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WORKSHOP MANUAL
DIESEL ENGINE
03-M-DI-E2B SERIES
KiSC issued 02, 2007 A
TO THE READER
This Workshop Manual has been prepared to provide servicing personnel with
information on the mechanism, service and maintenance of 03-M-DI-E2B series. It is
divided into three parts, “General”, “Mechanism” and “Servicing”.
■ General
Information on the engine identification, the general precautions, maintenance check
list, check and maintenance and special tools are described.
■ Mechanism
Information on the construction and function are included. This part should be
understood before proceeding with troubleshooting, disassembling and servicing.
Refer to Diesel Engine Mechanism Workshop Manual (Code No. 9Y021-01874) for
the one which has not been described to this workshop manual.
■ Servicing
Information on the troubleshooting, servicing specification lists, tightening torque,
checking and adjusting, disassembling and assembling, and servicing which cover
procedures, precautions, factory specifications and allowable limits.
All information illustrations and specifications contained in this manual are based on
the latest product information available at the time of publication.
The right is reserved to make changes in all information at any time without notice.
Due to covering many models of this manual, information or picture being used have
not been specified as one model.
February 2004
© KUBOTA Corporation 2004
KiSC issued 02, 2007 A
1
03-M-DI-E2B, WSM SAFETY INSTRUCTIONS
SAFETY INSTRUCTIONS
BEFORE SERVICING AND REPAIRING
• Read all instructions and safety instructions in this
manual and on your engine safety decals.
• Clean the work area and engine.
• Park the machine on a firm and level ground.
• Allow the engine to cool before proceeding.
• Stop the engine, and remove the key.
• Disconnect the battery negative cable.
• Hang a “DO NOT OPERATE” tag in operator
station.
SAFETY FIRST
This symbol, the 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.
DANGER : Indicates an imminently hazardous situation which, if not avoided, will result in
death or serious injury.
WARNING : Indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION : Indicates a potentially hazardous situation which, if not avoided, may result in
minor or moderate injury.
■ IMPORTANT : Indicates that equipment or property damage could result if instructions are not
followed.
■ NOTE : Gives helpful information.
KiSC issued 02, 2007 A
2
03-M-DI-E2B, WSM SAFETY INSTRUCTIONS
SAFETY STARTING
• Do not start the engine by shorting across starter
terminals or bypassing the safety start switch.
• Unauthorized modifications to the engine may impair
the function and / or safety and affect engine life.
SAFETY WORKING
• Do not work on the machine while under the influence
of alcohol, medication, or other substances or while
fatigued.
• Wear close fitting clothing and safety equipment
appropriate to the job.
• Use tools appropriate to the work. Makeshift tools,
parts, and procedures are not recommended.
• When servicing is performed together by two or more
persons, take care to perform all work safely.
• Do not touch the rotating or hot parts while the engine
is running.
• Never remove the radiator cap while the engine is
running, or immediately after stopping. Otherwise, hot
water will spout out from radiator. Only remove
radiator cap when cool enough to touch with bare
hands. Slowly loosen the cap to first stop to relieve
pressure before removing completely.
• Escaping fluid (fuel or hydraulic oil) under pressure
can penetrate the skin causing serious injury. Relieve
pressure before disconnecting hydraulic or fuel lines.
Tighten all connections before applying pressure.
• Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable
or uncomfortable loud noises.
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.
KiSC issued 02, 2007 A
3
03-M-DI-E2B, WSM SAFETY INSTRUCTIONS
VENTILATE WORK AREA
• If the engine must be running to do some work, make
sure the area is well ventilated. Never run the engine
in a closed area. The exhaust gas contains poisonous
carbon monoxide.
DISPOSE OF FLUIDS PROPERLY
• Do not pour fluids into the ground, down a drain, or
into a stream, pond, or lake. Observe relevant
environmental protection regulations when disposing
of oil, fuel, coolant, electrolyte and other harmful
waste.
PREVENT ACID BURNS
• Sulfuric acid in battery electrolyte is poisonous. It is
strong enough to burn skin, clothing and cause
blindness if splashed into eyes. Keep electrolyte
away from eyes, hands and clothing. If you spill
electrolyte on yourself, flush with water, and get
medical attention immediately.
PREPARE FOR EMERGENCIES
• Keep a first aid kit and fire extinguisher handy at all
times.
• Keep emergency numbers for doctors, ambulance
service, hospital and fire department near your
telephone.
KiSC issued 02, 2007 A
4
03-M-DI-E2B, WSM SPECIFICATIONS
SPECIFICATIONS
* The specification described above is of the standard engine of each model.
* Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW
W10275180
Model D1503-M-DI D1503-M-DI-T
Number of Cylinders 3
Type Vertical, Water-cooled, 4 cycle diesel engine
Bore × Stroke 83 × 92.4 mm (3.27 × 3.64 in.)
Total Displacement 1499 cm3 (91.47 cu.in.)
ISO Net Continuous 20.6 kW / 2800 min-1
(rpm)
(27.6 HP / 2800 min-1 (rpm))
27.0 kW / 2800 min-1
(rpm)
(36.2 HP / 2800 min-1 (rpm))
ISO/SAE Net Intermittent 23.7 kW / 2800 min-1 (rpm)
(31.8 HP / 2800 min-1
(rpm))
31.1 kW / 2800 min-1 (rpm)
(41.7 HP / 2800 min-1
(rpm))
SAE Gross Intermittent 24.9 kW / 2800 min-1 (rpm)
(33.4 HP / 2800 min-1
(rpm))
32.4 kW / 2800 min-1 (rpm)
(43.4 HP / 2800 min-1
(rpm))
Maximum Bare Speed 3000 min-1
(rpm)
Minimum Bare Idling Speed 850 to 950 min-1 (rpm)
Combustion Chamber Reentrant Type (Direct Injection)
Fuel Injection Pump Bosch “K” Type Mini Pump
Governor All speed mechanical governor
Direction of Rotation Counter-clockwise (viewed from flywheel side)
Injection Nozzle Bosch “P” Type Hole Nozzle
Injection Timing 0.127 rad (7.25 °) before T.D.C. 0.135 rad (7.75 °) before T.D.C.
Firing Order 1-2-3
Injection
Pressure
1st Stage 18.6 MPa (190 kgf/cm2
, 2702 psi)
2nd Stage 22.6 MPa (230 kgf/cm2
, 3271 psi)
Compression Ratio 20 : 1
Lubricating System Forced Lubrication by Trochoid Pump
Oil Pressure Indicating Electrical type switch
Lubricating Filter Full flow paper filter (cartridge type)
Cooling System Pressurized radiator, forced circulation with water pump
Starting System Electric Starting with Starter
Starting Motor 12 V, 1.2 kW
Starting Support Device By glow plug in combustion chamber
Battery 12 V, 60 AH equivalent
Charging Alternator 12 V, 360 W
Fuel Diesel Fuel No.2-D (ASTM D975)
Lubricating Oil Class CF lubricating oil as per API classification is recommended.
If this class of lubricating oil is not available, preferably use Class CD or CE lubricating oil.
For details on recommended lubricating oils, see page G-5, 13.
Lubricating Oil
Capacity
Oil Pan Depth
90 mm (3.54 in.)
5.6 L (1.48 U.S.gals)
Oil Pan Depth
124 mm (4.88 in.)
7.0 L (1.85 U.S.gals)
Weight (Dry) 148 kg (326 lbs) 152 kg (335 lbs)
KiSC issued 02, 2007 A
5
03-M-DI-E2B, WSM SPECIFICATIONS
* The specification described above is of the standard engine of each model.
* Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW
W10314320
Model D1703-M-DI D1803-M-DI
Number of Cylinders 3
Type Vertical, Water-cooled, 4 cycle diesel engine
Bore × Stroke 87 × 92.4 mm (3.43 × 3.64 in.) 87 × 102.4 mm (3.43 × 4.03 in.)
Total Displacement 1647 cm3
(100.51 cu.in.) 1826 cm3
(111.43 cu.in.)
ISO Net Continuous 22.7 kW / 2800 min-1
(rpm)
(30.4 HP / 2800 min-1
(rpm))
23.9 kW / 2600 min-1
(rpm)
(32.0 HP / 2600 min-1
(rpm))
ISO/SAE Net Intermittent 26.1 kW / 2800 min-1
(rpm)
(35.0 HP / 2800 min-1 (rpm))
27.2 kW / 2600 min-1
(rpm)
(36.5 HP / 2600 min-1 (rpm))
SAE Gross Intermittent 27.4 kW / 2800 min-1
(rpm)
(36.7 HP / 2800 min-1 (rpm))
28.4 kW / 2600 min-1
(rpm)
(38.1 HP / 2600 min-1 (rpm))
Maximum Bare Speed 3000 min-1 (rpm) 2800 min-1 (rpm)
Minimum Bare Idling Speed 850 to 950 min-1
(rpm)
Combustion Chamber Reentrant Type (Direct Injection)
Fuel Injection Pump Bosch “K” Type Mini Pump
Governor All speed mechanical governor
Direction of Rotation Counter-clockwise (viewed from flywheel side)
Injection Nozzle Bosch “P” Type Hole Nozzle
Injection Timing 0.134 rad (7.7 °) before T.D.C. 0.096 rad (5.5 °) before T.D.C.
Firing Order 1-2-3
Injection
Pressure
1st Stage 18.6 MPa (190 kgf/cm2
, 2702 psi)
2nd Stage 22.6 MPa (230 kgf/cm2
, 3271 psi)
Compression Ratio 20 : 1
Lubricating System Forced Lubrication by Trochoid Pump
Oil Pressure Indicating Electrical type switch
Lubricating Filter Full flow paper filter (cartridge type)
Cooling System Pressurized radiator, forced circulation with water pump
Starting System Electric Starting with Starter
Starting Motor 12 V, 1.2 kW 12 V, 1.4 kW
Starting Support Device By glow plug in combustion chamber
Battery 12 V, 60 AH equivalent 12 V, 88 AH equivalent
Charging Alternator 12 V, 480 W
Fuel Diesel Fuel No.2-D (ASTM D975)
Lubricating Oil Class CF lubricating oil as per API classification is recommended.
If this class of lubricating oil is not available, preferably use Class CD or CE lubricating oil.
For details on recommended lubricating oils, see page G-5, 13.
Lubricating Oil
Capacity
Oil Pan Depth
90 mm (3.54 in.)
5.6 L (1.48 U.S.gals)
Oil Pan Depth
124 mm (4.88 in.)
7.0 L (1.85 U.S.gals)
Weight (Dry) 148 kg (326 lbs) 151 kg (333 lbs)
KiSC issued 02, 2007 A
6
03-M-DI-E2B, WSM SPECIFICATIONS
* The specification described above is of the standard engine of each model.
* Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW
W10329950
Model V2203-M-DI V2003-M-DI-T
Number of Cylinders 4
Type Vertical, Water-cooled, 4 cycle diesel engine
Bore × Stroke 87 × 92.4 mm (3.43 × 3.64 in.) 83 × 92.4 mm (3.27 × 3.64 in.)
Total Displacement 2197 cm3
(134.07 cu.in.) 1999 cm3
(121.99 cu.in.)
ISO Net Continuous 30.2 kW / 2800 min-1
(rpm)
(40.5 HP / 2800 min-1
(rpm))
35.6 kW / 2800 min-1
(rpm)
(47.7 HP / 2800 min-1
(rpm))
ISO/SAE Net Intermittent 34.8 kW / 2800 min-1
(rpm)
(46.6 HP / 2800 min-1 (rpm))
41.0 kW / 2800 min-1
(rpm)
(55.0 HP / 2800 min-1 (rpm))
SAE Gross Intermittent 36.4 kW / 2800 min-1
(rpm)
(48.8 HP / 2800 min-1 (rpm))
44.0 kW / 2800 min-1
(rpm)
(59.0 HP / 2800 min-1 (rpm))
Maximum Bare Speed 3000 min-1 (rpm)
Minimum Bare Idling Speed 850 to 950 min-1
(rpm)
Combustion Chamber Reentrant Type (Direct Injection)
Fuel Injection Pump Bosch “K” Type Mini Pump
Governor All speed mechanical governor
Direction of Rotation Counter-clockwise (viewed from flywheel side)
Injection Nozzle Bosch “P” Type Hole Nozzle
Injection Timing 0.143 rad (8.2 °) before T.D.C. 0.161 rad (9.25 °) before T.D.C.
Firing Order 1-3-4-2
Injection
Pressure
1st Stage 18.6 MPa (190 kgf/cm2
, 2702 psi)
2nd Stage 22.6 MPa (230 kgf/cm2
, 3271 psi)
Compression Ratio 20 : 1
Lubricating System Forced Lubrication by Trochoid Pump
Oil Pressure Indicating Electrical type switch
Lubricating Filter Full flow paper filter (cartridge type)
Cooling System Pressurized radiator, forced circulation with water pump
Starting System Electric Starting with Starter
Starting Motor 12 V, 1.4 kW
Starting Support Device By glow plug in combustion chamber
Battery 12 V, 88 AH equivalent
Charging Alternator 12 V, 480 W
Fuel Diesel Fuel No.2-D (ASTM D975)
Lubricating Oil Class CF lubricating oil as per API classification is recommended.
If this class of lubricating oil is not available, preferably use Class CD or CE lubricating oil.
For details on recommended lubricating oils, see page G-5, 13.
Lubricating Oil
Capacity
Oil Pan Depth
90 mm (3.54 in.)
7.6 L (2.01 U.S.gals) 7.9 L (2.09 U.S.gals)
Oil Pan Depth
124 mm (4.88 in.)
9.5 L (2.51 U.S.gals) 9.8 L (2.59 U.S.gals)
Weight (Dry) 180 kg (397 lbs) 184 kg (406 lbs)
KiSC issued 02, 2007 A
7
03-M-DI-E2B, WSM SPECIFICATIONS
* The specification described above is of the standard engine of each model.
* Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW
W10373510
Model V2403-M-DI V2403-M-DI-T
Number of Cylinders 4
Type Vertical, Water-cooled, 4 cycle diesel engine
Bore × Stroke 87 × 102.4 mm (3.43 × 4.03 in.)
Total Displacement 2434 cm3
(148.53 cu.in.)
ISO Net Continuous 31.8 kW / 2600 min-1
(rpm)
(42.6 HP / 2600 min-1
(rpm))
37.9 kW / 2550 min-1
(rpm)
(50.8 HP / 2550 min-1
(rpm))
ISO/SAE Net Intermittent 36.6 kW / 2600 min-1
(rpm)
(49.1 HP / 2600 min-1 (rpm))
43.6 kW / 2550 min-1
(rpm)
(58.5 HP / 2550 min-1 (rpm))
SAE Gross Intermittent 38.0 kW / 2600 min-1
(rpm)
(50.9 HP / 2600 min-1 (rpm))
46.5 kW / 2550 min-1
(rpm)
(62.3 HP / 2550 min-1 (rpm))
Maximum Bare Speed 2800 min-1 (rpm)
Minimum Bare Idling Speed 850 to 950 min-1
(rpm) 1550 to 1650 min-1
(rpm)
Combustion Chamber Reentrant Type (Direct Injection)
Fuel Injection Pump Bosch “K” Type Mini Pump
Governor All speed mechanical governor
Direction of Rotation Counter-clockwise (viewed from flywheel side)
Injection Nozzle Bosch “P” Type Hole Nozzle
Injection Timing 0.113 rad (6.5 °) before T.D.C. 0.096 rad (5.5 °) before T.D.C.
Firing Order 1-3-4-2
Injection
Pressure
1st Stage 18.6 MPa (190 kgf/cm2
, 2702 psi)
2nd Stage 22.6 MPa (230 kgf/cm2
, 3271 psi)
Compression Ratio 20 : 1
Lubricating System Forced Lubrication by Trochoid Pump
Oil Pressure Indicating Electrical type switch
Lubricating Filter Full flow paper filter (cartridge type)
Cooling System Pressurized radiator, forced circulation with water pump
Starting System Electric Starting with Starter
Starting Motor 12 V, 2.0 kW 12 V, 2.5 kW
Starting Support Device By glow plug in combustion chamber
Battery 12 V, 92 AH equivalent 12 V, 88 AH equivalent
Charging Alternator 12 V, 480 W
Fuel Diesel Fuel No.2-D (ASTM D975)
Lubricating Oil Class CF lubricating oil as per API classification is recommended.
If this class of lubricating oil is not available, preferably use Class CD or CE lubricating oil.
For details on recommended lubricating oils, see page G-5, 13.
Lubricating Oil
Capacity
Oil Pan Depth
90 mm (3.54 in.)
7.6 L (2.01 U.S.gals) –
Oil Pan Depth
124 mm (4.88 in.)
9.5 L (2.51 U.S.gals) 9.8 L (2.59 U.S.gals)
Weight (Dry) 184 kg (406 lbs) 215 kg (474 lbs)
KiSC issued 02, 2007 A
8
03-M-DI-E2B, WSM DIMENSIONS
DIMENSIONS
W1031045
D1503-M-DI D1503-M-DI-T D1703-M-DI D1803-M-DI
A 572.1 mm (22.52 in.) 572.1 mm (22.52 in.) 572.1 mm (22.52 in.) 575.9 mm (22.67 in.)
B 499.0 mm (19.65 in.) 499.0 mm (19.65 in.) 499.0 mm (19.65 in.) 499.0 mm (19.65 in.)
C 660.0 mm (25.98 in.) 680.8 mm (26.80 in.) 660.0 mm (25.98 in.) 665.0 mm (26.18 in.)
KiSC issued 02, 2007 A
9
03-M-DI-E2B, WSM DIMENSIONS
W1028881
V2203-M-DI V2003-M-DI-T V2403-M-DI V2403-M-DI-T
A 667.1 mm (26.26 in.) 667.1 mm (26.26 in.) 670.9 mm (26.41 in.) 688.4 mm (27.10 in.)
B 499.0 mm (19.65 in.) 499.0 mm (19.65 in.) 499.0 mm (19.65 in.) 520.4 mm (20.49 in.)
C 659.5 mm (25.96 in.) 683.9 mm (26.93 in.) 664.5 mm (26.16 in.) 719.4 mm (28.32 in.)
KiSC issued 02, 2007 A
CONTENTS
GENERAL
1. ENGINE IDENTIFICATION............................................................................. G-1
[1] MODEL NAME AND ENGINE SERIAL NUMBER ................................ G-1
[2] E2B ENGINE............................................................................................. G-2
[3] CYLINDER NUMBER ............................................................................... G-2
2. GENERAL PRECAUTIONS ............................................................................ G-3
3. MAINTENANCE CHECK LIST....................................................................... G-4
4. CHECK AND MAINTENANCE....................................................................... G-6
[1] DAILY CHECK POINTS........................................................................... G-6
[2] CHECK POINTS OF INITIAL 50 HOURS............................................. G-8
[3] CHECK POINTS OF EVERY 50 HOURS........................................... G-10
[4] CHECK POINTS OF EVERY 100 HOURS......................................... G-11
[5] CHECK POINTS OF EVERY 200 HOURS......................................... G-13
[6] CHECK POINTS OF EVERY 400 HOURS......................................... G-15
[7] CHECK POINTS OF EVERY 500 HOURS......................................... G-17
[8] CHECK POINTS OF EVERY 1 OR 2 MONTHS............................... G-19
[9] CHECK POINTS OF EVERY YEAR .................................................... G-20
[10]CHECK POINTS OF EVERY 800 HOURS......................................... G-21
[11]CHECK POINTS OF EVERY 1500 HOURS....................................... G-22
[12]CHECK POINTS OF EVERY 3000 HOURS....................................... G-23
[13]CHECK POINTS OF EVERY 2 YEARS.............................................. G-25
5. SPECIAL TOOLS.......................................................................................... G-29
KiSC issued 02, 2007 A
G-1
03-M-DI-E2B, WSM G GENERAL
1. ENGINE IDENTIFICATION
[1] MODEL NAME AND ENGINE SERIAL NUMBER
When contacting the manufacture, always specify your engine
model name and serial number.
The engine model and its serial number need to be identified
before the engine can be serviced or parts replaced.
■ Engine Serial Number
The engine serial number is an identified number for the engine.
It is marked after the engine model number.
It indicates month and year of manufacture as follows.
• Year of manufacture
W1010477
Alphabet or
Number
Year
Alphabet or
Number
Year
1 2001 F 2015
2 2002 G 2016
3 2003 H 2017
4 2004 J 2018
5 2005 K 2019
6 2006 L 2020
7 2007 M 2021
8 2008 N 2022
9 2009 P 2023
A 2010 R 2024
B 2011 S 2025
C 2012 T 2026
D 2013 V 2027
E 2014
(1) Engine Model Name and Serial
Number
KiSC issued 02, 2007 A
G-2
03-M-DI-E2B, WSM G GENERAL
• Month of manufacture
e.g. D1803-3A0001
“3” indicates 2003 and “A” indicates January.
So, 3A indicates that the engine was manufactured in January,
2003.
W1011076
[2] E2B ENGINE
[ex. Model Name D1803-M-DI-E2B-XXXX]
The emission controls that have been put into effect in various countries to prevent air pollution will be stepped up.
The time to enforce the regulations differs depending on the engine output classifications.
Kubota has been supplying the diesel engines conforming to the emission regulations in respective countries.
Exhaust emissions regulations shift to the second stage. Kubota executed the improvement of the engine according
to this regulation.
In order to discriminate the engines conforming to Tier 1 / Phase 1 requirements and those conforming to Tier 2 /
Phase 2 requirements, we have adopted E2B as a new model name for the engines conforming Tier 2 / Phase 2
regulations.
In the after-sale services for 03-M-DI-E2B series engines, only use the dedicated parts for E2B models and carry
out the maintenance services accordingly.
[3] CYLINDER NUMBER
The cylinder numbers of KUBOTA diesel engine are designated
as shown in the figure.
The sequence of cylinder numbers is given as No.1, No.2, No.3
and No.4 starting from the gear case side.
W1011077
Month
Engine Serial Number
0001 ~ 9999 10000 ~
January A0001 ~ A9999 B0001 ~
February C0001 ~ C9999 D0001 ~
March E0001 ~ E9999 F0001 ~
April G0001 ~ G9999 H0001 ~
May J0001 ~ J9999 K0001 ~
June L0001 ~ L9999 M0001 ~
July N0001 ~ N9999 P0001 ~
August Q0001 ~ Q9999 R0001 ~
September S0001 ~ S9999 T0001 ~
October U0001 ~ U9999 V0001 ~
November W0001 ~ W9999 X0001 ~
December Y0001 ~ Y9999 Z0001 ~
KiSC issued 02, 2007 A
G-3
03-M-DI-E2B, WSM G GENERAL
2. GENERAL PRECAUTIONS
• During disassembly, carefully arrange removed parts in a clean
area to prevent confusion later. Screws, bolts and nuts should be
replaced in their original position to prevent reassembly errors.
• When special tools are required, use KUBOTA genuine special
tools. Special tools which are not frequently used should be
made according to the drawings provided.
• Before disassembling or servicing live wires, make sure to
always disconnect the grounding cable from the battery first.
• Remove oil and dirt from parts before measuring.
• Use only KUBOTA genuine parts for parts replacement to
maintain engine performance and to ensure safety.
• Gaskets and O-rings must be replaced during reassembly.
Apply grease to new O-rings or oil seals before assembling.
• When reassembling external or internal snap rings, position them
so that the sharp edge faces against the direction from which
force is applied.
• Be sure to perform run-in the serviced or reassembled engine.
Do not attempt to give heavy load at once, or serious damage
may result to the engine.
W1011734
(1) Grease
(2) Force
(3) Place the Sharp Edge against the
Direction of Force
(A) External Snap Ring
(B) Internal Snap Ring
KiSC issued 02, 2007 A
G-4
03-M-DI-E2B, WSM G GENERAL
3. MAINTENANCE CHECK LIST
To maintain long-lasting and safe engine performance, make it a rule to carry out regular inspections by following
the table below.
★ Change engine oil and replace oil filter cartridge after the first 50 hours of operation.
* The items listed above (* marked) are registered as emission related critical parts by KUBOTA in the U.S. EPA
nonroad emission regulation. As the engine owner, you are responsible for the performance of the required
maintenance on the engine according to the above instruction.
W1029462
Item
Service Interval
Every
50
hrs
100
hrs
200
hrs
400
hrs
500
hrs
1 or 2
months
1
year
800
hrs
1500
hrs
3000
hrs
2
years
* Checking fuel hoses and clamp bands ✩
Changing engine oil
(depending on the oil pan)
(1) Oil pan depth
(90 mm, 3.54 in.)
★ ✩
(2) Oil pan depth
(124 mm, 4.88 in.)
★ ✩
*Cleaning air cleaner element
(replace the element after 6-times cleanings) ✩
*Cleaning fuel filter (Element type) ✩
Checking battery electrolyte level ✩
Checking fan belt tension and damage ✩
Replacing oil filter cartridge
(1) Oil pan depth
(90 mm, 3.54 in.)
★ ✩
(2) Oil pan depth
(124 mm, 4.88 in.)
★ ✩
Checking radiator hoses and clamp bands ✩
* Checking intake air line ✩
Replacing fuel filter cartridge ✩
Cleaning water jacket and radiator interior ✩
Replacing fan belt ✩
Recharging battery ✩
* Replacing air cleaner element ✩
Checking valve clearance ✩
* Checking injection nozzle condition ✩
* Checking turbocharger ✩
* Checking injection pump ✩
* Replacing intake air line ✩
Replacing battery ✩
Replacing radiator hoses and clamp bands ✩
* Replacing fuel hoses and clamps ✩
Changing radiator coolant (L.L.C.) ✩
KiSC issued 02, 2007 A
Thank you very much for
your reading. Please Click
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G-5
03-M-DI-E2B, WSM G GENERAL
CAUTION
• When changing or inspecting, be sure to level and stop the engine.
NOTE■
• Lubricating Oil
With the emission control now in effect, the CF-4 and CG-4 lubricating oils have been developed for use of a low-
sulfur fuel on-road vehicle engines. When an off-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 fuel, change the lubricating oil at shorter intervals.
• Lubricating oil recommended when a low-sulfur or high-sulfur fuel is employed.
❍ : Recommendable X : Not recommendable
W1035555
Fuel
Lubricating
oil class
Low sulfur
(0.5 % ≥)
High sulfur Remarks
CF ❍ ❍ TBN ≥ 10
CF-4 ❍ X
CG-4 ❍ X
KiSC issued 02, 2007 A
G-6
03-M-DI-E2B, WSM G GENERAL
4. CHECK AND MAINTENANCE
[1] DAILY CHECK POINTS
Checking Engine Oil Level
1. Level the engine.
2. To check the oil level, draw out the dipstick (1), wipe it clean,
reinsert it, and draw it out again.
Check to see that the oil level lies between the two notches.
3. If the level is too low, add new oil to the specified level.
IMPORTANT■
• When using an oil of different maker or viscosity from the
previous one, drain old oil. Never mix two different types of
oil.
NOTE■
• Be sure to inspect the engine, locating it on a horizontal
place. If placed on gradients, accurately, oil quantity may
not be measured.
• Be sure to keep the oil level between upper and lower limits
of the dipstick. Too much oil may cause a drop in output or
excessive blow-by gas. On the closed breather type engine
in which mist is sucked through port, too much oil may
caused oil hammer. While too little oil, may seize the
engine’s rotating and sliding parts.
W1016222
(1) Dipstick (a) Maximum
(b) Minimum
KiSC issued 02, 2007 A
G-7
03-M-DI-E2B, WSM G GENERAL
Checking and Replenish Coolant
1. Without recovery tank :
Remove the radiator cap (1) and check to see that the coolant
level is just below the port.
With recovery tank (2) :
Check to see that the coolant level lies between FULL (A) and
LOW (B).
2. If coolant level is too low, check the reason for decreasing
coolant.
(Case 1)
If coolant is decreasing by evaporation, replenish only fresh, soft
water.
(Case 2)
If coolant is decreasing by leak, replenish coolant of the same
manufacture and type in the specified mixture ratio (fresh, soft
water and L.L.C.). If the coolant brand cannot be identified, drain
out all of the remaining coolant and refill with a totally new brand
of coolant mix.
CAUTION
• Do not remove the radiator cap until coolant temperature is
below its boiling point. Then loosen the cap slightly to
relieve any excess pressure before removing the cap
completely.
IMPORTANT■
• During filling the coolant, air must be vented from the engine
coolant passages. The air vents by jiggling the radiator
upper and lower hoses.
• Be sure to close the radiator cap securely. If the cap is loose
or improperly closed, coolant may leak out and the engine
could overheat.
• Do not use an antifreeze and scale inhibitor at the same time.
• Never mix the different type or brand of L.L.C..
W1035779
(1) Radiator Cap
(2) Recovery Tank
A: FULL
B: LOW
KiSC issued 02, 2007 A
G-8
03-M-DI-E2B, WSM G GENERAL
[2] CHECK POINTS OF INITIAL 50 HOURS
Changing Engine Oil
CAUTION
• Be sure to stop engine before changing engine oil.
1. Start and warm up the engine for approx. 5 minutes.
2. Place an oil pan underneath the engine.
3. To drain the used oil, remove the drain plug (1) at the bottom of
the engine and drain the oil completely.
4. Screw the drain plug (1).
5. Fill new oil up to upper line on the dipstick (2).
IMPORTANT■
• When using an oil of different maker or viscosity from the
previous one, remove all of the old oil.
• Never mix two different types of oil.
• Engine oil should have properties of API classification CD/
CE/CF/CF-4/CG-4.
• Use the proper SAE Engine Oil according to ambient
temperature.
*90 mm (3.54 in.) oil pan depth is optional.
W1016604
Above 25 °C (77 °F)
SAE 30 or SAE 10W-30
SAE 10W-40
0 °C to 25 °C (32 °F to 77 °F)
SAE 20 or SAE 10W-30
SAE 10W-40
Below 0 °C (32 °F)
SAE 10W or SAE 10W-30
SAE 10W-40
Models
Oil pan depth
124 mm (4.88 in.) *90 mm (3.54 in.)
D1503-M-DI
D1503-M-DI-T
D1703-M-DI
D1803-M-DI
7.0 L
1.85 U.S.gals
5.6 L
1.48 U.S.gals
V2203-M-DI
V2403-M-DI
9.5 L
2.51 U.S.gals
7.6 L
2.01 U.S.gals
V2003-M-DI-T
9.8 L
2.59 U.S.gals
7.9 L
2.09 U.S.gals
V2403-M-DI-T
9.8 L
2.59 U.S.gals
–
(1) Drain Plug (2) Dipstick
KiSC issued 02, 2007 A

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Kubota v2403 m-di diesel engine service repair manual

  • 1. WORKSHOP MANUAL DIESEL ENGINE 03-M-DI-E2B SERIES KiSC issued 02, 2007 A
  • 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-DI-E2B series. It is divided into three parts, “General”, “Mechanism” and “Servicing”. ■ General Information on the engine identification, the general precautions, maintenance check list, check and maintenance and special tools are described. ■ Mechanism Information on the construction and function are included. This part should be understood before proceeding with troubleshooting, disassembling and servicing. Refer to Diesel Engine Mechanism Workshop Manual (Code No. 9Y021-01874) for the one which has not been described to this workshop manual. ■ Servicing Information on the troubleshooting, servicing specification lists, tightening torque, checking and adjusting, disassembling and assembling, and servicing which cover procedures, precautions, factory specifications and allowable limits. All information illustrations and specifications contained in this manual are based on the latest product information available at the time of publication. The right is reserved to make changes in all information at any time without notice. Due to covering many models of this manual, information or picture being used have not been specified as one model. February 2004 © KUBOTA Corporation 2004 KiSC issued 02, 2007 A
  • 3. 1 03-M-DI-E2B, WSM SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS BEFORE SERVICING AND REPAIRING • Read all instructions and safety instructions in this manual and on your engine safety decals. • Clean the work area and engine. • Park the machine on a firm and level ground. • Allow the engine to cool before proceeding. • Stop the engine, and remove the key. • Disconnect the battery negative cable. • Hang a “DO NOT OPERATE” tag in operator station. SAFETY FIRST This symbol, the 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. DANGER : Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING : Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION : Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. ■ IMPORTANT : Indicates that equipment or property damage could result if instructions are not followed. ■ NOTE : Gives helpful information. KiSC issued 02, 2007 A
  • 4. 2 03-M-DI-E2B, WSM SAFETY INSTRUCTIONS SAFETY STARTING • Do not start the engine by shorting across starter terminals or bypassing the safety start switch. • Unauthorized modifications to the engine may impair the function and / or safety and affect engine life. SAFETY WORKING • Do not work on the machine while under the influence of alcohol, medication, or other substances or while fatigued. • Wear close fitting clothing and safety equipment appropriate to the job. • Use tools appropriate to the work. Makeshift tools, parts, and procedures are not recommended. • When servicing is performed together by two or more persons, take care to perform all work safely. • Do not touch the rotating or hot parts while the engine is running. • Never remove the radiator cap while the engine is running, or immediately after stopping. Otherwise, hot water will spout out from radiator. Only remove radiator cap when cool enough to touch with bare hands. Slowly loosen the cap to first stop to relieve pressure before removing completely. • Escaping fluid (fuel or hydraulic oil) under pressure can penetrate the skin causing serious injury. Relieve pressure before disconnecting hydraulic or fuel lines. Tighten all connections before applying pressure. • Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises. 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. KiSC issued 02, 2007 A
  • 5. 3 03-M-DI-E2B, WSM SAFETY INSTRUCTIONS VENTILATE WORK AREA • If the engine must be running to do some work, make sure the area is well ventilated. Never run the engine in a closed area. The exhaust gas contains poisonous carbon monoxide. DISPOSE OF FLUIDS PROPERLY • Do not pour fluids into the ground, down a drain, or into a stream, pond, or lake. Observe relevant environmental protection regulations when disposing of oil, fuel, coolant, electrolyte and other harmful waste. PREVENT ACID BURNS • Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, clothing and cause blindness if splashed into eyes. Keep electrolyte away from eyes, hands and clothing. If you spill electrolyte on yourself, flush with water, and get medical attention immediately. PREPARE FOR EMERGENCIES • Keep a first aid kit and fire extinguisher handy at all times. • Keep emergency numbers for doctors, ambulance service, hospital and fire department near your telephone. KiSC issued 02, 2007 A
  • 6. 4 03-M-DI-E2B, WSM SPECIFICATIONS SPECIFICATIONS * The specification described above is of the standard engine of each model. * Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW W10275180 Model D1503-M-DI D1503-M-DI-T Number of Cylinders 3 Type Vertical, Water-cooled, 4 cycle diesel engine Bore × Stroke 83 × 92.4 mm (3.27 × 3.64 in.) Total Displacement 1499 cm3 (91.47 cu.in.) ISO Net Continuous 20.6 kW / 2800 min-1 (rpm) (27.6 HP / 2800 min-1 (rpm)) 27.0 kW / 2800 min-1 (rpm) (36.2 HP / 2800 min-1 (rpm)) ISO/SAE Net Intermittent 23.7 kW / 2800 min-1 (rpm) (31.8 HP / 2800 min-1 (rpm)) 31.1 kW / 2800 min-1 (rpm) (41.7 HP / 2800 min-1 (rpm)) SAE Gross Intermittent 24.9 kW / 2800 min-1 (rpm) (33.4 HP / 2800 min-1 (rpm)) 32.4 kW / 2800 min-1 (rpm) (43.4 HP / 2800 min-1 (rpm)) Maximum Bare Speed 3000 min-1 (rpm) Minimum Bare Idling Speed 850 to 950 min-1 (rpm) Combustion Chamber Reentrant Type (Direct Injection) Fuel Injection Pump Bosch “K” Type Mini Pump Governor All speed mechanical governor Direction of Rotation Counter-clockwise (viewed from flywheel side) Injection Nozzle Bosch “P” Type Hole Nozzle Injection Timing 0.127 rad (7.25 °) before T.D.C. 0.135 rad (7.75 °) before T.D.C. Firing Order 1-2-3 Injection Pressure 1st Stage 18.6 MPa (190 kgf/cm2 , 2702 psi) 2nd Stage 22.6 MPa (230 kgf/cm2 , 3271 psi) Compression Ratio 20 : 1 Lubricating System Forced Lubrication by Trochoid Pump Oil Pressure Indicating Electrical type switch Lubricating Filter Full flow paper filter (cartridge type) Cooling System Pressurized radiator, forced circulation with water pump Starting System Electric Starting with Starter Starting Motor 12 V, 1.2 kW Starting Support Device By glow plug in combustion chamber Battery 12 V, 60 AH equivalent Charging Alternator 12 V, 360 W Fuel Diesel Fuel No.2-D (ASTM D975) Lubricating Oil Class CF lubricating oil as per API classification is recommended. If this class of lubricating oil is not available, preferably use Class CD or CE lubricating oil. For details on recommended lubricating oils, see page G-5, 13. Lubricating Oil Capacity Oil Pan Depth 90 mm (3.54 in.) 5.6 L (1.48 U.S.gals) Oil Pan Depth 124 mm (4.88 in.) 7.0 L (1.85 U.S.gals) Weight (Dry) 148 kg (326 lbs) 152 kg (335 lbs) KiSC issued 02, 2007 A
  • 7. 5 03-M-DI-E2B, WSM SPECIFICATIONS * The specification described above is of the standard engine of each model. * Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW W10314320 Model D1703-M-DI D1803-M-DI Number of Cylinders 3 Type Vertical, Water-cooled, 4 cycle diesel engine Bore × Stroke 87 × 92.4 mm (3.43 × 3.64 in.) 87 × 102.4 mm (3.43 × 4.03 in.) Total Displacement 1647 cm3 (100.51 cu.in.) 1826 cm3 (111.43 cu.in.) ISO Net Continuous 22.7 kW / 2800 min-1 (rpm) (30.4 HP / 2800 min-1 (rpm)) 23.9 kW / 2600 min-1 (rpm) (32.0 HP / 2600 min-1 (rpm)) ISO/SAE Net Intermittent 26.1 kW / 2800 min-1 (rpm) (35.0 HP / 2800 min-1 (rpm)) 27.2 kW / 2600 min-1 (rpm) (36.5 HP / 2600 min-1 (rpm)) SAE Gross Intermittent 27.4 kW / 2800 min-1 (rpm) (36.7 HP / 2800 min-1 (rpm)) 28.4 kW / 2600 min-1 (rpm) (38.1 HP / 2600 min-1 (rpm)) Maximum Bare Speed 3000 min-1 (rpm) 2800 min-1 (rpm) Minimum Bare Idling Speed 850 to 950 min-1 (rpm) Combustion Chamber Reentrant Type (Direct Injection) Fuel Injection Pump Bosch “K” Type Mini Pump Governor All speed mechanical governor Direction of Rotation Counter-clockwise (viewed from flywheel side) Injection Nozzle Bosch “P” Type Hole Nozzle Injection Timing 0.134 rad (7.7 °) before T.D.C. 0.096 rad (5.5 °) before T.D.C. Firing Order 1-2-3 Injection Pressure 1st Stage 18.6 MPa (190 kgf/cm2 , 2702 psi) 2nd Stage 22.6 MPa (230 kgf/cm2 , 3271 psi) Compression Ratio 20 : 1 Lubricating System Forced Lubrication by Trochoid Pump Oil Pressure Indicating Electrical type switch Lubricating Filter Full flow paper filter (cartridge type) Cooling System Pressurized radiator, forced circulation with water pump Starting System Electric Starting with Starter Starting Motor 12 V, 1.2 kW 12 V, 1.4 kW Starting Support Device By glow plug in combustion chamber Battery 12 V, 60 AH equivalent 12 V, 88 AH equivalent Charging Alternator 12 V, 480 W Fuel Diesel Fuel No.2-D (ASTM D975) Lubricating Oil Class CF lubricating oil as per API classification is recommended. If this class of lubricating oil is not available, preferably use Class CD or CE lubricating oil. For details on recommended lubricating oils, see page G-5, 13. Lubricating Oil Capacity Oil Pan Depth 90 mm (3.54 in.) 5.6 L (1.48 U.S.gals) Oil Pan Depth 124 mm (4.88 in.) 7.0 L (1.85 U.S.gals) Weight (Dry) 148 kg (326 lbs) 151 kg (333 lbs) KiSC issued 02, 2007 A
  • 8. 6 03-M-DI-E2B, WSM SPECIFICATIONS * The specification described above is of the standard engine of each model. * Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW W10329950 Model V2203-M-DI V2003-M-DI-T Number of Cylinders 4 Type Vertical, Water-cooled, 4 cycle diesel engine Bore × Stroke 87 × 92.4 mm (3.43 × 3.64 in.) 83 × 92.4 mm (3.27 × 3.64 in.) Total Displacement 2197 cm3 (134.07 cu.in.) 1999 cm3 (121.99 cu.in.) ISO Net Continuous 30.2 kW / 2800 min-1 (rpm) (40.5 HP / 2800 min-1 (rpm)) 35.6 kW / 2800 min-1 (rpm) (47.7 HP / 2800 min-1 (rpm)) ISO/SAE Net Intermittent 34.8 kW / 2800 min-1 (rpm) (46.6 HP / 2800 min-1 (rpm)) 41.0 kW / 2800 min-1 (rpm) (55.0 HP / 2800 min-1 (rpm)) SAE Gross Intermittent 36.4 kW / 2800 min-1 (rpm) (48.8 HP / 2800 min-1 (rpm)) 44.0 kW / 2800 min-1 (rpm) (59.0 HP / 2800 min-1 (rpm)) Maximum Bare Speed 3000 min-1 (rpm) Minimum Bare Idling Speed 850 to 950 min-1 (rpm) Combustion Chamber Reentrant Type (Direct Injection) Fuel Injection Pump Bosch “K” Type Mini Pump Governor All speed mechanical governor Direction of Rotation Counter-clockwise (viewed from flywheel side) Injection Nozzle Bosch “P” Type Hole Nozzle Injection Timing 0.143 rad (8.2 °) before T.D.C. 0.161 rad (9.25 °) before T.D.C. Firing Order 1-3-4-2 Injection Pressure 1st Stage 18.6 MPa (190 kgf/cm2 , 2702 psi) 2nd Stage 22.6 MPa (230 kgf/cm2 , 3271 psi) Compression Ratio 20 : 1 Lubricating System Forced Lubrication by Trochoid Pump Oil Pressure Indicating Electrical type switch Lubricating Filter Full flow paper filter (cartridge type) Cooling System Pressurized radiator, forced circulation with water pump Starting System Electric Starting with Starter Starting Motor 12 V, 1.4 kW Starting Support Device By glow plug in combustion chamber Battery 12 V, 88 AH equivalent Charging Alternator 12 V, 480 W Fuel Diesel Fuel No.2-D (ASTM D975) Lubricating Oil Class CF lubricating oil as per API classification is recommended. If this class of lubricating oil is not available, preferably use Class CD or CE lubricating oil. For details on recommended lubricating oils, see page G-5, 13. Lubricating Oil Capacity Oil Pan Depth 90 mm (3.54 in.) 7.6 L (2.01 U.S.gals) 7.9 L (2.09 U.S.gals) Oil Pan Depth 124 mm (4.88 in.) 9.5 L (2.51 U.S.gals) 9.8 L (2.59 U.S.gals) Weight (Dry) 180 kg (397 lbs) 184 kg (406 lbs) KiSC issued 02, 2007 A
  • 9. 7 03-M-DI-E2B, WSM SPECIFICATIONS * The specification described above is of the standard engine of each model. * Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW W10373510 Model V2403-M-DI V2403-M-DI-T Number of Cylinders 4 Type Vertical, Water-cooled, 4 cycle diesel engine Bore × Stroke 87 × 102.4 mm (3.43 × 4.03 in.) Total Displacement 2434 cm3 (148.53 cu.in.) ISO Net Continuous 31.8 kW / 2600 min-1 (rpm) (42.6 HP / 2600 min-1 (rpm)) 37.9 kW / 2550 min-1 (rpm) (50.8 HP / 2550 min-1 (rpm)) ISO/SAE Net Intermittent 36.6 kW / 2600 min-1 (rpm) (49.1 HP / 2600 min-1 (rpm)) 43.6 kW / 2550 min-1 (rpm) (58.5 HP / 2550 min-1 (rpm)) SAE Gross Intermittent 38.0 kW / 2600 min-1 (rpm) (50.9 HP / 2600 min-1 (rpm)) 46.5 kW / 2550 min-1 (rpm) (62.3 HP / 2550 min-1 (rpm)) Maximum Bare Speed 2800 min-1 (rpm) Minimum Bare Idling Speed 850 to 950 min-1 (rpm) 1550 to 1650 min-1 (rpm) Combustion Chamber Reentrant Type (Direct Injection) Fuel Injection Pump Bosch “K” Type Mini Pump Governor All speed mechanical governor Direction of Rotation Counter-clockwise (viewed from flywheel side) Injection Nozzle Bosch “P” Type Hole Nozzle Injection Timing 0.113 rad (6.5 °) before T.D.C. 0.096 rad (5.5 °) before T.D.C. Firing Order 1-3-4-2 Injection Pressure 1st Stage 18.6 MPa (190 kgf/cm2 , 2702 psi) 2nd Stage 22.6 MPa (230 kgf/cm2 , 3271 psi) Compression Ratio 20 : 1 Lubricating System Forced Lubrication by Trochoid Pump Oil Pressure Indicating Electrical type switch Lubricating Filter Full flow paper filter (cartridge type) Cooling System Pressurized radiator, forced circulation with water pump Starting System Electric Starting with Starter Starting Motor 12 V, 2.0 kW 12 V, 2.5 kW Starting Support Device By glow plug in combustion chamber Battery 12 V, 92 AH equivalent 12 V, 88 AH equivalent Charging Alternator 12 V, 480 W Fuel Diesel Fuel No.2-D (ASTM D975) Lubricating Oil Class CF lubricating oil as per API classification is recommended. If this class of lubricating oil is not available, preferably use Class CD or CE lubricating oil. For details on recommended lubricating oils, see page G-5, 13. Lubricating Oil Capacity Oil Pan Depth 90 mm (3.54 in.) 7.6 L (2.01 U.S.gals) – Oil Pan Depth 124 mm (4.88 in.) 9.5 L (2.51 U.S.gals) 9.8 L (2.59 U.S.gals) Weight (Dry) 184 kg (406 lbs) 215 kg (474 lbs) KiSC issued 02, 2007 A
  • 10. 8 03-M-DI-E2B, WSM DIMENSIONS DIMENSIONS W1031045 D1503-M-DI D1503-M-DI-T D1703-M-DI D1803-M-DI A 572.1 mm (22.52 in.) 572.1 mm (22.52 in.) 572.1 mm (22.52 in.) 575.9 mm (22.67 in.) B 499.0 mm (19.65 in.) 499.0 mm (19.65 in.) 499.0 mm (19.65 in.) 499.0 mm (19.65 in.) C 660.0 mm (25.98 in.) 680.8 mm (26.80 in.) 660.0 mm (25.98 in.) 665.0 mm (26.18 in.) KiSC issued 02, 2007 A
  • 11. 9 03-M-DI-E2B, WSM DIMENSIONS W1028881 V2203-M-DI V2003-M-DI-T V2403-M-DI V2403-M-DI-T A 667.1 mm (26.26 in.) 667.1 mm (26.26 in.) 670.9 mm (26.41 in.) 688.4 mm (27.10 in.) B 499.0 mm (19.65 in.) 499.0 mm (19.65 in.) 499.0 mm (19.65 in.) 520.4 mm (20.49 in.) C 659.5 mm (25.96 in.) 683.9 mm (26.93 in.) 664.5 mm (26.16 in.) 719.4 mm (28.32 in.) KiSC issued 02, 2007 A
  • 12. CONTENTS GENERAL 1. ENGINE IDENTIFICATION............................................................................. G-1 [1] MODEL NAME AND ENGINE SERIAL NUMBER ................................ G-1 [2] E2B ENGINE............................................................................................. G-2 [3] CYLINDER NUMBER ............................................................................... G-2 2. GENERAL PRECAUTIONS ............................................................................ G-3 3. MAINTENANCE CHECK LIST....................................................................... G-4 4. CHECK AND MAINTENANCE....................................................................... G-6 [1] DAILY CHECK POINTS........................................................................... G-6 [2] CHECK POINTS OF INITIAL 50 HOURS............................................. G-8 [3] CHECK POINTS OF EVERY 50 HOURS........................................... G-10 [4] CHECK POINTS OF EVERY 100 HOURS......................................... G-11 [5] CHECK POINTS OF EVERY 200 HOURS......................................... G-13 [6] CHECK POINTS OF EVERY 400 HOURS......................................... G-15 [7] CHECK POINTS OF EVERY 500 HOURS......................................... G-17 [8] CHECK POINTS OF EVERY 1 OR 2 MONTHS............................... G-19 [9] CHECK POINTS OF EVERY YEAR .................................................... G-20 [10]CHECK POINTS OF EVERY 800 HOURS......................................... G-21 [11]CHECK POINTS OF EVERY 1500 HOURS....................................... G-22 [12]CHECK POINTS OF EVERY 3000 HOURS....................................... G-23 [13]CHECK POINTS OF EVERY 2 YEARS.............................................. G-25 5. SPECIAL TOOLS.......................................................................................... G-29 KiSC issued 02, 2007 A
  • 13. G-1 03-M-DI-E2B, WSM G GENERAL 1. ENGINE IDENTIFICATION [1] MODEL NAME AND ENGINE SERIAL NUMBER When contacting the manufacture, always specify your engine model name and serial number. The engine model and its serial number need to be identified before the engine can be serviced or parts replaced. ■ Engine Serial Number The engine serial number is an identified number for the engine. It is marked after the engine model number. It indicates month and year of manufacture as follows. • Year of manufacture W1010477 Alphabet or Number Year Alphabet or Number Year 1 2001 F 2015 2 2002 G 2016 3 2003 H 2017 4 2004 J 2018 5 2005 K 2019 6 2006 L 2020 7 2007 M 2021 8 2008 N 2022 9 2009 P 2023 A 2010 R 2024 B 2011 S 2025 C 2012 T 2026 D 2013 V 2027 E 2014 (1) Engine Model Name and Serial Number KiSC issued 02, 2007 A
  • 14. G-2 03-M-DI-E2B, WSM G GENERAL • Month of manufacture e.g. D1803-3A0001 “3” indicates 2003 and “A” indicates January. So, 3A indicates that the engine was manufactured in January, 2003. W1011076 [2] E2B ENGINE [ex. Model Name D1803-M-DI-E2B-XXXX] The emission controls that have been put into effect in various countries to prevent air pollution will be stepped up. The time to enforce the regulations differs depending on the engine output classifications. Kubota has been supplying the diesel engines conforming to the emission regulations in respective countries. Exhaust emissions regulations shift to the second stage. Kubota executed the improvement of the engine according to this regulation. In order to discriminate the engines conforming to Tier 1 / Phase 1 requirements and those conforming to Tier 2 / Phase 2 requirements, we have adopted E2B as a new model name for the engines conforming Tier 2 / Phase 2 regulations. In the after-sale services for 03-M-DI-E2B series engines, only use the dedicated parts for E2B models and carry out the maintenance services accordingly. [3] CYLINDER NUMBER The cylinder numbers of KUBOTA diesel engine are designated as shown in the figure. The sequence of cylinder numbers is given as No.1, No.2, No.3 and No.4 starting from the gear case side. W1011077 Month Engine Serial Number 0001 ~ 9999 10000 ~ January A0001 ~ A9999 B0001 ~ February C0001 ~ C9999 D0001 ~ March E0001 ~ E9999 F0001 ~ April G0001 ~ G9999 H0001 ~ May J0001 ~ J9999 K0001 ~ June L0001 ~ L9999 M0001 ~ July N0001 ~ N9999 P0001 ~ August Q0001 ~ Q9999 R0001 ~ September S0001 ~ S9999 T0001 ~ October U0001 ~ U9999 V0001 ~ November W0001 ~ W9999 X0001 ~ December Y0001 ~ Y9999 Z0001 ~ KiSC issued 02, 2007 A
  • 15. G-3 03-M-DI-E2B, WSM G GENERAL 2. GENERAL PRECAUTIONS • During disassembly, carefully arrange removed parts in a clean area to prevent confusion later. Screws, bolts and nuts should be replaced in their original position to prevent reassembly errors. • When special tools are required, use KUBOTA genuine special tools. Special tools which are not frequently used should be made according to the drawings provided. • Before disassembling or servicing live wires, make sure to always disconnect the grounding cable from the battery first. • Remove oil and dirt from parts before measuring. • Use only KUBOTA genuine parts for parts replacement to maintain engine performance and to ensure safety. • Gaskets and O-rings must be replaced during reassembly. Apply grease to new O-rings or oil seals before assembling. • When reassembling external or internal snap rings, position them so that the sharp edge faces against the direction from which force is applied. • Be sure to perform run-in the serviced or reassembled engine. Do not attempt to give heavy load at once, or serious damage may result to the engine. W1011734 (1) Grease (2) Force (3) Place the Sharp Edge against the Direction of Force (A) External Snap Ring (B) Internal Snap Ring KiSC issued 02, 2007 A
  • 16. G-4 03-M-DI-E2B, WSM G GENERAL 3. MAINTENANCE CHECK LIST To maintain long-lasting and safe engine performance, make it a rule to carry out regular inspections by following the table below. ★ Change engine oil and replace oil filter cartridge after the first 50 hours of operation. * The items listed above (* marked) are registered as emission related critical parts by KUBOTA in the U.S. EPA nonroad emission regulation. As the engine owner, you are responsible for the performance of the required maintenance on the engine according to the above instruction. W1029462 Item Service Interval Every 50 hrs 100 hrs 200 hrs 400 hrs 500 hrs 1 or 2 months 1 year 800 hrs 1500 hrs 3000 hrs 2 years * Checking fuel hoses and clamp bands ✩ Changing engine oil (depending on the oil pan) (1) Oil pan depth (90 mm, 3.54 in.) ★ ✩ (2) Oil pan depth (124 mm, 4.88 in.) ★ ✩ *Cleaning air cleaner element (replace the element after 6-times cleanings) ✩ *Cleaning fuel filter (Element type) ✩ Checking battery electrolyte level ✩ Checking fan belt tension and damage ✩ Replacing oil filter cartridge (1) Oil pan depth (90 mm, 3.54 in.) ★ ✩ (2) Oil pan depth (124 mm, 4.88 in.) ★ ✩ Checking radiator hoses and clamp bands ✩ * Checking intake air line ✩ Replacing fuel filter cartridge ✩ Cleaning water jacket and radiator interior ✩ Replacing fan belt ✩ Recharging battery ✩ * Replacing air cleaner element ✩ Checking valve clearance ✩ * Checking injection nozzle condition ✩ * Checking turbocharger ✩ * Checking injection pump ✩ * Replacing intake air line ✩ Replacing battery ✩ Replacing radiator hoses and clamp bands ✩ * Replacing fuel hoses and clamps ✩ Changing radiator coolant (L.L.C.) ✩ KiSC issued 02, 2007 A
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  • 18. G-5 03-M-DI-E2B, WSM G GENERAL CAUTION • When changing or inspecting, be sure to level and stop the engine. NOTE■ • Lubricating Oil With the emission control now in effect, the CF-4 and CG-4 lubricating oils have been developed for use of a low- sulfur fuel on-road vehicle engines. When an off-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 fuel, change the lubricating oil at shorter intervals. • Lubricating oil recommended when a low-sulfur or high-sulfur fuel is employed. ❍ : Recommendable X : Not recommendable W1035555 Fuel Lubricating oil class Low sulfur (0.5 % ≥) High sulfur Remarks CF ❍ ❍ TBN ≥ 10 CF-4 ❍ X CG-4 ❍ X KiSC issued 02, 2007 A
  • 19. G-6 03-M-DI-E2B, WSM G GENERAL 4. CHECK AND MAINTENANCE [1] DAILY CHECK POINTS Checking Engine Oil Level 1. Level the engine. 2. To check the oil level, draw out the dipstick (1), wipe it clean, reinsert it, and draw it out again. Check to see that the oil level lies between the two notches. 3. If the level is too low, add new oil to the specified level. IMPORTANT■ • When using an oil of different maker or viscosity from the previous one, drain old oil. Never mix two different types of oil. NOTE■ • Be sure to inspect the engine, locating it on a horizontal place. If placed on gradients, accurately, oil quantity may not be measured. • Be sure to keep the oil level between upper and lower limits of the dipstick. Too much oil may cause a drop in output or excessive blow-by gas. On the closed breather type engine in which mist is sucked through port, too much oil may caused oil hammer. While too little oil, may seize the engine’s rotating and sliding parts. W1016222 (1) Dipstick (a) Maximum (b) Minimum KiSC issued 02, 2007 A
  • 20. G-7 03-M-DI-E2B, WSM G GENERAL Checking and Replenish Coolant 1. Without recovery tank : Remove the radiator cap (1) and check to see that the coolant level is just below the port. With recovery tank (2) : Check to see that the coolant level lies between FULL (A) and LOW (B). 2. If coolant level is too low, check the reason for decreasing coolant. (Case 1) If coolant is decreasing by evaporation, replenish only fresh, soft water. (Case 2) If coolant is decreasing by leak, replenish coolant of the same manufacture and type in the specified mixture ratio (fresh, soft water and L.L.C.). If the coolant brand cannot be identified, drain out all of the remaining coolant and refill with a totally new brand of coolant mix. CAUTION • Do not remove the radiator cap until coolant temperature is below its boiling point. Then loosen the cap slightly to relieve any excess pressure before removing the cap completely. IMPORTANT■ • During filling the coolant, air must be vented from the engine coolant passages. The air vents by jiggling the radiator upper and lower hoses. • Be sure to close the radiator cap securely. If the cap is loose or improperly closed, coolant may leak out and the engine could overheat. • Do not use an antifreeze and scale inhibitor at the same time. • Never mix the different type or brand of L.L.C.. W1035779 (1) Radiator Cap (2) Recovery Tank A: FULL B: LOW KiSC issued 02, 2007 A
  • 21. G-8 03-M-DI-E2B, WSM G GENERAL [2] CHECK POINTS OF INITIAL 50 HOURS Changing Engine Oil CAUTION • Be sure to stop engine before changing engine oil. 1. Start and warm up the engine for approx. 5 minutes. 2. Place an oil pan underneath the engine. 3. To drain the used oil, remove the drain plug (1) at the bottom of the engine and drain the oil completely. 4. Screw the drain plug (1). 5. Fill new oil up to upper line on the dipstick (2). IMPORTANT■ • When using an oil of different maker or viscosity from the previous one, remove all of the old oil. • Never mix two different types of oil. • Engine oil should have properties of API classification CD/ CE/CF/CF-4/CG-4. • Use the proper SAE Engine Oil according to ambient temperature. *90 mm (3.54 in.) oil pan depth is optional. W1016604 Above 25 °C (77 °F) SAE 30 or SAE 10W-30 SAE 10W-40 0 °C to 25 °C (32 °F to 77 °F) SAE 20 or SAE 10W-30 SAE 10W-40 Below 0 °C (32 °F) SAE 10W or SAE 10W-30 SAE 10W-40 Models Oil pan depth 124 mm (4.88 in.) *90 mm (3.54 in.) D1503-M-DI D1503-M-DI-T D1703-M-DI D1803-M-DI 7.0 L 1.85 U.S.gals 5.6 L 1.48 U.S.gals V2203-M-DI V2403-M-DI 9.5 L 2.51 U.S.gals 7.6 L 2.01 U.S.gals V2003-M-DI-T 9.8 L 2.59 U.S.gals 7.9 L 2.09 U.S.gals V2403-M-DI-T 9.8 L 2.59 U.S.gals – (1) Drain Plug (2) Dipstick KiSC issued 02, 2007 A