Nanni N4.40 Workshop Manual
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Nanni N4.40 Workshop Manual

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WORK SHOP MANUAL
ENGINE BASE
N4.40
(Starting serial number KTF08040093)
NANNI INDUSTRIES S.A.S – Zone Industrielle
11 avenue MARIOTTE
B.P.107 – 33260 LA TESTE - FRANCE
60300209

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Summary of Contents for Nanni N4.40

  • Page 1 WORK SHOP MANUAL ENGINE BASE N4.40 (Starting serial number KTF08040093) NANNI INDUSTRIES S.A.S – Zone Industrielle 11 avenue MARIOTTE B.P.107 – 33260 LA TESTE - FRANCE 60300209...

  • Page 2: Safety First

    TO THE READER This Workshop Manual tells the servicing personnel about the mechanism, servicing and maintenance of the 03-M-E3B, the 03-M-DI-E3B and the 03-M-E3BG series. It contains 4 parts: "Information", "General", "Mechanism" and "Servicing". Information This section contains information below. •...
  • Page 3 INFORMATION KiSC issued 06, 2009 A...
  • Page 4 INFORMATION CONTENTS 1. SAFETY FIRST ..........................I-1 2. SPECIFICATION ..........................I-4 3. DIMENSIONS ..........................I-15 4. WIRING DIAGRAM........................I-21 KiSC issued 06, 2009 A...
  • Page 5 INFORMATION 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM 1. SAFETY FIRST 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. •...
  • Page 6 INFORMATION 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM OPERATE SAFELY • Do not use the machine after you consume alcohol or medication or when you are tired. • Put on applicable clothing and safety equipment. • Use applicable tools only. Do not use alternative tools or parts.
  • Page 7 INFORMATION 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM KEEP A GOOD AIRFLOW IN THE WORK AREA • If the engine is in operation, make sure that the area has good airflow. Do not operate the engine in a closed area. The exhaust gas contains poisonous carbon monoxide.

  • Page 8: Technical Data

    19/02/2009 TECHNICAL DATA ENGINE MODEL N4.40 (Since serial number: KTF08040093) ENGINE SPECIFICATIONS LUBRIFICATION Number of cylinders: 4 Oil pressure at idle RPM: 1 bar Displacement: 1999 cc Oil pressure at maximum load: 3 to 4.5 b Bore - Stroke: 83 X 92.4 mm...
  • Page 14 GENERAL KiSC issued 06, 2009 A...

  • Page 15: Table Of Contents

    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......................G-4 3. MAINTENANCE CHECK LIST ..................... G-5 4. CHECK AND MAINTENANCE ..................... G-8 [1] DAILY CHECK POINTS ......................

  • Page 16: Engine Identification

    GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM 1. ENGINE IDENTIFICATION [1] MODEL NAME AND ENGINE SERIAL NUMBER You must identify the engine model name and serial number before you start a job. When you get in touch with the manufacturer, always tell your engine model name and serial number.
  • Page 17 GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM (Continued) 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 J0001 ~ J9999 K0001 ~ KZ999 June...

  • Page 18: E3B Engine

    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 Nonroad Emission Standards continue to change. The timing or applicable date of the specific Nonroad Emission regulations depends on the engine output classification.

  • Page 19: General Precautions

    GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM 2. GENERAL PRECAUTIONS • When you disassemble, carefully put the parts in a clean area to make it easy to find the parts. You must install the screws, bolts and nuts in their initial position to prevent the reassembly errors.

  • Page 20: Maintenance Check List

    GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM 3. MAINTENANCE CHECK LIST To make sure that the engine operates safely for a long time, refer to the table below to do regular inspections. [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] Service Interval Every Item...
  • Page 21 GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM [D1803-M-DI, V2403-M-DI, V2403-M-DI-T] Service Interval Every Item 1 or 2 1500 3000 1 year 2 years months * Check of fuel hoses and clamp bands (1) Oil pan depth Change of engine oil (90 mm, 3.5 in.) (depending on the oil (2) Oil pan depth pan)
  • Page 22 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. 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 23: Check And Maintenance

    GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM 4. CHECK AND MAINTENANCE [1] DAILY CHECK POINTS Check of Engine Oil Level 1. Make the engine level. 2. Pull out the dipstick (1) and clean it. 3. Put in and pull it out again. Make sure that the oil level is between the 2 notches.
  • Page 24 GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Check of Coolant Level and Replenishment CAUTION • Do not remove the radiator cap when the engine is hot. Then loosen the cap slightly to release unwanted pressure before you remove the cap fully. 1. Without recovery tank Remove the radiator cap (1) and make sure that the coolant level is immediately below the port.

  • Page 25: Check Points For The Initial 50 Hours

    GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM [2] CHECK POINTS FOR THE INITIAL 50 HOURS Change of Engine Oil CAUTION • Make sure that you stop the engine before you change the engine oil. 1. Start and warm-up the engine for approximately 5 minutes. 2.
  • Page 26 GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Replacement of Oil Filter Cartridge CAUTION • Make sure that you stop the engine before you replace the oil filter cartridge. 1. Remove the oil filter cartridge (1) with the filter wrench. 2. Apply a thin layer of oil on the new cartridge gasket. 3.

  • Page 27: Check Points For Every 50 Hours

    GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM [3] CHECK POINTS FOR EVERY 50 HOURS Check of Fuel Hoses and Clamp Bands CAUTION • Stop the engine before you do the check below. 1. If the clamp (2) is loose, apply oil to the threads and tighten it again correctly.

  • Page 28: Check Points For Every 100 Hours

    GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM [4] CHECK POINTS FOR EVERY 100 HOURS Cleaning of Air Cleaner Element 1. Remove the air cleaner element. 2. Use clean dry compressed air on the inner side of the element. The pressure of compressed air must be less than 210 kPa (2.1 kgf/cm , 30 psi).
  • Page 29 GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Fan Belt Damage and Wear 1. Examine the fan belt for damage. 2. If the fan belt has a damage, replace it. 3. Examine if the fan belt is worn out and sunk in the pulley groove. 4.

  • Page 30: Check Points For Every 150 Hours

    GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM [5] CHECK POINTS FOR EVERY 150 HOURS Change of Engine Oil (for 90 mm (3.5 in.) Depth Oil Pan) [D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M, D1703-M-BG, V2003-M-BG, V2003-M-T-BG, V2203-M-BG, V2403-M-BG] CAUTION • Make sure that you stop the engine before you change the engine oil.
  • Page 31 GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Replacement of 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] CAUTION • Make sure that you stop the engine before you replace the oil filter cartridge.

  • Page 32: Check Points For Every 200 Hours

    GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM [6] CHECK POINTS FOR EVERY 200 HOURS Change of 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] CAUTION • Make sure that you stop the engine before you change the engine oil.
  • Page 33 GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Change of Engine Oil (for 90 mm (3.5 in.) Depth Oil Pan) [D1803-M-DI, V2403-M-DI, V2403-M-DI-T] CAUTION • Make sure that you stop the engine before you change the engine oil. 1. Start and warm-up the engine for approximately 5 minutes. 2.
  • Page 34 GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Replacement of 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] CAUTION • Make sure that you stop the engine before you replace the oil filter cartridge.

  • Page 35: Check Points For Every 400 Hours

    GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Check of Intake Air Line 1. Make sure that the intake air hose(s) connections are correct for every 200 hours of operation. 2. If the clamp is loose, apply oil to the threads and tighten it again correctly.
  • Page 36 GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Replacement of Oil Filter Cartridge (for 124 mm (4.88 in.) Depth Oil Pan) [D1803-M-DI, V2403-M-DI, V2403-M-DI-T] CAUTION • Make sure that you stop the engine before you replace the oil filter cartridge. 1. Remove the oil filter cartridge (1) with the filter wrench. 2.

  • Page 37: Check Points For Every 500 Hours

    GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM [8] CHECK POINTS FOR EVERY 500 HOURS Cleaning of Water Jacket and Radiator Interior CAUTION • Do not remove the radiator cap when the engine is hot. Then loosen the cap slightly to release unwanted pressure before you remove the cap fully.
  • Page 38 GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Anti-freeze • There are 2 types of anti-freeze available : use the permanent type (PT) for this engine. • When you add anti-freeze for the first time, flush the water jacket and radiator interior with clean, soft water several times. •...

  • Page 39: Check Points For Every 1 Or 2 Months

    GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM [9] CHECK POINTS FOR EVERY 1 OR 2 MONTHS Recharge of Battery CAUTION • The battery gas can cause an explosion. Keep the sparks and open flames away from the battery at all times, especially when you charge the battery. •...

  • Page 40: Check Points For Every Year

    GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Battery Specific Gravity 1. Measure the specific gravity of the electrolyte in each cell with a hydrometer. 2. If the electrolyte temperature is different from the one that the hydrometer calibrated, correct specific gravity measurement. Use the formula below in (Reference). 3.

  • Page 41: Check Points For Every 800 Hours

    GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM [11] CHECK POINTS FOR EVERY 800 HOURS Valve Clearance IMPORTANT • You must examine and adjust the valve clearance when the engine is cold. 1. Remove the head cover. 2. Align the "1TC" mark line (3) on the flywheel and projection (2) on the housing.

  • Page 42: Check Points For Every 1500 Hours

    GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM [12] CHECK POINTS FOR EVERY 1500 HOURS CAUTION • Examine the injection pressure and condition after you make sure that there is no one in the direction of the fumes. • If the fumes from the nozzle directly touches the human body, they can cause damage to the cells and blood poisoning.
  • Page 43 GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Fuel Injection Pressure [D1803-M-DI, V2403-M-DI, V2403-M-DI-T] 1. Set the injection nozzle to a nozzle tester. 2. Slowly move the tester lever to measure the pressure at which the fuel start to jet out from the nozzle. 3.
  • Page 44 GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Nozzle Holder [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. Hold the nozzle retaining nut (7) with a vise. 2. Remove the nozzle holder (1), and remove the internal parts. (When reassembling) •...

  • Page 45: Check Points For Every 3000 Hours

    GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM [13] CHECK POINTS FOR EVERY 3000 HOURS Check of Turbocharger Turbine Side 1. Examine the exhaust port (2) and the inlet port (3) side of the turbine housing (1) for exhaust gas leakage. 2. If you find a gas leakage, tighten the bolts and nuts again or replace the gasket with a new one.
  • Page 46 GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Check of 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 engine stop solenoid. 2. Remove the injection pipes and glow plugs. 3.
  • Page 47 GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Check of Injection Pump [D1803-M-DI, V2403-M-DI, V2403-M-DI-T] Fuel Tightness of Pump Element 1. Remove the engine stop solenoid. 2. Remove the injection pipes and glow plugs. 3. Set the injection pump pressure tester to the injection pump. 4.

  • Page 48: Check Points For Every 2 Years

    GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM [14] CHECK POINTS FOR EVERY 2 YEARS Replacement of Intake Air Line 1. Loosen the clamp (2). 2. Remove the intake air hose (1) and clamp (2). 3. Replace the intake air hose (1) and clamp (2) with new ones. 4.
  • Page 49 GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Replacement of Fuel Hoses and Clamp Bands CAUTION • Stop the engine before you do the check below. 1. Loosen the clamp (2) and remove the fuel hose (1). 2. Replace the fuel hose (1) and clamp (2) with new ones. 3.
  • Page 50 GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Change of Radiator Coolant (L.L.C.) CAUTION • Do not remove the radiator cap when the engine is hot. Then loosen the cap slightly to release unwanted pressure before you remove the cap fully. 1. Stop the engine and let the coolant temperature decreases. 2.
  • Page 51 GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM (Continued) Anti-freeze • There are 2 types of anti-freeze available : use the permanent type (PT) for this engine. • When you add anti-freeze for the first time, flush the water jacket and radiator interior with clean, soft water several times. •...

  • Page 52: Special Tools

    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) • 07909-30934 (A to F) • 07909-31211 (E and F) • 07909-31231 (H) •...
  • Page 53 GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM NOTE • You do not have the special tools below. Refer to the figure to make them yourselves. M00000003GEG0056US1 Injection Pump Pressure Tester Application • To examine the fuel tightness of injection pumps. Pressure gauge full scale : More than 29.4 MPa (300 kgf/cm 4267 psi) PF 1/2 Copper gasket...
  • Page 54 GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Valve Guide Replacing Tool Application • To press out and press fit the valve guide. 225 mm (8.86 in.) 70 mm (2.8 in.) 45 mm (1.8 in.) 20 mm dia. (0.79 in. dia.) 12.7 to 12.9 mm dia. (0.500 to 0.507 in. dia.) 7.50 to 7.60 mm dia.
  • Page 55 GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Crankshaft Bearing 1 Replacing Tool Application • To press out and press fit the crankshaft bearing 1. [1] Extracting tool 135 mm (5.31 in.) 72 mm (2.8 in.) 40 mm radius (1.6 in. radius) 10 mm (0.39 in.) 20 mm (0.79 in.) 20 mm dia.
  • Page 56 GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Auxiliary Socket for Fixing Crankshaft Sleeve Application • To fix the crankshaft sleeve of the diesel engine. 80.0 mm (3.15 in.) 60.10 to 60.30 mm (2.367 to 2.374 in.) 80.0 mm dia. (3.15 in. dia.) 85.0 mm dia.
  • Page 57 GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM (Continued) Application • To fix the crankshaft sleeve of the diesel engine. 42.0 mm (1.65 in.) 30.50 to 30.60 mm (1.201 to 1.204 in.) 23.0 mm (0.906 in.) 20.0 mm (0.787 in.) 2.0 mm (0.079 in.) 31.911 to 31.950 mm dia.
  • Page 58 GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Balancer Metal Replacing Tool (for Removing) Application • To remove the metal bearing. 41 mm (1.6 in.) 41.934 to 41.950 mm dia. (1.6510 to 1.6515 in. dia.) 32.5 mm (1.28 in.) 24.959 to 24.980 mm dia. (0.98264 to 0.98346 in. dia.) Chamfer 0.3 mm (0.01 in.) 21.947 to 21.960 mm dia.
  • Page 59 GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Balancer Metal Replacing Tool (for Fitting) Application • To press fit the metal bearing. 182 mm (7.17 in.) 60 mm dia. (2.4 in. dia.) 140 mm (5.51 in.) 46.950 to 46.975 mm dia. (1.8485 to 1.8494 in. dia.) 37 mm (1.5 in.) 43.934 to 43.950 mm dia.
  • Page 60 GENERAL 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Idle Gear 2 Puller Application • To remove the idle gear 2 from the shaft. 24 mm (0.94 in.) 10 mm dia. (0.39 in. dia.) 0.5 mm radius (0.02 in. radius) M20 × Pitch 2.0 10 mm (0.39 in.) 20 mm (0.79 in.) 5 mm (0.2 in.)
  • Page 61 ENGINE KiSC issued 06, 2009 A...
  • Page 62 MECHANISM CONTENTS 1. ENGINE BODY........................... 1-M1 [1] PISTON ..........................1-M1 [2] BUILT-IN DYNAMIC BALANCER (BALANCER MODEL ONLY) ......... 1-M2 [3] HALF-FLOATING HEAD COVER ..................1-M3 2. COOLING SYSTEM ........................1-M4 [1] BOTTOM BYPASS SYSTEM ....................1-M4 3. FUEL SYSTEM........................... 1-M5 [1] GOVERNOR.........................

  • Page 63: Engine Body

    ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM 1. ENGINE BODY [1] PISTON The piston skirt has a layer of molybdenum disulfide , which decreases the piston slap noise and thus the all the engine noise. Molybdenum disulfide (MoS The molybdenum disulfide (1) is a solid lubricant, like Graphite or Teflon.
  • Page 64 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM [2] BUILT-IN DYNAMIC BALANCER (BALANCER MODEL ONLY) The engine causes vibration because of the reciprocation of the piston. This 3-cylinder engine is much less possible to cause vibration than a 4-cylinder one (second inertia, etc.). But all engines have many parts that moves and thus cannot be fully free from vibration.
  • Page 65 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM [3] HALF-FLOATING HEAD COVER The rubber packing is attached to keep the cylinder head cover approximately 0.5 mm (0.02 in.) off the cylinder head. This decreases the noise from the cylinder head. (1) Cylinder Head Cover (2) Rubber Packing M00000003ENM0003US1 1-M3...

  • Page 66: Cooling System

    ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM 2. COOLING SYSTEM [1] BOTTOM BYPASS SYSTEM The 03-M Series have a bottom bypass system to enhance the cooling performance. When the temperature of the coolant in the engine is low, the thermostat (1) stays closed. This lets the coolant flow through the bypass pipe and around the engine.

  • Page 67: Fuel System

    ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM 3. FUEL SYSTEM [1] GOVERNOR The governor refers to the load changes to adjust the fuel quantity supplied to the engine automatically. This make sure that the engine speed stays constant. This engine uses an all-speed governor that controls the centrifugal force of the steel ball (1) weight.
  • Page 68 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM In Normal Operating Temperature On start up of the engine, the rack of the fuel injection pump is pushed into the position by the start spring where the amount of injection comes to maximum. The start up of the engine in this condition makes the fuel injected more than it requires on starting up in normal operating temperature, and smoke is generated.
  • Page 69 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) Stop Solenoid (5) Plunger (6) Stop Solenoid Guide (7) Hi-Idling Body M00000003ENM0009US1 Fuel supply increases when boost pressure increases to make sure that the turbocharger gives sufficient power to the engine.
  • Page 70 SERVICING CONTENTS 1. TROUBLESHOOTING.........................1-S1 [1] ENGINE BODY........................1-S1 [2] ELECTRONIC GOVERNOR ....................1-S8 2. SERVICING SPECIFICATIONS ....................1-S10 3. TIGHTENING TORQUES......................1-S20 [1] TIGHTENING TORQUES OF SCREWS, BOLTS AND NUTS FOR GENERAL USE..1-S20 [2] TIGHTENING TORQUES OF THE SCREWS, BOLTS AND NUTS FOR SPECIAL USE ..1-S21 4.

  • Page 71: Troubleshooting

    ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM 1. TROUBLESHOOTING [1] ENGINE BODY Reference Symptom Probable Cause Solution Page The engine does not No fuel Fill up the fuel G-12 start Air in the fuel system Bleed the air G-12 Water in the fuel system Change the fuel and –...
  • Page 72 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Reference Symptom Probable Cause Solution Page The engine does not Incorrect valve timing Correct or replace the 1-S61, start timing gear 1-S62 Piston ring and cylinder are worn out Replace 1-S22, 1-S23, 1-S65, 1-S66, 1-S67, 1-S68, 1-S90, 1-S91,...
  • Page 73 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Reference Symptom Probable Cause Solution Page The engine revolution The fuel filter is clogged or dirty Replace G-21 is not smooth The air cleaner is clogged Clean or replace G-13, G-20, G-25 Fuel leakage because of loose injection pipe Tighten the retaining 1-S48 retaining nut...
  • Page 74 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Reference Symptom Probable Cause Solution Page The exhaust gas is Overload Decrease the load – black or dark gray The grade of the fuel is low Use the specified fuel The fuel filter is clogged Replace G-21 The air cleaner is clogged...
  • Page 75 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Reference Symptom Probable Cause Solution Page The lubricant oil The gap of the piston ring points to the same Move the ring gap 1-S65, consumption is too direction direction 1-S66 much The oil ring is worn out or cannot move Replace 1-S67, 1-S68,...
  • Page 76 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Reference Symptom Probable Cause Solution Page The oil pressure is The engine oil is not sufficient Fill up again The oil strainer is clogged Clean 1-S64 The relief valve does not operate with dirt Clean –...
  • Page 77 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Reference Symptom Probable Cause Solution Page The battery is The battery electrolyte is not sufficient Fill in distilled water G-13, G-24 discharged quickly and charge The fan belt slips Adjust belt tension or G-13, replace G-14, G-23 The wires connection is incorrect Connect again...
  • Page 78 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM [2] ELECTRONIC GOVERNOR IMPORTANT • The engine trouble divides into an electronic governor, the main body of the engine, and the operating constancy. This manual describes it concerning the check of an electronic governor. Refer to WSM of engine and operator's manual if you cannot find trouble related to an electronic governor by checking an electronic governor.
  • Page 79 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 Solenoid (more than 115 %) (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 Water temperature sensor abnormal...

  • Page 80: Specification

    ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM 2. SERVICING SPECIFICATIONS ENGINE BODY Item Factory Specification Allowable Limit Valve Clearance (When Cold) 0.18 to 0.22 mm – 0.0071 to 0.0086 in. Compression Pressure 3.24 to 3.72 MPa / 2.55 MPa / (When You Crank the Engine with the Starter) 290 min (rpm) 290 min...
  • Page 81 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Item Factory Specification Allowable Limit Valve Seat Width (Intake) 2.12 mm – 0.0835 in. Width (Exhaust) 2.12 mm – 0.0835 in. Valve Seat Angle (Intake) 1.0 rad – [D1503-M, D1703-M, D1803-M, V2003-M, 60 ° V2203-M, V2403-M, V2403-M-T, D1703-M-BG, V2003-M-BG, Angle (Exhaust) 0.79 rad...
  • Page 82 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Item Factory Specification Allowable Limit Valve Timing (Exhaust Valve) Open 0.72 rad (41 °) – [D1803-M-DI, V2403-M-DI] before B.D.C. Close 0.2 rad (9 °) – after T.D.C. Valve Timing (Exhaust Valve) Open 0.96 rad (55 °) –...
  • Page 83 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Item Factory Specification Allowable Limit Timing Gear • Crank Gear to Idle Gear Backlash 0.04150 to 0.1122 mm 0.15 mm 0.001634 to 0.004417 in. 0.0059 in. • Idle Gear to Cam Gear Backlash 0.04150 to 0.1154 mm 0.15 mm 0.001634 to 0.004543 in.
  • Page 84 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Item Factory Specification Allowable Limit Height 33.47 mm 33.42 mm [V2403-M-DI-T] (Intake) 1.318 in. 1.316 in. Height 33.00 mm 32.95 mm (Exhaust) 1.299 in. 1.297 in. Height 33.27 mm 33.22 mm [D1703-M-BG] (Intake / Exhaust) 1.310 in.
  • Page 85 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Item Factory Specification Allowable Limit Piston Pin Bore I.D. 25.000 to 25.013 mm 25.05 mm 0.98426 to 0.98476 in. 0.9862 in. Top Ring to Ring Groove Clearance 0.050 to 0.090 mm 0.20 mm [D1803-M-DI, V2403-M-DI] 0.0020 to 0.0035 in.
  • Page 86 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Item Factory Specification Allowable Limit Crankshaft Bend – 0.02 mm 0.0008 in. Crankshaft Journal to Crankshaft Bearing 1 Oil Clearance 0.0400 to 0.118 mm 0.20 mm 0.00158 to 0.00464 in. 0.0079 in. • Crankshaft Journal O.D.
  • Page 87 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM LUBRICATING SYSTEM Item Factory Specification Allowable Limit Engine Oil Pressure At Idle Speed More than 50 kPa 98 kPa 0.5 kgf/cm 1.0 kgf/cm 7 psi 14 psi At Rated Speed 300 to 440 kPa 250 kPa 3.0 to 4.5 kgf/cm 2.5 kgf/cm 43 to 64 psi...
  • Page 88 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM FUEL SYSTEM Item Factory Specification Allowable Limit Injection Pump Injection Timing 0.253 to 0.279 rad – [D1503-M, V2003-M-T-BG] (14.5 to 16.0 °) before T.D.C. Injection Pump Injection Timing 0.271 to 0.296 rad – [D1703-M, D1803-M, V2003-M, V2203-M, (15.5 to 17.0 °) V2403-M] before T.D.C.
  • Page 89 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Item Factory Specification Allowable Limit Injection Nozzle Valve Seat Valve Seat No fuel leak at – [D1803-M-DI, V2403-M-DI, V2403-M-DI-T] Tightness 16.67 MPa 170.0 kgf/cm 2418 psi ELECTRICAL SYSTEM Item Factory Specification Allowable Limit Starter • Commutator [D1503-M, D1703-M, V2003-M, O.D.

  • Page 90: Tightening Torques

    ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM 3. TIGHTENING TORQUES Use a torque wrench to tighten the screws, bolts and nuts to the specified torque. Tighten the screws, bolts and nuts used, such as on the cylinder head in the correct sequence and torque. M00000003ENS0012US1 [1] TIGHTENING TORQUES OF SCREWS, BOLTS AND NUTS FOR GENERAL USE...

  • Page 91: Dimensions

    ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM [2] TIGHTENING TORQUES OF THE SCREWS, BOLTS AND NUTS FOR SPECIAL USE NOTE • For the screws, bolts and nuts with the mark "*", apply engine oil to their threads and seats before you tighten. •...
  • Page 92 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. Operate the engine for warming-up. 2. Stop the engine. 3.
  • Page 93 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. Operate the engine for warming-up. 2. Stop the engine. 3. Disconnect the 2P connector from the stop solenoid to stop the fuel supply. 4. Remove the air cleaner, the muffler and all glow plugs. 5.
  • Page 94 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Valve Clearance IMPORTANT • You must examine and adjust the valve clearance when the engine is cold. 1. Remove the head cover. 2. Align the "1TC" mark line (3) on the flywheel and projection (2) on the housing.
  • Page 95 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 the oil pressure tester (Code No. : 07916-32032). (Adaptor screw : PT 1/8) 2. Operate the engine for warming-up. 3. Measure the oil pressure at the idle speed and rated speed. 4.
  • Page 96 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Fan Belt Damage and Wear 1. Examine the fan belt for damage. 2. If the fan belt has a damage, replace it. 3. Examine if the fan belt is worn out and sunk in the pulley groove. 4.
  • Page 97 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Opening-temperature of Thermostat Valve 1. Hang the thermostat in the water by a string with its end put between the valve and the seat. 2. Increase the temperature of the water gradually, read the temperature when the valve opens and disconnects the string. 3.
  • Page 98 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 solenoid. 2. Remove the injection pipes and the glow plugs. 3. Set the speed control lever to the position of maximum fuel discharge.
  • Page 99 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM (Continued) NOTE • The sealant is applied to the 2 sides of the soft metal gasket shim. The liquid gasket is not necessary to assemble. • The shims are available in thickness of 0.175 mm (0.00689 in.) (6), 0.20 mm (0.0079 in.) (3), 0.25 mm (0.0098 in.) (4) and 0.30 mm (0.012 in.) (5).
  • Page 100 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 solenoid. 2. Remove the injection pipes and the glow plugs. 3. Set the speed control lever to the position of maximum fuel discharge. (Reference) • Turn the flywheel with screwdriver. 4.
  • Page 101 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. Set the injection pump pressure tester to the injection pump. 4.
  • Page 102 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 the injection pump pressure tester to the injection pump. 4.
  • Page 103 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 the injection pump pressure tester to the injection pump. 4. Set the injection nozzle (2) jetted with the correct injection pressure to the injection pump pressure tester (1).
  • Page 104 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM CAUTION • Examine the injection pressure and condition after you make sure that there is no one in the direction of the fumes. • If the fumes from the nozzle directly touches the human body, they can cause damage to the cells and blood poisoning.
  • Page 105 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Fuel Injection Pressure [D1803-M-DI, V2403-M-DI, V2403-M-DI-T] 1. Set the injection nozzle to a nozzle tester. 2. Slowly move the tester lever to measure the pressure at which the fuel start to jet out from the nozzle. 3.
  • Page 106 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Nozzle Holder [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. Hold the nozzle retaining nut (7) with a vise. 2. Remove the nozzle holder (1), and remove the internal parts. (When reassembling) •...
  • Page 107 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Battery Specific Gravity 1. Measure the specific gravity of the electrolyte in each cell with a hydrometer. 2. If the electrolyte temperature is different from the one that the hydrometer calibrated, correct specific gravity measurement. Use the formula below in (Reference). 3.
  • Page 108 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Motor Test CAUTION • Hold the starter to prevent its movement when you do a test on the motor. 1. Disconnect the negative cable from the battery. 2. Disconnect the positive cable from the battery. 3.
  • Page 109 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Alternator-on Unit Test Before testing • Before the alternator-on unit test, do a check of the list below : – Battery terminal connections – Circuit connection – Fan belt tension – Charge indicator lamp – Fuses on the circuit –...
  • Page 110 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 (4). Then connect from the switch (4) to the battery positive terminal.
  • Page 111 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM (7) Electronic Governor Speed Sensor 1. Disconnect the connector of the speed sensor (1) (3P). 2. Examine the condition of the harness. 3. If the harness is defective, replace it with a new one. Then replace the ECU with a new one. 4.
  • Page 112 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Oil Pressure Switch 1. Disconnect the connector of the oil pressure switch (1) (1P). 2. Examine the condition of the harness. 3. If the harness is defective, replace it with a new one. 4. Measure the resistance between the terminal of the connector (harness side) and chassis.
  • Page 113 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Solenoid 1. Disconnect the connector of the solenoid (1) (2P). 2. Examine the condition of the harness. 3. If the harness is defective, replace it with a new one. 4. Turn the key switch to the ACC position. 5.
  • Page 114 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Glow Plug Harness 1. Disconnect the wiring (1) of the glow plug. 2. Examine the condition of the wiring. 3. If the wiring is defective, replace it with a new one. 4. Turn the key switch to the ACC position. 5.
  • Page 115 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Emergency Stop Switch 1. Disconnect the connector of the emergency stop switch. 2. Examine the condition of the harness. 3. If the harness is defective, replace it with a new one. 4. Measure the resistance between the terminals of the emergency stop switch when the emergency stop switch turn on or off.
  • Page 116 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM [2] DISASSEMBLING AND ASSEMBLING (1) Draining Engine Oil and Coolant Draining Engine Oil 1. Start and increase the temperature of the engine for approximately 5 minutes. 2. Put an oil pan below the engine. 3. Remove the drain plug (1) to drain the oil. 4.
  • Page 117 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM (2) External Components Air Cleaner, Muffler and Others 1. Remove the air cleaner and muffler. 2. Remove the fan (1), fan belt (4), alternator (2) and starter (3). (When reassembling) • Examine for cracks on the belt surface. IMPORTANT •...
  • Page 118 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) •...
  • Page 119 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) with a 21 mm-deep socket wrench.
  • Page 120 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Service Procedure of Nozzle Heat Seal [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] IMPORTANT • Use a plus (phillips head) screwdriver (1) that has a diameter larger than the heat seal hole (Approximately 6 mm (1/4 in.)).
  • Page 121 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 sequence of (n or r) to (a). 3. Lift up the cylinder head (3) to remove. 4.
  • Page 122 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM (Continued) IMPORTANT • After you replace an item below, you have to select a cylinder head gasket. – Piston – Piston pin – Small end bushing – Connecting rod – Crankpin bearings To select the cylinder head gasket 1.
  • Page 123 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Valves 1. Remove the valve caps (3). 2. Push the valve spring retainer with the valve spring replacer (1) and remove the valve spring collets (4). 3. Remove the valve spring retainer (5) and valve spring (6). 4.
  • Page 124 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM (4) Gear Case and Timing Gears Injection Pump (for Non Turbocharger Model) IMPORTANT • Before you remove the injection pump assembly (2), remove the solenoid (4), hi-idling body (1), engine stop lever (3) and solenoid guide (6). 1.
  • Page 125 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Injection Pump (for Turbocharger Model) IMPORTANT • Before you remove the injection pump assembly (1), remove the boost compensator assembly (2), hi-idling body (4), solenoid (3) and solenoid guide (5). 1. Remove the boost compensator assembly (2). 2.
  • Page 126 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Injection Pump (for Smoke Reduction Device) IMPORTANT • Before you remove the injection pump assembly (1), remove the smoke reduction device (2), hi-idling body (4), solenoid (3) and solenoid guide (5). 1. Remove the smoke reduction device (2). 2.
  • Page 127 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Governor Springs and Speed Control Plate NOTE • Specified tool (1) 1.2 mm (0.047 in.) diameter hard wire with its end hooked, total length 200 mm (7.87 in.). The point of the wire is bent like a hook to hang the governor springs.
  • Page 128 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM (Continued) (When reassembling) • Set the small governor 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).
  • Page 129 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Fan Drive Pulley 1. Lock the flywheel with the flywheel stopper. 2. Remove the mounting nut (1) of the fan drive pulley with a 46 mm (1.8 in.) deep socket wrench (3). 3. Remove the fan drive pulley (2) with a gear puller (4). 4.
  • Page 130 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 attached). 2. Remove the gear case cover (1). 3. Remove the hydraulic pump base assembly (2). 4.
  • Page 131 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. • Make sure that there are 4 O-rings (2) in the gear case (1). •...
  • Page 132 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Idle Gear (for Balancer Model) 1. Remove the external snap ring. 2. Remove the idle gear collar. 3. Remove the idle gear (2). (When reassembling) • Align each gear with its mark. – Cam gear (3) and balancer gear (4) –...
  • Page 133 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. Remove the fuel camshaft stopper (1). 3. Remove the 3 mounting screws (2) of the fork lever holder. 4. Pull out the fuel camshaft assembly (5), (6) and fork lever assembly (3), (4), (7) at the same time.
  • Page 134 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 mounting screws of the oil pan. 2. Tap lightly on the rim of the pan with a wooden hammer to remove the oil pan (3). 3.
  • Page 135 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. Fully clean the carbon (1) in the cylinders. 2. Remove the connecting rod cap (3). 3. Turn the flywheel and move the piston to the top dead center. 4.
  • Page 136 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Pistons [D1803-M-DI, V2403-M-DI, V2403-M-DI-T] 1. Fully clean the carbon (1) in the cylinders. 2. Remove the connecting rod cap (3). 3. Turn the flywheel and move the piston to top dead center. 4. Lightly tap the piston from the bottom of the crankcase with the grip of a hammer to pull the piston out.
  • Page 137 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) and (3) with a piston ring tool. 2. Remove the piston pin (9) to disconnect the connecting rod (7) from the piston (6).
  • Page 138 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) and (3) with a piston ring tool. 2. Remove the piston pin (8) to disconnect the connecting rod (6) from the piston (5). (When reassembling) •...
  • Page 139 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM (6) Flywheel and Crankshaft Flywheel 1. Attach the stopper to the flywheel (1). 2. Remove 2 flywheel screws (2). 3. Put the 2 flywheel guide screws (3) in the holes. 4. Remove all the flywheel screws (2). 5.
  • Page 140 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Crankshaft NOTE • Before you disassemble, measure the side clearance of crankshaft. Measure it when you assemble again. [D1503-M, D1703-M, V2003-M, V2203-M, D1703-M-BG, V2003-M-BG, V2003-M-T-BG, V2203-M-BG] 1. Remove the screw 2 (1) of the main bearing case. 2.
  • Page 141 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Main Bearing Case Assembly 1. Remove the screws 1 of the main bearing case (7). Then remove the main bearing case. 2. Remove other main bearing cases as above. (When reassembling) • Clean the oil channel in the main bearing case. •...
  • Page 142 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM (7) Starter Starter (1) Through Bolt (2) Brush (3) C Terminal Nut (4) Yoke (5) Armature (6) Overrunning Clutch (7) Idle Gear (8) End Frame (9) Brush Holder (10) Magnet Switch Cover (11) Plunger (12) B Terminal Nut (13) Housing 1.
  • Page 143 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM (8) Alternator Alternator (1) Pulley (2) Drive End Frame (3) Stator (4) Bearing (5) Retainer Plate (6) Rotor (7) Bearing (8) Rear End Frame (9) Rectifier (10) IC Regulator (11) Brush Holder (12) Rear End Cover 1.
  • Page 144 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 attach a strip of fuse on the piston head at 3 positions 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.
  • Page 145 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Cylinder Head Surface Flatness 1. Clean the cylinder head surface. 2. Put a straightedge on the cylinder head. 3. Measure the clearance with a feeler gauge at the 6 places (see the figure). 4. If the measurement is more than the allowable limit, make it straight with a surface grinder.
  • Page 146 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. Set the valve into the valve guide. 3. Measure the valve recessing with a depth gauge. 4. If the measurement is more than the allowable limit, replace the valve.
  • Page 147 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 external micrometer. 3. Measure the valve guide I.D. with a small hole gauge, and calculate the clearance.
  • Page 148 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Valve Seating 1. Apply a thin layer of Prussian Blue on the valve face. Then put the valve on its seat to examine the contact. 2. If the valve is not fully around the seat or the contact is less than 70 % of the factory specification, correct the valve seat.
  • Page 149 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Correction of Valve and Valve Seat NOTE • Before you correct the valve and seat, examine the valve stem and measure the I.D. of the valve guide section. Repair them if necessary. • After you correct the valve seat, be sure to examine the valve recessing.
  • Page 150 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM E N G IN E Valve Lapping 1. Apply the compound equally to the valve lapping surface. 2. Put the valve into the valve guide. Lap the valve on its seat with a valve lapping tool. 3.
  • Page 151 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 external micrometer. 2. Measure the rocker arm I.D. with an internal micrometer. 3. Calculate the oil clearance. 4.
  • Page 152 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 point on the gear tooth. 2. Hold the mating gear and move the gear to measure the backlash. 3. If the backlash is more than the allowable limit, measure the oil clearance in the journal part of each shaft.
  • Page 153 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Side Clearance of Idle Gear 1. Set a dial indicator with its point on the idle gear. 2. Move the idle gear to the front and rear to measure the side clearance. 3. If the measurement is more than the allowable limit, replace the idle gear collar.
  • Page 154 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 external micrometer. 2. If the measurement is less than the allowable limit, replace the camshaft. D1503-M, 33.27 mm D1703-M-BG 1.310 in. V2003-M, V2403-M-DI-T, 33.47 mm...
  • Page 155 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM (Continued) D1503-M, 33.47 mm V2003-M, 1.318 in. V2003-M-T-BG D1703-M, D1803-M, V2203-M, 33.90 mm V2403-M, 1.335 in. D1803-M-DI, Factory V2403-M-DI, spec. V2403-M-BG V2403-M-T, D1703-M-BG, 33.27 mm V2003-M-BG, 1.310 in. V2203-M-BG 33.00 mm V2403-M-DI-T 1.299 in. Cam height of exhaust D1503-M, 33.42 mm...
  • Page 156 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 external micrometer. 2. Measure the idle gear bushing I.D. with an internal micrometer. 3. Calculate the oil clearance. 4.
  • Page 157 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 external micrometer. 2. Measure the cylinder block bore I.D. for the balancer shaft with an internal micrometer or cylinder gauge. 3.
  • Page 158 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM (3) Piston and Connecting Rod Piston Pin Bore I.D. 1. Measure the piston pin bore I.D. in the horizontal and vertical directions with a cylinder gauge. 2. If the measurement is more than the allowable limit, replace the piston.
  • Page 159 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Connecting Rod Alignment NOTE • Make sure that the oil clearance of the small end bushing is less than the allowable limit. 1. Install the piston pin into the connecting rod. 2. Install the connecting rod on the alignment tool of the connecting rod.
  • Page 160 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Piston Ring Gap 1. Put 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 ring gap is more than the allowable limit, replace the ring. D1503-M, V2003-M, V2403-M-T,...
  • Page 161 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.
  • Page 162 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 point on the end of the crankshaft. 2. Move the crankshaft to the front and rear to measure the side clearance. 3. If the measurement is more than the allowable limit, replace the thrust bearings.
  • Page 163 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.
  • Page 164 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 external micrometer. 2. Measure the I.D. of the crankshaft bearing 1 with an internal micrometer. 3. Calculate the oil clearance. 4.
  • Page 165 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.
  • Page 166 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Replacement of 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) (see the figure). 4. Increase the temperature of a new sleeve to between 150 and 200 °C (302 and 392 °F).
  • Page 167 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 6 positions (see figure) with a cylinder gauge. 2. Find the maximum and minimum inner diameters. 3. Find the difference between the maximum and the minimum inner diameters.
  • Page 168 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Cylinder Correction (Oversize) 1. If the cylinder wear is more than the allowable limit, bore and hone it to the specified dimension. D1503-M, V2003-M, 83.250 to 83.272 mm V2003-M-BG, 3.2776 to 3.2784 in. V2003-M-T-BG D1703-M, D1803-M, V2203-M, Factory...
  • Page 169 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM (6) Oil Pump Rotor Lobe Clearance 1. Measure the clearance between the 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.
  • Page 170 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Commutator and Mica 1. Examine the contact of the commutator for wear, and grind the commutator with emery paper if it is lightly worn. 2. Measure the commutator O.D. with an external micrometer at some points. 3.
  • Page 171 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM (Continued) D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M, V2403-M-T, 0.45 to 0.75 mm D1803-M-DI, 0.018 to 0.029 in. Factory V2403-M-DI, spec. Mica undercut V2403-M-DI-T, D1703-M-BG, V2003-M-BG, V2003-M-T-BG, V2203-M-BG 0.55 to 0.85 mm V2403-M-BG 0.022 to 0.033 in. 0.20 mm Allowable limit 0.0079 in.
  • Page 172 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Armature Coil 1. Examine the continuity across the commutator and armature coil core with the resistance range of circuit tester. 2. If electricity flows, replace the armature assembly. 3. Examine the continuity across the segments of the commutator with the resistance range of circuit tester.
  • Page 173 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Stator 1. Measure the resistance across each lead of the stator coil with the resistance range of circuit tester. 2. If the measurement is not in the factory specification, replace the stator assembly. 3. Examine the continuity across each stator coil lead and core with the resistance range of circuit tester.
  • Page 174 ENGINE 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG, WSM Rectifier 1. Examine the continuity across each diode of rectifier with the resistance range of circuit tester. 2. The rectifier is correct if the diode in the rectifier conducts electricity only in one direction. M00000003ENS0158US1 IC Regulator 1.
  • Page 175 EDITOR : KUBOTA FARM & INDUSTRIAL MACHINERY SERVICE, LTD. 64, ISHIZU-KITAMACHI, SAKAI-KU, SAKAI-CITY, OSAKA, 590-0823, JAPAN PHONE : ( 81 ) 72-241-1129 : ( 81 ) 72-245-2484 E-mail : ksos-pub@kubota.co.jp Printed in Japan 2009. 06, S, EI, EI, e Code No.9Y111-02570 KUBOTA Corporation 2009.

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