Kubota D1503-M-DI Instruction manual

WORKSHOP MANUAL
DIESEL ENGINES
03-M-DI SERIES
KiSC issued 10, 2009 A

TO THE READER
This Workshop Manual has been prepared to provide servicing personnel with
information on the mechanism, service and maintenance of KUBOTA Diesel Engine 03-
M-DI Series. It is divided into two parts, “Mechanism” and “Servicing” for each section.
QMechanism
Information on the Features and New Mechanisms are described. This information
should be understood before proceeding with troubleshooting, disassembling and
servicing.
QServicing
The heading “General” includes general precautions, check and maintenance and
special tools. There are troubleshooting, checking and adjusting, disassembling and
assembling, and servicing which cover procedures, precautions, factory specifications
and allowable limits.
All information illustrations and specifications contained in this manual are based on
the latest product information available at the time of publication. The right is reserved
to make changes in all information at any time without notice.
Due to covering many models of this manual, illustration being used, have not been
specified as one model.
March 2002
© KUBOTA Corporation 2002
KiSC issued 10, 2009 A

1
SAFETY INSTRUCTIONS
03-M-DI Series, WSM
SAFETY INSTRUCTIONS
BEFORE SERVICING AND REPAIRING
• Read all instructions and safety instructions in this
manual and on your engine safety decals.
• Clean the work area and engine.
• Park the machine on a firm and level ground.
• Allow the engine to cool before proceeding.
• Stop the engine, and remove the key.
• Disconnect the battery negative cable.
• Hang a “DO NOT OPERATE” tag in operator
station.
SAFETY FIRST
This symbol, the industry’s “Safety Alert Symbol”, is used throughout this manual and on labels on
the machine itself to warn of the possibility of personal injury. Read these instructions carefully.
It is essential that you read the instructions and safety regulations before you attempt to repair or use
this unit.
DANGER : Indicates an imminently hazardous situation which, if not avoided, will result in
death or serious injury.
WARNING : Indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION : Indicates a potentially hazardous situation which, if not avoided, may result in
minor or moderate injury.
QIMPORTANT : Indicates that equipment or property damage could result if instructions are not
followed.
QNOTE : Gives helpful information.
KiSC issued 10, 2009 A

2
03-M-DI Series, WSM SAFETY INSTRUCTIONS
SAFETY STARTING
• Do not start the engine by shorting across starter
terminals or bypassing the safety start switch.
• Unauthorized modifications to the engine may impair
the function and / or safety and affect engine life.
SAFETY WORKING
• Do not work on the machine while under the influence
of alcohol, medication, or other substances or while
fatigued.
• Wear close fitting clothing and safety equipment
appropriate to the job.
• Use tools appropriate to the work. Makeshift tools,
parts, and procedures are not recommended.
• When servicing is performed together by two or more
persons, take care to perform all work safely.
• Do not touch the rotating or hot parts while the engine
is running.
• Never remove the radiator cap while the engine is
running, or immediately after stopping. Otherwise, hot
water will spout out from radiator. Only remove
radiator cap when cool enough to touch with bare
hands. Slowly loosen the cap to first stop to relieve
pressure before removing completely.
• Escaping fluid (fuel or hydraulic oil) under pressure
can penetrate the skin causing serious injury. Relieve
pressure before disconnecting hydraulic or fuel lines.
Tighten all connections before applying pressure.
• Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable
or uncomfortable loud noises.
AVOID FIRES
• Fuel is extremely flammable and explosive under
certain conditions. Do not smoke or allow flames or
sparks in your working area.
• To avoid sparks from an accidental short circuit,
always disconnect the battery negative cable first and
connect it last.
• Battery gas can explode. Keep sparks and open
flame away from the top of battery, especially when
charging the battery.
• Make sure that no fuel has been spilled on the engine.
KiSC issued 10, 2009 A

3
SAFETY INSTRUCTIONS
03-M-DI Series, WSM
VENTILATE WORK AREA
• If the engine must be running to do some work, make
sure the area is well ventilated. Never run the engine
in a closed area. The exhaust gas contains poisonous
carbon monoxide.
DISPOSE OF FLUIDS PROPERLY
• Do not pour fluids into the ground, down a drain, or
into a stream, pond, or lake. Observe relevant
environmental protection regulations when disposing
of oil, fuel, coolant, electrolyte and other harmful
waste.
PREVENT ACID BURNS
• Sulfuric acid in battery electrolyte is poisonous. It is
strong enough to burn skin, clothing and cause
blindness if splashed into eyes. Keep electrolyte
away from eyes, hands and clothing. If you spill
electrolyte on yourself, flush with water, and get
medical attention immediately.
PREPARE FOR EMERGENCIES
• Keep a first aid kit and fire extinguisher handy at all
times.
• Keep emergency numbers for doctors, ambulance
service, hospital and fire department near your
telephone.
KiSC issued 10, 2009 A

4
03-M-DI Series, WSM SPECIFICATIONS
SPECIFICATIONS
* The specification described above is of the standard engine of each model.
* Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW
W10275180
Model D1503-M-DI D1503-M-DI-T D1703-M-DI D1803-M-DI
Number of Cylinders 3
Type Vertical, Water-cooled, 4 cycle DI diesel engine
Bore ×Stroke mm ×mm
(in. ×in.)
83 ×92.4
(3.26 ×3.64)
87 ×92.4
(3.43 ×3.64)
87 ×102.4
(3.43 ×4.04)
Total Displacement cm3(cu.in.) 1499 (91.47) 1647 (100.51) 1826 (111.43)
SAE Net Cont. kW/min-1 (rpm)
(HP/min-1 (rpm))
20.1 / 2800
(27.0 / 2800)
27.2 / 2800
(36.5 / 2800)
22.7 / 2800
(30.4 / 2800)
23.9 / 2600
(32.1 / 2600)
SAE Net Intermittent kW/min-1 (rpm)
(HP/min-1 (rpm))
23.5 / 2800
(31.5 / 2800)
31.3 / 2800
(42.0 / 2800)
26.1 / 2800
(35.0 / 2800)
27.2 / 2600
(36.5 / 2600)
SAE Gross Intermittent kW/min-1 (rpm)
(HP/min-1 (rpm))
24.8 / 2800
(33.2 / 2800)
32.7 / 2800
(43.8 / 2800)
27.4 / 2800
(36.7 / 2800)
28.4 / 2600
(38.1 / 2600)
Maximum Bare Speed min-1 (rpm) 3000 2800
Maximum Idling Speed min-1 (rpm) 750 to 850
Combustion Chamber Troiddal Type (Direct Injection)
Fuel Injection Pump Bosch “K” Type Mini Pump
Governor Centrifugal Ball Type, All Speed Mechanical Governor
Direction of Rotation Counter-Clockwise (viewed from flywheel side)
Injection Nozzle Bosch “P” Type Hole Nozzle
Injection Timing 0.201 rad (11.5 °) Before T.D.C. 0.175 rad (10 °) Before T.D.C.
Firing Order 1-2-3
Injection Pressure 1st. Stage 18.6 MPa (190 kgf/cm2, 2702 psi)
2nd. Stage 22.6 MPa (230 kgf/cm2, 3271 psi)
Compression Ratio 20 19 20
Lubricating System Forced Lubrication by Trochoid Pump
Cooling System Pressurized radiation, forced circulation with water pump
Starting System Electric Starting with Starter
12 V, 1.4 kW
Starting Support Device Pre-heating by Glow Plug in Combustion Chamber
Battery 12 V, 60 A (75D31R) 12 V, 88 A
(115E41R)
Charging Alternator 12 V, 360 W 12 V, 480 W
Fuel Diesel Fuel No.2-D or No.2-DLS
Lubricating Oil Better than CD class (API)
Lubricating Oil
Capacity
Oil Pan Depth
90 mm (3.54 in.) 5.6 L (1.48 U.S.gals)
Oil Pan Depth
124 mm (4.88 in.) 7.0 L (1.85 U.S.gals)
Weight (Dry) BB spec. kg (lbs) 148 (326) 152 (335) 148 (326) 151 (333)
KiSC issued 10, 2009 A

5
SPECIFICATIONS
03-M-DI Series, WSM
* The specification described above is of the standard engine of each model.
* Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW
W10299960
Model V2203-M-DI V2403-M-DI
Number of Cylinders 4
Type Vertical, Water-cooled, 4 cycle DI diesel engine
Bore ×Stroke mm ×mm
(in. ×in.)
87 ×92.4
(3.43 ×3.64)
87 ×102.4
(3.43 ×4.04)
Total Displacement cm3(cu.in.) 2197 (134.07) 2434 (148.53)
SAE Net Cont. kW/min-1 (rpm)
(HP/min-1 (rpm))
30.2 / 2800
(40.5 / 2800)
31.8 / 2600
(42.6 / 2600)
SAE Net Intermittent kW/min-1 (rpm)
(HP/min-1 (rpm))
34.8 / 2800
(46.7 / 2800)
36.6 / 2600
(34.8 / 2800)
SAE Gross Intermittent kW/min-1 (rpm)
(HP/min-1 (rpm))
36.4 / 2800
(48.8 / 2800)
38.0 / 2600
(51.0 / 2600)
Maximum Bare Speed min-1 (rpm) 3000 3000
Maximum Idling Speed min-1 (rpm) 750 to 850
Combustion Chamber Troiddal Type (Direct Injection)
Fuel Injection Pump Bosch “K” Type Mini Pump
Governor Centrifugal Ball Type, All Speed Mechanical Governor
Direction of Rotation Counter-Clockwise (viewed from flywheel side)
Injection Nozzle Bosch “P” Type Hole Nozzle
Injection Timing 0.192 rad (11 °) Before T.D.C.
Firing Order 1-3-4-2
Injection Pressure 1st. Stage 18.6 MPa (190 kgf/cm2, 2702 psi)
2nd. Stage 22.6 MPa (230 kgf/cm2, 3271 psi)
Compression Ratio 20
Lubricating System Forced Lubrication by Trochoid Pump
Cooling System Pressurized radiation, forced circulation with water pump
Starting System Electric Starting with Starter
12 V, 1.4 kW 12 V, 2.0 kW
Starting Suport Device Pre-heating by Glow Plug in Combustion Chamber
Battery 12 V, 88 A (115E41R) 12 V, 92 A (130E41R)
Charging Alternator 12 V, 480 W
Fuel Diesel Fuel No.2-D or No.2-DLS
Lubricating Oil Better than CD class (API)
Lubricating Oil
Capacity
Oil Pan Depth
90 mm (3.54 in.) 7.6 L (2.01 U.S.gals)
Oil Pan Depth
124 mm (4.88 in.) 9.5 L (2.51 U.S.gals)
Weight (Dry) BB spec. kg (lbs) 180 (397) 184 (406)
KiSC issued 10, 2009 A

6
03-M-DI Series, WSM DIMENSIONS
DIMENSIONS
W1031045
D1503-M-DI D1503-M-DI-T D1703-M-DI D1803-M-DI
A 599.2 mm
(23.59 in.)
599.2 mm
(23.59 in.)
572.1 mm
(22.52 in.)
575.9 mm
(22.67 in.)
B 643.5 mm
(25.33 in.)
644.0 mm
(25.35 in.)
643.3 mm
(25.33 in.)
685.0 mm
(26.97 in.)
C 414.2 mm
(16.31 in.)
414.2 mm
(16.31 in.)
414.0 mm
(16.30 in.)
419.0 mm
(16.50 in.)
D 229.3 mm
(9.03 in.)
229.8 mm
(9.05 in.)
229.3 mm
(9.03 in.)
266.0 mm
(10.47 in.)
E 514.4 mm
(20.25 in.)
514.4 mm
(20.25 in.)
507.1 mm
(19.96 in.)
499.0 mm
(19.65 in.)
KiSC issued 10, 2009 A

7
DIMENSIONS
03-M-DI Series, WSM
W1031355
V2203-M-DI V2403-M-DI
A 667.1 mm
(26.26 in.)
670.9 mm
(26.41 in.)
B 635.0 mm
(25.00 in.)
684.5 mm
(26.95 in.)
C 414.0 mm
(16.30 in.)
419.0 mm
(16.50 in.)
D 221.0 mm
(8.70 in.)
265.5 mm
(10.45 in.)
E 507.1 mm
(19.96 in.)
499.0 mm
(19.65 in.)
KiSC issued 10, 2009 A

CONTENTS
MECHANISM
1. ENGINE BODY ............................................................................................... M-1
[1] HOLLOW CORE ....................................................................................... M-1
[2] PISTON...................................................................................................... M-1
[3] BUILT-IN DYNAMIC BALANCER (BALANCER MODEL ONLY) ......... M-2
[4] HALF-FLOATING HEAD COVER ............................................................ M-2
2. COOLING SYSTEM........................................................................................ M-3
[1] BOTTOM BYPASS SYSTEM................................................................... M-3
3. FUEL SYSTEM ............................................................................................... M-4
[1] GOVERNOR .............................................................................................. M-4
4. ELECTRICAL SYSTEM .................................................................................. M-6
[1] STARTER AUTO REDUCTION UNIT..................................................... M-6
(1) General ................................................................................................ M-6
(2) Basic Circuit ......................................................................................... M-6
(3) Component .......................................................................................... M-7
(4) Function ............................................................................................... M-7
KiSC issued 10, 2009 A