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Kubota D1102-B User Manual

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

Table of Contents

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Kubota D1102-B Specifications

General IconGeneral
Engine ModelD1102-B
Number of Cylinders3
Displacement1.123 L
AspirationNatural
Fuel SystemDirect Injection
Starting SystemElectric Starter
Type4-cycle, water-cooled, diesel
Bore x Stroke78 mm x 78.4 mm
Compression Ratio23:1
Lubrication SystemForced lubrication
Cooling SystemWater-cooled
Power Output18.5 kW (24.8 HP) @ 2800 rpm

Summary

Section I: Specifications and Performance Curves

D1102-B Specifications

Detailed specifications and performance curves for the D1102-B engine.

D1302-B Specifications

Detailed specifications and performance curves for the D1302-B engine.

D1402-B Specifications

Detailed specifications and performance curves for the D1402-B engine.

V1502-B Specifications

Detailed specifications and performance curves for the V1502-B engine.

V1702-B Specifications

Detailed specifications and performance curves for the V1702-B engine.

V1902-B Specifications

Detailed specifications and performance curves for the V1902-B engine.

Engine Dimensions (D-Series)

Physical dimensions for D1101-B, D1302-B, D1402-B engines.

Engine Dimensions (V-Series)

Physical dimensions for V1502-B, V1702-B, V1902-B engines.

Section II: General Description

Engine Features Overview

General features and technologies of Kubota diesel engines.

Engine Components

Details on cylinder block, head, valves, piston and rings.

Lubrication System

Description of the engine's lubrication system.

Cooling System

Description of the engine's cooling system.

Fuel System

Details on fuel filter, pump, injection pump, nozzle, and governor.

Electrical System

Details on cranking and charging systems.

Section III: Engine

Troubleshooting Engine Issues

Guide to identifying and resolving engine problems.

Engine Disassembly and Reassembly

Procedures for disassembling and reassembling engine components.

Cylinder Head Cover Removal

Steps to remove the cylinder head cover.

Alternator and Fan Belt Removal

Steps to remove the alternator and fan belt.

Rocker Arm and Push Rod Removal

Steps to remove rocker arms and push rods.

Cylinder Head Removal

Procedures for removing the cylinder head.

Valve Disassembly

Steps for disassembling valves, springs, and retainers.

Tappet Removal

Steps to remove engine tappets.

Nozzle Holder, Pipe & Manifold Removal

Steps for removing nozzle holder, injection pipe, and inlet manifold.

Nozzle Holder Disassembly

Steps to disassemble the nozzle holder.

Starter Removal

Steps to remove the starter motor.

Injection Pump Cover Removal

Steps to remove the injection pump cover.

Injection Pump Removal

Procedures for removing the injection pump.

Gear Case, Timing Gear, Camshaft, Oil Pump Disassembly

Procedures for disassembling gear case, timing gear, camshaft, and oil pump.

Governor Spring Detachment

Steps to detach the governor springs.

Speed Control Plate Removal

Steps to remove the speed control plate and governor spring.

Start Spring Detachment

Steps to detach the start spring from the gear case.

Fan Drive Pulley Removal

Steps to remove the fan drive pulley and key.

Gear Case Assembly Removal

Steps to remove the gear case assembly.

Crankshaft Collar and Oil Slinger Removal

Steps to remove crankshaft collar, O-ring, and oil slinger.

Idle Gear and Camshaft Removal

Steps to remove idle gear and camshaft.

Fuel Feed Pump Removal

Steps to remove the fuel feed pump.

Fuel Camshaft and Fork Lever Holder Removal

Steps to remove fuel camshaft and fork lever holder.

Crank Gear Removal

Steps to detach the crank gear.

Oil Pump Removal

Steps to detach the pump drive gear and oil pump.

Thermostat and Water Pump Disassembly

Procedures for thermostat and water pump disassembly.

Thermostat Removal

Steps to remove the thermostat cover and thermostat.

Water Pump Removal

Steps to detach the water pump from the gear case.

Water Pump Disassembly

Steps for disassembling the water pump.

Piston and Crankshaft Procedures

Procedures related to piston and crankshaft.

Oil Pan and Oil Filter Removal

Steps to detach the oil pan and remove the oil filter.

Connecting Rod Removal

Steps to detach connecting rod bolts and remove the cap.

Piston Removal

Steps to drive out the piston and tag it.

Piston Ring Removal

Steps to remove piston rings and piston pin.

Flywheel Removal

Steps to detach flywheel bolts and remove the flywheel.

Bearing Case Bolt Removal

Steps to detach bearing case bolts.

Bearing Cover Removal

Steps to remove bearing cover bolts and the cover.

Crankshaft Removal

Steps to remove the crankshaft.

Bearing Case Removal

Steps to remove main bearing case assemblies.

Engine Servicing Procedures

Detailed steps for servicing engine components.

Compression Pressure Check

Procedure to check engine compression pressure.

Cylinder Head Surface Distortion Check

How to check for distortion of the cylinder head surface.

Cylinder Head Surface Flaw Check

How to check for flaws on the cylinder head surface using spray.

Valve Seat Width Check and Refinement

How to measure and refine valve seat width.

Valve Recessing Check

How to measure valve recessing depth.

Stem Guide Clearance Check

How to measure stem guide clearance.

Valve Spring Free Length Check

How to measure the free length of valve springs.

Valve Spring Squareness Check

How to check valve spring squareness.

Valve Spring Tension Check

How to check valve spring tension.

Rocker Arm Shaft-Bushing Oil Clearance Check

How to check oil clearance between rocker arm shaft and bushing.

Rocker Arm Shaft-Rocker Arm Oil Clearance Check

How to check oil clearance between rocker arm shaft and rocker arm.

Top Clearance Check

How to check the top clearance of the piston.

Valve Clearance Adjustment

Steps for adjusting valve clearance.

Compression Release Adjustment

How to adjust the compression release mechanism.

Air Cleaner Element Cleaning

Procedures for cleaning the air cleaner element.

Nozzle Opening Pressure Test

How to test the opening pressure of the nozzle.

Nozzle Valve Seat Fuel-Tightness Check

How to check fuel tightness of the nozzle valve seat.

Nozzle Tip Fume Shape Check

How to check the fume shape across the nozzle tip.

Fuel Injection Pump Plunger Fuel-Tightness Check

How to check fuel tightness of the injection pump plunger.

Delivery Valve Fuel-Tightness Check

How to check fuel tightness of the delivery valve.

Injection Timing Check and Adjustment

How to check and adjust engine injection timing.

Fuel Filter Replacement

Steps for replacing the fuel filter.

Camshaft Oil Clearance Check

How to measure camshaft oil clearance.

Camshaft Alignment Check

How to check camshaft alignment using dial gauge.

Intake and Exhaust Cam Height Check

How to measure intake and exhaust cam heights.

Gear Backlash Check

How to check gear backlash using a lever-type indicator.

Oil Pressure Test

How to test engine oil pressure at idling and rated speed.

Oil Pump Rotor Lobe Clearance Check

How to check rotor lobe clearance in the oil pump.

Oil Pump Radial Clearance Check

How to check radial clearance in the oil pump.

Oil Pump End Clearance Check

How to check end clearance in the oil pump rotor and cover.

Oil Filter Check and Replacement

How to check and replace the oil filter.

Piston Boss Inside Diameter Check

How to measure the inside diameter of piston bosses.

Piston Pin-Rod Small-End Bushing Clearance Check

How to check clearance between piston pin and rod bushing.

Piston Ring Gap Check

How to measure the piston ring gap.

Ring Groove Side Clearance Check

How to check ring side clearance in the groove.

Connecting Rod Alignment Check

How to check connecting rod alignment.

Crankshaft Alignment Check

How to check crankshaft alignment.

Crankshaft Journal-Bearing 1 Oil Clearance Check

How to check oil clearance between crankshaft journal and bearing 1.

Crankshaft Journal-Bearing 2 Oil Clearance Check

How to check oil clearance between crankshaft journals and bearing 2.

Crankshaft End Play Check

How to check crankshaft end play.

Crankshaft Sleeve Wear Check

How to measure crankshaft sleeve wear.

Crankshaft Sleeve Replacement

Steps for replacing the crankshaft sleeve.

Cylinder Liner Wear Check

How to measure cylinder liner wear.

Fan Belt Tension Check and Adjustment

How to check and adjust fan belt tension.

Radiator Water Tightness Test

How to test radiator water tightness.

Radiator Cap Opening Pressure Test

How to test the opening pressure of the radiator cap.

Thermostat Operating Temperature Test

How to test the operating temperature of the thermostat.

Section N: Electrical System

Electrical System Troubleshooting

Guide to identifying and resolving electrical system problems.

Alternator and Regulator

Details on alternator and regulator checks, disassembly, and servicing.

Alternator Output Current Check

Procedure to check the alternator's output current.

Alternator Coupler Voltage Check

How to check the voltage of the alternator coupler.

Alternator No-Load Test

How to perform a no-load test on the alternator.

Rotor Coil, Slip Ring, Brush Check

How to check the alternator's rotor coil, slip ring, and brush.

Alternator Cut-In Voltage Check

How to check the alternator's cut-in voltage.

Alternator No-Load Regulating Voltage Check

How to check the alternator's no-load regulating voltage.

Regulator Checks

How to perform checks on the regulator.

Alternator No-Load Test Procedure

Detailed procedure for the alternator no-load test.

Regulator IG-F Terminals Check

How to check regulator terminals IG and F.

Regulator L-E/N-E/B-E/B-L Terminals Check

How to check regulator terminals L-E, N-E, B-E, and B-L.

Alternator and Regulator Disassembly and Reassembly

Procedures for alternator and regulator disassembly and reassembly.

Pulley Removal

Steps to remove the alternator pulley and fan.

Drive Side End Frame Removal

Steps to remove the drive side end frame.

Rotor Removal

Steps to draw out the alternator rotor.

Alternator and Regulator Servicing

Procedures for servicing the alternator and regulator.

Slip Ring Check and Refinement

How to check and refine the slip ring.

Rectifier Removal

Steps to remove the rectifier.

Rotor Coil Resistance Check

How to measure the resistance of the rotor coil.

Rotor Coil Grounding Check

How to check rotor coil grounding.

Brush Wear Check

How to check brush length and wear.

Starter Coil Breakage Check

How to check for starter coil breakage.

Stator Coil Grounding Check

How to check stator coil grounding.

Positive Diodes Check

How to check the positive diodes.

Negative Diodes Check

How to check the negative diodes.

N Terminal and Coil Connecting Terminal Conduction Check

How to check conduction between N terminal and coil connecting terminal.

Starter and Glow Plug

Details on starter and glow plug checks, disassembly, and servicing.

Battery Terminal Check

How to check battery terminals.

Wiring Check

How to check the starter system wiring.

Starter No-Load Test

Procedure to test the starter at no-load.

Motor Test

How to perform a motor test on the starter.

Magnet Switch Check

How to check the starter magnet switch.

Magnet Switch Pull-In Coil Test

How to test the pull-in coil (attraction) of the magnet switch.

Magnet Switch Holding Coil Test

How to test the holding coil (retention) of the magnet switch.

Glow Plug Check

How to check the glow plug resistance.

Starter and Glow Plug Disassembly and Reassembly

Procedures for starter and glow plug disassembly and reassembly.

Magnet Switch Removal

Steps to remove the starter magnet switch.

Armature Brake Removal

Steps to remove the armature brake components.

End Frame Removal

Steps to remove the starter end frame.

Brush Holder Removal

Steps to remove the starter brush holder.

Yoke Removal

Steps to draw out the starter yoke.

Armature Removal

Steps to draw out the starter armature.

Motor Unit Removal

Steps to remove the motor unit.

Reduction Type Starter Brush Holder Removal

Steps to remove brush holder from reduction type starter.

Reduction Type Starter Armature Removal

Steps to draw out armature from reduction type starter.

Drive End Frame Removal (Reduction Type)

Steps to remove drive end frame and gears.

Plunger Removal

Steps to remove plunger from magnet switch.

Starter and Glow Plug Servicing

Procedures for servicing the starter and glow plug.

Commutator Staining/Burning Check

How to check for commutator staining or burning.

Commutator Wear Check

How to measure commutator diameter and check wear.

Mica Undercut Check

How to check and rectify mica undercutting.

Armature Coil Grounding Check

How to check armature coil grounding.

Armature Flexure Check

How to measure armature flexure.

Armature Coil Short-Circuit Check

How to check for armature coil short-circuits.

Field Coil Breakage Check

How to check for field coil breakage.

Field Coil Grounding Check

How to check field coil grounding.

Brush Wear Check (Starter)

How to check starter brush wear.

Brush Spring Tension Check

How to measure brush spring tension.

Pinion Gap Check and Adjustment (Magnet Switch)

How to check and adjust pinion gap.

Brush Holder Grounding Check

How to check brush holder insulation.

Clutch Check

How to check the starter clutch gear for wear or damage.

Shaft and Bush Gap Check (Magnet Switch)

How to check gap between shaft and bush.

Bearing Check (Reduction Type)

How to check starter bearing operation.

Section V: Service Directions

Cylinder Head Specifications

Specifications for cylinder head distortion, gasket, clearance, and valves.

Valve Specifications

Specifications for valve seat width, recessing, clearance, springs, and rocker arms.

Camshaft Specifications

Specifications for camshaft journals, alignment, height, and backlash.

Cylinder Liner Specifications

Specifications for cylinder liner ID and wear.

Piston and Ring Specifications

Specifications for piston bosses, pins, rings, and connecting rod alignment.

Crankshaft Specifications

Specifications for crankshaft journals, bearings, pins, and end play.

Fuel Injection Specifications

Specifications for nozzle pressure and injection timing.

Oil Pump Specifications

Specifications for oil pressure and rotor clearances.

Bolt Torques

Torque specifications for various bolt sizes and grades.

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