Kubota D1102-B Workshop Manual
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Kubota D1102-B Workshop Manual

Kubota D1102-B Workshop Manual

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WORKSHOP MANUAL
DIESEL ENGINES
D1102-B,D1302-B,D1402-B,
V1502-B,V1702-B,V1902-B
KiSC issued 09, 2007 A
 

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  • Page 1 WORKSHOP MANUAL DIESEL ENGINES D1102-B,D1302-B,D1402-B, V1502-B,V1702-B,V1902-B KiSC issued 09, 2007 A  ...
  • Page 2 • Section V "Service Directions" covers all reference values and allowable limits required for servicing. 0078 P001 KUBOTA Corporation reserves the right to change the specifications without notice. No part of this manual may be reproduced without permission of KUBOTA Corporation.
  • Page 3 CONT ENTS SPECIFICATIONS AND PERFORMANCE CURVES ......... 3 Section GENER AL DESCRIPTION ................13 Section II 1. Engine 2. Lubrication System 3. Cooling System 4. Fuel System 5. Electrical System ENGINE ......................27 Section 1. Troubleshooting 2. Disassembly and Reassembly 3.
  • Page 4 Section SPECIFICATIONS AND PERFORMANCE CURVES " « ;;/. " "' • D1102-B ........................4 • D1302-B ........................5 ......................... 6 • D1402-B • V1502-B ........................7 ......................... 8 • V1702-B • V1902-B ........................9 • DIMENSIONS ........................10 KiSC issued 09, 2007 A...
  • Page 5 Section SPECIFICATIONS AND PERFORMANCE CURVES • D1102-B Specifications Model D1102-B Maximum Bare Speed 3000 min· (rpm) Vertical, water-cooled, Minimum Bare Idling Speed 800 min (rpm) Type 4-cycle diesel engine Combustion Chamber Spherical Type Number of Cylinders Fuel Injection Pump Bosch K Type mini pump...
  • Page 6 • 01302-B Specifications Model D1302-B Maximum Bare Speed 3000 min- (rpm) Vertical, water-cooled, Minimum Bare Idling Speed 800 min- (rpm) Type 4-cycle diesel engine Combustion Chamber Spherical Type Number of Cylinders Fuel Injection Pump Bosch K Type mini pump Bore x Stroke mm (inch) 82 x 82 L ( 3.23 x 3.23 L)
  • Page 7 • 01402-e Specifications Model D1402-B Maximum Bare Speed 3000 min- (rpm) Vertical, water-cooled, Minimum Bare Idling Speed 800 min- (rpm) Type 4-cycle diesel engine Combustion Chamber Spherical Type Number of Cylinders Fuel Injection Pump Bosch K Type mini pump Bore x Stroke mm (inch) 82 L ( 3.25...
  • Page 8 • v1so2-e Specifications 3000 min·1(rpm) Model V1502 B Maximum Bare Speed Vertical, water-cooled, Minimum Bare Idling Speed 800 min-1(rpm) Type 4-cycle diesel engine Combustion Chamber Spherical Type Number of Cylinders Fuel Injection Pump Bosch K Type mini pump 2.99 3.23 Bore Stroke mm (inch}...
  • Page 9 • V1702-B Specifications Model V1702-B Maximum Bare Speed 3000 min- (rpm) Vertical, water-cooled, Minimum Bare Idling Speed 800 min- (rpm) Type 4-cycle diesel engine Spherical Type Combustion Chamber Number of Cylinders Fuel Injection Pump Bosch K Type mini pump 82 L ( 3.23 3.23 L) Bore x Stroke...
  • Page 10 • v1so2-e Specifications Model V1902-B Maximum Bare Speed 3000 min- (rpm) Vertical, water-cooled, Minimum Bare Idling Speed 800 min- (rpm) Type 4-cycle diesel engine Combustion Chamber Spherical Type Number of Cylinders Fuel Injection Pump Bosch K Type mini pump Bore x Stroke mm (inch) q;...
  • Page 11 • DIMENSIONS (01101-B, 01302-B, 01402-B) - ---- ---------- ----- ----- ----- i--- - - - 512 mm (20. 16")- - - - - ....i 257mm (10.12") - - 580mm (22,83")-01102-B, 01302-B ------------------- i 568mm (22.36")-01402-B 10mm (0.39") 240mm (9.45") i--- - - - -544mm (21.42")1- ......
  • Page 12 (V1502-B, V1702-B, V1902-B) 512mm (20.16") 662mm (26.06")-V1502-B 257mm 652mm (25.67")-V1702-B, V1902-B (1012") 2-08.2 0073F014 KiSC issued 09, 2007 A  ...
  • Page 13 KiSC issued 09, 2007 A  ...
  • Page 14 Section GENEIIAt. DEIGRIPf:101 · · ti> "' ": ""' " ,,," .,., FEATURE ............. 14 4. FUEL SYSTEM 1. ENGINE 4.1 Fuel Filter (Optional Part) ......19 1.1 Cylinder Block ....16 4.2 Fuel Pump .
  • Page 15 The D 1102-8, 01302-B, D 1402-B, V1502-B, V1702-B, V1902-B are water-cooled, 4-cycle diesel engines, they concentrate Kubota's foremost technologies. With Kubota's designed spherical combustion chamber, well-known Bosch K type injection pump, well-balance designs, they feature greater power, low fuel consumption, little vibration limited noise.
  • Page 16 KiSC issued 09, 2007 A  ...
  • Page 17 1-1 CYLINDER BLOCK (A) Tunnel Cylinder Block The engi ne f eatu res a h igh d u ra bi l ity tu nnel-ty pe cyl i nder bl ock. F urthermore, d ry-type cyl i nder l i ners a re pressure- fitted i nto cyl i nders a l low ef fective cool i ng, l ess d istort ion, h igher wear-resista nce q ua l ity a nd each cyl i nder has its own cha mber hel ps to m i n i m i ze noise.
  • Page 18 and Piston Rings 1-3 PISTON AND PISTON RINGS A piston of special el l i ptic shape is designed i n consideration of explosion heat. Fu rther more, to enha nce piston's strength , a rib is prov ided between the piston a nd the piston boss. Th ree piston ri ngs a re provided;...
  • Page 19 (A) Lubrication System The l u brication system consists of a trochoide rotor-type driven oil pu mp, oil filter cartridge, oil pressure regulati ng valve, oil switch a nd oi l filter. Oil is sucked by the oil pu mp (b) from the oi l pa n (o) through the oil f ilter (a) , a nd the oi l is kept at 294 to 441 kPa (3.0 to 4.5 kgf/cm 42 to 64 psi) by a n oil pressure regulati ng va lve...
  • Page 20 (A) Fuel System In operation, fuel from the fuel tank (a) enters the filter (b), (f ) where it is cleaned and absorb- ed by the suction of fuel pump (c). ( V1502-B, V1702-B, V1902-B are available) The pump then pushes it to the injection pump (d), where it is pressurized under high pressure and through the injection pipe...
  • Page 21 Discharge Stroke (A) Inlet Stroke 4-2 FUEL PUMP The f uel pu m p sucks the f i ltered f uel a nd, forces it u nder pressu re to the i njection pum p. Suck i ng a nd d ischa rgi ng are done by the vertica l movement of the d ia phragm ( b) , wh ich is operated by a cam of the f uel ca mshaf t (a) .
  • Page 22 (A) Pressurization of Fuel How it works: 1 ) When the pl u nger is at the bottom of its stroke, f uel from the f uel cha mber enters the del ivery chamber through the f eed hole ( F ig. As the ca mshaf t rotates, pl u nger moves u pward, the stroke of f uel pressu ri zation begi ns.
  • Page 23 (a) Control rack Feed hole Control groove (d) Effective Stroke Fig. 3 (el Effective Stroke maximum 0011F045   KiSC issued 09, 2007 A...
  • Page 24 (Al Injection Nozzle 4-4 INJECTION NOZZLE The nozzle is a throttl e-type one, it f eatures l ow f uel con- sum ption a nd works wel l with K u bota's spherica l combus- tion chamber. The nozzle valve open i ng pressu re is abou t 13.7 to 14.7 MPa (140 to 150 kgf /cm 1990 to 2130 psi) , the pressu re over- comes the cou nterforce of nozzl e val ve spri ng ( b) , and push...
  • Page 25 Electrical System 0073F021 (A) N-30 Construction 5-1 CRANK ING SYSTEM The cran ki ng system consists of a battery of 12V, magnet sta rter, glow pl ugs a nd a oi l switch. Starter The magnet-switch ty pe starter is composed of two mai n section.
  • Page 26 (A) Starter Circuit 0011F173 (A) When Key Switch is On: How it works: • W hen Key Switch is On: Wh en the key sw itch is tu rned on, a cur rent flows from the battery th rough the pu l l-i n coil i n the magnet sw itch section to the hold i ng coi l , energizi ng the pl u nger to pu l l it i n.
  • Page 27 Alternator 5-2 CHARGING SYSTEM The chargi ng system consists of an         (f ) (g) (h) AC a l ternator a regu l ator               (option). The alternator generates      ...
  • Page 28 KiSC issued 09, 2007 A...
  • Page 29 Section 1. TROUBLESHOOTING ....28 3. SERVICING Cylinder Head ....• . . 49 2.
  • Page 30 1.TROUBLESHOOTI NG Crankshaft does not turn. No or small fuel injection sounds. Crankshaft turns. Fuel injection sounds. KiSC issued 09, 2007 A  ...
  • Page 31 Reference .---- Cran kshaft and cam shaft have seized u p . 59,63 Piston a nd cy l i nder l i ner have seized u p. Fricti onal resistance of movi ng 62,68 ..,.. parts is too m uch. Bea ri ngs a re oil-stuck.
  • Page 32 Revolution is not smooth at high speeds. Revel ution irregular. Idling not smooth. , : ;, < s;,-· ·1 "'' ffl l i cnNf; OTelJT Slow engine revolutions. ;:::rNSUF F IClENT. : · "' · .? , . . ' , , , , . . : ·:,<...
  • Page 33 Reference r--- Fuel filter clogged. L...-   Fuel pipes broken or loose.   Air in pump. ---..Pump capacity not constant..Injection pump wrong.   ---,... Tappet roller and pin worn. ------ Delivery valve not completely oil-tight.   Injection nozzle faulty. i,...,..
  • Page 34 Wh ite or bl ue exhaust f umes. Black or dark gray exhaust f umes. EXCESSIVE LUBRICANT CONSUMPTION. LUBRICANT INCREAsu, 1G. KiSC issued 09, 2007 A  ...
  • Page 35 Reference Piston ri n g stuck. Piston ri ng worn. --------- Lu bricant rises th rough piston gap. Excessive gap between cyl i nder I i ner and piston. 62,69 ------- Too much oi l.   I n jecti on misti med. I njection too early.
  • Page 36 DISASSEMBLY CHART INJECTION PUMP COV ER CYLINDER INJECTION HEAD COVER PUMP GOVER NOR V ALV E ROCKER AR M SPR ING       CY LINDER INJECTION STA RT HEAD PIPE SPR ING   NOZZLE STAR T INLET ® TAPPET CONTR OL PLATE MANIFOLD HOLDER...
  • Page 37 KiSC issued 09, 2007 A  ...
  • Page 38 2.DISASSEMBLY AND REASSEMBLY • ATTENTION: When reassembling, replace all the 0-ring and gaskets by new ones. Removing Cylinder Head Cover 1) Remove cap nuts from the cylinder head cover. 2) Remove the cyl inder head cover and the gasket from the cyl inder head.
  • Page 39 • Do not forget to ref it the 0-ring. Tightening Torque Remarks Model Serial Number D1102-B "' 25273 01302-B - 22541 Bolt and 78.5 to 83.4 N• m (A) Cylinder head tightening steps ,..15906...
  • Page 40 Removing Starter 1) Remove the starter. Removing Nozzle Holder, Injection Pipe, Inlet Manifold 1) Disconnect the injection pipe. 2) Remove the nozzle holder and the copper gasket. 3) Detach the inlet manifold. ( Note for reassembling) • Take care against the entry of carbon, waste and dirt. •...
  • Page 41   Removing Injection Pump Cover 1) Remove the injection pump cover. Removing Injection Pump 1) Line up the control rack pin to the slot on the crank case. Remove the injection pump. 2) Remove the injection pump shims. Take down the number of the shims for reference.
  • Page 42   Detaching Governor Spring 1) Detach the governor spring 1 and 2 from the governor fork lever 2. (A) How to remove governor spring (b) Gear case governor spring (a) Detach on the side of fork - (cl Fork lever 2 C019 F002 Removing Speed Control Plate 1) Remove the speed control plate and governor spring.
  • Page 43   Detachi ng Start Spring 1) Remove the sta rt spri ng from the gear case. (A) How to remove start spring (a) Detach start spring on the side of gear case (b) Gear case C019 FO 03 Removing Fan Drive Pu lley 1) Remove the fan d ri ve pu l ley.
  • Page 44 (b) 0-ring Removing Crankshaft Collar and Oil Slinger 1) Remove the crankshaft collar, the 0-ring, oil slinger and the crank gear collar (D1102-B, D1302·B, D1402·B only) in that order. ( Note for reassem bling) • Apply oil to the 0-ring. Do not conf use assem bl ing order.
  • Page 45   Removing Idle Gear and Camshaft 1) Remove the external ci rcl i p and detach the collar 2, the idle gear and the col lar 1 i n that order. 2) Remove the camshaf t stopper bolt. 3) Detach the camshaft. ( I mportant) •...
  • Page 46   Removing Crank Gear ) Detach the cran k gear wi th a pu l ler. • Removing Oil Pump 1) Detach the pu m p d rive gear. 2) Detach the oi l pu m p. Removing Thermostat 1) R emove the thermostat cover. 2) R emove the t hermostat.
  • Page 47   Removing Water Pump 1) Detach th e water pu m p from the gear case. Disassembling the Water Pump ( 1) Removing Fan Pulley 1) Straig hten the l ock washer. R emove the fa n pu lley. (2) Removing Water Pump Shaft and Bearing Assembly 1) Remove th e snap pin.
  • Page 48   (3) Removing Seal Set 1) Remove the seal set. (1) Slinger (2) Seal set Removing Oil Pan, Oil Filter 1 1) Detach the oil pan. 2) Remove the oil filter 1. Be careful of the 0-ring. Removing Connecting Rod 1) Detach the connecting rod bolt.
  • Page 49   Removing Piston 1) Drive out the piston to the cylinder head side with a hammer grip. 2) After driving the piston out, attach a tag to each piston to indicate its number. (A) Markings on the piston head [V1902-B] (01402-BJ A069F002 Removing Piston Ring...
  • Page 50 • Line u p the hole on the bearing case with that on the crankcase, then tighten bearing case bolts 2. Model Serial Number Tightening Torque Remarks D1102-B "" 38579 D1302-B "" 33413 63.7 to 68.6 N,m 01402-B ,..., 43733 Bolt and 6.5 to 7.0 kgf ,m...
  • Page 51 ·1i? ) • Be sure to install the side metal with its oil groove (2) facing outward. Model Serial Number Tightening Torque Remarks D1102-B -38538 D1302-B -33385 29.4 to 34.3 N m Bolt and D1402-B -43007 3.0 to 3.5 kgf·m...
  • Page 52   3.SERVICING Checking Compression Pressure 1) ) Warm u p the engine. 2) R emove the ai r cleaner a nd th e m uffler. Remove the nozzl e hol ders from al l the cy l i nd ers. Attach compression tester to the cyl i nder to be measu r- 5) R u n the engine wi th the starter at 200 to 300 mi n-1{rpm)
  • Page 53   Checking Distortion of Cylinder Head Surface 1 ) ) Clea n the su rface of the cyl i nder head. 2 ) Pu t a straigh t edge on the fou r sides and d iagonal l i nes of the cy l i nder head to check the straigh tness of the su r- face, as shown at the left.
  • Page 54   Checking and Refining Valve Seat Width 1) Clean the val ve seat su rface. 2) Measu re the width of the seat usi ng a set of vern ier cal i pers. 3) Appl y red lead on the val ve to check if the seat is scratch- ed or not.
  • Page 55   Checking Free Length of Valve Spring 1) Measu re the spring with a set of vern ier cal i pers. 2) I f the measu rement exceeds the allowa ble l i m i t, replace the val ve spring. 41.7 to 42.2 mm 1.6417 to 1.6614 ..--...
  • Page 56   Cli) -m Checking Oil Clearance between Rocker Arm Shaft and Bushing 1) Measure the inside diameter of the rocker arm bushing. 2) Measure the rocker arm shaft diameter. Calculate the clearance value. 3) If the clearance exceeds the allowable limit, replace. C 019 F023 Cli)-(11) Checking Oil Clearance between Rocker...
  • Page 57   KiSC issued 09, 2007 A  ...
  • Page 58   Adjusting Valve Clearance 1) Remove the cylinder head cover. 2) Turn the flywheel and align the 1TC or 1- 4TC mark with the projection in the window on the flywheel housing to position the 1st cylinder at the top dead center during comPfession.
  • Page 59 ,30psi). 2) How to clean by using solution: (0.03 Add 15 g lb.) Kubota genuine element detergent to (0.26 1 liter gal.) water. Let the element soak in the solution for 15 minutes and then wash it well in the solution.
  • Page 60   Checking Fuel·Tightness of Nozzle Valve Seat ) Appl y pressu re 980.6 k Pa. {10 kgf /cm 142.2 l b./sq.i n.) lower than the open i ng pressu re. Af ter keepi ng the nozzle u nder the specif ied pressu re for 10 seconds, check to see that f uel does not lea k from the nozzle val ve seat.
  • Page 61   Checking Fuel-Tightness of Fuel Injection Pump Plunger 1) ) Attach a pressu re ga uge to the pu mp. Rotate th e f l ywheel to i ncrease the pressu re to 58.8 MPa. (600 kgf /cm 8532 l b./sq.i n.) . Al ign the pl u nger wi th the top dead center.
  • Page 62   Checking and Adjusting Injection Timing 1) Remove the injection pipes. 2) Set the speed control lever to maximum fuel discharge position. Turn the flywheel couterclockwise (facing flywheel) until the fuel fills up to the hole of delivery valve holder for 1st cylinder. Turn the flywheel further and stop turning when the fuel begin to flow over, to get the present injection timing.
  • Page 63   Checking Oil Clearance of Camshaft 1 ) Measure the camshaft bearing in the crankcase with a inside micrometer. 2) Measure the camshaft journal with a outside micrometer. Calculate the clearance. 3) If the measurement exceeds the allowable limit, replace the camshaft.
  • Page 64   Checking Gear Backlash ) I nstall a lever-type i ndicator between gear teeth. Clamp one gea r, rotate the other, and measu re the back- lash . Replace if the measu rement exceeds the al l owable l i m i t. Testing Oil Pressure 1) Detach the oi l swi tch and attach a pressu re gauge.
  • Page 65   (2) Checking Radial Clearance between Oil Pump Outer Rotor and Body 1) I nsert a feeler gauge i nto the gap between the body and the ou ter rotor. I f the measu rement exceeds the al l owa ble l im i t, replace. Ol 9 F049 (3) Checking End Clearance between Rotor and Cover...
  • Page 66   Checking Inside Diameter of Piston Bosses 1) Measure the piston pin hole with an inside micrometer. 2) If the measurement exceeds the allowable limit, replace it. 23.053 mm 0.9076 in. C01 9 F052 Checking Clearance between Piston Pin and Rod Small-End Bushing 1) Measure the piston pin with an outside micrometer.
  • Page 67   Checking Side Clearance of R ing in Groove 1) Remove the piston ri ng from the piston. Place the ri ng i n its groove as is shown at lef t, and measu re the cleara nce. I f the measu rement is not wi th i n the reference val ue, replace the ri ng.
  • Page 68   Check ing Oil Clearance between Crankshaf t Journal and Crankshaf t Beari ng 1 1) Measure the crankshaft journal (on the side of the crank- shaft bearing with an outside micrometer. Measure the crankshaft bearing with an inside micro- meter.
  • Page 69   Check ing Oil Clearance between Crankshaf t Journals and Crankshaf t Beari ng 2 1) ) Paste a press gau ge wi th grease on the cran kshaft bea ri n g 2. Tigh ten the beari ng case onto the cran k jou rnal to the specif ied torq ue N- m., kgf - m.,...
  • Page 70   Check ing Oi l Clearance between Crank Pi ns and Crank Pin Bearings 1) Paste a press gauge with grease on the c rank pin bearing. Tighten the connecting rod onto the crank pin to the (36.3 41.2 specified torque N-m., kgf,m., 26.8 to 30.4 lb.ft.)
  • Page 71   Checking End Play of Crankshaft 1) Move the crankshaft to the crank gear side. 2) Set a dial gauge on the crankshaft. 3) Push the crankshaft toward the flywheel and measure the clearance. 4) If the measurement exceeds the allowable limit, replace the side metal with oversize one.
  • Page 72   Crankshaft Sleeve Wear ( ,) 1) ) Measu re the wear of the cra n ksh af t sl eeve usi ng a su rface rough ness tester. I f the m easu remen t exceeds the al l owabl e l i m i t, repl ace the cra n kshaf t sl eeve.
  • Page 73 (A) Measuring points of cylinder liner hone it. ( B) 2) Middle 3) Bottom (Skirt) Reference value Allowable limit Model 76.000 to 76.019 mm D1102-B V1502-B 2.9921 to 2.9929 in. D1302-B 82.000 to 82.022 mm +0.15 mm V1702-B 3.2283 to 3.2292 in. +0.0059 in.
  • Page 74   Testing Water Tightness of Radiator 1 ) ) Pou r the specified am ou n t of water i nto the radi ator. Start engi ne wa rm-u p. Attach a radiator tester. I ncrease water pressu re to the specified pressu re 88.3 kPa.
  • Page 75   Section N 1. TROUBLESHOOTING ...................... 72 2. ALTERNATOR AND REGULATOR Checks ............................76 Disassembl y and Reassembly ....................80 ..........................81 Servici ng 3. STARTER AND GLOW PLUG Checks ..........................85 Diassembly and Reassembly ....................88 Servicing ........................92 KiSC issued 09, 2007 A  ...
  • Page 76   1. TROUBLESHOOTI NG Charge warni ng lam p does not go off . --1-.-c )1- - ------ Charge warning lam p di m. Al ternator r u ns normal l y. ( t'ge warning lam p goes) .-- - - - - - - (Slow speed.
  • Page 77   )1-------   KiSC issued 09, 2007 A...
  • Page 78   Fa ulty alternator. Fa ul ty regulator. Chargi ng current too low.   Fa ul ty battery. Cha rgi ng current normal.   Al ternator speed too sl ow.   Extra el ectrica l loads (such as l amp) i nstal led. KiSC issued 09, 2007 A  ...
  • Page 79   SI ow engine speed. Not mesh ing sound from pi nion and n ng gea r )1 - - ------------------- repeatedl y ( Pinion shifts al l. Does not tu rn )1--- ( Turns red quickl y...
  • Page 80   KiSC issued 09, 2007 A  ...
  • Page 81   Reference   Over-running clutch slips. Poor contact of contact plate. 85,86 Faulty starter. 92, 94 Poor contact between brush and commutator. 85,86   Armature and field coil shorted. 93. 94 95,96 Bearing worn.   Main switch faulty. 85.86 Faulty magnet switch. Pinion does not pop out by the attraction force of magnet switch.
  • Page 82   2.ALTERNATOR AND REGULATOR Checking Sequence If the charging system is malfunctioning, check as follows to find the cause. ( B) Coupler voltage check (2) ==1- (C) No load testing of alternator Rotor coil, slip ring and brush (3) - { D) (A) Output current check (1) { E) Cut-in voltage check (5) check (4)
  • Page 83   No- Load Testing of Alternator 1) Remove the al ternator's coupl er, connect the al ternator's term i nal to B termi n al, and grou nd E termi nal to the body. 2) Con nect a vol tmeter across B termi n al a nd the grou nd. 3) Start the engine and speed u p the alternator to the specif i- ed rate 1300 Next, tu rn the mai n switch off ,...
  • Page 84   Checking No-Load Regulating Voltage 1) ) Con nect a vol tmeter across the alternator's B termi nal and the ground. 2) Start the engi ne, speed u p to a rate (a pprox. 1300 min- where the alternator is self-excited, a nd d iscon nect (rpm)) the battery's negative cable.
  • Page 85   Checking Test Terminals L-E/N-E/B-E/B-L 1) Test the termi n als L-E, N-E, 8-E a nd 8-L with the same method as above. • R esista nces of regu lator The nomi na l resista nces between term i nals of t he reg u lator a re given below for reference.
  • Page 86   Removing Pulley 1) Clamp the shaft with a hexagonal wrench and remove the nut.· 2) Remove the pulley. 3) Remove the fan. Removing Drive Side End Frame 1) Remove the three through bolts. 2) Remove the drive end frame. ( Note for reassembli ng) •...
  • Page 87   Removing Rectifier 1) Remove the n uts. Remove the end cover. Remove the rectif ier. (Note for reassembling) • Make su re the i nsu l ation washe r on the posi tive d i ode holder. Insulation washer Positive diode holder Checking and Refining Slip R ing 1) ) Check to see if the sl i p ri ng is flawed.
  • Page 88   Checking Rotor Coil Resistance 1) ) Measu re the resistance across the sl i p ri ngs. 2) I f the measu rement is above or u nder the reference val ue, repl ace. Grounding of Rotor Coil 1) Check conduction across the sl i p ri ng and core. 2) I f cond uctin g, repl ace.
  • Page 89   Checking Startor Coil Breakage 1) Check conduction across each leads of the stator coil. 2) If not conducting, replace. • Stator coil C022F045 Grounding of Stator Coil 1) Check conduction across the stator coil's terminal and core. 2) If conducting, replace. Should not be cor1du1ctEtd Checking Positive Diodes 1) Check the conduction across each M6 screw and coi I...
  • Page 90   Checking Negative Diodes Check the conduction across each M5 screw and coil connecting terminal (outside). 2) If any diode is faulty, replace its whole negative diode assembly. (Important) sensi- • When reassembling, remember that diodes are very tive to heat. Reference value If the ohmmeter indicates a specified value when the positive probe is applied to the coil connecting terminal and the nega-...
  • Page 91   J.S TARTER AND GLOW PLUG Checking Sequence If the starter system malf u nct ions, do the following checks to l ocate the cause: - -( B) Battery term i nal check (A) Check the circu it ----- '-----(C) Wi ri ng check Motor test ( 2).
  • Page 92   Motor Test 1) Remove the connecti ng leads from the starter's C terminal and connect them directly to the battery's posi tive termi nal. Then con nect the battery's negati ve term inal to the starter body. 2) If the starter ru ns n ormall y, the magnet switch is defec- tive;...
  • Page 93   (2) Holding Coil (Retention Test) 1) Appl y 1/2 the rated vol tage (approx. 6V) across the S term i nal and the body, push the pl u nger i n by hand, and then release it. 2) If the pl u nger stays attracted, the holdi ng coil is good; if not, it is defecti ve.
  • Page 94   • MAGNET SWITCH TYPE STARTER Removing Magnet Switch 1) Remove the connecti ng lead . 2) Remove the set screws. 3) Detach the magnet switch l ifti ng i t u p wh i l e taki ng care th at it d oes not contact the d ri ve lever. Removing Armature Brake 1) Remove the end frame cap.
  • Page 95   Removing Voke 1) ) Draw out the yoke from the d rive end frame. (Note for reassembling) • Take care for yoke knock pin. Removing Armature 1) Rem ove the set bol t from the d ri ve lever. 2) Draw out the a rmatu re from the d ri ve end frame.
  • Page 96   • REDUCTION TYPE STARTER Removing Motor 1) Discon nect the connecti ng l ead . 2) Remove the th rough bol ts. 3) Remove the motor un it. Removing Brush Holder 1) ) Release the spri n g and d raw the brush out from the holder. Remove the brush holder.
  • Page 97   Removing Drive End Frame 1) Remove the drive end frame. 2) Remove the gears (drive pinion, idler gear) and clutch. Removing Plunger 1) Remove the end cover from the magnet switch. 2) Draw the plunger out. 3) Remove steel balls. KiSC issued 09, 2007 A  ...
  • Page 98 3) If the com m utator diameter m ust be grou nd to below the al lowable l im i t, replace it. Commutator diameter Model Reference value Allowable limit 32.7 32.5 D1102-B D1302-B 1.2874 1.2795 D1402-B V1502-B 30.0 29.0 V1702-B 1.1811...
  • Page 99   Grounding of Armature Coil 1 ) Check conduction across com mutator a rmatu re shaft. I f cond ucti n g, repl ace. Checking Armature Flexure 1) Measu re the amoun t of flexu re; i f the measu remen t exceeds the reference val ue, replace.
  • Page 100 I f wear exceeds the al l owable l i mi t, repl ace. • Starter brush dimensions ,;"''   Thickness Model Length Width C022F059 7 mm 19 mm 12 mm D1102-B 0.7480 in. 0.4724 in. 0.2756 in. D1302-B D1402-B 8 mm V1502-B 19 mm 25 mm V1702-B 0.7480 in.
  • Page 101   Grounding of Brush Holder 1) Check the insulation of the positive brush holder. 2) If the insulation is defective, replace. Checking Clutch 1) Check to see if the clutch gear is worn or damaged. 2) Check to see if the gear locks in the driving direction and rotates smoothly in reverse.
  • Page 102 I f the ga p exceeds the allowa ble l i mi t, use an u ndersi ze bush.   D1102-B, D1302-B • Dia s of 12.5mm, 0.4921 in. Drive shaft dia.
  • Page 103   Section SERVICE DIRECTIONS Service Di rections ........................... 98 Bolt Torques .......................... 102 KiSC issued 09, 2007 A  ...
  • Page 104   D1402-B V1502-B V1702-B V1902-B D1102-B D1302-B CYLINDER HEAD Distortion of cylinder head surface 0.05 mm (0.0020 in.) 1.30 to 1.60 mm (0.0512 to 0.0630 in.) Thickness of gasket 0.2 mm (0.0079 in.) Thickness of gasket shims 0.7 to 0.9 mm (0.0276 to 0.0354 in.) Top clearance  ...
  • Page 105   D1102-B D1302-B D1402-B V1502-B V1702-B V1902-B CAMSHAFT O.D. of camshaft bearing journal 39.934 to 39.950 mm ( 1.5722 to 1.5728 in.) I.D. of camshaft bearing 40.000 to 40.025 mm ( 1.5748 to 1.5758 in.) ( R.V.) 0.050 to 0.091 mm (0.0020 to 0.0036 in.)
  • Page 106   D1102-B D1302-B D1402-B V1502-B V1702-B V1902-B     CRANKSHAFT R.V.: Reference Value A.L.: Allowable Limit     ( R.V.) 0.02 mm (0.0008 in.) Crankshaft alignment ( A.L.) 0.08 mm (0.0031 in.)         0.D. of crankshaft journals 51.921 to 51.940 mm (2.0441 to 2.0449 in.)
  • Page 107   V1902-B V1702-B D1302-B D1402-B V1502-B D1102-B RADI ATOR Opening pressure of cap 88.3 kPa. (0.9 kgf/cm 12.8 lb./sq. in.) Test pressure 88.3 kPa. (0.9 kgf/cm 12.8 lb./sq. in.) THERMOSTAT (beginning) 80.5°C to 83.5°C (176.9°F to 182.3°F) Opening temperature  ...
  • Page 108   Bolt Torques Material Grade Standard Bolt Special Bolt Special Bolt Nominal Dia. SS41, S20C S43C, S48C (Refined) SCR3, SCM3 (Refined) 1---- 9.3 N·m 9.8 - 11.3 N-m 12.3 14.2 N·m 0.95 kgf,m 0.80 1.00 1.15 kgf-m 1.25 1.45 kgf.m 5.8 - 6.9 lb.ft.
  • Page 109   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 2007. 09, S, T, EI, e Code No.9Y011-02600...

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