Kubota D1503-M Workshop Manual
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Kubota D1503-M Workshop Manual

Wsm 03-m-e3b series, 03-m-di-e3b series, 03-m-e3bg series
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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

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Summary of Contents for Kubota D1503-M

  • Page 1 WORKSHOP MANUAL DIESEL ENGINE 03-M-E3B SERIES, 03-M-DI-E3B SERIES, 03-M-E3BG SERIES KiSC issued 07, 2008 A...
  • Page 2 The right is reserved to make changes in all information at any time without notice. Due to covering many models of this manual, information or picture being used, have not been specified as one model. March 2007 © KUBOTA Corporation 2007 KiSC issued 07, 2008 A...
  • Page 3 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS 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.
  • Page 4 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG 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 •...
  • Page 5 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM SAFETY INSTRUCTIONS 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.
  • Page 6 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM SAFETY INSTRUCTIONS 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 07, 2008 A...

  • Page 7: Specifications

    03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM SPECIFICATIONS SPECIFICATIONS Model D1503-M D1703-M Number of Cylinders Type Vertical, Water-cooled, 4 cycle diesel engine Bore × Stroke 83.0 X 92.4 mm (3.27 X 3.64 in.) 87.0 X 92.4 mm (3.43 X 3.64 in.) Total Displacement 1499 cm (91.47 cu.in.)
  • Page 8 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM SPECIFICATIONS Model D1803-M Number of Cylinders Type Vertical, Water-cooled, 4 cycle diesel engine Bore × Stroke 87.0 X 102.4 mm (3.43 X 4.031 in.) Total Displacement 1826 cm (111.4 cu.in.) ISO Net Continuous 22.8 KW / 2700 min (rpm) (30.6 HP / 2700 min (rpm))
  • Page 9 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM SPECIFICATIONS Model V2003-M V2203-M Number of Cylinders Type Vertical, Water-cooled, 4 cycle diesel engine Bore × Stroke 83.0 X 92.4 mm (3.27 X 3.64 in.) 87.0 X 92.4 mm (3.43 X 3.64 in.) Total Displacement 1999 cm (122.0 cu.in.) 2197 cm (134.1 cu.in.)
  • Page 10 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM SPECIFICATIONS Model V2403-M V2403-M-T Number of Cylinders 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 cm (148.5 cu.in.) ISO Net Continuous 30.2 KW / 2700 min (rpm) 36.4 KW / 2700 min (rpm)
  • Page 11 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM SPECIFICATIONS Model D1803-M-DI Number of Cylinders Type Vertical, Water-cooled, 4 cycle diesel engine Bore × Stroke 87.0 X 102.4 mm (3.43 X 4.031 in.) Total Displacement 1826 cm (111.4 cu.in.) ISO Net Continuous 23.2 KW / 2700 min (rpm) (31.1 HP / 2700 min (rpm))
  • Page 12 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM SPECIFICATIONS Model V2403-M-DI V2403-M-DI-T Number of Cylinders 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 cm (148.5 cu.in.) ISO Net Continuous 30.5 KW / 2700 min (rpm) 30.7 KW / 2400 min (rpm)
  • Page 13 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM SPECIFICATIONS Model D1703-M-BG Number of Cylinders Type Vertical, Water-cooled, 4 cycle diesel engine Bore × Stroke 87.0 X 92.4 mm (3.43 X 3.64 in.) Total Displacement 1647 cm (100.5 cu.in.) ISO Net Continuous 14.0 KW / 1500 min (rpm) 16.9 KW / 1800 min (rpm)
  • Page 14 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM SPECIFICATIONS Model V2003-M-BG Number of Cylinders Type Vertical, Water-cooled, 4 cycle diesel engine Bore × Stroke 83.0 X 92.4 mm (3.27 X 3.64 in.) Total Displacement 1999 cm (122.0 cu.in.) ISO Net Continuous 17.5 KW / 1500 min (rpm) 20.3 KW / 1800 min (rpm)
  • Page 15 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM SPECIFICATIONS Model V2003-M-T-BG Number of Cylinders Type Vertical, Water-cooled, 4 cycle diesel engine Bore × Stroke 83.0 X 92.4 mm (3.27 X 3.64 in.) Total Displacement 1999 cm (122.0 cu.in.) ISO Net Continuous 22.3 KW / 1500 min (rpm) 25.7 KW / 1800 min (rpm)
  • Page 16 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM SPECIFICATIONS Model V2203-M-BG Number of Cylinders Type Vertical, Water-cooled, 4 cycle diesel engine Bore × Stroke 87.0 X 92.4 mm (3.43 X 3.64 in.) Total Displacement 2197 cm (134.1 cu.in.) ISO Net Continuous 18.8 KW / 1500 min (rpm) 22.6 KW / 1800 min (rpm)
  • Page 17 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM SPECIFICATIONS Model V2403-M-BG Number of Cylinders 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 cm (148.5 cu.in.) ISO Net Continuous 21.5 KW / 1500 min (rpm) 25.1 KW / 1800 min (rpm)
  • Page 18 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIMENSIONS DIMENSIONS D1503-M D1703-M D1803-M 567.0 mm (22.32 in.) 560.0 mm (22.05 in.) 560.0 mm (22.05 in.) 512.0 mm (20.16 in.) 480.0 mm (18.90 in.) 480.0 mm (18.90 in.) 643.0 mm (25.31 in.) 643.0 mm (25.31 in.) 648.0 mm (25.51 in.)
  • Page 19 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIMENSIONS V2003-M V2203-M V2403-M V2403-M-T 652.0 mm (25.67 in.) 652.0 mm (25.67 in.) 652.0 mm (25.67 in.) 667.1 mm (26.26 in.) 480.0 mm (18.90 in.) 480.0 mm (18.90 in.) 480.0 mm (18.90 in.) 449.0 mm (17.68 in.) 643.0 mm (25.31 in.) 643.0 mm (25.31 in.) 648.0 mm (25.51 in.)
  • Page 20 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIMENSIONS D1803-M-DI 560.0 mm (22.05 in.) 492.0 mm (19.37 in.) 636.0 mm (25.04 in.) W1035766 KiSC issued 07, 2008 A...
  • Page 21 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIMENSIONS V2403-M-DI V2403-M-DI-T 655.0 mm (25.79 in.) 667.1 mm (26.26 in.) 492.0 mm (19.37 in.) 449.0 mm (17.68 in.) 636.0 mm (25.04 in.) 737.3 mm (29.03 in.) W1035816 KiSC issued 07, 2008 A...
  • Page 22 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIMENSIONS D1703-M-BG 605.6 mm (23.84 in.) 505.0 mm (19.88 in.) 642.8 mm (25.31 in.) W1036026 KiSC issued 07, 2008 A...
  • Page 23 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIMENSIONS V2003-M-BG V2003-M-T-BG V2203-M-BG V2403-M-BG 700.6 mm (27.58 in.) 700.6 mm (27.58 in.) 700.6 mm (27.58 in.) 700.6 mm (27.58 in.) 505.0 mm (19.88 in.) 505.0 mm (19.88 in.) 505.0 mm (19.88 in.) 505.0 mm (19.88 in.) 633.3 mm (24.93 in.) 674.0 mm (26.54 in.) 633.3 mm (24.93 in.)

  • Page 24: Wiring Diagram

    03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM WIRING DIAGRAM WIRING DIAGRAM Start Relay ECU (Electronic Control Unit) 1.25 Solenoid 1.25 1.25 Slowdown(1200 min (rpm)) Speed Switch (1800 min (rpm)/1500 min (rpm)) Alternator Manual Stop Switch (Run/Stop) Engine Speed Sensor Starter Water Temp. Sensor 0.85 Oil Switch Water Temp.

  • Page 25: Table Of Contents

    GENERAL CONTENTS 1. ENGINE IDENTIFICATION ................G-1 [1] MODEL NAME AND ENGINE SERIAL NUMBER ........ G-1 [2] E3B ENGINE..................... G-3 [3] CYLINDER NUMBER ................G-3 2. GENERAL PRECAUTIONS ................G-4 3. MAINTENANCE CHECK LIST ............... G-5 4. CHECK AND MAINTENANCE ............... G-8 [1] DAILY CHECK POINTS................

  • Page 26: Engine Identification

    03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM G GENERAL 1. ENGINE IDENTIFICATION [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.
  • Page 27 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM G 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 J0001 ~ J9999 K0001 ~ KZ999 June...

  • Page 28: E3B Engine

    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).

  • Page 29: General Precautions

    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.

  • Page 30: Maintenance Check List

    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.
  • Page 31 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.
  • Page 32 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.

  • Page 33: Check And Maintenance

    03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM G GENERAL 4. CHECK AND MAINTENANCE [1] 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.
  • Page 34 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM G 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).

  • Page 35: Check Points Of Initial 50 Hours

    SAE 10W-40 SAE 10W or SAE 10W-30 Below 0 °C (32 °F) SAE 10W-40 Oil pan depth Models 124 mm (4.88 in.) *90 mm (3.5 in.) D1503-M, D1703-M 7.0 L 5.6 L D1803-M, D1803-M-DI 1.8 U.S.gals 1.5 U.S.gals D1703-M-BG V2003-M, V2203-M V2403-M, V2403-M-DI, 9.5 L...
  • Page 36 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 W1013487...

  • Page 37: Check Points Of Every 50 Hours

    03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM G GENERAL [3] CHECK POINTS OF EVERY 50 HOURS Checking Fuel Hoses and Clamp Bands 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.

  • Page 38: Check Points Of Every 100 Hours

    03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM G GENERAL [4] 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/cm 30 psi).
  • Page 39 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM G GENERAL 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.

  • Page 40: Check Points Of Every 150 Hours

    03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM G GENERAL [5] CHECK POINTS OF EVERY 150 HOURS Changing Engine Oil (for 90 mm (3.5 in.) Depth Oil Pan) [D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M] [D1703-M-BG, V2003-M-BG, V2003-M-T-BG, V2203-M-BG, V2403-M-BG] CAUTION • Be sure to stop engine before changing engine oil.
  • Page 41 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM G GENERAL Replacing Oil Filter Cartridge (for 90 mm (3.5 in.) Depth Oil Pan) [D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M] [D1703-M-BG, V2003-M-BG, V2003-M-T-BG, V2203-M-BG, V2403-M-BG] CAUTION • Be sure to stop the engine before replacing filter cartridge.

  • Page 42: Check Points Of Every 200 Hours

    03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM G GENERAL [6] CHECK POINTS OF EVERY 200 HOURS Changing Engine Oil (for 124 mm (4.88 in.) Depth Oil Pan) [D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M, V2403-M-T] [D1703-M-BG, V2003-M-BG, V2003-M-T-BG, V2203-M-BG, V2403-M-BG] CAUTION • Be sure to stop engine before changing engine oil.
  • Page 43 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM G GENERAL Changing Engine Oil (for 90 mm (3.5 in.) Depth Oil Pan) [D1803-M-DI, V2403-M-DI, V2403-M-DI-T] CAUTION • Be sure to stop engine before changing engine oil. 1. Start and warm up the engine for approx. 5 minutes. 2.
  • Page 44 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM G GENERAL Replacing Oil Filter Cartridge (for 124 mm (4.88 in.) Depth Oil Pan) [D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M, V2403-M-T] [D1703-M-BG, V2003-M-BG, V2003-M-T-BG, V2203-M-BG, V2403-M-BG] CAUTION • Be sure to stop the engine before replacing filter cartridge.
  • Page 45 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM G GENERAL 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.

  • Page 46: Check Points Of Every 400 Hours

    03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM G GENERAL [7] CHECK POINTS OF EVERY 400 HOURS Changing Engine Oil (for 124 mm (4.88 in.) Depth Oil Pan) [D1803-M-DI, V2403-M-DI, V2403-M-DI-T] CAUTION • Be sure to stop engine before changing engine oil. 1. Start and warm up the engine for approx. 5 minutes. 2.
  • Page 47 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 W1036519 Replacing Fuel Filter Cartridge (Cartridge Type) Water and dust in fuel are collected in the filter cartridge.

  • Page 48: Check Points Of Every 500 Hours

    03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM G GENERAL [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.
  • Page 49 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM G 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. •...

  • Page 50: Check Points Of Every 1 Or 2 Months

    03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM G GENERAL [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.

  • Page 51: Check Points Of Every Year

    03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM G 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).

  • Page 52: Check Points Of Every 800 Hours

    03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM G GENERAL [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.

  • Page 53: Check Points Of Every 1500 Hours

    • 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 [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,...
  • Page 54 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM G GENERAL Fuel Injection Pressure [D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M, V2403-M-T] [D1703-M-BG, V2003-M-BG, V2003-M-T-BG, V2203-M-BG, V2403-M-BG] 1. 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.
  • Page 55 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM G 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/cm 1849 psi) for 10 seconds.

  • Page 56: Check Points Of Every 3000 Hours

    03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM G GENERAL [13] CHECK POINTS OF EVERY 3000 HOURS Checking Turbocharger (Turbine Side) 1. Check the exhaust port (2) and inlet port (3) side of turbine housing (1) to see if there is no exhaust gas leak. 2.
  • Page 57 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.
  • Page 58 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.

  • Page 59: Check Points Of Every 2 Years

    03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM G GENERAL [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.
  • Page 60 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM G GENERAL 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). CAUTION • Stop the engine when attempting the check and change prescribed above.
  • Page 61 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM G 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.
  • Page 62 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM G 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. •...

  • Page 63: Special Tools

    03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM G GENERAL 5. SPECIAL TOOLS Diesel Engine Compression Tester [D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M, V2403-M-T] [D1703-M-BG, V2003-M-BG, V2003-M-T-BG, V2203-M-BG, V2403-M-BG] Code No: 07909-30208 (Assembly) 07909-31251 (G) 07909-30934 (A to F) 07909-31271 (I) 07909-31211 (E and F)
  • Page 64 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM G 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 (300 kgf/cm , 4267 psi) PF 1/2...
  • Page 65 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM G GENERAL Bushing Replacing Tools Application: Use to press out and to press fit the bushing. 1. For small end bushing 162 mm (6.38 in.) 35 mm (1.4 in.) 27 mm (1.1 in.) 35 mm dia. (1.4 in. dia.) 27.90 to 27.95 mm dia.
  • Page 66 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM G GENERAL Socket Wrench for Crank Pulley Nut (46 mm Deep Socket Wrench) Application: Use to loosen and tighten the fan drive pulley mounting nut. 100 mm (3.94 in.) 25.0 mm (0.984 in.) 27.0 mm (1.06 in.) 45.0 mm dia.
  • Page 67 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM G GENERAL Auxiliary Socket for Fixing Crankshaft Sleeve (Continued) Application: Use to fix the crankshaft sleeve of the diesel engine. 42.0 mm (1.65 in.) 30.50 to 30.60 mm (1.201 to 1.204 in.) 23.0 mm (0.906 in.) 20.0 mm (0.787 in.) 2.0 mm (0.079 in.) 31.911 to 31.950 mm dia.
  • Page 68 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM G GENERAL Balancer Metal Replacing Tool (for Removing) Application: Use to remove the metal bearing. 41 mm (1.6 in.) 41.934 to 41.950 mm dia. (1.6510 to 1.6515 in. dia.) 32.5 mm (1.28 in.) 24.959 to 24.980 mm dia. (0.98264 to 0.98346 in. dia.) Chamfer 0.3 mm (0.01 in.) 21.947 to 21.960 mm dia.
  • Page 69 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM G GENERAL Balancer Metal Replacing Tool (for Fitting) Application: Use to press fit the metal bearing. 182 mm (7.17 in.) 60 mm dia. (2.4 in. dia.) 140 mm (5.51 in.) 46.950 to 46.975 mm dia. (1.8485 to 1.8494 in. dia.) 37 mm (1.5 in.) 43.934 to 43.950 mm dia.
  • Page 70 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM G GENERAL Idle Gear 2 Puller Application: Use for remove the idle gear 2 from the shaft. 24 mm (0.94 in.) 10 mm dia. (0.39 in. dia.) 0.5 mm radius (0.02 in. radius) M20 x Pitch 2.0 10 mm (0.39 in.) 20 mm (0.79 in.) 5 mm (0.2 in.)
  • Page 71 MECHANISM CONTENTS 1. ENGINE BODY ....................M-1 [1] PISTON...................... M-1 [2] BUILT-IN DYNAMIC BALANCER (BALANCER MODEL ONLY)..M-2 [3] HALF-FLOATING HEAD COVER ............M-3 2. COOLING SYSTEM ..................M-4 [1] BOTTOM BYPASS SYSTEM..............M-4 3. FUEL SYSTEM ....................M-5 [1] GOVERNOR ....................M-5 4.

  • Page 72: Engine Body

    Molybdenum disulfide (MoS 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 [A] D1503-M, D1703-M D1803-M, V2003-M V2203-M, V2403-M V2403-M-T D1703-M-BG, V2003-M-BG...
  • Page 73 This engine is internally provide with two balancers (1), one at the suction side and the other at the exhaust side. (1) Balancer [A] D1503-M, D1703-M D1803-M, V2003-M V2203-M, V2403-M V2403-M-T [B] D1803-M-DI, V2403-M-DI V2403-M-DI-T...
  • Page 74 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE [3] 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.

  • Page 75: Cooling System

    03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE 2. COOLING SYSTEM [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.

  • Page 76: Fuel System

    03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE 3. FUEL SYSTEM [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.
  • Page 77 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE 4. TURBOCHARGER SYSTEM [1] BOOST COMPENSATOR (1) Injection Pump Assembly (2) Boost Compensator Assembly (3) Actuator (4) Solenoid (5) Plunger (6) Solenoid Guide (7) Hi-Idling Body W1014318 The higher the boost pressure rises, the more fuel is fed.
  • Page 78 SERVICING CONTENTS 1. TROUBLESHOOTING ..................S-1 [1] ENGINE BODY ..................S-1 [2] ELECTRONIC GOVERNOR ..............S-5 2. SERVICING SPECIFICATIONS ..............S-7 3. TIGHTENING TORQUES ................S-19 [1] TIGHTENING TORQUES FOR GENERAL USE SCREWS, BOLTS AND NUTS....................S-19 [2] TIGHTENING TORQUES FOR SPECIAL USE SCREWS, BOLTS AND NUTS....................S-20 4.

  • Page 79: Troubleshooting

    03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE 1. TROUBLESHOOTING [1] ENGINE BODY Reference Symptom Probable Cause Solution Page Engine Does Not No fuel Replenish fuel G-12 Start Air in the fuel system Vent air G-12 Water in the fuel system Change fuel and –...
  • Page 80 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE Reference Symptom Probable Cause Solution Page Engine Revolution Is Fuel filter clogged or dirty Replace G-22 Not Smooth Air cleaner clogged Clean or replace G-13, 20, Fuel leak due to loose injection pipe retaining nut Tighten retaining nut S-48 Injection pump malfunctioning...
  • Page 81 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE Reference Symptom Probable Cause Solution Page Deficient Output Incorrect injection timing Adjust S-27, 28 Engine’s moving parts seem to be seizing Repair or replace – Injection pump malfunctioning Repair or replace S-29, 30, 31, 32, 54, Deficient nozzle injection Repair or replace S-33, 34,...
  • Page 82 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE Reference Symptom Probable Cause Solution Page Low Oil Pressure Engine oil insufficient Replenish Oil strainer clogged Clean S-63 Relief valve stuck with dirt Clean – Relief valve spring weaken or broken Replace – Excessive oil clearance of crankshaft bearing Replace S-70, 92, Excessive oil clearance of crankpin bearing...
  • Page 83 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE [2] ELECTRONIC GOVERNOR IMPORTANT • The engine trouble divides into an electronic governor, the main body of the engine, and the operating constancy. This manual describes it concerning the check of an electronic governor. Refer to WSM of engine and operator's manual if you cannot find trouble related to an electronic governor by checking an electronic governor.
  • Page 84 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE Blinking Pattern of Glow Lamp Cause Refer to Checking (1-Long and 1-Short) Overrunning (more than Solenoid 115 %) (1-Long and 2-Short) Low oil pressure Oil sensor (1-Long and 3-Short) Defect of alternator Alternator (1-Long and 4-Short) Coolant temperature is Water temperature sensor abnormal...
  • Page 85 0.0071 to 0.0086 in. Compression Pressure 3.24 to 3.72 MPa / 2.55 MPa / (When Cranking with Starting Motor) 290 min (rpm) 290 min (rpm) [D1503-M], [D1703-M] 33.0 to 38.0 kgf/cm 26.0 kgf/cm [D1803-M], [V2003-M] 290 min (rpm) 290 min (rpm) [V2203-M], [V2403-M]...
  • Page 86 0.3134 to 0.3139 in. Valve Guide I.D. 8.015 to 8.030 mm – 0.3156 to 0.3161 in. Valve Face Angle (Intake) 1.0 rad – [D1503-M], [D1703-M] 60 ° [D1803-M], [V2003-M] [V2203-M], [V2403-M] Angle (Exhaust) 0.79 rad – [V2403-M-T] 45 ° [D1703-M-BG], [V2003-M-BG]...
  • Page 87 [V2403-M-DI] Close 0.68 rad (39 °) – after B.D.C. Valve Timing (Exhaust Valve) Open 1.0 rad (60 °) – [D1503-M] before B.D.C. [V2003-M] Close 0.21 rad (12 °) – after T.D.C. Valve Timing (Exhaust Valve) Open 0.99 rad (57 °) –...
  • Page 88 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE ENGINE BODY (Continued) Item Factory Specification Allowable Limit 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 –...
  • Page 89 33.00 mm 33.95 mm 1.299 in. 1.297 in. [V2403-M-T] 33.27 mm 33.22 mm [D1703-M-BG], [V2003-M-BG] 1.310 in. 1.308 in. [V2203-M-BG] [D1503-M], [D2003-M] 33.47 mm 33.42 mm [V2003-M-T-BG] 1.318 in. 1.316 in. [D1703-M], [D1803-M] 33.90 mm 33.85 mm [V2203-M], [V2403-M] 1.335 in.
  • Page 90 0.20 mm [D1803-M-DI] 0.0020 to 0.0035 in. 0.0079 in. [V2403-M-DI] Second Ring to Ring Groove Clearance 0.0930 to 0.128 mm 0.20 mm [D1503-M], [D1703-M] 0.00367 to 0.00503 in. 0.0079 in. [D1803-M], [V2003-M] [V2203-M], [V2403-M] [V2403-M-T], [V2403-M-DI-T] [D1703-M-BG], [V2003-M-BG] [V2003-M-T-BG], [V2203-M-BG] [V2403-M-BG]...
  • Page 91 ENGINE BODY (Continued) Item Factory Specification Allowable Limit Top Ring Ring Gap 0.20 to 0.35 mm 1.25 mm [D1503-M], [V2003-M], [V2403-M-T] 0.0079 to 0.013 in. 0.0492 in. [D1803-M-DI], [V2403-M-DI] [V2403-M-DI-T] [V2003-M-BG], [V2003-M-T-BG], Top Ring Ring Gap 0.25 to 0.40 mm 1.25 mm...
  • Page 92 0.15 to 0.31 mm 0.5 mm 0.0059 to 0.012 in. 0.02 in. Cylinder Bore (Standard) I.D. 83.000 to 83.022 mm 83.170 mm [D1503-M], [V2003-M] 3.2678 to 3.2685 in. 3.2744 in. [V2003-M-BG], [V2003-M-T-BG] Cylinder Bore (Standard) I.D. 87.000 to 87.022 mm 87.170 mm [D1703-M], [D1803-M] 3.4252 to 3.4260 in.
  • Page 93 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 – [D1503-M], [D1703-M] Temperature 157.1 to 162.5 °F [D1803-M], [V2003-M] (At Beginning) [V2203-M], [V2403-M] [V2403-M-T] Valve Opening 85 °C –...
  • Page 94 FUEL SYSTEM Item Factory Specification Allowable Limit Injection Pump Injection Timing 0.253 to 0.279 rad – [D1503-M], [V2003-M-T-BG] (14.5 to 16.0 °) before T.D.C. Injection Pump Injection Timing 0.271 to 0.296 rad – [D1703-M], [D1803-M] (15.5 to 17.0 °) before [V2003-M], [V2203-M] T.D.C.
  • Page 95 DIESEL ENGINE FUEL SYSTEM (Continued) Item Factory Specification Allowable Limit Injection Nozzle Injection Pressure 13.73 to 14.70 MPa – [D1503-M], [D1703-M] 140.0 to 150.0 kgf/cm [D1803-M], [V2003-M] 1992 to 2133 psi [V2203-M], [V2403-M] [V2403-M-T] [D1703-M-BG], [V2003-M-BG] [V2003-M-T-BG], [V2203-M-BG] [V2403-M-BG] Injection Nozzle Injection Pressure 18.64 to 20.10 MPa...
  • Page 96 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE ELECTRICAL SYSTEM Item Factory Specification Allowable Limit Starter Commutator O.D. 30.0 mm 29.0 mm [D1503-M], [D1703-M] 1.18 in. 1.14 in. [V2003-M], [V2203-M] [D1803-M-DI] [D1703-M-BG], [V2003-M-BG] [V2003-M-T-BG], [V2203-M-BG] Commutator O.D. 35.0 mm 34.0 mm [D1803-M], [V2403-M] 1.38 in.

  • Page 97: Tightening Torques

    03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE 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. [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.
  • Page 98 (Side PTO model only) Starter’s terminal B mounting nut 5.9 to 11 0.60 to 1.2 4.4 to 8.6 IDI : 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 DI : D1803-M-DI, V2403-M-DI, V2403-M-DI-T W1013236 S-20 KiSC issued 07, 2008 A...
  • Page 99 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING (1) Engine Body Compression Pressure [D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M, V2403-M-T] [D1703-M-BG, V2003-M-BG, V2003-M-T-BG, V2203-M-BG, V2403-M-BG] 1. Run the engine until it is warmed up.
  • Page 100 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE Compression Pressure [D1803-M-DI, V2403-M-DI, V2403-M-DI-T] 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 glow plugs. 4.
  • Page 101 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE 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.
  • Page 102 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE (2) 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.
  • Page 103 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE 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.
  • Page 104 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. D1503-M D1703-M D1803-M V2003-M V2203-M V2403-M 69.5 to 72.5 °C...
  • Page 105 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE (4) Fuel System Injection Timing [D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M, V2403-M-T] [D1703-M-BG, V2003-M-BG, V2003-M-T-BG, V2203-M-BG, V2403-M-BG] 1. Remove the stop solenoid. 2. Remove the injection pipes and nozzle. 3. Set the speed control lever to maximum fuel discharge position.
  • Page 106 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE Injection Timing [D1803-M-DI, V2403-M-DI, V2403-M-DI-T] 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.
  • Page 107 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...
  • Page 108 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. 18.63 MPa...
  • Page 109 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 13.73 → 12.75 MPa Factory spec.
  • Page 110 17.65 MPa (190.0 to 180.0 kgf/cm , 2702 to 2560 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 18.63 → 17.65 MPa Factory spec.
  • Page 111 • 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 [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,...
  • Page 112 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE Fuel Injection Pressure [D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M, V2403-M-T] [D1703-M-BG, V2003-M-BG, V2003-M-T-BG, V2203-M-BG, V2403-M-BG] 1. 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.
  • Page 113 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE 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/cm 1849 psi) for 10 seconds.
  • Page 114 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE (5) 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. •...
  • Page 115 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE 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).
  • Page 116 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE 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.
  • Page 117 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE 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.
  • Page 118 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE 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.
  • Page 119 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE (7) Electronic Governor Speed Sensor 1. Disconnect the speed sensor connector (2) (3P). 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.
  • Page 120 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE 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.
  • Page 121 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE 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).
  • Page 122 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE 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.
  • Page 123 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE 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.
  • Page 124 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE [2] DISASSEMBLING AND ASSEMBLING (1) 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.
  • Page 125 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE Turbocharger (equipped with Turbocharger Model) CAUTION • While the engine is running and or just after it stops, the turbocharger is hot, be careful not to touch the turbocharger. NOTE • When detaching and attaching the turbocharger assembly, be very careful not to allow dust, dirt and other foreign matters in the oil pipes.
  • Page 126 (4) Lead W1060460 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. D1503-M D1703-M D1803-M V2003-M V2203-M 25 to 34 N·m V2403-M 2.5 to 3.5 kgf·m V2403-M-T 18 to 25 lbf·ft...
  • Page 127 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE Nozzle Holder Assembly and Glow Plug [D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M, V2403-M-T] [D1703-M-BG, V2003-M-BG, V2003-M-T-BG, V2203-M-BG, V2403-M-BG] 1. Remove the overflow pipe assembly (3). 2. Remove the nozzle holder assemblies (4) using a 21 mm deep socket wrench.
  • Page 128 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE Nozzle Heat Seal Service Removal Procedure [D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M, V2403-M-T] [D1703-M-BG, V2003-M-BG, V2003-M-T-BG, V2203-M-BG, V2403-M-BG] IMPORTANT • Use a plus (phillips head) screw driver (1) that has a diameter which is bigger than the heat seal hole (Approx. 6 mm (1/4 in.)).
  • Page 129 (5) of cylinder head gasket in the original engine, and replace the same marking as the original cylinder head gasket. Model Gasket V2203-M Marking & D1703-M V2403-M Code D1503-M D1803-M V2003-M V2403-M-T Number D1803-M-DI V2403-M-DI V2403-M-DI-T 1G720-03600 1G750-03600...
  • Page 130 0.0256 to 0.0271 in. 0.0246 to 0.0266 in. 0.700 to 0.740 mm 0.675 to 0.725 mm 0.0276 to 0.0291 in. 0.0266 to 0.0285 in. (6) Measuring Points [A] 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 [B] D1803-M-DI, V2403-M-DI...
  • Page 131 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE 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).
  • Page 132 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE (4) 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 •...
  • Page 133 • Be sure to insert the push rod of the 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 torque Hi-idling body 4.5 to 5.0 kgf·m 33 to 36 lbf·ft...
  • Page 134 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE 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.
  • Page 135 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE 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).
  • Page 136 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE 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.
  • Page 137 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE 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.
  • Page 138 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE 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). •...
  • Page 139 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE Idle Gear (For Balancer Model) 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 (6), cam gear (3) and balancer gear (4) - Cam gear (3) and idle gear (2)
  • Page 140 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE 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.
  • Page 141 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE (5) 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.
  • Page 142 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE Pistons [D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M, V2403-M-T] [D1703-M-BG, V2003-M-BG, V2003-M-T-BG, V2203-M-BG, V2403-M-BG] 1. 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.
  • Page 143 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE Pistons [D1803-M-DI, V2403-M-DI, V2403-M-DI-T] 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.
  • Page 144 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE Piston Ring and Connecting Rod [D1503-M, D1703-M, D1803-M, V2003-M, V2203-M, V2403-M, V2403-M-T] [D1703-M-BG, V2003-M-BG, V2003-M-T-BG, V2203-M-BG, V2403-M-BG] 1. Remove the piston rings (1), (2), (3) using a piston ring tool. 2. Remove the piston pin (9), and separate the connecting rod (7) from the piston (6).
  • Page 145 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE Piston Ring and Connecting Rod [D1803-M-DI, V2403-M-DI, V2403-M-DI-T] 1. Remove the piston rings (1), (2), (3) using a piston ring tool. 2. Remove the piston pin (8), and separate the connecting rod (6) from the piston (5). (When reassembling) •...
  • Page 146 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE (6) 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.
  • Page 147 NOTE • Before disassembling, check the side clearance of crankshaft. Also check it during reassembling. For D1503-M, D1703-M, V2003-M, V2203-M, D1703-M-BG, V2003-M-BG, V2003-M-T-BG and V2203-M-BG 1. Remove the main bearing case screw 2 (1). 2. Pull out the crankshaft assembly, taking care not to damage the crankshaft bearing 1 (3).
  • Page 148 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE 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) •...
  • Page 149 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE (7) 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 W1222714 1.
  • Page 150 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE (8) 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 W1224079 1.
  • Page 151 0.024 to 0.027 in. V2403-M-DI-T 93.2 to 98.0 N·m Tightening torque Cylinder head screws 9.50 to 10.0 kgf·m 68.8 to 72.3 lbf·ft (1) Piston [A] D1503-M, D1703-M, D1803-M (2) Fuse 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 [B] D1803-M-DI, V2403-M-DI...
  • Page 152 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE 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.
  • Page 153 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. D1503-M D1703-M D1803-M V2003-M V2203-M 0.05 (protrusion) to...
  • Page 154 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE 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.
  • Page 155 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE 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.
  • Page 156 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. [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] 1.0 rad...
  • Page 157 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE 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.
  • Page 158 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE 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.
  • Page 159 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE (2) 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.
  • Page 160 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE 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.
  • Page 161 DIESEL ENGINE 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. D1503-M 33.27 mm D1703-M-BG 1.310 in. V2003-M V2403-M-DI-T 33.47 mm...
  • Page 162 2. If the measurement is less than the allowable limit, replace the camshaft. 33.00 mm V2403-M-DI-T 1.299 in. V2403-M-T D1703-M-BG 33.27 mm V2003-M-BG 1.310 in. V2203-M-BG D1503-M 33.47 mm Factory V2003-M 1.318 in. spec. V2003-M-T-BG D1703-M D1803-M V2203-M 33.90 mm V2403-M 1.335 in.
  • Page 163 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE 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.
  • Page 164 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE Oil Clearance of Balancer Shaft Journal (for Balancer Model Only) 1. Measure the balancer shaft journal O.D. with an outside micrometer. 2. Measure the cylinder block bore I.D. for balancer shaft with an inside micrometer or cylinder gauge. 3.
  • Page 165 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE 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.
  • Page 166 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. D1503-M V2003-M V2403-M-T D1803-M-DI 0.20 to 0.35 mm...
  • Page 167 V2003-M-T-BG V2203-M-BG V2403-M-BG D1803-M-DI 0.030 to 0.070 mm V2403-M-DI 0.0012 to 0.0027 in. 0.15 mm Allowable limit 0.0059 in. (A) D1503-M, D1703-M, D1803-M (B) D1803-M-DI, V2403-M-DI V2003-M, V2203-M, V2403-M V2403-M-DI-T V2403-M-T D1703-M-BG, V2003-M-BG V2003-M-T-BG, V2203-M-BG V2403-M-BG W1032489 S-89 KiSC issued 07, 2008 A...
  • Page 168 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE (4) 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.
  • Page 169 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE Oil Clearance between Crankpin and Crankpin Bearing 1. Clean the crankpin and crankpin bearing. 2. Put a strip of plastigage on the center of the crankpin. 3. Install the connecting rod cap and tighten the connecting rod screws to the specified torque, and remove the cap again.
  • Page 170 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE 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.
  • Page 171 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE 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.
  • Page 172 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE 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.
  • Page 173 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”.) D1503-M V2003-M 83.000 to 83.022 mm V2003-M-BG 3.2678 to 3.2685 in.
  • Page 174 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE Correcting Cylinder (Oversize) 1. When the cylinder is worn beyond the allowable limit, bore and hone it to the specified dimension. D1503-M V2003-M 83.250 to 83.272 mm V2003-M-BG 3.2776 to 3.2784 in. V2003-M-T-BG D1703-M...
  • Page 175 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE (6) 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.
  • Page 176 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. D1503-M D1703-M V2003-M V2203-M 30.0 mm D1803-M-DI 1.18 in.
  • Page 177 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. D1503-M D1703-M D1803-M V2003-M V2203-M...
  • Page 178 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE 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. W1156895 Armature Coil 1. Check the continuity across the commutator and armature coil core with resistance range of circuit tester.
  • Page 179 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE (8) Alternator Bearing 1. Check the bearing for smooth rotation. 2. If it does not rotate smoothly, replace it. W1019790 Stator 1. Measure the resistance across each lead of the stator coil with resistance range of circuit tester. 2.
  • Page 180 03-M-E3B, 03-M-DI-E3B, 03-M-E3BG WSM DIESEL ENGINE 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. W1020452 IC Regulator 1.
  • Page 181 EDITOR : KUBOTA FARM & INDUSTRIAL MACHINERY SERVICE, LTD. 64, ISHIZU-KITAMACHI, SAKAI-KU, SAKAI-CITY, OSAKA, 590-0823, JAPAN PHONE : ( 81 ) 72-241-1129 : ( 81 ) 72-245-2484 E-mail : ksos-pub@kubota.co.jp Printed in Japan 2008. 07, S, EI, EI, e Code No.9Y111-00142 KUBOTA Corporation 2007.

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