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S-43

03-M-DI Series, WSM

DIESEL ENGINE

[2] DISASSEMBLING AND ASSEMBLING

(1) Draining Coolant and Oil

NOTE

• Some types of gearcases are provided with an oil filter port. When the cylinder head has been

reassembled or when the valve clearance has been readjusted, apply an enough amount of oil to the intake
and exhaust valves, push rod and rocker arm just before fitting the head cover in position.

Draining Coolant and Engine Oil

CAUTION

• Never remove radiator cap until coolant temperature is

below its boiling point. Then loosen cap slightly to the stop
to relieve any excess pressure before removing cap
completely.

1. Prepare a bucket. Open the coolant drain cock (1) to drain

coolant.

2. Prepare an oil pan. Remove the oil drain plug (2) to drain engine

oil in the pan.
See page S-24, 26.

W1060189

(2) External Components

Air Cleaner, Muffler and Others

1. Remove the air cleaner and muffler.
2. Remove the fan (1), fan belt (2), alternator (3) and starter (4).

(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. See page S-28.

• Do not confuse the direction of the fan.

W1060302

(1) Coolant Drain Cock

(2) Oil Drain Plug

(1) Fan
(2) Fan Belt

(3) Alternator
(4) Starter

KiSC issued 10, 2009 A

Содержание D1503-M-DI

Страница 1: ...WORKSHOP MANUAL DIESEL ENGINES 03 M DI SERIES KiSC issued 10 2009 A...

Страница 2: ...ng General includes general precautions check and maintenance and special tools There are troubleshooting checking and adjusting disassembling and assembling and servicing which cover procedures preca...

Страница 3: ...n 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...

Страница 4: ...ing 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 complete...

Страница 5: ...lations when disposing of oil fuel coolant electrolyte and other harmful waste PREVENT ACID BURNS Sulfuric acid in battery electrolyte is poisonous It is strong enough to burn skin clothing and cause...

Страница 6: ...50 Combustion Chamber Troiddal Type Direct Injection Fuel Injection Pump Bosch K Type Mini Pump Governor Centrifugal Ball Type All Speed Mechanical Governor Direction of Rotation Counter Clockwise vie...

Страница 7: ...p Bosch K Type Mini Pump Governor Centrifugal Ball Type All Speed Mechanical Governor Direction of Rotation Counter Clockwise viewed from flywheel side Injection Nozzle Bosch P Type Hole Nozzle Inject...

Страница 8: ...m 22 52 in 575 9 mm 22 67 in B 643 5 mm 25 33 in 644 0 mm 25 35 in 643 3 mm 25 33 in 685 0 mm 26 97 in C 414 2 mm 16 31 in 414 2 mm 16 31 in 414 0 mm 16 30 in 419 0 mm 16 50 in D 229 3 mm 9 03 in 229...

Страница 9: ...355 V2203 M DI V2403 M DI A 667 1 mm 26 26 in 670 9 mm 26 41 in B 635 0 mm 25 00 in 684 5 mm 26 95 in C 414 0 mm 16 30 in 419 0 mm 16 50 in D 221 0 mm 8 70 in 265 5 mm 10 45 in E 507 1 mm 19 96 in 499...

Страница 10: ...ALANCER BALANCER MODEL ONLY M 2 4 HALF FLOATING HEAD COVER M 2 2 COOLING SYSTEM M 3 1 BOTTOM BYPASS SYSTEM M 3 3 FUEL SYSTEM M 4 1 GOVERNOR M 4 4 ELECTRICAL SYSTEM M 6 1 STARTER AUTO REDUCTION UNIT M...

Страница 11: ...This design allows smoother cooling water flow through the cylinder block which cools down a wider range between the cylinders more effectively W1013048 2 PISTON Piston s skirt is coated with molybden...

Страница 12: ...ation The four cylinders engine V2203 and V2403 can be fitted with balance weight on crankcase to absorb the second inertia mentioned above and reduce vibration This engine is internally provide with...

Страница 13: ...w the thermostat 1 is held closed and the coolant is allowed to flow through the bypass pipe and to circulate in the engine When the temperature exceeds the thermostat valve opening level the thermost...

Страница 14: ...battery current into the engine stop solenoid 16 the plunger 17 is actuated to arrow direction Since the steel ball 1 have no centrifugal force the control rack 14 is pushed to the right by the start...

Страница 15: ...eed is dropped and fork lever 2 9 is pulled to the right by the governor springs 1 7 and 2 8 increasing fuel injection Though fork lever 2 9 becomes ineffective in increasing fuel injection when it is...

Страница 16: ...tarter 5 is automatically cut off even if the key switch 2 is at the START position c Safety mechanism in case of engine stall If the engine stalls with the key switch 2 at AC or START position the ke...

Страница 17: ...Switch 2 Battery 3 Alternator 4 P terminal 5 Detection High rpm N2 6 Delay Curcuit 7 Detection Low rpm N1 8 Self Holding Circuit 9 Self Holding Circuit 10 External Relay 11 Starter A Key Switch AC Te...

Страница 18: ...tch AC Terminal Voltage B Key Switch 50 Terminal Voltage C Alternator Revolution min 1 rpm D Starter ST Terminal Voltage N1 Detection Low rpm N2 Detection High rpm A Key Switch AC Terminal Voltage B K...

Страница 19: ...ing Engine Start W1015212 A Key Switch AC Terminal Voltage B Key Switch 50 Terminal Voltage C Alternator Revolution min 1 rpm D Starter ST Terminal Voltage E Output for Confirming Engine Start Voltage...

Страница 20: ...9 8 Check Point of Every Year S 31 9 Check Point of Every 800 Hours S 31 10 Check Points of Every 1500 Hours S 32 11 Check Point of Every 3000 Hours S 33 12 Check Points of Every 2 Years S 33 8 SPECIA...

Страница 21: ...91 4 Engine Stop Solenoid S 91 5 Glow Lamp Relay S 92 6 Starter Auto Reduction Unit S 92 2 DISASSEMBLING AND ASSEMBLING S 93 1 Starter S 93 2 Alternator S 93 3 SERVICING S 96 1 Starter S 96 2 Alternat...

Страница 22: ...e g D1803 1A0001 1 indicates 2001 and A indicates January So 1A indicates that the engine was manufactured on January 2001 W1010477 Alphabet or Number Year Alphabet or Number Year 1 2001 F 2015 2 2002...

Страница 23: ...Cylinder Number The cylinder numbers of 03 M DI Series diesel engine are designated as shown in the figure The sequence of cylinder numbers is given as No 1 No 2 No 3 and No 4 starting from the gear c...

Страница 24: ...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 replac...

Страница 25: ...unting nut Bearing case cover screw Glow plug Nozzle holder clamp screw Oil Switch taper screw Injection pipe retaining nut Overflow pipe assembly retaining screw Camshaft set screw Hi idling body M6...

Страница 26: ...l system Clean Clean or change Use specified fuel or engine oil Use specified fuel Tighten retaining nut Adjust Replace Replace Replace Repair or replace Replace head gasket tighten cylinder head scre...

Страница 27: ...p malfunctioning Deficient nozzle injection Compression leak Gas leak from exhaust system Air leak from compressor discharge side Air cleaner dirty or clogged Compressor wheel turning heavily Adjust R...

Страница 28: ...tive Use specified type of oil Replace S 23 Engine Overheated Engine oil insufficient Fan belt broken or elongated Coolant insufficient Radiator net and radiator fin clogged with dust Inside of radiat...

Страница 29: ...or less Top Clearance 0 60 to 0 70 mm 0 0236 to 0 0276 in Valve Clearance When Cold 0 18 to 0 22 mm 0 0071 to 0 0087 in Valve Seat Width Intake Width Exhaust 2 12 mm 0 0835 in 2 12 mm 0 0835 in Valve...

Страница 30: ...kgf 35 0 mm 26 4 lbs 1 3780 in 41 2 mm 1 6220 in 100 0 N 35 0 mm 10 2 kgf 35 0 mm 22 5 lbs 1 3780 in 1 0 mm 0 039 in Rocker Arm Shaft to Rocker Arm Rocker Arm Shaft Rocker Arm Clearance O D I D 0 016...

Страница 31: ...r Bushing Idle Gear Shaft Idle Gear Bushing Clearance O D I D 0 025 to 0 066 mm 0 00098 to 0 00260 in 37 959 to 37 975 mm 1 49445 to 1 49508 in 38 000 to 38 025 mm 1 49606 to 1 49705 in 0 1 mm 0 0039...

Страница 32: ...476 in 25 05 mm 0 9862 in Top Ring to Ring Groove D1703 M DI D1803 M DI V2203 M DI V2403 M DI Clearance 0 050 to 0 090 mm 0 0020 to 0 0035 in 0 2 mm 0 0079 in Second Ring to Ring Groove D1503 M DI D15...

Страница 33: ...mm 0 00079 in Crankshaft Journal to Crankshaft Bearing 1 Serial No below 3R9999 Crankshaft Journal Crankshaft Bearing 1 D1503 M DI D1503 M DI T D1703 M DI V2203 M DI D1803 M DI V2403 M DI D1503 M DI...

Страница 34: ...ring 2 Serial No above 3S0001 Crankshaft Journal Crankshaft Bearing 2 Oil Clearance O D I D 0 040 to 0 104 mm 0 00157 to 0 00409 in 59 921 to 59 940 mm 2 35909 to 2 35984 in 59 980 to 60 025 mm 2 3614...

Страница 35: ...3 in 87 250 to 87 272 mm 3 43503 to 3 43590 in 83 150 mm 3 2736 in 87 150 mm 3 4311 in 83 400 mm 3 2835 in 87 400 mm 3 4409 in Engine Oil Pressure At Idle Speed At Rated Speed 294 to 441 kPa 3 0 to 4...

Страница 36: ...iator Cap Pressure Falling Time 10 seconds or more for pressure falling from 88 to 59 kPa from 0 9 to 0 6 kgf cm2 from 13 to 9 psi Injection Pump D1503 M DI D1503 M DI T D1703 M DI D1803 M DI V2203 M...

Страница 37: ...50 to 0 80 mm 0 0197 to 0 0315 in 0 50 to 0 90 mm 0 0197 to 0 0354 in 15 0 mm 0 591 in Infinity 29 0 mm 1 142 in 34 0 mm 1 339 in 0 20 mm 0 0079 in 0 20 mm 0 0079 in 11 0 mm 0 433 in Alternator Stato...

Страница 38: ...s 2 years Checking fuel pipes and clamp bands Changing Engine oil depending on the oil pan 1 Oil pan depth 90 mm 3 54 in 2 Oil pan depth 124 mm 4 88 in Cleaning air cleaner element Cleaning fuel filte...

Страница 39: ...f road vehicle engine runs on a high sulfur fuel it is advisable to employ the CF CD or CE lubricating oil with a high total base number If the CF 4 or CG 4 lubricating oil is used with a high sulfur...

Страница 40: ...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 an...

Страница 41: ...stem 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 ven...

Страница 42: ...y 6th cleaning W1045746 Cleaning Fuel Filter Normal Type only 1 Close the fuel cock 3 2 Unscrew the retaining ring 6 and remove the cup 5 and rinse the inside with kerosene 3 Take out the element 4 an...

Страница 43: ...8 to 0 35 in 2 If the deflection is not within the factory specifications adjust with the tension pulley adjusting bolts W1057138 Checking Fan Belt Damage 1 Check the fan belt for damage 2 Check if th...

Страница 44: ...e water pipe is made of rubber and tends to age It must be changed every two years Also change the clamp and tighten it securely W1050147 Checking Intake Air Line 1 Check to see if the intake air hose...

Страница 45: ...C 77 F SAE 30 or 10W 30 0 C to 25 C 32 F to 77 F SAE 20 or 10W 30 Below 0 C 32 F SAE 10W or 10W 30 Q NOTE Lubricating Oil With the emission control now in effect the CF 4 and CG 4 lubricating oils ha...

Страница 46: ...cing Fuel Filter Cartridge Cartridge Type Water and dust in fuel are collected in the filter cartridge 1 So change the filter cartridge 1 every 400 hours service 1 Remove the used filter cartridge 1 w...

Страница 47: ...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 mark on...

Страница 48: ...spheric 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 th...

Страница 49: ...alternator 1 2 Remove the fan belt 2 3 Replace new fan belt 4 Install the alternator 1 5 Check the fan belt tension W1052220 Deflection A Factory spec 7 0 to 9 0 mm 98 N or 10 kgf 0 28 to 0 35 in 98 N...

Страница 50: ...ld 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...

Страница 51: ...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...

Страница 52: ...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...

Страница 53: ...factory specifications replace the injection nozzle assembly W10408820 Nozzle Spraying Condition 1 Set the injection nozzle to a nozzle tester Code No 07909 31361 and check the nozzle spraying conditi...

Страница 54: ...eck Points of Every 2 Years Replacing Intake Air Line See page S 23 W1117974 Replacing Battery See page S 21 30 W1056352 Replacing Radiator Hoses and Clamp Bands See page S 23 W1056385 Replacing Fuel...

Страница 55: ...the cylinder W1024100 Piston Ring Tool Code No 07909 32121 Application Use exclusively for removing or installing the piston ring with ease W1024150 Diesel Engine Compression Tester for Glow Plug Code...

Страница 56: ...cap pressure and leaks from cooling system Remarks Adapter 1 BANZAI Code No RCT 2A 30S W1024532 Connecting Rod Alignment Tool Code No 07909 31661 Application Use to check the connecting rod alignment...

Страница 57: ...001 to 0 003 in range Red 0 051 to 0 152 mm 0 002 to 0 006 in Blue 0 102 to 0 229 mm 0 004 to 0 009 in W1024719 Red Check Code No 07909 31371 Application Use to check cracks on cylinder head cylinder...

Страница 58: ...dia D 225 mm 8 86 in E 70 mm 2 76 in F 45 mm 1 77 in G 25 mm 0 98 in H 5 mm 0 197 in I 6 7 to 7 0 mm dia 0 263 to 0 275 in dia J 20 mm dia 0 787 in dia K 12 5 to 12 8 mm dia 0 492 to 0 504 in dia L 8...

Страница 59: ...2 236 to 2 240 in dia H 51 8 to 51 9 mm dia 2 039 to 2 043 in dia A 130 mm 5 12 in B 72 mm 2 83 in C R40 mm R1 57 in D 9 mm 0 35 in E 4 mm 0 16 in F 20 mm 0 79 in G 20 mm dia 0 79 in dia H 68 mm dia 2...

Страница 60: ...947 to 21 960 mm dia 0 8641 to 0 8646 in dia D 0 52 rad 30 O 28 mm 1 10 in E 46 950 to 46 975 mm dia 1 8484 to 1 8494 in dia P 29 mm 1 14 in F 43 934 to 43 950 mm dia 1 7297 to 1 7303 in dia Q 5 mm 0...

Страница 61: ...in dia T 60 mm dia 2 36 in dia G 60 mm dia 2 36 in dia U 46 950 to 46 975 mm dia 1 8484 to 1 8494 in dia H 37 mm 1 46 in V 44 950 to 44 975 mm dia 1 7697 to 1 7707 in dia I 21 947 to 21 960 mm dia 0 8...

Страница 62: ...mm Deep Socket Wrench Application Use to loosen and tighten the fan drive pulley mounting nut W1044361 A 100 mm 3 94 in B 25 0 mm 0 98 in C 27 0 mm 1 06 in D 45 0 mm dia 1 77 in dia E 35 0 mm dia 1 3...

Страница 63: ...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 Top Clearan...

Страница 64: ...slightly to the stop to relieve any excess pressure before removing cap completely 1 Prepare a bucket Open the coolant drain cock 1 to drain coolant 2 Prepare an oil pan Remove the oil drain plug 2 t...

Страница 65: ...Pipes 1 Loosen the screws on the pipe clamps 1 2 Detach the injection pipes 2 When reassembling Blow out dust inside the pipes W1060970 Tightening torque Cylinder head cover screw 6 9 to 11 3 N m 0 7...

Страница 66: ...ts 3 check to see if their ends are properly engaged with the dimples IMPORTANT Q After installing the rocker arm be sure to adjust the valve clearance See page S 31 W1021437 Tightening torque Nozzle...

Страница 67: ...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 W1021755 Tigh...

Страница 68: ...sing 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...

Страница 69: ...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 3 lightly tap the stem to assure proper fit wi...

Страница 70: ...the hi idling body gasket 6 with a new one Before fitting the stop lever 3 to the gear case install the stop solenoid guide 5 first into position Then attach the stop lever and use it to see if it fun...

Страница 71: ...and bolts 3 Using the specific tool 1 undo the large governor spring 2 from the fork lever 3 4 Using the specific tool 1 undo the small governor spring 4 from the fork lever 3 5 Set the speed control...

Страница 72: ...long because otherwise it may get deformed permanently Using the specific tool 1 hook the large governor spring 2 onto the fork lever 3 Make sure both the governor springs 2 4 are tight on the fork l...

Страница 73: ...sket if equipped 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 cas...

Страница 74: ...ligning mark Idle gear 2 and crank gear 5 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...

Страница 75: ...ever 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 2 4...

Страница 76: ...il strainer 3 and O ring 4 When reassembling After cleaning the oil strainer 3 check to see that the filter mesh in clean and install it Visually check the O ring 4 apply engine oil and install it Sec...

Страница 77: ...ad 120 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 disu...

Страница 78: ...oil ring gap 11 Apply engine oil to the piston pin 7 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 7 to the...

Страница 79: ...er 5 to remove it IMPORTANT Q The length of inside screws 6 and outside screws 3 are different Do not take a mistake using inside screws and outside screws When reassembling Fit the bearing case gaske...

Страница 80: ...nter of the third cylinder 4 Repeat the above steps to draw out all the crankshaft For V2403 M DI 1 Remove the main bearing case screw 2 1 2 Turn the crankshaft to set the crank pin of the 4th cylinde...

Страница 81: ...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 bearin...

Страница 82: ...heck the valve recessing after correcting W1027737 Cylinder Head Flaw 1 Prepare an air spray red check Code No 07909 31371 2 Clean the surface of the cylinder head with detergent 2 3 Spray the cylinde...

Страница 83: ...eter 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...

Страница 84: ...uide with a hammer during replacement W1027889 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 wa...

Страница 85: ...ply 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 a...

Страница 86: ...e 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...

Страница 87: ...Allowable limit 0 07 mm 0 0028 in Tappet O D Factory spec 23 959 to 23 980 mm 0 94327 to 0 94410 in Tappet guide bore I D Factory spec 24 000 to 24 021 mm 0 94488 to 0 94571 in Backlash between idle...

Страница 88: ...e limit replace the camshaft stopper W1030012 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 bal...

Страница 89: ...er shaft bearing 1 I D Factory spec 43 980 to 44 045 mm 1 73149 to 1 73405 in Oil clearance of balancer shaft journal 2 Factory spec 0 030 to 0 111 mm 0 00118 to 0 00437 in Allowable limit 0 2 mm 0 00...

Страница 90: ...e 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 camsh...

Страница 91: ...nd bushing I D with an inside micrometer and calculate the oil clearance 3 If the oil clearance exceeds the allowable limit replace the bushing If it still exceeds the allowable limit replace the pist...

Страница 92: ...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 0 20 to 0 35 mm 0 0079 to 0 0138 in Allowa...

Страница 93: ...r 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 5 If the measurement e...

Страница 94: ...he measurement 3 If the misalignment exceeds the allowable limit replace the crankshaft W1033001 Crankshaft side clearance Factory spec D1503 M DI D1503 M DI T D1703 M DI V2203 M DI 0 15 to 0 35 mm 0...

Страница 95: ...il hole Be sure not to move the crankshaft while the connecting rod screws are tightened Reference Undersize dimensions of crankpin W1033106 Oil clearance between crankpin and crankpin bearing Factory...

Страница 96: ...above 3S0001 W1033717 Oil clearance between crankshaft journal and crankshaft bearing 1 Factory spec 0 040 to 0 118 mm 0 00157 to 0 00465 in Allowable limit 0 2 mm 0 0079 in Crankshaft journal O D Fac...

Страница 97: ...n relief 1 0 to 1 5 mm relief 0 0394 to 0 0591 in relief C D1503 M DI D1503 M DI T D1703 M DI V2203 M DI 51 721 to 51 740 mm 2 03626 to 2 03701 in 51 521 to 51 540 mm 2 02839 to 2 02913 in D1803 M DI...

Страница 98: ...he crankshaft while the bearing case screws are tightened Serial No below 3R9999 Serial No above 3S0001 W1083821 Oil clearance between crankshaft and crankshaft bearing 2 Factory spec 0 040 to 0 104 m...

Страница 99: ...DI T D1703 M DI V2203 M DI 51 721 to 51 740 mm 2 03626 to 2 03701 in 51 521 to 51 540 mm 2 02839 to 2 02913 in D1803 M DI V2403 M DI 59 721 to 59 740 mm 2 35122 to 2 35197 in 59 521 to 59 540 mm 2 343...

Страница 100: ...ximum 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 Correctin...

Страница 101: ...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 DI D1503 M DI T 83 250 to 83 272 mm 3 27756 to 3 2784...

Страница 102: ...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 reassembl...

Страница 103: ...of plastigage Code No 07909 30241 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 gaug...

Страница 104: ...specifications loosen the alternator mounting screws and relocate the alternator to adjust W1035667 Fan Belt Damage and Wear 1 Check the fan belt for damage 2 If the fan belt is damaged replace it 3...

Страница 105: ...er leaks 4 For water leak from the pinhole repair with the radiator cement When water leak is excessive replace the radiator W10389070 Thermostat Valve Opening Temperature 1 Suspend the thermostat in...

Страница 106: ...over gasket 2 W1105115 Water Pump Assembly 1 Loosen the alternator mounting bolts and remove the fan belt 2 Remove the fan and fan pulley 3 Remove the water pump assembly from the gear case cover 4 Re...

Страница 107: ...inder 2 Turn the flywheel further and stop turning when the fuel begins to flow over to get the present injection timing 3 The flywheel has mark 1TC and four lines indicating every 0 087 rad 5 of cran...

Страница 108: ...of 0 20 mm 0 25 mm 0 30 mm and 0 35 mm Combine these shims for adjustments Addition or reduction of shim 0 05 mm 0 0020 in delays or advances the injection timing by approx 0 0087 rad 0 5 In disassemb...

Страница 109: ...s replace the injection nozzle assembly W1037197 Nozzle Spraying Condition 1 Set the injection nozzle to a nozzle tester Code No 07909 31361 and check the nozzle spraying condition 2 If the spraying c...

Страница 110: ...r dose not run check the motor W1145152 Magnetic Switch Test 1 Disconnect the battery negative cable from the battery 2 Disconnect the battery positive cable and the leads from the starter B terminal...

Страница 111: ...n the factory specifications W1150547 No load Characteristics 1 Make the connection as shown in the figure and turn on switch SW1 2 Increase the alternator speed so that the pointer of the ammeter swi...

Страница 112: ...W1015115 4 Engine Stop Solenoid Connector Voltage 1 Disconnect the 2P connector from engine stop solenoid 2 Turn the main switch key to the ON position 3 Measure the voltage with voltmeter between th...

Страница 113: ...lamp relay 1 is proper W1016173 6 Starter Auto Reduction Unit Continuity 1 Disconnect the 6P connector from the starter auto reduction unit 2 Remove the starter auto reduction unit from the machine 3...

Страница 114: ...ling Apply grease to the gear teeth of the gear 5 and overrunning clutch 2 and ball 3 W1016728 Plunger 1 Remove the end cover 1 2 Take out the plunger 2 W1016883 2 Alternator Pulley 1 Secure the hexag...

Страница 115: ...9054 IC Regulator 1 Unscrew the three screws holding the IC regulator 1 and remove the IC regulator 1 W1019123 Rectifier 1 Remove the four screws holding the rectifier 1 and the stator lead wires 2 Re...

Страница 116: ...g the retainer plate 1 and remove the retainer plate 1 W1019542 Bearing on Drive End Side 1 Press out the bearing from drive end frame 3 with a press and jig 1 W1019611 Bearing at Slip Ring Side 1 Lig...

Страница 117: ...t smooth rotation replace it W1156718 Brush Wear 1 If the connect 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 tha...

Страница 118: ...e brush 2 and yoke 3 with an ohmmeter 4 If it conducts replace the yoke assembly W1156968 Armature Coil 1 Check the continuity across the commutator and armature coil core with an ohmmeter 2 If it con...

Страница 119: ...he segment edges W1155802 2 Alternator Bearing 1 Check the bearing for smooth rotation 2 If it does not rotate smoothly replace it W1019790 Commutator O D Factory spec D1503 M DI D1503 M DI T D1703 M...

Страница 120: ...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 Rectifier 1 Check the continuity across each diode of rec...

Страница 121: ...ause it will destroy the IC regulator NOTE Q Do not use an auto digital multimeter Because it s very hard to check the continuity of IC regulator by using it W1020645 3 Wiring Diagram 1 Starter Auto R...

Страница 122: ...hten the bolts and nuts or replace the gasket with new one W1069824 Compressor Side 1 Check the inlet pipe 1 1 of the compressor cover 2 to see if there is no air leak 2 Check for loose connections or...

Страница 123: ...When reassembling Replace the gasket with new one W1070719 Oil Pipe 1 Remove the joint bolt 1 2 and take off the oil pipe 1 3 2 Remove the bolts 4 and release the clamp 5 3 Disconnect the oil pipe 2...

Страница 124: ...RY 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 Printed in Japan 2009 10 S EI EI e Code No 9Y011 02153...

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