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

03-m-di series
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WORKSHOP MANUAL

DIESEL ENGINES

03-M-DI SERIES
KiSC issued 10, 2009 A

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Do you have a question about the D1503-M-DI and is the answer not in the manual?

Questions and answers

Akio
April 2, 2025

How do i remove the crankshaft pulley?

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1 comments:
Mr. Anderson
April 2, 2025

To remove the crankshaft pulley on a Kubota D1503-M-DI:

1. Prevent the flywheel from turning using a flywheel stopper.
2. Use a 46 mm deep socket wrench to remove the fan drive pulley mounting nut.
3. Remove the fan drive pulley using a gear puller.
4. Remove the feather key.

Note: When reassembling, apply grease to the splines of the coupling. Tighten the fan drive pulley mounting nut to 137.3 to 156.9 N·m (101.3 to 115.7 ft-lbs).

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Summary of Contents for Kubota D1503-M-DI

  • Page 1: Diesel Engines

    WORKSHOP MANUAL DIESEL ENGINES 03-M-DI SERIES KiSC issued 10, 2009 A...
  • Page 2 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.
  • Page 3 SAFETY INSTRUCTIONS 03-M-DI Series, WSM 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 SAFETY INSTRUCTIONS 03-M-DI Series, WSM 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 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 •...

  • Page 6: Specifications

    SPECIFICATIONS 03-M-DI Series, WSM SPECIFICATIONS Model D1503-M-DI D1503-M-DI-T D1703-M-DI D1803-M-DI Number of Cylinders Type Vertical, Water-cooled, 4 cycle DI diesel engine Bore × Stroke mm × mm 83 × 92.4 87 × 92.4 87 × 102.4 (in. × in.) (3.26 × 3.64) (3.43 ×...
  • Page 7 SPECIFICATIONS 03-M-DI Series, WSM Model V2203-M-DI V2403-M-DI Number of Cylinders Type Vertical, Water-cooled, 4 cycle DI diesel engine Bore × Stroke mm × mm 87 × 92.4 87 × 102.4 (in. × in.) (3.43 × 3.64) (3.43 × 4.04) Total Displacement (cu.in.) 2197 (134.07) 2434 (148.53)

  • Page 8: Dimensions

    DIMENSIONS 03-M-DI Series, WSM DIMENSIONS D1503-M-DI D1503-M-DI-T D1703-M-DI D1803-M-DI 599.2 mm 599.2 mm 572.1 mm 575.9 mm (23.59 in.) (23.59 in.) (22.52 in.) (22.67 in.) 643.5 mm 644.0 mm 643.3 mm 685.0 mm (25.33 in.) (25.35 in.) (25.33 in.) (26.97 in.) 414.2 mm...
  • Page 9 DIMENSIONS 03-M-DI Series, WSM V2203-M-DI V2403-M-DI 667.1 mm 670.9 mm (26.26 in.) (26.41 in.) 635.0 mm 684.5 mm (25.00 in.) (26.95 in.) 414.0 mm 419.0 mm (16.30 in.) (16.50 in.) 221.0 mm 265.5 mm (8.70 in.) (10.45 in.) 507.1 mm 499.0 mm (19.96 in.) (19.65 in.)

  • Page 10: Table Of Contents

    MECHANISM CONTENTS 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.

  • Page 11: Engine Body

    DIESEL ENGINE 03-M-DI Series, WSM 1. ENGINE BODY [1] HOLLOW CORE The cylinder block has a hollow core (1) already cast inside the cylinder-to-cylinder water jacket. In this core, there is a pair of vertical cooling passages (right and left) as well as multiple horizontal cooling channels that interconnect these cooling passages.

  • Page 12: Built-In Dynamic Balancer (Balancer Model Only

    DIESEL ENGINE 03-M-DI Series, WSM [3] BUILT-IN DYNAMIC BALANCER (BALANCER MODEL ONLY) Engine are sure to vibrate by piston’s reciprocation. Theoretically, three-cylinder engines are much less prone to cause vibration than four-cylinder ones (second inertia, etc.). However, any engine has many moving parts in addition to its pistons and cannot be completely free from vibration.

  • Page 13: Cooling System

    DIESEL ENGINE 03-M-DI Series, WSM 2. COOLING SYSTEM [1] BOTTOM BYPASS SYSTEM Bottom bypass system is introduced in 03-M-DI 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 14: Fuel System

    DIESEL ENGINE 03-M-DI Series, WSM 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 15 DIESEL ENGINE 03-M-DI Series, WSM At Idling When the speed control lever is set at the idling position after the engine starts, the governor spring 1 (7) does not work at all and the governor spring 2 (8) does only act slightly. The governor sleeve (2) is pushed leftward by a centrifugal force of steel ball (1).

  • Page 16: Electrical System

    DIESEL ENGINE 03-M-DI Series, WSM 4. ELECTRICAL SYSTEM [1] STARTER AUTO REDUCTION UNIT (1) General The starter auto reduction unit (7) is designed to start the machine equipped with engine more reliably. This unit has the following function by integrating an alternator (1) that puts out rpm-proportional pulses. 1.

  • Page 17: Component

    DIESEL ENGINE 03-M-DI Series, WSM (3) Component (1) Key Switch (2) Battery (3) Alternator (4) P terminal (5) Detection High rpm (N2) (6) Delay Curcuit (7) Detection Low rpm (N1) (8) Self Holding Circuit (9) Self Holding Circuit (10) External Relay (11) Starter W1014290 (4) Function...
  • Page 18 DIESEL ENGINE 03-M-DI Series, WSM b) When Engine Starts Normally A : Key Switch AC Terminal (Voltage) B : Key Switch 50 Terminal (Voltage) C : Alternator Revolution (min (rpm)) D : Starter ST Terminal (Voltage) N1 :Detection Low rpm N2 :Detection High rpm W1014965 c) When Engine Stalls...
  • Page 19 DIESEL ENGINE 03-M-DI Series, WSM d) Output Terminal for Confirming Engine Start A : Key Switch AC Terminal (Voltage) B : Key Switch 50 Terminal (Voltage) C : Alternator Revolution (min (rpm)) D : Starter ST Terminal (Voltage) E : Output for Confirming Engine Start (Voltage) N1 :Detection Low rpm N2 :Detection High rpm...
  • Page 20 SERVICING CONTENTS 1. GENERAL ......................S-1 [1] ENGINE IDENTIFICATION................S-1 (1) Model Name and Engine Serial Number ..........S-1 (2) Cylinder Number ...................S-2 [2] GENERAL PRECAUTION .................S-3 [3] TIGHTENING TORQUES ................S-4 (1) Tightening Torques for Special Use Screws, Bolts and Nuts ....S-4 (2) Tightening Torques for General Use Screws, Bolts and Nuts ....S-4 [4] TROUBLESHOOTING ................S-5 [5] SERVICING SPECIFICATIONS ..............S-8 [6] MAINTENANCE CHECK LIST..............S-17...
  • Page 21 (1) Injection Pump..................S-86 (2) Injection Nozzle .................. S-88 6. ELECTRICAL SYSTEM................. S-89 [1] CHECKING ....................S-89 (1) Starter....................S-89 (2) Alternator.................... S-90 (3) Glow Plug ................... S-91 (4) Engine Stop Solenoid................. S-91 (5) Glow Lamp Relay ................S-92 (6) Starter Auto Reduction Unit..............S-92 [2] DISASSEMBLING AND ASSEMBLING ..........

  • Page 22: General

    DIESEL ENGINE 03-M-DI Series, WSM 1. 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 23: Cylinder Number

    DIESEL ENGINE 03-M-DI Series, WSM (2) Cylinder Number The cylinder numbers of 03-M-DI Series diesel engine are designated as shown in the figure. The sequence of cylinder numbers is given as No.1, No.2, No.3 and No.4 starting from the gear case side. W1011077 KiSC issued 10, 2009 A...

  • Page 24: General Precaution

    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 25: Tightening Torques

    DIESEL ENGINE 03-M-DI Series, WSM [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 Special Use Screws, Bolts and Nuts NOTE •...

  • Page 26: Troubleshooting

    DIESEL ENGINE 03-M-DI Series, WSM [4] TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Engine Does Not • No fuel Replenish fuel – Start • Air in the fuel system Vent air S-20 • Water in the fuel system Change fuel and S-20, 21, repair or replace fuel system...
  • Page 27 DIESEL ENGINE 03-M-DI Series, WSM Reference Symptom Probable Cause Solution Page Either White or Blue • Excessive engine oil Reduce to specified S-19 Exhaust Gas Is level Observed • Piston ring and liner worn or stuck Repair or replace S-42, 56, 57, 71, 72, •...
  • Page 28 DIESEL ENGINE 03-M-DI Series, WSM Reference Symptom Probable Cause Solution Page Low Oil Pressure • Engine oil insufficient Replenish S-19 • Oil strainer clogged Clean S-55 • Relief valve stuck with dirt Clean – • Relief valve spring weaken or broken Replace –...

  • Page 29: Servicing Specifications

    DIESEL ENGINE 03-M-DI Series, WSM [5] SERVICING SPECIFICATIONS ENGINE BODY Item Factory Specification Allowable Limit Cylinder Head Surface Flatness – 0.05 mm / 500 mm 0.0020 in. / 19.69 in. Compression Pressure 2.94 to 3.24 MPa / 2.35 MPa / (When Cranking with Starting Motor) 290 min (rpm)
  • Page 30 DIESEL ENGINE 03-M-DI Series, WSM ENGINE BODY (Continued) Item Factory Specification Allowable Limit Valve Timing (Intake Valve) Open 0.16 rad (9 °) – before T.D.C. Close 0.79 rad (45 °) – after B.D.C. Valve Timing (Exhaust Valve) Open 0.87 rad (50 °) –...
  • Page 31 DIESEL ENGINE 03-M-DI Series, WSM ENGINE BODY (Continued) Item Factory Specification Allowable Limit Timing Gear Crank Gear to Idle Gear Backlash 0.0415 to 0.1122 mm 0.15 mm 0.00163 to 0.00442 in. 0.0059 in. Idle Gear to Cam Gear Backlash 0.0415 to 0.1154 mm 0.15 mm 0.00163 to 0.00454 in.
  • Page 32 Clearance 0.050 to 0.090 mm 0.2 mm D1803-M-DI 0.0020 to 0.0035 in. 0.0079 in. V2203-M-DI V2403-M-DI Second Ring to Ring D1503-M-DI Clearance 0.093 to 0.128 mm 0.2 mm Groove D1503-M-DI-T 0.0037 to 0.0050 in. 0.0079 in. D1703-M-DI 0.050 to 0.090 mm 0.2 mm...
  • Page 33 DIESEL ENGINE 03-M-DI Series, WSM ENGINE BODY (Continued) Item Factory Specification Allowable Limit Oil Ring D1503-M-DI Ring Gap 0.25 to 0.45 mm 1.25 mm D1503-M-DI-T 0.0098 to 0.0177 in. 0.0492 in. D1703-M-DI 0.20 to 0.40 mm 1.25 mm D1803-M-DI 0.0079 to 0.0157 in.
  • Page 34 Oil Clearance 0.040 to 0.104 mm 0.2 mm Crankshaft Bearing 2 0.00157 to 0.00409 in. 0.0079 in. (Serial No. : below 3R9999) Crankshaft Journal D1503-M-DI O.D. 51.921 to 51.940 mm – D1503-M-DI-T 2.04413 to 2.04488 in. D1703-M-DI V2203-M-DI D1803-M-DI 59.921 to 59.940 mm –...
  • Page 35 DIESEL ENGINE 03-M-DI Series, WSM ENGINE BODY (Continued) Item Factory Specification Allowable Limit Cylinder Bore [Standard] D1503-M-DI I.D. 83.000 to 83.022 mm 83.150 mm D1503-M-DI-T 3.26772 to 3.26858 in. 3.2736 in. D1703-M-DI 87.000 to 87.022 mm 87.150 mm D1803-M-DI 3.42519 to 3.42606 in.
  • Page 36 88 to 59 kPa from 0.9 to 0.6 kgf/cm from 13 to 9 psi W1013874 FUEL SYSTEM Injection Pump D1503-M-DI Injection Timing 0.18 to 0.22 rad (10.5 to – D1503-M-DI-T 12.5 °) before T.D.C. D1703-M-DI 0.16 to 0.19 rad (9.0 to D1803-M-DI 11.0 °) before T.D.C.
  • Page 37 DIESEL ENGINE 03-M-DI Series, WSM ELECTRICAL SYSTEM Item Factory Specification Allowable Limit Starter Commutator D1503-M-DI O.D. 30.0 mm 29.0 mm D1503-M-DI-T 1.181 in. 1.142 in. D1703-M-DI D1803-M-DI V2203-M-DI V2403-M-DI 35.0 mm 34.0 mm 1.378 in. 1.339 in. Mica D1503-M-DI Under Cut 0.50 to 0.80 mm...

  • Page 38: 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 39 DIESEL ENGINE 03-M-DI Series, WSM CAUTION • When changing or inspecting, be sure to level and stop the engine. NOTE Lubricating Oil With the emission control now in effect, the CF-4 and CG-4 lubricating oils have been developed for use of a low- sulfur fuel on-road vehicle engines.

  • Page 40: Check And Maintenance

    DIESEL ENGINE 03-M-DI Series, WSM [7] 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 41: Check Points Of Every 50 Hours

    DIESEL ENGINE 03-M-DI Series, WSM (2) Check Points of Every 50 Hours Checking Fuel Pipe 1. If the clamp (1) is loose, apply oil to the threads and securely retighten it. 2. The fuel pipe (2) is made of rubber and ages regardless of the period service.

  • Page 42: Check Points Of Every 100 Hours

    DIESEL ENGINE 03-M-DI Series, WSM (3) 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 205 kPa (2.1 kgf/cm 30 psi).
  • Page 43 DIESEL ENGINE 03-M-DI Series, WSM Checking Fan Belt Tension 1. Press the fan belt between fan pulley and pulley at force of 98 N (10 kgf, 22 lbs). Check if the fan belt deflection is 7 to 9 mm (0.28 to 0.35 in.). 2.

  • Page 44: Check Point Of Every 200 Hours

    DIESEL ENGINE 03-M-DI Series, WSM (4) Check Point of Every 200 Hours Changing Engine Oil (For 90 mm (3.54 in.) depth oil pan) See page S-24. Replacing Oil Filter Cartridge (For 90 mm (3.54 in.) depth oil pan) See page S-25. W1036826 Checking Radiator Hoses 1.

  • Page 45: Check Points Of Every 400 Hours

    5. Reinstall the drain plug. 6. Fill the new engine oil up to the upper mark on the dipstick (2). Oil pan depth Models 124 mm (4.88 in.) *90 mm (3.54 in.) D1503-M-DI 7.0 L 5.6 L D1503-M-DI-T 1.85 U.S.gal. 1.48 U.S.gal.
  • Page 46 IMPORTANT • To prevent serious damage to the engine, replacement engine oil filter cartridge (1) must be highly efficient. Use only a genuine KUBOTA filter cartridge or its equivalent. (1) Engine Oil Filter Cartridge W1037215 Replacing Fuel Filter Cartridge (Cartridge Type) Water and dust in fuel are collected in the filter cartridge (1).

  • Page 47: Check Points Of 500 Hours

    DIESEL ENGINE 03-M-DI Series, WSM (6) Check Points of 500 Hours Cleaning Fuel Tank Inside W1051414 Cleaning Water Jacket and Radiator Interior CAUTION • Do not remove the radiator cap (1) when the engine is hot. Then loosen cap slightly to the stop to relieve any excess pressure before removing cap completely.
  • Page 48 DIESEL ENGINE 03-M-DI Series, WSM 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 49 DIESEL ENGINE 03-M-DI Series, WSM Replacing Fan Belt 1. Remove the alternator (1). 2. Remove the fan belt (2). 3. Replace new fan belt. 4. Install the alternator (1). 5. Check the fan belt tension. 7.0 to 9.0 mm / 98 N or 10 kgf Deflection (A) Factory spec.

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

    DIESEL ENGINE 03-M-DI Series, WSM (7) 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 DIESEL ENGINE 03-M-DI Series, WSM 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 Point Of Every Year

    • After turning the flywheel counterclockwise twice or three times, recheck the valve clearance (1). • After adjusting the valve clearance (1), firmly tighten the lock nut of the adjusting screw. D1503-M-DI Valve D1503-M-DI-T V2203-M-DI arrangement...

  • Page 53: Check Points Of Every 1500 Hours

    DIESEL ENGINE 03-M-DI Series, WSM (10) Check Points of Every 1500 Hours CAUTION • 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.

  • Page 54: Check Point Of Every 3000 Hours

    DIESEL ENGINE 03-M-DI Series, WSM (11) Check Point of Every 3000 Hours Checking Turbocharger See page S-101. W1056274 (12) Check Points of Every 2 Years Replacing Intake Air Line See page S-23. W1117974 Replacing Battery See page S-21, 30. W1056352 Replacing Radiator Hoses and Clamp Bands See page S-23.

  • Page 55: Special Tools

    DIESEL ENGINE 03-M-DI Series, WSM [8] SPECIAL TOOLS Special Use Puller Set Code No: 07916-09032 Application: Use exclusively for pulling out bearing, gears and other parts with ease. W1024050 Piston Ring Compressor Code No: 07909-32111 Application: Use exclusively for pushing in the piston with piston rings into the cylinder.
  • Page 56 DIESEL ENGINE 03-M-DI Series, WSM Oil Pressure Tester Code No: 07916-32032 Application: Use to measure lubricating oil pressure. (1) Gauge (5) Adaptor 2 (2) Cable (6) Adaptor 3 (3) Threaded Joint (7) Adaptor 4 (4) Adaptor 1 (8) Adaptor 5 W1024318 Valve Seat Cutter Code No:...
  • Page 57 DIESEL ENGINE 03-M-DI Series, WSM Plastigage Code No: 07909-30241 Application: Use to check the oil clearance between crankshaft and bearing, etc. Measuring: Green ..0.025 to 0.076 mm (0.001 to 0.003 in.) range Red..0.051 to 0.152 mm (0.002 to 0.006 in.) Blue ..
  • Page 58 DIESEL ENGINE 03-M-DI Series, WSM NOTE • The following special tools are not provided, so make them referring to the figure. Valve Guide Replacing Tool Application: Use to press out and press fit the valve guide. 20 mm dia. (0.79 in. dia.) 11.7 to 11.9 mm dia.
  • Page 59 DIESEL ENGINE 03-M-DI Series, WSM Crankshaft Bearing 1 Replacing Tool Application: Use to press out and press fit the crankshaft bearing 1. 1. Extracting tool (D1503, D1703, V2203 : Serial No. : below 3R9999) 135 mm (5.31 in.) 72 mm (2.83 in.) R40 mm (R1.57 in.) 10 mm (0.39 in.) 20 mm (0.79 in.)
  • Page 60 DIESEL ENGINE 03-M-DI Series, WSM Balancer Metal Replacing Tool (for Removing) Application: Use to remove the metal bearing. 25 mm (0.98 in. dia.) 41.934 to 41.950 mm dia. (1.6509 to 1.6516 in. dia.) 10 mm (0.39 in.) 24.959 to 24.980 mm dia. (0.9826 to 0.9835 in. dia.) Chamfer 0.3 mm (0.01 in.) 21.947 to 21.960 mm dia.
  • Page 61 DIESEL ENGINE 03-M-DI Series, WSM Balancer Metal Replacing Tool (for Fitting) Application: Use to press fit the metal bearing. 0.52 rad (30 °) 5 mm (0.20 in.) 10 mm (0.39 in.) 3.3 to 3.7 mm (0.130 to 0.146 in.) Chamfer 0.3 mm (0.01 in.) 43.934 to 43.950 mm dia.
  • Page 62 DIESEL ENGINE 03-M-DI Series, WSM 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 (0.98 in.) 27.0 mm (1.06 in.) 45.0 mm dia.

  • Page 63: Engine Body

    DIESEL ENGINE 03-M-DI Series, WSM 2. ENGINE BODY [1] CHECKING AND ADJUSTING Compression Pressure 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.

  • Page 64: Disassembling And Assembling

    DIESEL ENGINE 03-M-DI Series, WSM [2] DISASSEMBLING AND ASSEMBLING (1) Draining Coolant and Oil NOTE • Some types of gearcases are provided with an oil filter port. When the cylinder head has been reassembled or when the valve clearance has been readjusted, apply an enough amount of oil to the intake and exhaust valves, push rod and rocker arm just before fitting the head cover in position.

  • Page 65: Cylinder Head And Valves

    DIESEL ENGINE 03-M-DI Series, WSM (3) Cylinder Head and Valves Cylinder Head Cover 1. Remove the lead (1). 2. Remove the breather hose (2). 3. Remove the head cover screws (3). 4. Remove the cylinder head cover (4). (When reassembling) •...
  • Page 66 DIESEL ENGINE 03-M-DI Series, WSM Nozzle Holder Assembly and Glow Plug 1. Remove the overflow pipe assembly. 2. Remove the glow plugs (1). 3. Remove the nozzle holder assemblies (2). (When reassembling) • Replace the copper gasket with new one. 25.5 to 29.4 N·m Nozzle holder clamp screw 2.6 to 3.0 kgf·m...
  • Page 67 • To replace the cylinder head gasket (4), in advance make sure the marking (5) of cylinder head gasket in the original engine, and replace the same marking as the original cylinder head gasket. Model D1503-M-DI D1703-M-DI V2203-M-DI Gasket Marking & D1503-M-DI-T...
  • Page 68 DIESEL ENGINE 03-M-DI Series, WSM Cylinder Head (Continued) IMPORTANT • When replacing piston, piston pin, small end bushing, connecting rod, or crankpin bearings, measure piston head’s protrusion or recessing from the level of crankcase cylinder face (average of 4 pistons) after installing the pistons, and select the cylinder head gasket following the below table.
  • Page 69 DIESEL ENGINE 03-M-DI Series, WSM Valves 1. Remove the valve caps (2). 2. Remove the valve spring collet (3), pushing the valve spring retainer (4) by valve spring replacer (1). 3. Remove the valve spring retainer (4), valve spring (5) and valve stem seal (6).

  • Page 70: Timing Gears, Camshaft And Fuel Camshaft

    DIESEL ENGINE 03-M-DI Series, WSM (4) Timing Gears, Camshaft and Fuel Camshaft Injection Pump 1. Remove the stop solenoid (1) and hi-idling body (2). 2. Remove the engine stop lever (3) and stop solenoid guide (5). 3. Remove the fuel injection pump assembly (4). IMPORTANT •...
  • Page 71 DIESEL ENGINE 03-M-DI Series, WSM 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 72 DIESEL ENGINE 03-M-DI Series, WSM Governor Springs and Speed Control Plate (Continued) (When reassembling) • Hook the small spring (4) first and then the large governor spring (2) on the speed control plate (6). • Put the specific tool (1) from the injection pump side to catch the large governor spring (2).
  • Page 73 DIESEL ENGINE 03-M-DI Series, WSM 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 74: Idle Gear

    DIESEL ENGINE 03-M-DI Series, WSM Idle Gear 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 (4) - Idle gear (2) and cam gear (3) - Idle gear (2) and injection pump gear (1) (1) Injection Pump Gear...
  • Page 75 DIESEL ENGINE 03-M-DI Series, WSM Camshaft and Balancer Shaft (For Balancer Model) 1. Remove the camshaft set bolts and draw out the camshaft (1). 2. Remove the balancer shaft 1 (2) set bolts and draw out the balancer shaft 1 (2). 3.

  • Page 76: Piston And Connecting Rod

    DIESEL ENGINE 03-M-DI Series, WSM Crank Gear 1. Draw out the crank gear (1) with a puller (2). 2. Remove the feather key. (1) Crank Gear (2) Gear Puller W1025476 (5) Piston and Connecting Rod Oil Pan and Oil Strainer 1.
  • Page 77 DIESEL ENGINE 03-M-DI Series, WSM Pistons 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 78 DIESEL ENGINE 03-M-DI Series, WSM Piston Ring and Connecting Rod 1. Remove the piston rings (1), (2), (3) using a piston ring tool (Code No. 07909-32121). 2. Remove the piston pin (7), and separate the connecting rod (6) from the piston (5). (When reassembling) •...

  • Page 79: Crankshaft

    DIESEL ENGINE 03-M-DI Series, WSM (6) 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 80 • Before disassembling, check the side clearance of crankshaft. Also check it during reassembling. For D1503-M-DI, D1503-M-DI-T, D1703-M-DI and V2203-M-DI 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 81 DIESEL ENGINE 03-M-DI Series, WSM Main Bearing Case Assembly 1. Remove the two main bearing case screws 1 (8), 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 82: Servicing

    DIESEL ENGINE 03-M-DI Series, WSM [3] SERVICING (1) Cylinder Head and Valves Cylinder Head Surface Flatness 1. Clean the cylinder head surface. 2. Place a straightedge on the cylinder head’s four sides and two diagonal as shown in the figure. 3.
  • Page 83 DIESEL ENGINE 03-M-DI Series, WSM Valve Recessing 1. Clean the cylinder head surface (1), valve face and valve seat. 2. Insert the valve into the valve guide. 3. Measure the valve recessing with a depth gauge. 4. If the measurement exceeds the allowable limit, replace the valve.
  • Page 84 DIESEL ENGINE 03-M-DI Series, WSM Replacing Valve Guide (A) (When removing) 1. Press out the used valve guide using a valve guide replacing tool. (B) (When installing) 1. Clean a new valve guide and valve guide bore, and apply engine oil to them.
  • Page 85 DIESEL ENGINE 03-M-DI Series, WSM Correcting Valve and Valve Seat NOTE • Before correcting the valve and seat, check the valve stem and the I.D. of valve guide section, and repair them if necessary. • After correcting the valve seat, be sure to check the valve recessing.
  • Page 86 DIESEL ENGINE 03-M-DI Series, WSM Free Length and Tilt of Valve Spring 1. Measure the free length A of valve spring with vernier calipers. If the measurement is less than the allowable limit, replace it. 2. Put the valve spring on a surface plate, place a square on the side of the valve spring.

  • Page 87: Timing Gears, Camshaft And Fuel Camshaft

    DIESEL ENGINE 03-M-DI Series, WSM Oil Clearance between Tappet and Tappet Guide Bore 1. Measure the tappet O.D. with an outside micrometer. 2. Measure the I.D. of the tappet guide bore with a cylinder gauge, and calculate the oil clearance. 3.

  • Page 88: Idle Gear, Camshaft, Balancer Shaft Clearance

    DIESEL ENGINE 03-M-DI Series, WSM Idle Gear Side Clearance 1. Set a dial indicator with its tip on the idle gear. 2. Measure the side clearance by moving the idle gear to the front and rear. 3. If the measurement exceeds the allowable limit, replace the idle gear collar.
  • Page 89 DIESEL ENGINE 03-M-DI Series, WSM 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 90 DIESEL ENGINE 03-M-DI Series, WSM Replacing Idle Gear Bushing (A) (When removing) 1. Using an idle gear bushing replacing tool, press out the used bushing. (B) (When installing) 1. Clean a new idle gear bushing and idle gear bore, and apply engine oil to them.

  • Page 91: Piston And Connecting Rod

    DIESEL ENGINE 03-M-DI Series, WSM Oil Clearance of Camshaft Journal 1. Measure the camshaft journal O.D. with an outside micrometer. 2. Measure the cylinder block bore I.D. for camshaft with a cylinder gauge, and calculate the oil clearance. 3. If the oil clearance exceeds the allowable limit, replace the camshaft.
  • Page 92 0.20 to 0.35 mm Factory spec. 0.0079 to 0.0138 in. Top ring 1.25 mm Allowable limit 0.0492 in. 0.30 to 0.45 mm D1503-M-DI 0.012 to 0.018 in. 0.40 to 0.55 mm D1503-M-DI-T Factory 0.016 to 0.022 in. spec. D1703-M-DI Second ring D1803-M-DI 0.35 to 0.50 mm...
  • Page 93 D1803-M-DI 0.050 to 0.090 mm spec. V2203-M-DI 0.0020 to 0.0035 in. Top Ring V2403-M-DI 0.2 mm Allowable limit 0.0079 in. D1503-M-DI 0.093 to 0.128 mm D1503-M-DI-T 0.0037 to 0.0050 in. Factory D1703-M-DI spec. D1803-M-DI 0.050 to 0.090 mm Second ring V2203-M-DI 0.0020 to 0.0035 in.

  • Page 94: Crankshaft

    3. Measure the end play by pulling the crankshaft toward the crank gear. 4. If the measurement exceeds the allowable limit, replace the thrust bearing 1 and 2. (Serial No : below 3R9999) D1503-M-DI D1503-M-DI-T 0.15 to 0.35 mm D1703-M-DI 0.0059 to 0.0138 in.
  • Page 95 DIESEL ENGINE 03-M-DI Series, WSM Oil Clearance between Crankpin and Crankpin Bearing 1. Clean the crankpin and crankpin bearing. 2. Put a strip of plastigage (Code No.: 07909-30241) on the center of the crankpin in each direction as shown in the figure. 3.

  • Page 96: Oil Clearance: Crankshaft Journal, Crankshaft Bearing

    Oil clearance between 0.00157 to 0.00465 in. crankshaft journal and 0.2 mm crankshaft bearing 1 Allowable limit 0.0079 in. (Serial No. : below 3R9999) D1503-M-DI D1503-M-DI-T 51.921 to 51.940 mm D1703-M-DI 2.04413 to 2.04488 in. Crankshaft journal Factory V2203-M-DI O.D.
  • Page 97 0.1102 to 0.1260 in. radius 1.0 to 1.5 mm relief 1.0 to 1.5 mm relief 0.0394 to 0.0591 in. relief 0.0394 to 0.0591 in. relief D1503-M-DI D1503-M-DI-T 51.721 to 51.740 mm 51.521 to 51.540 mm D1703-M-DI 2.03626 to 2.03701 in.
  • Page 98 Factory spec. Oil clearance between 0.00157 to 0.00409 in. crankshaft and 0.20 mm crankshaft bearing 2 Allowable limit 0.0079 in. (Serial No. : below 3R9999) D1503-M-DI D1503-M-DI-T 51.921 to 51.940 mm D1703-M-DI 2.04413 to 2.04488 in. Crankshaft journal Factory V2203-M-DI O.D.
  • Page 99 1.0 to 1.5 mm relief 1.0 to 1.5 mm relief 0.0394 to 0.0591 in. 0.0394 to 0.0591 in. relief relief D1503-M-DI D1503-M-DI-T 51.721 to 51.740 mm 51.521 to 51.540 mm D1703-M-DI 2.03626 to 2.03701 in. 2.02839 to 2.02913 in.

  • Page 100: Cylinder

    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 bores. (Refer to “Correcting Cylinder”.) D1503-M-DI 83.000 to 83.022 mm D1503-M-DI-T 3.26772 to 3.26858 in. Factory D1703-M-DI Cylinder I.D.
  • Page 101 DIESEL ENGINE 03-M-DI Series, WSM Correcting Cylinder (Oversize +0.25 mm) 1. When the cylinder is worn beyond the allowable limit, bore and hone it to the specified dimension. D1503-M-DI 83.250 to 83.272 mm D1503-M-DI-T 3.27756 to 3.27843 in. Oversize cylinder...

  • Page 102: Engine Oil Pressure

    DIESEL ENGINE 03-M-DI Series, WSM 3. LUBRICATING SYSTEM [1] Checking Engine Oil Pressure 1. Remove the engine oil pressure switch, and set a oil pressure tester (Code No.: 07916-32032). 2. Start the engine. After warming up, measure the oil pressure of both idling and rated speeds.

  • Page 103: Servicing

    DIESEL ENGINE 03-M-DI Series, WSM [2] Servicing 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. 3.

  • Page 104: Cooling System

    DIESEL ENGINE 03-M-DI Series, WSM 4. COOLING SYSTEM [1] CHECKING AND ADJUSTING Fan Belt Tension 1. Measure the deflection (A), depressing the belt halfway between the fan drive pulley and alternator pulley at specified force (98 N, 10 kgf, 22 lbs). 2.
  • Page 105 DIESEL ENGINE 03-M-DI Series, WSM CAUTION • When removing the radiator cap, wait at least ten minutes after the engine has stopped and cooled down. Otherwise, hot water way gush out, scalding nearby people. Radiator Cap Air Leakage 1. Set a radiator tester (1) and adaptor (2) (BANZAI Code No. RCT- 2A-30S) on the radiator cap.

  • Page 106: Disassembling And Assembling

    DIESEL ENGINE 03-M-DI Series, WSM [2] DISASSEMBLING AND ASSEMBLING CAUTION • When removing the radiator cap, wait at least ten minutes after the engine has stopped and cooled down. Otherwise, hot water way gush out, scalding nearby people. Thermostat Assembly 1.

  • Page 107: Fuel System

    If the calculation differs from specified injection timing, add or remove the shim to adjust. Model Injection Timing D1503-M-DI 0.18 to 0.22 rad (10.5 ° to 12.5 °) B.T.D.C. D1503-M-DI-T D1703-M-DI 0.16 to 0.19 rad (9.0 ° to 11.0 °) B.T.D.C.
  • Page 108 DIESEL ENGINE 03-M-DI Series, WSM Injection Timing (Continued) NOTE • The sealant is applied to both sides of the soft metal gasket shim. The liquid gasket is not required for assembling. • Shims are available in thickness of 0.20 mm, 0.25 mm, 0.30 mm and 0.35 mm.

  • Page 109: Injection Nozzle

    DIESEL ENGINE 03-M-DI Series, WSM (2) Injection Nozzle CAUTION • Check the nozzle 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.

  • Page 110: Electrical System

    DIESEL ENGINE 03-M-DI Series, WSM 6. ELECTRICAL SYSTEM [1] CHECKING (1) Starter 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.

  • Page 111: Alternator

    DIESEL ENGINE 03-M-DI Series, WSM (2) Alternator (Precaution when checking) • If disconnect the B terminal or coupler, engine will stop by emergency device. • Do not directory connect the L terminal with the B terminal. Otherwise the three exciting diodes may be damaged. When connecting the L terminal, insert a 3.4 W lamp between the L and B terminals.

  • Page 112: Glow Plug

    DIESEL ENGINE 03-M-DI Series, WSM (3) Glow Plug Lead Terminal Voltage 1. Disconnect the wiring lead (1) from the glow plug (2) after turning the main switch off. 2. Turn the main switch key to the “PREHEAT” position, and measure the voltage between the lead terminal and the chassis. 3.

  • Page 113: Glow Lamp Relay

    DIESEL ENGINE 03-M-DI Series, WSM (5) Glow Lamp Relay Glow Lamp and Glow Lamp Relay 1. Check the glow lamp indicator lights up then lights off after about 5 seconds when main switch (2) is turned to glow position (1). 2.

  • Page 114: Disassembling And Assembling

    DIESEL ENGINE 03-M-DI Series, WSM [2] DISASSEMBLING AND ASSEMBLING (1) Starter Disassembling Motor 1. Disconnect the connecting lead (9) from the magnet switch (8). 2. Remove the screws (6), and then separate the end frame (4), yoke (2) and armature (1). 3.
  • Page 115 DIESEL ENGINE 03-M-DI Series, WSM Rear End Cover 1. Unscrew the three rear end cover screws and the B terminal nut, and remove the rear end cover. W1018982 Brush Holder 1. Unscrew the two screws holding the brush holder (1), and remove the brush holder (1).
  • Page 116 DIESEL ENGINE 03-M-DI Series, WSM Rotor 1. Press out the rotor (1) from drive end frame (3). IMPORTANT • Take special care not to drop the rotor and damage the slip ring or fan, etc.. (1) Rotor (3) Drive End Frame (2) Block W1019438 Retainer Plate...

  • Page 117: Servicing

    DIESEL ENGINE 03-M-DI Series, WSM [3] SERVICING (1) Starter Overrunning Clutch 1. Inspect the pinion for wear or damage. 2. If there is any defect, replace the overrunning clutch assembly. 3. Check that the pinion turns freely and smoothly in the overrunning direction and dose not slip in the cranking directions.
  • Page 118 DIESEL ENGINE 03-M-DI Series, WSM Field Coil 1. Check the continuity across the lead (1) and brush (2) with an ohmmeter. 2. If it dose not conduct, replace the yoke assembly. 3. Check the continuity across the brush (2) and yoke (3) with an ohmmeter.

  • Page 119: Alternator

    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-DI D1503-M-DI-T 30.0 mm D1703-M-DI 1.181 in.
  • Page 120 2. If the resistance is not the factory specification, replace it. 3. Check the continuity across the slip ring and core with an ohmmeter. 4. If infinity is not indicated, replace it. 2.9 Ω D1503-M-DI D1503-M-DI-T Factory D1703-M-DI Resistance spec.

  • Page 121: Wiring Diagram

    DIESEL ENGINE 03-M-DI Series, WSM IC Regulator 1. Check the continuity across the B terminal and the F terminal of IC regulator with an analog ohmmeter. Conduct the test in the (R × 1) setting. 2. The IC regulator is normal if the IC regulator conducts in one direction and does not conduct in the reverse direction.

  • Page 122: Turbo Charger System

    DIESEL ENGINE 03-M-DI Series, WSM 7. TURBO CHARGER SYSTEM [1] CHECKING Turbine Side 1. Check the exhaust port (3) and inlet port (2) side of the turbine housing (1) to see if there is no exhaust gas leak. 2. If any gas leak is found, retighten the bolts and nuts or replace the gasket with new one.

  • Page 123: Disassembling And Assembling

    DIESEL ENGINE 03-M-DI Series, WSM [2] DISASSEMBLING AND ASSEMBLING 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 124 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 2009. 10, S, EI, EI, e Code No.9Y011-02153 KUBOTA Corporation 2002.

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D1503-m-di-tV2203-m-diV2403-m-diD1703-m-diD1803-m-di

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