Kubota Z482-E2B Workshop Manual
  1. Manuals
  2. Brands
  3. Kubota Manuals
  4. Engine
  5. Z482-E2B
  6. Workshop manual

Kubota Z482-E2B Workshop Manual

Sm-e2b series
Hide thumbs
Table of Contents

Advertisement

Quick Links

WORKSHOP MANUAL
DIESEL ENGINE
SM-E2B SERIES
KiSC issued 06, 2006 A

Advertisement

Table of Contents
loading

Related Manuals for Kubota Z482-E2B

Summary of Contents for Kubota Z482-E2B

  • Page 1 WORKSHOP MANUAL DIESEL ENGINE SM-E2B SERIES KiSC issued 06, 2006 A...
  • Page 2 The right is reserved to make changes in all information at any time without notice. Due to covering many models of this manual, information or picture being used have not been specified as one model. November 2004 © KUBOTA Corporation 2004 KiSC issued 06, 2006 A...
  • Page 3 SM-E2B SERIES, WSM SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS 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. It is essential that you read the instructions and safety regulations before you attempt to repair or use this unit.
  • Page 4 SM-E2B SERIES, WSM SAFETY INSTRUCTIONS SAFETY STARTING • Do not start the engine by shorting across starter terminals or bypassing the safety start switch. • Unauthorized modifications to the engine may impair the function and / or safety and affect engine life. SAFETY WORKING •...
  • Page 5 SM-E2B SERIES, WSM SAFETY INSTRUCTIONS VENTILATE WORK AREA • If the engine must be running to do some work, make sure the area is well ventilated. Never run the engine in a closed area. The exhaust gas contains poisonous carbon monoxide. DISPOSE OF FLUIDS PROPERLY •...

  • Page 6: Specifications

    SM-E2B SERIES, WSM SPECIFICATIONS SPECIFICATIONS Model Z482-E2B Z602-E2B Number of Cylinders Type Vertical, Water-cooled, 4 cycle IDI diesel engine Bore × Stroke 67 × 68 (2.64 × 2.68) 72 × 73.6 (2.83 × 2.90) mm (in.) Total Displacement (cu.in.) 479 (29.23) 599 (36.55)
  • Page 7 SM-E2B SERIES, WSM SPECIFICATIONS Model D662-E2B D722-E2B Number of Cylinders Type Vertical, Water-cooled, 4 cycle IDI diesel engine Bore × Stroke 64 × 68 (2.52 × 2.68) 67 × 68 (2.64 × 2.68) mm (in.) Total Displacement (cu.in.) 656 (40.03) 719 (43.88) ISO Net Continuous 11.2 / 3600 (15.0 / 3600)
  • Page 8 SM-E2B SERIES, WSM SPECIFICATIONS Model D782-E2B D902-E2B Number of Cylinders Type Vertical, Water-cooled, 4 cycle IDI diesel engine Bore × Stroke 67 × 73.6 (2.64 × 2.90) 72 × 73.6 (2.83 × 2.90) mm (in.) Total Displacement (cu.in.) 778 (47.48) 898 (54.80) ISO Net Continuous 11.7 / 3200 (15.7 / 3200)

  • Page 9: Performance Curves

    SM-E2B SERIES, WSM PERFORMANCE CURVES PERFORMANCE CURVES Z482-E2B (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 10 SM-E2B SERIES, WSM PERFORMANCE CURVES Z602-E2B (3200 min (rpm) spec.) (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 11 SM-E2B SERIES, WSM PERFORMANCE CURVES Z602-E2B (3600 min (rpm) spec.) (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 SM-E2B SERIES, WSM PERFORMANCE CURVES D662-E2B (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 SM-E2B SERIES, WSM PERFORMANCE CURVES D722-E2B (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 14 SM-E2B SERIES, WSM PERFORMANCE CURVES D782-E2B (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 15 SM-E2B SERIES, WSM PERFORMANCE CURVES D902-E2B (3200 min (rpm) spec.) (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 16 SM-E2B SERIES, WSM PERFORMANCE CURVES D902-E2B (3600 min (rpm) spec.) (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 17 SM-E2B SERIES, WSM DIMENSIONS DIMENSIONS Z482-E2B KiSC issued 06, 2006 A...
  • Page 18 SM-E2B SERIES, WSM DIMENSIONS Z602-E2B KiSC issued 06, 2006 A...
  • Page 19 SM-E2B SERIES, WSM DIMENSIONS D662-E2B, D722-E2B KiSC issued 06, 2006 A...
  • Page 20 SM-E2B SERIES, WSM DIMENSIONS D782-E2B KiSC issued 06, 2006 A...
  • Page 21 SM-E2B SERIES, WSM DIMENSIONS D902-E2B KiSC issued 06, 2006 A...

  • Page 22: Table Of Contents

    GENERAL CONTENTS 1. ENGINE IDENTIFICATION ................G-1 [1] MODEL NAME AND ENGINE SERIAL NUMBER ........ G-1 [2] E2B ENGINE..................... G-2 [3] CYLINDER NUMBER ................G-2 2. GENERAL PRECAUTIONS ................G-3 3. MAINTENANCE CHECK LIST ............... G-4 4. CHECK AND MAINTENANCE ............... G-6 [1] DAILY CHECK POINTS................

  • Page 23: Engine Identification

    SM-E2B SERIES, WSM G GENERAL 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. Engine Serial Number The engine serial number is an identified number for the engine.

  • Page 24: E2B Engine

    The time to enforce the regulations differs depending on the engine output classifications. Kubota has been supplying the diesel engines conforming to the emission regulations in respective countries. Exhaust emissions regulations shift to the second stage. Kubota executed the improvement of the engine according to this regulation.

  • Page 25: General Precautions

    Screws, bolts and nuts should be replaced in their original position to prevent reassembly errors. • When special tools are required, use KUBOTA genuine special tools. Special tools which are not frequently used should be made according to the drawings provided.

  • 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 Changing radiator coolant (L.L.C.) * 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 28: Check And Maintenance

    SM-E2B SERIES, WSM G GENERAL 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. Check to see that the oil level lies between the two notches.
  • Page 29 SM-E2B SERIES, WSM G GENERAL Checking and Replenish Coolant 1. Without recovery tank : 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

    Below 0 °C (32 °F) SAE 10W-40 Oil pan depth Engine oil capacity 101 mm (3.98 in.) 121 mm (4.76 in.) Models 2.1 L 2.5 L *Z482-E2B 0.55 U.S.gals 0.66 U.S.gals *D662-E2B 3.2 L 3.8 L *D722-E2B 0.85 U.S.gals 1.00 U.S.gals 3.6 L...
  • 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- E2B, D662-E2B and D722-E2B.

  • Page 32: Check Point Of Every 50 Hours

    SM-E2B SERIES, WSM G GENERAL [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 Point Of Every 75 Hours

    Below 0 °C (32 °F) SAE 10W-40 Oil pan depth Engine oil capacity 101 mm (3.98 in.) 121 mm (4.76 in.) Models 2.1 L 2.5 L *Z482-E2B 0.55 U.S.gals 0.66 U.S.gals *D662-E2B 3.2 L 3.8 L *D722-E2B 0.85 U.S.gals 1.00 U.S.gals 3.6 L...

  • Page 34: Check Points Of Every 100 Hours

    Below 0 °C (32 °F) SAE 10W-40 Oil pan depth Engine oil capacity 101 mm (3.98 in.) 121 mm (4.76 in.) Models 2.1 L 2.5 L *Z482-E2B 0.55 U.S.gals 0.66 U.S.gals *D662-E2B 3.2 L 3.8 L *D722-E2B 0.85 U.S.gals 1.00 U.S.gals 3.6 L...
  • Page 35 SM-E2B SERIES, WSM G GENERAL 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 lbs). 2. If the measurement is not within the factory specifications, loosen the alternator mounting screws and relocate the alternator to adjust.
  • Page 36 SM-E2B SERIES, WSM G GENERAL Cleaning Fuel Filter (Element Type only) 1. Close the fuel cock (3). 2. Unscrew the retaining ring (6) and remove the filter cup (5), and rinse the inside with kerosene. 3. Take out the element (4) and dip it in the kerosene to rinse. 4.

  • Page 37: Check Point 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 [a] Standard Type...

  • Page 38: Check Points Of Every 400 Hours

    SM-E2B SERIES, WSM G GENERAL Checking Radiator Hoses and Clamp Bands 1. Check to see if the radiator hoses are properly fixed every 200 hours of operation or every six months, whichever comes first. 2. If the clamp is loose, apply oil to the threads and retighten it securely.

  • Page 39: Check Points Of Every 500 Hours

    SM-E2B SERIES, WSM G GENERAL [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 SM-E2B SERIES, WSM G GENERAL 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

    SM-E2B SERIES, WSM G GENERAL [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 SM-E2B SERIES, WSM G GENERAL Battery Specific Gravity 1. Check the specific gravity of the electrolyte in each cell with a hydrometer. 2. When the electrolyte temperature differs from that at which the hydrometer was calibrated, correct the specific gravity reading following the formula mentioned in (Reference).

  • Page 43: Check Point Of Every Year

    SM-E2B SERIES, WSM G GENERAL [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

    • After adjusting the valve clearance, secure the adjusting screw with the lock nut. (1) Cylinder Head Cover A : Gear Case Side (2) “1TC” Mark [a] Z482-E2B, Z602-E2B (3) Alignment Mark [b] D662-E2B, D722-E2B, D782-E2B, D902-E2B W10113200 KiSC issued 06, 2006 A...

  • Page 45: Check Points Of Every 1500 Hours

    SM-E2B SERIES, WSM G GENERAL [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 SM-E2B SERIES, WSM G GENERAL 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

    SM-E2B SERIES, WSM G GENERAL [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 • Refer to figure of the shim to check the thickness of the shims. • The injection timing might be changed by the application. (Reference) • Injection Timing Map (before T.D.C.) Model Z482-E2B Z602-E2B Rated Speed D662-E2B D782-E2B D902-E2B Specification...
  • 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

    SM-E2B SERIES, WSM G GENERAL [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). 4.
  • Page 51 SM-E2B SERIES, WSM G GENERAL 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 SM-E2B SERIES, WSM G GENERAL 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.
  • Page 53 SM-E2B SERIES, WSM G GENERAL Changing Radiator Coolant (L.L.C.) (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

    SM-E2B SERIES, WSM G GENERAL 5. SPECIAL TOOLS Diesel Engine Compression Tester (for Injection Nozzle) Code No: 07909-30208 (Assembly) 07909-31251 (G) 07909-30934 (A to F) 07909-31271 (I) 07909-31211 (E and F) 07909-31281 (J) 07909-31231 (H) Application: Use to measure diesel engine compression and diagnosis of need for major overhaul.
  • Page 55 SM-E2B SERIES, WSM G GENERAL NOTE • The following special tools are not provided, so make them referring to the figure. Injection Pump Pressure Tester Application: Use to check fuel tightness of injection pumps. Pressure gauge full scale : More than 29.4 MPa (300 kgf/cm , 4267 psi) PF 1/2...
  • Page 56 SM-E2B SERIES, WSM G GENERAL Bushing Replacing Tool Application: Use to press out and press fit the bushing. 1. For small end bushing 145 mm (5.71 in.) 20 mm (0.79 in.) 100 mm (3.94 in.) 19.90 to 19.95 mm dia. (0.7835 to 0.7854 in. dia.) 21.90 to 21.95 mm dia.
  • Page 57 SM-E2B SERIES, WSM G GENERAL Crankshaft Bearing 1 Replacing Tool Application: Use to press out and press fit the crankshaft bearing 1. [Press Out] 135 mm (5.31 in.) 72 mm (2.83 in.) 40 mm radius (1.57 in. radius) 10 mm (0.39 in.) 22 mm (0.87 in.) 20 mm dia.
  • Page 58 SM-E2B SERIES, WSM G GENERAL Crank Sleeve Setter (for Z482/D662/D722/D782-E2B) 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 (3.23 in.) 72 mm (2.83 in.) 67 mm (2.64 in.) 47 mm (1.85 in.) 37.0 to 37.2 mm (1.457 to 1.465 in.)
  • Page 59 MECHANISM CONTENTS 1. ENGINE BODY ....................M-1 [1] HALF-FLOATING HEAD COVER ............M-1 [2] CLOSED BREATHER................M-1 [3] PISTON (Z602-E2B, D902-E2B)............... M-2 [4] OIL PAN (Z602-E2B, D902-E2B)............. M-2 2. COOLING SYSTEM ..................M-2 [1] COOLING FIN (Z602-E2B, D902-E2B)............ M-3 KiSC issued 06, 2006 A...

  • Page 60: Engine Body

    SM-E2B SERIES, WSM DIESEL ENGINE 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 61 SM-E2B SERIES, WSM DIESEL ENGINE [3] PISTON (Z602-E2B, D902-E2B) Piston’s skirt coated with molybdenum disulfied , 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 62: Cooling System

    SM-E2B SERIES, WSM DIESEL ENGINE 2. COOLING SYSTEM [1] COOLING FIN (Z602-E2B, D902-E2B) 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. (1) Cooling Fin W1013135 KiSC issued 06, 2006 A...
  • Page 63 SERVICING CONTENTS 1. TROUBLESHOOTING ..................S-1 2. SERVICING SPECIFICATIONS ..............S-4 3. TIGHTENING TORQUES ................S-11 [1] TIGHTENING TORQUES FOR GENERAL USE SCREWS, BOLTS AND NUTS....................S-11 [2] TIGHTENING TORQUES FOR SPECIAL USE SCREWS, BOLTS AND NUTS....................S-12 4. CHECKING, DISASSEMBLING AND SERVICING........S-13 [1] CHECKING AND ADJUSTING ...............S-13 (1) Engine Body..................S-13 (2) Lubricating System ................S-15 (3) Cooling System...................S-15...

  • Page 64: Troubleshooting

    SM-E2B SERIES, WSM DIESEL ENGINE 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Engine Does Not No fuel Replenish fuel G-10 Start Air in the fuel system Bleed G-10 Water in the fuel system Change fuel and – repair or replace fuel system Fuel hose clogged Clean or replace...
  • Page 65 SM-E2B SERIES, WSM DIESEL ENGINE Reference Symptom Probable Cause Solution Page Either White or Blue Excessive engine oil Reduce to specified Exhaust Gas Is level Observed Piston ring and cylinder worn or stuck Repair or replace S-43, 44, Incorrect injection timing Adjust S-17, 18 Either Black or Dark...
  • Page 66 SM-E2B SERIES, WSM DIESEL ENGINE Reference Symptom Probable Cause Solution Page Low Oil Pressure Engine oil insufficient Replenish Oil strainer clogged Clean S-34 Relief valve stuck with dirt Clean – Relief valve spring weaken or broken Replace – Excessive oil clearance of crankshaft bearing Replace S-47, 48, 66 to 69...
  • Page 67 Item Factory Specification Allowable Limit Valve Clearance (Cold) 0.145 to 0.185 mm – 0.00571 to 0.00728 in. Compression Pressure Z482-E2B 2.84 to 3.24 MPa 2.26 MPa D662-E2B 29.0 to 33.0 kgf/cm 23.0 kgf/cm D722-E2B 412 to 469 psi 327 psi...
  • Page 68 SM-E2B SERIES, WSM DIESEL ENGINE ENGINE BODY (Continued) Item Factory Specification Allowable Limit Rocker Arm Shaft to Rocker Arm Oil Clearance 0.016 to 0.045 mm 0.15 mm 0.00063 to 0.00177 in. 0.0059 in. Rocker Arm Shaft O.D. 10.473 to 10.484 mm –...
  • Page 69 I.D. 20.026 to 20.077 mm – 0.78843 to 0.79043 in. Piston Ring Gap Top Ring 0.15 to 0.30 mm 1.20 mm [Z482-E2B] 0.0059 to 0.0118 in. 0.0472 in. [D662-E2B] Second Ring 0.30 to 0.45 mm 1.20 mm [D722-E2B] 0.0118 to 0.0177 in.
  • Page 70 SM-E2B SERIES, WSM DIESEL ENGINE ENGINE BODY (Continued) Item Factory Specification Allowable Limit Crankpin to Crankpin Bearing Oil Clearance 0.020 to 0.051 mm 0.15 mm 0.00079 to 0.00201 in. 0.0059 in. Crankpin O.D. 33.959 to 33.975 mm – 1.33697 to 1.33760 in. Crankpin Bearing I.D.
  • Page 71 SM-E2B SERIES, WSM DIESEL ENGINE ENGINE BODY (Continued) Item Factory Specification Allowable Limit Cylinder Liner I.D. 64.000 to 64.019 mm 64.150 mm [D662-E2B] 2.51968 to 2.52043 in. 2.52559 in. Cylinder Liner I.D. 67.000 to 67.019 mm 67.150 mm [Z482/D722/D782-E2B] 2.63779 to 2.63854 in. 2.64370 in.
  • Page 72 SM-E2B SERIES, WSM DIESEL ENGINE COOLING SYSTEM Item Factory Specification Allowable Limit Fan Belt Tension 7.0 to 9.0 mm / 98 N – 0.28 to 0.35 in. / 98 N (10 kgf, 22 lbs) Thermostat Valve Opening 69.5 to 72.5 °C –...
  • Page 73 SM-E2B SERIES, WSM DIESEL ENGINE ELECTRICAL SYSTEM Item Factory Specification Allowable Limit Approx. 0.9 Ω Glow Plug Resistance – Starter (Electromagnetic Drive Type) Commutator O.D. 28.0 mm 27.0 mm 1.102 in. 1.063 in. Difference O.D. Less than 0.05 mm 0.4 mm 0.0002 in.

  • Page 74: Tightening Torques

    SM-E2B SERIES, WSM DIESEL ENGINE 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. [1] TIGHTENING TORQUES FOR GENERAL USE SCREWS, BOLTS AND NUTS When the tightening torques are not specified, tighten the screws, bolts and nuts according to the table below.
  • Page 75 SM-E2B SERIES, WSM DIESEL ENGINE [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 x 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 76 • Check the compression pressure with the specified valve clearance. • Always use a fully charged battery for performing this test. • Variances in cylinder compression values should be under 10 %. Z482-E2B 2.84 to 3.24 MPa D662-E2B 29 to 33 kgf/cm D722-E2B...
  • Page 77 • After adjusting the valve clearance, secure the adjusting screw with the lock nut. (1) Cylinder Head Cover A : Gear Case Side (2) “1TC” Mark [a] Z482-E2B, Z602-E2B (3) Alignment Mark [b] D662-E2B, D722-E2B, D782-E2B, D902-E2B W10172470 KiSC issued 06, 2006 A...
  • Page 78 SM-E2B SERIES, WSM DIESEL ENGINE (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 79 SM-E2B SERIES, WSM DIESEL ENGINE Fan Belt Damage and Wear 1. Check the fan belt for damage. 2. If the fan belt is damaged, replace it. 3. Check if the fan belt is worn and sunk in the pulley groove. 4.
  • Page 80 SM-E2B SERIES, WSM DIESEL ENGINE Thermostat Valve Opening Temperature 1. Suspend the thermostat in the water by a string with its end inserted between the valve and seat. 2. Heating the water gradually, read the temperature when the valve opens and leaves the string. 3.
  • Page 81 • Refer to figure of the shim to check the thickness of the shims. • The injection timing might be changed by the application. (Reference) • Injection Timing Map (before T.D.C.) Model Z482-E2B Z602-E2B Rated Speed D662-E2B D782-E2B D902-E2B Specification...
  • Page 82 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 83 SM-E2B SERIES, WSM DIESEL ENGINE CAUTION • Check the nozzle 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 84 SM-E2B SERIES, WSM DIESEL ENGINE 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 85 SM-E2B SERIES, WSM DIESEL ENGINE Battery Specific Gravity 1. Check the specific gravity of the electrolyte in each cell with a hydrometer. 2. When the electrolyte temperature differs from that at which the hydrometer was calibrated, correct the specific gravity reading following the formula mentioned in (Reference).
  • Page 86 SM-E2B SERIES, WSM DIESEL ENGINE 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. 3.
  • Page 87 SM-E2B SERIES, WSM DIESEL ENGINE 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 88 SM-E2B SERIES, WSM DIESEL ENGINE 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 MΩ meter. •...
  • Page 89 SM-E2B SERIES, WSM DIESEL ENGINE 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. •...
  • Page 90 SM-E2B SERIES, WSM DIESEL ENGINE 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 91 SM-E2B SERIES, WSM DIESEL ENGINE [2] DISASSEMBLING AND ASSEMBLING (1) Draining Engine Oil and Coolant Draining Engine Oil 1. Start and warm up the engine for approx. 5 minutes. 2. Place an oil pan underneath the engine. 3. Remove the drain plug (2) to drain oil. 4.
  • Page 92 SM-E2B SERIES, WSM DIESEL ENGINE (2) External Components Alternator, Starter and Others 1. Remove the air cleaner and muffler. 2. Remove the engine stop solenoid (1). 3. Remove the cooling fan (2), fan pulley and fan belt (3). 4. Remove the alternator. 5.
  • Page 93 SM-E2B SERIES, WSM DIESEL ENGINE Nozzle Holder Assembly and Glow Plug 1. Remove the overflow pipe (1). 2. Remove the nozzle holder assemblies (4). 3. Remove the copper gasket (5) and heat seal (6). 4. Remove the lead (2) from the glow plugs (3). 5.
  • Page 94 SM-E2B SERIES, WSM DIESEL ENGINE 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 95 A : Gear Case Side (2) Water Return Pipe (n or j) to (a) : To Loosen (3) O-ring (a) to (n or j) : To Tighten [a] Z482-E2B, Z602-E2B [b] D662-E2B, D722-E2B, D782-E2B, D902-E2B W1025645 Thermostat Assembly 1. Remove the thermostat cover mounting screws (1), and remove the thermostat cover (2).
  • Page 96 SM-E2B SERIES, WSM DIESEL ENGINE Water Pump Assembly 1. Loosen the alternator mounting screws, and remove the fan belt. 2. Remove the fan and fan pulley. 3. Remove the water pump assembly from the gear case cover. 4. Remove the water pump flange (1). 5.
  • Page 97 SM-E2B SERIES, WSM DIESEL ENGINE THIS PAGE INTENTIONALLY LEFT BLANK. S-32b - rev. 001 5-01-07...
  • Page 98 SM-E2B SERIES, WSM DIESEL ENGINE 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. IMPORTANT •...
  • Page 99 • Securely fit the O-ring to the oil strainer. • To avoid uneven tightening, tighten oil pan mounting screws in diagonal order form the center. For Z482-E2B, Z602-E2B • Using the hole (6) numbered “2”, install the oil strainer by mounting screw For D662-E2B, D722-E2B, D782-E2B, D902-E2B •...
  • Page 100 SM-E2B SERIES, WSM DIESEL ENGINE (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). 2.
  • Page 101 SM-E2B SERIES, WSM DIESEL ENGINE Injection Pump, Fuel Feed Pump and Speed Control Plate (for Energize to Run Type Engine Stop Solenoid) NOTE • Specific tool (1) : 1.2 mm 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 102 SM-E2B SERIES, WSM DIESEL ENGINE Injection Pump, Fuel Feed Pump and Speed Control Plate (for Energize to Run Type Engine Stop Solenoid) (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.
  • Page 103 SM-E2B SERIES, WSM DIESEL ENGINE 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 104 SM-E2B SERIES, WSM DIESEL ENGINE Gear Case 1. Disconnect the start spring (2) from the fork lever 1 (3). 2. Remove the screw (1) of inside the gear case and outside screws. 3. Remove the gear case (4). (When reassembling) •...
  • Page 105 SM-E2B SERIES, WSM DIESEL ENGINE 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 106 2. Remove the oil pump mounting screw (6) and the oil pump (5). 3. Remove the collar (4), O-ring (3) and crankshaft oil slinger (2). For Z482-E2B, D662-E2B, D722-E2B, D782-E2B 4. Remove the crankshaft gear (1) with a puller. (When reassembling) •...
  • Page 107 SM-E2B SERIES, WSM DIESEL ENGINE (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 108 • Carefully insert the piston using a piston ring compressor (1). Otherwise, their chrome-plated section may be scratched, causing trouble inside the cylinder. Models Mark Z482-E2B, D722-E2B D662-E2B D782-E2B Z602-E2B, D902-E2B (3200 min (rpm) spec.) Z602-E2B, D902-E2B (3600 min (rpm) spec.) (a) 0.785 rad (45 °)
  • Page 109 SM-E2B SERIES, WSM DIESEL ENGINE 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 110 SM-E2B SERIES, WSM DIESEL ENGINE (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 111 SM-E2B SERIES, WSM DIESEL ENGINE Crankshaft Assembly For Z482-E2B, D662-E2B, D722-E2B 1. Remove the main bearing case screw 2 (1). 2. Draw out all the crankshaft. For Z602-E2B 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 112 • Install the main bearing case assemblies in original positions. Since diameters of main bearing cases vary, install them in order of marking (b) (1 for Z482-E2B and 1, 2 for D662-E2B, D722- E2B, D782-E2B) from the gear case side. (Refer to the figure.).
  • Page 113 SM-E2B SERIES, WSM DIESEL ENGINE Main Bearing Case Assembly (Z602-E2B, D902-E2B) 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 114 SM-E2B SERIES, WSM DIESEL ENGINE (7) Starter Electromagnetic Drive Type (1) Solenoid Switch Mounting Nut (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 (11) Brush Spring (12) Connecting Lead...
  • Page 115 SM-E2B SERIES, WSM DIESEL ENGINE 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 (11) Armature (12) Yoke (13) Brush Holder...
  • Page 116 SM-E2B SERIES, WSM DIESEL ENGINE (8) Dynamo (1) Shaft (2) Pulley (3) Rotor (4) Collar (5) Bearing (6) Stator (7) Plate (8) Bearing W1036558 1. Remove the nut and separate the plate (7). 2. Tap out the shaft (1) from the rotor (3). 3.
  • Page 117 SM-E2B SERIES, WSM DIESEL ENGINE (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 W1224079 1.
  • Page 118 SM-E2B SERIES, WSM DIESEL ENGINE [3] SERVICING (1) Cylinder Head and Valves Top Clearance 1. Remove the cylinder head. (Do not attempt to remove the cylinder head gasket.) 2. Move the piston up and stick a strip of fuse [1.5 mm dia. (0.059 in.
  • Page 119 SM-E2B SERIES, WSM DIESEL ENGINE 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. 4.
  • Page 120 SM-E2B SERIES, WSM DIESEL ENGINE 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 121 SM-E2B SERIES, WSM DIESEL ENGINE 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 122 SM-E2B SERIES, WSM DIESEL ENGINE 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 123 SM-E2B SERIES, WSM DIESEL ENGINE 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 124 SM-E2B SERIES, WSM DIESEL ENGINE (2) Timing Gears Timing Gear Backlash 1. Set a dial indicator (lever type) with its tip on the gear tooth. 2. Move the gear to measure the backlash, holding its mating gear. 3. If the backlash exceeds the allowable limit, check the oil clearance of the shaft and the gear.
  • Page 125 SM-E2B SERIES, WSM DIESEL ENGINE Camshaft Alignment 1. Support the camshaft 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 camshaft alignment. 4. If the measurement exceeds the allowable limit, replace the camshaft.
  • Page 126 SM-E2B SERIES, WSM DIESEL ENGINE Oil Clearance between Idle Gear Shaft and Idle Gear Bushing 1. Measure the idle gear shaft O.D. with an outside micrometer. 2. Measure the idle gear bushing I.D. with an inside micrometer, and calculate the oil clearance. 3.
  • Page 127 SM-E2B SERIES, WSM DIESEL ENGINE Oil Clearance between Piton Pin and Small End Bushing 1. Measure the piston pin O.D. where it contacts the bushing with an outside micrometer. 2. Measure the small end bushing I.D. with an inside micrometer, and calculate the oil clearance.
  • Page 128 0.15 to 0.30 mm spec. 0.0059 to 0.0118 in. Top ring Allowable 1.20 mm limit 0.0472 in. Piston ring gap Factory 0.30 to 0.45 mm [Z482-E2B] spec. 0.0118 to 0.0177 in. [D662-E2B] Second ring Allowable 1.20 mm [D722-E2B] limit 0.0472 in. [D782-E2B] Factory 0.15 to 0.30 mm...
  • Page 129 SM-E2B SERIES, WSM DIESEL ENGINE (4) Crankshaft Crankshaft Side Clearance 1. Set a dial indicator with its tip on the end of the crankshaft. 2. Measure the side clearance by moving the crankshaft to the front and rear. 3. If the measurement exceeds the allowable limit, replace the thrust bearings.
  • Page 130 SM-E2B SERIES, WSM DIESEL ENGINE Oil Clearance between Crankpin and Crankpin Bearing 1. Clean the crankpin and crankpin bearing. 2. Put a strip of plastigage on the center of the crankpin. 3. Install the connecting rod cap and tighten the connecting rod screws to the specified torque, and remove the cap again.
  • Page 131 0.034 to 0.106 mm Factory spec. Oil Clearance between 0.00134 to 0.00417 in. crankshaft journal and 0.20 mm crankshaft bearing 1 Allowable limit 0.0079 in. Z482-E2B D662-E2B 39.934 to 39.950 mm D722-E2B 1.57221 to 1.57284 in. Factory Crankshaft journal O.D. D782-E2B spec.
  • Page 132 (See figure.) 0.0 to 0.3 mm Dimension (A) Factory spec. 0.0 to 0.0118 in. (1) Seam [a] Z482-E2B, D662-E2B, (2) Crankshaft Bearing 1 D722-E2B, D782-E2B (3) Cylinder Block [b] Z602-E2B, D902-E2B (A) Dimension (B) 0.366 rad (21 °)
  • Page 133 43.934 to 43.950 mm Factory spec. (Flywheel side) 1.72968 to 1.73031 in. Crankshaft bearing 2 43.978 to 43.993 mm Factory spec. I.D. 1.73142 to 1.73201 in. Z482-E2B D662-E2B 39.934 to 39.950 mm D722-E2B 1.57221 to 1.57284 in. Crankshaft journal O.D. Factory D782-E2B (Intermediate) spec.
  • Page 134 Oil Clearance between Crankshaft Journal and Crankshaft Bearing 2 and Crankshaft Bearing 3 (Continued) (Reference) • Undersize crankshaft bearing 2 and 3 (0.2 mm (0.008 in.)) Models Bearing Code Number Marking Z482-E2B Crankshaft bearing 2 02 15694-23930 D662-E2B D722-E2B Crankshaft bearing 3 02 15861-23860 020 US...
  • Page 135 SM-E2B SERIES, WSM DIESEL ENGINE Replacing Crankshaft Sleeve (Z482-E2B, D662-E2B, D722-E2B, D782-E2B) 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 136 Correcting Cylinder (Oversize) 1. When the cylinder is worn beyond the allowable limit, bore and hone it to the specified dimension. 64.250 to 64.269 mm D662-E2B 2.52953 to 2.53027 in. Z482-E2B Factory 67.250 to 67.269 mm D722-E2B spec. 2.64764 to 2.64839 in.
  • Page 137 SM-E2B SERIES, WSM DIESEL ENGINE Clearance between Rotor and Cover 1. Put a strip of plastigage onto the rotor face with grease. 2. Install the cover and tighten the screws. 3. Remove the cover carefully, and measure the amount of the flattening with the scale and get the clearance.
  • Page 138 SM-E2B SERIES, WSM DIESEL ENGINE 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. 3.
  • Page 139 SM-E2B SERIES, WSM DIESEL ENGINE Brush Wear 1. If the connect face of the brush is dirty or dusty, clean it with emery paper. 2. Measure the brush length (A) with vernier caliper. 3. If the length is than the allowable limit, replace the yoke assembly and brush holder.
  • Page 140 SM-E2B SERIES, WSM DIESEL ENGINE Field Coil 1. Check the continuity across the lead (1) and brush (2) with a circuit tester. 2. If it dose not conduct, replace the yoke assembly. 3. Check the continuity across the brush (2) and yoke (3) with a circuit tester.
  • Page 141 SM-E2B SERIES, WSM DIESEL ENGINE Slip Ring 1. Check the slip ring for score. 2. If scored, correct with an emery paper or on a lathe. 3. Measure the O.D. of slip ring with vernier calipers. 4. If the measurement is less than the allowable limit, replace it. 14.4 mm Factory spec.
  • Page 142 EDITOR : KUBOTA FARM & INDUSTRIAL MACHINERY SERVICE, LTD. 64, ISHIZU-KITAMACHI, SAKAI-KU, SAKAI-CITY, OSAKA, 590-0823, JAPAN PHONE : ( 81 ) 72-241-1129 : ( 81 ) 72-245-2484 E-mail : ksos-pub@kubota.co.jp Printed in Japan 2006. 02, S, EI, EI, e Code No.9Y011-03173 KUBOTA Corporation 2004.

This manual is also suitable for:

D662-e2bZ602-e2bD722-e2bD782-e2bD902-e2b

Table of Contents