Kubota D1503-M-E, Operator'S Manual

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Page 2: ...ERVICE INTERVALS 9 PERIODIC SERVICE 11 FUEL 11 Fuel level check and refueling 11 Air bleeding the fuel system 12 Checking the fuel pipes 13 Cleaning the fuel filter pot 13 Fuel filter cartridge replacement 14 ENGINE OIL 14 Checking oil level and adding engine oil 14 Changing engine oil 15 Replacing the oil filter cartridge 16 RADIATOR 17 Checking coolant level adding coolant 17 Changing coolant 18...

Page 3: ...RY 22 Battery charging 22 Direction for long term storage 23 ELECTRIC WIRING 23 FAN BELT 23 Adjusting Fan Belt Tension 23 CARRIAGE AND STORAGE 24 CARRIAGE 24 STORAGE 24 TROUBLESHOOTING 25 SPECIFICATIONS 27 WIRING DIAGRAMS 28 1ABK0000132 book 2 ページ ２００４年２月１９日 木曜日 午前１０時３０分 ...

Page 4: ...have the most up to date information Please do not hesitate to consult with them FOREWORD 3DANGER Indicates an imminently hazardous situation which if not avoided will result in death or serious injury 3WARNING Indicates a potentially hazardous situation which if not avoided COULD result in death or serious injury 3CAUTION Indicates a potentially hazardous situation which if not avoided MAY result...

Page 5: ...ENGLISH ...

Page 6: ...nd work safely Know your equipments and its limitations Always keep the engine in good condition A Before allowing other people to use your engine explain how to operate and have them read this manual before operation A DO NOT modify the engine by yourself UNAUTHORIZED MODIFICATIONS to the engine may impair the function and or safety and affect engine life 2 WEAR SAFETY CLOTHING A DO NOT wear loos...

Page 7: ...ve 4 KEEP AROUND THE ENGINE CLEAN A Be sure to stop the engine before cleaning A Keep the engine clean and free of accumulated dirt grease and trash to avoid a fire Store flammable fluids away from sparks and fire A DO NOT stop the engine without idling Temperatures around the engine rise suddenly Keep the engine idling for over about 5 minutes before stopping 5 SAFE HANDLING OF FUEL AND LUBRICANT...

Page 8: ...Keep all power connections clean Bare wire or frayed insulation can cause a dangerous electrical shock and personal injury 7 ESCAPING FLUID A Relieve all pressure in the air the oil and the cooling systems before any lines fittings or related items are removed or disconnected A Be alert for possible pressure when disconnecting any device from a system that utilizes pressure DO NOT check for pressu...

Page 9: ...ts fluid level stands below the LOWER mark Otherwise the component parts may deteriorate earlier than expected which may shorten the service life or cause an explosion Immediately add distilled water until the fluid level is between the UPPER and LOWER levels A Keep sparks and open flames away from the battery especially when charging the battery DO NOT strike a match near the battery A DO NOT che...

Page 10: ...engine before conducting service Put a DO NOT OPERATE tag in the key switch to avoid accidental starting A To avoid sparks from an accidental short circuit always disconnect the battery s ground cable first and connect it last A Be sure to stop the engine and remove the key when conducting daily and periodic maintenance servicing and cleaning A Check or conduct maintenance after the engine coolant...

Page 11: ...ning and caution label s affixed is replaced with new part make sure new label s is are attached in the same location s as the replaced component 5 Mount new warning and caution labels by applying on a clean dry surface and pressing any bubbles to outside edge 12 WARNING AND CAUTION LABELS Part No 19077 8724 1 or 16667 8724 1 55mm in diameter 37mm in diameter Part No TA040 4957 1 Stay clear of eng...

Page 12: ...when in need of parts or major service be sure to see your KUBOTA dealer For service contact the KUBOTA Dealership from which you purchased your engine or your local KUBOTA dealer When in need of parts be prepared to give your dealer the engine serial number Locate the serial number now and record them in the space provided Type Serial No Engine Date of Purchase Name of Dealer To be filled in by p...

Page 13: ...ion pump 5 Fuel feed pump 6 Cooling fan 7 Fan drive pulley 8 Oil filter cartridge 9 Water drain cock 10 Oil filler plug 11 Exhaust manifold 12 Alternator 13 Starter 14 Oil level gauge 15 Oil pressure switch 16 Flywheel 17 Oil drain plug 18 Oil pan 19 Engine hook 1ABK0000132 book 2 ページ ２００４年２月１９日 木曜日 午前１０時３０分 ...

Page 14: ...wide space when checking A Keep dust or fuel away from the battery wiring muffler and engine to prevent a fire Check and clear them before operating everyday Pay attention to the heat of the exhaust pipe or exhaust gas so that it can not ignite trash Item Ref page 1 Parts which had trouble in previous operation 2 By walking around the machine 1 Oil or water leaks 14 to 20 2 Engine oil level and co...

Page 15: ...hard hat safety boots or shoes eye and hearing protection gloves etc as appropriate or required A Do not wear radio or music headphones while operating engine A Check to see if it is safe around the engine before starting A Reinstall safeguards and shields securely and clear all maintenance tools when starting the engine after maintenance A Do not use ether or any starting fluid for starting the e...

Page 16: ...ine not only in winter but also in warmer seasons An insufficiently warmed up engine can shorten its service life A When there is fear of temperature dropping below 15 C 5 F detach the battery from the machine and keep it indoors in a safe area to be reinstalled just before the next operation 4 Insert the key into the key switch and turn it to the OPERATION position A OFF SWITCHED OFF B ON OPERATI...

Page 17: ... Check to see if there is any dirt or dust between radiator fins and tube 4 Check to see if the fan belt is too loose 5 Check to see if radiator water pipe is clogged and 6 Check to see if anti freeze is mixed to a 50 50 mix of water and anti freeze BOil pressure lamp The lamp lights up to warn the operator that the engine oil pressure has dropped below the prescribed level If this should happen d...

Page 18: ...s A Unusual noises suddenly appear A Exhaust fumes suddenly become very dark A The oil pressure lamp or the water temperature alarm lamp lights up REVERSED ENGINE REVOLUTION AND REMEDIES To avoid personal injury A Reversed engine operation can make the machine reverse and run it backwards It may lead to serious trouble A Reversed engine operation may make exhaust gas gush out into the intake side ...

Page 19: ...ne but use regular cleanser A Always use proper tools that are in good condition Make sure you understand how to use them before performing any service work A When installing be sure to tighten all bolts lest they should be loose Tighten the bolts by the specified torque A Do not put any tools on the battery or battery terminals may short out Severe burns or fire could result Detach the battery fr...

Page 20: ...e instruction Please see the Warranty Statement in detail Interval Item Ref page Every 50 hours Check of fuel pipes and clamp bands 13 See NOTE Change of engine oil depending on the oil pan 14 to 16 Every 100 hours Cleaning of air cleaner element 20 21 1 Cleaning of fuel filter 13 Check of battery electrolyte level 22 23 Check of fan belt tightness 23 Every 200 hours Check of radiator hoses and cl...

Page 21: ... high sulfur fuel it is advisable to employ the CF CD or CE lubricating oil with a high total base number If the CF 4 or CG 4 lubricating oil is used with a high sulfur fuel change the lubricating oil at shorter intervals A Lubricating oil recommended when a low sulfur or high sulfur fuel is employed Recommendable X Not recommendable Models Oil pan depth 124 mm 4 88 in 90 mm 3 54 in D1503 M E D170...

Page 22: ...verfill No 2 D is a distillate fuel oil of lower volatility for engines in industrial and heavy mobile service SAE J313 JUN87 Grade of Diesel Fuel Oil According to ASTM D975 The cetane number is required not to be less than 45 A Be sure to use a strainer when filling the fuel tank or dirt or sand in the fuel may cause trouble in the fuel injection pump A For fuel always use diesel fuel You are req...

Page 23: ... of the fuel injection pump A Always keep the air vent cock on the fuel injection pump closed except when air is vented or it may cause the engine to stop GRAVITY FEED SYSTEM PROCEDURE fuel tanks lower than injection pump 1 For fuel tanks that are lower than the injection pump The fuel system must be pressurized by the fuel system electric fuel pump 2 If an electric fuel pump is not used you must ...

Page 24: ...alled plug them at both ends with clean cloth or paper to prevent dirt from entering Dirt in the pipes can cause fuel injection pump malfunction BCleaning the fuel filter pot Every 100 hours of operation clean the fuel filter in a clean place to prevent dust intrusion 1 Close the fuel filter lever 2 Remove the top cap and rinse the inside with diesel fuel 3 Take out the element and rinse it with d...

Page 25: ...ngine and allow it to cool before conducting inspections maintenance or for a cleaning procedure A Contact with engine oil can damage your skin Put on gloves when using engine oil If you come in contact with engine oil wash it off immediately A Be sure to inspect the engine locating it on a level place If placed on gradients accurately oil quantity may not be measured BChecking oil level and addin...

Page 26: ...after running the engine Allow engine to cool down sufficiently 1 Change oil after the initial 50 hours of operation and every 200 hours thereafter See table below A Changing interval thereafter 90mm 3 54 in oil pan depth is optional Standard replacement interval A API service classification above CD grade A Ambient temperature below 35 C 95 F 2 Remove the drain plug at the bottom of the engine an...

Page 27: ...y hand When the gasket contacts the seal surface tighten the cartridge enough by hand Because if you tighten the cartridge with a wrench it will be tightened too much 5 After the new cartridge has been replaced the engine oil level normally decreases a little Thus run the engine for a while and check for oil leaks through the seal before checking the engine oil level Add oil if necessary A Wipe of...

Page 28: ...is hot When cool to the touch rotate cap to the first stop to allow excess pressure to escape Then remove cap completely If overheats should occur steam may gush out from the radiator or reserve tank Severe burns could result BChecking coolant level adding coolant 1 Remove the radiator cap after the engine has completely cooled and check to see that coolant reaches the supply port 2 If the radiato...

Page 29: ...tors 4 An improperly tightened radiator cap or a gap between the cap and the seat quickens loss of coolant 5 Coolant Radiator cleaner and anti freeze BRemedies for quick decrease of coolant 1 Check any dust and dirt between the radiator fins and tube If any remove them from the fins and the tube 2 Check the tightness of the fan belt If loose tighten it securely 3 Check the internal blockage in the...

Page 30: ...n some protection such as rubber gloves Anti freeze contains poison A If should drink anti freeze throw up at once and take medical attention A When anti freeze comes in contact with the skin or clothing wash it off immediately A Do not mix different types of anti freeze The mixture can produce chemical reaction causing harmful substances A Anti freeze is extremely flammable and explosive under ce...

Page 31: ...this happen however radiator cement can easily fix it If leakage is serious contact your local KUBOTA dealer AIR CLEANER Since the air cleaner employed on this engine is a dry type never apply oil to it 1 Open the evacuator valve once a week under ordinary conditions or daily when used in a dusty place This will get rid of large particles of dust and dirt 2 Wipe the inside air cleaner clean with c...

Page 32: ...lean out the dust cup before it becomes half full with dust usually once a week or even every day if the working surroundings are dusty Install the air cleaner dust cup with TOP indicated on the rear of the cup in the up position However it may be installed in either direction when the cover is placed at the lower part A If the dust cup is mounted incorrectly dust or dirt does not collect in the c...

Page 33: ... between the UPPER and LOWER levels To avoid personal injury A 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 A When charging the battery remove the battery vent plugs A When disconnecting the cable from the battery start with the negative termin...

Page 34: ...e to repair them before starting the engine Damaged wiring reduces the capacity of electrical parts Change or repair damaged wiring immediately FAN BELT BAdjusting Fan Belt Tension To avoid personal injury A Be sure to stop the engine and remove the key before checking the belt tension A Be sure to reinstall the detached safety shield after maintenance or checking 1 Stop the engine and remove the ...

Page 35: ...pressure cap Since water may freeze when the temperature drops below 0 C 32 F it is very important that no water is left in the machine 2 Remove dirty engine oil fill with new oil and run the engine for about 5 minutes to let the oil penetrate to all the parts 3 Check all the bolts and nuts and tighten if necessary 4 Remove the battery from the engine adjust the electrolyte level and recharge it S...

Page 36: ... temperature Low compression Bad valve or excessive wear of rings pistons and liners cause insufficient compression Replace with new parts Battery is discharged and the engine will not crank Charge battery In winter always remove battery from machine charge fully and keep indoors Install in machine at time of use Cause Countermeasures Carbon stuck around orifice of nozzle piece Clean orifice and n...

Page 37: ...asures Engine revolution suddenly decreases or increases Check the adjustments injection timing and the fuel system Unusual sound is heard suddenly Check all moving parts carefully Color of exhaust suddenly turns dark Check the fuel injection system especially the fuel injection nozzle Bearing parts are overheated Check the lubricating system Oil lamp lights up during operation Check the lubricati...

Page 38: ...35 4 2800 29 8 2800 40 0 2800 35 5 2800 47 6 2800 31 1 2600 41 6 2600 Maximum bare speed rpm 3000 2800 3000 2800 Maximum bare idling speed rpm 750 to 850 850 to 950 750 to 850 Order of firing 1 2 3 1 3 4 2 Direction of rotation Counter clockwise viewed from flywheel side Injection pump Bosch Type mini pump Injection pressure 13 73 MPa 1991 psi 140 kgf cm Injection timing Before T D C 0 314rad 18 C...

Page 39: ...28 WIRING DIAGRAMS ENGLISH WIRING DIAGRAMS 1ABK0000132 book 28 ページ ２００４年２月１９日 木曜日 午前１０時３０分 ...