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Kubota D1803-M-DI User Manual

Kubota D1803-M-DI
181 pages
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WORKSHOP MANUAL
DIESEL ENGINE
03-M-E3B SERIES,
03-M-DI-E3B SERIES,
03-M-E3BG SERIES
KiSC issued 07, 2008 A

Table of Contents

Questions and Answers:

Kubota D1803-M-DI Specifications

General IconGeneral
BrandKubota
ModelD1803-M-DI
CategoryEngine
LanguageEnglish

Summary

TO THE READER

General Engine Information

Information on engine identification, precautions, maintenance list, and special tools.

Engine Mechanism Details

Information on the construction and function of the engine.

Servicing Procedures Overview

Information on troubleshooting, specifications, and maintenance procedures.

SAFETY INSTRUCTIONS

Safety First Principles

Use of safety alert symbol and general safety precautions.

Pre-Servicing Safety Measures

Essential checks and safety steps before starting any repair.

Safe Engine Starting

Procedures for safely starting the engine.

Safe Working Practices

Guidelines for safe operation and maintenance work.

Fire Prevention and Safety

Measures to prevent fires and acid burns.

Work Area Ventilation and Fluid Disposal

Ensuring ventilation and proper disposal of fluids.

Emergency Preparedness

Steps to prepare for potential emergencies.

SPECIFICATIONS

DIMENSIONS

WIRING DIAGRAM

GENERAL

Engine Identification Details

Details on model name and serial number for engine identification.

General Precautions for Servicing

General safety and handling precautions during service operations.

Maintenance Check List

Schedule of maintenance tasks at different operational intervals.

CHECK AND MAINTENANCE

Daily Check Points

Points to check daily for engine health and operation.

Initial 50-Hour Check Points

Initial maintenance checks after 50 hours of operation.

100-Hour Check Points

Maintenance checks required every 100 hours of operation.

400-Hour Check Points

Maintenance checks required every 400 hours of operation.

500-Hour Check Points

Maintenance checks required every 500 hours of operation.

1-2 Month Check Points

Periodic maintenance checks required every 1 to 2 months.

Annual Check Points

Maintenance checks required annually.

800-Hour Check Points

Maintenance checks required every 800 hours of operation.

1500-Hour Check Points

Maintenance checks required every 1500 hours of operation.

3000-Hour Check Points

Maintenance checks required every 3000 hours of operation.

2-Year Check Points

Maintenance checks required every 2 years.

Special Tools for Maintenance

List of special tools required for maintenance procedures.

MECHANISM

Engine Body Components

Details on the engine's main body and its components.

Piston Details

Information on piston construction and skirt coating.

Built-in Dynamic Balancer

Description of the engine's vibration reduction system.

Half-Floating Head Cover

Details on cylinder head cover arrangement for noise reduction.

COOLING SYSTEM

Bottom Bypass System Function

Explanation of the bottom bypass system for cooling performance.

FUEL SYSTEM

Governor Operation

Description of the governor's role in regulating engine speed.

TURBOCHARGER SYSTEM

Boost Compensator Function

How the boost compensator adjusts fuel based on boost pressure.

SERVICING

Troubleshooting Engine Issues

Diagnosing and resolving common engine problems and symptoms.

Servicing Specifications and Limits

Technical data and allowable limits for engine components.

Tightening Torques

Specified torque values for general and special fasteners.

Checking and Adjusting Procedures

Procedures for checking and adjusting engine parameters.

Disassembling and Assembling Procedures

Step-by-step procedures for component removal and installation.

DISASSEMBLING AND ASSEMBLING PROCEDURES

Draining Oil and Coolant

Procedures for draining engine oil and coolant before service.

External Components Removal

Removing air cleaner, muffler, fan, alternator, and starter.

Cylinder Head Cover Service

Steps for removing and installing the cylinder head cover.

Injection Pipes Service

Procedure for removing and installing fuel injection pipes.

Nozzle Holder & Glow Plug Service

Removing and installing nozzle holders and glow plugs.

Nozzle Heat Seal Replacement

Procedure for removing and replacing the nozzle heat seal.

Rocker Arm and Push Rod Service

Steps for removing and installing rocker arms and push rods.

Cylinder Head Service

Removing and installing the cylinder head and gasket.

Valve Service Procedures

Removing and installing valves, springs, and stem seals.

Thermostat Assembly Service

Procedure for removing and installing the thermostat assembly.

Water Pump Assembly Service

Steps for removing and installing the water pump assembly.

Gear Case and Timing Gears Service

Disassembly procedures for gear case and timing gears.

Injection Pump Service (Non-Turbo)

Removing and installing the injection pump for non-turbo models.

Injection Pump Service (Turbo)

Removing and installing the injection pump for turbo models.

Governor Springs and Speed Control Plate

Service for governor springs and speed control plate.

Fan Drive Pulley Service

Procedure for removing and installing the fan drive pulley.

Idle Gear 2 & Hydraulic Pump Base Service

Service for idle gear 2 and hydraulic pump base assembly.

Gear Case Service

Removing and installing the gear case components.

Crankshaft Oil Slinger Service

Removing and installing the crankshaft oil slinger.

Idle Gear Service

Procedure for removing and installing the idle gear.

Idle Gear Service (Balancer Model)

Specific service for idle gear in balancer model engines.

Camshaft Service

Removing and installing the camshaft.

Camshaft & Balancer Shaft Service

Service procedures for camshaft and balancer shafts.

Fuel Camshaft & Fork Lever Assembly

Service for fuel camshaft and fork lever assembly.

Oil Pump Service

Procedure for removing and installing the oil pump.

Crank Gear Service

Removing and installing the crank gear.

Piston and Connecting Rod Service

Procedures for servicing pistons and connecting rods.

Oil Pan and Oil Strainer Service

Removing and cleaning the oil pan and oil strainer.

Piston Service

Removing and installing pistons and piston rings.

Piston Ring & Connecting Rod Service

Service procedures for piston rings and connecting rod.

Flywheel Service

Removing and installing the flywheel.

Bearing Case Cover Service

Removing and installing the bearing case cover.

Crankshaft Service

Procedures for removing and installing the crankshaft.

Main Bearing Case Assembly

Steps for assembling the main bearing cases.

Starter Service

Disassembling and assembling the starter motor.

Alternator Service

Disassembling and assembling the alternator.

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