...e 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 thei...

Page 129: ... torque Cylinder head screw 93 2 to 98 0 N m 9 50 to 10 0 kgf m 68 8 to 72 3 lbf ft 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 0362...

Page 130: ...r rotation If defect is found replace tappets Before installing the tappets apply engine oil thinly around them IMPORTANT Q 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 ...

Page 131: ...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...

Page 132: ...g 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 ...

Page 133: ...ide 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 solenoid into the hole at the center of the solenoid guide 5 I...

Page 134: ... 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 Spec...

Page 135: ...ing 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 sp...

Page 136: ... 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 N m 14 0 to 16 0 kgf m 102 to 115 lbf ft 1 Nut 2 Fan Drive Pulley 3 46 mm Deep Socket Wrench 4 Gear Puller KiSC issued 07 2008 A ...

Page 137: ...move 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 N m 2 4 to 2 8 kgf m 18 to 20 lbf ft Idle gear 2 stopper set screw 49 to 55 N m 5 0 to 5 7 kgf m 37 to 41 lbf ft 1 Gear Case Cover 2 Hydraulic Pump Base Assembly 3 Idle Gear 2 Stopper 4 Idle Ge...

Page 138: ...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 ...

Page 139: ...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 t...

Page 140: ... 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...

Page 141: ...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 ...

Page 142: ...iston 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 pin s 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 i...

Page 143: ...ings with their gaps at 2 09 rad 120 from the piston pin s 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 ...

Page 144: ... 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 NO...

Page 145: ...site 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 Q Mark the same n...

Page 146: ...e of bearing case cover 6 to remove it IMPORTANT Q 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 ...

Page 147: ...o 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 1 Remove the main bearing case screw 2 1 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 Wh...

Page 148: ...g 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 th...

Page 149: ...sing 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 Q 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 H...

Page 150: ...r 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 Rea...

Page 151: ...eck the oil clearances between the crankpin and bearing and between the piston pin and bushing NOTE Q 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 ...

Page 152: ... 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 he...

Page 153: ...ead 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 ...

Page 154: ...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 Q 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...

Page 155: ... 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 KiSC issued 07 2008 A ...

Page 156: ...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 D1703...

Page 157: ... 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...

Page 158: ...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 ...

Page 159: ...o 0 1154 mm 0 001634 to 0 004543 in Allowable limit 0 15 mm 0 0059 in Backlash between idle 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 Backlash between idle gear and balancer gear Inta...

Page 160: ... 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 4 If the measurement exceeds the allowable limit replace the 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 C...

Page 161: ...tory 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 ...

Page 162: ...ec 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 V220...

Page 163: ...he balancer shaft 2 Measure the side clearance by moving the balancer shaft to the front and rear 3 If the measurement exceeds the allowable limit replace the 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 sh...

Page 164: ...rnal 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 balancer shaft journal 2 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 2 O D Factory spec 41 934 to 41 950 mm 1 6509 to 1 6515 in Balancer shaft bearing 2 I D Factory spec ...

Page 165: ...od oil hole matches the bushing hole W1032140 Connecting Rod Alignment NOTE Q 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...

Page 166: ...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 D1...

Page 167: ...cond 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...

Page 168: ...s 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 4 If the measurement exceeds the allowable limit replace the 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...

Page 169: ...the crankshaft while the connecting rod screws are tightened Reference Undersize dimensions of crankpin W1033106 Oil clearance between 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...

Page 170: ...replacing tool press in a new bearing 1 2 so that its seam 1 directs toward the exhaust manifold side See figure W1033946 Oil clearance between 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 ...

Page 171: ...d Reference Undersize dimensions of crankshaft journal W1083821 Oil clearance between 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 0...

Page 172: ...mperature 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 Q 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 S...

Page 173: ...cratches 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...

Page 174: ...linder 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 ...

Page 175: ...lace 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 Q Do not wash off the grease in the ov...

Page 176: ... 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 ...

Page 177: ...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...

Page 178: ...f 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...

Page 179: ...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 leng...

Page 180: ...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 KiSC issued 07 2008 A ...

Page 181: ...ERY 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 ksos pub kubota co jp KUBOTA Corporation Printed in Japan 2008 07 S EI EI e Code No 9Y111 00142 2007 03 S EI EI e ...

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