Workshop Manual

ManualsBrandsKubota ManualsOtherWORKSHOP MANUAL DIESEL ENGINE 03-M-E3B SERIES, 03-M-DI-E3B SERIES, 03-M-E3BG SERIES

Table Of Contents

03-M-E3B SERIES,03-M-DI-E3B SERIES,03-M-E3BG SERIES

WORKSHOP MANUAL

DIESEL ENGINE

03-M-E3B SERIES,

03-M-DI-E3B SERIES,

03-M-E3BG SERIES

KiSC issued 07, 2008 A

Summary of content (181 pages)

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 THE READER This Workshop Manual has been prepared to provide servicing personnel with information on the mechanism, service and maintenance of 03-M-E3B, 03-M-DI-E3B and 03-M-E3BG series. It is divided into three parts, “General”, “Mechanism” and “Servicing”. Q General Information on the engine identification, the general precautions, maintenance check list, check and maintenance and special tools are described. Q Mechanism Information on the construction and function are included.
PAGE 3
SAFETY INSTRUCTIONS 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM SAFETY INSTRUCTIONS SAFETY FIRST This symbol, the industry’s “Safety Alert Symbol”, is used throughout this manual and on labels on the machine itself to warn of the possibility of personal injury. Read these instructions carefully. It is essential that you read the instructions and safety regulations before you attempt to repair or use this unit.
PAGE 4
SAFETY INSTRUCTIONS 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM SAFETY STARTING • Do not start the engine by shorting across starter terminals or bypassing the safety start switch. • Unauthorized modifications to the engine may impair the function and / or safety and affect engine life. SAFETY WORKING • Do not work on the machine while under the influence of alcohol, medication, or other substances or while fatigued. • Wear close fitting clothing and safety equipment appropriate to the job.
PAGE 5
SAFETY INSTRUCTIONS 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM AVOID FIRES • Fuel is extremely flammable and explosive under certain conditions. Do not smoke or allow flames or sparks in your working area. • To avoid sparks from an accidental short circuit, always disconnect the battery negative cable first and connect it last. • Battery gas can explode. Keep sparks and open flame away from the top of battery, especially when charging the battery. • Make sure that no fuel has been spilled on the engine.
PAGE 6
SAFETY INSTRUCTIONS 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM 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.
PAGE 7
SPECIFICATIONS 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM SPECIFICATIONS Model D1503-M D1703-M Number of Cylinders 3 Type Vertical, Water-cooled, 4 cycle diesel engine Bore × Stroke 83.0 X 92.4 mm (3.27 X 3.64 in.) Total Displacement 1499 cm3 87.0 X 92.4 mm (3.43 X 3.64 in.) 1647 cm3 (100.5 cu.in.) (91.47 cu.in.) ISO Net Continuous 19.5 KW / 2800 min-1 (rpm) (26.1 HP / 2800 min-1 (rpm)) 21.2 KW / 2800 min-1 (rpm) (28.4 HP / 2800 min-1 (rpm)) ISO/SAE Net Intermittent 22.
PAGE 8
SPECIFICATIONS 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Model D1803-M Number of Cylinders Type 3 Vertical, Water-cooled, 4 cycle diesel engine Bore × Stroke 87.0 X 102.4 mm (3.43 X 4.031 in.) Total Displacement 1826 cm3 (111.4 cu.in.) ISO Net Continuous 22.8 KW / 2700 min-1 (rpm) (30.6 HP / 2700 min-1 (rpm)) ISO/SAE Net Intermittent 26.3 KW / 2700 min-1 (rpm) (35.3 HP / 2700 min-1 (rpm)) SAE Gross Intermittent 27.9 KW / 2700 min-1 (rpm) (37.
PAGE 9
SPECIFICATIONS 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Model V2003-M V2203-M Number of Cylinders 4 Type Vertical, Water-cooled, 4 cycle diesel engine Bore × Stroke 83.0 X 92.4 mm (3.27 X 3.64 in.) 87.0 X 92.4 mm (3.43 X 3.64 in.) 3 Total Displacement 2197 cm3 (134.1 cu.in.) 1999 cm (122.0 cu.in.) min-1 ISO Net Continuous 26.7 KW / 2800 (rpm) (35.8 HP / 2800 min-1 (rpm)) 29.6 KW / 2800 min-1 (rpm) (39.7 HP / 2800 min-1 (rpm)) ISO/SAE Net Intermittent 30.8 KW / 2800 min-1 (rpm) (41.
PAGE 10
SPECIFICATIONS 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Model V2403-M V2403-M-T Number of Cylinders Type 4 Vertical, Water-cooled, 4 cycle diesel engine Bore × Stroke 87.0 X 102.4 mm (3.43 X 4.031 in.) 2434 cm3 (148.5 cu.in.) Total Displacement ISO Net Continuous 30.2 KW / 2700 (rpm) (40.5 HP / 2700 min-1 (rpm)) 36.4 KW / 2700 min-1 (rpm) (48.8 HP / 2700 min-1 (rpm)) ISO/SAE Net Intermittent 34.8 KW / 2700 min-1 (rpm) (46.7 HP / 2700 min-1 (rpm)) 41.9 KW / 2700 min-1 (rpm) (56.
PAGE 11
SPECIFICATIONS 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Model D1803-M-DI Number of Cylinders Type 3 Vertical, Water-cooled, 4 cycle diesel engine Bore × Stroke 87.0 X 102.4 mm (3.43 X 4.031 in.) Total Displacement 1826 cm3 (111.4 cu.in.) ISO Net Continuous 23.2 KW / 2700 min-1 (rpm) (31.1 HP / 2700 min-1 (rpm)) ISO/SAE Net Intermittent 26.7 KW / 2700 min-1 (rpm) (35.8 HP / 2700 min-1 (rpm)) SAE Gross Intermittent 27.9 KW / 2700 min-1 (rpm) (37.
PAGE 12
SPECIFICATIONS 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Model V2403-M-DI V2403-M-DI-T Number of Cylinders Type 4 Vertical, Water-cooled, 4 cycle diesel engine Bore × Stroke 87.0 X 102.4 mm (3.43 X 4.031 in.) 2434 cm3 (148.5 cu.in.) Total Displacement ISO Net Continuous 30.5 KW / 2700 (rpm) (40.9 HP / 2700 min-1 (rpm)) 30.7 KW / 2400 min-1 (rpm) (41.2 HP / 2400 min-1 (rpm)) ISO/SAE Net Intermittent 35.1 KW / 2700 min-1 (rpm) (47.1 HP / 2700 min-1 (rpm)) 35.3 KW / 2400 min-1 (rpm) (47.
PAGE 13
SPECIFICATIONS 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Model D1703-M-BG Number of Cylinders Type 3 Vertical, Water-cooled, 4 cycle diesel engine Bore × Stroke 87.0 X 92.4 mm (3.43 X 3.64 in.) 1647 cm3 (100.5 cu.in.) Total Displacement min-1 ISO Net Continuous 14.0 KW / 1500 (rpm) (18.8 HP / 1500 min-1 (rpm)) 16.9 KW / 1800 min-1 (rpm) (22.7 HP / 1800 min-1 (rpm)) ISO/SAE Net Intermittent 16.1 KW / 1500 min-1 (rpm) (21.6 HP / 1500 min-1 (rpm)) 19.5 KW / 1800 min-1 (rpm) (26.
PAGE 14
SPECIFICATIONS 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Model V2003-M-BG Number of Cylinders Type 4 Vertical, Water-cooled, 4 cycle diesel engine Bore × Stroke 83.0 X 92.4 mm (3.27 X 3.64 in.) 1999 cm3 (122.0 cu.in.) Total Displacement min-1 ISO Net Continuous 17.5 KW / 1500 (rpm) (23.5 HP / 1500 min-1 (rpm)) 20.3 KW / 1800 min-1 (rpm) (27.2 HP / 1800 min-1 (rpm)) ISO/SAE Net Intermittent 20.1 KW / 1500 min-1 (rpm) (27.0 HP / 1500 min-1 (rpm)) 23.4 KW / 1800 min-1 (rpm) (31.
PAGE 15
SPECIFICATIONS 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Model V2003-M-T-BG Number of Cylinders Type 4 Vertical, Water-cooled, 4 cycle diesel engine Bore × Stroke 83.0 X 92.4 mm (3.27 X 3.64 in.) 1999 cm3 (122.0 cu.in.) Total Displacement min-1 ISO Net Continuous 22.3 KW / 1500 (rpm) (29.9 HP / 1500 min-1 (rpm)) 25.7 KW / 1800 min-1 (rpm) (34.5 HP / 1800 min-1 (rpm)) ISO/SAE Net Intermittent 25.7 KW / 1500 min-1 (rpm) (34.5 HP / 1500 min-1 (rpm)) 29.6 KW / 1800 min-1 (rpm) (39.
PAGE 16
SPECIFICATIONS 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Model V2203-M-BG Number of Cylinders Type 4 Vertical, Water-cooled, 4 cycle diesel engine Bore × Stroke 87.0 X 92.4 mm (3.43 X 3.64 in.) 2197 cm3 (134.1 cu.in.) Total Displacement min-1 ISO Net Continuous 18.8 KW / 1500 (rpm) (25.2 HP / 1500 min-1 (rpm)) 22.6 KW / 1800 min-1 (rpm) (30.3 HP / 1800 min-1 (rpm)) ISO/SAE Net Intermittent 21.7 KW / 1500 min-1 (rpm) (29.1 HP / 1500 min-1 (rpm)) 26.0 KW / 1800 min-1 (rpm) (34.
PAGE 17
SPECIFICATIONS 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Model V2403-M-BG Number of Cylinders Type 4 Vertical, Water-cooled, 4 cycle diesel engine Bore × Stroke 87.0 X 102.4 mm (3.43 X 4.031 in.) 2434 cm3 (148.5 cu.in.) Total Displacement min-1 ISO Net Continuous 21.5 KW / 1500 (rpm) (28.8 HP / 1500 min-1 (rpm)) 25.1 KW / 1800 min-1 (rpm) (33.7 HP / 1800 min-1 (rpm)) ISO/SAE Net Intermittent 24.8 KW / 1500 min-1 (rpm) (33.3 HP / 1500 min-1 (rpm)) 28.9 KW / 1800 min-1 (rpm) (38.
PAGE 18
DIMENSIONS 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIMENSIONS 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.
PAGE 19
DIMENSIONS 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM V2003-M V2203-M V2403-M V2403-M-T A 652.0 mm (25.67 in.) 652.0 mm (25.67 in.) 652.0 mm (25.67 in.) 667.1 mm (26.26 in.) B 480.0 mm (18.90 in.) 480.0 mm (18.90 in.) 480.0 mm (18.90 in.) 449.0 mm (17.68 in.) C 643.0 mm (25.31 in.) 643.0 mm (25.31 in.) 648.0 mm (25.51 in.) 737.3 mm (29.03 in.
PAGE 20
DIMENSIONS 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM D1803-M-DI A 560.0 mm (22.05 in.) B 492.0 mm (19.37 in.) C 636.0 mm (25.04 in.
PAGE 21
DIMENSIONS 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM 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.
PAGE 22
DIMENSIONS 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM D1703-M-BG A 605.6 mm (23.84 in.) B 505.0 mm (19.88 in.) C 642.8 mm (25.31 in.
PAGE 23
DIMENSIONS 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM V2003-M-BG V2003-M-T-BG V2203-M-BG V2403-M-BG A 700.6 mm (27.58 in.) 700.6 mm (27.58 in.) 700.6 mm (27.58 in.) 700.6 mm (27.58 in.) B 505.0 mm (19.88 in.) 505.0 mm (19.88 in.) 505.0 mm (19.88 in.) 505.0 mm (19.88 in.) C 633.3 mm (24.93 in.) 674.0 mm (26.54 in.) 633.3 mm (24.93 in.) 684.0 mm (26.93 in.
PAGE 24
03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM WIRING DIAGRAM WIRING DIAGRAM Start Relay ECU (Electronic Control Unit) 1 2 3 11 19 10 18 4 12 20 7 6 5 13 21 14 22 15 23 17 25 34 26 2 4 9 8 16 24 1 3 1.25 Solenoid 1.25 1.25 3.0 B IG L Slowdown(1200 min-1(rpm)) Speed Switch (1800 min-1(rpm)/1500 min-1(rpm)) Alternator Manual Stop Switch (Run/Stop) Engine Speed Sensor Starter 0.85 0.85 3.0 ST Water Temp. Sensor B 0.85 3.0 Oil Switch 5A 5A 10A 10A 5A 3.0 Water Temp. Switch 3.
PAGE 25
GENERAL CONTENTS 1. ENGINE IDENTIFICATION ............................................................................. G-1 [1] MODEL NAME AND ENGINE SERIAL NUMBER ................................ G-1 [2] E3B ENGINE............................................................................................. G-3 [3] CYLINDER NUMBER ............................................................................... G-3 2. GENERAL PRECAUTIONS ........................................................................
PAGE 26
G GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM 1. ENGINE IDENTIFICATION [1] MODEL NAME AND ENGINE SERIAL NUMBER When contacting the manufacture, always specify your engine model name and serial number. The engine model and its serial number need to be identified before the engine can be serviced or parts replaced. Q Engine Serial Number The engine serial number is an identified number for the engine. It is marked after the engine model number. It indicates month and year of manufacture as follows.
PAGE 27
G GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM • Month of manufacture Month Engine Lot Number January A0001 ~ A9999 B0001 ~ BZ999 February C0001 ~ C9999 D0001 ~ DZ999 March E0001 ~ E9999 F0001 ~ FZ999 April G0001 ~ G9999 H0001 ~ HZ999 May J0001 ~ J9999 K0001 ~ KZ999 June L0001 ~ L9999 M0001 ~ MZ999 July N0001 ~ N9999 P0001 ~ PZ999 August Q0001 ~ Q9999 R0001 ~ RZ999 September S0001 ~ S9999 T0001 ~ TZ999 October U0001 ~ U9999 V0001 ~ VZ999 November W0001 ~ W9999 X0001 ~ XZ9
PAGE 28
G GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM [2] E3B ENGINE [Example : Engine Model Name D1803-M-E3B-XXXX or D1803-M-DI-E3B-XXXX] The emission controls previously implemented in various countries to prevent air pollution will be stepped up as Non-Road Emission Standards continue to change. The timing or applicable date of the specific Non-Road Emission regulations depends on the engine output classification.
PAGE 29
G GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM 2. GENERAL PRECAUTIONS • During disassembly, carefully arrange removed parts in a clean area to prevent confusion later. Screws, bolts and nuts should be replaced in their original position to prevent reassembly errors. • When special tools are required, use KUBOTA genuine special tools. Special tools which are not frequently used should be made according to the drawings provided.
PAGE 30
G GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM 3. MAINTENANCE CHECK LIST To maintain long-lasting and safe engine performance, make it a rule to carry out regular inspections by following the table below. [D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M, V2403-M-T] [D1703-M-BG, V2003-M-BG, V2003-M-T-BG, V2203-M-BG, V2403-M-BG] Item 50 hrs * 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.
PAGE 31
G GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM [D1803-M-DI, V2403-M-DI, V2403-M-DI-T] Item 50 hrs * 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.
PAGE 32
G GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM CAUTION • When changing or inspecting, be sure to level and stop the engine. Q NOTE Engine Oil : • Refer to the following table for the suitable American Petroleum Institute (API) classification of engine oil according to the engine type (with internal EGR, external EGR or non-EGR) and the Fuel Type Used : (Low Sulfur, Ultra Low Sulfur or High Sulfur Fuels).
PAGE 33
G GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM 4. CHECK AND MAINTENANCE [1] DAILY CHECK POINTS Checking Engine Oil Level 1. Level the engine. 2. To check the oil level, draw out the dipstick (1), wipe it clean, reinsert it, and draw it out again. Check to see that the oil level lies between the two notches. 3. If the level is too low, add new oil to the specified level. Q IMPORTANT • When using an oil of different maker or viscosity from the previous, drain old oil. Never mix two different types of oil.
PAGE 34
G GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Checking and Replenish Coolant 1. Without recovery tank : Remove the radiator cap (1) and check to see that the coolant level is just below the port. With recovery tank (2) : Check to see that the coolant level lies between FULL (A) and LOW (B). 2. If coolant level is too low, check the reason for decreasing coolant. (Case 1) If coolant is decreasing by evaporation, replenish only fresh, soft water.
PAGE 35
G GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM [2] CHECK POINTS OF INITIAL 50 HOURS Changing Engine Oil • 1. 2. 3. 4. 5. Q • • • • CAUTION Be sure to stop engine before changing engine oil. Start and warm up the engine for approx. 5 minutes. Place an oil pan underneath the engine. To drain the used oil, remove the drain plug (1) at the bottom of the engine and drain the oil completely. Screw the drain plug (1). Fill new oil up to upper line on the dipstick (2).
PAGE 36
G GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Replacing Oil Filter Cartridge • 1. 2. 3. 4. Q • CAUTION Be sure to stop the engine before replacing filter cartridge. Remove the oil filter cartridge (1) with the filter wrench. Apply a slight coat of oil onto the new cartridge gasket. To install the new cartridge, screw it in by hand. Over tightening may cause deformation of rubber gasket. After the new cartridge has been replaced, the engine oil normally decrease a little.
PAGE 37
G GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM [3] CHECK POINTS OF EVERY 50 HOURS Checking Fuel Hoses and Clamp Bands 1. If the clamp (2) is loose, apply oil to the threads and securely retighten it. 2. The fuel hose (1) is made of rubber and ages regardless of the period service. Change the fuel hose together with the clamp every two years. 3. However, if the fuel hose and clamp are found to be damaged or deteriorate earlier than two years, then change or remedy. 4.
PAGE 38
G GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM [4] CHECK POINTS OF EVERY 100 HOURS Cleaning Air Cleaner Element 1. Remove the air cleaner element. 2. Use clean dry compressed air on the inside of the element. Pressure of compressed air must be under 210 kPa (2.1 kgf/cm2, 30 psi). Maintain reasonable distance between the nozzle and the filter. Q NOTE • The air cleaner uses a dry element. Never apply oil to it. • Do not run the engine with filter element removed.
PAGE 39
G GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Fan Belt Damage and Wear 1. Check the fan belt for damage. 2. If the fan belt is damaged, replace it. 3. Check if the fan belt is worn and sunk in the pulley groove. 4. If the fan belt is nearly worn out and deeply sunk in the pulley groove, replace it.
PAGE 40
G GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM [5] CHECK POINTS OF EVERY 150 HOURS Changing Engine Oil (for 90 mm (3.5 in.) Depth Oil Pan) [D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M] [D1703-M-BG, V2003-M-BG, V2003-M-T-BG, V2203-M-BG, V2403-M-BG] • 1. 2. 3. 4. 5. Q • • • • CAUTION Be sure to stop engine before changing engine oil. Start and warm up the engine for approx. 5 minutes. Place an oil pan underneath the engine.
PAGE 41
G GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Replacing Oil Filter Cartridge (for 90 mm (3.5 in.) Depth Oil Pan) [D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M] [D1703-M-BG, V2003-M-BG, V2003-M-T-BG, V2203-M-BG, V2403-M-BG] • 1. 2. 3. 4. Q • CAUTION Be sure to stop the engine before replacing filter cartridge. Remove the oil filter cartridge (1) with the filter wrench. Apply a slight coat of oil onto the new cartridge gasket. To install the new cartridge, screw it in by hand.
PAGE 42
G GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM [6] CHECK POINTS OF EVERY 200 HOURS Changing Engine Oil (for 124 mm (4.88 in.) Depth Oil Pan) [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. 2. 3. 4. 5. Q • • • • CAUTION Be sure to stop engine before changing engine oil. Start and warm up the engine for approx. 5 minutes. Place an oil pan underneath the engine.
PAGE 43
G GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Changing Engine Oil (for 90 mm (3.5 in.) Depth Oil Pan) [D1803-M-DI, V2403-M-DI, V2403-M-DI-T] • 1. 2. 3. 4. 5. Q • • • • CAUTION Be sure to stop engine before changing engine oil. Start and warm up the engine for approx. 5 minutes. Place an oil pan underneath the engine. To drain the used oil, remove the drain plug (1) at the bottom of the engine and drain the oil completely. Screw the drain plug (1). Fill new oil up to upper line on the dipstick (2).
PAGE 44
G GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Replacing Oil Filter Cartridge (for 124 mm (4.88 in.) Depth Oil Pan) [D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M, V2403-M-T] [D1703-M-BG, V2003-M-BG, V2003-M-T-BG, V2203-M-BG, V2403-M-BG] • 1. 2. 3. 4. Q • CAUTION Be sure to stop the engine before replacing filter cartridge. Remove the oil filter cartridge (1) with the filter wrench. Apply a slight coat of oil onto the new cartridge gasket. To install the new cartridge, screw it in by hand.
PAGE 45
G GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Checking Intake Air Line 1. Check to see if the intake air hose(s) are properly fixed every 200 hours of operation. 2. If the clamp is loose, apply oil to the threads and retighten it securely. 3. The intake air hose(s) is made of rubber and tends to age. It must be changed every two years. Also change the clamp and tighten it securely. Q IMPORTANT • To prevent serious damage to the engine, keep out any dust inside the intake air line.
PAGE 46
G GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM [7] CHECK POINTS OF EVERY 400 HOURS Changing Engine Oil (for 124 mm (4.88 in.) Depth Oil Pan) [D1803-M-DI, V2403-M-DI, V2403-M-DI-T] • 1. 2. 3. 4. 5. Q • • • • CAUTION Be sure to stop engine before changing engine oil. Start and warm up the engine for approx. 5 minutes. Place an oil pan underneath the engine. To drain the used oil, remove the drain plug (1) at the bottom of the engine and drain the oil completely. Screw the drain plug (1).
PAGE 47
G GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Replacing Oil Filter Cartridge (for 124 mm (4.88 in.) Depth Oil Pan) [D1803-M-DI, V2403-M-DI, V2403-M-DI-T] • 1. 2. 3. 4. Q • CAUTION Be sure to stop the engine before replacing filter cartridge. Remove the oil filter cartridge (1) with the filter wrench. Apply a slight coat of oil onto the new cartridge gasket. To install the new cartridge, screw it in by hand. Over tightening may cause deformation of rubber gasket.
PAGE 48
G GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM [8] CHECK POINTS OF EVERY 500 HOURS Cleaning Water Jacket and Radiator Interior CAUTION • Do not remove the radiator cap when the engine is hot. Then loosen cap slightly to the stop to relieve any excess pressure before removing cap completely. 1. Stop the engine and let cool down. 2. To drain the coolant, open the radiator drain plug (2) and remove the radiator cap (1). Then radiator cap (1) must be removed to completely drain the coolant.
PAGE 49
G GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Anti-Freeze • There are two types of anti-freeze available: use the permanent type (PT) for this engine. • Before adding anti-freeze for the first time, clean the radiator interior by pouring fresh, soft water and draining it a few times. • The procedure for mixing water and anti-freeze differs according to the make of the anti-freeze and the ambient temperature. Basically, it should be referred to SAE J1034 standard, more specifically also to SAE J814c.
PAGE 50
G GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM [9] CHECK POINTS OF EVERY 1 OR 2 MONTHS Recharging CAUTION • When the battery is being activated, hydrogen and oxygen gases in the battery are extremely explosive. Keep open sparks and flames away from the battery at all times, especially when charging the battery. • When charging battery, remove battery vent plugs. • When disconnecting the cable from the battery, start with the negative terminal first.
PAGE 51
G GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Battery Specific Gravity 1. Check the specific gravity of the electrolyte in each cell with a hydrometer. 2. When the electrolyte temperature differs from that at which the hydrometer was calibrated, correct the specific gravity reading following the formula mentioned in (Reference). 3. If the specific gravity is less than 1.215 (after it is corrected for temperature), charge or replace the battery. 4.
PAGE 52
G GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM [11] CHECK POINTS OF EVERY 800 HOURS Valve Clearance Q IMPORTANT • Valve clearance must be checked and adjusted when engine is cold. 1. Remove the head cover. 2. Align the “1TC” mark line (3) on the flywheel and projection (2) on the housing so that the No.1 piston comes to the compression or overlap top dead center. 3. Check the following valve clearance (1) marked with “,” using a feeler gauge. 4.
PAGE 53
G GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM [12] CHECK POINTS OF EVERY 1500 HOURS CAUTION • Check the injection pressure and condition after confirming that there is nobody standing in the direction the fume goes. • If the fume from the nozzle directly contacts the human body, cells may be destroyed and blood poisoning may be caused. Nozzle Spraying Condition [D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M, V2403-M-T] [D1703-M-BG, V2003-M-BG, V2003-M-T-BG, V2203-M-BG, V2403-M-BG] 1.
PAGE 54
G GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Fuel Injection Pressure [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. 2. Slowly move the tester handle to measure the pressure at which fuel begins jetting out from the nozzle. 3. If the measurement is not within the factory specifications, replace the adjusting washer (1) in the nozzle holder to adjust it.
PAGE 55
G GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Valve Seat Tightness [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. 2. Raise the fuel pressure, and keep at 12.75 MPa (130.0 kgf/cm2, 1849 psi) for 10 seconds. 3. If any fuel leak is found, replace the nozzle piece. Valve seat tightness Factory spec. No fuel leak at 12.75 MPa 130.
PAGE 56
G GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM [13] CHECK POINTS OF EVERY 3000 HOURS Checking Turbocharger (Turbine Side) 1. Check the exhaust port (2) and inlet port (3) side of turbine housing (1) to see if there is no exhaust gas leak. 2. If any gas leak is found, retighten the bolts and nuts or replace the gasket with new one. (Compressor Side) 1. Check the inlet hose (4) of the compressor cover (5) to see if there is no air leak. 2.
PAGE 57
G GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Checking Injection Pump [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 of Pump Element) 1. Remove the solenoid. 2. Remove the injection pipes and glow plugs. 3. Install the injection pump pressure tester to the injection pump. 4. Install the injection nozzle (2) jetted with the proper injection pressure to the injection pump pressure tester (1).
PAGE 58
G GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Checking Injection Pump [D1803-M-DI, V2403-M-DI, V2403-M-DI-T] (Fuel Tightness of Pump Element) 1. Remove the solenoid. 2. Remove the injection pipes and glow plugs. 3. Install the injection pump pressure tester to the injection pump. 4. Install the injection nozzle (2) jetted with the proper injection pressure to the injection pump pressure tester (1). (Refer to the figure.) 5. Set the speed control lever to the maximum speed position. 6.
PAGE 59
G GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM [14] CHECK POINTS OF EVERY 2 YEARS Replacing Intake Air Line 1. Loosen the clamp (2). 2. Remove the intake air hose (1) and clamp (2). 3. Replace new intake air hose (1) and new clamp (2). 4. Tighten the clamp (2). Q NOTE • To prevent serious damage to the engine, keep out any dust inside the intake air line.
PAGE 60
G GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Replacing Fuel Hoses and Clamp Bands 1. Loosen the clamp (2) and remove the fuel hose (1). 2. Replace new fuel hose (1) and new clamp (2). 3. Tighten the clamp (2). CAUTION • Stop the engine when attempting the check and change prescribed above. (When bleeding fuel system) 1. Fill the tank with fuel and open the cock (4). ([B] only.) 2. Loosen the air vent plug (3) of the fuel filter a few turns. 3. Screw back the plug when bubbles do not come up any more. 4.
PAGE 61
G GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Changing Radiator Coolant (L.L.C.) • 1. 2. 3. 4. 5. 6. 7. 8. 9. Q • • • • CAUTION Do not remove the radiator cap when the engine is hot. Then loosen cap slightly to the stop to relieve any excess pressure before removing cap completely. Stop the engine and let cool down. To drain the coolant, open the radiator drain plug (2) and remove the radiator cap (1). Then radiator cap (1) must be removed to completely drain the coolant.
PAGE 62
G GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Changing Radiator Coolant (L.L.C.) (Continued) (Anti-freeze) • There are two types of anti-freeze available: use the permanent type (PT) for this engine. • Before adding anti-freeze for the first time, clean the radiator interior by pouring fresh, soft water and draining it a few times. • The procedure for mixing water and anti-freeze differs according to the make of the anti-freeze and the ambient temperature.
PAGE 63
G GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM 5. SPECIAL TOOLS Diesel Engine Compression Tester [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] Code No: 07909-30208 (Assembly) 07909-31251 (G) 07909-30934 (A to F) 07909-31271 (I) 07909-31211 (E and F) 07909-31281 (J) 07909-31231 (H) Application: Use to measure diesel engine compression and diagnosis of need for major overhaul.
PAGE 64
G GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Q NOTE • The following special tools are not provided, so make them referring to the figure. Injection Pump Pressure Tester Application: Use to check fuel tightness of injection pumps. A Pressure gauge full scale : More than 29.4 MPa (300 kgf/cm2, 4267 psi) B PF 1/2 C Copper gasket D Flange (Material : Steel) E Hex. nut 27 mm (1.1 in.
PAGE 65
G GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Bushing Replacing Tools Application: Use to press out and to press fit the bushing. 1. For small end bushing A 162 mm (6.38 in.) B 35 mm (1.4 in.) C 27 mm (1.1 in.) D 35 mm dia. (1.4 in. dia.) E 27.90 to 27.95 mm dia. (1.099 to 1.100 in. dia.) F 25.00 to 25.01 mm dia. (0.9843 to 0.9846 in. dia.) 2. For idle gear bushing 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.
PAGE 66
G GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Socket Wrench for Crank Pulley Nut (46 mm Deep Socket Wrench) Application: Use to loosen and tighten the fan drive pulley mounting nut. 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.) W1044361 Auxiliary Socket for Fixing Crankshaft Sleeve Application: Use to fix the crankshaft sleeve of the diesel engine. A 80.
PAGE 67
G GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Auxiliary Socket for Fixing Crankshaft Sleeve (Continued) Application: Use to fix the crankshaft sleeve of the diesel engine. J 42.0 mm (1.65 in.) K 30.50 to 30.60 mm (1.201 to 1.204 in.) L 23.0 mm (0.906 in.) M 20.0 mm (0.787 in.) N 2.0 mm (0.079 in.) O 31.911 to 31.950 mm dia. (1.2564 to 1.2578 in. dia.) P 30.0 mm dia. (1.18 in. dia.) Q 5.0 mm dia. (0.20 in. dia.) R 0.09 rad (5 °) S 25.0 mm dia. (0.984 in. dia.) T 60.0 mm dia. (2.36 in.
PAGE 68
G GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Balancer Metal Replacing Tool (for Removing) Application: Use to remove the metal bearing. A 41 mm (1.6 in.) L 41.934 to 41.950 mm dia. (1.6510 to 1.6515 in. dia.) B 32.5 mm (1.28 in.) M 24.959 to 24.980 mm dia. (0.98264 to 0.98346 in. dia.) C Chamfer 0.3 mm (0.01 in.) N 21.947 to 21.960 mm dia. (0.86406 to 0.86456 in. dia.) D 25 mm dia. (0.98 in. dia.) O 36 mm (1.4 in.) E 46.950 to 46.975 mm dia. (1.8485 to 1.8494 in. dia.) P 5 mm (0.
PAGE 69
G GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Balancer Metal Replacing Tool (for Fitting) Application: Use to press fit the metal bearing. A 182 mm (7.17 in.) O 60 mm dia. (2.4 in. dia.) B 140 mm (5.51 in.) P 46.950 to 46.975 mm dia. (1.8485 to 1.8494 in. dia.) C 37 mm (1.5 in.) Q 43.934 to 43.950 mm dia. (1.7297 to 1.7303 in. dia.) D 35 mm dia. (1.4 in. dia.) R 140 mm (5.51 in.) E 60 mm dia. (2.4 in. dia.) S 36 mm (1.4 in.) F 10 mm (0.39 in.) T 60 mm dia. (2.4 in. dia.) G 0.
PAGE 70
G GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Idle Gear 2 Puller Application: Use for remove the idle gear 2 from the shaft. A 24 mm (0.94 in.) B 10 mm dia. (0.39 in. dia.) C 0.5 mm radius (0.02 in. radius) D M20 x Pitch 2.0 E 10 mm (0.39 in.) F 20 mm (0.79 in.) G 5 mm (0.2 in.) H 95 mm (3.7 in.) I 125 mm (4.92 in.) J 0.87 rad (50 °) K 5 mm (0.2 in.) L 60 mm radius (2.4 in. radius) M M20 x Pitch 2.0 N 30 mm (1.2 in.) O 10 mm (0.39 in.) P 10 mm (0.39 in.) Q 10 mm (0.39 in.
PAGE 71
MECHANISM CONTENTS 1. ENGINE BODY ............................................................................................... M-1 [1] PISTON...................................................................................................... M-1 [2] BUILT-IN DYNAMIC BALANCER (BALANCER MODEL ONLY).......... M-2 [3] HALF-FLOATING HEAD COVER ............................................................ M-3 2. COOLING SYSTEM ...................................................................................
PAGE 72
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM 1. ENGINE BODY [1] PISTON Piston’s skirt is coated with molybdenum disulfide+, which reduces the piston slap noise and thus the entire operating noise. +Molybdenum disulfide (MoS2) The molybdenum disulfide (1) serves as a solid lubricant, like a Graphite or Teflon. This material helps resist metal wears even with little lube oil.
PAGE 73
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM [2] BUILT-IN DYNAMIC BALANCER (BALANCER MODEL ONLY) Engine are sure to vibrate by piston’s reciprocation. Theoretically, three-cylinder engines are much less prone to cause vibration than four-cylinder ones (second inertia, etc.). However, any engine has many moving parts in addition to its pistons and cannot be completely free from vibration.
PAGE 74
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM [3] HALF-FLOATING HEAD COVER The rubber packing is fitted in to maintain the cylinder head cover 0.5 mm (0.02 in.) or so off the cylinder head. This arrangement helps reduce noise coming from the cylinder head.
PAGE 75
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM 2. COOLING SYSTEM [1] BOTTOM BYPASS SYSTEM Bottom bypass system is introduced in 03-M Series for improving the cooling performance of the radiator. While the temperature of coolant in the engine is low, the thermostat (1) is held closed and the coolant is allowed to flow through the bypass pipe and to circulate in the engine.
PAGE 76
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM 3. FUEL SYSTEM [1] GOVERNOR The governor serves to keep engine speed constant by automatically adjusting the amount of fuel supplied to the engine according to changes in the load. This engine employs an all-speed governor which controls the centrifugal force of the steel ball (1) weight, produced by rotation of the fuel camshaft (5), and the tension of the governor spring 1 (7) and 2 (8) are balanced.
PAGE 77
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM 4. TURBOCHARGER SYSTEM [1] BOOST COMPENSATOR (1) Injection Pump Assembly (2) Boost Compensator Assembly (3) Actuator (4) Solenoid (5) Plunger (6) Solenoid Guide (7) Hi-Idling Body W1014318 The higher the boost pressure rises, the more fuel is fed. In this way, the turbocharger proves itself for highpower performance. W1014402 When the boost pressure drops, excess fuel is cut down, allowing much less black emission.
PAGE 78
SERVICING CONTENTS 1. TROUBLESHOOTING ......................................................................................S-1 [1] ENGINE BODY ..........................................................................................S-1 [2] ELECTRONIC GOVERNOR ......................................................................S-5 2. SERVICING SPECIFICATIONS ......................................................................S-7 3. TIGHTENING TORQUES ....................................................
PAGE 79
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM 1.
PAGE 80
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Symptom Engine Revolution Is Not Smooth Probable Cause Solution Reference Page Fuel filter clogged or dirty Replace Air cleaner clogged Clean or replace Fuel leak due to loose injection pipe retaining nut Tighten retaining nut Injection pump malfunctioning Repair or replace Incorrect nozzle opening pressure Adjust (IDI) Repair or replace (DI) S-34, 49 S-34, 49 Injection nozzle stuck or clogged Repair or replace S-34, 49 Governor malfunct
PAGE 81
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Symptom Deficient Output Excessive Lubricant Oil Consumption Fuel Mixed into Lubricant Oil Water Mixed into Lubricant Oil Probable Cause Solution Reference Page Incorrect injection timing Adjust S-27, 28 Engine’s moving parts seem to be seizing Repair or replace – Injection pump malfunctioning Repair or replace S-29, 30, 31, 32, 54, 55 Deficient nozzle injection Repair or replace nozzle S-33, 34, 35, 49 Compression leak Check the compr
PAGE 82
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Symptom Low Oil Pressure High Oil Pressure Engine overheated Battery Quickly Discharged Probable Cause Solution Reference Page Engine oil insufficient Replenish G-8 Oil strainer clogged Clean S-63 Relief valve stuck with dirt Clean – Relief valve spring weaken or broken Replace – Excessive oil clearance of crankshaft bearing Replace S-70, 92, 93 Excessive oil clearance of crankpin bearing Replace S-64, 65, 91 Excessive oil clearan
PAGE 83
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM [2] ELECTRONIC GOVERNOR Q IMPORTANT • The engine trouble divides into an electronic governor, the main body of the engine, and the operating constancy. This manual describes it concerning the check of an electronic governor. Refer to WSM of engine and operator's manual if you cannot find trouble related to an electronic governor by checking an electronic governor. Engine will not start.
PAGE 84
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Blinking Pattern of Glow Lamp Cause Refer to Checking (1-Long and 1-Short) Overrunning (more than 115 %) Solenoid (1-Long and 2-Short) Low oil pressure Oil sensor (1-Long and 3-Short) Defect of alternator Alternator (1-Long and 4-Short) Coolant temperature is abnormal Water temperature sensor (1-Long and 5-Short) Emergency stop switch operated Emergency stop switch (2-Long and 1-Short) Abnormality of speed sensor Speed sensor (2-Long
PAGE 85
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM 2. SERVICING SPECIFICATIONS ENGINE BODY Item Factory Specification Allowable Limit 0.18 to 0.22 mm 0.0071 to 0.0086 in. – Compression Pressure (When Cranking with Starting Motor) [D1503-M], [D1703-M] [D1803-M], [V2003-M] [V2203-M], [V2403-M] [V2403-M-T] [D1703-M-BG], [V2003-M-BG] [V2003-M-T-BG], [V2203-M-BG] [V2403-M-BG] 3.24 to 3.72 MPa / 290 min-1 (rpm) 33.0 to 38.0 kgf/cm2 / 290 min-1 (rpm) 470 to 540 psi / 290 min-1 (rpm) 2.
PAGE 86
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM ENGINE BODY (Continued) Item Factory Specification Allowable Limit Clearance 0.040 to 0.070 mm 0.0016 to 0.0027 in. 0.10 mm 0.0039 in. Valve Stem O.D. 7.960 to 7.975 mm 0.3134 to 0.3139 in. – Valve Guide I.D. 8.015 to 8.030 mm 0.3156 to 0.3161 in.
PAGE 87
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM ENGINE BODY (Continued) Item Factory Specification Allowable Limit Open 0.35 rad (20 °) before T.D.C. – Close 0.79 rad (45 °) after B.D.C. – Open 0.2 rad (9 °) before T.D.C. – Close 0.68 rad (39 °) after B.D.C. – Open 1.0 rad (60 °) before B.D.C. – Close 0.21 rad (12 °) after T.D.C. – Valve Timing (Exhaust Valve) [D1703-M], [D1803-M] [V2203-M], [V2403-M] [V2403-M-BG] Open 0.99 rad (57 °) before B.D.C. – Close 0.
PAGE 88
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM ENGINE BODY (Continued) Item Factory Specification Allowable Limit Oil Clearance 0.016 to 0.045 mm 0.00063 to 0.0017 in. 0.10 mm 0.0039 in. Rocker Arm Shaft O.D. 13.973 to 13.984 mm 0.55012 to 0.55055 in. – Rocker Arm I.D. 14.000 to 14.018 mm 0.55119 to 0.55188 in. – – 0.25 mm 0.0098 in. Rocker Arm Shaft to Rocker Arm Push Rod Alignment Tappet to Tappet Guide Oil Clearance 0.020 to 0.062 mm 0.00079 to 0.0024 in. 0.07 mm 0.003 in.
PAGE 89
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM ENGINE BODY (Continued) Item Factory Specification Allowable Limit 0.070 to 0.22 mm 0.0028 to 0.0086 in. 0.30 mm 0.012 in. – 0.01 mm 0.0004 in. 33.27 mm 1.310 in. 33.22 mm 1.308 in. [V2003-M] [V2403-M-DI-T] [V2003-M-BG] [V2203-M-BG] 33.47 mm 1.318 in. 33.42 mm 1.316 in. [D1703-M], [D1803-M] [V2203-M], [V2403-M] [V2403-M-T] [D1803-M-DI], [V2403-M-DI] [V2003-M-T-BG] [V2403-M-BG] 33.90 mm 1.335 in. 33.85 mm 1.333 in. 33.00 mm 1.299 in. 33.
PAGE 90
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM ENGINE BODY (Continued) Item Factory Specification Allowable Limit Oil Clearance 0.0300 to 0.111 mm 0.00119 to 0.00437 in. 0.20 mm 0.0079 in. Balancer Shaft Journal 1 O.D. 43.934 to 43.950 mm 1.7297 to 1.7303 in. – Balancer Shaft Bearing 1 I.D. 43.980 to 44.045 mm 1.7315 to 1.7340 in. – Oil Clearance 0.0300 to 0.111 mm 0.00119 to 0.00437 in. 0.20 mm 0.0079 in. Balancer Shaft Journal 2 O.D. 41.934 to 41.950 mm 1.6509 to 1.6515 in.
PAGE 91
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM ENGINE BODY (Continued) Item Factory Specification Allowable Limit Top Ring [D1503-M], [V2003-M], [V2403-M-T] [D1803-M-DI], [V2403-M-DI] [V2403-M-DI-T] [V2003-M-BG], [V2003-M-T-BG], Ring Gap 0.20 to 0.35 mm 0.0079 to 0.013 in. 1.25 mm 0.0492 in. Top Ring [D1703-M], [D1803-M] [V2203-M], [V2403-M] [D1703-M-BG], [V2203-M-BG] [V2403-M-BG] Ring Gap 0.25 to 0.40 mm 0.0099 to 0.015 in. 1.25 mm 0.0492 in.
PAGE 92
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM ENGINE BODY (Continued) Item Factory Specification Allowable Limit Oil Clearance 0.0400 to 0.104 mm 0.00158 to 0.00409 in. 0.20 mm 0.0079 in. Crankshaft Journal O.D. 59.921 to 59.940 mm 2.3591 to 2.3598 in. – Crankshaft Bearing 2 I.D. 59.980 to 60.025 mm 2.3615 to 2.3631 in. – Oil Clearance 0.025 to 0.087 mm 0.00099 to 0.0034 in. 0.20 mm 0.0079 in. Crankpin O.D. 46.959 to 46.975 mm 1.8488 to 1.8494 in. – Crankpin Bearing I.D. 47.
PAGE 93
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM LUBRICATING SYSTEM Item Engine Oil Pressure Factory Specification Allowable Limit At Idle Speed More than 98 kPa 1.0 kgf/cm2 14 psi 50 kPa 0.5 kgf/cm2 7 psi At Rated Speed 300 to 440 kPa 3.0 to 4.5 kgf/cm2 43 to 64 psi 250 kPa 2.5 kgf/cm2 36 psi Engine Oil Pressure Switch Working Pressure 50 kPa 0.5 kgf/cm2 7 psi – Inner Rotor to Outer Rotor Clearance 0.030 to 0.14 mm 0.0012 to 0.0055 in. 0.2 mm 0.008 in.
PAGE 94
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM FUEL SYSTEM Item Factory Specification Allowable Limit Injection Pump [D1503-M], [V2003-M-T-BG] Injection Timing 0.253 to 0.279 rad (14.5 to 16.0 °) before T.D.C. – Injection Pump [D1703-M], [D1803-M] [V2003-M], [V2203-M] [V2403-M] Injection Timing 0.271 to 0.296 rad (15.5 to 17.0 °) before T.D.C. – Injection Pump [V2403-M-T] Injection Timing 0.132 to 0.157 rad (7.55 to 9.05 °) before T.D.C.
PAGE 95
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM FUEL SYSTEM (Continued) Item Factory Specification Allowable Limit Injection Nozzle [D1503-M], [D1703-M] [D1803-M], [V2003-M] [V2203-M], [V2403-M] [V2403-M-T] [D1703-M-BG], [V2003-M-BG] [V2003-M-T-BG], [V2203-M-BG] [V2403-M-BG] Injection Pressure 13.73 to 14.70 MPa 140.0 to 150.0 kgf/cm2 1992 to 2133 psi – Injection Nozzle [D1803-M-DI], [V2403-M-DI] [V2403-M-DI-T] Injection Pressure (1st stage) 18.64 to 20.10 MPa 190.0 to 205.
PAGE 96
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM ELECTRICAL SYSTEM Item Factory Specification Allowable Limit O.D. 30.0 mm 1.18 in. 29.0 mm 1.14 in. Commutator [D1803-M], [V2403-M] [V2403-M-DI], [V2403-M-T] [V2403-M-DI-T] [V2403-M-BG] O.D. 35.0 mm 1.38 in. 34.0 mm 1.34 in. Mica [D1503-M], [D1703-M] [D1803-M], [V2003-M] [V2203-M], [V2403-M] [V2403-M-T] [D1803-M-DI], [V2403-M-DI] [V2403-M-DI-T] [D1703-M-BG], [V2003-M-BG] [V2003-M-T-BG], [V2203-M-BG] Under Cut 0.45 to 0.75 mm 0.018 to 0.029 in.
PAGE 97
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM 3. TIGHTENING TORQUES Screws, bolts and nuts must be tightened to the specified torque using a torque wrench, several screws, bolts and nuts such as those used on the cylinder head must be tightened in proper sequence and the proper torque. [1] TIGHTENING TORQUES FOR GENERAL USE SCREWS, BOLTS AND NUTS When the tightening torques are not specified, tighten the screws, bolts and nuts according to the table below.
PAGE 98
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM [2] TIGHTENING TORQUES FOR SPECIAL USE SCREWS, BOLTS AND NUTS Q NOTE • For “*” marked screws, bolts and nuts on the table, apply engine oil to their threads and seats before tightening. • The letter “M” in Size x Pitch means that the screw, bolt or nut dimension stands for metric. The size is the nominal outside diameter in mm of the threads. The pitch is the nominal distance in mm between two threads. Item Size x Pitch N·m kgf·m lbf·ft M6 x 1.0 9.
PAGE 99
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING (1) Engine Body Compression Pressure [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. Run the engine until it is warmed up. 2. Stop the engine and disconnect the 2P connector from the stop solenoid in order not to inject fuel. 3. Remove the air cleaner, the muffler and all injection nozzles. 4.
PAGE 100
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Compression Pressure [D1803-M-DI, V2403-M-DI, V2403-M-DI-T] 1. Run the engine until it is warmed up. 2. Stop the engine and disconnect the 2P connector from the stop solenoid in order not to inject fuel. 3. Remove the air cleaner, the muffler and all glow plugs. 4. Set a compression tester (07909-39081) with the adaptor K (07909-31291) to the glow plug hole. 5. While cranking the engine with the starter, measure the compression pressure. 6.
PAGE 101
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Valve Clearance Q IMPORTANT • Valve clearance must be checked and adjusted when engine is cold. 1. Remove the head cover. 2. Align the “1TC” mark line (3) on the flywheel and projection (2) on the housing so that the No.1 piston comes to the compression or overlap top dead center. 3. Check the following valve clearance (1) marked with “,” using a feeler gauge. 4. If the clearance is not within the factory specifications, adjust with the adjusting screw.
PAGE 102
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM (2) Lubricating System Engine Oil Pressure 1. Remove the engine oil pressure switch, and set an oil pressure tester (Code No.: 07916-32032). (Adaptor screw size : PT 1/8) 2. Start the engine. After warming up, measure the oil pressure of both idling and rated speeds. 3. If the oil pressure is less than the allowable limit, check the following. • Engine oil insufficient.
PAGE 103
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Fan Belt Damage and Wear 1. Check the fan belt for damage. 2. If the fan belt is damaged, replace it. 3. Check if the fan belt is worn and sunk in the pulley groove. 4. If the fan belt is nearly worn out and deeply sunk in the pulley groove, replace it. (A) Good (B) Bad W1020602 CAUTION • When removing the radiator cap, wait at least ten minutes after the engine has stopped and cooled down. Otherwise, hot water may gush out, scalding nearby people.
PAGE 104
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Thermostat Valve Opening Temperature 1. Suspend the thermostat in the water by a string with its end inserted between the valve and seat. 2. Heating the water gradually, read the temperature when the valve opens and leaves the string. 3. Continue heating and read the temperature when the valve opens approx. 6 mm (0.2 in.). 4. If the measurement is not within the factory specifications, replace the thermostat.
PAGE 105
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM (4) Fuel System Injection Timing [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. Remove the stop solenoid. 2. Remove the injection pipes and nozzle. 3. Set the speed control lever to maximum fuel discharge position. (Reference) • Turn the flywheel with screwdriver. 4.
PAGE 106
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Injection Timing [D1803-M-DI, V2403-M-DI, V2403-M-DI-T] 1. Remove the stop solenoid. 2. Remove the injection pipes and nozzle. 3. Set the speed control lever to maximum fuel discharge position. (Reference) • Turn the flywheel with screwdriver. 4. Turn the flywheel counterclockwise (facing the flywheel) until the fuel fills up to the hole of the delivery valve holder for 1st cylinder. 5.
PAGE 107
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Fuel Tightness of 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] 1. Remove the solenoid. 2. Remove the injection pipes and glow plugs. 3. Install the injection pump pressure tester to the injection pump. 4. Install the injection nozzle (2) jetted with the proper injection pressure to the injection pump pressure tester (1). (Refer to the figure.) 5.
PAGE 108
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Fuel Tightness of Pump Element [D1803-M-DI, V2403-M-DI, V2403-M-DI-T] 1. Remove the solenoid. 2. Remove the injection pipes and glow plugs. 3. Install the injection pump pressure tester to the injection pump. 4. Install the injection nozzle (2) jetted with the proper injection pressure to the injection pump pressure tester (1). (Refer to the figure.) 5. Set the speed control lever to the maximum speed position. 6. Run the starter to increase the pressure.
PAGE 109
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Fuel Tightness of Delivery Valve [D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M, V2403-M-T] [D1703-M-BG, V2003-M-BG, V2003-M-T-BG, V2203-M-BG, V2403-M-BG] 1. Remove the solenoid. 2. Remove the injection pipes and glow plugs. 3. Set a pressure tester to the fuel injection pump. 4. Install the injection nozzle (2) jetted with the proper injection pressure to the injection pump pressure tester (1). 5. Run the starter to increase the pressure. 6.
PAGE 110
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Fuel Tightness of Delivery Valve [D1803-M-DI, V2403-M-DI, V2403-M-DI-T] 1. Remove the solenoid. 2. Remove the injection pipes and glow plugs. 3. Set a pressure tester to the fuel injection pump. 4. Install the injection nozzle (2) jetted with the proper injection pressure to the injection pump pressure tester (1). 5. Run the starter to increase the pressure. 6. Stop the starter when the fuel jets from the injection nozzle.
PAGE 111
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM CAUTION • Check the injection pressure and condition after confirming that there is nobody standing in the direction the fume goes. • If the fume from the nozzle directly contacts the human body, cells may be destroyed and blood poisoning may be caused. Nozzle Spraying Condition [D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M, V2403-M-T] [D1703-M-BG, V2003-M-BG, V2003-M-T-BG, V2203-M-BG, V2403-M-BG] 1.
PAGE 112
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Fuel Injection Pressure [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. 2. Slowly move the tester handle to measure the pressure at which fuel begins jetting out from the nozzle. 3. If the measurement is not within the factory specifications, replace the adjusting washer (1) in the nozzle holder to adjust it.
PAGE 113
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Valve Seat Tightness [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. 2. Raise the fuel pressure, and keep at 12.75 MPa (130.0 kgf/cm2, 1849 psi) for 10 seconds. 3. If any fuel leak is found, replace the nozzle piece. Valve seat tightness Factory spec. No fuel leak at 12.75 MPa 130.
PAGE 114
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM (5) Electrical System • • • • Q • CAUTION To avoid accidental short circuit, be sure to attach the positive cable to the positive terminal before the negative cable is attached to the negative terminal. Never remove the battery cap while the engine is running. Keep electrolyte away from eyes, hands and clothes. If you are spattered with it, wash it away completely with water immediately. Keep open sparks and flames away from the battery at all times.
PAGE 115
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Battery Specific Gravity 1. Check the specific gravity of the electrolyte in each cell with a hydrometer. 2. When the electrolyte temperature differs from that at which the hydrometer was calibrated, correct the specific gravity reading following the formula mentioned in (Reference). 3. If the specific gravity is less than 1.215 (after it is corrected for temperature), charge or replace the battery. 4.
PAGE 116
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Motor Test • 1. 2. 3. 4. 5. 6. 7. Q • • CAUTION Secure the starter to prevent it from jumping up and down while testing the motor. Disconnect the battery negative cable from the battery. Disconnect the battery positive cable from the battery. Disconnect the leads from the starter B terminal. Remove the starter from the engine. Connect a jumper lead from the starter C terminal (1) to the battery positive terminal (2).
PAGE 117
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Alternator on Unit Test (Before testing) • Before alternator on unit test, check the battery terminal connections, circuit connection, fan belt tension, charging indicator lamp, fuses on the circuit, and abnormal noise from the alternator. • Prepare full charged battery for the test. Q NOTE • Be careful not to touch the rotating engine parts while engine is running. Keep safety distance from the engine rotating parts. 1. Start the engine. 2.
PAGE 118
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Engine Stop Solenoid 1. Remove the engine stop solenoid from the engine. 2. Connect the jumper leads from the pulling coil P terminal to the switch (3), and from switch (3) to the battery positive terminal. 3. Connect the jumper leads from the holding coil H terminal to the switch (4), and from switch (4) to the battery positive terminal. 4. Connect the jumper leads from the engine stop solenoid body to the battery negative terminal. 5.
PAGE 119
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM (7) Electronic Governor Speed Sensor 1. Disconnect the speed sensor connector (2) (3P). 2. Check the state of the harness and if it is abnormal, please replace it. 3. Turn the key switch to the ACC position. 4. Measure the voltage between the terminals of the connector (2) (harness side). 5. When the measurements are the below table value. The ECU is normal. The speed sensor (1) is failure, then please replace it. 6.
PAGE 120
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Oil Pressure Switch 1. Disconnect the connector of the oil pressure switch connector (1P). 2. Check the state of the harness and if it is abnormal, please replace 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.
PAGE 121
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Solenoid 1. Disconnect the connector of solenoid (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 connector of solenoid (2) (harness side). 5. When the measurements are the below table value. The ECU is normal. Check the solenoid (1) according to the procedure of confirming the solenoid’s movement. 6.
PAGE 122
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Glow Plug Harness 1. Disconnect the glow plug terminal (1). 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 glow pulg terminal (1) of the connector (harness side) and chassis. 5. When the measurements are the below table value. The ECU is normal. Some of the glow plugs are failure, then please replace them. 6.
PAGE 123
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Emergency Stop Switch 1. Check the state of the harness and if it is abnormal, please replace it. 2. When the emergency stop switch is turned ON and OFF, measure the resistance between the emergency stop switch (terminal side) (1) of it each time. 3. When the measurements are the below table value. The emergency stop switch is normal. The ECU is failure, then please replace it. 4. When the measurements are out of the below table value.
PAGE 124
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM [2] DISASSEMBLING AND ASSEMBLING (1) Draining Oil and Coolant Draining Engine Oil 1. Start and warm up the engine for approx. 5 minutes. 2. Place an oil pan underneath the engine. 3. Remove the drain plug (1) to drain oil. 4. After draining, screw in the drain plug. (When refilling) • Fill the engine oil up to the upper line on the dipstick (2). Q IMPORTANT • Never mix two different types of oil.
PAGE 125
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Turbocharger (equipped with Turbocharger Model) CAUTION • While the engine is running and or just after it stops, the turbocharger is hot, be careful not to touch the turbocharger. Q NOTE • When detaching and attaching the turbocharger assembly, be very careful not to allow dust, dirt and other foreign matters in the oil pipes. • When the turbocharger assembly has been replaced, pour fresh engine oil through the oil filter port of the turbocharger.
PAGE 126
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM (3) Cylinder Head and Valves Cylinder Head Cover 1. Remove the lead (4). 2. Remove the breather hose (1). 3. Remove the head cover screws (3). 4. Remove the cylinder head cover (2). (When reassembling) • Check to see if the cylinder head cover gasket (5) is not defective. Tightening torque (1) (2) (3) (4) Cylinder head cover screw Breather Hose Cylinder Head Cover Head Cover Screw Lead 9.81 to 11.2 N·m 1.00 to 1.15 kgf·m 7.24 to 8.
PAGE 127
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Nozzle Holder Assembly and Glow Plug [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. Remove the overflow pipe assembly (3). 2. Remove the nozzle holder assemblies (4) using a 21 mm deep socket wrench. 3. Remove the copper gasket and heat seal (5). 4. Remove the glow plugs (2). (When reassembling) • Replace the copper gasket and heat seal with new one.
PAGE 128
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Nozzle Heat Seal Service Removal Procedure [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] Q IMPORTANT • Use a plus (phillips head) screw driver (1) that has a diameter which is bigger than the heat seal hole (Approx. 6 mm (1/4 in.)). 1. Drive screw driver (1) lightly into the heat seal hole. 2. Turn screw driver three or four times each way. 3.
PAGE 129
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Cylinder Head 1. Loosen the pipe clamp (2), and remove the water return pipe (1). 2. Remove the cylinder head screw in the order of (n or r) to (a). 3. Lift up the cylinder head (3) to detach. 4. Remove the cylinder head gasket (4). (When reassembling) • Replace the cylinder head gasket (4) with a new one. • Tighten the cylinder head screws after applying sufficient oil.
PAGE 130
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Cylinder Head (Continued) Q IMPORTANT • When replacing piston, piston pin, small end bushing, connecting rod, or crankpin bearings, measure piston head’s protrusion or recessing from the level of crankcase cylinder face (average of all pistons) after installing the pistons, and select the cylinder head gasket following the below table. Selecting the cylinder head gasket 1.
PAGE 131
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Valves 1. Remove the valve caps (3). 2. Remove the valve spring collet (4), pushing the valve spring retainer (5) by valve spring replacer (1). 3. Remove the valve spring retainer (5), valve spring (6) and valve stem seal (2). 4. Remove the valve (7). (When reassembling) • Wash the valve stem and valve guide hole, and apply engine oil sufficiently.
PAGE 132
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM (4) Gear Case and Timing Gears Injection Pump (for Non Turbocharger Model) 1. Remove the solenoid (4) and hi-idling body (1). 2. Remove the engine stop lever (3) and solenoid guide (6). 3. Remove the fuel injection pump assembly (2). Q IMPORTANT • Before removing the injection pump assembly (2), be sure to remove the solenoid (4), hi-idling body (1), engine stop lever (3) and solenoid guide (6).
PAGE 133
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Injection Pump (for Turbocharger Model) 1. Remove the boost compensator assembly (2). 2. Remove the hi-idling body (4). 3. Remove the solenoid (3). 4. Remove the solenoid guide (5). 5. Remove the injection pump assembly (1). Q IMPORTANT • Before removing the injection pump assembly (1), be sure to remove the boost compensator assembly (2), hi-idling body (4), solenoid (3) and solenoid guide (5).
PAGE 134
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Governor Springs and Speed Control Plate Q NOTE • Specific tool (1) : 1.2 mm diameter hard wire with its end hooked, overall length 200 mm (7.87 in.). The tip of wire is bent like the hook to hang governor springs. 1. Remove the injection pump cover. 2. Remove the speed control plate (6) mounting nuts and bolts. 3. Using the specific tool (1), undo the large governor spring (3) from the fork lever (2). 4.
PAGE 135
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Governor Springs and Speed Control Plate (Continued) (When reassembling) • Hook the small spring (4) first and then the large governor spring (3) on the speed control plate (6). • Put the specific tool (1) from the injection pump side to catch the large governor spring (3). Keep this spring slightly extended and place the speed control plate (6) in its specified position.
PAGE 136
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Fan Drive Pulley 1. Lock the flywheel not to turn using the flywheel stopper. 2. Remove the fan drive pulley mounting nut (1) using 46 mm deep socket wrench (3). 3. Remove the fan drive pulley (2) with gear puller (4). 4. Remove the feather key. (When reassembling) • Apply grease to the splines of coupling. Tightening torque (1) Nut (2) Fan Drive Pulley Fan drive pulley mounting nut 138 to 156 N·m 14.0 to 16.
PAGE 137
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Idle Gear 2 and Hydraulic Pump Base Assembly (for Side PTO Model) 1. Remove the hour meter gear case (if equipped). 2. Remove the gear case cover (1). 3. Remove the hydraulic pump base assembly (2). 4. Remove the idle gear 2 stopper (3). 5. Remove the idle gear 2 (4) using the puller (5). 6. Remove the idle gear 2 shaft (7). (When reassembling) • Replace the washer (6) and gear case cover gasket. • Replace the gear case cover gasket with new one.
PAGE 138
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Gear Case (for Side PTO Model) 1. Remove the gear case (1). 2. Remove the O-rings (2). (When reassembling) • Replace the gear case gasket and O-rings. • Check to see if there are four O-rings (2) inside the gear case (1). • Apply a thin film of engine oil to the oil seal, and install it, noting the lip come off. • Before installing the gear case gasket, apply a non-drying adhesive. (1) Gear Case (2) O-rings W1034671 Gear Case 1.
PAGE 139
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Idle Gear (For Balancer Model) 1. Remove the external snap ring. 2. Detach the idle gear collar. 3. Detach the idle gear (2).
PAGE 140
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Fuel Camshaft and Fork Lever Assembly 1. Remove the fuel feed pump. 2. Detach the fuel camshaft stopper (1). 3. Remove the three fork lever holder mounting screws (2). 4. Draw out the fuel camshaft assembly (5), (6) and fork lever assembly (3), (4), (7) at the same time. (When reassembling) • After installation, check to see that the fork lever 1 (3) and lever 2 (4) are fixed to the fork lever shaft, and that they can turn smoothly in the holder (7).
PAGE 141
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM (5) Piston and Connecting Rod Oil Pan and Oil Strainer 1. Remove the oil pan mounting screws. 2. Remove the oil pan (3) by lightly tapping the rim of the pan with a wooden hammer. 3. Remove the oil pan gasket (2). 4. Remove the oil strainer (1) and O-ring (4). (When reassembling) • After cleaning the oil strainer (1), check to see that the filter mesh in clean, and install it. • Visually check the O-ring (4), apply engine oil, and install it.
PAGE 142
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Pistons [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. Completely clean carbon (1) in the cylinders. 2. Remove the connecting rod cap (3). 3. Turn the flywheel and bring the piston to top dead center. 4. Draw out the piston upward by lightly tapping it from the bottom of the crankcase with the grip of a hammer. 5. Draw out the other piston in the same method as above.
PAGE 143
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Pistons [D1803-M-DI, V2403-M-DI, V2403-M-DI-T] 1. Completely clean carbon (1) in the cylinders. 2. Remove the connecting rod cap (3). 3. Turn the flywheel and bring the piston to top dead center. 4. Draw out the piston upward by lightly tapping it from the bottom of the crankcase with the grip of a hammer. 5. Draw out the other piston in the same method as above.
PAGE 144
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Piston Ring and Connecting Rod [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. Remove the piston rings (1), (2), (3) using a piston ring tool. 2. Remove the piston pin (9), and separate the connecting rod (7) from the piston (6).
PAGE 145
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Piston Ring and Connecting Rod [D1803-M-DI, V2403-M-DI, V2403-M-DI-T] 1. Remove the piston rings (1), (2), (3) using a piston ring tool. 2. Remove the piston pin (8), and separate the connecting rod (6) from the piston (5). (When reassembling) • When installing the ring, assemble the rings so that the manufacturer’s mark (12) near the gap faces the top of the piston (5).
PAGE 146
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM (6) Flywheel and Crankshaft Flywheel 1. Fit the stopper to the flywheel (1). 2. At first, remove two pieces of the flywheel screws (2). 3. Insert two pieces of the flywheel guide screws (3) in the holes. 4. Remove the all flywheel screws (2). 5. Remove the flywheel (1) slowly along the flywheel guide screws (3). (When reassembling) • Insert two pieces of the flywheel guide screws (3).
PAGE 147
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Crankshaft Q NOTE • Before disassembling, check the side clearance of crankshaft. Also check it during reassembling. For D1503-M, D1703-M, V2003-M, V2203-M, D1703-M-BG, V2003-M-BG, V2003-M-T-BG and V2203-M-BG 1. Remove the main bearing case screw 2 (1). 2. Pull out the crankshaft assembly, taking care not to damage the crankshaft bearing 1 (3). For D1803-M and D1803-M-DI 1. Remove the main bearing case screw 2 (1). 2.
PAGE 148
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Main Bearing Case Assembly 1. Remove the two main bearing case screws 1 (7), and remove the main bearing case assembly being careful with thrust bearing and crankshaft bearing. 2. Remove the main bearing case 1, 2 as above. (When reassembling) • Clean the oil passage in the main bearing case. • Apply clean engine oil on the bearings. • Install the main bearing case assemblies in the original positions.
PAGE 149
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM (7) Starter (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) Through Bolt Brush C Terminal Nut Yoke Armature Overrunning Clutch Idle Gear End Frame Brush Holder Magnet Switch Cover Plunger B Terminal Nut Housing W1222714 1. Unscrew the C terminal nut (3), and disconnect the connecting lead. 2. Remove the two through bolts (1). 3. Detach the motor. 4. Remove the end frame (8). 5. Remove the brush from the brush holder while holding the spring up.
PAGE 150
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM (8) Alternator (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) Pulley Drive End Frame Stator Bearing Retainer Plate Rotor Bearing Rear End Frame Rectifier IC Regulator Brush Holder Rear End Cover W1224079 1. Remove the pulley (1). 2. Remove the rear end cover (12). 3. Remove the brush holder (11). 4. Remove the IC regulator (10). 5. Remove the four screws holding the stator lead wires. 6. Remove the rectifier (9). 7. Remove the rear end frame (8). 8.
PAGE 151
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM [3] SERVICING (1) Cylinder Head and Valves Top Clearance 1. Remove the cylinder head. 2. Move the piston up and stick a strip of fuse on the piston head at three position with grease. 3. Lower the piston and install the cylinder head. (Use a new cylinder head gasket and tighten with a specified tightening torque.) 4. Turn the flywheel until the piston exceeds top dead center. 5. Remove the cylinder head and measure the thickness of the fuses. 6.
PAGE 152
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Cylinder Head Surface Flatness 1. Clean the cylinder head surface. 2. Place a straightedge on the cylinder head’s four sides (A), (B), (C) and (D) and two diagonal (E) and (F) as shown in the figure. 3. Measure the clearance with a feeler gauge. 4. If the measurement exceeds the allowable limit, correct it with a surface grinder. Q IMPORTANT • Do not place the straightedge on the combustion chamber. • Be sure to check the valve recessing after correcting.
PAGE 153
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Valve Recessing 1. Clean the cylinder head surface, valve face and valve seat. 2. Insert the valve into the valve guide. 3. Measure the valve recessing with a depth gauge. 4. If the measurement exceeds the allowable limit, replace the valve. 5. If it still exceeds the allowable limit after replacing the valve, replace the cylinder head. Factory spec.
PAGE 154
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Clearance between Valve Stem and Valve Guide 1. Remove carbon from the valve guide section. 2. Measure the valve stem O.D. with an outside micrometer. 3. Measure the valve guide I.D. with a small hole gauge, and calculate the clearance. 4. If the clearance exceeds the allowable limit, replace the valves. If it still exceeds the allowable limit, replace the valve guide. Clearance between valve stem and valve guide Factory spec. 0.040 to 0.070 mm 0.
PAGE 155
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Valve Seating 1. Coat the valve face lightly with prussian blue and put the valve on its seat to check the contact. 2. If the valve does not seat all the way around the valve seat or the valve contact is less than 70 %, correct the valve seating as follows. 3. If the valve contact does not comply with the reference value, replace the valve or correct the contact of valve seating. Valve seat width (1) Correct (2) Incorrect Factory spec. 2.12 mm 0.
PAGE 156
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Correcting Valve and Valve Seat Q NOTE • Before correcting the valve and seat, check the valve stem and the I.D. of valve guide section, and repair them if necessary. • After correcting the valve seat, be sure to check the valve recessing. 1) Correcting Valve 1. Correct the valve with a valve refacer.
PAGE 157
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Valve Lapping 1. Apply compound evenly to the valve lapping surface. 2. Insert the valve into the valve guide. Lap the valve onto its seat with a valve flapper or screwdriver. 3. After lapping the valve, wash the compound away and apply oil, then repeat valve lapping with oil. 4. Apply prussian blue to the contact surface to check the seated rate. If it is less than 70 %, repeat valve lapping again.
PAGE 158
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM 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.
PAGE 159
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM (2) Timing Gears Timing Gear Backlash 1. Set a dial indicator (lever type) with its tip on the gear tooth. 2. Move the gear to measure the backlash, holding its mating gear. 3. If the backlash exceeds the allowable limit, check the oil clearance of the shafts and the gear. 4. If the oil clearance is proper, replace the gear.
PAGE 160
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Camshaft Side Clearance 1. Set a dial indicator with its tip on the camshaft. 2. Measure the side clearance by moving the cam gear to the front to rear. 3. If the measurement exceeds the allowable limit, replace the camshaft stopper. 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. W1030012 Camshaft Alignment 1. Support the camshaft with V blocks on the surface plate at both end journals.
PAGE 161
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Cam Height 1. Measure the height of the cam at its highest point with an outside micrometer. 2. If the measurement is less than the allowable limit, replace the camshaft. Factory spec. Cam height of intake Allowable limit 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.
PAGE 162
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Cam Height (Continued) 1. Measure the height of the cam at its highest point with an outside micrometer. 2. If the measurement is less than the allowable limit, replace the camshaft. Factory spec. Cam height of exhaust Allowable limit 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.
PAGE 163
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Oil Clearance between Idle Gear Shaft and Idle Gear Bushing 1. Measure the idle gear shaft O.D. with an outside micrometer. 2. Measure the idle gear bushing I.D. with an inside micrometer, 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 idle gear shaft. Oil clearance between idle gear shaft and idle gear bushing Factory spec. 0.025 to 0.
PAGE 164
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Oil Clearance of Balancer Shaft Journal (for Balancer Model Only) 1. Measure the balancer shaft journal O.D. with an outside micrometer. 2. Measure the cylinder block bore I.D. for balancer shaft with an inside micrometer or cylinder gauge. 3. If the clearance exceeds the allowable limit, replace the balancer shaft. Factory spec. 0.0300 to 0.111 mm 0.00119 to 0.00437 in. Allowable limit 0.20 mm 0.0079 in. Balancer shaft journal 1 O.D. Factory spec.
PAGE 165
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Oil Clearance between Piston Pin and Small End Bushing 1. Measure the piston pin O.D. where it contacts the bushing with an outside micrometer. 2. Measure the small end bushing I.D. with an inside micrometer, 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 piston pin. Oil clearance between piston pin and small end bushing Factory spec. 0.
PAGE 166
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Piston Ring Gap 1. Insert the piston ring into the lower part of the liner (the least worn out part) with the piston. 2. Measure the ring gap with a feeler gauge. 3. If the gap exceeds the allowable limit, replace the ring. Top ring Factory spec. D1503-M V2003-M V2403-M-T D1803-M-DI V2403-M-DI V2403-M-DI-T V2003-M-BG V2003-M-T-BG 0.20 to 0.35 mm 0.0079 to 0.013 in. D1703-M D1803-M V2203-M V2403-M D1703-M-BG V2203-M-BG V2403-M-BG 0.25 to 0.40 mm 0.
PAGE 167
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Clearance between Piston Ring and Groove 1. Clean the rings and the ring grooves, and install each ring in its groove. 2. Measure the clearance between the ring and the groove with a feeler gauge or depth gauge. 3. If the clearance exceeds the allowable limit, replace the piston ring. 4. If the clearance still exceeds the allowable limit with new ring, replace the piston. Top Ring Factory spec. D1803-M-DI V2403-M-DI 0.20 mm 0.0079 in.
PAGE 168
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM (4) Crankshaft Side Clearance of Crankshaft 1. Set a dial indicator with its tip on the end of the crankshaft. 2. Measure the side clearance by moving the crankshaft to the front and rear. 3. If the measurement exceeds the allowable limit, replace the thrust bearings. 4. If the same size bearing is useless because of the crankshaft journal wear, replace it with an oversize one referring to the table and figure. Crankshaft side clearance Factory spec. 0.
PAGE 169
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Oil Clearance between Crankpin and Crankpin Bearing 1. Clean the crankpin and crankpin bearing. 2. Put a strip of plastigage on the center of the crankpin. 3. Install the connecting rod cap and tighten the connecting rod screws to the specified torque, and remove the cap again. 4. Measure the amount of the flattening with the scale, and get the oil clearance. 5. If the oil clearance exceeds the allowable limit, replace the crankpin bearing. 6.
PAGE 170
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Oil Clearance between Crankshaft Journal and Crankshaft Bearing 1 1. Measure the O.D. of the crankshaft journal with an outside micrometer. 2. Measure the I.D. of the crankshaft bearing 1 with an inside micrometer, and calculate oil clearance. 3. If the clearance exceeds the allowable limit, replace the crankshaft bearing 1. 4.
PAGE 171
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Oil Clearance between Crankshaft Journal and Crankshaft Bearing 2 1. Put a strip of plastigage on the center of the journal. 2. Install the bearing case and tighten the baring case screws 1 to the specified torque, and remove the bearing case again. 3. Measure the amount of the flattening with the scale and get the oil clearance. 4. If the clearance exceeds the allowable limit, replace the crankshaft bearing 2. 5.
PAGE 172
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Replacing Crankshaft Sleeve 1. Remove the used crankshaft sleeve (3). 2. Set the sleeve guide (2) to the crankshaft (5). 3. Set the stopper (1) to the crankshaft (5) as shown in figure. 4. Heat a new sleeve to a temperature between 150 and 200 °C (302 and 392 °F), and fix the sleeve to the crankshaft (5) as shown in figure. 5. Press fit the sleeve using the auxiliary socket for pushing (4). (Refer to “SPECIAL TOOLS”.
PAGE 173
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM (5) Cylinder Cylinder Wear 1. Measure the I.D. of the cylinder at the six positions (see figure) with a cylinder gauge to find the maximum and minimum I.D.’s. 2. Get the difference (Maximum wear) between the maximum and the minimum I.D.’s. 3. If the wear exceeds the allowable limit, bore and hone to the oversize dimension. (Refer to “Correcting Cylinder”.) 4. Visually check the cylinder wall for scratches.
PAGE 174
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Correcting Cylinder (Oversize) 1. When the cylinder is worn beyond the allowable limit, bore and hone it to the specified dimension. Factory spec. Oversize cylinder I.D. Allowable limit Finishing 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.
PAGE 175
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM (6) Oil Pump Rotor Lobe Clearance 1. Measure the clearance between lobes of the inner rotor and the outer rotor with a feeler gauge. 2. Measure the clearance between the outer rotor and the pump body with a feeler gauge. 3. If the clearance exceeds the factory specifications, replace the oil pump rotor assembly. Clearance between inner rotor and outer rotor Factory spec. 0.030 to 0.14 mm 0.0012 to 0.0055 in. Allowable limit 0.2 mm 0.008 in.
PAGE 176
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Commutator and Mica 1. Check the contact of the commutator for wear, and grind the commutator with emery paper if it is slightly worn. 2. Measure the commutator O.D. with an outside micrometer at several points. 3. If the minimum O.D. is less than the allowable limit, replace the armature. 4. If the difference of the O.D.'s exceeds the allowable limit, correct the commutator on a lathe to the factory specification. 5. Measure the mica undercut. 6.
PAGE 177
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Commutator and Mica (Continued) 1. Check the contact of the commutator for wear, and grind the commutator with emery paper if it is slightly worn. 2. Measure the commutator O.D. with an outside micrometer at several points. 3. If the minimum O.D. is less than the allowable limit, replace the armature. 4. If the difference of the O.D.'s exceeds the allowable limit, correct the commutator on a lathe to the factory specification. 5.
PAGE 178
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Brush Holder 1. Check the continuity across the brush holder and the holder support with a circuit tester. 2. If it conducts, replace the brush holder. W1156895 Armature Coil 1. Check the continuity across the commutator and armature coil core with resistance range of circuit tester. 2. If it conducts, replace the armature. 3. Check the continuity across the segments of the commutator with resistance range of circuit tester. 4.
PAGE 179
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM (8) Alternator Bearing 1. Check the bearing for smooth rotation. 2. If it does not rotate smoothly, replace it. W1019790 Stator 1. Measure the resistance across each lead of the stator coil with resistance range of circuit tester. 2. If the measurement is not within factory specification, replace it. 3. Check the continuity across each stator coil lead and core with resistance range of circuit tester. 4. If infinity is not indicated, replace it.
PAGE 180
DIESEL ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM Rectifier 1. Check the continuity across each diode of rectifier with resistance range of circuit tester. 2. The rectifier is normal if the diode in the rectifier conducts in one direction and does not conduct in the reverse direction. W1020452 IC Regulator 1. Check the continuity across the B terminal (2) and the F terminal (1) of IC regulator with resistance range of circuit tester. 2.
PAGE 181
EDITOR: KUBOTA FARM & INDUSTRIAL MACHINERY SERVICE, LTD. 64, ISHIZU-KITAMACHI, SAKAI-KU, SAKAI-CITY, OSAKA, 590-0823, JAPAN PHONE : (81)72-241-1129 FAX : (81)72-245-2484 E-mail : ksos-pub@kubota.co.jp KUBOTA Corporation Printed in Japan 2008. 07, S, EI, EI, e 2007. 03, S, EI, EI, e Code No.