Service Manual: Diesel Engine

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The document outlines maintenance procedures and checks for a diesel engine, including specifications, dimensions, identification information, precautions, checklists, and testing procedures for various components.

The document discusses the engine body, cooling system, fuel system, lubrication system, and electrical system as main components. It also indexes specifications and dimensions.

The document outlines numerous maintenance checks that should be performed daily, initially at 50 hours, every 50 hours, 100 hours, 200 hours, 400 hours, 500 hours, monthly, yearly, 800 hours, 1500 hours, 3000 hours, and every 2 years. The frequency and components checked increase with running hours.

SB4400E00

Dec.2008

Service Manual
V2403 Diesel Engine

D15S-5, D18S-5, D20SC-5


D15G, D18G

Forklifts
Important Safety Information

Most accidents involving product operation, maintenance and repair are caused by failure to observe basic
safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations
before an accident occurs. A person must be alert to potential hazards. This person should also have the
necessary training, skills and tools to perform these functions properly.

Read and understand all safety precautions and warnings before operating or performing lubrication,
maintenance and repair on this product.

Basic safety precautions are listed in the “Safety” section of the Service or Technical Manual. Additional safety
precautions are listed in the “Safety” section of the owner/operation/maintenance publication. Specific safety
warnings for all these publications are provided in the description of operations where hazards exist.
WARNING labels have also been put on the product to provide instructions and to identify specific hazards. If
these hazard warnings are not heeded, bodily injury or death could occur to you or other persons. Warnings in
this publication and on the product labels are identified by the following symbol.

WARNING

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could
result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read
and understood the operation, lubrication, maintenance and repair information.

Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.

DOOSAN cannot anticipate every possible circumstance that might involve a potential hazard. The warnings
in this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or
operating technique not specifically recommended by DOOSAN is used, you must satisfy yourself that it is
safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the
operation, lubrication, maintenance or repair procedures you choose.

The information, specifications, and illustrations in this publication are on the basis of information available at
the time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and
other items can change at any time. These changes can affect the service given to the product. Obtain the
complete and most current information before starting any job. DOOSAN dealers have the most current
information available.

1
Index

1. General Information 3. Mechanism


1.1. Specifications................................................ 9 3.1. Engine Body................................................ 53
3.1.1. Piston ................................................. 53
1.2. Dimensions ................................................. 10 3.1.2. Half-Floating Head Cover.................... 53

3.2. Cooling System........................................... 54


3.2.1. Bottom Bypass System ....................... 54
2. General
3.3. Fuel System ................................................ 55
2.1. Engine Identification ................................... 11 3.3.1. Governor............................................. 55
2.1.1. Model Name And Engine Serial Number
..................................................................... 11
2.1.2. E3B Engine ......................................... 13
2.1.3. Cylinder Number ................................. 13 4. Servicing
2.2. General Precautions ................................... 14 4.1. Troubleshooting ......................................... 56
4.1.1. Engine Body ....................................... 56
2.3. Maintenance Check List.............................. 15
4.2. Servicing Specifications............................. 60
2.4. Check and Maintenance.............................. 18
2.4.1. Check Point When Required................ 18 4.3. Tightening Torques .................................... 66
2.4.2. Daily Check Points .............................. 19 4.3.1. Tightening Torques For General Use
2.4.3. Check Points of Initial 50 Hours........... 21 Screws, Bolts And Nuts ................................ 66
2.4.4. Check Points of Every 50 Hours .......... 23 4.3.2. Tightening Torques For Special Use
2.4.5. Check Points of Every 100 Hours ........ 24 Screws, Bolts And Nuts ................................ 67
2.4.6. Check Points of Every 200 Hours ........ 26
2.4.7. Check Points of Every 400 Hours ........ 29 4.4. Checking, Disassembling And Servicing .. 68
2.4.8. Check Points of Every 500 Hours ........ 30 4.4.1. Checking And Adjusting ...................... 68
2.4.9. Check Points of Every 1 or 2 Months... 33 4.4.2. Disassembling And Assembling .......... 92
2.4.10. Check Points of Every Year............... 35 4.4.3. Servicing............................................118
2.4.11. Check Points of Every 800 Hours ...... 35
2.4.12. Check Points of Every 1500 Hours .... 37
2.4.13. Check Points of Every 3000 Hours .... 39
2.4.14. Check Points of Every 2 Years .......... 40

2.5. Special Tools............................................... 44

V2403 Service Manual 3 Index


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.

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.

V2403 Service Manual 5


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.

• Do not open high-pressure fuel system.


High-pressure fluid remaining in fuel lines can
cause serious injury. Do not disconnect or attempt
to repair fuel lines, sensors, or any other
components between the high-pressure fuel pump
and injectors on engines with high pressure
common rail fuel system.

• High voltage exceeding 100 V is generated in the


ECU, and is applied to the injector.
Pay sufficient caution to electric shock when
performing work activities.

V2403 Service Manual 6


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.

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.

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.

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.

V2403 Service Manual 7


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.

V2403 Service Manual 8


1. General Information

1.1. Specifications

Model V2403-M
Number of Cylinders 4
Type Vertical, Water-cooled, 4 cycle diesel engine
Bore × Stroke 87.0 X 102.4 mm (3.43 X 4.031 in.)
Total Displacement 2434 cm3 (148.5 cu.in.)
SAE Gross Intermittent 34.1 kW @ 2400 rpm
(46.4 ps @ 2400 rpm)
High Idle Speed @ Dynamo 2670 ±50 rpm
Low Idle Speed @ Dynamo 775 ~ 825rpm (for D18G)
875 ~ 925rpm (for D18S)
Combustion Chamber Spherical Type (E-TVCS)
Fuel Injection Pump PFR 4M Type Mini Pump (DENSO)
Governor Mechanical all speed governor
Direction of Rotation Counter-clockwise (viewd from flywheel side)
Injection Nozzle OPD Mini Nozzle (DENSO)
Injection Timing 15.25 Before T.D.C
Firing Order 1-3-4-2
Injection Pressure 13.73 MPa (140.0 kgf/cm2, 1991 psi)
Compression Ratio 23.8 : 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
Starting Support Device By glow plug in combustion chamber
EGR NONE
Recommended Battery 12 V, 92 AH equivalent
Charging Alternator 12V, 40A
Recommended Fuel Diesel Fuel No.2-D (ASTM D975)
Lubricating Oil Class CF lubricating oil as per API classification is recommended.
Lubricating Oil Capacity For details on recommended lubricating oils, see page G-7, 10
9.5 L (2.5 U.S.gals)
Weight (Dry) 184 kg (406 lbf)

* The specification described above is of the standard engine of each model.


* Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW

V2403 Service Manual 9 1. General Information


1.2. Dimensions

V2403 (D18S) V2403 (D18G)


A 728.2 mm (28.67 in.) 768.2 mm (30.24 in.)
B 525.3 mm (20.68 in.) 525.3 mm (20.68 in.)
C 742.5 mm (29.23 in.) 691.2 mm (27.21in.)

V2403 Service Manual 10 1. General Information


2. General

2.1. Engine Identification

2.1.1. 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

Alphabet or Alphabet or
Year Year
Number Number
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

V2403 Service Manual 11 2. General


• Month of manufacture

Month Engine Lot Number


January A0001 ~ A9999 B0001 ~ BZ999
February C0001 ~ C9999 D0001 ~ DZ999
March E0001 ~ E9999 F0001 ~ FZ999
April G0001 ~ G9999 H0001 ~ HZ999
May J0001 ~ J9999 K0001 ~ KZ999
June L0001 ~ L9999 M0001 ~ MZ999
July N0001 ~ N9999 P0001 ~ PZ999
August Q0001 ~ Q9999 R0001 ~ RZ999
September S0001 ~ S9999 T0001 ~ TZ999
October U0001 ~ U9999 V0001 ~ VZ999
November W0001 ~ W9999 X0001 ~ XZ999
December Y0001 ~ Y9999 Z0001 ~ ZZ999

* Alphabetical letters “I” and “O” are not used.


e.g. D1803 - 7 B A001
(a) (b) (c) (d)
(a) Engine Model Name : D1803
(b) Year : 7 indicates 2007
(c) Month : A or B indicates January
(d) Lot number : (0001 ~ 9999 or A001 ~ Z999)

V2403 Service Manual 12 2. General


2.1.2. E3B Engine

[Example : Engine Model Name D1803-M-E3B-XXXX or D1803-M-DI-E3B-XXXX]

The emission controls previously implemented in various countries to prevent air pollution will be stepped up
as Non-Road Emission Standards continue to change. The timing or applicable date of the specific Non-Road
Emission regulations depends on the engine output classification.

Over the past several years, Kubota has been supplying diesel engines that comply with regulations in the
respective countries affected by Non-Road Emission regulations. For Kubota Engines, E3B will be the
designation that identifies engine models affected by the next emission phase (See the table below).

When servicing or repairing ###-E3B series engines, use only replacement parts for that specific E3B engine,
designated by the appropriate E3B Kubota Parts List and perform all maintenance services listed in the
appropriate Kubota Operator's Manual or in the appropriate E3B Kubota Workshop Manual. Use of incorrect
replacement parts or replacement parts from other emission level engines (for example: E2B engines), may
result in emission levels out of compliance with the original E3B design and EPA or other applicable
regulations.Please refer to the emission label located on the engine head cover to identify Output
classification and Emission Control Information. E3B engines are identified with "ET" at the end of the Model
designation, on the US EPA label. Please note : E3B is not marked on the engine.

Categ EU
Engine output classification
ory (1) regulation
K From 19 to less than 37 kW STAGE ΙΙΙA
J From 37 to less than 75 kW STAGE ΙΙΙA
I From 75 to less than 130 kW STAGE ΙΙΙA

Categ EPA
Engine output classification
ory (2) regulation
Less than 19kW Tier 4
From 19 to less than 56 kW Interim Tier 4
ET
From 56 to less than 75 kW Tier 3
From 75 to less than 130 kW Tier 3
(1) EU regulation engine output classification category
(2) “E3B” engines are identified with “ET” at the end of
the Model designation, on the US EPA label.
“E3B” designates Tier 3 and some Interim Tier 4 /
Tier 4 models, depending on engine output
classification.

2.1.3. 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.

V2403 Service Manual 13 2. General


2.2. 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.

(1) Grease (A) External Snap Ring


(2) Force (B) Internal Snap Ring
(3) Place the Sharp Edge against
the Direction of Force

V2403 Service Manual 14 2. General


2.3. 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.

Service Interval
Item Every
50 100 150 200 400 500 1 or 2 1 800 1500 3000 2
hrs hrs hrs hrs hrs hrs months year hrs hrs hrs years
* Checking fuel hoses and clamp

bands
Changing (1) Oil pan depth
★ ☆
engine oil (90 mm, 3.5 in.)
(depending
(2) Oil pan depth
on the oil ★ ☆
(124 mm, 4.88 in.)
pan)
*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
(1) Oil pan depth
Replacing oil ★ ☆
(90 mm, 3.5 in.)
filter
cartridge (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.) ☆
★ 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.

V2403 Service Manual 15 2. General


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).

Engine oil classification (API classification)


Fuel Type Engines with non-EGR
Engines with external EGR
Engines with internal EGR

CF
High Sulfur Fuel
(If the "CF-4, CG-4, CH-4, or CI-4" engine
[0.05 % (500 ppm) ≤
oil is used with a high-sulfur fuel, change -
Sulfur Content <
the engine oil at shorter intervals.
0.50 % (5000 ppm)]
(approximately half))

Low Sulfur Fuel


[Sulfur Content < CF or CI-4
0.05 % (500 ppm)] or (Class CF-4, CG-4 and CH-4 engine
CF, CF-4, CG-4, CH-4 or CI-4
Ultra Low Sulfur Fuel oils cannot be used on EGR type
[Sulfur Content < engines.)
0.0015 % (15 ppm)]
EGR : Exhaust Gas Re-circulation

• CJ-4 classification oil is intended for use in engines equipped with DPF (Diesel Particulate Filter) and
is Not Recommended for use in Kubota E3 specification engines.

• Oil used in the engine should have API classification and Proper SAE Engine Oil Viscosity according
to the ambient temperatures where the engine is operated.

• With strict emission control regulations now in effect, the CF-4 and CG-4 engine oils have been
developed for use with low sulfur fuels, for On-Highway vehicle engines. When a Non-Road engine
runs on high sulfur fuel, it is advisable to use a "CF or better" classification engine oil with a high
Total Base Number (a minimum TBN of 10 is recommended).

Fuel :

• Cetane Rating : The minimum recommended Fuel Cetane Rating is 45. A cetane rating greater than
50 is preferred, especially for ambient temperatures below .20 °C (.4 °F) or elevations above 1500 m
(5000 ft).

• Diesel Fuel Specification Type and Sulfur Content % (ppm) used, must be compliant with all
applicable emission regulations for the area in which the engine is operated.

• Use of diesel fuel with sulfur content less than 0.10 % (1000 ppm) is strongly recommended.

• If high-sulfur fuel (sulfur content 0.50 % (5000 ppm) to 1.0 % (10000 ppm)) is used as a diesel fuel,
change the engine oil and oil filter at shorter intervals. (approximately half)

V2403 Service Manual 16 2. General


• DO NOT USE Fuels that have sulfur content greater than 1.0 % (10000 ppm).

• Diesel fuels specified to EN 590 or ASTM D975 are recommended.

• No.2-D is a distillate fuel of lower volatility for engines in industrial and heavy mobile service. (SAE
J313 JUN87)

• Since KUBOTA diesel engines of less than 56 kW (75 hp) utilize EPA Tier 4 and Interim Tier 4
standards, the use of low sulfur fuel or ultra low sulfur fuel is mandatory for these engines, when
operated in US EPA regulated areas. Therefore, please use No.2-D S500 or S15 diesel fuel as an
alternative to No.2-D, and use No.1-D S500 or S15 diesel fuel as an alternative to No.1-D for ambient
temperatures below .10 °C (14 °F).

1) SAE : Society of Automotive Engineers

2) EN : European Norm

3) ASTM : American Society of Testing and Materials

4) US EPA : United States Environmental Protection Agency

5) No.1-D or No.2-D, S500 : Low Sulfur Diesel (LSD) less than 500 ppm or 0.05 wt.%
No.1-D or No.2-D, S15 : Ultra Low Sulfur Diesel (ULSD) 15 ppm or 0.0015 wt.%

V2403 Service Manual 17 2. General


2.4. Check and Maintenance

2.4.1. Check Point When Required Draining the Water from the Fuel Filter

1. Check "Diesel Engine Water in fuel filter indicator


Priming the Fuel System light" in instrument panel. Refer to, "Diesel Engine
Water in Fuel Filter Indicator Light" in Operator's
Bleeding the Fuel System Station and Monitoring Systems section.
After changing the fuel filter cartridge assembly, or
after having serviced any part of the fuel system,
make sure that the air is bled from the system.
1

2. Turn the wing nut (1) counter clockwise more than


two turns. The wing nut (1) is located near fuel's
inlet side. Some times later, "w" marking will be
added as illustrated in Top View below.
1. Open the air vent cock on top of the fuel injection
pump.

3 3. Turn the wing nut (2) counter clockwise more than


six turns to open the drain valve on the bottom of
the fuel filter.
2. Push the priming pump on top of the fuel filter
housing against the spring to allow air mixed with
fuel to escape through the bleeding screw. Ensure
that excess fuel is collected in a container or rag
to prevent fuel from getting onto engine parts.

3. Repeat the pumping action until no bubbles are


visible in the flowing fuel.

4. Tighten the bleed screw and the air rent cock.


2
5. Start the engine and check fuel system for leaks.

4. Drain some fuel (and any water) until the clean


fuel flows out from the filter.

V2403 Service Manual 18 2. General


2.4.2. 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, 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.

(1) Dipstick (a) Maximum


(b) Minimum

V2403 Service Manual 19 2. 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..

(1) Radiator Cap A : FULL


(2) Recovery Tank B : LOW

V2403 Service Manual 20 2. General


2.4.3. 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 CF (See page G-7).
• Use the proper SAE Engine Oil according to
ambient temperature.

SAE 30 or SAE 10W-30


Above 25 °C (77 °F)
SAE 10W-40
0 °C to 25 °C SAE 20 or SAE 10W-30
(32 °F to 77 °F) SAE 10W-40
SAE 10W or SAE 10W-30
Below 0 °C (32 °F)
SAE 10W-40
*Lubricating oil Capacity is 9.5L (2.5 U.S.gals).

(1) Drain Plug (2) Dipstick

V2403 Service Manual 21 2. General


Replacing Oil Filter Cartridge

CAUTION
• Be sure to stop the engine before replacing filter
cartridge.
1. Remove the oil filter cartridge (1) with the filter
wrench.
2. Apply a slight coat of oil onto the new cartridge
gasket.
3. To install the new cartridge, screw it in by hand.
Over tightening may cause deformation of rubber
gasket.
4. After the new cartridge has been replaced, the
engine oil normally decrease a little. Thus see
that the engine oil does not leak through the seal
and be sure to read the oil level on the dipstick.
Then, replenish the engine oil up to the specified
level.

IMPORTANT
To prevent serious damage to the engine,
replacement element must be highly efficient. Use
only a KUBOTA genuine filter or its equivalent.

(1) Engine Oil Filter Cartridge

V2403 Service Manual 22 2. General


2.4.4. Check Points of Every 50 Hours

Checking Fuel Hoses and Clamp Bands


[A]
1. If the clamp (2) is loose, apply oil to the threads and
securely retighten it.

2. The fuel hose (1) is made of rubber and ages


regardless of the period service.
Change the fuel hose together with the clamp every
two years.

3. However, if the fuel hose and clamp are found to be


damaged or deteriorate earlier than two years, then
change or remedy.

4. After the fuel hose and the clamp have been


[B]
changed, bleed the fuel system.

[A] Cartridge Type


[B] Element Type

CAUTION
Stop the engine when attempting the check and
change prescribed above.

V2403 Service Manual 23 2. General


2.4.5. Check Points of Every 100 Hours

Cleaning Air Cleaner Element

1. Remove the air cleaner element.

2. Use clean dry compressed air on the inside of the


element.
Pressure of compressed air must be under 210 kPa
(2.1 kgf/cm², 30 psi).
Maintain reasonable distance between the nozzle
and the filter.

NOTE
• The air cleaner uses a dry element. Never apply oil
to it.
• Do not run the engine with filter element removed.
• Change the element once a year or every 6th
cleaning.

Cleaning Fuel Filter (Element Type only)

1. Close the fuel cock (3).

2. Unscrew the retaining ring (6) and remove the filter


cup (5), and rinse the inside with kerosene.

3. Take out the element (4) and dip it in the kerosene to


rinse.

4. After cleaning, reassemble the fuel filter, keeping out


dust and dirt.

5. Bleed the fuel system.

IMPORTANT
If dust and dirt enter the fuel, the fuel injection
pump and injection nozzle will wear quickly. To
prevent this, be sure to clean the fuel filter cup (5)
periodically.

(1) Cock Body (4) Filter Element


(2) Air Vent Plug (5) Filter Cup
(3) Fuel Cock (6) Retaining Ring

V2403 Service Manual 24 2. General


Checking Battery Electrolyte Level

1. Check the battery electrolyte level.

2. If the level is below than lower level line (2), and the
distilled water to pour level of each cell.

(1) Upper Level Line (2) Lower Level Line

Fan Belt Tension

1. Measure the deflection (A), depressing the belt


halfway between the fan drive pulley and alternator
pulley at specified force 98 N (10 kgf, 22 lbf).

2. If the measurement is not within the factory


specifications, loosen the alternator mounting screws
and relocate the alternator to adjust.

7.0 to 9.0 mm
Deflection (A) Factory spec.
0.28 to 0.35 in.

(A) Deflection

Fan Belt Damage and Wear

1. Check the fan belt for damage.

2. If the fan belt is damaged, replace it.

3. Check if the fan belt is worn and sunk in the pulley


groove.

4. If the fan belt is nearly worn out and deeply sunk in


the pulley groove, replace it.

(A) Good (B) Bad

V2403 Service Manual 25 2. General


2.4.6. Check Points of Every 200 Hours
Changing Engine Oil (for 124 mm (4.88 in.) Depth
Oil Pan)

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 CF (See page G-7).
• Use the proper SAE Engine Oil according to
ambient temperature.

SAE 30 or SAE 10W-30


Above 25 °C (77 °F)
SAE 10W-40
0 °C to 25 °C SAE 20 or SAE 10W-30
(32 °F to 77 °F) SAE 10W-40
SAE 10W or SAE 10W-30
Below 0 °C (32 °F)
SAE 10W-40
*Lubricating oil Capacity is 9.5L (2.5 U.S.gals).

(1) Drain Plug (2) Dipstick

V2403 Service Manual 26 2. General


Replacing Oil Filter Cartridge (for 124 mm (4.88 in.)
Depth Oil Pan)

CAUTION
• Be sure to stop the engine before replacing filter
cartridge.
1. Remove the oil filter cartridge (1) with the filter
wrench.
2. Apply a slight coat of oil onto the new cartridge
gasket.
3. To install the new cartridge, screw it in by hand.
Over tightening may cause deformation of rubber
gasket.
4. After the new cartridge has been replaced, the
engine oil normally decrease a little. Thus see
that the engine oil does not leak through the seal
and be sure to read the oil level on the dipstick.
Then, replenish the engine oil up to the specified
level.

IMPORTANT
To prevent serious damage to the engine,
replacement element must be highly efficient. Use
only a KUBOTA genuine filter or its equivalent.

(1) Engine Oil Filter Cartridge

V2403 Service Manual 27 2. General


Checking Radiator Hoses and Clamp Bands

1. Check to see if the radiator hoses are properly fixed


every 200 hours of operation or every six months,
whichever comes first.

2. If the clamp is loose, apply oil to the threads and


retighten it securely.

3. The water hose is made of rubber and tends to age.


It must be replaced every two years. Also replace the
clamp and tighten it securely.

(1) Upper Hose (2) Lower Hose

Checking Intake Air Line

1. Check to see if the intake air hose(s) are properly


fixed every 200 hours of operation.

2. If the clamp is loose, apply oil to the threads and


retighten it securely.

3. The intake air hose(s) is made of rubber and tends to


age. It must be changed every two years. Also
change the clamp and tighten it securely.

IMPORTANT
To prevent serious damage to the engine, keep out
any dust inside the intake air line.

(1) Intake Air Hose (2) Clamp

V2403 Service Manual 28 2. General


2.4.7. Check Points of Every 400 Hours

Replacing Fuel Filter

Park lift truck with the forks lowered, parking brake


applied, transmission in neutral, engine stopped and
cool.

1. Raise the hood and seat assembly.

WARNING
Fuel leaked or spilled onto hot surfaces or
electrical components can cause a fire.
Turn the disconnect switch OFF if fitted or
disconnect the battery when changing fuel filters.

2. Remove fuel filter cartridge assembly.

3. Remove sensor assembly from cartridge


assembly.

4. Before installing a new cartridge assembly,


assemble existing sensor assembly, apply a small
amount

NOTICE
Do not fill fuel filters with fuel before installing them.
Contaminated fuel will cause accelerated wear to
fuel system parts.

5. Install the new fuel filter cartridge assembly.

6. Turn the new fuel filter cartridge assembly until


the filter gasket is fitted against the sealing face.

7. Turn the fuel filter cartridge assembly an


additional 2/3 of turn.

V2403 Service Manual 29 2. General


2.4.8. Check Points of Every 500 Hours

Cleaning Water Jacket and Radiator Interior

CAUTION
• Do not remove the radiator cap when the engine is
hot. Then loosen cap slightly to the stop to
relieve any excess pressure before removing cap
completely.
1. Stop the engine and let cool down.
2. To drain the coolant, open the radiator drain plug
(2) and remove the radiator cap (1). Then radiator
cap (1) must be removed to completely drain the
coolant. And open the drain cock (3).
3. After all coolant is drained, close the drain plug.
4. Fill with clean water and cooling system cleaner.
5. Follow directions of the cleaner instruction.
6. After flushing, fill with clean water and anti-
freeze until the coolant level is just below the port.
Install the radiator cap (1) securely.
7. Fill with coolant up to “FULL” (A) mark on the
recovery tank (4).
8. Start and operate the engine for few minutes.
9. Stop the engine and let cool. Check coolant level
of radiator and recovery tank (4) and add coolant
if necessary.

IMPORTANT
• Do not start engine without coolant.
• Use clean, fresh, soft water and anti-freeze to fill
the radiator and recovery tank.
• When the anti-freeze is mixed with fresh, soft
water, the antifreeze mixing ratio must be less
than 50 %.
• Securely tighten radiator cap. If the cap is loose or
improperly fitted, water may leak out and the
engine could overheat.

(1) Radiator Cap A : Full


(2) Drain Plug B : Low
(3) Drain Cock
(4) Recovery Tank

V2403 Service Manual 30 2. General


Anti-Freeze

• There are two types of anti-freeze available: use the


permanent type (PT) for this engine.

• Before adding anti-freeze for the first time, clean the


radiator interior by pouring fresh, soft water and
draining it a few times.

• The procedure for mixing water and anti-freeze differs


according to the make of the anti-freeze and the
ambient temperature.
Basically, it should be referred to SAE J1034 standard,
more specifically also to SAE J814c.

• Mix the anti-freeze with fresh, soft water, and then fill
into the radiator.

IMPORTANT
When the anti-freeze is mixed with fresh, soft water,
the antifreeze mixing ratio must be less than 50 %.

Vol % Freezing point Boiling point*


anti-freeze °C °F °C °F
40 -24 -11 106 223
50 -37 -35 108 226

* At 1.01 × 100000 Pa (760 mmHg) pressure


(atmospheric). A higher boiling point is obtained by
using a radiator pressure cap which permits the
development of pressure within the cooling system.

NOTE
• The above data represents industrial standards
that necessitate a minimum glycol content in the
concentrated anti-freeze.
• When the coolant level drops due to evaporation,
add fresh, soft water only to keep the anti-freeze
mixing ratio less than 50 %. In case of leakage,
add anti-freeze and fresh, soft water in the
specified mixing ratio.
• Anti-freeze absorbs moisture. Keep unused anti-
freeze in a tightly sealed container.
• Do not use radiator cleaning agents when anti-
freeze has been added to the coolant.
(Anti-freeze contains an anti-corrosive agent,
which will react with the radiator cleaning agent
forming sludge which will affect the engine parts.)

V2403 Service Manual 31 2. General


Replacing Fan Belt

1. Remove the alternator.

2. Remove the fan belt (1).

3. Replace new fan belt.

4. Install the alternator.

5. Check the fan belt tension.

7.0 to 9.0 mm / 98 N
Deflection (A) Factory spec. 0.28 to 0.35 in. / 98 N
(10 kgf, 22 lbf)

(1) Fan Belt (A) Deflection

V2403 Service Manual 32 2. General


2.4.9. Check Points of Every 1 or 2 Months

Recharging

CAUTION
• When the battery is being activated, hydrogen and oxygen gases in the battery are extremely
explosive. Keep open sparks and flames away from the battery at all times, especially when
charging the battery.
• When charging battery, remove battery vent plugs.
• When disconnecting the cable from the battery, start with the negative terminal first. When
connecting the cable to the battery, start with the positive terminal first.
• Never check battery charge by placing a metal object across the posts.
Use a voltmeter or hydrometer.

1) Slow Charging

1. Add distilled water if the electrolyte level is low. When charging, the amount of electrolyte should be slightly
lower than the specified level to prevent overflow.

2. Connect the battery to the charging unit, following the manufacture’s instructions.

3. As the electrolyte generates gas while charging, remove all port caps.

4. The electrolyte temperature must not exceed 40 °C (104 °F) during charging. If it exceed 40 °C (104 °F),
decrease the charging amperage or stop charging for a while.

5. When charging several batteries in series, charge at the rate of the smallest battery in the line.

2) Quick Charging

1. Determine the proper charging current and charging time with the tester attached to the quick charger.

2. Determine the proper charging current as 1/1 of the battery capacity. If the battery capacity exceeds 50 Ah,
consider 50 A as the maximum.

■ Precaution for Operating a Quick Charger

• Operate with a quick charger differs according to the type.


Consult the instruction manual and use accordingly.

V2403 Service Manual 33 2. General


Battery Specific Gravity

1. Check the specific gravity of the electrolyte in each


cell with a hydrometer.

2. When the electrolyte temperature differs from that at


which the hydrometer was calibrated, correct the
specific gravity reading following the formula
mentioned in (Reference).

3. If the specific gravity is less than 1.215 (after it is


corrected for temperature), charge or replace the
battery.

4. If the specific gravity differs between any two cells by


more than 0.05, replace the battery.

NOTE
• Hold the hydrometer tube vertical without
removing it from the electrolyte.
• Do not suck too much electrolyte into the tube.
• Allow the float to move freely and hold the
hydrometer at eye level.
• The hydrometer reading must be taken at the
highest electrolyte level.

(Reference)

• Specific gravity slightly varies with temperature. To be


exact, the specific gravity decreases by 0.0007 with an
increase of 1 °C (0.0004 with an increase of 1 °F) in
temperature, and increases by 0.0007 with a
decreases of 1 °C (0.0004 with a decrease of 1 °F).
Therefore, using 20 °C (68 °F) as a reference, the
specific gravity reading must be corrected by the
following formula :

- Specific gravity at 20 °C = Measured value + 0.0007


× (electrolyte temperature : 20 °C)

- Specific gravity at 68 °F = Measured value + 0.0004


× (electrolyte temperature : 68 °F)

Specific Gravity State of Charge


1.260 Sp. Gr. 100 % Charged
1.230 Sp. Gr. 75 % Charged
1.200 Sp. Gr. 50 % Charged
1.170 Sp. Gr. 25 % Charged
1.140 Sp. Gr. Very Little Useful Capacity
1.110 Sp. Gr. Discharged
At an electrolyte temperature of 20 °C (68 °F)

(a) Good (c) Bad


(b) Bad

V2403 Service Manual 34 2. General


2.4.10. Check Points of Every Year

Replacing Air Cleaner Element

1. Remove used air cleaner element.

2. Replace new air cleaner element.

NOTE
• The air cleaner uses a dry element. Never apply
oil to it.
• Do not run the engine with filter element
removed.

2.4.11. Check Points of Every 800 Hours

Valve Clearance

IMPORTANT
Valve clearance must be checked and adjusted
when engine is cold.

1. Remove the head cover.

2. Align the “1TC” mark line (3) on the flywheel and


projection (2) on the housing so that the No.1 piston
comes to the compression or overlap top dead center.

3. Check the following valve clearance (1) marked with


“☆” using a feeler gauge.

4. If the clearance is not within the factory specifications,


adjust with the adjusting screw.

Valve 0.18 to 0.22 mm


Factory spec.
clearance 0.0071 to 0.0086 in.

V2403 Service Manual 35 2. General


NOTE
• The “1TC” mark line on the flywheel is just for No.
1 cylinder.
There is no “TC” marking for the other cylinders.
• No. 1 piston comes to the top dead center
position when the “TC” marking is aligned with
the projection (2) in the window on flywheel-
housing. Turn the flywheel 0.26 rad (15 °)
clockwise and counterclockwise to see if the
piston is at the compression top dead center or
the overlap position. Now referring to the table
below, readjust the valve clearance (1).
(The piston is at the top dead center when both
the IN. and EX. valves do not move; it is at the
overlap position when both the valves move.)
• Finally turn the flywheel 6.28 rad (360 °) and align
the “1TC” mark line and the projection (2)
perfectly. Adjust all the other valve clearance as
required.
• After turning the flywheel counterclockwise twice
or three times, recheck the valve clearance (1).
• After adjusting the valve clearance (1), firmly
tighten the lock nut of the adjusting screw.

Valve arrangement 4 Cylinder


Adjustable
cylinder IN. EX.
location of piston
No. 1 . ☆ ☆
No. 2 . ☆
When No. 1 piston is at compression top dead center
No. 3 . ☆
No. 4 .
No. 1 .
No. 2 . ☆
When No. 1 piston is at overlap position
No. 3 . ☆
No. 4 . ☆ ☆

(1) Valve Clearance (3) 1TC Mark Line


(2) Projection

V2403 Service Manual 36 2. General


2.4.12. Check Points of Every 1500 Hours

CAUTION
• Check the injection pressure and condition after confirming that there is nobody standing in the
direction the fume goes.
• If the fume from the nozzle directly contacts the human body, cells may be destroyed and blood
poisoning may be caused.

Nozzle Spraying Condition

1. Set the injection nozzle to a nozzle tester, and check


the nozzle spraying condition.

2. If the spraying condition is defective, replace the


nozzle piece.

(a) Good (b) Bad

Fuel Injection Pressure

1. Set the injection nozzle to a nozzle tester.

2. Slowly move the tester handle to measure the


pressure at which fuel begins jetting out from the
nozzle.

3. If the measurement is not within the factory


specifications, replace the adjusting washer (1) in the
nozzle holder to adjust it.

(Reference)

• Pressure variation with 0.025 mm (0.00098 in.)


difference of adjusting washer thickness.
Approx. 590 kPa (6.0 kgf/cm², 85 psi)

13.73 to 14.70 MPa


Fuel injection
Factory spec. 140.0 to 150.0 kgf/cm2
pressure
1992 to 2133 psi

(1) Adjusting Washer

V2403 Service Manual 37 2. General


Valve Seat Tightness

[D1503-M, D1703-M, D1803-M, V2003-M, V2203-M,


V2403-M, V2403-M-T]
[D1703-M-BG, V2003-M-BG, V2003-M-T-BG, V2203-
M-BG, V2403-M-BG]

1. Set the injection nozzle to a nozzle tester.

2. Raise the fuel pressure, and keep at 12.75 MPa


(130.0 kgf/cm², 1849 psi) for 10 seconds.

3. If any fuel leak is found, replace the nozzle piece.

No fuel leak at
Valve seat 12.75 MPa
Factory spec. 2
tightness 130.0 kgf/cm
1849 psi

Nozzle Holder

1. Secure the nozzle retaining nut (7) with a vise.

2. Remove the nozzle holder (1), and take out parts


inside.

(When reassembling)

• Assemble the nozzle in clean fuel oil.

• Install the push rod (4), noting its direction.

• After assembling the nozzle, be sure to adjust the fuel


injection pressure.

35 to 39 N·m
Nozzle holder 3.5 to 4.0 kgf·m
26 to 28 lbf·ft
20 to 24 N·m
Tightening Overflow pipe
2.0 to 2.5 kgf·m
torque retaining nut
15 to 18 lbf·ft
49 to 68 N·m
Nozzle holder
5.0 to 7.0 kgf·m
assembly
37 to 50 lbf·ft

(1) Nozzle Holder (5) Distance Piece


(2) Adjusting Washer (6) Nozzle Piece
(3) Nozzle Spring (7) Nozzle Retaining Nut
(4) Push Rod

V2403 Service Manual 38 2. General


2.4.13. Check Points of Every 3000 Hours

Checking Injection Pump

(Fuel Tightness of Pump Element)

1. Remove the solenoid.


2. Remove the injection pipes and glow plugs.
3. Install the injection pump pressure tester to the
injection pump.
4. Install the injection nozzle (2) jetted with the proper
injection pressure to the injection pump pressure
tester (1). (Refer to the figure.)
5. Set the speed control lever to the maximum speed
position.
6. Run the starter to increase the pressure.
7. If the pressure can not reach the allowable limit, replace the pump with new one or repair with a Kubota-
authorized pump service shop.

(Fuel Tightness of Delivery Valve)

1. Remove the solenoid.


2. Remove the injection pipes and glow plugs.
3. Set a pressure tester to the fuel injection pump.
4. Install the injection nozzle (2) jetted with the proper injection pressure to the injection pump pressure tester
(1).
5. Run the starter to increase the pressure.
6. Stop the starter when the fuel jets from the injection nozzle. After that, turn the flywheel by the hand and
raise the pressure to approx. 13.73 MPa (140.0 kgf/cm², 1991 psi).
7. Now turn the flywheel back about half a turn (to keep the plunger free). Maintain the flywheel at this position
and clock the time taken for the pressure to drop from 13.73 to 12.75 MPa (from 140.0 to 130.0 kgf/cm²,
from 1991 to 1849 psi).
8. Measure the time needed to decrease the pressure from 13.73 to 12.75 MPa (from 140.0 to 130.0 kgf/cm²,
from 1991 to 1849 psi).
9. If the measurement is less than allowable limit, replace the pump with new one or repair with a Kubota-
authorized pump service shop.

13.73 MPa
2
Fuel tightness of pump element Allowable limit 140.0 kgf/cm
1991 psi

10 seconds
13.73 → 12.75 MPa
Factory spec. 2
140.0 → 130.0 kgf/cm
1991 → 1849 psi
Fuel tightness of delivery valve
5 seconds
13.73 → 12.75 MPa
Allowable limit 2
140.0 → 130.0 kgf/cm
1991 → 1849 psi

NOTE : Never try to disassemble the injection pump assembly. For repairs, you are strongly requested to
contact a Kubotaauthorized pump service shop.

(1) Injection Pump Pressure Tester (3) Protection Cover for Jetted Fuel
(2) Injection Nozzle

V2403 Service Manual 39 2. General


2.4.14. Check Points of Every 2 Years

Replacing Intake Air Line

1. Loosen the clamp (2).

2. Remove the intake air hose (1) and clamp (2).

3. Replace new intake air hose (1) and new clamp (2).

4. Tighten the clamp (2).

NOTE : To prevent serious damage to the engine, keep


out any dust inside the intake air line.

(1) Intake Air Hose (2) Clamp

Replacing Battery

CAUTION
• When the battery is being activated, hydrogen and
oxygen gases in the battery are extremely
explosive. Keep open sparks and flames away
from the battery at all times, especially when
charging the battery.
• When charging battery, remove battery vent plugs.
• When disconnecting the cable from the battery,
start with the negative terminal first. When
connecting the cable to the battery, start with the
positive terminal first.
• Never check battery charge by placing a metal
object across the posts.

1. Disconnect the negative terminal and positive


terminal.

2. Remove the battery holder.

3. Remove the used battery.

4. Replace the new battery.

5. Tighten the battery holder.

6. Connect the positive terminal.

7. Connect the negative terminal.

V2403 Service Manual 40 2. General


Replacing Radiator Hoses and Clamp Bands

CAUTION
Do not remove the radiator cap when the engine is
hot. Then loosen cap slightly to the stop to relieve
any excess pressure before removing cap
completely.

1. Drain the coolant.

2. Loosen the clamp bands.

3. Remove the upper hose (1) and lower hose (2).

4. Replace new upper / lower hose (1), (2) and clamp


bands.

5. Tighten the clamp bands.

6. Fill with clean water and anti-freeze until the coolant


level is just below the port. Install the radiator cap
securely.

(1) Upper Hose (2) Lower Hose

[A] Replacing Fuel Hoses and Clamp Bands

1. Loosen the clamp (2) and remove the fuel hose (1).

2. Replace new fuel hose (1) and new clamp (2).

3. Tighten the clamp (2).

[A] Cartridge Type


[B] Element Type

CAUTION
Stop the engine when attempting the check and
[B] change prescribed above.

V2403 Service Manual 41 2. General


Changing Radiator Coolant (L.L.C.)

CAUTION
Do not remove the radiator cap when the engine is
hot. Then loosen cap slightly to the stop to relieve
any excess pressure before removing cap
completely.

1. Stop the engine and let cool down.

2. To drain the coolant, open the radiator drain plug (2)


and remove the radiator cap (1). Then radiator cap
(1) must be removed to completely drain the coolant.
And open the drain cock of engine body.

3. After all coolant is drained, close the drain plug.

4. Fill with clean water and cooling system cleaner.

5. Follow directions of the cleaner instruction.

6. After flushing, fill with clean water and anti-freeze


until the coolant level is just below the port. Install the
radiator cap (1) securely.

7. Fill with coolant up to “FULL” (A) mark on the


recovery tank (3).

8. Start and operate the engine for few minutes.

9. Stop the engine and let cool. Check coolant level of


radiator and recovery tank (3) and add coolant if
necessary.

IMPORTANT
• Do not start engine without coolant.
• Use clean, fresh, soft water and anti-freeze to fill
the radiator and recovery tank.
• When the anti-freeze is mixed with fresh, soft
water, the antifreeze mixing ratio must be less
than 50 %.
• Securely tighten radiator cap. If the cap is loose or
improperly fitted, water may leak out and the
engine could overheat.

(1) Radiator Cap A : Full


(2) Drain Plug B : Low
(3) Recovery Tank

V2403 Service Manual 42 2. General


Changing Radiator Coolant (L.L.C.) (Continued)

(Anti-freeze)

• There are two types of anti-freeze available: use the


permanent type (PT) for this engine.

• Before adding anti-freeze for the first time, clean the


radiator interior by pouring fresh, soft water and
draining it a few times.

• The procedure for mixing water and anti-freeze differs


according to the make of the anti-freeze and the
ambient temperature.
Basically, it should be referred to SAE J1034 standard,
more specifically also to SAE J814c.
.
• Mix the anti-freeze with fresh, soft water, and then fill
into the radiator.

IMPORTANT
When the anti-freeze is mixed with fresh, soft water,
the antifreeze mixing ratio must be less than 50 %.

Vol % Freezing point Boiling point*


anti-freeze °C °F °C °F
40 -24 -11 106 223
50 -37 -35 108 226

* At 1.01 × 100000 Pa (760 mmHg) pressure


(atmospheric). A higher boiling point is obtained by
using a radiator pressure cap which permits the
development of pressure within the cooling system.

NOTE
• The above data represents industrial standards
that necessitate a minimum glycol content in the
concentrated anti-freeze.
• When the coolant level drops due to evaporation,
add fresh, soft water only to keep the anti-freeze
mixing ratio less than 50 %. In case of leakage,
add anti-freeze and fresh, soft water in the
specified mixing ratio.
• Anti-freeze absorbs moisture. Keep unused anti-
freeze in a tightly sealed container.
• Do not use radiator cleaning agents when anti-
freeze has been added to the coolant.
(Anti-freeze contains an anti-corrosive agent,
which will react with the radiator cleaning agent
forming sludge which will affect the engine
parts.)

V2403 Service Manual 43 2. General


2.5. Special Tools

Diesel Engine Compression Tester

Code No: 07909-30208 (Assembly) 07909-31251 (G)


07909-30934 (A to F) 07909-31271 (I)
07909-31211 (E and F) 07909-31281 (J)
07909-31231 (H)

Application: Use to measure diesel engine compression


and diagnosis of need for major overhaul.

(1) Gauge (7) Adaptor F


(2) L Joint (8) Adaptor G
(3) Adaptor A (9) Adaptor H
(4) Adaptor B (10) Adaptor I
(5) Adaptor C (11) Adaptor J
(6) Adaptor E

Oil Pressure Tester

Code No: 07916-32032

Application: Use to measure lubricating oil pressure.

(1) Gauge (5) Adaptor 2


(2) Cable (6) Adaptor 3
(3) Threaded Joint (7) Adaptor 4
(4) Adaptor 1 (8) Adaptor 5

V2403 Service Manual 44 2. General


NOTE : The following special tools are not provided, so make them referring to the figure.

Injection Pump Pressure Tester

Application: Use to check fuel tightness of injection


pumps.

Pressure gauge full scale : More than 29.4 MPa


A
(300 kgf/cm², 4267 psi)
B PF 1/2
C Copper gasket
D Flange (Material : Steel)
E Hex. nut 27 mm (1.1 in.) across the plat
F Adhesive application
G Fillet welding on the enter circumference
H Retaining nut
I 17 mm dia. (0.67 in. dia.)
J 8 mm dia. (0.3 in. dia.)
K 1.0 mm (0.039 in.)
L 17 mm dia. (0.67 in. dia.)
M 6.10 to 6.20 mm dia. (0.241 to 0.244 in. dia.)
N 8 mm (0.3 in.)
O 4 mm (0.2 in.)
P 11.97 to 11.99 mm dia. (0.4713 to 0.4720 in. dia.)
Q PF 1/2
R 23 mm (0.91 in.)
S 17 mm (0.67 in.)
T 4 mm (0.2 in.)
U 12.00 to 12.02 mm dia. (0.4725 to 0.4732 in. dia.)
V 100 mm (3.94 in.)
W M12 × P1.5
X 5 mm (0.2 in.)

V2403 Service Manual 45 2. General


Valve Guide Replacing Tool

Application: Use to press out and press fit the valve


guide.

A 225 mm (8.86 in.)


B 70 mm (2.8 in.)
C 45 mm (1.8 in.)
D 20 mm dia. (0.79 in. dia.)
E 12.7 to 12.9 mm dia. (0.500 to 0.507 in. dia.)
F 7.50 to 7.60 mm dia. (0.296 to 0.299 in. dia.)
G 25 mm dia. (0.98 in. dia.)
H 7.70 to 8.00 mm dia. (0.304 to 0.314 in. dia.)
I 5 mm (0.2 in.)
J 20 mm dia. (0.79 in. dia.)
K 13.5 to 13.8 mm dia. (0.532 to 0.543 in. dia.)
L 8.90 to 9.10 mm (0.351 to 0.358 in.)
C1 Chamfer 1.0 mm (0.039 in.)
C2 Chamfer 2.0 mm (0.079 in.)
C0.3 Chamfer 0.3 mm (0.01 in.)

Bushing Replacing Tools

Application: Use to press out and to press fit the


bushing.

1. For small end bushing

A 162 mm (6.38 in.)


B 35 mm (1.4 in.)
C 27 mm (1.1 in.)
D 35 mm dia. (1.4 in. dia.)
E 27.90 to 27.95 mm dia. (1.099 to 1.100 in. dia.)
F 25.00 to 25.01 mm dia. (0.9843 to 0.9846 in. dia.)

2. For idle gear bushing

A 175 mm (6.89 in.)


B 40 mm (1.6 in.)
C 38 mm (1.5 in.)
D 45 mm dia. (1.8 in. dia.)
E 41.90 to 41.95 mm dia. (1.650 to 1.651 in. dia.)
37.950 to 37.970 mm dia.
F
(1.4941 to 1.4948 in. dia.)

V2403 Service Manual 46 2. General


Flywheel Stopper

Application: Use to loosen and tighten the flywheel


screw.
A 20 mm (0.79 in.)
B 15 mm (0.59 in.)
C 10 mm dia. (0.39 in. dia.)
D 30 mm (1.2 in.)
E 8 mm (0.3 in.)
F 200 mm (7.87 in.)

Crankshaft Bearing 1 Replacing Tool

Application: Use to press out and press fit the


crankshaft bearing 1.

1. Extracting tool

A 135 mm (5.31 in.)


B 72 mm (2.8 in.)
C 40 mm radius (1.6 in. radius)
D 10 mm (0.39 in.)
E 20 mm (0.79 in.)
F 20 mm dia. (0.79 in. dia.)
G 64.80 to 64.90 mm dia. (2.552 to 2.555 in. dia.)
H 59.80 to 59.90 mm dia. (2.355 to 2.358 in. dia.)

2. Inserting tool

A 130 mm (5.12 in.)


B 72 mm (2.8 in.)
C 40 mm radius (1.6 in. radius)
D 9 mm (0.4 in.)
E 4 mm (0.2 in.)
F 20 mm (0.79 in.)
G 20 mm dia. (0.79 in. dia.)
H 68 mm dia. (2.7 in. dia.)
I 59.80 to 59.90 mm dia. (2.355 to 2.358 in. dia.)
J 64.80 to 64.90 mm dia. (2.552 to 2.555 in. dia.)

V2403 Service Manual 47 2. General


Socket Wrench for Crank Pulley Nut (46 mm Deep
Socket Wrench)

Application: Use to loosen and tighten the fan drive


pulley mounting nut.

A 100 mm (3.94 in.)


B 25.0 mm (0.984 in.)
C 27.0 mm (1.06 in.)
D 45.0 mm dia. (1.77 in. dia.)
E 35.0 mm dia. (1.38 in. dia.)
F 62.5 mm dia. (2.46 in. dia.)
G 46.0 mm (1.81 in.)

Auxiliary Socket for Fixing Crankshaft Sleeve

Application: Use to fix the crankshaft sleeve of the


diesel engine.

A 80.0 mm (3.15 in.)


B 60.10 to 60.30 mm (2.367 to 2.374 in.)
C 80.0 mm dia. (3.15 in. dia.)
D 85.0 mm dia. (3.35 in. dia.)
E 60.10 to 60.30 mm dia. (2.367 to 2.374 in. dia.)
F 26.30 to 26.40 mm (1.036 to 1.039 in.)
G 25.85 to 25.90 mm (1.018 to 1.019 in.)
H 15.0 mm (0.591 in.)
I 5.0 mm (0.20 in.)

(1) Stopper (3) Auxiliary Socket for Pushing


(2) Sleeve Guide

V2403 Service Manual 48 2. General


Auxiliary Socket for Fixing Crankshaft Sleeve
(Continued)

Application: Use to fix the crankshaft sleeve of the


diesel engine.

J 42.0 mm (1.65 in.)


K 30.50 to 30.60 mm (1.201 to 1.204 in.)
L 23.0 mm (0.906 in.)
M 20.0 mm (0.787 in.)
N 2.0 mm (0.079 in.)
31.911 to 31.950 mm dia.
O
(1.2564 to 1.2578 in. dia.)
P 30.0 mm dia. (1.18 in. dia.)
Q 5.0 mm dia. (0.20 in. dia.)
R 0.09 rad (5 °)
S 25.0 mm dia. (0.984 in. dia.)
T 60.0 mm dia. (2.36 in. dia.)
79.80 to 79.85 mm dia.
U
(3.142 to 3.143 in. dia.)
V 10.0 mm (0.394 in.)
W 0.04 mm dia. (0.002 in. dia.)
X 140 mm (5.51 in.)
Y 120 mm (4.72 in.)
Z 110 mm (4.33 in.)
a 50.0 mm (1.97 in.)
b 39.90 to 40.00 mm (1.571 to 1.574 in.)
c 25.0 mm (0.984 in.)
d 90.0 mm dia. (3.54 in. dia.)
e 81.0 mm dia. (3.19 in. dia.)
80.10 to 80.15 mm dia.
f
(3.154 to 3.155 in. dia.)
g 30.0 mm dia. (1.18 in. dia.)
h 5.0 mm dia. (0.20 in. dia.)
i 70.0 mm (2.76 in.)
j 50.0 mm (1.97 in.)
k 40.0 mm dia. (1.57 in. dia.)
C1 Chamfer 1.0 mm (0.039 in.)
C5 Chamfer 5.0 mm (0.20 in.)
C0.3 Chamfer 0.3 mm (0.01 in.)
R1 1.0 mm radius (0.039 in. radius)
R2 2.0 mm radius (0.079 in. radius)
R10 10.0 mm radius (0.394 in. radius)

(2) Sleeve Guide (3) Auxiliary Socket for Pushing

V2403 Service Manual 49 2. General


Balancer Metal Replacing Tool (for Removing)

Application: Use to remove the metal bearing.

41.934 to 41.950 mm dia.


A 41 mm (1.6 in.) L
(1.6510 to 1.6515 in. dia.)
24.959 to 24.980 mm dia.
B 32.5 mm (1.28 in.) M
(0.98264 to 0.98346 in. dia.)
21.947 to 21.960 mm dia.
C Chamfer 0.3 mm (0.01 in.) N
(0.86406 to 0.86456 in. dia.)

D 25 mm dia. (0.98 in. dia.) O 36 mm (1.4 in.)

46.950 to 46.975 mm dia.


E P 5 mm (0.2 in.)
(1.8485 to 1.8494 in. dia.)

F 0.52 rad (30 °) Q 29.0 mm (1.14 in.)

43.934 to 43.950 mm dia.


G R 28.0 mm (1.10 in.)
(1.7297 to 1.7303 in. dia.)

H 148.5 mm (5.846 in.) S 195.25 to 195.75 mm (7.6870 to 7.7066 in.)

I 10 mm (0.39 in.) T 145 mm (5.71 in.)

46.50 to 46.75 mm dia.


J U 384.75 to 385.25 mm (15.148 to 15.167 in.)
(1.831 to 1.840 in. dia.)
44.950 to 44.975 mm dia.
K
(1.7697 to 1.7706 in. dia.)

V2403 Service Manual 50 2. General


Balancer Metal Replacing Tool (for Fitting)

Application: Use to press fit the metal bearing.

A 182 mm (7.17 in.) O 60 mm dia. (2.4 in. dia.)


46.950 to 46.975 mm dia.
B 140 mm (5.51 in.) P
(1.8485 to 1.8494 in. dia.)
43.934 to 43.950 mm dia.
C 37 mm (1.5 in.) Q
(1.7297 to 1.7303 in. dia.)
D 35 mm dia. (1.4 in. dia.) R 140 mm (5.51 in.)
E 60 mm dia. (2.4 in. dia.) S 36 mm (1.4 in.)
F 10 mm (0.39 in.) T 60 mm dia. (2.4 in. dia.)
46.950 to 46.975 mm dia.
G 0.52 rad (30°) U
(1.8485 to 1.8494 in. dia.)
21.947 to 21.960 mm dia. 44.950 to 44.975 mm dia.
H V
(0.86406 to 0.86456 in. dia.) (1.7697 to 1.7706 in. dia.)
24.959 to 24.980 mm dia. 41.934 to 41.950 mm dia.
I W
(0.98264 to 0.98346 in. dia.) (1.6510 to 1.6515 in. dia.)
J Chamfer 0.3 mm (0.01 in.) X 145 mm (5.71 in.)
K 8.8 to 9.2 mm (0.35 to 0.36 in.) Y 195.25 to 195.75 mm (7.6870 to 7.7066 in.)
L 5 mm (0.2 in.) Z 29 mm (1.1 in.)
M 3.3 to 3.7 mm (0.13 to 0.14 in.) a 36 mm (1.4 in.)
N 25 mm dia. (0.98 in. dia.)

V2403 Service Manual 51 2. General


Idle Gear 2 Puller

Application: Use for remove the idle gear 2 from the


shaft.

A 24 mm (0.94 in.)
B 10 mm dia. (0.39 in. dia.)
C 0.5 mm radius (0.02 in. radius)
D M20 x Pitch 2.0
E 10 mm (0.39 in.)
F 20 mm (0.79 in.)
G 5 mm (0.2 in.)
H 95 mm (3.7 in.)
I 125 mm (4.92 in.)
J 0.87 rad (50 °)
K 5 mm (0.2 in.)
L 60 mm radius (2.4 in. radius)
M M20 x Pitch 2.0
N 30 mm (1.2 in.)
O 10 mm (0.39 in.)
P 10 mm (0.39 in.)
Q 10 mm (0.39 in.)
R 35.5 mm (1.40 in.)
S 4.5 mm radius (0.18 in. radius)
T 40 mm (1.6 in.)
U 40 mm (1.6 in.)
V 12 mm (0.47 in.)
W 120 mm (4.72 in.)
C2 Chamfer 2.0 mm (0.079 in.)

V2403 Service Manual 52 2. General


3. Mechanism

3.1. Engine Body

3.1.1. Piston

Piston’s skirt is coated with molybdenum disulfide★,


which reduces the piston slap noise and thus the entire
operating noise.

★ Molybdenum disulfide (MoS2)

The molybdenum disulfide (1) serves as a solid


lubricant, like a Graphite or Teflon. This material helps
resist metal wears even with little lube oil.

(1) Molybdenum Disulfide

3.1.2. Half-Floating Head Cover

The rubber packing is fitted in to maintain the cylinder


head cover 0.5 mm (0.02 in.) or so off the cylinder head.
This arrangement helps reduce noise coming from the
cylinder head.

(1) Cylinder Head Cover (2) Rubber Packing

V2403 Service Manual 53 3. Mechanism


3.2. Cooling System

3.2.1. Bottom Bypass System

Bottom bypass system is introduced in 03-M Series for


improving the cooling performance of the radiator.

While the temperature of coolant in the engine is low,


the thermostat (1) is held closed and the coolant is
allowed to flow through the bypass pipe and to circulate
in the engine.

When the temperature exceeds the thermostat valve


opening level, the thermostat (1) fully opens itself to
prevent the hot coolant from flowing through the bypass
into the engine.

In this way, the radiator can increase its cooling


performance.

(1) Thermostat (A) Bypass Opened


(B) Bypass Closed

V2403 Service Manual 54 3. Mechanism


3.3. Fuel System

3.3.1. Governor

The governor serves to keep engine speed constant by


automatically adjusting the amount of fuel supplied to
the engine according to changes in the load. This
engine employs an all-speed governor which controls
the centrifugal force of the steel ball (1) weight,
produced by rotation of the fuel camshaft (5), and the
tension of the governor spring 1 (7) and 2 (8) are
balanced.

(1) Steel Ball (7) Governor Spring 1


(2) Governor Sleeve (8) Governor Spring 2
(3) Steel Ball (9) Fork Lever 2
(4) Governor Ball Case (10) Fork Lever 1
(5) Fuel Camshaft (11) Fork Lever Shaft
(6) Governor Lever (12) Fork Lever Holder

V2403 Service Manual 55 3. Mechanism


4. Servicing

4.1. Troubleshooting

4.1.1. Engine Body

Symptom Probable Cause Solution Reference Page


No fuel Replenish fuel 22
Air in the fuel system Vent air 22
Change fuel and repair or
Water in the fuel system -
replace fuel system
Fuel hose clogged Clean or replace 22
Fuel filter clogged Replace 29
Excessively high viscosity of
fuel or engine oil at low Use specified fuel or engine oil 9, 20
temperature
Fuel with low cetane number Use specified fuel 9
Fuel leak due to loose injection
Tighten retaining nut 97
pipe retaining nut
Incorrect injection timing Adjust 78,79
Engine Does Not Fuel camshaft worn Replace 113, 114
Start Injection nozzle clogged Clean or replace (IDI) 82, 83 , 97
80, 81,
Injection pump malfunctioning Repair or replace
104, 105
Seizure of crankshaft,
112 to 117
camshaft, piston, cylinder or Repair or replace
140 to 147
bearing
Replace head gasket, tighten
Compression leak from
cylinder head screw, glow plug 98 to 102
cylinder
and nozzle holder
Improper valve timing Correct or replace timing gear 110 to 113
71, 115 to 117
Piston ring and cylinder worn Replace
138, 139, 146
Excessive valve clearance Adjust 72
Solenoid malfunctioning Replace 104, 105
Battery discharged Charge 33, 34
86, 87, 95,
Starter Does Not Starter malfunctioning Repair or replace
121, 148
Run
Key switch malfunctioning Replace -
Wiring disconnected Connect -

V2403 Service Manual 56 4. Servicing


Symptom Probable Cause Solution Reference Page
Fuel filter clogged or dirty Replace 29
Air cleaner clogged Clean or replace 24, 28, 34
Fuel leak due to loose injection
Tighten retaining nut 97
pipe retaining nut
80, 81,
Injection pump malfunctioning Repair or replace
104, 105
Incorrect nozzle opening
Adjust (IDI) 82, 98
pressure
Injection nozzle stuck or
Engine Revolution Repair or replace 82, 98
clogged
Is Not Smooth
106, 107,
Governor malfunctioning Repair
113, 114
Replace the turbocharger
Turbocharger bearing worn out -
assembly
Replace the turbocharger
Turbocharger shaft bent -
assembly
Turbocharger fin or other part
Replace the turbocharger
damaged due to foreign -
assembly
matters
Excessive engine oil Reduce to specified level 18
Either White or
Piston ring and cylinder worn 71, 115 to 117
Blue Exhaust Gas Repair or replace
or stuck 138, 139, 146
Is Observed
Incorrect injection timing Adjust 78,79
Oil Leak into Oil pipe clogged or deformed Repair or replace -
Exhaust Pipe or Turbocharger’s piston ring seal Replace the turbocharger
Suction Pipe -
faulty assembly
Overload Reduce the load -
Either Black or Low grade fuel used Use specified fuel 9
Dark Gray Exhaust Fuel filter clogged Replace 29
Gas Is Observed Air cleaner clogged Clean or replace 24, 28, 34
Deficient nozzle injection Repair or replace nozzle 82, 83 , 97
Incorrect injection timing Adjust 78,79
Engine’s moving parts seem to
Repair or replace -
be seizing
80, 81,
Injection pump malfunctioning Repair or replace
104, 105
Deficient nozzle injection Repair or replace nozzle 82, 83 , 97
Check the compression
Deficient Output Compression leak 71
pressure and repair
Gas leak from exhaust system Repair or replace -
Air leak from compressor
Repair or replace -
discharge side
Air cleaner dirty or clogged Clean or replace 24, 28, 34
Turbocharger compressor Replace the turbocharger
-
wheel turning heavily assembly

V2403 Service Manual 57 4. Servicing


Symptom Probable Cause Solution Reference Page
Piston ring’s gap facing the
Shift ring gap direction 115, 116
same direction
Oil ring worn or stuck Replace 117, 138, 139
Piston ring groove worn Replace piston 117, 139
Excessive
Lubricant Oil Valve stem and valve guide
Replace 102, 103, 126
worn
Consumption
Crankshaft bearing, and crank 115, 116, 120
Replace
pin bearing worn 141 to 144
Oil leaking due to defective
Replace -
seals or packing
80, 81,
Injection pump’s plunger worn Repair or replace
Fuel Mixed into 104, 105
Lubricant Oil Deficient nozzle injection Repair or replace nozzle 82, 83 , 97
Injection pump broken Replace 104, 105
Head gasket defective Replace 100 to 102
Water Mixed into
Lubricant Oil Cylinder block or cylinder head
Replace 100, 124
flawed
Engine oil insufficient Replenish 18
Oil strainer clogged Clean 115
Relief valve stuck with dirt Clean -
Relief valve spring weaken or
Replace -
broken
Excessive oil clearance of
Replace 120, 142 to 144
crankshaft bearing
Low Oil Pressure Excessive oil clearance of
Replace 115, 116, 141
crankpin bearing
Excessive oil clearance of
Replace 99, 129 to 131
rocker arm
Oil passage clogged Clean -
Different type of oil Use specified type of oil 9, 20
74, 113,
Oil pump defective Replace
114, 148
Different type of oil Use specified type of oil 9, 20
High Oil Pressure
Relief valve defective Replace -
Engine oil insufficient Replenish 20
Fan belt broken or elongated Replace or adjust 25, 31, 32
Coolant insufficient Replenish 19
Radiator net and radiator fin
Clean -
clogged with dust
Inside of radiator corroded Clean or replace 30
Engine overheated
Coolant flow route corroded Clean or replace 30 to 32
Radiator cap defective Replace 71, 72
Overload running Reduce the load -
Head gasket defective Replace 104, 105
Incorrect injection timing Adjust 78, 79
Unsuitable fuel used Use specified fuel 9

V2403 Service Manual 58 4. Servicing


Symptom Probable Cause Solution Reference Page
Replenish distilled water and
Battery electrolyte insufficient 24, 25, 33
charge
Fan belt slips Adjust belt tension or replace 24, 25, 31, 32
Battery Quickly
Wiring disconnected Connect -
Discharged
Rectifier defective Replace 121, 155
Alternator defective Replace 122, 153, 154
Battery defective Replace -

V2403 Service Manual 59 4. Servicing


4.2. Servicing Specifications

Engine Body
Item Factory Specification Allowable Limit
0.18 to 0.22 mm
Valve Clearance (When Cold)
0.0071 to 0.0086 in.
3.24 to 3.72 MPa / 290 2.55 MPa / 290
min-1 (rpm) -1
min (rpm)
2 2
Compression Pressure 33.0 to 38.0 kgf/cm / 290 26.0 kgf/cm / 290
-1 -1
(When Cranking with Starting Motor) min (rpm) min (rpm)
-1 -1
470 to 540 psi / 290 min 370 psi / 290 min
(rpm) (rpm)
0.575 to 0.675 mm
Top Clearance -
0.0227 to 0.0265 in.
0.05 mm / 500 mm
Cylinder Head Surface Flatness
0.002 in. / 19.7 in.
0.05 mm
Protrusion
0.002 in.
Valve Recessing
(Protrusion to Recessing) Recessing
0.15 mm 0.40 mm
0.0059 in. 0.016 in.
Valve Recessing Recessing 0.65 to 0.85 mm -
[D1803-M-DI], [V2403-M-DI] 0.026 to 0.033 in.
[V2403-M-DI-T]

Engine Body (Continued)


Item Factory Specification Allowable Limit
Valve Stem to Valve Guide Clearance 0.040 to 0.070 mm 0.10 mm
0.0016 to 0.0027 in. 0.0039 in.

Valve Stem O.D. 7.960 to 7.975 mm -


0.3134 to 0.3139 in.

Valve Guide I.D. 8.015 to 8.030 mm -


0.3156 to 0.3161 in.
Angle (Intake) 1.0 rad -
60 °
Valve Face
Angle (Exhaust) 0.79 rad -
45 °

Valve Seat Width (Intake) 2.12 mm -


0.0835 in.

Width (Exhaust) 2.12 mm . -


0.0835 in.

Angle (Intake) 1.0 rad -


60 °
Valve Seat
Angle (Exhaust) 0.79 rad
45 °

V2403 Service Manual 60 4. Servicing


Engine Body (Continued)
Item Factory Specification Allowable Limit
Open 0.21 rad (12 °) -
before T.D.C.
Valve Timing (Intake Valve)
Close 0.63 rad (36 °) -
after B.D.C.
Open 0.99 rad (57 °) -
before B.D.C.
Valve Timing (Exhaust Valve)
Close 0.21 rad (12 °) -
after T.D.C.
Valve Spring Free Length 41.7 to 42.2 mm 41.2 mm
1.65 to 1.66 in. 1.62 in.

Setting Load / 118 N / 35.0 mm 100 N / 35.0 mm


Setting Length 12.0 kgf / 35.0 mm 10.2 kgf / 35.0 mm
26.5 lbf / 1.38 in. 22.5 lbf /1.38 in.

Tilt - 1.0 mm
0.039 in.

Rocker Arm Shaft to Rocker Arm Oil Clearance 0.016 to 0.045 mm 0.10 mm
0.00063 to 0.0017 in. 0.0039 in.

Rocker Arm Shaft O.D. 13.973 to 13.984 mm -


0.55012 to 0.55055 in.

Rocker Arm I.D. 14.000 to 14.018 mm -


0.55119 to 0.55188 in.

0.25 mm
Push Rod Alignment -
0.0098 in.

Tappet to Tappet Guide Oil Clearance 0.020 to 0.062 mm 0.07 mm


0.00079 to 0.0024 in. 0.003 in.

Tappet O.D. 23.959 to 23.980 mm -


0.94327 to 0.94409 in.

Tappet Guide I.D. 24.000 to 24.021 mm -


0.94489 to 0.94570 in.

V2403 Service Manual 61 4. Servicing


Engine Body (Continued)
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. 0.0059 in.

Idle Gear to Injection Pump Gear Backlash 0.04150 to 0.1154 mm 0.15 mm


0.001634 to 0.004543 in. 0.0059 in.

Crank Gear to Oil Pump Gear Backlash 0.04150 to 0.1090 mm 0.15 mm


0.001634 to 0.004291 in. 0.0059 in.

Idle Gear to Balancer Gear Backlash 0.03500 to 0.1160 mm 0.15 mm


(Balancer Model Only) 0.001378 to 0.004566 in. 0.0059 in.

Cam Gear to Balancer Gear Backlash 0.03500 to 0.1160 mm 0.15 mm


(Balancer Model Only) 0.001378 to 0.004566 in. 0.0059 in.

Crank Gear to Idle Gear 2 Backlash 0.04150 to 0.1154 mm 0.15 mm


(Side PTO Model Only) 0.001634 to 0.004543 in. 0.0059 in.

Idle Gear 2 to Hydraulic Pump Drive Backlash 0.03080 to 0.1062 mm 0.15 mm


Gear (Side PTO Model Only) 0.001213 to 0.004181 in. 0.0059 in.
0.12 to 0.48 mm 0.9 mm
Idle Gear Side Clearance
0.0048 to 0.018 in. 0.04 in.
Idle Gear Shaft to Idle Gear Bushing Oil Clearance 0.025 to 0.066 mm 0.10 mm
0.00099 to 0.0025 in. 0.0039 in.

Idle Gear Shaft O.D. 37.959 to 37.975 mm . -


1.4945 to 1.4950 in.

Idle Gear Bushing I.D. 38.000 to 38.025 mm -


1.4961 to 1.4970 in.
Camshaft Side Clearance 0.070 to 0.22 mm 0.30 mm
0.0028 to 0.0086 in. 0.012 in.
Camshaft - Alignment 0.01 mm
0.0004 in.
Height 33.90 mm 33.85 mm
Cam (Intake)
1.335 in. 1.333 in.
Height 33.90 mm 33.85 mm
Cam (Exhaust)
1.335 in. 1.333 in.
Camshaft Journal to Cylinder Block Oil Clearance 0.050 to 0.091 mm 0.15 mm
Bore 0.0020 to 0.0035 in. 0.0059 in.

Camshaft Journal O.D. 39.934 to 39.950 mm -


1.5722 to 1.5728 in.

Cylinder Block Bore I.D. 40.000 to 40.025 mm -


1.5748 to 1.5757 in.
Piston Pin Bore I.D. 25.000 to 25.013 mm 25.05 mm
0.98426 to 0.98476 in. 0.9862 in.

V2403 Service Manual 62 4. Servicing


Engine Body (Continued)
Item Factory Specification Allowable Limit
Second Ring to Ring Groove Clearance 0.0930 to 0.128 mm 0.20 mm
0.00367 to 0.00503 in. 0.0079 in.
Oil Ring to Ring Groove Clearance 0.020 to 0.060 mm 0.15 mm
0.00079 to 0.0023 in. 0.0059 in.
Top Ring Ring Gap 0.25 to 0.40 mm 1.25 mm
0.0099 to 0.015 in. 0.0492 in.
Second Ring Ring Gap 0.30 to 0.45 mm 1.25 mm
0.012 to 0.017 in. 0.0492 in.
Oil Ring Ring Gap 0.25 to 0.45 mm 1.25 mm
0.0099 to 0.017 in. 0.0492 in.
Connecting Rod Alignment - 0.05 mm
0.002 in.

Piston Pin to Small End Bushing Oil Clearance 0.014 to 0.036 mm 0.15 mm
0.00056 to 0.0014 in. 0.0059 in.

Piston Pin O.D. 25.004 to 25.011 mm -


0.98441 to 0.98468 in.

Small End Bushing I.D. 25.025 to 25.040 mm -


0.98524 to 0.98582 in.

Crankshaft Alignment 0.02 mm


0.0008 in.
Crankshaft Journal to Crankshaft Oil Clearance 0.0400 to 0.118 mm 0.20 mm
Bearing 1 0.00158 to 0.00464 in. 0.0079 in.

Crankshaft Journal O.D. 59.921 to 59.940 mm -


2.3591 to 2.3598 in.

Crankshaft Bearing 1 I.D. 59.980 to 60.039 mm -


2.3615 to 2.3637 in.
Crankshaft Journal to Crankshaft Oil Clearance 0.0400 to 0.104 mm 0.20 mm
Bearing 2 0.00158 to 0.00409 in. 0.0079 in.

Crankshaft Journal O.D. 59.921 to 59.940 mm -


2.3591 to 2.3598 in.

Crankshaft Bearing 2 I.D. 59.980 to 60.025 mm -


2.3615 to 2.3631 in.
Crankpin to Crankpin Bearing Oil Clearance 0.025 to 0.087 mm 0.20 mm
0.00099 to 0.0034 in. 0.0079 in.

Crankpin O.D. 46.959 to 46.975 mm -


1.8488 to 1.8494 in.

Crankpin Bearing I.D. 47.000 to 47.046 mm -


1.8504 to 1.8522 in.
Crankshaft Side Clearance 0.15 to 0.31 mm 0.5 mm
0.0059 to 0.012 in. 0.02 in.
Cylinder Bore (Standard) I.D. 87.000 to 87.022 mm 87.170 mm
3.4252 to 3.4260 in. 3.4319 in.

V2403 Service Manual 63 4. Servicing


Engine Body (Continued)
Item Factory Specification Allowable Limit
Cylinder Bore (Oversize) I.D. 87.250 to 87.272 mm 87.420 mm
3.4351 to 3.4359 in. 3.4417 in.
Difference among Minimum Wear to 0.15 mm
-
Maximum Wear 0.0059 in.

Lubricating System
Item Factory Specification Allowable Limit
Engine Oil Pressure At Idle Speed More than 98 kPa 50 kPa
2 2
1.0 kgf/cm 0.5 kgf/cm
14 psi 7 psi

At Rated Speed 300 to 440 kPa 250 kPa


2 2
3.0 to 4.5 kgf/cm 2.5 kgf/cm
43 to 64 psi 36 psi
Engine Oil Pressure Switch Working 50 kPa -
2
Pressure 0.5 kgf/cm
7 psi
Inner Rotor to Outer Rotor Clearance 0.030 to 0.14 mm 0.2 mm
0.0012 to 0.0055 in. 0.008 in.
Outer Rotor to Pump Body Clearance 0.11 to 0.19 mm 0.25 mm
0.0044 to 0.0074 in. 0.0098 in.
Inner Rotor to Cover Clearance 0.105 to 0.150 mm 0.20 mm
0.00414 to 0.00590 in. 0.008 in.

Cooling System
Item Factory Specification Allowable Limit
Fan Belt Tension 7.0 to 9.0 mm (0.28 to -
0.35 in.) deflection at 98
N (10 kgf, 22 lbf) of force
Thermostat Valve Opening 69.5 to 72.5 °C -
Temperature (At 157.1 to 162.5 °F
Beginning)

Valve Opening 85 °C -
Temperature 185 °F
(Opened
Completely)
Radiator Water Tightness No leak at specified -
pressure
Radiator Cap Pressure Falling More than 10 seconds -
Time for pressure fall from 90
to 60 kPa from 0.9 to 0.6
2
kgf/cm from 10 to 9 psi

V2403 Service Manual 64 4. Servicing


Fuel System
Item Factory Specification Allowable Limit
Injection Pump Injection Timing 0.271 to 0.296 rad
(15.5 to 17.0 °) before -
T.D.C.
Pump Element Fuel Tightness 13.73 MPa
2
- 140.0 kgf/cm
1991 psi
Delivery Valve Fuel Tightness 10 seconds 5 seconds
13.73 → 12.75 MPa 13.73 → 12.75
2
140.0 → 130.0 kgf/cm MPa
1991 → 1849 psi 140.0 → 130.0
2
kgf/cm
1991 → 1849 psi
Injection Nozzle Injection 13.73 to 14.70 MPa
2
Pressure 140.0 to 150.0 kgf/cm -
1992 to 2133 psi
Injection Nozzle Valve Seat When the pressure is
Valve Seat 12.75 MPa
2
Tightness (130.0 kgf/cm , 1849 -
psi), the valve seat must
be fuel tightness.

Electrical System
Item Factory Specification Allowable Limit
Starter

Commutator O.D. 35.0 mm 34.0 mm


1.38 in. 1.34 in.

Mica Under Cut 0.45 to 0.75 mm 0.20 mm


0.018 to 0.029 in. 0.0079 in.

Brush Length 15.0 mm 9.0 mm


0.591 in. 0.35 in.

Brush Holder and Holder Support Resistance Infinity -

Alternator No-load voltage More than 13.5 V -

Stator Resistance Less than 1.0 Ω -

Rotor Resistance 2.9 Ω -

Slip Ring O.D. 14.4 mm 14.0 mm


0.567 in. 0.551 in.

Brush Length 10.5 mm 8.4 mm


0.413 in. 0.33 in.
Glow Plug Resistance Approx. 0.9 Ω -

V2403 Service Manual 65 4. Servicing


4.3. Tightening Torques

Screws, bolts and nuts must be tightened to the specified torque using a torque wrench, several screws, bolts
and nuts such as those used on the cylinder head must be tightened in proper sequence and the proper
torque.

4.3.1. Tightening Torques For General Use Screws, Bolts And Nuts

When the tightening torques are not specified, tighten the screws, bolts and nuts according to the table below.

Grade Standard Screw and Bolt Special Screw and Bolt

Unit

Nominal N·m kgf·m lbf·ft N·m kgf·m lbf·ft


Diameter
M6 7.9 to 9.3 0.80 to 0.95 5.8 to 6.8 9.81 to 11.2 1.00 to 1.15 7.24 to 8.31
M8 18 to 20 1.8 to 2.1 13 to 15 24 to 27 2.4 to 2.8 18 to 20
M10 40 to 45 4.0 to 4.6 29 to 33 49 to 55 5.0 to 5.7 37 to 41
M12 63 to 72 6.4 to 7.4 47 to 53 78 to 90 7.9 to 9.2 58 to 66

Screw and bolt material grades are shown by numbers punched on the screw and bolt heads. Prior to
tightening, be sure to check out the numbers as shown below.

Punched number Screw and bolt material grade


None or 4 Standard screw and bolt SS41, S20C
7 Special screw and bolt S43C, S48C (Refined)

V2403 Service Manual 66 4. Servicing


4.3.2. Tightening Torques For Special Use Screws, Bolts And Nuts

NOTE
For “*” marked screws, bolts and nuts on the table, apply engine oil to their threads and seats before
tightening.

The letter “M” in Size x Pitch means that the screw, bolt or nut dimension stands for metric. The size
is the nominal outside diameter in mm of the threads. The pitch is the nominal distance in mm
between two threads.

Item Size x Pitch N·m kgf·m lbf·ft


Cylinder head cover screw M6 x 1.0 9.81 to 11.2 1.00 to 1.15 7.24 to 8.31
*Cylinder head screw M11 x 1.25 93.2 to 98.0 9.50 to 10.0 68.8 to 72.3
*Main bearing case screw 1 M9 x 1.25 46 to 50 4.7 to 5.2 34 to 37
*Main bearing case screw 2 M10 x 1.25 69 to 73 7.0 to 7.5 51 to 54
*Flywheel screw M12 x 1.25 98.1 to 107 10.0 to 11.0 72.4 to 79.5
*Connecting rod screw M8 x 1.0 45 to 49 4.5 to 5.0 33 to 36
*Rocker arm bracket screw M8 x 1.25 24 to 27 2.4 to 2.8 18 to 20
*Idle gear shaft screw M8 x 1.25 24 to 27 2.4 to 2.8 18 to 20
Fan drive pulley mounting nut M30 x 1.5 138 to 156 14.0 to 16.0 102 to 115
*Bearing case cover mounting screw M8 x 1.25 24 to 27 2.4 to 2.8 18 to 20
Glow plug M10 x 1.25 20 to 24 2.0 to 2.5 15 to 18
Nozzle holder assembly M20 x 1.5 49 to 68 5.0 to 7.0 37 to 50
Nozzle holder - 35 to 39 3.5 to 4.0 26 to 28
Oil pressure switch R 1/8 15 to 19 1.5 to 2.0 11 to 14
Injection pipe retaining nut M12 x 1.5 25 to 34 2.5 to 3.5 18 to 25
Overflow pipe assembly retaining nut M12 x 1.5 20 to 24 2.0 to 2.5 15 to 18
Camshaft set screw M8 x 1.25 24 to 27 2.4 to 2.8 18 to 20
Hi-idling body M14 x 1.0 45 to 49 4.5 to 5.0 33 to 36
Balancer shaft set bolt (Balancer model only) M8 x 1.25 24 to 27 2.4 to 2.8 18 to 20
Alternator’s pulley nut - 58.4 to 78.9 5.95 to 8.05 43.1 to 58.2
Idle gear 2 stopper set screw
- 49 to 55 5.0 to 5.7 37 to 41
(Side PTO model only)
Idle gear 2 shaft set screw
- 24 to 27 2.4 to 2.8 18 to 20
(Side PTO model only)
Starter’s terminal B mounting nut M8 5.9 to 11 0.60 to 1.2 4.4 to 8.6

V2403 Service Manual 67 4. Servicing


4.4. Checking, Disassembling And Servicing

4.4.1. Checking And Adjusting

Engine Body

Compression Pressure

1. Run the engine until it is warmed up.

2. Stop the engine and disconnect the 2P connector


from the stop solenoid in order not to inject fuel.

3. Remove the air cleaner, the muffler and all injection


nozzles.

4. Set a compression tester with the adaptor to the


nozzle hole.

5. After making sure that the stop lever is set at the stop position (non-injection).

6. While cranking the engine with the starter, measure the compression pressure.

7. Repeat steps 4 through 6 for each cylinder.

8. If the measurement is below the allowable limit, apply a small amount of oil to the cylinder wall through the
nozzle hole and measure the compression pressure again.

9. If the compression pressure is still less than the allowable limit, check the top clearance, valve and cylinder
head.

10. If the compression pressure increases after applying oil, check the cylinder wall and piston rings.

NOTE
• Check the compression pressure with the specified valve clearance.

• Always use a fully charged battery for performing this test.

• Variances in cylinder compression values should be under 10 %.

3.24 to 3.72 MPa


Factory spec. 33.0 to 38.0 kgf/cm2
470 to 540 psi
Compression pressure
2.55 MPa
2
Allowable limit 26.0 kgf/cm
370 psi

V2403 Service Manual 68 4. Servicing


Valve Clearance

IMPORTANT
Valve clearance must be checked and adjusted
when engine is cold.

1. Remove the head cover.

2. Align the “1TC” mark line (3) on the flywheel and


projection (2) on the housing so that the No.1 piston
comes to the compression or overlap top dead center.

3. Check the following valve clearance (1) marked with


“☆” using a feeler gauge.

4. If the clearance is not within the factory specifications,


adjust with the adjusting screw.

Valve 0.18 to 0.22 mm


Factory spec.
clearance 0.0071 to 0.0086 in.

NOTE
• The “1TC” mark line on the flywheel is just for No.
1 cylinder.
There is no “TC” marking for the other cylinders.
• No. 1 piston comes to the top dead center
position when the “TC” marking is aligned with
the projection (2) in the window on flywheel-
housing. Turn the flywheel 0.26 rad (15 °)
clockwise and counterclockwise to see if the
piston is at the compression top dead center or
the overlap position. Now referring to the table
below, readjust the valve clearance (1). (The
piston is at the top dead center when both the IN.
and EX. valves do not move; it is at the overlap
position when both the valves move.)
• Finally turn the flywheel 6.28 rad (360 °) and align
the “1TC” mark line and the projection (2)
perfectly. Adjust all the other valve clearance as
required.
• After turning the flywheel counterclockwise twice
or three times, recheck the valve clearance (1).
• After adjusting the valve clearance (1), firmly
tighten the lock nut of the adjusting screw.

V2403 Service Manual 69 4. Servicing


Valve arrangement
4 Cylinder
Adjustable
cylinder IN. EX.
location of piston
No. 1 ☆ ☆
When No. 1 piston is at No. 2 ☆
compression top dead center No. 3 ☆
No. 4
No. 1
When No. 1 piston is at overlap No. 2 ☆
position No. 3 ☆
No. 4 ☆ ☆

(1) Valve Clearance (3) 1TC Mark Line


(2) Projection

V2403 Service Manual 70 4. Servicing


Lubricating System

Engine Oil Pressure

1. Remove the engine oil pressure switch, and set an


oil pressure tester (Code No.: 07916-32032).
(Adaptor screw size : PT 1/8)

2. Start the engine. After warming up, measure the oil


pressure of both idling and rated speeds.

3. If the oil pressure is less than the allowable limit,


check the following.

• Engine oil insufficient.

• Oil pump defective

• Oil strainer clogged

• Oil filter cartridge clogged

• Oil gallery clogged

• Excessive oil clearance

• Foreign matter in the relief valve

More than 98 kPa


Factory 2
1.0 kgf/cm
spec.
At idle 14 psi
speed 50 kPa
Allowable 2
0.5 kgf/cm
limit
7 psi
Engine oil pressure
300 to 440 kPa
Factory 2
3.0 to 4.5 kgf/cm
spec.
At rated 43 to 64 psi
speed 250 kPa
Allowable 2
2.5 kgf/cm
limit
36 psi

(When reassembling)

• After checking the engine oil pressure, tighten the engine oil pressure switch to the specified torque.

15 to 19 N·m
Tightening torque Oil pressure switch 1.5 to 2.0 kgf·m
11 to 14 lbf·ft

V2403 Service Manual 71 4. Servicing


Cooling System

Fan Belt Tension

1. Measure the deflection (A), depressing the belt


halfway between the fan drive pulley and alternator
pulley at specified force 98 N (10 kgf, 22 lbf).

2. If the measurement is not within the factory


specifications, loosen the alternator mounting screws
and relocate the alternator to adjust.

7.0 to 9.0 mm
Deflection (A) Factory spec.
0.28 to 0.35 in.

(A) Deflection

Fan Belt Damage and Wear

1. Check the fan belt for damage.

2. If the fan belt is damaged, replace it.

3. Check if the fan belt is worn and sunk in the pulley


groove.

4. If the fan belt is nearly worn out and deeply sunk in


the pulley groove, replace it.

(A) Good
(B) Bad

CAUTION
When removing the radiator cap, wait at least ten minutes after the engine has stopped and cooled
down. Otherwise, hot water may gush out, scalding nearby people.

V2403 Service Manual 72 4. Servicing


Radiator Cap Air Leakage

1. Set a radiator tester and an adaptor on the radiator


cap.
2
2. Apply the specified pressure 90 kPa (0.9 kgf/cm , 10
psi), and measure the time for the pressure to fall to
2
60 kPa (0.6 kgf/cm , 9 psi).

3. If the measurement is less than the factory


specification, replace the radiator cap.

More than 10 seconds


for pressure fall from 90 to
Pressure Factory
60 kPa
falling time spec. 2
(from 0.9 to 0.6 kgf/cm ,
from 10 to 9 psi)

Radiator Water Leakage

1. Pour a specified amount of water into the radiator.

2. Set a radiator tester and an adaptor and raise the


water pressure to the specified pressure.

3. Check the radiator for water leaks.

4. For water leak from the pinhole, replace the radiator


or repair with the radiator cement. When water leak is
excessive, replace the radiator.

Radiator water Factory No leak at specified


leakage test pressure spec. pressure

NOTE : The pressure of the leak test is different from


each radiator specification. Thus, do the leak test, refer
to the test pressure of each radiator specification.

V2403 Service Manual 73 4. Servicing


Thermostat Valve Opening Temperature

1. Suspend the thermostat in the water by a string with


its end inserted between the valve and seat.

2. Heating the water gradually, read the temperature


when the valve opens and leaves the string.

3. Continue heating and read the temperature when the


valve opens approx. 6 mm (0.2 in.).

4. If the measurement is not within the factory


specifications, replace the thermostat.

Thermostat’s valve opening 69.5 to 72.5 °C


Factory spec.
temperature 157.1 to 162.5 °F
Temperature at which thermostat 85 °C
Factory spec.
completely opens 185 °F

V2403 Service Manual 74 4. Servicing


Fuel System

Injection Timing

1. Remove the stop solenoid.

2. Remove the injection pipes and nozzle.

3. Set the speed control lever to maximum fuel


discharge position.

(Reference)

• Turn the flywheel with screwdriver.

4. Turn the flywheel counterclockwise (facing the


flywheel) until the fuel fills up to the hole of the
delivery valve holder for 1st cylinder.

5. Turn the flywheel further and stop turning when the


fuel begins to flow over, to get the present injection
timing.

6. (The flywheel has mark 1TC and four lines indicating


every 0.09 rad (5 °) of crank angle from 0.17 rad
(10 °) to 0.44 rad (25 °) before mark 1TC) Calculate
the angle which the center of the window points out.
If the calculation differs from specified injection timing,
add or remove the shim to adjust.

7. Injection Timing is 15.25 before T.D.C.

V2403 Service Manual 75 4. Servicing


NOTE
• The sealant is applied to both sides of the soft
metal gasket
shim. The liquid gasket is not required for
assembling.
• Shims are available in thickness of 0.175 mm (6),
0.20 mm (3), 0.25 mm (4) and 0.30 mm (5).
Combine these shims for adjustments.
• The 0.175 mm thick shim is coated only on the
lower face. Therefore, do not use the 0.175 mm
thick shim as the top shim of the combination
(injection pump side), because this cause oil
leakage.
• Addition or reduction of shim (0.05 mm, 0.002 in.)
delays or advances the injection timing by approx.
0.009 rad (0.5 °).
• In disassembling and replacing, be sure to use the
same number of new gasket shims with the same
thickness.

(1) Delivery Valve Holder (A) 3 Cylinder


(2) Timing Mark (B) 4 Cylinder
(3) 2-Holes: 0.20 mm (Shim)
(4) 1-hole: 0.25 mm (Shim)
(5) Without hole: 0.30 mm (Shim)
(6) 2-Holes: 0.175 mm (Shim)

V2403 Service Manual 76 4. Servicing


Fuel Tightness of Pump Element

1. Remove the solenoid.

2. Remove the injection pipes and glow plugs.

3. Install the injection pump pressure tester to the


injection pump.

4. Install the injection nozzle (2) jetted with the proper


injection pressure to the injection pump pressure
tester (1). (Refer to the figure.)

5. Set the speed control lever to the maximum speed


position.

6. Run the starter to increase the pressure.

7. If the pressure can not reach the allowable limit,


replace the pump with new one or repair with a
Kubota-authorized pump service shop.

13.73 MPa
Fuel tightness of 2
Allowable limit 140.0 kgf/cm
pump element
1991 psi

NOTE : Never try to disassemble the injection pump


assembly. For repairs, you are strongly requested to
contact a Kubotaauthorized pump service shop.

(1) Injection Pump Pressure Tester


(2) Injection Nozzle
(3) Protection Cover for Jetted Fuel

V2403 Service Manual 77 4. Servicing


Fuel Tightness of Delivery Valve

1. Remove the solenoid.

2. Remove the injection pipes and glow plugs.

3. Set a pressure tester to the fuel injection pump.

4. Install the injection nozzle (2) jetted with the proper


injection pressure to the injection pump pressure
tester (1).

5. Run the starter to increase the pressure.

6. Stop the starter when the fuel jets from the injection
nozzle. After that, turn the flywheel by the hand and
raise the pressure to approx. 13.73 MPa (140.0
2
kgf/cm , 1991 psi).

7. Now turn the flywheel back about half a turn (to keep
the plunger free). Maintain the flywheel at this
position and clock the time taken for the pressure to
drop from 13.73 to 12.75 MPa (140.0 to 130.0
2
kgf/cm , 1991 to 1849 psi).

8. Measure the time needed to decrease the pressure


2
from 13.73 to 12.75 MPa (140.0 to 130.0 kgf/cm ,
1991 to 1849 psi).

9. If the measurement is less than allowable limit,


replace the pump with new one or repair with a
Kubota-authorized pump service shop.

10 seconds
Factory 13.73 → 12.75 MPa
2
spec. 140.0 → 130.0 kgf/cm
Fuel tightness 1991 → 1849 psi
of delivery
valve 5 seconds
Allowable 13.73 → 12.75 MPa
2
limit 140.0 → 130.0 kgf/cm
1991 → 1849 psi

NOTE : Never try to disassemble the injection pump


assembly. For repairs, you are strongly requested to
contact a Kubotaauthorized pump service shop.

(1) Injection Pump Pressure Tester


(2) Injection Nozzle
(3) Protection Cover for Jetted Fuel

V2403 Service Manual 78 4. Servicing


CAUTION
• Check the injection pressure and condition after confirming that there is nobody standing in the
direction the fume goes.
• If the fume from the nozzle directly contacts the human body, cells may be destroyed and blood
poisoning may be caused.

Nozzle Spraying Condition

1. Set the injection nozzle to a nozzle tester, and check


the nozzle spraying condition.

2. If the spraying condition is defective, replace the


nozzle piece.

(a) Good (b) Bad

Fuel Injection Pressure

1. Set the injection nozzle to a nozzle tester.

2. Slowly move the tester handle to measure the


pressure at which fuel begins jetting out from the
nozzle.

3. If the measurement is not within the factory


specifications, replace the adjusting washer (1) in the
nozzle holder to adjust it.

(Reference)

• Pressure variation with 0.025 mm (0.00098 in.)


difference of adjusting washer thickness.
2
Approx. 590 kPa (6.0 kgf/cm , 85 psi)

13.73 to 14.70 MPa


Fuel injection Factory 2
140.0 to 150.0 kgf/cm
pressure spec.
1992 to 2133 psi

(1) Adjusting Washer

V2403 Service Manual 79 4. Servicing


Valve Seat Tightness

1. Set the injection nozzle to a nozzle tester.

2. Raise the fuel pressure, and keep at 12.75 MPa


2
(130.0 kgf/ cm , 1849 psi) for 10 seconds.

3. If any fuel leak is found, replace the nozzle piece.

No fuel leak at
12.75 MPa
Valve seat tightness Factory spec. 2
130.0 kgf/cm
1849 psi

Nozzle Holder

1. Secure the nozzle retaining nut (7) with a vise.

2. Remove the nozzle holder (1), and take out parts


inside.

(When reassembling)

• Assemble the nozzle in clean fuel oil.

• Install the push rod (4), noting its direction.

• After assembling the nozzle, be sure to adjust the fuel


injection pressure.

35 to 39 N·m
Nozzle holder 3.5 to 4.0 kgf•m
26 to 28 lbf•ft
20 to 24 N·m
Tightening Overflow pipe
2.0 to 2.5 kgf•m
torque retaining nut
15 to 18 lbf•ft
49 to 68 N•m
Nozzle holder
5.0 to 7.0 kgf•m
assembly
37 to 50 lbf•ft

(1) Nozzle Holder (5) Distance Piece


(2) Adjusting Washer (6) Nozzle Piece
(3) Nozzle Spring (7) Nozzle Retaining Nut
(4) Push Rod

V2403 Service Manual 80 4. Servicing


Electrical System

CAUTION
• To avoid accidental short circuit, be sure to attach the positive cable to the positive terminal before
the negative cable is attached to the negative terminal.
• Never remove the battery cap while the engine is running.
• Keep electrolyte away from eyes, hands and clothes. If you are spattered with it, wash it away
completely with water immediately.
• Keep open sparks and flames away from the battery at all times. Hydrogen gas mixed with oxygen
becomes very explosive.

IMPORTANT
If the machine is to be operated for a short time without battery (using a slave battery for starting), use
additional current (lights) while engine is running and insulate terminal of battery. If this advice is
disregarded, damage to alternator and regulator may result.

Battery Voltage

1. Stop the engine.

2. Measure the voltage with a circuit tester between the


battery terminals.

3. If the battery voltage is less than the factory


specification, check the battery specific gravity and
recharge the battery.

Battery voltage Factory spec. More than 12 V

(1) Positive Terminal (2) Negative Terminal

V2403 Service Manual 81 4. Servicing


Battery Specific Gravity

1. Check the specific gravity of the electrolyte in each


cell with a hydrometer.

2. When the electrolyte temperature differs from that at


which the hydrometer was calibrated, correct the
specific gravity reading following the formula
mentioned in (Reference).

3. If the specific gravity is less than 1.215 (after it is


corrected for temperature), charge or replace the
battery.

4. If the specific gravity differs between any two cells by


more than 0.05, replace the battery.

NOTE
• Hold the hydrometer tube vertical without
removing it from the electrolyte.
• Do not suck too much electrolyte into the tube.
• Allow the float to move freely and hold the
hydrometer at eye level.
• The hydrometer reading must be taken at the
highest electrolyte level.

(Reference)
• Specific gravity slightly varies with temperature. To be
exact, the specific gravity decreases by 0.0007 with an
increase of 1 °C (0.0004 with an increase of 1 °F) in
temperature, and increases by 0.0007 with a
decreases of 1 °C (0.0004 with a decrease of 1 °F).

Therefore, using 20 °C (68 °F) as a reference, the


specific gravity reading must be corrected by the
following formula :

- Specific gravity at 20 °C = Measured value + 0.0007


× (electrolyte temperature : 20 °C)

- Specific gravity at 68 °F = Measured value + 0.0004


× (electrolyte temperature : 68 °F)

Specific Gravity State of Charge


1.260 Sp. Gr. 100 % Charged
1.230 Sp. Gr. 75 % Charged
1.200 Sp. Gr. 50 % Charged
1.170 Sp. Gr. 25 % Charged
1.140 Sp. Gr. Very Little Useful Capacity
1.110 Sp. Gr. Discharged
At an electrolyte temperature of 20 °C (68 °F)

(a) Good (c) Bad


(b) Bad

V2403 Service Manual 82 4. Servicing


Motor Test

CAUTION
Secure the starter to prevent it from jumping up
and down while testing the motor.

1. Disconnect the battery negative cable from the


battery.

2. Disconnect the battery positive cable from the battery.

3. Disconnect the leads from the starter B terminal.

4. Remove the starter from the engine.

5. Connect a jumper lead from the starter C terminal (1)


to the battery positive terminal (2).

6. Connect a jumper lead momentarily between the


starter’s body and the battery negative terminal (3).

7. If the motor does not run, starter is failure.


Repair or replace the starter.

NOTE
• B terminal : It is the terminal which connects the
cable from the battery to the starter.
• C terminal : It is the terminal which connects the
cable from the motor to the magnet switch.

(1) C Terminal (3) Negative Terminal


(2) Positive Terminal

V2403 Service Manual 83 4. Servicing


Magnetic Switch Test

1. Disconnect the battery negative cable from the


battery.

2. Disconnect the battery positive cable from the battery.

3. Disconnect the leads from the starter B terminal.

4. Remove the starter from the engine.

5. Connect a jumper lead from the starter S terminal (1)


to the battery positive terminal (2).

6. Connect a jumper lead momentarily between the


starter’s body and the battery negative terminal (3).

7. If the pinion gear does not pop out, the magnetic


switch is failure.
Repair or replace the starter.

NOTE
• B terminal : It is the terminal which connects the
cable from the battery to the starter.
• S terminal : It is the terminal which connects the
cable from the starter switch to the magnet switch.

(1) S Terminal (3) Negative Terminal


(2) Positive Terminal

Magnet Switch Continuity Test

1. Check the continuity across the C terminal (1) and


the B terminal (2) with a circuit tester, pushing in the
plunger.

2. If not continuous or if a certain value is indicated,


replace the magnet switch.

(1) C Terminal (2) B Terminal

V2403 Service Manual 84 4. Servicing


Alternator on Unit Test

(Before testing)

• Before alternator on unit test, check the battery


terminal connections, circuit connection, fan belt
tension, charging indicator lamp, fuses on the circuit,
and abnormal noise from the alternator.

• Prepare full charged battery for the test.

NOTE : Be careful not to touch the rotating engine parts


while engine is running. Keep safety distance from the
engine rotating parts.

1. Start the engine.

2. When the engine is operating measure the voltage


between two battery terminals. If the voltage is
between 13.8 V and 14.8 V, the alternator is
operating normally.

3. If the results of alternator on unit test are not within


the specifications, disassemble the alternator and
check the each component part for finding out the
failure. See the “DISASSEMBLING AND
ASSEMBLING” and “SERVICING” for alternator.

Regulating voltage Factory 13.8 to 14.8 V at


at no load spec. 25 °C (77 °F)

Glow Plug Lead Terminal Voltage

1. Turn the key switch to the “GLOW (or PREHEAT)”


position, and measure the voltage with a circuit tester
between the lead terminal and the engine body.

2. If the voltage differs from the battery voltage, the


wiring harness or main switch is faulty.

Main switch key at Approx. battery


Voltage
GLOW (or PREHEAT) voltage

V2403 Service Manual 85 4. Servicing


Glow Plug Continuity

1. Remove the glow plug.

2. Measure the resistance with a circuit tester between


the glow plug terminal and the glow plug housing.

3. If the factory specification is not indicated, glow plug


is faulty.

Resistance Factory spec. Approx. 0.9 Ω

Engine Stop Solenoid

1. Remove the engine stop solenoid from the engine.

2. Connect the jumper leads from the pulling coil P


terminal to the switch (3), and from switch (3) to the
battery positive terminal.

3. Connect the jumper leads from the holding coil H


terminal to the switch (4), and from switch (4) to the
battery positive terminal.

4. Connect the jumper leads from the engine stop


solenoid body to the battery negative terminal.

5. When switch (4) is turn on, the plunger pull into the
solenoid body and then turn off the switch (4), the
plunger comes out.

6. Turn on the switch (3) then turn on the switch (4), the
plunger pull into the solenoid body and it keep in
holding position after turn off the switch (4).

7. If the plunger is not attracted, the engine stop


solenoid is faulty.

IMPORTANT
Never apply the current for pulling coil more than
two seconds when inspecting.

(1) Connector P : Terminal for Pulling Coil


(2) Battery H : Terminal for Holding Coil
(3) Switch for Holding Coil
(4) Switch for Pulling Coil

V2403 Service Manual 86 4. Servicing


Oil Pressure Switch

1. Disconnect the connector of the oil pressure switch


connector (1P).

2. Check the state of the harness and if it is abnormal,


please replace it.

3. Measure the resistance between the terminal of the


connector (harness side) and chassis.

4. When the measurements are the below table value.


The ECU is normal. The oil pressure switch (1) is
failure, then please replace it.

5. When the measurements are out of the below table


value. The ECU is failure, then please replace it.

Resistance Terminal 1 - Chassis Infinity

(1) Oil Pressure Switch

V2403 Service Manual 87 4. Servicing


Solenoid

1. Disconnect the connector of solenoid (2) (2P).

2. Check the state of the harness and if it is abnormal,


please replace it.

3. Turn the key switch to the ACC position.

4. Measure the voltage between the connector of


solenoid (2) (harness side).

5. When the measurements are the below table value.


The ECU is normal. Check the solenoid (1) according
to the procedure of confirming the solenoid’s
movement.

6. When the measurements are out of the below table


value. The ECU is failure, then please replace it.

Voltage Terminal 1 - Terminal 2 12 V

(Reference)
• The procedure of confirming the solenoid’s movement

1. Measure the resistance between the connector of


solenoid (2).

2. When the measurements are the below table value.


The solenoid (1) is normal electrically. Check the
solenoid’s movement.
[A]
3. When the measurements are out of the below table
value.
The solenoid (1) is failure, then please replace it.

4. Remove the solenoid (1) from the engine.

5. Supply the voltage (12 V) to the solenoid (1).

6. When the rod of the solenoid (1) moves smoothly.


The solenoid (1) is normal.

7. When the rod of the solenoid (1) does not move


smoothly.
The solenoid (1) is failure, then please replace it.
[B]
CAUTION
Please note handling, the solenoid (1) becomes a
high temperature.

Resistance Terminal 1 - Terminal 2 2 to 4 Ω

(1) Solenoid (A) Key Switch OFF Position


(2) Connector of Solenoid (B) Key Switch ON Position
(3) Terminal 2 (.)
(4) Terminal 1 (+)

V2403 Service Manual 88 4. Servicing


Glow Plug Harness

1. Disconnect the glow plug terminal (1).

2. Check the state of the harness and if it is abnormal,


please replace it.

3. Turn the key switch to the ACC position.

4. Measure the voltage between the glow pulg terminal


(1) of the connector (harness side) and chassis.

5. When the measurements are the below table value.


The ECU is normal. Some of the glow plugs are
failure, then please replace them.

6. When the measurements are out of the below table


value.
The ECU is failure, then please replace it.

Voltage Terminal - Chassis 12 V

(1) Glow Plug Terminal

Alternator

1. Disconnect the terminal L (2) of the alternator (2P).

2. Check the state of the harness and if it is abnormal,


please replace it.

3. Measure the resistance between the terminal L (2) of


the connector (harness side) and chassis.

4. When the measurements are the below table value.


The ECU is normal. The alternator is failure, then
please replace it.

5. When the measurements are out of the below table


value.
The ECU is failure, then please replace it.

Resistance Terminal L - Chassis Infinity

(1) Alternator
(2) Terminal L (Harness Side)

V2403 Service Manual 89 4. Servicing


Speed Switch

1. Check the state of the harness and if it is abnormal,


please replace it.

2. When the speed switch is turned ON and OFF,


measure the resistance between the speed switch
(terminal side) (1) of it each time.

3. When the measurements are the below table value.


The speed switch is normal. The ECU is failure, then
please replace it.

4. When the measurements are out of the below table


value.
The speed switch is failure, then please replace it.

ON 0Ω
Resistance
OFF Infinity

(1) Speed Switch (A) Single Pole, Single Throw


(Terminal Side) (B) Single Pole, Double Throw

Emergency Stop Switch

1. Check the state of the harness and if it is abnormal,


please replace it.

2. When the emergency stop switch is turned ON and


OFF, measure the resistance between the
emergency stop switch (terminal side) (1) of it each
time.

3. When the measurements are the below table value.


The emergency stop switch is normal. The ECU is
failure, then please replace it.

4. When the measurements are out of the below table


value.
The emergency stop switch is failure, then please
replace it.

ON 0Ω
Resistance
OFF Infinity

(1) Emergency Stop Switch (A) Single Pole, Single Throw


(Terminal Side) (B) Single Pole, Double Throw

V2403 Service Manual 90 4. Servicing


Slow Down Switch

1. Check the state of the harness and if it is abnormal,


please replace it.

2. When the slow down switch is turned ON and OFF,


measure the resistance between the slow down
switch (terminal side) (1) of it each time.

3. When the measurements are the below table value.


The slow down switch is normal. The ECU is failure,
then please replace it.

4. When the measurements are out of the below table


value.
The slow down switch is failure, then please replace
it.

ON 0Ω
Resistance
OFF Infinity

(1) Slow Down Switch (Terminal Side)


(A) Single Pole, Single Throw
(B) Single Pole, Double Throw

Battery

1. Measure the voltage of the battery (1) with the


engine stopped.

2. When the measurements are the below table value.


The battery is normal. The ECU is failure, then
please replace it.

3. When the measurements are out of the below table


value.
The battery is failure, then please replace it.

Voltage + terminal - . terminal 12 V

(1) Battery

V2403 Service Manual 91 4. Servicing


4.4.2. Disassembling And Assembling

Draining Oil and Coolant

Draining Engine Oil

1. Start and warm up the engine for approx. 5 minutes.

2. Place an oil pan underneath the engine.

3. Remove the drain plug (1) to drain oil.

4. After draining, screw in the drain plug.

(When refilling)

• Fill the engine oil up to the upper line on the dipstick


(2).

IMPORTANT
• Never mix two different types of oil.
• Use the proper SAE Engine Oil according to
ambient temperature.

(1) Drain Plug


(2) Dipstick

Draining Coolant

CAUTION
Never remove radiator cap while operating or
immediately after stopping. Otherwise, hot water
will spout out from the radiator. Wait for more than
ten minutes to cool the radiator, before opening the
cap.

1. Prepare a bucket. Open the coolant drain cock.

(1) Coolant Drain Cock

V2403 Service Manual 92 4. Servicing


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)

• Check to see that there are no cracks on the belt


surface.

IMPORTANT
• After reassembling the fan belt, be sure to adjust
the fan belt tension.
• Do not confuse the direction of the fan.

(1) Fan
(3) Starter
(2) Alternator
(4) Fan Belt

V2403 Service Manual 93 4. Servicing


Cylinder Head and Valves

Cylinder Head Cover

1. Remove the lead (4).

2. Remove the breather hose (1).

3. Remove the head cover screws (3).

4. Remove the cylinder head cover (2).

(When reassembling)

• Check to see if the cylinder head cover gasket (5) is


not defective.

9.81 to 11.2 N·m


Tightening Cylinder head
1.00 to 1.15 kgf·m
torque cover screw
7.24 to 8.31 lbf·ft

(1) Breather Hose (5) Cylinder Head Cover Gasket


(2) Cylinder Head Cover (6) Breather Valve
(3) Head Cover Screw (7) Plate
(4) Lead

Injection Pipes

1. Loosen the screws on the pipe clamps (2).

2. Detach the injection pipes (1).

(When reassembling)

• Blow out dust inside the pipes.

25 to 34 N·m
Tightening Injection pipe
2.5 to 3.5 kgf·m
torque retaining nut
18 to 25 lbf·ft

(1) Injection Pipe (2) Pipe Clamp

V2403 Service Manual 94 4. Servicing


Nozzle Holder Assembly and Glow Plug

1. Remove the overflow pipe assembly (3).

2. Remove the nozzle holder assemblies (4) using a 21


mm deep socket wrench.

3. Remove the copper gasket and heat seal (5).

4. Remove the glow plugs (2).

(When reassembling)

• Replace the copper gasket and heat seal with new


one.

49 to 68 N·m
Nozzle holder assembly 5.0 to 7.0 kgf·m
37 to 50 lbf·ft
20 to 24 N·m
Tightening torque Overflow pipe assembly retai ning nut 2.0 to 2.5 kgf·m
15 to 18 lbf·ft
20 to 24 N·m
Glow plug 2.0 to 2.5 kgf·m
15 to 18 lbf·ft

(1) Lead (2) Glow Plug (3) Overflow Pipe Assembly (4) Nozzle Holder Assembly (5) Heat Seal

Nozzle Heat Seal Service Removal Procedure

IMPORTANT
Use a plus (phillips head) screw driver (1) that has
a diameter which is bigger than the heat seal hole
(Approx. 6 mm (1/4 in.)).

1. Drive screw driver (1) lightly into the heat seal hole.

2. Turn screw driver three or four times each way.

3. While turning the screw driver, slowly pull the heat


seal (4) out together with the injection nozzle gasket
(3).

4. If the heat seal drops, repeat the above procedure.

(When reassembling)
• Heat seal and injection nozzle gasket must be
changed when the injection nozzle is removed for
cleaning or for service.

(1) Plus Screw Driver (3) Injection Nozzle Gasket


(2) Injection Nozzle (4) Heat Seal

V2403 Service Manual 95 4. Servicing


Rocker Arm and Push Rod

1. Remove the rocker arm bracket screws.

2. Detach the rocker arm assembly (1).

3. Remove the push rods (2).

(When reassembling)
• When putting the push rods (2) onto the tappets (3),
check to see if their ends are properly engaged with
the grooves.

IMPORTANT
After installing the rocker arm, be sure to adjust the
valve clearance.

24 to 27 N•m
Tightening Rocker arm bracket
2.4 to 2.8 kgf•m
torque screw
18 to 20 lbf•ft

(1) Rocker Arm Assembly (3) Tappet


(2) Push Rod

V2403 Service Manual 96 4. Servicing


Cylinder Head

1. Loosen the pipe clamp (2), and remove the water


return pipe (1).

2. Remove the cylinder head screw in the order of (n or


r) to (a).

3. Lift up the cylinder head (3) to detach.

4. Remove the cylinder head gasket (4).

(When reassembling)

• Replace the cylinder head gasket (4) with a new one.

• Tighten the cylinder head screws after applying


sufficient oil.

• Tighten the cylinder head screws in diagonal


sequence starting from the center in the order of (a) to
(n or r).

• Tighten them uniformly, or the head may deform in the


long run.

93.2 to 98.0 N•m


Tightening Cylinder head
9.50 to 10.0 kgf•m
torque screw
68.8 to 72.3 lbf•ft

IMPORTANT
To replace the cylinder head gasket (4), in advance
make sure the marking (5) of cylinder head gasket
in the original engine, and replace the same
marking as the original cylinder head gasket.

Gasket Marking & Model


Code Number V2403
15 1G790-03600
20 1G790-03310
25 1G790-03610
30 1G790-03620
35 1G790-03630

(1) Return Pipe (n or r) to (a) : To Loosen


(2) Pipe Clamp (a) to (n or r) : To Tighten
(3) Cylinder Head (A) Gear Case Side
(4) Cylinder Head Gasket (B) Flywheel Side
(5) Marking

V2403 Service Manual 97 4. Servicing


Cylinder Head (Continued)

IMPORTANT
When replacing piston, piston pin, small end
bushing, connecting rod, or crankpin bearings,
measure piston head’s protrusion or recessing
from the level of crankcase cylinder face (average
of all pistons) after installing the pistons, and
select the cylinder head gasket following the below
table.

Selecting the cylinder head gasket

1. Measure the piston head’s protrusion or recessing


from the crankcase cylinder face 4 spots per each
piston (average of all pistons) using the dial gauge.

2. Select the suitable cylinder need gasket refer to the


table below.

Gasket Size (Number) Piston Protrusion

0.500 to 0.540 mm
15
0.0197 to 0.0212 in.
0.550 to 0.590 mm
20
0.0217 to 0.0232 in.
0.600 to 0.640 mm
25
0.0237 to 0.0251 in.
0.650 to 0.690 mm
30
0.0256 to 0.0271 in.
0.700 to 0.740 mm
35
0.0276 to 0.0291 in.

(6) Measuring Points

V2403 Service Manual 98 4. Servicing


Tappets

1. Remove the tappets (1) from the crankcase.

(When reassembling)

• Visually check the contact between tappets and cams


for proper rotation. If defect is found, replace tappets.

• Before installing the tappets, apply engine oil thinly


around them.

IMPORTANT
Do not change the combination of tappet and
tappet guide.

(1) Tappet

Valves

1. Remove the valve caps (3).

2. Remove the valve spring collet (4), pushing the valve


spring retainer (5) by valve spring replacer (1).

3. Remove the valve spring retainer (5), valve spring (6)


and valve stem seal (2).

4. Remove the valve (7).

(When reassembling)

• Wash the valve stem and valve guide hole, and apply
engine oil sufficiently.

• After installing the valve spring collets (4), lightly tap


the stem to assure proper fit with a plastic hammer.

IMPORTANT
Do not change the combination of valve and valve
guide.

(1) Valve Spring Replacer (5) Valve Spring Retainer


(2) Valve Stem Seal (6) Valve Spring
(3) Valve Cap (7) Valve
(4) Valve Spring Collet

V2403 Service Manual 99 4. Servicing


Thermostat Assembly

1. Remove the thermostat cover mounting screws, and


remove the thermostat cover (1).

2. Remove the thermostat assembly (3).

(When reassembling)

• Replace the thermostat cover gasket (2) with new one.

• Apply a liquid gasket (Three Bond 1215 or equivalent)


to the water flange 1 (4) and flange 2 (5)

(1) Thermostat Cover (4) Water Flange 1


(2) Thermostat Cover Gasket (5) Water Flange 2
(3) Thermostat Assembly

Water Pump Assembly (If necessary)

1. Remove the water pump assembly (1) from the gear


case.

(When reassembling)

• Replace the gasket (2) with new one.

(1) Water Pump Assembly (2) Gasket

V2403 Service Manual 100 4. Servicing


Gear Case and Timing Gears

Injection Pump (for Non Turbocharger Model)

1. Remove the solenoid (4) and hi-idling body (1).

2. Remove the engine stop lever (3) and solenoid guide


(6).

3. Remove the fuel injection pump assembly (2).

IMPORTANT
Before removing the injection pump assembly (2),
be sure to remove the solenoid (4), hi-idling body
(1), engine stop lever (3) and solenoid guide (6).

(When reassembling)

• Before attaching the solenoid (4), hi-idling body (1)


and solenoid guide (6), install the injection pump first
into position.

• Replace the hi-idling body gasket (5) with a new one.

• Before fitting the stop lever (3) to the gear case, install
the solenoid guide (6) first into position. Then attach
the stop lever and use it to see if it functions well.

• When installing the solenoid (4), be careful to keep the


O-ring in place.

• Be sure to insert the push rod of the stop solenoid into


the hole at the center of the solenoid guide (6).

45 to 49 N·m
Tightening Hi-idling body 4.5 to 5.0 kgf·m
torque
33 to 36 lbf·ft

(1) Hi-idling Body (4) Slenoid


(2) Injection Pump Assemply (5) Hi-idling Body Gasket
(3) Stop Lever (6) Solenoid Guide

V2403 Service Manual 101 4. Servicing


Injection Pump (for Turbocharger Model)

1. Remove the boost compensator assembly (2).

2. Remove the hi-idling body (4).

3. Remove the solenoid (3).

4. Remove the solenoid guide (5).

5. Remove the injection pump assembly (1).

IMPORTANT
Before removing the injection pump assembly (1),
be sure to remove the boost compensator
assembly (2), hi-idling body (4), solenoid (3) and
solenoid guide (5).

(When reassembling)

• Before attaching the boost compensator assembly (2),


hi-idling body (4), solenoid (3) and solenoid guide (5),
install the injection pump first into position.

• Replace the hi-idling body gasket with a new one.

• Before fitting the boost compensator assembly (2) to


the gear case, make sure that the solenoid guide (5) is
at the initial position.

• When installing the solenoid (3), be careful to keep the


O-ring in place.

• Be sure to insert the push rod of the stop solenoid into


the hole at the center of the solenoid guide (5).

IMPORTANT
If you replace new boost compensator, it is
necessary to adjust it.
Get the adjustment procedure from KUBOTA.

45 to 49 N·m
Tightening
Hi-idling body 4.5 to 5.0 kgf·m
torque
33 to 36 lbf·ft

(1) Injection Pump Assembly (4) Hi-idling Body


(2) Boost Compensator Assembly (5) Solenoid Guide
(3) Solenoid

V2403 Service Manual 102 4. Servicing


Governor Springs and Speed Control Plate

NOTE
Specific tool (1) :
1.2 mm diameter hard wire with its end hooked,
overall length 200 mm (7.87 in.).
The tip of wire is bent like the hook to hang
governor springs.

1. Remove the injection pump cover.

2. Remove the speed control plate (6) mounting nuts


and bolts.

3. Using the specific tool (1), undo the large governor


spring (3) from the fork lever (2).

4. Using the specific tool (1), undo the small governor


spring (4) from the fork lever (2).

5. Set the speed control lever (5) as shown in the figure.

6. Take out the speed control plate (6) with care not to
let the large (3) and small (4) governor springs come
off this plate and fall in to the gear case.

(1) Specific Tool (4) Small Governor Spring


(2) Fork Lever (5) Speed Control Lever
(3) Large Governor Spring (6) Speed Control Plate

V2403 Service Manual 103 4. Servicing


Governor Springs and Speed Control Plate
(Continued)

(When reassembling)

• Hook the small spring (4) first and then the large
governor spring (3) on the speed control plate (6).

• Put the specific tool (1) from the injection pump side to
catch the large governor spring (3). Keep this spring
slightly extended and place the speed control plate (6)
in its specified position.

• Using the specific tool (1), hook the small governor


spring (4) onto the fork lever (2).

NOTE
• Be careful not to stretch the small governor
spring (4) too long because otherwise it may get
deformed permanently.
• Using the specific tool (1), hook the large
governor spring (3) onto the fork lever (2).
• Make sure both the governor springs (3), (4) are
tight on the fork lever (2).
• Apply and tighten up the two bolts and two nuts
on the speed control plate (6).
• Check that the speed control lever (5) positions
low idle, after assembling governor springs.
• Check that the speed control lever (5) returns to
the high idle position rather than the low idle
position, after moving the lever to the maximum
speed position.
• Finally attach the injection pump cover in position.

(1) Specific Tool (4) Small Governor Spring


(2) Fork Lever (5) Speed Control Lever
(3) Large Governor Spring (6) Speed Control Plate

V2403 Service Manual 104 4. Servicing


Fan Drive Pulley

1. Lock the flywheel not to turn using the flywheel


stopper.

2. Remove the fan drive pulley mounting nut (1) using


46 mm deep socket wrench (3).

3. Remove the fan drive pulley (2) with gear puller (4).

4. Remove the feather key.

(When reassembling)

• Apply grease to the splines of coupling.

138 to 156 N·m


Tightening Fan drive pulley
14.0 to 16.0 kgf·m
torque mounting nut
102 to 115 lbf·ft

(1) Nut (3) 46 mm Deep Socket Wrench


(2) Fan Drive Pulley (4) Gear Puller

V2403 Service Manual 105 4. Servicing


Idle Gear 2 and Hydraulic Pump Base Assembly (for
Side PTO Model)

1. Remove the hour meter gear case (if equipped).

2. Remove the gear case cover (1).

3. Remove the hydraulic pump base assembly (2).

4. Remove the idle gear 2 stopper (3).

5. Remove the idle gear 2 (4) using the puller (5).

6. Remove the idle gear 2 shaft (7).

(When reassembling)

• Replace the washer (6) and gear case cover gasket.

• Replace the gear case cover gasket with new one.

24 to 27 N·m
Idle gear 2 shaft
2.4 to 2.8 kgf·m
set screw
Tightening 18 to 20 lbf·ft
torque Idle gear 2 49 to 55 N·m
stopper set 5.0 to 5.7 kgf·m
screw 37 to 41 lbf·ft

(1) Gear Case Cover


(2) Hydraulic Pump Base Assembly
(3) Idle Gear 2 Stopper
(4) Idle Gear 2
(5) Puller
(6) Washer
(7) Idle Gear 2 Shaft
(8) Idle Gear 2 Stopper Set Screw
(9) Idle Gear 2 Shaft Set Screw

V2403 Service Manual 106 4. Servicing


Gear Case (for Side PTO Model)

1. Remove the gear case (1).

2. Remove the O-rings (2).

(When reassembling)

• Replace the gear case gasket and O-rings.

• Check to see if there are four O-rings (2) inside the


gear case (1).

• Apply a thin film of engine oil to the oil seal, and install
it, noting the lip come off.

• Before installing the gear case gasket, apply a non-


drying adhesive.

(1) Gear Case (2) O-rings

Gear Case

1. Remove the hour meter gear case (if equipped).

2. Remove the gear case (1).

3. Remove the O-rings (2).

(When reassembling)

• Replace the gear case gasket and O-rings (2).

• Replace the hour meter gear case gasket with new


one.

• Check to see if there are four O-rings (2) inside the


gear case (1).

• Apply a thin film of engine oil to the oil seal (3), and
install it, noting the lip come off.

• Before installing the gear case gasket, apply a non-


drying adhesive.

(1) Gear Case (3) Oil Seal


(2) O-ring

V2403 Service Manual 107 4. Servicing


Crankshaft Oil Slinger

1. Remove the crankshaft collar (3).

2. Remove the O-ring (2).

3. Detach the crankshaft oil slinger (1).

(When reassembling)

• Insert the crankshaft collar (3) after install the gear


case to cylinder body.

(1) Crankshaft Oil Slinger (3) Crankshaft Collar


(2) O-ring

Idle Gear

1. Remove the external snap ring.

2. Detach the idle gear collar.

3. Detach the idle gear (2).

(When reassembling)

• Check to see each gear is aligned with its aligning


mark

- Idle gear (2) and crank gear (4)

- Idle gear (2) and cam gear (3)

- Idle gear (2) and injection pump gear (1)

(1) Injection Pump Gear (4) Crank Gear


(2) Idle Gear (5) Oil Pump Drive Gear
(3) Cam Gear

Camshaft

1. Remove the camshaft set screws (1) and draw out


the camshaft (2).

(When reassembling)

• When installing the idle gear, be sure to align the


alignment marks on gears.

24 to 27 N·m
Tightening Camshaft set
2.4 to 2.8 kgf·m
torque screw
18 to 20 lbf·ft

(1) Camshaft Set Screw (2) Camshaft

V2403 Service Manual 108 4. Servicing


Fuel Camshaft and Fork Lever Assembly

1. Remove the fuel feed pump.

2. Detach the fuel camshaft stopper (1).

3. Remove the three fork lever holder mounting screws


(2).

4. Draw out the fuel camshaft assembly (5), (6) and fork
lever assembly (3), (4), (7) at the same time.

(When reassembling)

• After installation, check to see that the fork lever 1 (3)


and lever 2 (4) are fixed to the fork lever shaft, and
that they can turn smoothly in the holder (7).

(1) Fuel Camshaft Stopper


(2) Fork Lever Holder Mounting Screws
(3) Fork Lever 1
(4) Fork Lever 2
(5) Injection Pump Gear
(6) Fuel Camshaft
(7) Fork Lever Holder

Oil Pump

1. Remove the nut.

2. Draw out the oil pump drive gear (2) with gear puller
(1).

3. Remove the four oil pump mounting screws. Detach


the oil pump (3).

(1) Gear Puller


(3) Oil Pump
(2) Oil Pump Drive Gear

Crank Gear

1. Draw out the crank gear (2) with a puller (1).

2. Remove the feather key.

(1) Crank Puller


(2) Crank Gear

V2403 Service Manual 109 4. Servicing


Piston and Connecting Rod

Oil Pan and Oil Strainer

1. Remove the oil pan mounting screws.

2. Remove the oil pan (3) by lightly tapping the rim of


the pan with a wooden hammer.

3. Remove the oil pan gasket (2).

4. Remove the oil strainer (1) and O-ring (4).

(When reassembling)

• After cleaning the oil strainer (1), check to see that the
filter mesh in clean, and install it.

• Visually check the O-ring (4), apply engine oil, and


install it.

• Securely fit the O-ring (4) to the oil strainer (1).

• Replace the oil pan gasket (2) with new one.

• To avoid uneven tightening, tighten oil pan mounting


screws in diagonal order from the center.

(1) Oil Strainer (3) Oil Pan


(2) Oil Pan Gasket (4) O-ring

Pistons

1. Completely clean carbon (1) in the cylinders.

2. Remove the connecting rod cap (3).

3. Turn the flywheel and bring the piston to top dead


center.

4. Draw out the piston upward by lightly tapping it from


the bottom of the crankcase with the grip of a
hammer.

5. Draw out the other piston in the same method as


above.

(When reassembling)

• Before inserting piston into the cylinder, apply enough


engine oil to the piston.

V2403 Service Manual 110 4. Servicing


• When inserting the piston into the cylinder, face the
mark on the connecting rod to the injection pump.

IMPORTANT
• Do not change the combination of cylinder and
piston. Make sure of the position of each piston
by marking. For example, mark “1” on the No. 1
piston.
• Place the piston rings with their gaps at 0.79 rad
(45 °) from the piston pin’s direction as shown in
the figure.
• Carefully insert the pistons using a piston ring
compressor (6).
• When inserting the piston in place, be careful not
to get the molybdenum disulfide coating torn off
its skirt. This coating is useful in minimizing the
clearance with the cylinder liner. Just after the
piston pin has been press-fitted, in particular, the
piston is still hot and the coating is easy to peel
off. Wait until the piston cools down.

45 to 49 N·m
Tightening Connecting rod
4.5 to 5.0 kgf·m
torque screw
33 to 36 lbf·ft

(1) Carbon (A) Top Ring Gap


(2) Connecting Rod Screw (B) Second Ring Gap
(3) Connecting Rod Cap (C) Oil Ring Gap
(4) Connecting Rod (D) Piston Pin Hole
(5) Molybdenum Disulfide Coating in
Piston Skirt (a) 0.79 rad (45 °)
(6) Piston Ring Compressor

V2403 Service Manual 111 4. Servicing


Piston Ring and Connecting Rod

1. Remove the piston rings (1), (2), (3) using a piston


ring tool.

2. Remove the piston pin (9), and separate the


connecting rod (7) from the piston (6).

(When reassembling)

• When installing the rings, assemble the rings so that


the manufacturer’s mark (12) near the gap faces the
top of the piston (6).

• When installing the oil ring (3) onto the piston (6),
place the expander joint (10) on the opposite side of
the oil ring gap (11).

• Apply engine oil to the piston pin (9).

• When installing the connecting rod (7) to the piston (6),


immerse the piston (6) in 80 °C (176 °F) oil for 10 to
15 minutes and insert the piston pin (9) to the piston
(6).

• When installing the connecting rod (7) to the piston (6),


align the mark (8) on the connecting rod (7) to the fan-
shaped concave (5).

NOTE : Mark the same number on the connecting rod


(7) and the piston (6) so as not to change the
combination.

(1) Top Ring (7) Connecting Rod


(2) Second Ring (8) Mark
(3) Oil Ring (9) Piston Pin
(4) Piston Pin Snap Ring (10) Expander Joint
(5) Fan-Shaped Concave (11) Oil Ring Gap
(6) Piston (12) Manufacturer’s Mark

V2403 Service Manual 112 4. Servicing


Flywheel and Crankshaft

Flywheel

1. Fit the stopper to the flywheel (1).

2. At first, remove two pieces of the flywheel screws (2).

3. Insert two pieces of the flywheel guide screws (3) in


the holes.

4. Remove the all flywheel screws (2).

5. Remove the flywheel (1) slowly along the flywheel


guide screws (3).

(When reassembling)

• Insert two pieces of the flywheel guide screws (3).

• Check to see that there are no metal particles left on


the flywheel mounting surfaces.

• Apply engine oil to the threads and the undercut


surface of the flywheel bolt and fit the bolt.

98.1 to 107 N·m


Tightening
Flywheel screw 10.0 to 11.0 kgf·m
torque
72.4 to 79.5 lbf·ft

(1) Flywheel (3) Flywheel Guide Screws


(2) Flywheel Screw

Bearing Case Cover

1. Remove the bearing case cover mounting screws.


First, remove inside screws (5) and then outside
screws (3).

2. Screw two removed screws into the screw hole of


bearing case cover (6) to remove it.

IMPORTANT
The length of inside screws (5) and outside screws
(3) are different. Do not take a mistake using inside
screws and outside screws.

(When reassembling)

• Fit the bearing case gasket (1) and the bearing case
cover gasket (2) with correct directions.

• Install the bearing case cover (6) to position the


casting mark “UP” on it upward.

V2403 Service Manual 113 4. Servicing


• Apply engine oil to the oil seal lip and take care that it
is not rolled when installing.

• Tighten the bearing case cover mounting screws with


even force on the diagonal line.

Bearing case 24 to 27 N·m


Tightening
cover mounting 2.4 to 2.8 kgf·m
torque
screw 18 to 20 lbf·ft

(1) Bearing Case Gasket


(2) Bearing Case Cover Gasket
(3) Bearing Case Cover Mounting Screw
(4) Oil Seal
(5) Bearing Case Cover Mounting Screw
(6) Bearing Case Cover
(a) Upside

Crankshaft

NOTE : Before disassembling, check the side


clearance of crankshaft. Also check it during
reassembling.

1. Remove the main bearing case screw 2 (1).

2. Turn the crankshaft to set the crank pin of the 4th


cylinder to the horizontal directions (Right or Left).
Then draw out all the crankshaft, holding the crank
pins to the horizontal directions (Right or Left).

(When reassembling)

IMPORTANT
• Install the crankshaft sub assembly, aligning the
screw hole of main bearing case 2 (2) with the
screw hole of cylinder block.
• When tightening the main bearing case screw 2
(1), apply oil to the screw and screw by hand
before tightening the specific torque.
If not smooth to screw by hand, align the screw
holes between the cylinder block and the main
bearing case.

69 to 73 N·m
Tightening Main bearing
2 7.0 to 7.5 kgf·m
torque case screw
51 to 54 lbf·ft

(1) Main Bearing Case Screw 2


(2) Main Bearing Case 2
(3) Crankshaft Bearing 1

V2403 Service Manual 114 4. Servicing


Main Bearing Case Assembly

1. Remove the two main bearing case screws 1 (7), and


remove the main bearing case assembly being
careful with thrust bearing and crankshaft bearing.

2. Remove the main bearing case 1, 2 as above.

(When reassembling)

• Clean the oil passage in the main bearing case.

• Apply clean engine oil on the bearings.

• Install the main bearing case assemblies in the


original positions.
Since diameters of main bearing cases vary, install
them in order of makings (A, B for 3 cylinders and A, B,
C for 4 cylinders) from the gear case side.

• Match the alignment numbers (1) and mark (2) on the


main bearing case.

• When installing the main bearing case 1 and 2, face


the mark “FLYWHEEL” to the flywheel.

• Install the thrust bearing with its oil groove (8) facing
outward.

• Confirm that the main bearing case moves smoothly


after tightening the main bearing case screw 1 (7) to
the specified torque.

46 to 50 N·m
Tightening Main bearing
1 4.7 to 5.2 kgf·m
torque case screw
34 to 37 lbf·ft

(1) Alignment Number (5) C


(2) Alignment Mark (6) No Mark
(3) A (7) Main Bearing Case Screw 1
(4) B (8) Oil Groove

V2403 Service Manual 115 4. Servicing


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. Unscrew the C terminal nut (3), and disconnect the connecting lead.
2. Remove the two through bolts (1).
3. Detach the motor.
4. Remove the end frame (8).
5. Remove the brush from the brush holder while holding the spring up.
6. Remove the brush holder (9).
7. Draw out the armature (5) from the yoke (4).
8. Remove the housing (13).
9. Remove the idle gear (7) and the overrunning clutch (6).
10. Remove the magnet switch cover (10).
11. Remove the plunger (11).

NOTE : Do not damage to the brush and commutator.

(When reassembling)

• Apply grease (DENSO No. 50 or equivalent) to the idle gear and overrunning clutch portions.

5.9 to 11 N·m
Tightening torque B terminal nut 0.60 to 1.2 kgf·m
4.4 to 8.6 lbf·ft

V2403 Service Manual 116 4. Servicing


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. Remove the pulley (1).


2. Remove the rear end cover (12).
3. Remove the brush holder (11).
4. Remove the IC regulator (10).
5. Remove the four screws holding the stator lead wires.
6. Remove the rectifier (9).
7. Remove the rear end frame (8).
8. Press out the rotor (6) from drive end frame (2).
9. Remove the retainer plate (5).
10. Press out the bearing (4) from drive end frame (2) with a press and jig.
11. Lightly secure the rotor with a vise to prevent damage, and remove the bearing (7) with a puller.

(When reassembling)

58.4 to 78.9 N·m


Tightening torque Pulley nut 5.95 to 8.05 kgf·m
43.1 to 58.2 lbf·ft

V2403 Service Manual 117 4. Servicing


4.4.3. Servicing

Cylinder Head and Valves

Top Clearance

1. Remove the cylinder head.

2. Move the piston up and stick a strip of fuse on the


piston head at three position with grease.

3. Lower the piston and install the cylinder head.


(Use a new cylinder head gasket and tighten with a
specified tightening torque.)

4. Turn the flywheel until the piston exceeds top dead


center.

5. Remove the cylinder head and measure the


thickness of the fuses.

6. If the measurement is not within the factory


specifications, check the oil clearances between the
crankpin and bearing and between the piston pin and
bushing.

NOTE : After checking the top clearance, be sure to


assemble the cylinder head with a new cylinder head
gasket.

0.575 to 0.675 mm
Top clearance Factory spec.
0.0227 to 0.0265 in.

93.2 to 98.0 N·m


Tightening Cylinder
9.50 to 10.0 kgf·m
torque head screws
68.8 to 72.3 lbf·ft

(1) Piston
(2) Fuse

V2403 Service Manual 118 4. Servicing


Cylinder Head Surface Flatness

1. Clean the cylinder head surface.

2. Place a straightedge on the cylinder head’s four


sides (A), (B), (C) and (D) and two diagonal (E) and
(F) as shown in the figure.

3. Measure the clearance with a feeler gauge.

4. If the measurement exceeds the allowable limit,


correct it with a surface grinder.

IMPORTANT
• Do not place the straightedge on the combustion
chamber.
• Be sure to check the valve recessing after
correcting.

Cylinder head Allowable 0.05 mm


surface flatness limit 0.002 in.

Cylinder Head Flaw

1. Prepare an air spray red check.

2. Clean the surface of the cylinder head with the


detergent (2).

3. Spray the cylinder head surface with the red


permeative liquid (1). Leave it five to ten minutes
after spraying.

4. Wash away the red permeative liquid on the cylinder


head surface with the detergent (2).

5. Spray the cylinder head surface with the white


developer (3).

6. If flawed, it can be identified as red marks.

(1) Red Permeative Liquid (3) White Developer


(2) Detergent

V2403 Service Manual 119 4. Servicing


Valve Recessing

1. Clean the cylinder head surface, valve face and


valve seat.

2. Insert the valve into the valve guide.

3. Measure the valve recessing with a depth gauge.

4. If the measurement exceeds the allowable limit,


replace the valve.

5. If it still exceeds the allowable limit after replacing the


valve, replace the cylinder head.

0.05 (protrusion) to
0.15 (recessing) mm
Factory spec.
0.002 (protrusion) to
Valve recessing 0.0059 (recessing) in.
0.40 (recessing) mm
Allowable limit
0.016 (recessing) in.

(1) Cylinder Head Surface (A) Recessing


(B) Protrusion

V2403 Service Manual 120 4. Servicing


Clearance between Valve Stem and Valve Guide

1. Remove carbon from the valve guide section.

2. Measure the valve stem O.D. with an outside


micrometer.

3. Measure the valve guide I.D. with a small hole gauge,


and calculate the clearance.

4. If the clearance exceeds the allowable limit, replace


the valves.
If it still exceeds the allowable limit, replace the valve
guide.

Clearance Factory 0.040 to 0.070 mm


between valve spec. 0.0016 to 0.0027 in.
stem and valve Allowable 0.10 mm
guide limit 0.0039 in.

Valve stem Factory 7.960 to 7.975 mm


O.D. spec. 0.3134 to 0.3139 in.
Valve guide Factory 8.015 to 8.030 mm
I.D. spec. 0.3156 to 0.3161 in.

Replacing Valve Guide

(When removing)

1. Press out the used valve guide using a valve guide


replacing tool. (See page “SPECIAL TOOLS”.)

(When installing)

1. Clean a new valve guide and valve guide bore, and


apply engine oil to them.

2. Press in a new valve guide using a valve guide


replacing tool.

3. Ream precisely the I.D. of the valve guide to the


specified dimension.

Valve guide I.D. Factory 8.015 to 8.030 mm


(Intake and exhaust) spec. 0.3156 to 0.3161 in.

IMPORTANT
Do not hit the valve guide with a hammer during
replacement.

(A) When Removing (B) When Installing

V2403 Service Manual 121 4. Servicing


Valve Seating

1. Coat the valve face lightly with prussian blue and put
the valve on its seat to check the contact.

2. If the valve does not seat all the way around the
valve seat or the valve contact is less than 70 %,
correct the valve seating as follows.

3. If the valve contact does not comply with the


reference value, replace the valve or correct the
contact of valve seating.

2.12 mm
Valve seat width Factory spec.
0.0835 in.

(1) Correct (3) Incorrect


(2) Incorrect

Correcting Valve and Valve Seat

NOTE
• Before correcting the valve and seat, check the
valve stem and the I.D. of valve guide section, and
repair them if necessary.
• After correcting the valve seat, be sure to check
the valve recessing.

1) Correcting Valve

1. Correct the valve with a valve refacer.

1.0 rad
IN.
Valve face Factory 60 °
angle spec. 0.79 rad
EX.
45 °

V2403 Service Manual 122 4. Servicing


1.0 rad
Valve seat IN.
Factory 60 °
angle spec. 0.79 rad
EX.
45 °

(1) Valve Seat Width


(2) Identical Dimensions
(A) Check Contact
(B) Correct Seat Width
(C) Check Contact
(a) 0.26 rad (15 °) or 0.52 rad (30 °)
(b) 0.79 rad (45 °) or 1.0 rad (60 °)
(c) 0.52 rad (30 °) or 0.26 rad (15 °)

Valve Lapping

1. Apply compound evenly to the valve lapping surface.

2. Insert the valve into the valve guide. Lap the valve
onto its seat with a valve flapper or screwdriver.

3. After lapping the valve, wash the compound away


and apply oil, then repeat valve lapping with oil.

4. Apply prussian blue to the contact surface to check


the seated rate. If it is less than 70 %, repeat valve
lapping again.

IMPORTANT
When valve lapping is performed, be sure to check
the valve recessing and adjust the valve clearance
after assembling the valve.

V2403 Service Manual 123 4. Servicing


Free Length and Tilt of Valve Spring

1. Measure the free length (B) of valve spring with


vernier calipers. If the measurement is less than the
allowable limit, replace it.

2. Put the valve spring on a surface plate, place a


square on the side of the valve spring.

3. Check to see if the entire side is in contact with the


square.
Rotate the valve spring and measure the maximum
tilt (A).
If the measurement exceeds the allowable limit,
replace it.

4. Check the entire surface of the valve spring for


scratches.
If there is any defect, replace it.

1.0 mm
Tilt (A) Allowable limit
0.039 in.

41.7 to 42.2 mm
Factory spec.
1.65 to 1.66 in.
Free length (B)
41.2 mm
Allowable limit
1.62 in.

(A) Tilt (B) Free Length

Valve Spring Setting Load

1. Place the valve spring on a tester and compress it to


the same length it is actually compressed in the
engine.

2. Read the compression load on the gauge.

3. If the measurement is less than the allowable limit,


replace it.

118 N / 35.0 mm
Factory spec. 12.0 kgf / 35.0 mm
Setting load / 26.5 lbf / 1.38 in.
Setting length 100 N / 35.0 mm
Allowable
10.2 kgf / 35.0 mm
limit
22.5 lbf / 1.38 in.

V2403 Service Manual 124 4. Servicing


Oil Clearance between Rocker Arm and Rocker Arm
Shaft

1. Measure the rocker arm shaft O.D. with an outside


micrometer.

2. Measure the rocker arm I.D. with an inside


micrometer, and then calculate the oil clearance.

3. If the oil clearance exceeds the allowable limit,


replace the rocker arm and measure the oil clearance
again. If it still exceeds the allowable limit, replace
also the rocker arm shaft.

Oil clearance Factory 0.016 to 0.045 mm


between rocker spec. 0.00063 to 0.0017 in.
arm and rocker Allowabl 0.10 mm
arm shaft e limit 0.0039 in.

Rocker arm Factory 13.973 to 13.984 mm


shaft O.D. spec. 0.55012 to 0.55055 in.
Factory 14.000 to 14.018 mm
Rocker arm I.D.
spec. 0.55119 to 0.55188 in.

Push Rod Alignment

1. Place the push rod on V blocks.

2. Measure the push rod alignment.

3. If the measurement exceeds the allowable limit,


replace the push rod.

Push rod 0.25 mm


Allowable limit
alignment 0.0098 in.

V2403 Service Manual 125 4. Servicing


Oil Clearance between Tappet and Tappet Guide
Bore

1. Measure the tappet O.D. with an outside micrometer.

2. Measure the I.D. of the tappet guide bore with a


cylinder gauge, and calculate the oil clearance.

3. If the oil clearance exceeds the allowable limit or the


tappet is damaged, replace the tappet.

Oil Clearance Factory 0.020 to 0.062 mm


between tappet spec. 0.00079 to 0.0024 in.
and tappet guide Allowabl 0.07 mm
bore e limit 0.003 in.

Factory 23.959 to 23.980 mm


Tappet O.D.
spec. 0.94327 to 0.94409 in.
Tappet guide Factory 24.000 to 24.021 mm
bore I.D. spec. 0.94489 to 0.94570 in.

V2403 Service Manual 126 4. Servicing


Timing Gears

Timing Gear Backlash

1. Set a dial indicator (lever type) with its tip on the gear
tooth.

2. Move the gear to measure the backlash, holding its


mating gear.

3. If the backlash exceeds the allowable limit, check the


oil clearance of the shafts and the gear.

4. If the oil clearance is proper, replace the gear.

0.04150 to 0.1122 mm
Factory spec.
Backlash between idle gear and 0.001634 to 0.004417 in.
crank gear 0.15 mm
Allowable limit
0.0059 in.

0.04150 to 0.1154 mm
Factory spec.
Backlash between idle gear and 0.001634 to 0.004543 in.
cam gear 0.15 mm
Allowable limit
0.0059 in.

0.04150 to 0.1154 mm
Factory spec.
Backlash between idle gear and 0.001634 to 0.004543 in.
injection pump gear 0.15 mm
Allowable limit
0.0059 in.

0.04150 to 0.1090 mm
Factory spec.
Backlash between crank gear and 0.001634 to 0.004291 in.
oil pump gear 0.15 mm
Allowable limit
0.0059 in.

For Side PTO Model Only

0.04150 to 0.1154 mm
Factory spec.
Backlash between crank gear and 0.001634 to 0.004543 in.
idle gear 2 0.15 mm
Allowable limit
0.0059 in.

0.03080 to 0.1062 mm
Factory spec.
Backlash between idle gear 2 and 0.001213 to 0.004181 in.
hydraulic pump drive gear 0.15 mm
Allowable limit
0.0059 in.

V2403 Service Manual 127 4. Servicing


Idle Gear Side Clearance

1. Set a dial indicator with its tip on the idle gear.

2. Measure the side clearance by moving the idle gear


to the front and rear.

3. If the measurement exceeds the allowable limit,


replace the idle gear collar.

Factory 0.12 to 0.48 mm


Idle gear side spec. 0.0048 to 0.018 in.
clearance Allowabl 0.9 mm
e limit 0.04 in.

Camshaft Side Clearance

1. Set a dial indicator with its tip on the camshaft.

2. Measure the side clearance by moving the cam gear


to the front to rear.

3. If the measurement exceeds the allowable limit,


replace the camshaft stopper.

Factory 0.070 to 0.22 mm


Camshaft side spec. 0.0028 to 0.0086 in.
clearance Allowabl 0.30 mm
e limit 0.012 in.

Camshaft Alignment

1. Support the camshaft with V blocks on the surface


plate at both end journals.

2. Set a dial indicator with its tip on the intermediate


journal.

3. Measure the camshaft alignment.

4. If the measurement exceeds the allowable limit,


replace the camshaft.

Camshaft Allowabl 0.01 mm


alignment e limit 0.0004 in.

V2403 Service Manual 128 4. Servicing


Cam Height

1. Measure the height of the cam at its highest point


with an outside micrometer.

2. If the measurement is less than the allowable limit,


replace the camshaft.

33.90 mm
Factory spec.
Cam height of 1.335 in.
intake 33.85 mm
Allowable limit
1.333 in.

33.90 mm
Factory spec.
Cam height of 1.335 in.
exhaust 33.85 mm
Allowable limit
1.333 in.

Oil Clearance of Camshaft Journal

1. Measure the camshaft journal O.D. with an outside


micrometer.

2. Measure the cylinder block bore I.D. for camshaft


with a cylinder gauge, and calculate the oil clearance.

3. If the oil clearance exceeds the allowable limit,


replace the camshaft.

Factory 0.050 to 0.091 mm


Oil clearance of spec. 0.0020 to 0.0035 in.
camshaft journal
Allowabl 0.15 mm
e limit 0.0059 in.

Camshaft journal Factory 39.934 to 39.950 mm


O.D. spec. 1.5722 to 1.5728 in.
Cylinder block Factory 40.000 to 40.025 mm
bore I.D. spec. 1.5748 to 1.5757 in.

V2403 Service Manual 129 4. Servicing


Oil Clearance between Idle Gear Shaft and Idle Gear
Bushing

1. Measure the idle gear shaft O.D. with an outside


micrometer.

2. Measure the idle gear bushing I.D. with an inside


micrometer, and calculate the oil clearance.

3. If the oil clearance exceeds the allowable limit,


replace the bushing.
If it still exceeds the allowable limit, replace the idle
gear shaft.

Oil clearance Factory 0.025 to 0.066 mm


between idle spec. 0.00099 to 0.0025 in.
gear shaft and
idle gear Allowabl 0.10 mm
bushing e limit 0.0039 in.

Idle gear shaft Factory 37.959 to 37.975 mm


O.D. spec. 1.4945 to 1.4950 in.
Idle gear Factory 38.000 to 38.025 mm
bushing I.D. spec. 1.4961 to 1.4970 in.

Replacing Idle Gear Bushing

(When removing)

1. Press out the used idle gear bushing using an idle


gear bushing replacing tool. (See page “SPECIAL
TOOLS”.)

(When installing)

1. Clean a new idle gear bushing and idle gear bore,


and apply engine oil to them.

2. Press in a new bushing using an idle gear bushing


replacing tool, until it is flush with the end of the idle
gear.

(A) When Removing (B) When Installing

V2403 Service Manual 130 4. Servicing


Piston and Connecting Rod

Piston Pin Bore I.D.

1. Measure the piston pin bore I.D. in both the


horizontal and vertical directions with a cylinder
gauge.

2. If the measurement exceeds the allowable limit,


replace the piston.

Factory 25.000 to 25.013 mm


Piston pin bore spec. 0.98426 to 0.98476 in.
I.D. Allowabl 25.05 mm
e limit 0.9862 in.

Oil Clearance between Piston Pin and Small End


Bushing

1. Measure the piston pin O.D. where it contacts the


bushing with an outside micrometer.

2. Measure the small end bushing I.D. with an inside


micrometer, and calculate the oil clearance.

3. If the oil clearance exceeds the allowable limit,


replace the bushing. If it still exceeds the allowable
limit, replace the piston pin.

Oil clearance Factory 0.014 to 0.036 mm


between piston spec. 0.00056 to 0.0014 in.
pin and small Allowabl 0.15 mm
end bushing e limit 0.0059 in.

Factory 25.004 to 25.011 mm


Piston pin O.D.
spec. 0.98441 to 0.98468 in.
Small end Factory 25.025 to 25.040 mm
bushing I.D. spec. 0.98524 to 0.98582 in.

V2403 Service Manual 131 4. Servicing


Replacing Connecting Rod Small End Bushing

(When removing)

1. Press out the used small end bushing using a small


end bushing replacing tool. (See page “SPECIAL
TOOLS”.)

(When installing)

1. Clean a new small end bushing and bore, and apply


engine oil to them.

2. Using a small end bushing replacing tool, press in a


new bushing taking due care to see that the
connecting rod oil hole matches the bushing hole.
(A) When removing (B) When installing

Connecting Rod Alignment

NOTE : Since the I.D. of the connecting rod small end


bushing is the basis of this check, check bushing for
wear beforehand.

1. Install the piston pin into the connecting rod.

2. Install the connecting rod on the connecting rod


alignment tool.

3. Put a gauge over the piston pin, and move it against


the face plate.

4. If the gauge does not fit squarely against the face


plate, measure the space between the pin of the
gauge and the face plate.

5. If the measurement exceeds the allowable limit,


replace the connecting rod.

CoConnecting AAllowa 0.05 mm


rod alignment ble limit 0.002 in.

V2403 Service Manual 132 4. Servicing


Piston Ring Gap

1. Insert the piston ring into the lower part of the liner
(the least worn out part) with the piston.

2. Measure the ring gap with a feeler gauge.

3. If the gap exceeds the allowable limit, replace the


ring.

0.25 to 0.40 mm
Factory spec.
0.0099 to 0.015 in.
Top ring
1.25 mm
Allowable limit
0.0492 in.

0.30 to 0.45 mm
Factory spec.
0.012 to 0.017 in.
Second ring
1.25 mm
Allowable limit
0.0492 in.

0.25 to 0.45 mm
Factory spec.
0.0099 to 0.017 in.
Oil ring
1.25 mm
Allowable limit
0.0492 in.

Clearance between Piston Ring and Groove

1. Clean the rings and the ring grooves, and install each
ring in its groove.

2. Measure the clearance between the ring and the


groove with a feeler gauge or depth gauge.

3. If the clearance exceeds the allowable limit, replace


the piston ring.

4. If the clearance still exceeds the allowable limit with


new ring, replace the piston.

0.20 mm
Top Ring Allowable limit
0.0079 in.

0.0930 to 0.128 mm
Factory spec.
0.00367 to 0.00503 in.
Second ring
0.20 mm
Allowable limit
0.0079 in.

0.020 to 0.060 mm
Factory spec.
0.00079 to 0.0023 in.
Oil ring
0.15 mm
Allowable limit
0.0059 in.

V2403 Service Manual 133 4. Servicing


Crankshaft

Side Clearance of Crankshaft

1. Set a dial indicator with its tip on the end of the


crankshaft.

2. Measure the side clearance by moving the


crankshaft to the front and rear.

3. If the measurement exceeds the allowable limit,


replace the thrust bearings.

4. If the same size bearing is useless because of the


crankshaft journal wear, replace it with an oversize
one referring to the table and figure.

Factory 0.15 to 0.31 mm


Crankshaft side spec. 0.0059 to 0.012 in.
clearance Allowabl 0.5 mm
e limit 0.02 in.

(Reference)

• Oversize dimensions of crankshaft journal

0.2 mm 0.4 mm
Oversize
0.008 in. 0.02 in.
54.50 to 54.70 mm 54.60 to 54.80 mm
Dimension A
2.146 to 2.153 in. 2.150 to 2.157 in.
26.20 to 26.25 mm 26.40 to 26.45 mm
Dimension B
1.032 to 1.033 in. 1.040 to 1.041 in.
2.8 to 3.2 mm radius 2.8 to 3.2 mm radius
Dimension C
0.11 to 0.12 in. radius 0.11 to 0.12 in. radius
(0.4S)
The crankshaft journal must be fine-finished to higher than ∇∇∇∇

Crankshaft Alignment

1. Support the crankshaft with V blocks on the surface


plate at both end journals.

2. Set a dial indicator with its tip on the intermediate


journal.

3. Measure the crankshaft alignment.

4. If the measurement exceeds the allowable limit,


replace the crankshaft.

Crankshaft 0.02 mm
Allowable limit
alignment 0.0008 in.

V2403 Service Manual 134 4. Servicing


Oil Clearance between Crankpin and Crankpin
Bearing

1. Clean the crankpin and crankpin bearing.

2. Put a strip of plastigage on the center of the crankpin.

3. Install the connecting rod cap and tighten the


connecting rod screws to the specified torque, and
remove the cap again.

4. Measure the amount of the flattening with the scale,


and get the oil clearance.

5. If the oil clearance exceeds the allowable limit,


replace the crankpin bearing.

6. If the same size bearing is useless because of the


crankpin wear, replace it with an undersize one
referring to the table and figure.

NOTE
• Never insert the plastigage into the crankpin oil
hole.
• Be sure not to move the crankshaft while the
connecting rod screws are tightened.

Oil clearance Factory 0.025 to 0.087 mm


between spec. 0.00099 to 0.0034 in.
crankpin and Allowabl 0.20 mm
crankpin bearing e limit 0.0079 in.

Factory 46.959 to 46.975 mm


Crankpin O.D.
spec. 1.8488 to 1.8494 in.
Crankpin Factory 47.000 to 47.046 mm
bearing I.D. spec. 1.8504 to 1.8522 in.

(Reference)

• Undersize dimensions of crankpin

0.2 mm 0.4 mm
Undersize
0.008 in. 0.02 in.
3.3 to 3.7 mm radius 3.3 to 3.7 mm radius
Dimension A
0.13 to 0.14 in. radius 0.13 to 0.14 in. radius
1.0 to 1.5 mm relief 1.0 to 1.5 mm relief
*Dimension B
0.040 to 0.059 in. relief 0.040 to 0.059 in. relief
46.759 to 46.775 mm dia. 46.559 to 46.575 mm dia.
Dimension C
1.8409 to 1.8415 in. dia. 1.8331 to 1.8336 in. dia.
(0.4S)
The crankpin must be fine-finished to higher than ∇∇∇∇
*Holes to be de-burred and edges rounded with 1.0 to 1.5 mm
(0.040 to 0.059 in.) relief.

V2403 Service Manual 135 4. Servicing


Oil Clearance between Crankshaft Journal and
Crankshaft Bearing 1

1. Measure the O.D. of the crankshaft journal with an


outside micrometer.

2. Measure the I.D. of the crankshaft bearing 1 with an


inside micrometer, and calculate oil clearance.

3. If the clearance exceeds the allowable limit, replace


the crankshaft bearing 1.

4. If the same size bearing is useless because of the


crankshaft journal wear, replace it with an undersize
one referring to the table and figure.

Oil clearance Factory 0.0400 to 0.118 mm


between spec. 0.00158 to 0.00464 in.
crankshaft
journal and
crankshaft Allowabl 0.20 mm
bearing 1 e limit 0.0079 in.

Crankshaft Factory 59.921 to 59.940 mm


journal O.D. spec. 2.3591 to 2.3598 in.
Crankshaft Factory 59.980 to 60.039 mm
bearing 1 I.D. spec. 2.3615 to 2.3637 in.

(Reference)

• Undersize dimensions of crankshaft journal

0.2 mm 0.4 mm
Undersize
0.008 in. 0.02 in.
2.8 to 3.2 mm radius 2.8 to 3.2 mm radius
Dimension A
0.11 to 0.12 in. radius 0.11 to 0.12 in. radius
1.0 to 1.5 mm relief 1.0 to 1.5 mm relief
*Dimension B
0.040 to 0.059 in. relief 0.040 to 0.059 in. relief
59.721 to 59.740 mm dia. 59.521 to 59.540 mm dia.
Dimension C
2.3513 to 2.3519 in. dia. 2.3434 to 2.3440 in. dia.
(0.4S)
The crankshaft journal must be fine-finished to higher than ∇∇∇∇
*Holes to be de-burred and edges rounded with 1.0 to 1.5 mm
(0.040 to 0.059 in.) relief.

V2403 Service Manual 136 4. Servicing


Replacing Crankshaft Bearing 1

(When removing)

1. Press out the used crankshaft bearing 1 using a


crankshaft bearing 1 replacing tool. (See page
“SPECIAL TOOLS”.)

(When installing)

1. Clean a new crankshaft bearing 1 and crankshaft


journal bore, and apply engine oil to them.

2. Using a crankshaft bearing 1 replacing tool, press in


a new bearing 1 (2) so that its seam (1) directs
toward the exhaust manifold side. (See figure.)

4.20 to 4.50 mm
Dimension (A) Factory spec.
0.166 to 0.177 in.

(1) Seam (3) Cylinder Block


(2) Crankshaft Bearing 1 (A) Dimension

V2403 Service Manual 137 4. Servicing


Oil Clearance between Crankshaft Journal and
Crankshaft Bearing 2

1. Put a strip of plastigage on the center of the journal.

2. Install the bearing case and tighten the baring case


screws 1 to the specified torque, and remove the
bearing case again.

3. Measure the amount of the flattening with the scale


and get the oil clearance.

4. If the clearance exceeds the allowable limit, replace


the crankshaft bearing 2.

5. If the same size bearing is useless because of the


crankshaft journal wear, replace it with an undersize
one referring to the table and figure.

NOTE : Be sure not to move the crankshaft while the


bearing case screws are tightened.

0.0400 to 0.104 mm
Factory spec.
Oil clearance between crankshaft 0.00158 to 0.00409 in.
and crankshaft bearing 2 0.20 mm
Allowable limit
0.0079 in.

59.921 to 59.940 mm
Crankshaft journal O.D. Factory spec.
2.3591 to 2.3598 in.
59.980 to 60.025 mm
Crankshaft bearing 2 I.D. Factory spec.
2.3615 to 2.3631 in.

(Reference)

• Undersize dimensions of crankshaft journal

0.2 mm 0.4 mm
Undersize
0.008 in. 0.02 in.
2.8 to 3.2 mm radius 2.8 to 3.2 mm radius
Dimension A
0.11 to 0.12 in. radius 0.11 to 0.12 in. radius
1.0 to 1.5 mm relief 1.0 to 1.5 mm relief
*Dimension B
0.040 to 0.059 in. relief 0.040 to 0.059 in. relief
59.721 to 59.740 mm dia. 59.521 to 59.540 mm dia.
Dimension C, D
2.3513 to 2.3519 in. dia. 2.3434 to 2.3440 in. dia.
(0.4S)
The crankshaft journal must be fine-finished to higher than ∇∇∇∇
*Holes to be de-burred and edges rounded with 1.0 to 1.5 mm
(0.040 to 0.059 in.) relief.

V2403 Service Manual 138 4. Servicing


Replacing Crankshaft Sleeve

1. Remove the used crankshaft sleeve (3).

2. Set the sleeve guide (2) to the crankshaft (5).

3. Set the stopper (1) to the crankshaft (5) as shown in


figure.

4. Heat a new sleeve to a temperature between 150


and 200 °C (302 and 392 °F), and fix the sleeve to
the crankshaft (5) as shown in figure.

5. Press fit the sleeve using the auxiliary socket for


pushing (4). (Refer to “SPECIAL TOOLS”.)

NOTE
• Mount the sleeve with its largely chamfered
surface facing outward.
• Should heating is not enough, a sleeve might stop
halfway, so careful.

(1) Stopper (4) Auxiliary Socket for Pushing


(2) Sleeve Guide (5) Crankshaft
(3) Crankshaft Sleeve

V2403 Service Manual 139 4. Servicing


Cylinder

Cylinder Wear

1. Measure the I.D. of the cylinder at the six positions


(see figure) with a cylinder gauge to find the
maximum and minimum I.D.’s.

2. Get the difference (Maximum wear) between the


maximum and the minimum I.D.’s.

3. If the wear exceeds the allowable limit, bore and


hone to the oversize dimension. (Refer to
“Correcting Cylinder”.)

4. Visually check the cylinder wall for scratches. If deep


scratches are found, the cylinder should be bored.
(Refer to “Correcting Cylinder”.)

87.000 to
87.022 mm
Factory spec.
3.4252 to
Cylinder I.D. 3.4260 in.
87.170 mm
Allowable limit
3.4319 in.

A : Top (a) Right-angled to Piston Pin


B : Middle (b) Piston Pin Direction
C : Bottom (Skirt)

V2403 Service Manual 140 4. Servicing


Correcting Cylinder (Oversize)

1. When the cylinder is worn beyond the allowable limit,


bore and hone it to the specified dimension.

83.250 to 83.272 mm
3.2776 to 3.2784 in.
Factory spec.
Oversize 87.250 to 87.272 mm
cylinder 3.4351 to 3.4359 in.
V2403-M- 83.420 mm
BG I.D. 3.2843 in.
Allowable limit
87.420 mm
3.4417 in.
Hone to 2.2 to 3.0 μmRz
Finishing (0.000087 to 0.000118 in.Rz)
∇∇∇.

2. Replace the piston and piston rings with oversize


ones.
Oversize : 0.25 mm (0.0098 in.)

NOTE : When the oversize cylinder is worn beyond the


allowable limit, replace the cylinder block with a new
one.

(1) Cylinder I.D. (Before Correction)


(2) Cylinder I.D. (Oversize)

V2403 Service Manual 141 4. Servicing


Oil Pump

Rotor Lobe Clearance

1. Measure the clearance between lobes of the inner


rotor and the outer rotor with a feeler gauge.

2. Measure the clearance between the outer rotor and


the pump body with a feeler gauge.

3. If the clearance exceeds the factory specifications,


replace the oil pump rotor assembly.

Clearance Factory 0.030 to 0.14 mm


between inner spec. 0.0012 to 0.0055 in.
rotor and outer Allowabl 0.2 mm
rotor e limit 0.008 in.

Clearance Factory 0.11 to 0.19 mm


between outer spec. 0.0044 to 0.0074 in.
rotor and pump Allowabl 0.25 mm
body e limit 0.0098 in.

Clearance between Rotor and Cover

1. Put a strip of plastigage onto the rotor face with


grease.

2. Install the cover and tighten the screws.

3. Remove the cover carefully, and measure the width


of the press gauge with a sheet of gauge.

4. If the clearance exceeds the factory specifications,


replace oil pump rotor assembly.

Factory 0.105 to 0.150 mm


ClearClearance spec. 0.00414 to 0.00590 in.
between inner
rotor and cover Allowabl 0.20 mm
e limit 0.008 in.

V2403 Service Manual 142 4. Servicing


Starter

Overrunning Clutch

1. Check the pinion and if worn or damage, replace the


clutch assembly.

2. Check that the pinion turns freely and smoothly in the


overrunning direction and does not slip in the
cranking direction.

3. If the pinion slips or does not turn in both directions,


replace the overrunning clutch assembly.

NOTE : Do not wash off the grease in the overrunning


clutch with the chemicals or oils.

Commutator and Mica

1. Check the contact of the commutator for wear, and


grind the commutator with emery paper if it is slightly
worn.

2. Measure the commutator O.D. with an outside


micrometer at several points.

3. If the minimum O.D. is less than the allowable limit,


replace the armature.

4. If the difference of the O.D.'s exceeds the allowable


limit, correct the commutator on a lathe to the factory
specification.

5. Measure the mica undercut.

6. If the undercut is less than the allowable limit, correct


it with a saw blade and chamfer the segment edges.

35.0 mm
Factory spec.
Commutator 1.38 in.
O.D. Allowable 34.0 mm
limit 1.34 in.

Factory Less than 0.02 mm


Difference of spec. 0.0008 in.
O.D.’s Allowable 0.05 mm
limit 0.002 in.

(1) Segment (a) Correct


(2) Depth of Mica (b) Incorrect
(3) Mica

V2403 Service Manual 143 4. Servicing


Commutator and Mica (Continued)

1. Check the contact of the commutator for wear, and


grind the commutator with emery paper if it is slightly
worn.

2. Measure the commutator O.D. with an outside


micrometer at several points.

3. If the minimum O.D. is less than the allowable limit,


replace the armature.

4. If the difference of the O.D.'s exceeds the allowable


limit, correct the commutator on a lathe to the factory
specification.

5. Measure the mica undercut.

6. If the undercut is less than the allowable limit, correct


it with a saw blade and chamfer the segment edges.

0.45 to 0.75 mm
0.018 to 0.029 in.
Factory spec.
Mica under 0.55 to 0.85 mm
cut 0.022 to 0.033 in.
0.20 mm
Allowable limit
0.0079 in.

(1) Segment (a) Correct


(2) Depth of Mica (b) Incorrect
(3) Mica

V2403 Service Manual 144 4. Servicing


Brush Wear

1. If the contact face of the brush is dirty or dusty, clean


it with emery paper.

2. Measure the brush length (A) with vernier caliper.

3. If the length is less than the allowable limit, replace


the yoke assembly and brush holder.

15.0 mm
Factory spec.
0.591 in.
Brush length (A)
9.0 mm
Allowable limit
0.35 in.

Brush Holder

1. Check the continuity across the brush holder and the


holder support with a circuit tester.

2. If it conducts, replace the brush holder.

V2403 Service Manual 145 4. Servicing


Armature Coil

1. Check the continuity across the commutator and


armature coil core with resistance range of circuit
tester.

2. If it conducts, replace the armature.

3. Check the continuity across the segments of the


commutator with resistance range of circuit tester.

4. If it does not conduct, replace the armature.

Field Coil

1. Check the continuity across the lead (1) and brush


(2) with a circuit tester.

2. If it does not conduct, replace the yoke assembly.

3. Check the continuity across the brush (2) and yoke


(3) with a circuit tester.

4. If it conducts, replace the yoke assembly.

(1) Lead (3) Yoke


(2) Bush

V2403 Service Manual 146 4. Servicing


Alternator

Bearing

1. Check the bearing for smooth rotation.

2. If it does not rotate smoothly, replace it.

Stator

1. Measure the resistance across each lead of the


stator coil with resistance range of circuit tester.

2. If the measurement is not within factory specification,


replace it.

3. Check the continuity across each stator coil lead and


core with resistance range of circuit tester.

4. If infinity is not indicated, replace it.

Resistance Factory spec. Less than 1.0 Ω

Rotor

1. Measure the resistance across the slip rings.

2. If the resistance is not the factory specification,


replace it.

3. Check the continuity across the slip ring and core


with resistance range of circuit tester.

4. If infinity is not indicated, replace it.

Resistance Factory spec. 2.9 Ω

V2403 Service Manual 147 4. Servicing


Slip Ring

1. Check the slip ring for score.

2. If scored, correct with an emery paper or on a lathe.

3. Measure the O.D. of slip ring with vernier calipers.

4. If the measurement is less than the allowable limit,


replace it.

14.4 mm
Factory spec.
0.567 in.
Slip ring O.D.
14.0 mm
Allowable limit
0.551 in.

Brush Wear

1. Measure the brush length with vernier calipers.

2. If the measurement is less than allowable limit,


replace it.

3. Make sure that the brush moves smoothly.

4. If the brush is defective, replace it.

10.5 mm
Factory spec.
0.413 in.
Brush length
8.4 mm
Allowable limit
0.33 in.

V2403 Service Manual 148 4. Servicing


Rectifier

1. Check the continuity across each diode of rectifier


with resistance range of circuit tester.

2. The rectifier is normal if the diode in the rectifier


conducts in one direction and does not conduct in the
reverse direction.

IC Regulator

1. Check the continuity across the B terminal (2) and


the F terminal (1) of IC regulator with resistance range
of circuit tester.

2. The IC regulator is normal if the conducts in one


direction and does not conduct in the reverse direction.

(1) F Terminal (2) B Terminal

V2403 Service Manual 149 4. Servicing

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