Table Of Contents - Kubota D1503-M Workshop Manual

Table of Contents

Safety First3
Before Servicing And Repairing3
Specifications7
Dimensions18
Wiring Diagram24
General25
Table Of Contents25
Engine Identification26
Model Name And Engine Serial Number26
Month Of Manufacture27
E3B Engine28
Cylinder Number28
General Precautions29
Maintenance Check List30
Check And Maintenance33
Daily Check Points33
Checking Engine Oil Level33
Checking And Replenish Coolant34
Check Points Of Initial 50 Hours35
Changing Engine Oil35
Replacing Oil Filter Cartridge36
Check Points Of Every 50 Hours37
Checking Fuel Hoses And Clamp Bands37
Check Points Of Every 100 Hours38
Cleaning Air Cleaner Element38
Cleaning Fuel Filter38
Checking Battery Electrolyte Level38
Fan Belt Damage And Wear39
Check Points Of Every 150 Hours40
Changing Engine Oil For 90 Mm Depth Oil Pan40
Replacing Oil Filter Cartridge For 90 Mm Depth Oil Pan41
Check Points Of Every 200 Hours42
Changing Engine Oil For 124 Mm Depth Oil Pan42
Replacing Oil Filter Cartridge For 124 Mm Depth Oil Pan44
Checking Radiator Hoses And Clamp Bands44
Checking Intake Air Line45
Check Points Of Every 400 Hours46
Replacing Fuel Filter Cartridge47
Replacing Fuel Filter Element47
Check Points Of Every 500 Hours48
Cleaning Water Jacket And Radiator Interior48
Anti-Freeze49
Replacing Fan Belt49
Check Points Of Every 1 Or 2 Months50
Recharging50
Precaution For Operating A Quick Charger50
Check Points Of Every Year51
Battery Specific Gravity51
Replacing Air Cleaner Element51
Check Points Of Every 800 Hours52
Valve Clearance52
Check Points Of Every 1500 Hours53
Nozzle Spraying Condition53
Fuel Injection Pressure54
Valve Seat Tightness55
Nozzle Holder55
Check Points Of Every 3000 Hours56
Checking Turbocharger56
Checking Injection Pump57
Check Points Of Every 2 Years59
Replacing Intake Air Line59
Replacing Battery59
Replacing Radiator Hoses And Clamp Bands59
Replacing Fuel Hoses And Clamp Bands60
Changing Radiator Coolant61
Special Tools63
Diesel Engine Compression Tester63
Oil Pressure Tester63
Injection Pump Pressure Tester64
Valve Guide Replacing Tool64
Bushing Replacing Tools65
Flywheel Stopper65
Crankshaft Bearing 1 Replacing Tool65
Socket Wrench For Crank Pulley Nut66
Auxiliary Socket For Fixing Crankshaft Sleeve66
Balancer Metal Replacing Tool68
Idle Gear 2 Puller70
Mechanism71
Engine Body72
Piston72
Built-In Dynamic Balancer (Balancer Model Only73
Half-Floating Head Cover74
Cooling System75
Bottom Bypass System75
Fuel System76
Governor76
Turbocharger System77
Boost Compensator77
Servicing78
Troubleshooting79
Clean Or Replace79
Replace80
Use Specified Fuel 5 To80
Adjust S-2780
Repair Or Replace S-2980
Electronic Governor83
Servicing Specifications85
Timing Gear88
Tightening Torques For General Use Screws, Bolts And Nuts97
Tightening Torques For Special Use Screws, Bolts And Nuts98
Checking And Adjusting99
Compression Pressure99
Checking, Disassembling And Servicing99
Lubricating System102
Engine Oil Pressure102
Fan Belt Tension102
Adjust102
Radiator Cap Air Leakage103
Radiator Water Leakage103
Thermostat Valve Opening Temperature104
Injection Timing105
Fuel Tightness Of Pump Element107
Fuel Tightness Of Delivery Valve109
Electrical System114
Battery Voltage114
Motor Test116
Magnetic Switch Test116
Magnet Switch Continuity Test116
Alternator On Unit Test117
Glow Plug Lead Terminal Voltage117
Glow Plug Continuity117
Engine Stop Solenoid118
Turbine Side118
Compressor Side118
Radial Clearance118
Turbocharger118
Speed Sensor119
Water Temperature Sensor119
Oil Pressure Switch120
Solenoid121
Glow Plug Harness122
Alternator122
Speed Switch122
Emergency Stop Switch123
Slow Down Switch123
Battery123
Disassembling And Assembling124
Draining Oil And Coolant124
External Components124
Air Cleaner, Muffler And Others124
Cylinder Head And Valves126
Injection Pipes126
Nozzle Holder Assembly And Glow Plug127
Nozzle Heat Seal Service Removal Procedure128
Rocker Arm And Push Rod128
Cylinder Head129
Tappets130
Valves131
Thermostat Assembly131
Water Pump Assembly131
Gear Case And Timing Gears132
Injection Pump132
Governor Springs And Speed Control Plate134
Fan Drive Pulley136
Idle Gear 2 And Hydraulic Pump Base Assembly137
Gear Case138
Crankshaft Oil Slinger138
Idle Gear138
Camshaft And Balancer Shaft139
Fuel Camshaft And Fork Lever Assembly140
Oil Pump140
Crank Gear140
Piston And Connecting Rod141
Oil Pan And Oil Strainer141
Pistons142
Piston Ring And Connecting Rod144
Flywheel And Crankshaft146
Bearing Case Cover146
Main Bearing Case Assembly148
Starter149
Top Clearance151
Cylinder Head Surface Flatness152
Cylinder Head Flaw152
Valve Recessing153
Clearance Between Valve Stem And Valve Guide154
Replacing Valve Guide154
Valve Seating155
Correcting Valve And Valve Seat156
Valve Lapping157
Free Length And Tilt Of Valve Spring157
Valve Spring Setting Load157
Oil Clearance Between Rocker Arm And Rocker Arm Shaft158
Push Rod Alignment158
Oil Clearance Between Tappet And Tappet Guide Bore158
Timing Gear Backlash159
Idle Gear Side Clearance159
Camshaft Side Clearance160
Camshaft Alignment160
Cam Height161
Oil Clearance Of Camshaft Journal162
Oil Clearance Between Idle Gear Shaft And Idle Gear Bushing163
Replacing Idle Gear Bushing163
Balancer Shaft Side Clearance163
Balancer Shaft Alignment163
Oil Clearance Of Balancer Shaft Journal164
Piston Pin Bore I.d.164
Oil Clearance Between Piston Pin And Small End Bushing165
Replacing Connecting Rod Small End Bushing165
Connecting Rod Alignment165
Piston Ring Gap166
Clearance Between Piston Ring And Groove167
Side Clearance Of Crankshaft168
Crankshaft Alignment168
Oil Clearance Between Crankpin And Crankpin Bearing169
Oil Clearance Between Crankshaft Journal And Crankshaft Bearing170
Replacing Crankshaft Bearing170
Replacing Crankshaft Sleeve172
Cylinder Wear173
Correcting Cylinder174
Rotor Lobe Clearance175
Clearance Between Rotor And Cover175
Overrunning Clutch175
Commutator And Mica176
Brush Wear177
Brush Holder178
Armature Coil178
Field Coil178
Bearing179
Stator179
Rotor179
Slip Ring179
Rectifier180
Ic Regulator180