Kubota D1503-M-DI Gebrauchsanweisung

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

KiSC issued 10, 2009 A

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

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

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

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

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

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

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

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