Kubota SM-E4B Series Workshop Manual
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Kubota SM-E4B Series Workshop Manual

Kubota SM-E4B Series Workshop Manual

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WORKSHOP MANUAL
DIESEL ENGINE
SM-E4B SERIES
KiSC issued 01, 2013 A

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Summary of Contents for Kubota SM-E4B Series

  • Page 1 WORKSHOP MANUAL DIESEL ENGINE SM-E4B SERIES KiSC issued 01, 2013 A...
  • Page 2 TO THE READER This Workshop Manual tells the servicing personnel about the mechanism, servicing and maintenance of SM-E4B series. It contains 4 parts: "Information", "General", "Mechanism" and "Servicing". Information This section primarily contains information below. • Safety First • Specification •...
  • Page 3 INFORMATION KiSC issued 01, 2013 A...
  • Page 4 INFORMATION CONTENTS 1. SAFETY FIRST ..........................I-1 2. SPECIFICATIONS.......................... I-4 3. PERFORMANCE CURVES......................I-6 4. DIMENSIONS ..........................I-11 KiSC issued 01, 2013 A...

  • Page 5: Safety First

    INFORMATION SM-E4B SERIES, WSM 1. SAFETY FIRST SAFETY FIRST • This symbol, the industry's "Safety Alert Symbol", is used throughout this manual and on labels on the machine itself to warn of the possibility of personal injury. Read these instructions carefully.
  • Page 6 INFORMATION SM-E4B SERIES, WSM OPERATE SAFELY • Do not use the machine after you consume alcohol or medication or when you are tired. • Put on applicable clothing and safety equipment. • Use applicable tools only. Do not use alternative tools or parts.
  • Page 7 INFORMATION SM-E4B SERIES, WSM KEEP A GOOD AIRFLOW IN THE WORK AREA • If the engine is in operation, make sure that the area has good airflow. Do not operate the engine in a closed area. The exhaust gas contains poisonous carbon monoxide.

  • Page 8: Specifications

    INFORMATION SM-E4B SERIES, WSM 2. SPECIFICATIONS Model Z482-E4B Z602-E4B Number of Cylinder Type Vertical, Water-cooled, 4 cycle IDI diesel engine Bore × Stroke 67.0 × 68.0 mm (2.64 × 2.68 in.) 72.0 × 73.6 mm (2.83 × 2.90 in.) Total Displacement 479.0 cm...
  • Page 9 INFORMATION SM-E4B SERIES, WSM Model D722-E4B D782-E4B D902-E4B Number of Cylinder Type Vertical, Water-cooled, 4 cycle IDI diesel engine Bore × Stroke 67.0 × 68.0 mm (2.64 × 2.68 in.) 67.0 × 73.6 mm (2.64 × 2.90 in.) 72.0 × 73.6 mm (2.83 × 2.90 in.) Total Displacement 719.0 cm...

  • Page 10: Performance Curves

    INFORMATION SM-E4B SERIES, WSM 3. PERFORMANCE CURVES Z482-E4B (1) Brake Horsepower (6) Net Intermittent Torque (11) Net Intermittent B.S.F.C. (15) Gross B.H.P. (2) Engine Speed (7) Net Continuous Torque (12) Gross Torque (16) Overload B.H.P. (3) B.S.F.C. (8) Gross Intermittent B.H.P.
  • Page 11 INFORMATION SM-E4B SERIES, WSM Z602-E4B (1) Brake Horsepower (5) Gross Intermittent Torque (9) Net Intermittent B.S.F.C. (12) Gross B.H.P. (2) Engine Speed (6) Net Intermittent Torque (10) Gross Torque (13) Overload B.H.P. (3) B.S.F.C. (7) Gross Intermittent B.H.P. (11) Overload Torque (14) Overload B.S.F.C.
  • Page 12 INFORMATION SM-E4B SERIES, WSM D722-E4B (1) Brake Horsepower (6) Net Intermittent Torque (11) Net Intermittent B.S.F.C. (15) Gross B.H.P. (2) Engine Speed (7) Net Continuous Torque (12) Gross Torque (16) Overload B.H.P. (3) B.S.F.C. (8) Gross Intermittent B.H.P. (13) Overload Torque (17) Continuous B.H.P.
  • Page 13 INFORMATION SM-E4B SERIES, WSM D782-E4B (1) Brake Horsepower (5) Gross Intermittent Torque (9) Net Intermittent B.H.P. (13) Overload Torque (2) Engine Speed (6) Net Intermittent Torque (10) Net Continuous B.H.P. (14) Gross B.H.P. (3) B.S.F.C. (7) Net Continuous Torque (11) Net Intermittent B.S.F.C.
  • Page 14 INFORMATION SM-E4B SERIES, WSM D902-E4B (1) Brake Horsepower (5) Gross Intermittent Torque (9) Net Intermittent B.S.F.C. (12) Gross B.H.P. (2) Engine Speed (6) Net Intermittent Torque (10) Gross Torque (13) Overload B.H.P. (3) B.S.F.C. (7) Gross Intermittent B.H.P. (11) Overload Torque (14) Overload B.S.F.C.

  • Page 15: Dimensions

    INFORMATION SM-E4B SERIES, WSM 4. DIMENSIONS Z482-E4B 9Y1210785INI0007US0 I-11 KiSC issued 01, 2013 A...
  • Page 16 INFORMATION SM-E4B SERIES, WSM Z602-E4B 9Y1210785INI0008US0 I-12 KiSC issued 01, 2013 A...
  • Page 17 INFORMATION SM-E4B SERIES, WSM D722-E4B 9Y1210785INI0009US0 I-13 KiSC issued 01, 2013 A...
  • Page 18 INFORMATION SM-E4B SERIES, WSM D782-E4B 9Y1210785INI0010US0 I-14 KiSC issued 01, 2013 A...
  • Page 19 INFORMATION SM-E4B SERIES, WSM D902-E4B 9Y1210785INI0011US0 I-15 KiSC issued 01, 2013 A...
  • Page 20 GENERAL KiSC issued 01, 2013 A...

  • Page 21: Table Of Contents

    GENERAL CONTENTS 1. ENGINE IDENTIFICATION ......................G-1 [1] MODEL NAME AND ENGINE SERIAL NUMBER..............G-1 [2] E4B ENGINE .......................... G-3 [3] CYLINDER NUMBER ......................G-3 2. GENERAL PRECAUTION ......................G-4 3. MAINTENANCE CHECK LIST ..................... G-5 4. CHECK AND MAINTENANCE ..................... G-7 [1] DAILY CHECK POINTS ......................

  • Page 22: Engine Identification

    GENERAL SM-E4B SERIES, WSM 1. ENGINE IDENTIFICATION [1] MODEL NAME AND ENGINE SERIAL NUMBER When contacting the manufacture, always specify your engine model name and serial number. The engine model and its serial number need to be identified before the engine can be serviced or parts replaced.
  • Page 23 GENERAL SM-E4B SERIES, WSM (Continued) Production Month and Lot Number Month Engine Lot Number January A0001 ~ A9999 B0001 ~ February C0001 ~ C9999 D0001 ~ March E0001 ~ E9999 F0001 ~ April G0001 ~ G9999 H0001 ~ J0001 ~ J9999...

  • Page 24: E4B Engine

    Non-Road Emission Standards continue to change. The timing or applicable date of the specific Non-Road Emission regulations depends on the engine output classification. Over the past several years, KUBOTA has been supplying diesel engines that comply with regulations in the respective countries affected by Non-Road Emission regulations. For KUBOTA Engines, E4B will be the designation that identifies engine models affected by the next emission phase (See the table below).

  • Page 25: General Precaution

    • When it is necessary to use special tools, use KUBOTA special tools. Refer to the drawings when you make special tools that you do not use frequently.

  • Page 26: Maintenance Check List

    : Change engine oil and replace oil filter cartridge after the first 50 hours of operation. • * : The items listed above (* marked) are registered as emission related critical parts by KUBOTA in the U.S. EPA nonroad emission regulation. As the engine owner, you are responsible for the performance of the required maintenance on the engine according to the above instruction.
  • Page 27 JUN87) • Since KUBOTA diesel engines of less than 56 kW (75 hp) utilize EPA Tier 4 and Interim Tier 4 standards, the use of low sulfur fuel or ultra low sulfur fuel is mandatory for these engines, when operated in US EPA regulated areas.

  • Page 28: Check And Maintenance

    GENERAL SM-E4B SERIES, WSM 4. CHECK AND MAINTENANCE [1] DAILY CHECK POINTS Checking Engine Oil Level 1. Level the engine. 2. To check the oil level, draw out the dipstick (1), wipe it clean, reinsert it, and draw it out again.
  • Page 29 GENERAL SM-E4B SERIES, WSM Checking and Replenish Coolant 1. Without recovery tank (2) : Remove the radiator cap (1) and check to see that the coolant level is just below the port. With recovery tank (2) : Check to see that the coolant level lies between FULL "A" and LOW "B".

  • Page 30: Check Points Of Initial 50 Hours

    GENERAL SM-E4B SERIES, WSM [2] CHECK POINTS OF INITIAL 50 HOURS Changing Engine Oil CAUTION • Be sure to stop engine before changing engine oil. 1. Start and warm up the engine for approx. 5 minutes. 2. Place an oil pan underneath the engine.
  • Page 31 Then, replenish the engine oil up to the specified level. IMPORTANT • To prevent serious damage to the engine, replacement element must be highly efficient. Use only a KUBOTA genuine filter or its equivalent. NOTE • The oil pan of 101 mm (3.98 in.) depth is optional for Z482-E4B and D722-E4B.

  • Page 32: Check Point Of Every 50 Hours

    GENERAL SM-E4B SERIES, WSM [3] CHECK POINT OF EVERY 50 HOURS Checking Fuel Hose 1. If the clamp (2) is loose, apply oil to the threads and securely retighten it. 2. The fuel hose (1) is made of rubber and ages regardless of the period service.

  • Page 33: Check Points Of Every 75 Hours

    GENERAL SM-E4B SERIES, WSM [4] CHECK POINTS OF EVERY 75 HOURS Changing Engine Oil (for Optional Depth Oil Pans) CAUTION • Be sure to stop engine before changing engine oil. 1. Start and warm up the engine for approx. 5 minutes.

  • Page 34: Check Points Of Every 100 Hours

    GENERAL SM-E4B SERIES, WSM [5] CHECK POINTS OF EVERY 100 HOURS Changing Engine Oil (for Standard Depth Oil Pans) CAUTION • Be sure to stop engine before changing engine oil. 1. Start and warm up the engine for approx. 5 minutes.
  • Page 35 GENERAL SM-E4B SERIES, WSM Fan Belt Tension 1. Measure the deflection (A), depressing the belt halfway between the fan drive pulley and alternator pulley at specified force 98 N (10 kgf, 22 lbf). 2. If the measurement is not within the factory specifications, loosen the alternator mounting screws and relocate the alternator to adjust.

  • Page 36: Check Points Of Every 150 Hours

    Then, replenish the engine oil up to the specified level. IMPORTANT • To prevent serious damage to the engine, replacement element must be highly efficient. Use only a KUBOTA genuine filter or its equivalent. (1) Engine Oil Filter Cartridge...

  • Page 37: Check Points Of Every 200 Hours

    Then, replenish the engine oil up to the specified level. IMPORTANT • To prevent serious damage to the engine, replacement element must be highly efficient. Use only a KUBOTA genuine filter or its equivalent. (1) Engine Oil Filter Cartridge...

  • Page 38: Check Points Of Every 400 Hours

    GENERAL SM-E4B SERIES, WSM [8] CHECK POINTS OF EVERY 400 HOURS Replacing Fuel Filter Cartridge (Cartridge Type) Water and dust in fuel are collected in the filter cartridge. So, change the filter cartridge every 400 hours service. 1. Remove the used filter cartridge with filter wrench.

  • Page 39: Check Points Of Every 500 Hours

    GENERAL SM-E4B SERIES, WSM [9] CHECK POINTS OF EVERY 500 HOURS Cleaning Water Jacket and Radiator Interior CAUTION • Do not remove the radiator cap when the engine is hot. Then loosen cap slightly to the stop to relieve any excess pressure before removing cap completely.
  • Page 40 GENERAL SM-E4B SERIES, WSM Anti-Freeze • There are two types of anti-freeze available: use the permanent type (PT) for this engine. • Before adding anti-freeze for the first time, clean the radiator interior by pouring fresh, soft water and draining it a few times.

  • Page 41: Check Points Of Every 1 Or 2 Months

    GENERAL SM-E4B SERIES, WSM [10] CHECK POINTS OF EVERY 1 OR 2 MONTHS Recharging CAUTION • When the battery is being activated, hydrogen and oxygen gases in the battery are extremely explosive. Keep open sparks and flames away from the battery at all times, especially when charging the battery.
  • Page 42 GENERAL SM-E4B SERIES, WSM Battery Specific Gravity CAUTION • If battery acid (dilute sulfuric acid) gets on you it could cause blindness or burns, or could cause corrosion of machinery and tools so please be careful when handling. • Wear safety glasses and rubber gloves when performing battery maintenance and inspection (measuring specific gravity, replenishing water, or charging).

  • Page 43: Check Point Of Every Year

    GENERAL SM-E4B SERIES, WSM [11] CHECK POINT OF EVERY YEAR Replacing Air Cleaner Element 1. Remove used air cleaner element. 2. Replace new air cleaner element. NOTE • The air cleaner uses a dry element. Never apply oil to it.

  • Page 44: Check Point Of Every 800 Hours

    GENERAL SM-E4B SERIES, WSM [12] CHECK POINT OF EVERY 800 HOURS Checking Valve Clearance IMPORTANT • Valve clearance must be checked and adjusted when engine is cold. 1. Remove the cylinder head cover (1) and the glow plugs. 2. Align the "1TC" mark (2) on the flywheel and alignment mark (3) on the rear end plate so that the No.

  • Page 45: Check Points Of Every 1500 Hours

    GENERAL SM-E4B SERIES, WSM [13] CHECK POINTS OF EVERY 1500 HOURS CAUTION • Check the injection pressure and condition after confirming that there is nobody standing in the direction the fume goes. • If the fume from the nozzle directly contacts the human body, cells may be destroyed and blood poisoning may be caused.
  • Page 46 GENERAL SM-E4B SERIES, WSM Nozzle Holder 1. Secure the nozzle retaining nut (7) with a vise. 2. Remove the nozzle holder (1), and take out parts inside. (When reassembling) • Assemble the nozzle in clean fuel oil. • Install the push rod (4), noting its direction.

  • Page 47: Check Points Of Every 3000 Hours

    GENERAL SM-E4B SERIES, WSM [14] CHECK POINTS OF EVERY 3000 HOURS Injection Timing 1. Remove the injection pipes. 2. Remove the engine stop solenoid. 3. Turn the flywheel counterclockwise (viewed from flywheel side) until the fuel fills up to the hole of the delivery valve holder (3) for No.
  • Page 48 GENERAL SM-E4B SERIES, WSM (Continued) NOTE • The liquid gasket is not required for assembling. • Shims are available in thickness of 0.20 mm (0.0079 in.), 0.25 mm (0.0098 in.), 0.30 mm (0.012 in.), 0.35 mm (0.014 in.) and 0.175 mm (0.00689 in.). Combine these shims for adjustments.
  • Page 49 5. Set the speed control lever to the maximum speed position. 6. Run the starter to increase the pressure. 7. If the pressure can not reach the allowable limit, replace the pump with new one or repair with a KUBOTA-authorized pump service shop. (Fuel Tightness of Delivery Valve) 1.

  • Page 50: Check Points Of Every 2 Years

    GENERAL SM-E4B SERIES, WSM [15] CHECK POINTS OF EVERY 2 YEARS Replacing Intake Air Line 1. Loosen the clamp (2). 2. Remove the intake air hose (1) and clamp (2). 3. Replace new intake air hose (1) and new clamp (2).
  • Page 51 GENERAL SM-E4B SERIES, WSM Replacing Fuel Hoses and Clamp Bands 1. Loosen the clamp (2) and remove the fuel hose (1). 2. Replace new fuel hose (1) and new clamp (2). 3. Tighten the clamp (2). CAUTION • Stop the engine when attempting the check and change prescribed above.
  • Page 52 GENERAL SM-E4B SERIES, WSM Cleaning Water Jacket and Radiator Interior CAUTION • Do not remove the radiator cap when the engine is hot. Then loosen cap slightly to the stop to relieve any excess pressure before removing cap completely. 1. Stop the engine and let cool down.
  • Page 53 GENERAL SM-E4B SERIES, WSM (Continued) (Anti-freeze) • There are two types of anti-freeze available: use the permanent type (PT) for this engine. • Before adding anti-freeze for the first time, clean the radiator interior by pouring fresh, soft water and draining it a few times.

  • Page 54: Special Tools

    GENERAL SM-E4B SERIES, WSM 5. SPECIAL TOOLS Diesel Engine Compression Tester (for Injection Nozzle) Code No. • 07909-30208 (Assembly) • 07909-30934 (A to F) • 07909-31211 (E and F) • 07909-31231 (H) • 07909-31251 (G) • 07909-31271 (I) • 07909-31281 (J) Application •...
  • Page 55 GENERAL SM-E4B SERIES, WSM NOTE • The following special tools are not provided, so make them referring to the figure. 9Y1210785GEG0043US0 Injection Pump Pressure Tester Application • Use to check fuel tightness of injection pumps. Pressure gauge full scale : More than 29.4 MPa...
  • Page 56 GENERAL SM-E4B SERIES, WSM Valve Guide Replacing Tool Application • Use to press out and press fit the valve guide. 220 mm (8.66 in.) 80 mm (3.1 in.) 40 mm (1.6 in.) 20 mm dia. (0.79 in. dia.) 9.960 to 9.980 mm dia. (0.3922 to 0.3929 in. dia.) 5.50 to 5.70 mm dia.
  • Page 57 GENERAL SM-E4B SERIES, WSM Flywheel Stopper Application • Use to loosen and tighten the flywheel screw. 20 mm (0.79 in.) 15 mm (0.59 in.) 10 mm dia. (0.39 in. dia.) 30 mm (1.2 in.) 8.0 mm (0.31 in.) 200 mm (7.87 in.)
  • Page 58 GENERAL SM-E4B SERIES, WSM Crank Sleeve Setter (for Z482/D722-E4B, D782-E4B) Application • Use to fix the crankshaft sleeve. (1) Auxiliary Socket for Pushing 130 mm (5.12 in.) 112 mm (4.41 in.) 107 mm (4.21 in.) 82 mm (3.2 in.) 72 mm (2.8 in.) 67 mm (2.6 in.)
  • Page 59 ENGINE KiSC issued 01, 2013 A...
  • Page 60 MECHANISM CONTENTS 1. ENGINE BODY........................... 1-M1 [1] HALF-FLOATING HEAD COVER ..................1-M1 [2] CLOSED BREATHER ......................1-M1 [3] PISTON (Z602-E4B, D782-E4B, D902-E4B) ............... 1-M2 [4] OIL PAN (Z602-E4B, D902-E4B) ..................1-M2 2. COOLING SYSTEM ........................1-M3 [1] COOLING FIN (Z602-E4B, D902-E4B) ................1-M3 KiSC issued 01, 2013 A...

  • Page 61: Engine Body

    ENGINE SM-E4B SERIES, WSM 1. ENGINE BODY [1] HALF-FLOATING HEAD COVER The rubber packing is fitted in to maintain the cylinder head cover 0.5 mm (0.02 in.) or so off the cylinder head. This arrangement helps reduce noise coming from the cylinder head.

  • Page 62: Piston (Z602-E4B, D782-E4B, D902-E4B)

    ENGINE SM-E4B SERIES, WSM [3] PISTON (Z602-E4B, D782-E4B, D902-E4B) Piston's skirt coated with molybdenum disulfide*, which reduces the piston slap noise and thus the entire operating noise. *Molybdenum disulfide (MoS The molybdenum disulfide (1) serves as a solid lubricant, like a Graphite or Teflon. This material helps resist metal wears even with little lube oil.

  • Page 63: Cooling System

    ENGINE SM-E4B SERIES, WSM 2. COOLING SYSTEM [1] COOLING FIN (Z602-E4B, D902-E4B) The cooling fin is set up around the oil passage in the gear case. Therefore, the temperature of oil is decreased by the wind generated by the cooling fan.
  • Page 64 SERVICING CONTENTS 1. TROUBLESHOOTING.........................1-S1 2. SERVICING SPECIFICATIONS ....................1-S4 3. TIGHTENING TORQUES......................1-S12 [1] TIGHTENING TORQUES FOR GENERAL USE SCREWS, BOLTS AND NUTS....1-S12 [2] TIGHTENING TORQUES FOR SPECIAL USE SCREWS, BOLTS AND NUTS....1-S13 4. CHECKING, DISASSEMBLING AND SERVICING ..............1-S14 [1] CHECKING AND ADJUSTING....................1-S14 (1) Engine Body ........................1-S14 (2) Lubricating System ......................1-S16 (3) Cooling System ......................1-S17...

  • Page 65: Troubleshooting

    ENGINE SM-E4B SERIES, WSM 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Engine Does Not No fuel Replenish fuel G-11 Start Air in the fuel system Bleed G-11 Water in the fuel system Change fuel and G-11 repair or replace fuel...
  • Page 66 ENGINE SM-E4B SERIES, WSM Reference Symptom Probable Cause Solution Page Engine Revolution Is Fuel filter clogged or dirty Replace G-17 Not Smooth Air cleaner clogged Clean or replace G-14 Fuel leak due to loose injection pipe retaining nut Tighten retaining nut...
  • Page 67 ENGINE SM-E4B SERIES, WSM Reference Symptom Probable Cause Solution Page Water Mixed into Head gasket defective Replace 1-S32 Lubricant Oil Cylinder block or cylinder head flawed Replace 1-S51 Low Oil Pressure Engine oil insufficient Replenish I-4, Oil strainer clogged Clean...

  • Page 68: Servicing Specifications

    ENGINE SM-E4B SERIES, WSM 2. SERVICING SPECIFICATIONS ENGINE BODY Item Factory Specification Allowable Limit Valve Clearance (Cold) 0.145 to 0.185 mm – 0.00571 to 0.00728 in. Compression Pressure Z482-E4B 2.85 to 3.23 MPa 2.26 MPa D722-E4B 29.0 to 33.0 kgf/cm 23.0 kgf/cm...
  • Page 69 ENGINE SM-E4B SERIES, WSM Item Factory Specification Allowable Limit Exhaust Valve Timing Open 0.87 rad (50 °) – [Z602/D902-E4B] before B.D.C. Close 0.26 rad (15 °) – after T.D.C. Valve Spring (Intake and Exhaust) Tilt – 1.2 mm 0.047 in.
  • Page 70 ENGINE SM-E4B SERIES, WSM Item Factory Specification Allowable Limit Cam Height [Z482/D722/D782-E4B] Intake 26.88 mm 26.83 mm 1.058 in. 1.056 in. [Z482/D722/D782-E4B] Exhaust 25.88 mm 25.83 mm 1.019 in. 1.017 in. [Z602/D902-E4B] Intake and Exhaust 26.88 mm 26.83 mm 1.058 in.
  • Page 71 ENGINE SM-E4B SERIES, WSM Item Factory Specification Allowable Limit Piston Ring to Piston Ring Groove • Second Ring Clearance 0.0900 to 0.120 mm 0.15 mm 0.00355 to 0.00472 in. 0.0059 in. • Oil Ring Clearance 0.040 to 0.080 mm 0.15 mm 0.0016 to 0.0031 in.
  • Page 72 ENGINE SM-E4B SERIES, WSM Item Factory Specification Allowable Limit Crankshaft Journal to Crankshaft Bearing 3 Oil Clearance 0.028 to 0.059 mm 0.20 mm (Intermediate) 0.0011 to 0.0023 in. 0.0079 in. [Z602/D902-E4B] • Crankshaft Journal O.D. 43.934 to 43.950 mm –...
  • Page 73 ENGINE SM-E4B SERIES, WSM LUBRICATING SYSTEM Item Factory Specification Allowable Limit Engine Oil Pressure At Idle Speed More than – 49 kPa 0.50 kgf/cm 7.1 psi At Rated Speed 197 to 441 kPa 147 kPa 2.00 to 4.50 kgf/cm 1.50 kgf/cm 28.5 to 64.0 psi...
  • Page 74 ENGINE SM-E4B SERIES, WSM FUEL SYSTEM Item Factory Specification Allowable Limit Injection Pump Injection Timing 0.3186 to 0.3447 rad – [Z482/D602-E4B] (3600 min (rpm)) (18.25 to 19.75 °) before T.D.C. Injection Pump Injection Timing 0.3360 to 0.3621 rad – [D722-E4B]...
  • Page 75 ENGINE SM-E4B SERIES, WSM ELECTRICAL SYSTEM Item Factory Specification Allowable Limit Glow Plug Resistance Approx. 1.1 Ω – Starter (Electromagnetic Drive Type) • Commutator O.D. 28.0 mm 27.0 mm 1.10 in. 1.06 in. • Difference O.D. Less than 0.40 mm 0.05 mm...

  • Page 76: Tightening Torques

    ENGINE SM-E4B SERIES, WSM 3. TIGHTENING TORQUES Screws, bolts and nuts must be tightened to the specified torque using a torque wrench, several screws, bolts and nuts such as those used on the cylinder head must be tightened in proper sequence and the proper torque.

  • Page 77: Tightening Torques For Special Use Screws, Bolts And Nuts

    ENGINE SM-E4B SERIES, WSM [2] TIGHTENING TORQUES FOR SPECIAL USE SCREWS, BOLTS AND NUTS NOTE • For "*" marked screws, bolts and nuts on the table, apply engine oil to their threads and seats before tightening. • The letter "M" in Size × Pitch means that the screw, bolt or nut dimension stands for metric. The size is the nominal outside diameter in mm of the threads.

  • Page 78: Checking, Disassembling And Servicing

    ENGINE SM-E4B SERIES, WSM 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING (1) Engine Body Compression Pressure 1. Run the engine until it is warmed up. 2. Stop the engine. 3. [a] Nozzle Hole Adaptor Setting : Remove the air cleaner, the muffler and all injection nozzles.
  • Page 79 ENGINE SM-E4B SERIES, WSM Checking Valve Clearance IMPORTANT • Valve clearance must be checked and adjusted when engine is cold. 1. Remove the cylinder head cover (1) and the glow plugs. 2. Align the "1TC" mark (2) on the flywheel and alignment mark (3) on the rear end plate so that the No.

  • Page 80: Lubricating System

    ENGINE SM-E4B SERIES, WSM (2) Lubricating System Engine Oil Pressure 1. Remove the engine oil pressure switch, and set an oil pressure tester. (Code No. : 07916-32032) 2. Start the engine. After warming up, measure the oil pressure of both idling and rated speeds.

  • Page 81: Cooling System

    ENGINE SM-E4B SERIES, WSM (3) Cooling System Fan Belt Tension 1. Measure the deflection (A), depressing the belt halfway between the fan drive pulley and alternator pulley at specified force 98 N (10 kgf, 22 lbf). 2. If the measurement is not within the factory specifications, loosen the alternator mounting screws and relocate the alternator to adjust.
  • Page 82 ENGINE SM-E4B SERIES, WSM CAUTION • When removing the radiator cap, wait at least ten minutes after the engine has stopped and cooled down. Otherwise, hot water may gush out, scalding nearby people. 9Y1210785ENS0008US0 Radiator Cap Air Leakage 1. Set a radiator tester (1) and an adaptor (2) on the radiator cap.

  • Page 83: Fuel System

    ENGINE SM-E4B SERIES, WSM (4) Fuel System Injection Timing 1. Remove the injection pipes. 2. Remove the engine stop solenoid. 3. Turn the flywheel counterclockwise (viewed from flywheel side) until the fuel fills up to the hole of the delivery valve holder (3) for No.
  • Page 84 ENGINE SM-E4B SERIES, WSM (Continued) NOTE • The liquid gasket is not required for assembling. • Shims are available in thickness of 0.20 mm (0.0079 in.), 0.25 mm (0.0098 in.), 0.30 mm (0.012 in.), 0.35 mm (0.014 in.) and 0.175 mm (0.00689 in.). Combine these shims for adjustments.
  • Page 85 5. Set the speed control lever to the maximum speed position. 6. Run the starter to increase the pressure. 7. If the pressure can not reach the allowable limit, replace the pump with new one or repair with a KUBOTA-authorized pump service shop. 13.73 MPa...
  • Page 86 ENGINE SM-E4B SERIES, WSM CAUTION • Check the injection pressure and condition after confirming that there is nobody standing in the direction the fume goes. • If the fume from the nozzle directly contacts the human body, cells may be destroyed and blood poisoning may be caused.

  • Page 87: Electrical System

    ENGINE SM-E4B SERIES, WSM Nozzle Holder 1. Secure the nozzle retaining nut (7) with a vise. 2. Remove the nozzle holder (1), and take out parts inside. (When reassembling) • Assemble the nozzle in clean fuel oil. • Install the push rod (4), noting its direction.
  • Page 88 ENGINE SM-E4B SERIES, WSM Battery Specific Gravity CAUTION • If battery acid (dilute sulfuric acid) gets on you it could cause blindness or burns, or could cause corrosion of machinery and tools so please be careful when handling. • Wear safety glasses and rubber gloves when performing battery maintenance and inspection (measuring specific gravity, replenishing water, or charging).
  • Page 89 ENGINE SM-E4B SERIES, WSM Motor Test CAUTION • Secure the starter to prevent it from jumping up and down while testing the motor. 1. Disconnect the battery negative cable from the battery. 2. Disconnect the battery positive cable from the battery.
  • Page 90 ENGINE SM-E4B SERIES, WSM Magnet Switch Continuity Test 1. Check the continuity across the C terminal (1) and the B terminal (2) with a circuit tester, pushing in the plunger. 2. If not continuous or if a certain value is indicated, replace the magnet switch.
  • Page 91 ENGINE SM-E4B SERIES, WSM Continuity across Regulator's Terminals 1. Measure with a circuit tester according to the list below. NOTE • For this test, use only Analog Meter and do not use a high voltage tester such as a M Ω meter.
  • Page 92 ENGINE SM-E4B SERIES, WSM Alternator on Unit Test (Before testing) • Before alternator on unit test, check the battery terminal connections, circuit connection, fan belt tension, charging indicator lamp, fuses on the circuit, and abnormal noise from the alternator. • Prepare full charged battery for the test.

  • Page 93: Disassembling And Assembling

    ENGINE SM-E4B SERIES, WSM Engine Stop Solenoid Test (Energize to Run Type) 1. Disconnect the 3P connector (3) from the engine stop solenoid (1) wiring harness. 2. Remove the engine stop solenoid (1) from the engine. 3. Connect the jumper leads from the pulling coil terminal (6) to the switch (7), and from switch (7) to the battery positive terminal (10).

  • Page 94: External Components

    ENGINE SM-E4B SERIES, WSM Draining Coolant CAUTION • Never remove radiator cap while operating or immediately after stopping. Otherwise, hot water will spout out from the radiator. Wait for more than ten minutes to cool the radiator, before opening the cap.
  • Page 95 ENGINE SM-E4B SERIES, WSM Injection Pipes 1. Loosen the screws to the pipe clamp (2). 2. Detach the injection pipes (1). (When reassembling) • Sent compressed air into the pipes to blow out dust. Then, reassemble the pipes in the reverse order.
  • Page 96 ENGINE SM-E4B SERIES, WSM Rocker Arm and Push Rod 1. Remove the rocker arm bracket screws (2). 2. Detach the rocker arm assembly (1). 3. Remove the push rods (3). (When reassembling) • When putting the push rods (3) onto the tappets (4), check to see if their ends are properly engaged with the dimples.
  • Page 97 ENGINE SM-E4B SERIES, WSM Tappets 1. Remove the tappets (1) from the crankcase. (When reassembling) • Visually check the contact between tappets and cams for proper rotation. If defect is found, replace tappets. • Before installing the tappets, apply engine oil thinly around them.
  • Page 98 ENGINE SM-E4B SERIES, WSM Oil Pan and Oil Strainer 1. Remove the oil pan mounting screws (2). 2. Remove the oil pan (1) by lightly tapping the rim of the pan with a wooden hammer. 3. Remove the oil strainer (3).

  • Page 99: Gear Case And Timing Gears

    ENGINE SM-E4B SERIES, WSM (4) Gear Case and Timing Gears Injection Pump, Fuel Feed Pump and Speed Control Plate (for Energize to Stop Type Engine Stop Solenoid) 1. Remove the socket head screws and nuts, and remove the injection pump (1).
  • Page 100 ENGINE SM-E4B SERIES, WSM (Continued) NOTE • Specific tool (1) : 1.2 mm (0.047 in.) diameter hard wire with its end hooked, overall length 200 mm (7.87 in.). The tip of wire is bent like the hook to hang governor springs.
  • Page 101 ENGINE SM-E4B SERIES, WSM (Continued) (When reassembling) 1. Move the fork lever (2) to the gear case side. 2. Hook the start spring (6) to the injection pump control rack pin (5). 3. Put the specific tool (7) through the fork lever hole of cylinder block (9) and hook the start spring (6).
  • Page 102 ENGINE SM-E4B SERIES, WSM Fan Drive Pulley 1. Secure the flywheel to keep it from turning. 2. Remove the fan drive pulley screw. 3. Draw out the fan drive pulley with a puller. (When reassembling) • Install the pulley to crankshaft, aligning the mark (1) on them.
  • Page 103 ENGINE SM-E4B SERIES, WSM Idle Gear 1. Remove the external snap ring (3), the collar (2) and the idle gear (1). 2. Remove the idle gear shaft mounting screws (4). 3. Remove the idle gear shaft (5) (if necessary). (When reassembling) •...
  • Page 104 ENGINE SM-E4B SERIES, WSM Fuel Camshaft 1. Remove the retaining plate (6). 2. Remove the fork lever holder mounting screws (8), then draw out the injection pump gear (1) and fuel camshaft (7) with the governor fork assembly. (When reassembling) •...

  • Page 105: Piston And Connecting Rod

    ENGINE SM-E4B SERIES, WSM (5) Piston and Connecting Rod Connecting Rod Cap 1. Remove the connecting rod caps (1) using a bihexagonal 8 mm socket. (When reassembling) • Align the marks (a) with each other. (Face the marks toward the injection pump.)
  • Page 106 ENGINE SM-E4B SERIES, WSM Piston Ring and Connecting Rod 1. Remove the piston rings using a piston ring tool. 2. Remove the piston pin (7), and separate the connecting rod (6) from the piston (5). (When reassembling) • When installing the ring, assemble the rings so that the manufacturer's mark (12) near the gap faces the top of the piston.

  • Page 107: Flywheel And Crankshaft

    ENGINE SM-E4B SERIES, WSM (6) Flywheel and Crankshaft Flywheel 1. Secure the flywheel to keep it from turning using a flywheel stopper. (Refer to "SPECIAL TOOLS".) 2. Remove all flywheel screws (1) and then remove the flywheel (2). (When reassembling) •...
  • Page 108 ENGINE SM-E4B SERIES, WSM Crankshaft Assembly For Z482-E4B, D722-E4B 1. Remove the main bearing case screw 2 (1). 2. Draw out all the crankshaft. For Z602-E4B 1. Remove the main bearing case screw 2 (1). 2. Turn the crankshaft to set the crankpin of the cylinder to the horizontal directions (right or left).
  • Page 109 ENGINE SM-E4B SERIES, WSM Main Bearing Case Assembly (Z482-E4B, D722-E4B, D782-E4B) 1. Remove the two main bearing case screws 1 (4), and remove the main bearing case assembly 1 (1), being careful with crankshaft bearing 3 (5). 2. Remove the main bearing case assembly 2 (2) and the main bearing case assembly (3) as above.
  • Page 110 ENGINE SM-E4B SERIES, WSM Main Bearing Case Assembly (Z602-E4B, D902-E4B) 1. Remove the two main bearing case screws 1 (4), and remove the main bearing case assembly 1 (1), being careful with crankshaft bearing 3 (5) (9). 2. Remove the main bearing case assembly 2 (2) and the main bearing case assembly (3) as above.

  • Page 111: Starter

    ENGINE SM-E4B SERIES, WSM (7) Starter Electromagnetic Drive Type (1) Solenoid Switch Mounting (2) Starter Drive Housing (3) Drive Lever (4) Gasket (5) Solenoid Switch (6) B Terminal Nut (7) C Terminal Nut (8) Snap RIng (9) Overrunning Clutch (10) Armature...
  • Page 112 ENGINE SM-E4B SERIES, WSM Planetary Gear Reduction Type (1) Magnetic Switch Mounting (2) Housing (3) Magnetic Switch (4) B Terminal Nut (5) C Terminal Nut (6) Drive Lever (7) Shaft Assembly (8) Overrunning Clutch (9) Connecting Lead (10) Mounting Screw...

  • Page 113: Dynamo

    ENGINE SM-E4B SERIES, WSM (8) Dynamo (1) Shaft (2) Pulley (3) Rotor (4) Collar (5) Bearing (6) Stator (7) Plate (8) Bearing 1. Remove the nut and separate the plate (7). 2. Tap out the shaft (1) from the rotor (3).

  • Page 114: Alternator

    ENGINE SM-E4B SERIES, WSM (9) Alternator (1) Pulley (2) Drive End Frame (3) Stator (4) Bearing (5) Retainer Plate (6) Rotor (7) Bearing (8) Rear End Frame (9) Rectifier (10) IC Regulator (11) Brush Holder (12) Rear End Cover 1. Remove the pulley (1).

  • Page 115: Servicing

    ENGINE SM-E4B SERIES, WSM [3] SERVICING (1) Cylinder Head and Valves Top Clearance 1. Remove the cylinder head. 2. With the piston at TDC, use grease to affix three or four plastigauges of a diameter 1.5 mm (0.059 in.) x 5.0 to 7.0 mm (0.20 to 0.27 in.) long to the crown of the piston;...
  • Page 116 ENGINE SM-E4B SERIES, WSM Cylinder Head Flaw 1. Prepare an air spray red check. 2. Clean the surface of the cylinder head with detergent (2). 3. Spray the cylinder head surface with the red permeative liquid (1). Leave it five to ten minutes after spraying.
  • Page 117 ENGINE SM-E4B SERIES, WSM Replacing Valve Guide (When removing) 1. Press out the used valve guide using a valve guide replacing tool. (Refer to "SPECIAL TOOLS".) (When installing) 1. Clean a new valve guide and valve guide bore, and apply engine oil to them.

  • Page 118: Specifications

    ENGINE SM-E4B SERIES, WSM Correcting Valve and Valve Seat NOTE • Before correcting the valve and seat, check the valve stem and the I.D. of valve guide section, and repair them if necessary. • After correcting the valve seat, be sure to check the valve recessing.
  • Page 119 ENGINE SM-E4B SERIES, WSM Free Length and Tilt of Valve Spring 1. Measure the free length (B) of valve spring with vernier calipers. If the measurement is less than the allowable limit, replace it. 2. Put the valve spring on a surface plate, place a square on the side of the valve spring.

  • Page 120: Timing Gears

    ENGINE SM-E4B SERIES, WSM Push Rod Alignment 1. Place the push rod on V blocks. 2. Measure the push rod alignment. 3. If the measurement exceeds the allowable limit, replace the push rod. 0.25 mm Push rod alignment Allowable limit 0.0098 in.
  • Page 121 ENGINE SM-E4B SERIES, WSM Idle Gear Side Clearance 1. Set a dial indicator with its tip on the idle gear. 2. Measure the side clearance by moving the idle gear to the front and rear. 3. If the measurement exceeds the allowable limit, replace the idle gear collar.
  • Page 122 ENGINE SM-E4B SERIES, WSM Oil Clearance of Camshaft Journal 1. Measure the camshaft journal O.D. with an outside micrometer. 2. Measure the cylinder block bore I.D. for camshaft with a inside micrometer, and calculate the oil clearance. 3. If the oil clearance exceeds the allowable limit, replace the camshaft.

  • Page 123: Piston And Connecting Rod

    ENGINE SM-E4B SERIES, WSM (3) Piston and Connecting Rod Piston Pin Bore I.D. 1. Measure the piston pin bore I.D. in both the horizontal and vertical directions with a cylinder gauge. 2. If the measurement exceeds the allowable limit, replace the piston.
  • Page 124 ENGINE SM-E4B SERIES, WSM Connecting Rod Alignment NOTE • Since the I.D. of the connecting rod small end bushing is the basis of this check, check bushing for wear beforehand. 1. Install the piston pin into the connecting rod. 2. Install the connecting rod on the connecting rod alignment tool.

  • Page 125: Crankshaft

    ENGINE SM-E4B SERIES, WSM Clearance between Piston Ring and Piston Ring Groove 1. Clean the rings and the ring grooves, and install each ring in its groove. 2. Measure the clearance between the ring and the groove with a feeler gauge.
  • Page 126 ENGINE SM-E4B SERIES, WSM Crankshaft Alignment 1. Support the crankshaft with V blocks on the surface plate at both end journals. 2. Set a dial indicator with its tip on the intermediate journal. 3. Measure the crankshaft alignment. 4. If the measurement exceeds the allowable limit, replace the crankshaft.
  • Page 127 ENGINE SM-E4B SERIES, WSM Oil Clearance between Crankshaft Journal and Crankshaft Bearing 1 1. Measure the O.D. of the crankshaft front journal with an outside micrometer. 2. Measure the I.D. of the crankshaft bearing 1 with an inside micrometer, and calculate the oil clearance.
  • Page 128 ENGINE SM-E4B SERIES, WSM (Continued) (Reference) • Undersize crankshaft bearing 1 Code Undersize Models Bearing Marking Number Z482-E4B D722-E4B 15861-23910 0.20 mm Crankshaft D782-E4B 020 US 0.0079 in. bearing 1 02 Z602-E4B 1G460-23910 D902-E4B Z482-E4B D722-E4B 15861-23920 0.40 mm Crankshaft...
  • Page 129 ENGINE SM-E4B SERIES, WSM Oil Clearance between Crankshaft Journal and Crankshaft Bearing 2 and Crankshaft Bearing 3 1. Put a strip of plastigage on the center of the journal. 2. Install the bearing case and tighten the bearing case screws 1 to the specified torque, and remove the bearing case again.
  • Page 130 ENGINE SM-E4B SERIES, WSM (Continued) (Reference) • Undersize crankshaft bearing 2 and 3 Code Undersize Models Bearing Marking Number Crankshaft 15694-23930 Z482-E4B bearing 2 02 D722-E4B Crankshaft D782-E4B 15861-23860 bearing 3 02 0.20 mm 020 US 0.0079 in. Crankshaft 1G460-23930...

  • Page 131: Cylinder

    ENGINE SM-E4B SERIES, WSM Replacing Crankshaft Sleeve (Z482-E4B, D722-E4B, D782-E4B) 1. Remove the used crankshaft sleeve (2). 2. Set the sleeve guide (3) to the crankshaft (1). 3. Heat a new sleeve to a temperature between 150 and 200 °C (302 and 392 °F), and fix the sleeve to the crankshaft as shown...

  • Page 132: Oil Pump

    ENGINE SM-E4B SERIES, WSM Correcting Cylinder (Oversize) 1. When the cylinder is worn beyond the allowable limit, bore and hone it to the specified dimension. Z482-E4B 67.250 to 67.269 mm D722-E4B Factory 2.6477 to 2.6483 in. D782-E4B specifica- tion Z602-E4B 72.250 to 72.269 mm...

  • Page 133: Starter

    ENGINE SM-E4B SERIES, WSM (7) Starter Overrunning Clutch 1. Check the pinion and if worn or damage, replace the clutch assembly. 2. Check that the pinion turns freely and smoothly in the overrunning direction and does not slip in the cranking direction.
  • Page 134 ENGINE SM-E4B SERIES, WSM Commutator and Mica 1. Check the contact of the commutator for wear, and grind the commutator with emery paper if it is slightly worn. 2. Measure the commutator O.D. with an outside micrometer at several points.
  • Page 135 ENGINE SM-E4B SERIES, WSM Brush Holder 1. Check the continuity across the brush holder and the holder support with a circuit tester. 2. If it conducts, replace the brush holder. 9Y1210785ENS0104US0 Armature Coil 1. Check the continuity across the commutator and armature coil core with resistance range of circuit tester.

  • Page 136: Alternator

    ENGINE SM-E4B SERIES, WSM (8) Alternator Bearing 1. Check the bearing for smooth rotation. 2. If it does not rotate smoothly, replace it. 9Y1210785ENS0107US0 Stator 1. Measure the resistance across each lead of the stator coil with resistance range of circuit tester.
  • Page 137 ENGINE SM-E4B SERIES, WSM Rectifier 1. Check the continuity across each diode of rectifier with resistance range of circuit tester. 2. The rectifier is normal if the diode in the rectifier conducts in one direction and does not conduct in the reverse direction.
  • Page 138 EDITOR : KUBOTA FARM & INDUSTRIAL MACHINERY SERVICE, LTD. 64, ISHIZU-KITAMACHI, SAKAI-KU, SAKAI-CITY, OSAKA, 590-0823, JAPAN PHONE : ( 81 ) 72-241-1129 : ( 81 ) 72-245-2484 E-mail : ks_g.ksos-pub@kubota.com Printed in Japan 2012. 12, S, EI, EI, engusa Code No.9Y111-07850...

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