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KUBOTA D1102-B WORKSHOP MANUAL

Quick Links
D1402-B
V1502-B
V1702-B
V1902-B
Table of Contents
Table of contents
Table of Contents
Specifications and performance curves
D1102-B
D1302-B
D1402-B
V1502-B
V1702-B
V1902-B
Dimensions
General description
FEATURE
Product view
Cylinder block
Cylinder head
Engine
Inlet and Exhaust Valves
Piston and Piston Rings
Cooling system
Lubrication system
Fuel Filter (Optional Part)
Fuel system
Fuel Injection Pump
Fuel Pump
Quantity control of fuel injection
Governor
Injection Nozzle
Cranking System
Electrical system
When Contact Plate Is Closed
When Key Switch is On
When Key Switch Is Released
Charging System
Regulator
Engine information
Engine does not start
Engine troubleshooting
Engine does not turn normally
Color of exhaust fumes not normal
Excessive lubricant consumption
Cylinder Head
Engine disassembly chart
Engine disassembly and reassembly procedure
Removing Cylinder Head Cover
Removing Alternator and Fan Belt
Removing Rocker Arm and Push Rod
Disassembling Valve
Removing Cylinder Head
Disassembling Nozzle Holder
Removing Nozzle Holder, Injection Pipe, Inlet Manifold
Removing Starter
Removing Injection Pump Cover
Removing Injection Pump
Detaching Governor Spring
Removing Speed Control Plate
Detaching Start Spring
Removing Fan Drive Pulley
Removing Gear Case Assembly
Removing Crankshaft Collar and Oil Slinger
Removing Idle Gear and Camshaft
Removing Fuel Camshaft and Fork Lever Holder
Removing Thermostat
Removing Crank Gear
Removing Oil Pump
Removing Water Pump
Disassembling the Water Pump
Removing Water Pump Shaft and Bearing Assembly
Removing Seal Set
Removing Oil Pan, Oil Filter
Removing Connecting Rod
Removing Piston Ring
Removing Piston
Removing Bearing Case Bolt 2
Removing Bearing Cover
Removing Flywheel
Removing Crankshaft
Removing Bearing Case
Cylinder Head Servicing
Checking Compression Pressure
Checking Distortion of Cylinder Head Surface
Checking Flaw of Cylinder Head Surface
Checking Stem Guide Clearance
Checking and Refining Valve Seat Width
Checking Valve Recessing
Checking Valve Spring Squareness
Checking Valve Spring Tension
Checking Free Length of Valve Spring
Checking Oil Clearance between Rocker Arm Shaft and Bushing
Checking Oil Clearance between Rocker Arm Shaft and Rocker Arm
Checking Top Clearance
Adjusting Valve Clearance
Adjustment of Compression Release
Testing Opening Pressure of Nozzle
Fuel System Servicing
Cleaning Air Cleaner Element
Checking Fuel Tightness of Nozzle Valve Seat
Checking Shape of Fume across Nozzle Tip
Checking Fuel-Tightness of Fuel Injection Pump Plunger
Checking Fuel-Tightness of Delivery Valve of Fuel Injection Pump
Checking and Adjusting Injection Timing
Replacing Fuel Filter
Checking Cam Heights of Intake and Exhaust
Checking Camshaft Alignment
Checking Oil Clearance of Camshaft
Timing Gear, Camshaft Servicing
Lubrication
Checking Gear Backlash
Testing Oil Pressure
Oil Pump (Rotor Type) - Checking Rotor Lobe Clearance
Checking Radial Clearance between Oil Pump Outer Rotor and Body
Checking End Clearance between Rotor and Cover
Checking and Replacing Oil Filter
Checking Piston Ring Gap
Checking Inside Diameter of Piston Bosses
Checking Clearance between Piston Pin and Rod Small-End Bushing
Piston, Connecting Rod Servicing
Crankshaft Servicing
Checking Side Clearance of Ring in Groove
Checking Connecting Rod Alignment
Checking Crankshaft Alignment
Check Oil Clearance between Crankshaft Journal and Crankshaft
Bearing
Checking Oil Clearance between Crank Pins and Crank Pin Bearings
Checking End Play of Crankshaft
Replacing Crankshaft Sleeve
Crankshaft Sleeve Wear
Cylinder Liner Servicing
Checking Wear of Cylinder Liner
Cooling System Servicing
Testing Water Tightness of Radiator
Testing Opening Pressure of Radiator Cap
Testing Operating Temperature of Thermostat
Electrical system information
Electrical system troubleshooting
Battery discharges quickly
Glow plug indicator does not turn red properly
Starter does not drive engine properly
Alternator and regulator checks
Checking Output Current
Checking Coupler Voltage
No- Load Testing of Alternator
Checking Rotor Coil, Slip Ring and Brush
Checking Cut-In-Voltage
Checking No-Load Regulating Voltage
Regulator - Checking Test Terminals IG-F
Checking Test Terminals L-E/N-E/B-E/B-L
Removing Rotor
Removing Pulley
Removing Drive Side End Frame
Electrical system disassembly and reassembly
Electrical system servicing
Removing Rectifier
Checking and Refining Slip Ring
Checking Rotor Coil Resistance
Grounding of Rotor Coil
Checking Brush Wear
Checking Positive Diodes
Grounding of Stator Coil
Checking Startor Coil Breakage
Checking Negative Diodes
Checking Conduction across N Terminal and Coil Connecting Terminal
Starter and glow plug checks
No-Load Testing of Starter
Motor Test
Magnet Switch
Holding Coil (Retention Test)
Checking Glow Plug
Removing Brush Holder
Removing Armature Brake/Removing End Frame
Removing Magnet Switch
Magnet switch type starter disassembly and assembly
Removing Voke
Removing Armature
Reduction type starter disassembly
Staining or Burning of Commutator
Checking Commutator Wear
Checking Mica (Undercut)
Checking Field Coil Breakage
Checking Armature Coil Short-Circuited
Checking Armature Flexure
Grounding of Armature Coil
Grounding of Field Coil
Checking Brush Spring Tension
Grounding of Brush Holder
Checking Clutch
Checking and Adjusting Pinion Gap (Magnet Switch Type)
Checking Gap between Shaft and Bush (Magnet Switch Type)
Checking Bearing (Reduction Type)
Service directions
Bolt Torques
 WORKSHOP MANUAL
DIESEL ENGINES

D1102-B,D1302-B,D1402-B,
V1502-B,V1702-B,V1902-B

KiSC issued 09, 2007 A

 INT RODUCTION
• This Workshop Manual provides general description, and comprehensive
information for servicing Kubota 01102-8, 01302-8, 01402-B, V1502-B,
V1702-B, V1902-B diesel engines. It consists of five sections as following:
• Section I"Specifications and Performance Curves" covers specif ications and
performance curves.
• Section II "General Description" covers newest information on the features,
functions and constructions of these Kubota engines.
• Section illand N "Engine" and "Electrical System" cover disassembling and
assembling procedures, checking and servicing instructions. In addition, a
troubleshooting chart with reference pages given is provided at the begin-
ning of each section, it helps you find out the cause of malfunction easily.
• 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.

KiSC issued 09, 2007 A

 CONT ENTS
Section I SPECIFICATIONS AND PERFORMANCE CURVES ................................. 3
Section II GENER AL DESCRIPTION .......................................................................... 13
1. Engine
2. Lubrication System
3. Cooling System
4. Fuel System
5. Electrical System
Section ill ENGINE ........................................................................................................ 27
1. Troubleshooting
2. Disassembly and Reassembly
3. Servicing
Section IV ELECTRICAL SYSTEM ............................................................................. 71
1. Troubleshooting
2. Alternator and Regulator
3. Starter and Glow Plug
Section V SER VICE DIRECTIONS.............................................................................. 97

2
KiSC issued 09, 2007 A
Section I

SPECIFICATIONS AND PERFORMANCE CURVES «

"
;;/.
;
" "' p

• D1102-B .................................................................................................................... 4
• D1302-B .................................................................................................................... 5
• D1402-B ......................................................................................................................... 6
• V1502-B .................................................................................................................... 7
• V1702-B ................................................................................................................. 8
• V1902-B .................................................................................................................... 9
• DIMENSIONS .................................................................................................................. 10

3 KiSC issued 09, 2007 A

 Section I

SPECIFICATIONS AND PERFORMANCE CURVES

• D1102-B

Specifications

Model D1102-B Maximum Bare Speed 3000 min·1(rpm)

Vertical, water-cooled, Minimum Bare Idling Speed 800 min1(rpm)
Type
4-cycle diesel engine Combustion Chamber Spherical Type
Number of Cylinders 3 Fuel Injection Pump Bosch K Type mini pump
Bore x Stroke mm (inch) Ji 76 x 82 L ( Ji 2.99 x 3.23 L) Governor Centrifugal Ball Mechanical Governor
Total Displacement cm3 (cu.in.) 1115 (68.04) Injection Nozzle DN 12 SD 12
14.3 kW / 2800 min·1(rpm) Injection liming 0.436 rad. (25'') before T.D.C.
DIN 6270-NA
(19.4 P.S./ 2800 min·1(rpm)) Injection Pressure 13.73 MPa (140 kgf/cm2, 1991 psi)
16.2 kW I 2800 min1(rpm) Compression Ratio 21
DIN 6270-NB
(22.0 P.S./ 2800 min·1(rpm)) Pressurized radiator (8.83 x 104 Pa, 0.9 kgf/cm2,
Cooling System
17.7 kW I 2800 min1(rpm) 12.8 psi) Forced circulation (with water pump)
DIN 70020
(24.0 P.S./ 2800 min·1(rpm)) Starting System Electric Starting with Cell starter (12 V, 1.0kW)
Brake H.P.
19.0 kW / 2800 min·1(rpm) Dynamo for Charging 12 V,300 W
SAE Gross H.P.
(25.5 H.P./ 2800 min1(rpm)) Fuel Diesel Fuel No.2-D
16.8 kW / 2800 min1(rpm) Weight (Dry) 146 kg (321.9 lbs.)
SAE Intermittent H.P.
(22.5 H.P./ 2800 min1(rpm)) Battery 12 V, 80AH, equivalent
14.5 kW I 2800 min1(rpm) Direction of Rotation Counter-clockwise from flywheel side
SAE Cont. H.P.
(19.4 H.P./ 2800 min·1(rpm)) Application General Power Source

Performance Curves

-·-· -· I -·---
Mr 7.0
.............. r-,....._
j r---- .... - - 6.5
--. MB r----

--
i-...
' .
r--.
-
r---1'-,...
I 6.0 1
1--.-- --t-.......... ...... r-,....., w
--A

--.. ._ 5 5 6
a::
-,_ 0

-
.,5.0

24 v.. . .
-·-j......-- -- ·•-·
·
L/v"
k'. -
(/)

/..... 1 ,,,.i..,.---
CL
a: 20
w .,v /V
s:
0 18 1--._._ >-·
I

v 1.,/VNB 1.,..--l.--"'
1--

ll.
v,
w
16
t:7' v .Y
C( L/ ,)-" _v NA

--
0
I 14 V I/ v
w
:.: 1 ?
v /
V' , ,_ 1--
. CI
I
V r.h
aIDi::< - ll.

-
10 I'--... 210
t'--,.
t--
.. b( Nr) _I...-
i.,...
200 ,:;:;

-+-- 190 2
1 400 1600 1800 2000 2200 2400 ?600 2800 1400 1600 1600 2000 2200 2400 2600 2800
ENGINE min-1(rpm) ENGINE tnin-1(rprn)

Note: Note:
Each per formance curves, obtained i n accordance with DIN 6270 Each performance curves, obtained in accordance with SAE J816b,
and DIN 70020, ar e corrected to 101kPa ( 760mmHg ) , and 20° C, are corrected to 101kPa ( 760mmHg ) , and 20° C, 60% humidity.
60% humidity.

4 KiSC issued 09, 2007 A

• 01302-B

Specifications
Model D1302-B Maximum Bare Speed 3000 min-1(rpm)
Vertical, water-cooled, Minimum Bare Idling Speed 800 min-1(rpm)
Type
4-cycle diesel engine Combustion Chamber Spherical Type
Number of Cylinders 3 Fuel Injection Pump Bosch K Type mini pump
Bore x Stroke mm (inch) ¢ 82 x 82 L ( ¢ 3.23 x 3.23 L) Governor Centrifugal Ball Mechanical Governor
Total Displacement cm3 (cu.in.) 1299 (79.27) Injection Nozzle DN 12 SD 12
17.3 kW I 2800 min-1(rpm) Injection liming 0.436 rad. (25') before T.D.C.
D1N 6270-NA
(23.5 P.S./ 2800 min-1(rpm)) Injection Pressure 13.73 MPa (140 kgf/cm2, 1991 psi)
18.8 kW I 2800 min-1(rpm) Compression Ratio 21
DIN 6270-NB
(25.5 P.S./ 2800 min-1(rpm)) Pressurized radiator (8.83 x 1a4Pa, 0.9 kgf/cm2,
21.0 kW I 2800 min-1(rpm) Cooling System
12.8 psi) Forced circulation (with water pump)
DIN 70020
(28.5 P.S./ 2800 min-1(rpm)) Starting System Electric Starting with Cell starter (12 V, 1.0kW)
Brake H.P.
22.4 kW I 2800 min-1(rpm) Dynamo for Charging 12 V, 300 W
SAE Gross H.P.
(30.0 H.P./ 2800 min-1(rpm)) Fuel Diesel Fuel No.2-D
20.1 kW I 2800 min·1(rpm) Weight (Dry) 147 kg (324.1 lbs.)
SAE Intermittent H.P.
(27.0 H.P./ 2800 min-1(rpm)) Battery 12 V, 80AH, equivalent
17.5 kW I 2800 min-1(rpm) Direction of Rotation Counter-clockwise from flywheel side
SAE Cont. H.P.
(23.5 H.P./ 2800 min-1(rpm)) Application General Power Source

Performance Curves

- 8.5 I I I I
GROSS TORQUE --
I I I

--· 6065
--- -
...... m

- --
M;-" 80 E r I r-i.....l I ...J
6, ,.c_
I -r--,..._ I
::.:: "i--1-.l r- I LL
7.5
!',,.., INTERMITIENT TORQUC r--... ......
UJ

-- ....... :) 55
MB 7.0 0 i--.... 0
i5
-- .. ._ --MA·
---- ""- ;::::--b,, --
0a:
6.5 ,-
""t-t--k 50
I-

LL
,._._..

.-
CONT TORQUE -r-- 45
30 r-,.. 6.0
-- - 30
28 , ,,,,, .,...,.......
--
v.. . . 28 I I I I I

26
.,. v"
" 26
GROSS 8 HP _i..--
v
I

., 1/..,.
v ... ./
(/)
Cl..
24 /1 ,,.. ·v _i.--1
Cl..
I24
•\ ..., B.
INTERMITIENr
a: 22 ,,/'
J
N _..,... ..... a:
UJ ...v.../ H Pi.-,....
UJ
?; V .,,,,,,, /
?;
0
22
/ / .... v
2UJ 20
/ / Cl..
UJ 20 // V
"NA -
18 / V / ..... (/)
er: 18 !/:V V a:
_
(/)
er:
0 / ,,/' V 0
I
.. /,,'./ ,..,,,,CONT _B H P
Cl..
I 16 -
a: 16 V
/ /, ,,
-- V I

--
UJ
UJ
-· I :.::
::.:: 14 L Ji ,./ '!)

--
<(
-· ·-· - ·--- 210
<(
a: 14 . ·- ··-·- 0.5
er: Cl.. V I I I I I a:i
Cl)
12
b( NF) _j.-
. - 200 di
..J
Cl)
12 FUL l
1
i
TER ITIENT) 0.45
I
1 90 LJ.J
:::i
0.4
LL LL

1400 1600 1800 2000 2200 2400 2600 2800 1400 1600 1800 2000 2200 2400 2600 2800
ENGINE min-1(rpm) ENGINE min-1(rpml

Note: Note:
Each performance curves, obtained in accordance with DIN 6270 Each performance curves, obtai ned in accordance with SAE J816b
and DIN 70020, are corrected to 101kPa ( 760mmHg ) , and 20"C, are corrected to 101kPa ( 760 mmHg ) , and 20° C, 60% humidity. '
60% humidity.

5 KiSC issued 09, 2007 A

• 01402-e

Specifications
Model D1402-B Maximum Bare Speed 3000 min-1(rpm)
Vertical, water-cooled, Minimum Bare Idling Speed 800 min-1(rpm)
Type
4-cycle diesel engine Combustion Chamber Spherical Type
Number of Cylinders 3 Fuel Injection Pump Bosch K Type mini pump
Bore x Stroke mm (inch) ¢ 85 X 82 L ( ¢ 3.25 X 3.23 L) Governor Centrifugal Ball Mechanical Governor
Total Displacement cm3 (cu.in.) 1395 (85.13) Injection Nozzle DN 12 SD 12
18.4 kW I 2800 miff1(rpm) Injection liming 0.436 rad. (25') before T.D.C.
DIN 6270-NA
(25.0 P.S./ 2800 miff1(rpm)) Injection Pressure 13.73 MPa (140 kgf/cm2, 1991 psi)
19.9 kW I 2800 min-1(rpm) Compression Ratio 21
DIN 6270-NB
(27.0 P.S./ 2800 min-1(rpm)) Pressurized radiator (8.83 x 104 Pa, 0.9 kgf/cm2,
Cooling System
22.4 kW I 2800 min-1(rpm) 12.8 psi) Forced circulation (with water pump)
DIN 70020
(30.5 P.S./ 2800 min-1(rpm)) Starting System Electric Starting with Cell starter (12 V, 1.4kW)
Brake H.P.
23.9 kW I 2800 min-1(rpm) Dynamo for Charging 12 V,300 W
SAE Gross H.P.
(32.0 H.P./ 2800 min·1(rpm)) Fuel Diesel Fuel No.2-D
21.3 kW I 2800 miff1(rpm) Weight (Dry) 148.2 kg (326.7 lbs.)
SAE Intermittent H.P.
(28.5 H.P./ 2800 min-1(rpm)) Battery 12 V, 110AH, equivalent
18.7 kW I 2800 min·1(rpm) Direction of Rotation Counter-clockwise from flywheel side
SAE Cont. H.P.
(25.0 H.P./ 2800 min-1(rpm)) Application General Power Source

Performance Curves

I
MF GROSS TORQUE
---,_ - 90
-+---k I I 65
-
- -
I r--1"-- - E 'f--+.....L. QJ

-
-i---
MB
-i--
..... 8.0 O>
ll:'.
60
.INTERMITIENT TORQUE'..... .......
w
- --. - --.I'--
r-- r--.. 7.0
0
:)
I I I I I
H---+-L
55
0
CI:
0 CONT TORQUE t-- .. 50
6.0 "'"

--
"'" 0.
45
I
a: 35
LJ.J
1--

LU
30
GROSS B H P
_.v
(/)
I I I / t "'-".._.
1 /1...--r--
CI:
25
'i..' t..- L, .
LU
ll:'.
<! v::V'f,\S""
20 I/ t:;,, \ oc
I
v;:v v CONT BH P
Q.
-j--
a:
....
v I

·+-+--,, ..
I 15
1--1--+-+---+ ·--+--+- +-+---+--l---l---<1---1---1--!----I- 210 g' I . 0.5 aJ
-
1--i--
T T
r-i_ ...- 200 FUEL [lTERMITIENT) 0.45 ....J
....J
H-f-1-::i=;ab;( N=F ).-+=,i-.-
- "' . ._ 190 0.4
l.l.. u.
1400 1600 1800 2000 2200 2400 2600 2800 1400 1600 1800 2000 2200 2400 2600 2800
ENGINE min-1(rpm) ENGINE min-1(rpm)

Note: Note:
Each perf ormance curves, obtained in accordance with DIN 6270 Each performance curves, obtained in accordance wi th SAE J816b,
and DIN 70020, are corrected to 101kPa (760mmHg ) , and 20°C, are corrected to 101kPa ( 760 mm Hg ) , and 20° C, 60% humidity.
60% humidity.

6 KiSC issued 09, 2007 A

• v1so2-e
Specifications
Model V1502 B Maximum Bare Speed 3000 min·1(rpm)
Vertical, water-cooled, Minimum Bare Idling Speed 800 min-1(rpm)
Type
4-cycle diesel engine Combustion Chamber Spherical Type
Number of Cylinders 4 Fuel Injection Pump Bosch K Type mini pump
Bore x Stroke mm (inch} ef, 76 X 82 L ( ef, 2.99 X 3.23 L} Governor Centrifugal Ball Mechanical Governor
Total Displacement cm3 (cu.in.) 1487 (90.74) Injection Nozzle DN 12 SD 12
19.1 kW I 2800 min-1(rpm) Injection liming 0.436 rad. (25'} before T.D.C.
DIN 6270-NA
(26.0 P.S./ 2800 min-1(rpm)) Injection Pressure 13.73 MPa (140 kgf/cm2, 1991 psi)
21.3 kW I 2800 min-1(rpm) Compression Ratio 21
DIN 6270-NB
(29.0 P.S./ 2800 min-1(rpm)) Pressurized radiator (8.83 x 104Pa, 0.9 kgf/cm2,
Cooling System
23.5 kW I 2800 min-1(rpm) 12.8 psi) Forced circulation (with water pump)
DIN 70020
(32.0 P.S./ 2800 min-1(rpm)) Starting System Electric Starting with Cell starter (12 V, 1.4kW)
Brake H.P.
25.4 kW I 2800 min-1(rpm) Dynamo for Charging 12 V, 300 W
SAE Gross H.P.
(34.0 H.P./ 2800 min-1(rpm)) Fuel Diesel Fuel No.2-D
22.4 kW I 2800 min-1(rpm) Weight (Dry) 175.7 kg (387.3 lbs.)
SAE Intermittent H.P.
(30.0 H.P./ 2800 min-1(rpm)) Battery 12 V, 110AH, equivalent
19.4 kW I 2800 min-1(rpm) Direction of Rotation Counter-clockwise from flywheel side
SAE Cont. H.P.
(26.0 H.P./ 2800 min-1(rpm)) Application General Power Source

Performance Curves

----
I I I I I
GROSS TORQUE
M, I -........L I I I 70

·-· ,-..i--
9.0

&,
INTERMITT
-t-+-[ -,-_ ,..._
ENT r- ,.._
-- i::::
- 60

--·-
r-.,. 8.0 TORQUE --..
ti:
,..._ MA r-- i-- 70 ""::,
LU
CONT. TORQUE -r-r-..... fiO w

32 -0 34
--
=>
0

I -t-
a:
30 >-··· 1--+-.... +--
v
i..--'""' 0
I-
32 -GROSS
I I .;., v I/
B i::
V
0
I-

.,...v 1 .-1.--" 30 _i--

28 N
V 1...,.,-"'
,,VNe ........... V 28 V v-
26 1 v / / ""'INTERMITTENT
UJ
a. 1 _...-
...... a.
I 26 / ,,V
a: 24 ··- - BHP.---·-
v.... -
/ V CX:

--
LU LU
-- ,,/ /
/ V/ y ./ ?;;: 24

_
22 ,,/" .v
a. /_
/ c.V.,,e".'.'.'. ...t:-J-"-+ t;J .,...v
LU
22 V /
:?a

/ r --
a:
0 / ..
·- ,/ ,,V V ex:
I 18 / /
§? 20 V,,/ -7coNT BHP "" - I
LU
V /
LU
V 0:
a: ;:; 18 / I
16 I ex:
V (/)
I I I ... --
al
ca 16 -
14 2 10 '!- l7 05 ':9
r-_ b(NF ) i-- i--- 200 _,
0\

LU
14 .. FUEL (INTERMITTENT) '- 045 .J
LU
I90 ::,
u.. 04 i;l
1400 1600 1800 2000 2200 2400 2600 2800 1400 1600 1800 2000 2200 2400 2600 2800
ENGINE min"1(rpm) ENGINE rni11-1(rpm)

Note: Note:
Each performance curves, obtained in accordance with DIN 6270 Each performance curves, obtained in accordance with SAE J816b,
and DIN 70020, are corrected to 101kPa ( 760mmHg ) , and 20°C, are corrected to 101kPa ( 760 mm Hg ) , and 20° C, 60% humidity.
60% humidity .

7 KiSC issued 09, 2007 A

• V1702-B

Specifications

Model V1702-B Maximum Bare Speed 3000 min-1(rpm)

Vertical, water-cooled, Minimum Bare Idling Speed 800 min-1(rpm)
Type
4-cycle diesel engine Combustion Chamber Spherical Type
Number of Cylinders 4 Fuel Injection Pump Bosch K Type mini pump
Bore x Stroke mm (inch) ¢ 82 X 82 L ( <h 3.23 X 3.23 L) Governor Centrifugal Ball Mechanical Governor
Total Displacement cm3 (cu.in.) 1732 (105.69) Injection Nozzle DN 12 SD 12
22.8 kW I 2800 min-1(rpm) Injection liming 0.436 rad. (25'') before T.D.C.
DIN 6270-NA
(31.0 P.S./ 2800 min-1(rpm)) Injection Pressure 13.73 MPa (140 kgf/cm2, 1991 psi)
25.0 kW I 2800 min-1(rpm) Compression Ratio 21
DIN 6270-NB
(34.0 P.S./ 2800 min-1(rpm)) Pressurized radiator (8.83 x 1a4 Pa, 0.9 kgf/cm2,
Cooling System
27.9 kW I 2800 min-1(rpm) 12.8 psi) Forced circulation (with water pump)
DIN 70020
(38.0 P.S./ 2800 min-1(rpm)) Starting System Electric Starting with Cell starter (12 V, 1.4kW)
Brake H.P.
29.8 kW I 2800 min-1(rpm) Dynamo for Charging 12 V,300 W
SAE Gross H.P.
(40.0 H.P./ 2800 min-1(rpm)) Fuel Diesel Fuel No.2-D
26.9 kW I 2800 min-1(rpm) Weight (Dry) 177.1 kg (390.4 lbs.)
SAE Intermittent H.P.
(36.0 H.P./ 2800 min-1(rpm)) Battery 12 V, 110AH, equivalent
23.1 kW I 2800 min-1(rpm) Direction of Rotation Counter-clockwise from flywheel side
SAE Cont. H.P.
(31.0 H.P./ 2800 min-1(rpm)) Application General Power Source

Performance Curves

I I I I I I
MF
---
GROSS TORQUE- !---·-- 1---f--
1--1.- 1 -+-l I I
,-.
L1
80
r-..r-- H--l rt--._
- :
J3 ,-...
-1---
t--,.... i-.... co
r--,-......_ E I I
I I -,....... '- ' -,;
INTERMITTENT TORQUE
·I· ......... ,-.... ..... 70 >-
I

I
, A -t--,........._ 9 uJ I I I LL
w
r-r-- g .J. I . -::::-r--
:::J

----
·-·-
-!:::: II I
60 0
er:

H cmJT
1---t-- 1-- -···!-+--·
r: -r--
40 - -
8 2 ·r--- I I
2
36
v.... 40
I
r- t;;;;.a
..,...v I
I I
v" v
-- .,......
GROSS B.H P
'

N '..,..V _vJ.,.- 36
1/

--
n_ I .i..--
32
----
./,.; L--- I
,/ / ..... 11\11 1,,, ,1v
II
uJ
v" - _,..
II 32 I I '-N

/ uJ I I/ //
S: 28
uJ
g°: 24
y /
_,,,/
//
V
/
/v
NA
0
3:i
(/')
a:
28 ---
//
,,V:V
/ ......
_Y ..- I

0 / V v /.,,- I
I
vv 24
-H P- ....
---- ,-- II

:.V" LL I-
./" CON I.
-- w ...

=,l[ b( t
20 e--
) n_
.,: ::.::

--
I
II 20 I
CD 16 Cll
/,/ I
CD
1--- :
--
-? 0.5 ':J
... ---- 1
·-
?
16
l FUEL \ ll'< J t:r,rvrr r t:l'<-J [ .. ...- 045
1 0.4 ij:
1 400 1 600 1 800 2000 2ioo 2400 2600 2800 1400 1600 1800 2000 2200 2400 2600 2800
ENGINE min-11rpm) ENGINE min·1(rpm)

Note: Note:
Each performance curves, obtained in accordance with DIN 6270 Each perf ormance curves, obtained in accordance with SAE J816b
and DIN 70020, are corrected to 101kPa ( 760mmHg ), and 20° C, are corrected to 101kPa ( 760mmHg ), and 20° C, 60% humidity. '
60% humidity.

8 KiSC issued 09, 2007 A

• v1so2-e
Specifications
Model V1902-B Maximum Bare Speed 3000 min-1(rpm)
Vertical, water-cooled, Minimum Bare Idling Speed 800 min-1(rpm)
Type
4-cycle diesel engine Combustion Chamber Spherical Type
Number of Cylinders 4 Fuel Injection Pump Bosch K Type mini pump
Bore x Stroke mm (inch) q; 85 X 82 L ( q; 3.35 X 3.23 L) Governor Centrifugal Ball Mechanical Governor
Total Displacement cm3 (cu.in.) 1861 (113.57) Injection Nozzle DN 12 SD 12
24.3 kW I 2800 min-1(rpm) Injection liming 0.436 rad. (25) before T.D.C.
DIN 6270-NA
(33.0 P.S./ 2800 min-1(rpm)) Injection Pressure 13.73 MPa (140 kgf/cm2, 1991 psi)
26.5 kW I 2800 min-1(rpm) Compression Ratio 21
DIN 6270-NB
(36.0 P.S./ 2800 min-1(rpm)) Pressurized radiator (8.83 x 1Q4 Pa, 0.9 kgf/cm2,
30.2 kW I 2800 min-1(rpm) Cooling System
12.8 psi) Forced circulation (with water pump)
DIN 70020
(41.0 P.S./ 2800 min-1(rpm)) Starting System Electric Starting with Cell starter (12 V, 1.4kW)
Brake H.P.
32.1 kW I 2800 min·1(rpm) Dynamo for Charging 12 V, 300 W
SAE Gross H.P.
(43.0 H.P./ 2800 min-1(rpm)) Fuel Diesel Fuel No.2-D
28.7 kW I 2800 min-1(rpm) Weight (Dry) 178.2 kg (392.2 lbs.)
SAE Intermittent H.P.
(38.5 H.P./ 2800 min-1(rpm)) Battery 12 V, 110AH, equivalent
24.6 kW I 2800 min-1(rpm) Direction of Rotation Counter-clockwise from flywheel side
SAE Cont. H.P.
(33.0 H.P./ 2800 min-1(rpm)) Application General Power Source

Performance Curves

I I I I I I
- -
MF
- --r-- t-- ...._ 1
GROSS TORQUE 90

-
Me 1 T-t-

-
-i--,

MA -
1 r-+-L I- 80 cri
i--......
INTERMITIENT TORQUE r-. ,.'.;

--
r--i- LL.
-I L
70 w

-
:::J
45 CONT TORQUE- i-....
60
I-
8
40 i...,.- ..- 45
.,.. . . .v

-
N F,.V 40
-
_i,..-
GROSS. B.H.P:.,.,.....

w
Cl) 35
.,....r i....--
a.
J:
a: 35
J..,;f 1......
> ...v N a.v _1--"' UJ IX-.vt" -o·,>S
...Vj...A'. '\ L..,.,,...-
1........r
.,,,/' .... v
az
a:
w
(.)
30
I/ ....v y (/)
30
l/[/ ,-;; t L...-+-"'
V I/ l..-' N11 a: /_...V _1,.,1'"
I I
25
V ....v I/""" a:
....,",,V w
::.:
25
P' .v CONT. B.H.P J:
a:
LL. ri ;/
a: .,.v J: 20 J:
20 I/

-
ch Cil

-
210

i,......
b( N F) i-. ..- 200
Ol
..J
w
15
.... FUEL (INTERMITIENT) '--
0.5
0.45 LiJ
190 I 0.4 CT:
1400 1600 1800 2000 2200 2400 2600 2800 1400 1600 1800 2000 2200 2400 2600 2800
1
ENGINE min- (rpm) ENGINE min-1(rpm)

Note: Note:
Each perf ormance curves, obtained in accordance wi th DIN 6270 Each performance curves, obtained in accordance with SAE J816b,
and DIN 70020, are corrected to 101kPa ( 760mmHg ), and 20°C, are corrected to 101kPa ( 760 mmHg ), and 20° C, 60% humidity.
60% humidity.

9 KiSC issued 09, 2007 A

• 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- -
--
........................ i

4-M8 DEPTH 12 mm (0.47")

0073F013

10
KiSC issued 09, 2007 A
 (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
M8

0073F014

11 KiSC issued 09, 2007 A

12
KiSC issued 09, 2007 A
Section II

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 . . . . . . . . . . . . . . . . . . . . 20
1.2 Cylinder Head . . . . . . . . . . . . . . . . . . 16 4.3 Fuel Injection Pump . . . . . . . . . . . . . . 20
1.3 Piston and Piston Rings . . . . . . . . . . . . 17 4.4 Injection Nozzle . . . . . . . . . . . . . . . . . 22
1.4 Inlet and Exhaust Valves . . . . . . . . . . . 17 4.5 Governor . . . . . . . . . . . . . . . . . . . . . 22

2. LUBRICATION SYSTEM................................. 18 5. ELECTRICAL SYSTEM

5.1 Cranking System .......................................... 23
3. COOLING SYSTEM .......................................... 18 5.2 Charging System ............................................. 25

13
KiSC issued 09, 2007 A
FEATURE

0073FOI 5

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 and
limited noise.

14 KiSC issued 09, 2007 A

15 KiSC issued 09, 2007 A
 (A) Tunnel Cylinder Block 1-1 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.

\) .\, \:)
() C)
('.) \:)

" " "

0011 FOJ 2

(A) Cross-Faw Type Cylinder Head

(a)
1-2 CYLINDER HEAD
To prevent the eff ect of a i r ex pa nsi on d ue to exhausted heat,
cross-f low ty pe i n l et a nd exha ust ports are provided. The
K u bota 's excl usive spherical combustion cha m ber (e) cha nges
the entered a i r i nto a sw i rl i ng flow to i m prove combustion
and red uce f uel consu m pti on. I n add i ti on, the sheathed ty pe
gl ow pl ugs (c) perm i t easy a nd q u ick engi ne start, regard l ess
of weather cond i tion, even when the tem peratu re is -15°C
(5° F ) .
(a) Combustion Chamber
(b) Suction
(c) Exhaust

(c) (c) (c)

0011F014

(B) Combustion Chamber

(a) Nozzle Assembly

(bl (b) Nozzle Piece Gasket
(c) Glow Plug
(d) Cylinder Head
(e)
0011 F013 (e) Combustion Chamber

16
KiSC issued 09, 2007 A
 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; two com pression ri ngs a nd
(d) one oi l ri ng. Al l of them have d iff erent f u nct ions a nd sha pes.
¢> Be ca ref u l w hen reassem bl i ng.

(a) Plated Keystone Ring

(b) Undercut Ring
(c) Coil Expander Ring
(d) Taper and Inside Cut Ring
V1702-B Only I
[ Engine Serial Number : 37196 and beyond ,J

(A) Inlet and Exhaust Valve 1-4 INLET AND EXHAUST VALVES
Al I parts a re quenched a nd tempered to resist wear. For
enhanci ng the f ill i ng-u p of a ir i nto eng i ne, the i nl et va l ve
(a) head is bigger the exha ust ( h) one. To prevent the ca rbon
(b) ad hesion on exha ust va l ve stem, a "carbon-scra per" ( i ) is
(c) ------ prov ided at the l ower pa rt of ex ha ust val ve g u ide.
(d) -
--«-!

(e) --
(f )
(g)
(a) Valve Cap
(b) Valve Spring Retainer

0011 FOJ 9
(c) Valve Spring Collet
(d) Valve Spring
(e) Valve Stem Seal
(f ) Valve Guide
(g) Inlet Valve
(h) Exhaust Valve
(i) Carbon Scraper

17
KiSC issued 09, 2007 A
(A) Lubrication System
(i) 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
Im) the oil f ilter (a) , a nd the oi l is kept at 294 to 441 kPa (3.0 to
4.5 kgf/cm 2 , 42 to 64 psi) by a n oil pressure regulati ng va lve
(c) i nstalled i n the gear case. Then oi l flows towards the f i lter
ca rtridge where it wil l be f u rther f i ltered - To ensure the
suppl y ing of l u bricated oil, a by-pass valve (d) is prov ided,
the va lve opens when the f i lter element (e) is restr icted -.
From the f ilter cartridge, the pressured oil is then d istributed
i nto two parts: one pa rt wil l be f ed through cra nkshaf t
passage to the crank pi n bea ri ng a nd the other to the rocker
arm shaf t ( i) th rough the frame. Oi l then returns to oil pa n
by force of gravity.
A n oil pressure switch ( m) is provided on the way for watch-
i ng the oil pressure drop. The oil pressure switch can be con-
nected to the termi nals of the warni ng lamp on the hour-
meter u nit (optional part), the l ight wil l be l ight for warni ng
the operator if the oi l pressure drops below 50 kPa (0.5
kgf /cm 2 , 7 .1 psi) .
If the warn i ng la mp rema ins l ight wh i le engine is at normal
(o) operation, stop the engine im med iately a nd check the oil
pressure.
(a)
0073F017

(a) Oil filter (i) Rocker arm shaft

(b) Oil pump (j) Rocker-arm
(c) Pressure regulating valve {k) Push rod
(d) By-pass valve (I) Tappet
(e) Filter element (m) Oil pressure switch
(f) Crankshaft (n) Camshaft
(g) Piston (o) Oil pan
(h) Idle gear

The cool i ng system consists of a rad iator (optional part),

(A) Cooling System (g)
centrif uga l water pu mp, suction fa n and thermostat.
(a) The water flow is cooled th rough the rad iator core ( b) a nd
the fa n (c) set beh i nd the rad iator (a) pul ls cool i ng air
through the core to i mprove cool i ng.
The pump (d) sucks the cooled water, forces it i nto the
(b)
cy l i nder block (e) and draws out the hot water. Then the
cool i ng is repeated. F urthermore, to control tem perature of
water, a thermostat ( h) is provided on the way. When the
thermostat opens, t he water moves d i rectl y to rad iator, but
when it closes, the water moves toward the water pum p
th rough the by-pass ( i ) between thermostat and water pu mp.
The opening temperature of thermostat is about 82°C
(176.3°F).

0073F018

(a) Radiator (f) Cylinder head

(b) Radiator core (g) Water pipe
(c) Suction fan (h) Thermostat
(d) Water pump (i) By-pass
(e) Cylinder block

18 KiSC issued 09, 2007 A

(A) Fuel System In operation, fuel from the fuel
(a) (g)
(f ) tank (a) enters the filter (b),
(e) 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
(e), it is delivered to each injec-
tion nozzle (f), which atom-
iies and injects it into the com-
bustion chamber at the proper

- time and amount. Excessive

fuel from nozzles returns to
the fuel tank through fuel
overflow pipe (g).

OOJ1F035 (b) (c)

(a ) Fuel Tank (e) Injection Pipe

(b) Fuel Fiter (f ) Injection Nozzle
(c) Fuel Pump (g) Fuel Overflow Pipe
(d) Injection Pump

(A) Fuel Filter

(a)
4-1 FUEL FILTER (OPTIONAL PART)
For protecting injection pump and injection nozzles from
impurities, the fuel is sent through the filter before reaching
the fuel pump.
Fuel enters the filter, passes through the filter element (d)
circumference toward the center for filtering. The filteration
granular size is from 10 to 20µm (0.01 to 0.02mm).

0073F019

(a) Cock Body

(b) Retaining R i ng
(c) Filter Cup
(d) Element

19 KiSC issued 09, 2007 A

(A) Inlet Stroke (B) Discharge Stroke
4-2 FUEL PUMP
(a)
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) . F uel is sucked
on the downward stroke a nd d ischa rged on the u pwa rd
stroke.

0011F038 001 1 F039

(al From Fuel Filter (a) To Injection Pump
( bl Inlet Valve
(cl Outlet Valve
(di Diaphragm

(A) Fuel Injection Pump 4-3 FUEL INJECTION PUMP

The wel l-k nown Bosch K type m i n i pu m p is prov ided, it
f eatures h igh i njection q uality even at l ow eng i ne speed, a nd
the i njection ti m i ng could be cha nged easi l y by adjusti ng the
nu mber of shim.

(a) Delivery Valve Holder

(b) Delivery Valve
(cl Delivery Valve Spring
(d) Plunger Pump Element
(e) Cylinder Pump Element
(f ) Control Rack
(g) Tappet
(h) Plunger Spring
(i ) Air Vent Screw

0011 FO<il

20
KiSC issued 09, 2007 A
(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. 1)
(b)
2) As the ca mshaf t rotates, pl u nger moves u pward, the
(a) (c) stroke of f uel pressu ri zation begi ns. ( Fig. 2)
3) As the pl u nger moves u p, the pressu re i ncreases u nti l it
(d) opens the del ivery va l ue a nd sends the pressu ri zed f uel to
(f ) i nject ion nozzle th rough the i njection pi pe. ( Fig. 3)
4) Send i ng of f uel stops as soon as the control groove meets
(e) the f eed hol e. Fuel f l ows out th rough the pl u nger's center
hol e, control groove and feed hole, then backs to the f uel
Fig. 1 Fig. 2 cha m ber. As a resu lt, the pressu re fa l ls a nd the stroke is
com pleted. ( F i g. 4)

(A) Pressurization of fuel

(a) Delivery Chamber
(b) Delivery Valve
(c) Feed Hole
(d) Fuel Chamber
I (e) Plunger
Fig. 3 Fig. 4 (f ) Control Groove
0011F044

(A) Injection Control

Quantity control of fuel injection
1) No fuel
The f eed hole meets the control-groove before bei ng cl osed
by the pl u nger top. Th erefore, no f uel is pressu ri zed a nd
i njected. ( Fig. 1)
2) Partial fuel
Pl u nger rotates a certa i n a mou nt when the control rack is
moved i n the direction of the a r row. Ef f ective stroke A
mea ns the d ista nce wh ich the f eed hole is closed by the pl u n-
ger before meeti ng the control groove on th e pl u nger. There-
fore, f uel is i njected as mu ch as the amou nt of effective
stroke. (Fig. 2)
3) Maxim u m fuel
As the control rack moves the greatest possi ble a mou nt i n
the d i rection of the a rrow, the eff ective stroke A is max i-
mu m a nd the ma x i m u m a mou nt of f uel is i njected.( Fig. 3)

Fig. 1 Fig. 2

t (e)

KiSC issued 09, 2007 A

 (a) Control rack
(b) Feed hole
(c) Control groove
Fig. 3 (d) Effective Stroke
0011F045 (el Effective Stroke maximum

21

KiSC issued 09, 2007 A

(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 2 , 1990 to 2130 psi) , the pressu re over-
comes the cou nterforce of nozzl e val ve spri ng ( b) , and push
the val ve ( e) u p i nsta ntl y, the f uel is then i njected i n a pro-
per qua ntity i nto the swirl i ng a i r i n the combustion cha mber
(f ) for combustion. Add ition or red uction of sh i m ca n adjust
the openi ng pressure. A sh i m of 0.1 m m corresponds to
980 kPa ( 1O kgf /cm 2 , 142 psi) cha nge i n open i ng pressu re.

(f )

(a) Adjusting Washer

(b) Nozzle Spring
(c) Push Rod
(dl Nozzle Nut
(el Needle Valve
(f) Combustion Chamber
(gl Fuel Overflow Nipple
0011F046 (h) Fuel Overflow pipe

(A) Governor
4-5 GOVERNOR
The engi ne f eatu res K u bota's excl usive ba l l-ty pe va ria bl e
speed governor a nd a torq ue spr i ng is prov ided to i m prove
engi ne torq ue performa nce a nd to prevent engi ne from stal l-
i ng i n case of overload.
How it works:

When the speed control l ever is set at its ma x i mu m posit ion,

the governor spr i ng ( b) pul Is the control rack towa rd the
maxi mu m quantity th rough fork l evers 1 and 2 (e, f ). But as
the engine speed i ncreases, the governor bal ls (d ) on the ca m-
shaf t, by its centrif uga l force, move outwa rd a nd push back
the fork lever 1 a nd 2 th rough the governor sleeve ( g) . The
control rack position wil l be decided when the force created
by governor ba l l s eq ual s the cou nterforce of the governor
0073F020 spri ng.
As the engi ne speed d ecreases, the centrif uga l force d i m i n i-
shes a nd the ba l ls move i nwa rd. As a resu l t, the governor
(a) Injection pump (e) Fork lever 2
spr i ng tension pu l l s the control rack for i ncreasi ng the f uel.
(bl Goernor spring (f) Fork lever 1
Due to the ba la nce between spring tension a nd centr if uga l
(c) Torque spring (g) Governor sleeve
force of governor ba l ls, a near l y constant engi ne speed is
(d) Governor balls
obta i ned.

22 KiSC issued 09, 2007 A

(A) Electrical System
(b)

(g)

(h)

(c)

(e)
0 0 (a)

0073F021

(A) N-30 Construction

5-1 CRANK ING SYSTEM
li)
The cran ki ng system consists
of a battery of 12V, magnet
sta rter, glow pl ugs a nd a oi l
switch.
1 ) Starter
The magnet-switch ty pe starter
(a) is composed of two mai n
section.
The f i rst section converts ele-
ctrical energy i nto mechan ical
rotatio n to tu rn the engi ne
cran kshaf t. I t is composed of
(d)
the f ield coi l, armatu re, brush,
com mutator, pin ion, over ru n-
(el n i ng clutch, etc.
The second section al lows the
(f ) pi nion and f l ywheel to engage
together and cu rrent to f low
(g) throug the motor section. I t is
composed of the pu l l- i n coi l,
hold i ng coi l , pl unger, d ri ve
lever, contact plate, etc.
(v) (u) (t) ls)
0011?237

(a) Field Coil (I ) Magnet Switch

(b) Brush Spring (m) Pull-in Coil
(c) Brush Holder (n) Moving Core
(d) Brush (o) Drive Lever
(e) Commutator (p) Drive Spring
(f ) Through Bolt (q) Lever Set Bolt
(g) Pole Core (r) Bearing
(h) End Frame (s) Drive Side Housing
(i) Contact Bolt (t) Overrunning Clutch
(j) Contact Plate (u) Armature
(k) Holding Coil (v) Yoke

23 KiSC issued 09, 2007 A

(A) Starter Circuit (a) (b)

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.
At th is ti me, the pi n ion moves by the dr ive lever to engage
w ith the ri ng gea r.

(a) Battery (e) Spline Tube

(b) Starter Switch (fl Pinion
0011F174
(cl Ground (gl Ring Gear
(d) Return Spring (h) Operated by Lever

(A) When Contact Plate is Closed.

• When Contact Plate Is Closed:
When th e contact plate is closed , a la rge cu r rent flow th roug h
the motor section to generate a la rge mecha n ica l power
w hich tu rns the eng i ne cra nkshaft.
At th is time, the pi n ion is moved forward by the screw spl i ne
for more cont ct.
Since the pu l l-i n coi l ends a re short-ci rcu ited by the contact
plate, the pl u nger is hel d on l y by the force of the holdi ng
coi l.

0011F175

(A) When Key Switch is Released: • When Key Switch Is Released:

When the key sw itch is rel eased , a cu rrent flows i nsta nta ne-
ously throug h the pu l l-i n coi l i n the opposite d irection as
shown i n F ig. Therefore, the forces of th e hold ing coi l a nd
pu l l-in coi l are ba lanced. As a resu l t, t he pl u nger i s ret urned
by the retu rn spri ng. Si mu lta neousl y, the pi nion is dis·
engaged from the ri ng gea r, the contact plate is d iscon nected,
and the starter is prom ptl y stopped by the a rmatu re brake.

0011F176

(A) Construction of Bar Glow Plug

2) Glow pl ug

(a) (c) A glow pl ug is used for each pre-combustion cha mber of the

......f.l.,;J
cy l i nder head to make sta rti ng easier.

() (d)

(a) Insulating Powder (c) Heat Coil

0011F177 (b) Housing (d) Metal Tube

24 KiSC issued 09, 2007 A

(A) Alternator
5-2 CHARGING SYSTEM

(e) (f ) (g) (h) The chargi ng system consists of an

(I) AC a l ternator and a regu l ator
(option). The alternator generates
AC (Alternati ng Current) and the
regu lator converts AC i nto DC
( Di rect Cu r rent), also contra Is the
output voltage for cha rgi ng cu rrent
to the battery.
1) Alternator
The AC alternator prod uces h igher
voltage in slow speed, compa red
with DC dyna mo a nd cha rges more
current to battery even d u ri ng
engi ne id l i ng. The provided alter-
nator is an alternating cu rrent
generator contai n i ng a rectifier.
Al te rnati ng cu rrent is i nd uced i n a
stator coil by rotati ng mag netic
(a) (bl (c) (pl (j) (kl poles a rou nd the coi l. The alternat·
i ng cu r rent is then rectif ied i nto
0073F022 a d i rect cu rrent th rough diodes.

(a) Pulley (f) Armature (kl Cover (p) Bolt

(bl fan (g) Bearing (I I Holder
(c) Frame (hi Yoke (m) Brush
(di Bearing (ii Rectifier (nl Spring
(el Spacer (j) Frame (o) Insulator

2) R egulator (optional part)

The regu lator converts AC i nto DC, also regu lates the cha rg-
i ng vol tage. Si nce the al ternator speed is var ied by engi ne
speed va riation, the output vol tage from a l ternator va ries.
However, consta nt vol tage (1 2V ) m ust be su ppl ied to the
battery. That is the regu lator wh ich works to keep the cha rg-
i ng vol tage at 12V.

[Note]
• A regulator of 13.8V to 14.8V must be used.

(A) Regulator

(a) N terminal
(b) L terminal
(c) B terminal
(di F terminal
(e) IG terminal

0 (f) E terminal
(al (b) (cl (g) Control resistor
(h) Pressure coil
0073F023 (i) Voltage coil

25
KiSC issued 09, 2007 A
26 KiSC issued 09, 2007 A
Section Ill

1. TROUBLESHOOTING . . . . . . . . . . . . . . . 28 3. SERVICING
Cylinder Head . . . . . . . . . . . . . . . . . . • . . 49
2. DISASSEMBLV AND REASSEMBLY Fuel System ............................................................. 55
Cylinder Head . . . . . . . . . . . . . . . • .............. 35 Timing Gear, Camshaft .......................................59
Fuel Injection Nozzle . . . • ................................37 Lubrication ....................................................... 60
Gear Case, Timing Gear, Camshaft, Oil Pump . 39 Piston, Connecting Rod . . . . . . . . . • .............. 62
Crankshaft ...........................................................63
Thermostat, Water Pump ..................................... 43 Cooling System . . . . . • . . . . • . . . . . . . . • 70
Piston, Crankshaft . . . . . . . . . . . . . . . . . . 45 Cylinder Liner .......................................... 69

27 KiSC issued 09, 2007 A

1.TROUBLESHOOTI NG

Crankshaft does not turn.

No or small fuel injection

sounds.

Crankshaft turns.

Fuel injection sounds.

28 KiSC issued 09, 2007 A

 Reference

.---- Cran kshaft and cam shaft have seized u p . 59,63

Fricti onal resistance of movi ng Piston a nd cy l i nder l i ner have seized u p. 62,68
.....
parts is too m uch. .,.. Bea ri ngs a re oil-stuck. 48

- Lu bricati on system not workin g properl y. 60

r--- Starter faulty. 85

L Battery capacity is l ow or termi nal loose.

---
-----
Fuel pi pe broken.

ri Fuel suppl y to i n jecti on pum p

is insuff icient. - _.....,.
Ai r enters f uel pi pe th rough connection.
Fuel fil ter clogged. 58

----- Fuel pum p faulty . 42

.,... Control rack stays at non-i njecti ng poi nt. 38

I njecti on pum p does not send
-
on f uel.
-
.
Pl unge r is worm or seized u p. 57
_......,.. Del ivery val ve n ot completel y oi l -ti gh t. 57

------ Needl e val ve stuck. 55,56

-- ------
Nozzl e spring broken. 55,56
...... Fuel does not i nject th rough
injecti on nozzle.
I njecti on pressu re malad justed. 55,56
I njecti on pi pe mounti ng n ut l oose. 37

ri I njecti on m isti med. I njecti on ti m i ng maladjusted. 58

..... Contact between inta ke/exhaust valve and seat

----
not tight. 51

I nta ke/exha ust valve sprin g broke n. 52

I nta ke/exha ust va l ve stuck. 52
i---.,... Gasket faul ty . 36
- Com pressed ai r leaks. Ti ghtness torque of cyl i nder h ead not enough. 36
Piston ri ng stuck. 63

------ Piston ri ng worn.

Cy l i nder l i ner worn.

62
68

----- Ti ghtness torque of i njecti on nozzl e and glow

pl ug n ot enough. 37

y Val ve acti on ti ming i m proper. Val ve clearance excessive. 54

29
KiSC issued 09, 2007 A
 Revolution is not smooth
at high speeds.

Revel ution irregular.

Idling not smooth.

, : ;, < s;,-· ·1 "''

ffllicnNf; OTelJT
;:::rNSUFF IClENT.
Slow engine revolutions.
·"'·.? ,. ', , . : ·:,< •:'.:' .' ,,
: ::·· ' ' ,,,,, "'. '.'''' '", ';·· ,

30 KiSC issued 09, 2007 A

 Reference

r--- Fuel filter clogged. 58

L...- Fuel pipes broken or loose.

Air in pump.
---..... Pump capacity not constant.
...... Injection pump wrong. -
---,...
57

Tappet roller and pin worn.

------ Delivery valve not completely oil-tight. 57

i,...,.. Injection nozzle faulty.

k: Fuel leaks from nozzle tip.
Fuel not spraying properly.
56
56

r--- Governor spring deformed. 39

L...- Valve clearance incorrect. 54

Injection pump or nozzle not functioning

r-+-
56,
normally. 57
.L... Compression pressure is different among cylinders. 49

Governor not functioning

-_-_-_-.-.-. Governor sleeve not sliding properly.
Fork lever not functioning normally.
42

42
-
- normally.
Start spring deformed. 40
--------- Control rack not sliding properly. 38
---------
ldling regulator maladjusted.
L;r.,- ldling maladjusted.
Accelerator rod maladjusted.

r---11- Main moving parts have seized up almost. 45-48

---,... Engine overheated. 69
..,.. Injection mistimed. 58
.,.. Governor not functioning normally. 42

Filter clogged. 58

Fuel pipe broken or loose.

-
- Fuel supply insufficient.
Injection pump's capacity not enough. 57

Nozzle needle valve worn. 56

Air leaking. 49

Air cleaner clogged. 55

. 11o-1
1.
_--C
enoom
_u_p
g_h
re_.s_si_o_n_p_r_e_ss_u_r_
e_n_o_t
Valve clearance incorrect. 54

31 KiSC issued 09, 2007A

 Wh ite or bl ue exhaust f umes.

Black or dark gray exhaust

f umes.

EXCESSIVE LUBRICANT
CONSUMPTION.

LUBRICANT
INCREAsu,1G.
\.

32 KiSC issued 09, 2007 A

 Reference

-- Piston ri n g stuck. 63

- Lu bricant rises th rough piston gap. l ----------

Piston ri ng worn. 62

I Excessive gap between cyl i nder I i ner and piston. 62,69

------- Too much oi l.

I I n jecti on misti med. I -

I njection too early. 58
-I I -- I njection del ayed. 58

-- Pl unger does not return com pletel y because

Fuel pum p's i n jecti ng capacity spring is stuck or broken.
-- va ryi ng.
-- Pl unger worn. 57

- Needl e valve stuck. 56

Nozzle does not i n ject f uel Nozzle spring broken . 56

-
properl y. -
- Too much carbon sticks to nozz le ti p. 56
-- I njecti on pressure too low. 56

-----
I Com pressed air l eaks. 49

I -- Ai r not enough . 55

-- Excessive ga p between piston and l i ner.

- Piston ri ng stuck. 63
-- Piston ri ng worn. 62
Excessive ga p between i nta ke/exhaust val ve and
- val ve stem.
52
- Valve stem seal broken. 36
- Oil leaks from defective packin gs.

I njection pu m p pl unger leaks m uch f uel.

Fuel i n l ubr icant.
Fuel pu m p leaks m uch f uel. 42

Head gasket packi ng faulty . 36

Water i n l ubricant.
Crankcase cracked. 50

Gear oil i n l u bricant. Hyd ra ul ic pum p's oi l seal broken.

33
KiSC issued 09, 2007 A
DISASSEMBLY CHART
@ INJECTION
PUMP COV ER

@ CYLINDER INJECTION
HEAD COVER PUMP

@ V ALV E @ ROCKER AR M GOVER NOR

SPR ING

CY LINDER (J) INJECTION STA RT

HEAD PIPE SPR ING

NOZZLE CJ] STAR T

@ TAPPET ® INLET
HOLDER MANIFOLD CONTR OL PLATE

l
f
CD CYLINDER BLOCK

BEAR ING IDLE GEAR

STARTER PISTON
CASE

CONNECTING @ CAMSHA FT
CR ANKSHAFT WATER PIPE
ROD

BEAR ING FUEL @ WATER PUMP

OIL FILTER
COV ER CAMSHAFT

+
@ F LYWHEEL OIL PAN FOR K LEVER THER MOSTAT

CR ANK GEAR ...,._ @ GEAR CASE

OIL PUMP FAN PULLEY

KiSC issued 09, 2007 A

34

KiSC issued 09, 2007 A

2.DISASSEMBLY AND REASSEMBLY
• ATTENTION: When reassembling, replace all the 0-ring and gaskets by new ones.

0 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.

( Note for reassembl ing)

• Tighten the cap nu ts to 6.9 to 8.8 N•m. (0.7 to 0.9
kgf·m, 5.1 to 6.5 lb.ft.)
• Be caref ul to ref it the breather oil shield in the right
direction.

8 Removing Alternator and Fan Belt

1) Remove the alternator.
2) Detach the fan bel t.

( Note for reassembling)

• Fan belt tension
The belt should def lect approx. 7 to 9 mm (0.2756 to
0.3543 in.) when the center of belt is depressed with a
finger pressu re of 58.8 to 68.6 N. (6 to 7 kgf ., 13.2 to
15.4 l b.)

C, Removing Rocker Arm and Push Rod

1) Detach the rocker arm.
2) Remove the push-rods.

( Note for reassembl ing)

• I nsert the push-rods into the tappets secu rely.
• Tigh ten the rocker arm bracket mou nting nuts to 23.5 to
27.5 N-m. (2.4 to 2.8 kgf ,m, 17.4 to 20.3 l b.f t.)

35 KiSC issued 09, 2007 A

 0 Removing Cylinder Head
1 ) Detach the water retu rn pi pe.
2) Detach the cyl i nder head.
3) Remove the gasket a nd the 0-ring.
(Note for reassem bli ng)
• Apply engine oil to each bolt and nut; tighten them
equally and i n the right order.
(I mportant)
• When overhauli ng the engine, replace the gasket with a
new one without conf using its front and back. Retighten
the nuts af ter runni ng for 30 minutes.
• Do not forget to ref it the 0-ring.
Model Serial Number Tightening Torque Remarks
D1102-B "' 25273
01302-B - 22541
(A) Cylinder head tightening steps 78.5 to 83.4 N• m Bolt and
01402-B ,.... 15906
8.0 to 8.5 kgf •m plain washer
V1502-B - 7433
(a) .Gear case side 57 .8 to 61.5 lb. f t.
V1702-B - 1247
01102-B (c) Bolt
0 V1902·B ,.., 2322
01302-B
01402-B (d) Nut 01102-B 25274 -
D1302-B 22542 -
93.2 to 98.1 N· m
V1502-B 01402-B 15907 "'
9.5 to 10.0 kgf. m Flange bolt
V1702-B V1502·B 7434 ,..,,
V1902-B 68.7 to 72.3 lb.ft.
V1702-B 1248 ,....
CO J 9 F001 V1902·B 2323 "'

() Disassembling Valve
1) Remove the val ve cap and the val ve spring col let.
2) Remove the val ve spring retai ner a nd va l ve spring.
3) Remove the val ve stem seal and the valve.

( Note for reassembl ing)

• Replace the valve stem seal, apply a generous amou nt
of engine oil to the new seal and refit it.

(1) Valve guide (5) Valve stem seal

(2) Valve (6) Valve spring collet
(3) Valve spring (7) Valve cap
(4) Valve spring retainer

0 Removing Tappet
1) Remove the tappets.

36 KiSC issued 09, 2007 A

 7 Removing Starter
1) Remove the starter.

0 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.
• Replace the copper gasket.
• Tighten the nozzle holder to 29.4 to 49.0 N - m. (3 to 5
kgf , m, 21.7 to 36.2 l b.f t.)

f) Disassembling Nozzle Holder

1) Clamp the retaining ring nut in a vise.
2) Remove nut, eye joint and plain washer.
3) Remove the nozzle holder and take out parts inside.

• When disassem bling and assem bli ng the nozzle piece,

dip it in clean fuel.
( I m portant)
• When reassembl ing do not ref it the push rod u pside down.
• Tighten the retaini ng nut to 58.8 to 78.4 N·m. (6 to
8 kgf ,m., 43.4 to 57.9 l b.f t.)
Do not tighten it too much, or the needle valve will not
sl ide easily and injection performance will be decreased.

( 1) Retaining nut (7) Push rod

(2) Nozzle holder body (8) Nozzle spring
(3) Nozzle body (9) Adjust washer
(4) Nozzle piece (10) Plain washer
(5) Needle valve (11) Eye joint
(6) Distance piece (12) Nut

37
KiSC issued 09, 2007 A
 0 Removing Injection Pump Cover
1) Remove the injection pump cover.

0 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.

( I m portant)
• When reassembl ing, i nsert the pump rack pin i nto the fork
lever 1 slot surely.

(1) Slot of fork lever 1

(2) Insert surely

38 KiSC issued 09, 2007 A

 0 Detaching Governor Spring
1) Detach the governor spring 1 and 2 from the governor
fork lever 2.

(A) How to remove governor spring

(a) Detach governor spring (b) Gear case

on the side of fork !J -- - (cl Fork lever 2

C019 F002

@ Removing Speed Control Plate

1) Remove the speed control plate and governor spring.

(Note for reassembling)

• Be careful not to drop the governor spring in the gear
case.

39 KiSC issued 09, 2007 A

 C) 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

8 Removing Fan Drive Pu lley

1) Remove the fan d ri ve pu l ley.
2) Remove the key.

40
KiSC issued 09, 2007 A
 CD Removing Gear Case Assembly
1) Remove the gear case.
2) Remove the 0-ring.

(Important)
• When reassembl ing do not forget to refit the 0-ring.
• Apply some grease to the oil seal, and refit it carefully
so that its l i p will not peal off .

(A) Inside view of gear case assembly

(b) 0-ring

(f) 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.

(1) Oil slinger

(2) 0-ring
(3) Crank shaft collar
(4) Crank gear collar
(5) Oil slinger
(6) 0-ring
(7) Crank shaft collar

41
KiSC issued 09, 2007 A
 @ 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)
• When install ing the idle gear, be sure to align the al ignment
ma rks on geas.

(A) Gear marks

(b) Oil pump drive gear

C019F005

Removing Fuel Feed Pump

(V1502-B, V1702-B, V1902-B only)

1) Remove the f uel feed pump.

Ci) Removing Fuel Camshaft and Fork Lever Holder

1) Detach the f uel camshaft cover.

2) R emove the external ci r-cl i p and the col lar ( D1402·B, V1502-
B, V1702-B, V1902·B only).
3) Remove th ree fork lever holder set bolts.
4) Remove the f uel camshaf t and the fork lever shaf t at
the same ti me.

42
KiSC issued 09, 2007 A
 CD) Removing Crank Gear
1) ) 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.

0 Removing Thermostat
1) R emove the thermostat cover.
2) R emove the t hermostat.

43
KiSC issued 09, 2007 A
 @ 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.
2) R emove the fa n pu lley.

(2) Removing Water Pump Shaft and

Bearing Assembly
1) Remove th e snap pin. (Snap pin type only)
2) R emove the water pu m p shaft fla nge.
3) R emove the i m pel ler.
4) Dr i ve out the water pu m p shaft a nd bea ri ng assembl y
from the i m pel l er sid e of the water pu m p.

(I mporta nt)
• When reassembl i ng, replace the water pu mp shaft a nd
beari ng assembly by new one.

(1) Insert surely (Snap pin type only)

(2) Snap pin (Special) (Snap pin type only)
(3) Water pump shaft and bearing assembly

44 KiSC issued 09, 2007 A

 (3) Removing Seal Set
1) Remove the seal set.

(1) Slinger
(2) Seal set

0 Removing Oil Pan, Oil Filter 1

1) Detach the oil pan.
2) Remove the oil filter 1. Be careful of the 0-ring.

f) Removing Connecting Rod

1) Detach the connecting rod bolt.
2) Remove the cap of the large end of the connecting rod.

(Important)
• When reassembling, apply engine oil to the connect·
ing rod bolts.

Non 36.3 to 41.2 N-m

(A) 3.7 to 4.2 kgf-m
Flange
Tightening Bolt (3) 26.6 to 30.4 ft. lbs
torque 44.1 to 49.0 N-m
Flange
4.5 to 5.0 kgf m
Bolt (4) 32.5 to 36.2 ft.lbs
(A) Reassembling of connecting rod
(1) Align the marks with each other.
(B) Connecting rod bolt
(2) Face the marks toward the
injection pump.
(3) Non flange bolt (4) Flange bolt

- 1 ,
A069F001

45
KiSC issued 09, 2007 A
 @) 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

(01402-BJ [V1902-B]

A069F002

Removing Piston Ring

1) Remove the piston rings.
2) Remove the piston pin. Mark the piston head so that
the piston will be reassembled in the right direction.
Also, to avoid wrong reassembling, write down the
number of the piston and the connecting rod as a pair.

( Note for reassembl i ng)

• When reassembl ing, the connecti ng rod to the piston,
heat the piston well and tap in the piston pin. Make
sure that the piston is reassem bled with the right con-
necti ng rod. Face the mark on the piston head toward
the connecti ng rod.
• When install i ng a piston ring onto the piston, face the
(A) Reassembling of piston, piston rings and connecting rod mark (manufactu rer's name or "TOP") toward the piston
head.
(a) Mark before disassembl ing
When installing a piston, face this
• When install ing the coil expander i n the ri ng, place the
mark toward the alignment marks. expander joint on the opposite side ( 3.14 rad. (180°))
of the ring gap.
:TI (b) Plated Keystone ring • Place the piston ri ngs so that there are gaps every 1.57
=:c:i (c) Discontinuous undercut ring rad. ( 90° ) with no gap facing the piston pin in the
cyl i nder.

-
f
/
Engine serial number : 37196 and
beyond
(d) Coil expander ring
J
(g) Taper and inside cut ring [V1702·B
only

(f) Alignment marks

When installing a connecting
co19FOO!i rod face the alignment marks
toward the injection pump.

46
KiSC issued 09, 2007 A
 8 Removing Flywheel
1) Detach the flywheel bolts.
2) Remove the flywheel.
(I mportant)
• When reassembli ng, tighten the f lywheel bolts to 98.1 to
107.9 N , m (10 to 11 kgf ·m, 72.3 to 79.6 lb· f t.).
• To use a f langed bolt on the conventional f lywheel,
rework the chamfered protion of the bolt hole. (Chamfer:
C0.9 to C1.3)
If the f langed bolt is used without reworking, a clearance
will develop as shown below, resu lting in an i nsuff icient
tightening torque.

Model Serial Number Remark

(A) Reassembling of f lywheel washer D1102·B 38692 -
(a) Mark (b) Clearance D1302-B 33434 -
I nstall the flywheel washer D1402·B 44173 ,..., Flange bolt
(c) Flywheel
so that the mark is opposite V1502-B 21064 ,...., (without washer)
the flywheel surface. V1702-B 44933 -
V1902-B 67309 ,..,,

C019F007

8 Removing Bearing Case Bolt 2

1) Detach the bearing case bolt 2.
( Note for reassembli ng)
• 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
V1502-B ,..., 20822 washer
47 .0 to 50.6 lb. ft.
V1702-B ,..., 43698
V1902-B ,..., 65775
01102-B 38580 ,...,
D1302-B 33414
68.6 to 73.5 N• m
D1402-B 43734 ,...,
7.0 to 7.5 kgf • m Flange bolt
V1502-B 20823 ,...,
50.6 to 54.2 lb. f t.
V1702·B 43699 ,...,
V1902-B 65776 =

@ Removing Bearing Cover

1) R emove the bolts.
2) Drive two MS bolts into the bearing cover and then pull
the cover out.

( Note for reassembl ing)

• Grease the oil seal, be caref ul not to peal the l ip off .

47
KiSC issued 09, 2007 A
 8 Removing Crankshaft
1) Tap the cran kshaf t u nti l it comes ou t of the f l ywheel
side; be caref u l not to scratch the cra n kshaft beari ng 1 .

Ci) Removing Bearing Case

1) Remove the bearing case screws 1, then the main
bearing case assembly 1 (1), being careful with the
side metal (3) and crankshaft bearing 2.
2) Remove the main bearing case assemblies 2,3 and 4
( 4) as above.
(Note for reassembling)
• Clean the oil passage in the main bearing case.
• Apply clean engine oil on the crankshaft bearing 2 and
side metals.
• Since the diameters of main bearing cases vary, install
them in ordr of markings (1,2 and 3) from the gear
case side.
0087F051 • When installing the main bearing case assemblies 2,3
and 4, face the mark (·1i?) to the gear case side.
• 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
D1402-B -43007 Bolt and
3.0 to 3.5 kgf·m
,20589 washer
V1502-B 21.7 to 25.3 lb.ft
V1702-B -42863
V1902-B -62871
D1102-B 38539-
D1302-B 33386-
36.3 to 41.2 N·m
D1402-B 43008- 3.7 to 4.2 kgf.m Flange bolt
V1502-B 20590- 26.8 to 30.4 lb.ft.
V1702-B 42864--
V1902-B 62872-
(1) Main bearing case assembly 1
(2) Oil groove
(3) Side metal
(4) Main bearing case assembly 2,3 and 4

48
KiSC issued 09, 2007 A
3.SERVICING

0 Checking Compression Pressure

1) ) Warm u p the engine.
2) R emove the ai r cleaner a nd th e m uffler.
3) Remove the nozzl e hol ders from al l the cy l i nd ers.
4) Attach a compression tester to the cyl i nder to be measu r-
ed.
5) R u n the engine wi th the starter at 200 to 300 mi n-1{rpm)
and read constan t maxi m u m on the tester. E xecu te the
test at least twice. ( R u n the engi ne for 5 to 10 seconds
for each test.)

• For the test, use a f ully charged battery and the specif ied
valve clearance.
C Ol 9 F011 • If the compression pressure is below the given allowa ble
l i mit, pour a small amount of oi l through the nozzle
holder hole and test again.
• Judgment.
1) If the pressu re recovers to standard level, i nadequate
pressure may be ca used by wear or adhesion of the piston
rings. Check the related poi nts.
2) If the pressu re does not recover, cylinder head or valve
problems may be the cause. Check the related points.
3) If the compression d iff ers more than 10% a mong the
cylinders, trace the cause of pressure variation and take
corrective measures.

Reference value
-----·------- ·-- -----
2.9 to 3.2 MPa
Reference compression pressure 30 to 33 kgf/cm 2
427 to 469 lb./sq. in.
··-•-H-•-•••-
Compression pressure allowable
limit should be more than 75% 2.2 to 4.2 MPa
of reference compression 23 to 25 kgf/cm 2

pressure 320 to 352 lb./sq.in.

-
Difference in compression pressure among cylinders should be
ss than 10%.
"""·

49 KiSC issued 09, 2007 A

 fj 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.
3) I nsert a feeler gauge between the straight edge and the
cyl i nder head su rf ace.
4) The maxi mu m th ick ness i nserted is the amou nt of distor-
tion .
5) If the measu rement exceeds the al lowa ble l i m i t, correct
wi th a su rface gri nder.

C 019 F012
( Note)
• Do not place a straight edge on the combustion cha mber.
(A) How to check cylinder head surface

Reference value
0.05 mm (0.0020 in.) /
Allowable limit 100 mm (3.9370 in.)
of cylinder head surface length.

C 01 9 F01 3

@ Checking Flaw of Cylinder Head Surface

1) ) Clean the su rface of the cyl i nder head.
2) Spray the cyl i nder head su rface wi th the red permeati ve
l iqu id.
3) Wash away the red permeati ve l iqu id on the cyl i nder head
su rface wi th the detergent.
4) Spray the cyl i nder head su rface wi th the developer. I f
flawi ng, it can be identified as red marks.

Should be no

C 019 F014

(Al Air spray red check

(1) ) Detergent
(2) R ed permeative liquid
(3) White developer

50 KiSC issued 09, 2007 A

 0 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.

• To correct the dimensions of the valve seat usi ng a valve

seat cutter, follow the steps.
1) Use a cutter suitable for the valve guide and the valve
seat. (0.785 rad.(45°),¢8m m(0.315 in.))
2) Grind off the front surface of the valve seat by 0.262
C 019 F01 5 rad. ( 15°), since the seat surface becomes wider than
( A) How to repair the valve seat before.
3) Grind off the rear surface of the seat by usi ng 1.134 or
C (a) Valve contacting width 1.308 rad. (65 or 75°) cutter to finish the seat 2.1 m m
( 0.0827 i n .) wide.
4) Reface the valve.

2.1 mm
(b) Corrected
(cl U ncorrected surface 0.0827 in.
of valve seat
of va Ive seat

(d) A-0.785 rad.(45°) cutter

B-0.262 rad.(15°) cutter
C-1.134 or 1.308 rad.(65 or 75°) cutter
C 019 F016

C+) Checking Valve Recessing

1) Clean the face of the val ve.
2) Measu re the si n ki ng with a depth gau ge.
3) I f the measu rement exceeds the al l owa ble l i m i t, repl ace.

C 019 F017

(i) Checking Stem Guide Clearance

1) Remove carbon from the val ve gu i de.
2) Af ter ma ki ng su re th at the val ve stem is straight, i nsert
the val ve i nto the val vegu ide.
3) Measu re the stem gu ide clea rance wi th a d ial gauge.
4) I f the measu rement exceeds the al l owa ble l i m i t, repl ace
the stem gu i de and the val ve.

( Note for replacing )

• I nlet and exhaust valve guide resem ble each other i n
shape. To i nstall them, be su re that they a re on the proper
side.
0.04 to 0.07 mm
0.0016 to 0.0028 in.
·
---- - -----
0.10 mm
0.0039 in.

51
KiSC issued 09, 2007 A
 @ 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
..-- - --- --- --------- --
41.2 mm
1.6220 in.

C 0 1 9 F01 9

t1) Checking Valve Spring Squareness

1) Pu t the spring on a su rface plate, place a square on the
side of the spri ng, and check to see if the enti re side is
i n contact wi th the squ are.
2) Rotate the spring a nd measu re the maxi mu m B.
3) The flat su rface at the end of the spri ng coi l m ust exce·
ed two-th i rds of the f u ll ci rcu mference.
4) Check al l the su rface of the spring for scratches.
5) I f the measu rement exceeds the al l owa ble l i m i t, repl ace
the val ve spring.
Reference value
1.0 mm
0.0394 in.
--- -- --- -- -----
C 01 9 F020

(A) How to measure squareness of the valve spring

C 019 F021

fj) Checking Valve Spring Tension

1) Pl ace the spri ng on a tester, com press i t to the level to
wh ich the spri ng is actual l y compressed i n the engi ne.
2) R ead the com pression l oad on the gauge.
3) If the measurement exceeds the a llowa ble l i m it, replace
the va l ve spr i ng.

117.7 N./35.15 mm
12 kgf./35.15 mm
26.5 lb./1.3839 in.
·----·---l
100.0 N./35.15 mm
10.2 kgf./35.15 mm
22.5 lb./1.3839 in.
'--- - -- -- - ------- ---- --
C 019 F022

52 KiSC issued 09, 2007 A

 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

Arm Shaft and Rocker Arm (Bushless
Type)
1) Measure the inside diameter of the rocker arm.
2) Measure the rocker arm shaft diameter. Calculate the
clearance value.
3) If the measurement exceeds the allowable limit,
replace.

41, Checking Top Clearance

1) Detach the nozzle holder.
2) Lower the piston in the cylinder to be measured.
3) Insert a high-quality fuse from the nozzle holder hole.
Be careful not to let the fuse touch the valve surface.
4) Rotate the engine with your hand.
5) Take the fuse out carefully.
6) Measure with a set of vernier calipers where the fuse was
crushed.
7) If the measurement is not within the reference value,
adjust by inserting a shim between the cylinder head and
gasket.

KiSC issued 09, 2007 A

53

KiSC issued 09, 2007 A

 8 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.
3) Measure the clearance at the valves marked with in
the table below with a feeler gauge.
4) If the clearance is not within the factory specifications,
turn the adjusting screw to adjust.
5) Turn the flywheel just one turn to position the 1st
cylinder at the top dead center during overlap.
6) Measure the clearance at the valves marked with • in
the table below with a feeler gauge.
7) If the clearance is not within the factory specifications,
turn the adjusting screw to adjust.
(A) Valve clearance
(Note)
• Engine must be cool.
0.18 to 0.22 mm
Factory spec. 0.0071 to 0.0087 in.

Timing window

[V1502-B, V1702-B, V1902-Bl

C 019 F026 Cylinder No. 1 2 3 4
Valve IN. I EX. IN. I EX. IN. I EX. IN. I EX.

A069F003
Checking 0 I 0 I • • I 0 •I•

41.l Adjustment of Compression Release

1) Close the exhaust val ve completel y.
2) Remove the decompression adjust cover from the head
cover.
3) Pu l l the decompression lever.
4) Reduce the valve clearance to zero by means of the
decom pression adjust bol t. Gain access to the adju t
bol t th rough the wi ndqw. Then, screw i n the bol t by 1
to 1.5 tu rns and tighten the lock nu t.

( Note)
\\ • Af ter adjustment, turn the crankshaf t by hand and check
C Ol 9 F027 to see that the valve and the piston should not be i n
contact with each other because the depression clearance
(A) Compression release adjustment
is too small.
(a) Compression release window cover

(b) Compression
position

..:'.f'F;.Z:-=j'=:'.:::::::,.-lnj
i.
I
(d) 0.750 to 1.125mm
0.0295 to 0.0443 in. C 019 F028

54
KiSC issued 09, 2007 A
 CE, Cleaning Air Cleaner Element
For a dry type element
1) How to clean by using compressed air:
Directly blow compressed air from inside to outside.
Pressure of compressed air must be under 205kPa
(2.1kgf/cm2,30psi).
2) How to clean by using solution:
Add 15 g (0.03 lb.) Kubota genuine element detergent to
1 liter (0.26 gal.) water. Let the element soak in the
solution for 15 minutes and then wash it well in the
solution. R inse well in clean water and dry.
01102-B
01302-B
01402-B
0071 F001
• To remove d i rt and dust, use compressed air.
• To remove carbon and grease, use solution.

V1502-B
V1702-B
V1902-B
0071F 002

0 Testing Open i ng Pressu re of Nozzle

1) Move the tester handle up and down to prime fuel.
Measure the pressure of fuel gushing out from the nozzle
tip.
2) If the measurement is not within the reference value,
adjust with the adjustment washer inside the nozzle
holder. (See page 76) An increase of every 0.1 mm
( 0.0039 in.) of washer thickness causes an approximate
980.6 kPa. ( 10 kgf/cm2 , 142.2 lb./sq.in.) increase in fuel
injection pressure.

( Danger)
• Be caref ul not to touch the injected fumes directly. On
3TLABAB1 P040A touchi ng flesh, the f u mes destroy the organism. If it gets
i n the blood, it may cause blood poisoni ng.

,1 - otr:g -:-1
1990.8 to 2133.0 l b.ls
-
·
----··

55 KiSC issued 09, 2007 A

 @ Checking Fuel·Tightness of Nozzle Valve Seat

1) ) Appl y pressu re 980.6 k Pa. {10 kgf /cm 2 , 142.2 l b./sq.i

n.) lower than the open i ng pressu re.
2) 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.
3) I f the val ve seat shou l d lea k f uel , replace the nozzl e piece.

Reference val ue
980.6 kPa. (10 kgf./cm2 ,
pressu re, the valve seat

3TLABAB1P041A

(t Checking Shape of Fume across Nozzle Tip

1) Attach the nozzle to a nozzle tester and shoot it i n the ai r.
Check the shape of the f u me.
2) I f the shape is not accepta ble, repl ace the nozzle pi ece.

1.1i,l •
1

1
1
i· I

,· I

3TLABAB1P040A

{a)Good {b)Bad

C 01 9 F033

56 KiSC issued 09, 2007 A

 0 Checking Fuel-Tightness of Fuel Injection
Pump Plunger
1) ) Attach a pressu re ga uge to the pu mp.
2) Rotate th e f l ywheel to i ncrease the pressu re to 58.8 MPa. (600
kgf /cm 2 8532 l b./sq.i n.) .
3) Al ign the pl u nger wi th the top dead center.
4) Measu re the ti me needed to decrease the i n itial pressu re
2
f rom 58.8 MPa. to 49.0 MPa. (600 kgf /cm to 500 kgf I
2
cm , 8532 l b./sq.i n. to 7110 l b./sq.i n.)
5) I f the measu rement is not accepta ble, repl ace the pu m p
element. I n th is case, ask a repai r shop to do the repl ace-
ment. Be su re to give them adjustment reference data on
the f uel i njection pum p. (Shown l eft)
C O J 9 F034

(A) Profile of fuel pump cam

9 sct
<:)'.?>()·,
• Adjustment reference data of fuel injection pump
• Test Conditions
Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . DN12SD12
2
Opening pressure . . . . . . . . . . 13.73 MPa (140 kgf/cm )
Pipe . . . . . . . . . . . . . . . . 6 mm in diameter x 2 mm in
diameter x 600 mm
2
Fuel feed pressure . . . . . . . . . . . 19.6 kPa ( 0.2 kgf/cm )
Cam profile . . . . . . . • . • . . . • . . . . . . See Fig. below.
Prestroke . . . . . . . . . . . . . . . . . . . . . 2.2 ± 0.05 mm
Test fuel . . . . . . . . . . . . . • . . . • . Diesel Fuel No.2-D
C Ol 9 F036

• Adjustment of injection
1
Control rack position ( * 1 ) Speed (min- (rpm)) Amount o-f inj-ction (rnm 3/st) Allowance (mm 3 )( *3)
9 1400 23 ± 1 .5 ± 1.5 or less
8 1400 18.5 7.5 ± 3.8 or less
7 1400 13.5 ± 7.5 ± 3.8 or less
0 to 3.5 1550 0 ( *2)
" _, "

*1 Travel distance from non-injecting point of control rack

*2 Zero opening pressure and no injection
*3 Allowance on the basis of standard cylinder

0 Checking Fuel-Tightness of Delivery Valve of

Fuel Injection Pump
1) ) Attach a pressu re ga uge to t he pu m p.
2) Rotate th e flywheel to i ncrease the pressu re to 9.8 MPa.
(100 kgf /cm 2 , 1422 l b./sq.i n.) .
3) A l ign the pl u nger w ith the bottom dead center.
4) Measu re the t i me needed to decrease the i n itia l pressu re
2 2
from 9.8 M Pa. to 490.3 kPa. ( 100 kgf /cm to 5 kgf /cm
1422 l b./sq.i n. to 71.1 l b./sq.i n.)
5) If the measu rement is not accepta ble, replace the del ivery
va l ve.

57 KiSC issued 09, 2007 A

 C, Checking and Adjusting Injection Timing

1) Remove the injection pipes.

2) Set the speed control lever to maximum fuel discharge
position.
3) Turn the flywheel couterclockwise (facing the
flywheel) until the fuel fills up to the hole of the
delivery valve holder for 1st cylinder.
4) Turn the flywheel further and stop turning when the
fuel begin to flow over, to get the present injection
timing.
5) [Fl mark type] (The flywheel has marks TC and Fl for
each cylinder on its outer rim) If the Fl mark does not
align with the projection in the window on flywheel
housing, add or remove the shim to adjust.
6) [Markless type] (The flywheel has mark 1TC and four
(A) Fuel injection timing lines indicating every 0.087 rad. (5°) of crank angle
from 0.175 rad. (10°) to 0.436 rad. (25°) before mark
(a) Fl mark type (b) Markless type 1TC) Calculate the angle which the projection in the
I window points out. If the calculation differs from
specified injection timing, add or remove the shim
0.436 ra :
(25°) - to adjust.
0.35 rad.
(20°)
0.262 rad. 1

(15 °) • NOTE
0.175 rad. • Apply liquid gasket (Three Bond 1215 or equivalent) to
(100)
the shim, when reassembling.
A069F004
(Reference)
• The timing advances by removing 0.15 mm (0.006 in.)
of shim and retards by adding one, approx. 0.26 rad.
( Bl Adjustment of injection timing (1.5°) of crank angle.

(a) Injection timing

adjusting shim

C 019F039

@ Replacing Fuel Filter

1) Detach the filter with a filter wrench.
2) Replace the filter with a new one.

every 400 hours

58
KiSC issued 09, 2007 A
 0 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.

""
C 019 F042
C019F041

f) Checking Camshaft Alignment

1) Gently put the camshaft on V blocks.
2) Set a dial gauge on the journal.
3) While slowly rotating the camshaft, read the dial gauge.
The camshaft flexure is indicated by half of the reading.
4) If the measurement exceeds the allowable limit, replace
the camshaft.

C 019 F048

@ Checking Cam Heights of Intake and Exhaust

1) Measure the highest point of the cam with a micrometer.
2) If the measurement exceeds the allowable limit, replace.

C O l 9 F044

59
KiSC issued 09, 2007 A
 C, Checking Gear Backlash
1) ) I nstall a lever-type i ndicator between gear teeth.
)2 Clamp one gea r, rotate the other, and measu re the back-
lash .
3) Replace if the measu rement exceeds the al l owable l i m i t.

0 Testing Oil Pressure

1) Detach the oi l swi tch and attach a pressu re gauge.
2) Start the engi ne. Measu re oi l pressu res both at idl i ng and
the rated speed ru n n i ng.
3) I f the measu rement is not with i n the reference ra nge,
check the oi l pu m p, the oi l ways, the oi l cl eara nces a nd the
pressu re-regu l ating val ve.

(Note for measuring)

• Supply the specified amount of genuine oil.
• Keep the oil filter from being clogged or torn.

Reference value
!-------- ---
Approx. 98. 1 kPa.
At idling speed Approx. 1.0
Approx. 14.2
294.2 to 441.3
At rated engine speed 3.0 to 4.5
42.7 to 64.0

Oil Pump (Rotor Type)

( 1) Checking Rotor Lobe Clearance
1) ) Mate the projections of the i n ner and ou ter rotors. I
nsert a feeler gauge i nto the gap between the projections.
2) Repl ace if the measu rement exceeds the al l owable l i m i t.

Model Reference value

1-- -
- 1---
D1102- B
0.10 to 0.16 mm
D1302-B
D1402-B 0.0039 to 0.0063 in.

V1502-B
0.04 to 0.13 mm
V1702-B
V1902-B 0.0016 to 0.0051 in.
C 01 9 F048

60 KiSC issued 09, 2007 A

 (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.
2) I f the measu rement exceeds the al l owa ble l im i t, replace.

C Ol 9 F049

(3) Checking End Clearance between Rotor

and Cover
1) Paste a press gauge wi th grease on the su rface of the gear.
2) Attach the cover.
3) Detach the cover caref u l l y, and measu re the depression
of the press gauge wi th a sheet of gau ge ( pa per) .
4) I f the measu rement exceeds the al lowa ble l im it, replace.

C019 F050

(D Checking and Replacing Oil Filter

1) Detach the f i l ter wi th a f i l ter wrench .
2) Repl ace the oi l f i l ter cartridge.

( Note for reassembling)

• Apply a thin coat of oil to packi ng and tighten it securely
by hand.

61 KiSC issued 09, 2007 A

 0 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.
2) Measure the inside diameter of rod small-end bushing with
an inside micrometer. Calculate the clearance.
3) If the clearance exceeds the allowable limit, replace it.

0.014 to 0.038 mm
0.0006 to 0.0015 in.
Reference value
0.015 to 0.067 mm ]
[Service Part 0.0006 to 0.0026 in.

Allowable limit 0.15 mm

0.0059 in.
C01 9 F053

8 Checking Piston Ring Gap

1) Put the piston ring in the cylinder.
2) Stand the piston upside down and push the ring into the
cylinder with the piston head.
3) Insert a feeler gauge into the piston ring gap.
4) If the measurement exceeds the allowable limit, replace it.

( I m portant)
• Measure the piston ri ng gap at the poi nt of the mi nim u m
i nside d iameter of the cylinder li ner.
r'\
C019 F054 C
Top ring
Second ring

0.25 to
0.45
Oil ring
0.0098
0.0177

62
KiSC issued 09, 2007 A
 0 Checking Side Clearance of R ing in Groove
1) Remove the piston ri ng from the piston.
2) Place the ri ng i n its groove as is shown at lef t, and measu re
the cleara nce.
3) I f the measu rement is not wi th i n the reference val ue,
replace the ri ng.

( Note)
• As the top ring is a keyston type, it cannot be measured
by this method.

C019 F055

() Checking Connecting Rod Alignment

1) Remove the connecti ng rod crank pi n metal and tighten

the rod bol t.
2) Attach the connecti ng rod to the con necti ng rod al igner.
3) Place the ga uge on the piston pi n.
Measu re the ga p between the pi n of the gauge and the f lat
su rface of the a Iigner.
4) If the measurement exceeds the a l lowa bl e l i m it, replace
the rod.

( I m portant)
• Because the inside diameter· of the connecting rod small-
C019 F056
end bushing is used as the basis, check carefully if it is
worn or not.

0.02 mm
·· --t
0.05 mm

0 Checking Crankshaft Alignment

1) Place V-blocks on a su rface plate, and put either end of
the jou rnal on them.
2) Set a d ial gauge on the center journal .
3) R ead the d ia l ga uge wh i le rotati ng the cra nkshaf t slowly.
Cra n kshaf t flexure is i nd icated by ha lf of the read i ng.
4) If the read i ng exceeds the al lowa ble l i mit, replace the
era nkshaf t.

COJ 9 F057

63 KiSC issued 09, 2007 A

 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 1) with an outside micrometer.
2) Measure the crankshaft bearing 1 with an inside micro-
meter. Calculate the clearance.
3) If the clearance exceeds the allowable limit, replace the
crankshaft bearing 1 with undersize one. For undersize
bearing use, follow the precautions noted below.
1. . Cut corner, radius of the crank journal to
precisely 3.0R±0.2 mm (0.1181 R±0.0079 in.)
2. The crank journal must be fine-finished to higher than
'v"vVv (0.4S.)
C019 F058 C01 9 F059 3. Be sure to chamfer the oil hole circumference with an
oil stone.

(Al Crank journal for undersized beari ng 1

(a) Oil hole must be

1 to 1.5R mm
(0.0394 to 0.0591R in.)

(b) 3.0R±0.2 mm
(0.1181 R±0.0079 in.)

007 1 F008

Crankshaft journal dia A

Undersize Code Number Part Name Bearing Mark
(Shown in Fig )
·· -
51.721 to 51.740 mm
0.2 mm
15221-2391-1 Crankshaft bearing 1 0.2 minus 020 us
0.0079 in. 2.0363 to 2.0370 in.
51.521 to 51.540 mm
0.4 mm
15221-2392-1 Crankshaft bearing 1 0.4 minus 040 us
0.0157 in. 2.0284 to 2.0291 in.

0.D. of crankshaft journal I.D. of crankshaft

51.921 to 51.940 mm
2.0441 to 2.0449 in.

64 KiSC issued 09, 2007 A

 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.
2) Tigh ten the beari ng case onto the cran k jou rnal to the
specif ied torq ue (29.4 to 34.3 N- m., 3.0 to 3.5 kgf - m.,
21.7 to 25.3 l b.f t.) .
3) Detach the beari ng case sl owly, and measu re the depres-
sion of the p ress ga uge with a sheet of gau ge ( paper) .
4) I f the measu rement exceeds the al l owa ble l i m i t, repl ace
the cran kshaf t bea ri ng 2 with u nde rsize one. For u nder·
size beari ng use, follow the precau tions noted bel ow.
1 Cut corner radius of the cran k jou rnal to p recisel y
3.0R±0.2 m m ( 0.1181R±0.0079 i n.) .
C01 9 F060 2 The cra n k jou rnal m ust be fine-finished to h igher than
vVvv (0.4S.)
(A) ) Crank journal for undersized bearing 2.

(a) Oil hole must be 1 to 1.SR mm

(0.0394 to 0.0591R in.) ( Note for measu ri ng)
1) Fasten the crankshaft such that it does not tu rn.
(b) 3.0R ± 0.2mm 2) Do not i nsert the press gauge i nto the cran k pin holes.
(0.11BR ± 0.0079 in.)

007 1 F004

Crankshaft journal dia B

Undersize Code Number Part Name Bearing Mark
(shown in Fig.)
0.2 mm 51.721 to 51.740 mm
0.0079 in.
15221-2393-1 Crankshaft bearing 2 0.2 minus
2.0363 to 2.0370 in.
020 us
0.4 mm 51.521 to 51.540 mm
0.0157 in.
15221-2394-1 Crankshaft bearing 2 0.4 minus
2.0284 to 2.0291 in.
040 us

65
KiSC issued 09, 2007 A
 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.
2) Tighten the connecting rod onto the crank pin to the
specified torque (36.3 to 41.2 N-m., 3.7 to 4.2 kgf,m.,
26.8 to 30.4 lb.ft.)
3) Remove the large end cap carefu Ily, and measure the
depression of the press gauge with a sheet of gauge (paper) .
4) If the standard-size bearing cannot be employed due to
exessive wear of the crank pin, employ undersize bearing.
For undersize bearing use, follow the precautions noted
below.
1. Cut corner radius of the crank pin to precisely 3.5R±
0.2 mm ( 0.1378R±0.0079 in.)
2. Be sure to chamfer the oil hole circumference with an
oil stone.
(A) Crank pin for undersized bearing 3. The crank pin must be fine-finished to higher than
(a) 3.SR ± 0.2mm (b) Oil hole must be 1 to 1.5Rmm 'vVVv ( 0.4S) .
(0.1378R ± 0.0079 in.) (0.0394 to 0.0591R in.)
0.035 to 0.093 mm
0.0014 to 0.0037
-
-
·---·----<
0.20 mm
0.0079 in.

( Note for measu ri ng)

1) Fasten the cran kshaft so that it does not tu rn.
2) Do not i nsert the press gauge i nto the cran k pin hole.
(cl 3.SR ± 0.2mm 3) Crank pi n metal measuring poi nts are shown below:
0071 F005 (0.1378R ± 0.0079 in.)

(B) Crank pin measuring points

COJ 9F062

Model Undersize Code Number Part Name Crank pin dia. C Bearing Mark
(Shown in Fig.)
··- ·-· ---
0.2 mm
01102-8
01302-B 0.0079 in.
15221-2297-1 Crank pin bearing 0.2 minus 43.759 to 43.775 mm
1.7228 to 1.7234 in.
020 us
V1502-B 0.4 mm
V1702-B 0.0157 in.
15221-2298-1 Crank pin bearing 0.4 minus 43.559 to 43.575 mm
1.7149 to 1.7156 in.
040 us
-·-
0.2 mm
15471-2297-1 Crank pin bearing 0.2 minus I 43.759 to 43.775 mm 020 us
D1402-B 0.0079 in. 1.7228 to 1.7234 in.
V1902-B 0.4 mm 43.559 to 43,575 mm
0.0157 in.
15471-2298-1 Crank pin bearing 0.4 minus
1.7149 to 1.7156 in.
040 us
·-·"""'"'''"""' .... _
'' ' · --·-"-'""'· ----···--·-

66 KiSC issued 09, 2007 A

 C, 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.
For oversize metal use, follow the precautions noted
below.
1. Grind the crankpin and journal with a wheel which has
specified round corner and width without shoulder.
2. The crank journal side surface must be fine-finished to
higher than ( 0.4S) .
3. Be sure to chamfer the oil hole circumference to 1 to
1.5 mm (0.04 to 0.06 in.) radius with an oil stone.

(A) Crank journal for oversized side metal.

• When replacing the side metal, face the oil grooves of side
metal outwa rd. (See page 48).

0.15 to 0.31
Reference value
0.0059 to 0.01
(a) 3.0R ± 0.2mm
0.5 mm
(0.1181 R ± 0.0079 in.) Allowable limit
0.0197 in.

(b) 3.0R ± 0.2mm

0071 F006
(0.1181R ± 0.0079 in.)

Distance D
Oversize Code Number Part Name Metal Mark
(Shown in Fig.)
0.2 mm 15221-2395-1 Crankshaft side metal 1 0.2 plus 26.40 to 26.45 mm 020 OS
0.0079 in. 15221-2397-1 Crankshaft side metal 2 0.2 plus 1.0394 to 1.0413 in.
0.4 mm 15221-2346-1 Crankshaft side metal 1 0.4 plus 040 OS
0.0157 in. 15221-2398-1 80.
26 to 26 .85 mm
_ ,
ft side metal 2 0.4 Plus
Cran ksh
- - --------... . .

67
KiSC issued 09, 2007 A
 ( ,)
(it 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.
2) 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.

Crankshaft Allowable 0.1 mm

sleeve wear limit 0.0039 in

( 1) Wear

0 107F069

@ Replacing Crankshaft Sleeve

1) R emove the used cra n kshaf t sl eeve usi ng a speci a l -use
pu l l er set (Code No. 07916-09032) .
2) Set the sl eeve gu ide (4) to the cra n kshaf t.
3) Set the stoppe r (5) to th e cra n kshaf t as sh own i n f igu re.
4) Heat a new sl eeve to a tem peratu re between 150 a nd
200°C (302 a nd 392° F ), a nd f i x the sl eeve to the cra n k-
sh af t as shown i n f i gu re.
5) Press f i t the sl eeve usi ng the au x i l i a r y socket for push i ng
(3).

• Tool: Auxiliary socket for fixing the crankshaft

sleeve (Code No. 07916-32091)

( 5) ( ,) (2)

0107 F070

( 1) Crankshaf t Sleeve
( 2) Crankshaft
(3) Auxiliary Socket for Pushing
(4) Sleeve Guide
(5) Stopper

68 KiSC issued 09, 2007 A

 0 Checking Wear of Cylinder Liner
1) Adjust a cylinder gauge to a reference value of cylinder
liner with an outside micrometer.
2) To find out the maximum wear, measure six points of
cylinder diameters with the cylinder gauge, as shown
below.

• When the cylinder liner has worm beyond the allowable

limit, bore and hone the cylinder by 0.5 mm (0.0197 in.)
1) Finish the cylinder liner to the degree in Table 1.
2) The cylinder liner which has been oversized by 0.5 mm
(0.0197 in.) should use a piston and ring of the same
oversize. (See the Table 2)
• When the oversized cylinder liner is worn beyond the
allowable limit, replace the cylinder liner, and bore and
(A) Measuring points of cylinder liner hone it.
( B) 1) Top
2) Middle
3) Bottom (Skirt)

Model Reference value Allowable limit

D1102-B 76.000 to 76.019 mm
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.
(C) a) Right-angled in
relation to the D1402-B 85.000 to 85.022 mm
piston pin V1902-B 3.3465 to 3.3473 in.
b) In the direction
C019 F066 of the piston pin
Table 1
-
Model Oversized Cylinder Liner 1
·
D1102-B 76.500 to 76.519 mm
V1502-B 3.0118 to 3.0126 in.
D1302-B 82.500 to 82.522 mm
V1702-B Hone to 1.2 to 2µR max.
3.2480 to 3.2489 in.
·----
01402-B 85.500 to 85.522 mm
V1902-B 3.3661 to 3.3670 in.

Table 2
Oversize Model Code Number Part Name Mark

D1102-8 15221-2191-1 Piston 05

V1502-B 15501-2109-1 Piston 1 9 05 assembly
-
0.5 mm D1302-B 15201-2191-1 Piston 05
05 0S
0.0197in. V1702-B 15201-2109-1 Piston ring 05 assembly
D1402-B 15521-2191-1 Piston 05
V1902-B 15521-2109-1 Piston ring 05 assembly
-.

69
KiSC issued 09, 2007 A
 0 Testing Water Tightness of Radiator
1) ) Pou r the specified am ou n t of water i nto the radi ator.
2) Start engi ne wa rm-u p.
3) Attach a radiator tester. I ncrease water pressu re to the
specified pressu re 88.3 kPa. (0.9 kgf /cm 2 , 12.8 l b./sq.i n.).
4) Check to see if water lea ks from any part.

C042F055

f) Testing Opening Pressure of Radiator Cap

1) ) Attach a radi ator tester to the radi ator cap.

2) Appl y the specified p ressu re 88.3 kPa. ( 0.9 kgf /cm 2 , 12.8
12.8 l b./sq.i n.) .
3) Check that the pressu re does not d rop by more than 29.4
k Pa. ( 0.3 kgf /cm 2 , 4.3 l b./sq.i n .) i n 10 seconds.

C019F068

8 Testing Operating Temperature of Thermostat

1) ) Place a therm ostat and a the rm ometer i n water a nd
heat the water.
2) Check to see if the thermostat begi ns to open at 80.5 to
83.5°C ( 176.9 to 182.3°F) .
3) Check to see if the thermostat opens f u l l y arou n d 95°C
( 203° F ) .
4) I f the measu remen t is not accepta ble, repl ace the thermo-
stat.

Terriperciture opletely
opens
l
Distanc: ··I ift

95''C
C019 F069 l... 203"F

8 Checking and Adjusting Fan Belt Tension

(a) Fan pulley (b) Alternator pulley
1) ) Check to see i f bel t tension al l ows a depressi on of
the specif ied am ou nt when the belt is pressed down by
the thu m b m idway between the fa n pu l ley an d the al te
rnator pu l ley .
2) To adjust the tensi on , m ove the a l te rnator positi on.

Reference value
10 to 12 mm
(c) Fan drive pulley 0.394 to 0.472 in.
When the belt is pressed down with pressure of 98 N.(10 kgf.,
221b.)
C019 F070

70
KiSC issued 09, 2007 A
Section N

1. TROUBLESHOOTING ...................................................................................................... 72

2. ALTERNATOR AND REGULATOR

Checks ........................................................................................................................................ 76
Disassembl y and Reassembly .................................................................................................. 80
Servici ng ................................................................................................................................. 81

3. STARTER AND GLOW PLUG

Checks .................................................................................................................................85
Diassembly and Reassembly .................................................................................................... 88
Servicing ....................................................................................................................... 92

71
KiSC issued 09, 2007 A
1.TROUBLESHOOTI NG

Charge warni ng lam p does

not go off .

Al ternator r u ns normal l y. --1-.-cCharge warning lam p di m. )1--------

( t'ge warning lam p goes).--------

(Slow speed. )
Alternator does not run
normally.
72 C Does not

run at al I.

KiSC issued 09, 2007 A

)1-------

KiSC issued 09, 2007 A

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.

73
KiSC issued 09, 2007 A
 SI ow engine speed.

Not mesh ing sound from

pi nion and n ng gea r

(Pinion shifts repeatedl y )1---------------------

Does not tu rn red at al l.

(Turns red too quickl y )1---

74 KiSC issued 09, 2007 A
 Reference

Over-running clutch slips. 95

Poor contact of contact plate. 85,86

Faulty starter. Poor contact between brush and commutator. 92, 94

85,86
Armature and field coil shorted. 93. 94
Bearing worn. 95,96

Main switch faulty.

85.86
Pinion does not pop out by the Faulty magnet switch.
87
attraction force of magnet switch. Screw spline rusted.

Faulty battery.

Battery not sufficiently charged.

Faulty battery. Poor terminal contact.

Grounded poorly.

broken.

Incorrect wiring between battery and glow plug.

Glow plug indicator disconnected.

Glow plug disconnected.

Main switch or starter switch faulty.

Shorted between glow plug indicator and glow plug.

--------
....._
Circu it shorted. [
rt: Glow plug indicator shorted.
Glow plug shorted.

Glow plug cable shorted.

87

75
KiSC issued 09, 2007 A
2.ALTERNATOR AND REGULATOR

Checking Sequence
If the charging system is malfunctioning, check as
follows to find the cause.

( B) Coupler voltage check (2)

(A) Output current check (1) ==1-

(C) No load testing of alternator (3) -{ D) Rotor coil, slip ring and brush
{ E) Cut-in voltage check (5)
check (4)

( G) Regulator check (7)

( F) No-load regulating voltage
check (6)

0 Checking Output Current

1) Discon nect the cable from the al ternator's B termi nal and
con nect an am meter and vol tmete r to B te rmi nal. Then
switch on al l elect rical loads (such as l igh ts) an d read the
mete rs.

( Note for checking)

(b) Alternator • Be sure to disconnect the battery's negative cable before
setting the ammeter and voltmeter.
• When the electrical load is considerably low or the battery
is fully charged, the specified readi ng cannot be obtained.

C022 F037

f) Checking Coupler Voltage

1) ) Remove the cou pler from the al te rnator.
(a) Coupler 2) Tu rn the mai n switch on and then measure the vol tage
across the al tern ator couple r's F a nd E termi n als.

C022F038

76 KiSC issued 09, 2007 A

 @) No- Load Testing of Alternator
1) Remove the al ternator's coupl er, connect the al ternator's
F 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 min-1(rpm) Next, tu rn the mai n switch off ,
di sconnect the battery's negati ve cable and measu re
t he voltage.

( Note for testing)

• Be sure to disconnect the battery's negative cable before
C022F040 setting the voltmeter.

8 Checking Rotor Coil, Slip R ing and Brush

1 ) Discon nect the al ternator cou pl e r and then measu re th e
resistance across the al te rnator's F a nd E term i nals.

C022 F089

0 Checking Cut- In-Voltage

1 ) Con nect a vol tmete r across the al ternator's N termi nal and
the body.
2 ) Remove the 4th 8A f use from the left and connect a bul b
(30W) i n i ts place.
3) Speed up th e al ternator u n ti l the ch arge warni n g l am p
goes off or d i ms, then read the vol tmeter.

C022F041

77 KiSC issued 09, 2007 A

 0 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-1
(rpm)) where the alternator is self-excited, a nd d iscon nect
the battery's negative cable.
3) Read the vol tmeter while gradual l y accele rati n g the engine.

( Note for checking)

• Be sure to grad ually accelerate the engine whi le reading
C022F042 the voltmeter. Never obtain the specified engine speed by
decelerati ng the engine from maxi m um speed.

Regulator
(1) Checking Test Terminals IG-F
1) Con nect a ci rcuit tester across the regul ator's coupler I G
(bl ack /wh ite) and F (wh i te/green ) termi nal and measure
the resistance.
2) I f the readi ng exceeds zero ohms, the vol tage regul ator's
l ow-speed side contact is faul ty.

IG N F

(1) Voltage regulator

---
(2) I.G. (Black/white)
(3) F (White/green)
(4) Voltage relay

C022F046
E L B

(2) Checking Test Terminals IG-F

1) Con nect a ci rcui t tester across I G (bl ack/whi te) and F
(wh i te/green ) and read the tester wh i l e pressi ng the
vol tage regul ator with a finger.
2) I f the readin g is i nf in ity, the control resistor is broken .

(1) I.G. (black/white)

(2) F (white/green)

78
KiSC issued 09, 2007 A
 (3) 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.

-
Terminals Voltage Voltage Normal
Relay Re_g_'::'_lator Resistance n Failure and Probable Causes

Stationary If reading is over 0, bad contact on

state
- 0
L - E voltage relay point P1.
(white/red) (black) If reading is 0, deposition occurs on
Pull approx. 100 voltage relay point P1.
If reading is oo, voltage coil is cut.
1---
·---·· -·-- ·--·-- ..
-
'

N If reading is 0, relay coil is shorted.

(white/black) (black) - approx. 23
If reading is ""', pressure coil is cut.
--···
B - E If reading is not oo voltage relay
(white) (black) Stationary - 00
point P2 is melted and burned.
·-·
B L If reading is over 0, bad contact on
(white) (white/red) Pull - 0
voltage relay _point P2.
NOTES:
a) "Pull" means the condition where the armature point is contacting the high-speed side point P2
with finger pressure only.
b) "Stationary" means the condition where the armature point is in contact with the low-speed side
point P1.

79 KiSC issued 09, 2007 A

 0 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)

• Do not forget tc;> refit the collar and the spacer.

C, Removing Rotor
1) Draw the rotor out.

( Note for reassembli ng)

• To refit the rotor, thread a wi re th rough the access hole
and lif t the brush u p with it.

(d) End frame

(e) Slip ring (f ) Bearing

80 KiSC issued 09, 2007 A

 0 Removing Rectifier
1) Remove the n uts.
2) Remove the end cover.
3) 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.

(1) Insulation washer

(2) Positive diode holder

0 Checking and Refining Slip R ing

1) ) Check to see if the sl i p ri ng is flawed.
2 ) I f it is flawed , correct with sand paper or on a l athe.

( 1) Sand paper

81
KiSC issued 09, 2007 A
 f) 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.

0 Checking Brush Wear

1) ) Check the length of the brush. I f the length is shorter
than the l i m it, repl ace i t.
2) Ma ke sure th at n o powder cli n gs to the brush and that the
brush moves smooth l y.
3) I f the brush is fa ul ty, replace.

• Brush dimensions

82
KiSC issued 09, 2007 A
 (3 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
connecting terminal (outside).
2) If any diode is faulty, replace its whole positive diode
assembly.

(Im porta nt)

• When reassembli ng, remember that diodes are very sensi-
tive to heat.
Reference value
If the ohmmeter indicates a specified value when the positive
probe is applied to the M6 screw and the negative probe to the
coil connecting terminal, and if it indicates infinity when the
probes are reversed, the positive diodes are normal.

83
KiSC issued 09, 2007 A
 a
,.
w Checking Negative Diodes
1 ) 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)
• When reassembling, remember that diodes are very sensi-
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-
tive probe to the M5 screw, and if it indicates infinity when the
probes are reversed, the negative diodes are normal.

C)) Checking Conduction across N Terminal and

Coil Connecting Terminal
1) Check the conduction across N terminal and coil connect·
ing terminals (inside) .
2) If not conducting, replace.

(1) N terminal

84 KiSC issued 09, 2007 A

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

---• E) Motor test ( 2).

( D) Test the starter at no-l oad (1).
0-----·F ) Magnet switch check (3).

0 No- Load Testing of Starter

1) Connect the a m meter's positive probe to the battery's
positive term i nal and the nega tive probe to the sta rter's
B termi nal.
2) Con nect the battery 's negati ve termi nal to the sta rter
body.
3) Con nect the vol tmeter's posi tive probe to the sta rter's B
term i n al and the negative probe to the starter body.
4) Set a tachomete r.
5) Connect the starter's B termi nal to the magnet switch 's S
ter m i na l.
6) Check to see that the magnet switch is operat i ng a nd that
t he specif ied speed, current a nd vol tage are obta i ned.

( Note for checking)

• Use a fully .charged battery.
• Use an ammeter and leads of about 200A rating because a
large current flows when the starter is runni ng.

Model Current Voltage Rotational speed

D1102·B 45A or less
1
6000min (rpm) or more
D1302-B 11.0V

D1402-B
V 1502-B 1
3000min. (rpm) or more
90A or less 11.5V
V1702-B
V1902-B

(A) Electrical connections for no-load testing

C022F072

C022F056

85 KiSC issued 09, 2007 A

 f) 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; if not, the motor is defective.

(A) Electrical connections for motor test

(a) Starter

C022F073

(c)
B terminal
C022F057

Magnet Switch
(1) Pull-In Coil (Attraction Test)
1) Appl y 1/2 the rated vol tage (approx. 6V) across the S
termi n al and C termi nal .
2) I f the pl u nger is attracted strongl y , the pul l -i n coi l is good;
if not, it is defecti ve.

86
KiSC issued 09, 2007 A
 (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.

0 Checking Glow Plug

1) ) Discon nect the gl ow pl ug cables a nd leads.

2) Con nect a ci rcui t tester across the screw of the gl ow pl ug
end and the body.
• I f the resista nce is zero ohms, the glow pl ug is shorted.
• I f the resistance is i nfi ni te, the glow pl ug coi l is broken .

87 KiSC issued 09, 2007 A

• MAGNET SWITCH TYPE STARTER

0 Removing Magnet Switch

1) Remove the connecti ng lead .
2) Remove the set screws.
3) Detach the magnet switch by 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.

f) Removing Armature Brake

1) Remove the end frame cap.
2) Remove the washers.
3) Remove the packi ng.

8 Removing End Frame

1) R emove the t hrough bolts.
2) R emove the end frame.

e Removing Brush Holder

1) D raw out the brush from the holder whi le hold i ng the
spring up.
2) Take off the brush holder.

( Note for reassembli ng)

• Be sure not to mistake the d i rection a nd position of the
spring.
• Do not contact the body with the positive brush's lead.

88
KiSC issued 09, 2007 A
 Q Removing Voke
1) ) Draw out the yoke from the d rive end frame.

(Note for reassembling)

• Take care for yoke knock pin.

0 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.
3) Detach the d rive l eve r.

(Important)
• When reassembling, be sure not to mistake the installing
direction of the drive lever.

C0:!2F07-t

89 KiSC issued 09, 2007 A

• REDUCTION TYPE STARTER

0 Removing Motor
1) Discon nect the connecti ng l ead .
2) Remove the th rough bol ts.
3) Remove the motor un it.

fj Removing Brush Holder

1) ) Release the spri n g and d raw the brush out from the holder.
2) Remove the brush holder.

C) Removing Armature
1) ) Draw the armature out.

90
KiSC issued 09, 2007 A
 8 Removing Drive End Frame
1) Remove the drive end frame.
2) Remove the gears (drive pinion, idler gear) and clutch.

0 Removing Plunger
1) Remove the end cover from the magnet switch.
2) Draw the plunger out.
3) Remove steel balls.

91 KiSC issued 09, 2007 A

 0 Staining or Burning of Commutator
1) Check to see if the comm utator su rface is stained or bu rnt.
2) I f i t is bu rnt, gri nd off with fi ne-g rai n sand pa per.

(1) Sand paper

@ Checking Commutator Wear

1) Check to see if the contact face of the brush is scored.
2) If scored, gri nd off with sand paper or on a l athe.
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
D1102-B 32.7 mm 32.5 mm
D1302-B 1.2874 in. 1.2795 in.
D1402-B
V1502-B 30.0 mm 29.0 mm
V1702-B 1.1811 in. 1.1417 in.
V1902-B

(a) Bad (bl Good

8 Checking Mica (Undercut)
1) Check to see the mica unde rcut.

(c l B f)
2) I f i t has h igh m ica, rectif y with a saw blade. As the edge
of the segment wil l be rough, chamf er it.

(d) Mica

Good Mica depth

Model Reference value Allowable limit
01102-B 0.5 to 0.8 mm
01302-B 0.0197 to 0.315 in.
0.2 mm
D1402-B 0.0079 in.
V1502-B 0.5 to 0.9 mm
V1702·B 0.0197 to 0.0354 in.
C022 P058 V1902-B

92 KiSC issued 09, 2007 A

 0 Grounding of Armature Coil
1 ) Check conduction across the com mutator and the
a rmatu re shaft.
2) I f cond ucti n g, repl ace.

0 Checking Armature Flexure

1) Measu re the amoun t of flexu re; i f the measu remen t
exceeds the reference val ue, replace. Caref ul l y check to
see if the core is scratched.

C, Checking Armature Coil Short-Circuited

1) Set the armature on the ar matu re tester. Rotate the

armatu re whi le touch i n g it wi th steel piece.
2) I f the steel piece starts to vi brate or to be attracted some-
where on the armatu re, this suggests that the coi l contains
a l ayer short at that poi n t.
3) I f faul ty, repl ace.

@ Checking Field Coil Breakage

1) ) To check cond uction , pl ace the tester probes onto
the lead and b rush .
2) I f either are n ot cond ucti ng, replace.

93 KiSC issued 09, 2007 A

 (;) Grounding of Field Coil
1 ) To check the conducti on . Place the tester probes onto the
f ield coil and yoke.
2) If either are conducti ng, repl ace.

Should not

CJ) Checking Brush Wear

1) ) Check to see if the brush has worn to more than
2/3 below the standard dimensi ons.
2) I f wear exceeds the al l owable l i mi t, repl ace.

...
: :f
I
I
I
I
,;"''
,
,,'
I

J
,' • Starter brush dimensions
Model Length
...
Width Thickness
C022F059 19 mm 12 mm 7 mm
D1102-B
D1302-B 0.7480 in. 0.4724 in. 0.2756 in.
D1402-B
V1502-B 19 mm 25 mm 8 mm
V1702-B 0.7480 in. 0.9843 in. 0.3150 in.
V1402-B

Ci) Checking Brush Spring Tension

1) ) Measu re the tension with a new brush i n pl ace.
2) Replace if the tension is un der the reference val ue.

Reference value
(a) Spring hanger
Model Spring tension Commutator diameter

01102-B 11.8 N.
32.7 mm
1,200 g
D1302-B 1.2874 in.
(b) Attach the brush spring 2.64 lb
in this method. D1402-B
V1502-B 17.5 to 23.7N.
30.0mm
V1702-B 1,785 to 2,415 g
1.1811in.
3.94 to 5.33 Ib
V1902-B
Co22F077

94
KiSC issued 09, 2007 A
 4D Grounding of Brush Holder
1) Check the insulation of the positive brush holder.
2) If the insulation is defective, replace.

CB 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.

(A) Adjustment of pinion gap Checking and Adjusting Pinion Gap

(Magnet Switch Type)
1) Disconnect the connecting lead from C terminal.
2) Energize the magnet switch and measure the gap between
the pinion tip and the stop collar.
3) To adjust the gap, change the length of the magnet switch
joint to the specified one.

(a) Pinion gap _ I (b)

Pinion juts
out to this position

L
(d) T rning the joint
alters its length
C022F07fi

95
KiSC issued 09, 2007 A
 Checking Gap between Shaft and Bush
(Magnet Switch Type)
1 ) Measu re the i nside d iameters of the beari ng bush i ngs on
the side of the d ri ve and comm utator.
2) Measu re the d rive-side and comm utator-side shaf t
d iameters and calculate the gap.
3) I f the ga p exceeds the allowa ble l i mi t, use an u ndersi ze
bush.

----------
D1102-B, D1302-B

• Diameter
Drive s ofdia.
shaft shaft and bush 12.5mm, 0.4921 in.

Commutator shaft dia. 12.5mm, 0.4921 in.

Drive bushing ID 1 2.54mm, 0.4937 in.

Commutator bushing ID 12.56mm, 0.4945 in.

Cl) Checking Bearing (Reduction Type)

1 ) Apply torq ue to the i n ner ri n g with you r fin ger ti ps and
check to see if i t tu rns smoothl y.
2) Check to see if there a re a ny stran ge noises when d ri ven
quickl y.

96 KiSC issued 09, 2007 A

Section V

SERVICE DIRECTIONS
Service Di rections ...........................................................................................................................98
Bolt Torques .......................................................................................................................... 102

97 KiSC issued 09, 2007 A

 D1102-B D1302-B D1402-B V1502-B V1702-B V1902-B

CYLINDER HEAD
Distortion of cylinder head surface 0.05 mm (0.0020 in.)

Thickness of gasket 1.30 to 1.60 mm (0.0512 to 0.0630 in.)

Thickness of gasket shims 0.2 mm (0.0079 in.)

Top clearance 0.7 to 0.9 mm (0.0276 to 0.0354 in.)

VALVES * R.V.: R eference Value A.L.: Allowable Limit

Valve seat width 2.1 mm (0.0827 in.)
-" '"'-- --
Valve seat angle 0.785 rad. ( 45°)
I----- ..

0.0. of valve stems ( Intake, Exhaust) 7.960 to 7.975 mm (0.3134 to 0.3140 in.)

1. 0. of valve guides ( Intake, Exhaust) 8.015 to 8.030 mm (0.3156 to 0.3161 in.)

Clearance between valve stems and (R.V.) 0.04 to 0.07 mm (0.0016 to 0.0028 in.)
guides ( A.L.) 0.1 mm (0.0039 in.)

( R.V.) 1.1 to 1.3 mm (0.0433 to 0.0512 in.)

Valve recessing
( A.L.) 1.6 mm (0.0630 in.)

Valve clearance ( Intake, Exhaust) Cold 0.18 to 0.22 mm (0.0071 to 0.0087 in.)

VALVE SPR INGS

( R.V.) 41.7 to 42.2 mm ( 1.6417 to 1.6614 in.)
Free length
( A.L.) 41.2 mm (1.6220 in.)
-Fitted length ·-·
35.15 mm (1.3839 in.)

(R.V.) 117.7 N. (12 kgf., 26.5 lb.)

Load to compress to fitted length
( A.L.) 100.0 N. ( 10.2 kgf., 22.5 lb.)

Squareness 1.0 mm (0.0394 in.)

ROCKER ARMS
0.0. of rocker arm shafts 13.973 to 13.984 mm (0.5501 to 0.5506 in.)
1. 0. of rocker arm bushings 14.002 to 14.043 mm (0.5513 to 0.5529 in.)
1. 0. of rocker arm (Bushless type) 14.002 to 14.043 mm (0.5513 to 0.5529 in.)
Clearance between rocker arm shafts (R.V.) 0.018 to 0.070 mm (0.0007 to 0.0028 in.)
and bushings or rocker arms (A.L.) 0.15 mm (0.0059 in.)
Adjustment of compression release 0.750 to 1.125 mm (0.0295 to 0.0443 in.)

98 KiSC issued 09, 2007 A

 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.)

Clearance between camshaft bearing ( R.V.) 0.050 to 0.091 mm (0.0020 to 0.0036 in.)
journals and bearings (A.l.) 0.15 mm (0.0059 in.)

Alignment of camshaft ( A.L.) 0.01 mm (0.00039 in.)

( R.V.) 33.36 mm (1.3134 in.)
( Intake)
( A.L.) 33.31 mm (1.3114 in.)
Cam height -----
(R.V.) 33.36 mm (1.3134 in.)
( Exhaust) -- -·
( A.L.) 33.31 mm (1.3114 in.)

( R.V.) 0.042 to 0.115 mm (0.0017 to 0.0045 in.)

Gear backlash
( A.L.) 0.15 mm (0.0059 in.)

CYLINDER LINERS
76.000 to 82.000 to 85.000 to 76.000 to 82.000 to 85.000 to
76.019 mm 82.022 mm 85.022 mm 76.019 mm 82.022 mm 85.022 mm
( R.V.)
( 2.9921 to (3.2283 to (3.3465 to ( 2.9921 to (3.2283 to (3.3465 to
I.D. of cylinder liner
2.9929 in.) 3.2292 in.) 3.3473 in.) 2.9929 in.) 3.2292 in.) 3.3473 in.)
-
(A.L.) +0.15 mm (+0.0059 in.)

PISTON RINGS
( R.V.) 0.30 to 0.45 mm (0.0118 to 0.0177 in.)
(Top ring. 2nd ring)
( A.L.) 1.25 mm (0.0492 in.)
R ing gap
(R.V.) 0.25 to 0.45 mm (0.0098 to 0.0177 in.)
(Oil ring)
( A.L.) 1.25 mm (0.0492 in.)

(Top ring) -
---- ----
Side clearance of ring in groove ( 2nd ring) 0.093 to 0.120 mm (0.0037 to 0.0047 in.)
-,

(Oil ring) 0.020 to 0.052 mm (0.0008 to 0.0020 in.)

Oversizes of piston and ring 0.5 mm (0.0197 in.)

PISTONS
(R.V.) 23.000 to 23.013 mm (0.9055 to 0.9060 in.)
I.D. of piston bosses
(A.L.) 23.053 mm (0.9076 in.)
----
O.D. of piston pin 23.002 to 23.011 mm (0.9056 to 0.9059 in.)

I.D. of connecting rod small end bushings 23.025 to 23.040 mm (0.9065 to 0.9071 in.)
(fitted) [Service Part 23.026 to 23.069 mm (0.9065 to 0.9082 in).]

0.014 to 0.038 mm (0.0006 to 0.0015 in.)

Clearance between pi.ston pm.
and sma 11 (R.V.) [Service Part 0.015 to 0.067 mm (0.0006 to 0.0026 in.) ]
end bushings
(A.L.) 0.15 mm (0.0059 in.)

Connecting rod small end parent bore dia. 26.000 to 26.013 mm (1.0236 to 1.0241 in.)
(R.V.) 0.02 mm (0.0008 in.)
Connecting rod alignment
( A.L.) 0.05 mm (0.0020 in.)

99 KiSC issued 09, 2007 A

 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.)

I.D. of crankshaft bearing 1 51.980 to 52.039 mm (2.0465 to 2.0488 in.)

- - --··----- --·-·- -

I.D. of crankshaft bearing 2 51.980 to 52.025 mm (2.0465 to 2.0482 in.)

Clearance between crankshaft journal ( R.V.) 0.040 to 0.118 mm (0.0016 to 0.0046 in.)
---
and bearing 1 (A.L.) 0.20 mm (0.0079 in.)
-- . -····-·.

Clearance between crankshaft journals ( R.V.) 0.040 to 0.104 mm (0.0016 to 0.0041 in.)
and bearing 2 (A.L.) 0.20 mm (0.0079 in.)
---

Undersizes of crankshaft bearing 1 0.2 mm (0.0079 in.) 0.4 mm (0.0157 in.)

Undersizes of crankshaft bearing 2 0.2 mm (0.0079 in.) 0.4 mm (0.0157 in.)

0.D. of crankpins 43.959 to 43.975 mm (1.7307 to 1.7313 in.)
..... --··-··"· .. -- -
I.D. of crankpin bearings 44.010 to 44.052 mm (1.7327 to 1.7343 in.)
( R.V.) 0.035 to 0.093 mm (0.0014 to 0.0037 in.)
Clearance between crankpins and . .. ..-
bearings ( A.L.) 0.20 mm (0.0079 in.)
Undersizes of crankpin bearings 0.2 mm (0.0079 in.) 0.4 mm (0.0157 in.)
--

( R.V.) 0.15 to 0.31 mm (0.0059 to 0.0122 in.)

End play of crankshaft
( A.L.) 0.5 mm (0.0197 in.)

Oversizes of crankshaft side metal 1.2 0.2 mm (0.0079 in.) 0.4 mm (0.0157 in.)

FUEL INJECTION NOZZELS

Opening pressure 13.7 to 14.7 MPa. (140 to 150 kgf/cm2 1990.8 to 2133.0 lb./sq. in.)

Dry nozzle at 12.7 to 13.7 MPa.

Fuel tightness of nozzle valve seat 2
(130 to 140 kgf/cm , 1848.6 to 1990.8 lb./sq.in.)

INJECTION PUMP
8 seconds or more; initial pressure from 9.8 MPa. to 490.3 kPa.
( R.V.)
(600 to 500 kgf/cm2 8532,0 to 7110,0 lb./sq.in,)
Fuel tightness of plunger I

( A.L.) 4 seconds or less

.
.,.

10 seconds or more; initial pressure from 9.8 to 0.5 MPa.

( R.V.)
Fuel tightness of delivery valve ( 100 to 5 kgf/cm2 , 1422.0 to 71.1 lb./sq. in.)

( A.L.) 5 seconds or less

Injection timing 0.401 to 0.436 rad. ( 23 to 25°) before TDC

OIL PUMP
0iI pressure ( R.V.) 294.2 to 441.3 kPa. (3.0 to 4.5 kgf/cm 2 , 42. 7 to 64.0 lb./sq. in.)
(Normal running) ( A.L.) 245.2 kPa. (2.5 kgf/cm2 , 35.6 lb./sq. in.)

0. 10 to 0. 16 mm 0.04 to 0.13 mm
( R.V.)
Rotor lobe clearance (0.0039 to 0.0063 in.) (0.0016 to 0.0051 in.)
--

( A.L.) 0.20 mm (0.0079 in.)

ROTOR TYPE -·--
Radial clearance between outer rotor (R.V.) 0.11 to 0.19 mm ( 0.0043 to 0.0075 in.)
--
and pump body ( A.L.) 0.25 mm (0.0098 in.)

End clearance between rotor and ( R.V.) 0.105 to 0.150 mm (0.0041 to 0.0059 in.)
cover ( A.L.) 0.2 mm (0.0079 in.)

100 KiSC issued 09, 2007 A

 D1102-B D1302-B D1402-B V1502-B V1702-B V1902-B

RADI ATOR
Opening pressure of cap 88.3 kPa. (0.9 kgf/cm2 , 12.8 lb./sq. in.)
...
Test pressure 88.3 kPa. (0.9 kgf/cm2 , 12.8 lb./sq. in.)

THERMOSTAT
(beginning) 80.5°C to 83.5°C (176.9°F to 182.3°F)
Opening temperature
(full-open) 95°C (203°F)

Distance of lift 8 mm (0.3150 in.)

FANBELT

Belt sag under load of 98N. ( 10 kgf.,221b.) 10 to 12 mm (0.394 to 0.472 in.)

ALTERNATOR
Output current 25 A/14 V /4000 min-1(rpm)

Total resistance of rotor coil, measured ( R.V.) 6n

between terminal "F" and "E" ( A.L.) ,on
-- -
( R.V.) 15.5 mm (0.6102 in.)
Brush length
( A.L.) 10.3 mm (0.4055 in.)

R EGULATOR
Cut-in voltage 4.5 to 5.8 V

No-load regulating voltage 13.8 to 14.8 V

---.··-

R esistance between terminals:

"IG" and "F" with open contacts
on
·-·-·-
-

"IG" and "F" with contacts Approx. 11 n

--
··-
"L" and "E" with open contacts .,,, ,
on ,,,, ..
,

"L" and "E" with contacts

····-
Approx. 100 n
N" and E" Approx. 23 n
11 II

"B" and "E" with open contacts Infinity

..._,_ -· -··--····
·-· · -.., --·-
8" and "L" with contacts
11
on
Point gap 0.3 to 0.45 mm (0.0118 to 0.0177 in.)

STAR TER MOTOR

Current 45 A or less 90 A or less
-----·-
No-load test Voltage 11 V 11.5 V

Speed 6000min-1(rpm) or more 3500 min-1(rpm) or more

( R.V.) 32.7 mm ( 1.2874 in.) 30.0 mm ( 1.1811 in.)

0.D. of commutator
( A.L.) 32.5 mm ( 1.2795 in.) 29.0 mm (1.1417 in.)
..--· ··-
0.5 to 0.8 mm 0.5 to 0.9 mm
( R.V.)
Mica undercutting (0.0917 to 0.0315 in.) (0.0197 to 0.0354 in.)

( A.L.) 0.2 mm (0.0079 in.)

( R.V.) 19 mm (0.7480 in.)

Brush length --- --·--
( A.L.) 12.7 mm (0.5000 in.)

GLOW PLUG

101 KiSC issued 09, 2007 A

 Bolt Torques

Material Grade Standard Bolt Special Bolt Special Bolt

Nominal Dia. SS41, S20C S43C, S48C (Refined) SCR3, SCM3 (Refined)

1----

7.8 9.3 N·m 9.8 - 11.3 N-m 12.3 14.2 N·m

M 6 0.80 0.95 kgf,m 1.00 1.15 kgf-m 1.25 1.45 kgf.m
5.8 - 6.9 lb.ft. 7.2 - 8.3 lb.ft. 9.0 - 10.5 lb.ft.
·- --·-
17.7 - 20.6 N-m 23.5 27.5 N·m 29.4 - 34.3 N·m
M 8 1.80 2.10 kgf,m 2.40 2.80 kgf,m 3.00 3.50 kgf -m
13.0 - 15.2 Ib.ft. 17.4 20.3 lb.ft. 21.7 - 25.3 lb.ft.
--
39.2 45.1 N·m 48.0 - 55.9 N-m 60.8 - 70.6 N-m
M10 4.00 - 4.60 kgf·m 4.90 5.70 kgf·m 6.20 - 7.20 kgf ,m
28.9 - 33.3 lb.ft. 35.4 - 41.2 Ib.ft. 44.8 - 52.1 lb.ft.
-··
62.8 72.6 N,m 77 .5 - 90.2 N·m 103.0 117.7 N·m
M12 6.40 7.40 kgf -m 7.90 9.20 kgf·m 10.50 12.00 kgf·m
46.3 53.5 lb.ft. 57.1 - 66.5 lb)t. 75.9 - 86.8 lb.ft.
107.9 - 125.5 N,m 123.6 - 147.1 N,m 166.7 - 196.1 N·m
M14 11.00 - 12.80 kgf·m 12.60 15.00 kgf -m 17.00 - 20.00 kgf·m
79.6 - 92.6 lb.ft. 91.1 - 108.5 1b.ft. 123.0 - 144.7 lb.ft.
166.7 - 191.2 N·m 196.1 225.5 N-m 259.9 304.0 N·m
M16 17.00 19.50 kgf,m 20.00 23.00 kgf·m 26.50 31.00 kgf·m
123.0 - 141.0 lb.ft. 144.7 - 166 .4 Ib.ft. 191.7 - 224.2 lb.ft.
245.2 284.4 N-m 274.6 318.7 N·m 343.2 - 402.0 N·m
M18 25.00 - 29.00 kgf·m 28.00 - 32.50 kgf·m 35.00 - 41.00 kgf -m
180.0 - 209.8 lb.ft. 202.5 - 235.1 lb.ft. 253.2 296.5 I b.ft.
333.4 392.2 N·m 367.7 - 431 .5 N·m 490.3 - 568.7 N-m
M20 34.00 40.00 kgf·m 37.50 44.00 kgf·m 50.00 58.00 kgf·m
245.9 - 289.3 lb.ft. 271.2 - 318.2 lb.ft. 361.6 - 419.5 lb.ft.

Bolt material grades are shown by numbers punched on the bolt heads. Prior to tightening, be sure to check out the numbers as
shown below:

Punched
Bolt Material Grade
Number
Standard Bolts
None
SS41, S20C
Special Bolts
7
S43C, S48C (Refined)
Special Bolts
9 SCM3, SCR3 ( Refined)

102
KiSC issued 09, 2007 A
 EDITOR:
KUBOTA FARM & INDUSTRIAL MACHINERY SERVICE, LTD.
64, ISHIZU-KITAMACHI, SAKAI-KU, SAKAI-CITY, OSAKA, 590-0823, JAPAN
PHONE : (81)72-241-1129
FAX : (81)72-245-2484
E-mail : ksos-pub@kubota.co.jp

Printed in Japan 2007. 09, S, T, EI, e Code No.9Y011-02600

KUBOTA Corporation 2003. 08, S, T, EI, e