Kubota SM-E3B Series Workshop Manual
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Kubota SM-E3B Series Workshop Manual

Sm-e3b series
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WORKSHOP MANUAL
DIESEL ENGINE
SM-E3B SERIES
KiSC issued 03, 2011 A

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Summary of Contents for Kubota SM-E3B Series

  • Page 1 WORKSHOP MANUAL DIESEL ENGINE SM-E3B SERIES KiSC issued 03, 2011 A...
  • Page 2 TO THE READER This Workshop Manual has been prepared to provide servicing personnel with information on the mechanism, service and maintenance of SM-E3B series. It is divided into three parts, “General”, “Mechanism” and “Servicing”. General Information on the engine identification, the general precautions, maintenance check list, check and maintenance and special tools are described.
  • Page 3 SAFETY INSTRUCTIONS SM-E3B SERIES WSM 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.
  • Page 4 SAFETY INSTRUCTIONS SM-E3B SERIES WSM 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.
  • Page 5 SAFETY INSTRUCTIONS SM-E3B SERIES WSM AVOID FIRES • Fuel is extremely flammable and explosive under certain conditions. Do not smoke or allow flames or sparks in your working area. • To avoid sparks from an accidental short circuit, always disconnect the battery negative cable first and connect it last.
  • Page 6 SAFETY INSTRUCTIONS SM-E3B SERIES WSM PREPARE FOR EMERGENCIES • Keep a first aid kit and fire extinguisher handy at all times. • Keep emergency numbers for doctors, ambulance service, hospital and fire department near your telephone. KiSC issued 03, 2011 A...

  • Page 7: Specifications

    SPECIFICATIONS SM-E3B SERIES WSM SPECIFICATIONS Model Z482-E3B Z602-E3B Number of Cylinders 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 8 SPECIFICATIONS SM-E3B SERIES WSM Model D722-E3B D782-E3B D902-E3B Number of Cylinders Type Vertical, Water-cooled, 4 cycle IDI diesel engine 67.0 × 68.0 mm 67.0 × 73.6 mm 72.0 × 73.6 mm Bore × Stroke (2.64 × 2.68 in.) (2.64 × 2.90 in.) (2.83 ×...

  • Page 9: Performance Curves

    PERFORMANCE CURVES SM-E3B SERIES WSM PERFORMANCE CURVES Z482-E3B (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 PERFORMANCE CURVES SM-E3B SERIES WSM Z602-E3B (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 11 PERFORMANCE CURVES SM-E3B SERIES WSM D722-E3B (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 12 PERFORMANCE CURVES SM-E3B SERIES WSM D782-E3B (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 13 PERFORMANCE CURVES SM-E3B SERIES WSM D902-E3B (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 14 DIMENSIONS SM-E3B SERIES WSM DIMENSIONS Z482-E3B KiSC issued 03, 2011 A...
  • Page 15 DIMENSIONS SM-E3B SERIES WSM Z602-E3B KiSC issued 03, 2011 A...
  • Page 16 DIMENSIONS SM-E3B SERIES WSM D722-E3B KiSC issued 03, 2011 A...
  • Page 17 DIMENSIONS SM-E3B SERIES WSM D782-E3B KiSC issued 03, 2011 A...
  • Page 18 DIMENSIONS SM-E3B SERIES WSM D902-E3B KiSC issued 03, 2011 A...

  • Page 19: Table Of Contents

    GENERAL CONTENTS 1. ENGINE IDENTIFICATION ................G-1 [1] MODEL NAME AND ENGINE SERIAL NUMBER ........ G-1 [2] E3B ENGINE..................... G-2 [3] CYLINDER NUMBER ................G-2 2. GENERAL PRECAUTIONS ................G-3 3. MAINTENANCE CHECK LIST ............... G-4 4. CHECK AND MAINTENANCE ............... G-7 [1] DAILY CHECK POINTS................

  • Page 20: Engine Identification

    G GENERAL SM-E3B 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 21: E3B 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, E3B will be the designation that identifies engine models affected by the next emission phase (See the table below).

  • Page 22: 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 23: 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 24 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 25 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 26: Check And Maintenance

    G GENERAL SM-E3B 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 27 G GENERAL SM-E3B SERIES WSM 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 28: Check Points Of Initial 50 Hours

    G GENERAL SM-E3B 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 29 G GENERAL SM-E3B SERIES WSM Replacing Oil Filter Cartridge CAUTION • Be sure to stop the engine before changing filter cartridge. 1. Remove the oil filter cartridge (1) with the filter wrench. 2. Apply a slight coat of oil onto the new cartridge gasket.

  • Page 30: Check Point Of Every 50 Hours

    G GENERAL SM-E3B 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 31: Check Point Of Every 75 Hours

    G GENERAL SM-E3B SERIES WSM [4] CHECK POINT 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 32: Check Points Of Every 100 Hours

    G GENERAL SM-E3B 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 33 G GENERAL SM-E3B 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 34 G GENERAL SM-E3B SERIES WSM 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.

  • Page 35: Check Point Of Every 150 Hours

    G GENERAL SM-E3B SERIES WSM [6] CHECK POINT OF EVERY 150 HOURS Replacing Oil Filter Cartridge (for Optional Depth Oil Pans) CAUTION • Be sure to stop the engine before changing filter cartridge. 1. Remove the oil filter cartridge (1) with the filter wrench.

  • Page 36: Check Points Of Every 400 Hours

    G GENERAL SM-E3B SERIES WSM 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 37: Check Points Of Every 500 Hours

    G GENERAL SM-E3B 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 38 G GENERAL SM-E3B 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 39: Check Points Of Every 1 Or 2 Months

    G GENERAL SM-E3B 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 40 G GENERAL SM-E3B SERIES WSM 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 41: Check Point Of Every Year

    G GENERAL SM-E3B 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 42: Check Point Of Every 800 Hours

    G GENERAL SM-E3B 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 43: Check Points Of Every 1500 Hours

    G GENERAL SM-E3B 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 44 G GENERAL SM-E3B 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 45: Check Points Of Every 3000 Hours

    G GENERAL SM-E3B 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 46 G GENERAL SM-E3B SERIES WSM Injection Timing (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.).
  • Page 47 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 48: Check Points Of Every 2 Years

    G GENERAL SM-E3B 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 49 G GENERAL SM-E3B 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 50 G GENERAL SM-E3B 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.
  • Page 51 G GENERAL SM-E3B SERIES WSM 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 52: Special Tools

    G GENERAL SM-E3B SERIES WSM 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 53 G GENERAL SM-E3B SERIES WSM 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...
  • Page 54 G GENERAL SM-E3B SERIES WSM 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 55 G GENERAL SM-E3B SERIES WSM 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 (2.8 in.) 40 mm radius (1.6 in. radius) 10 mm (0.39 in.) 22 mm (0.87 in.)
  • Page 56 G GENERAL SM-E3B SERIES WSM Crank Sleeve Setter (for Z482/D722/D782-E3B) 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 57 MECHANISM CONTENTS 1. ENGINE BODY ....................M-1 [1] HALF-FLOATING HEAD COVER ............M-1 [2] CLOSED BREATHER................M-1 [3] PISTON (Z602-E3B, D782-E3B, D902-E3B) ..........M-2 [4] OIL PAN (Z602-E3B, D902-E3B)............. M-2 2. COOLING SYSTEM ..................M-3 [1] COOLING FIN (Z602-E3B, D902-E3B)............ M-3 KiSC issued 03, 2011 A...

  • Page 58: Engine Body

    DIESEL ENGINE SM-E3B 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 59: Piston (Z602-E3B, D782-E3B, D902-E3B

    DIESEL ENGINE SM-E3B SERIES WSM [3] PISTON (Z602-E3B, D782-E3B, D902-E3B) 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.

  • Page 60: Cooling System

    DIESEL ENGINE SM-E3B SERIES WSM 2. COOLING SYSTEM [1] COOLING FIN (Z602-E3B, D902-E3B) 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 61 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 62: Troubleshooting

    DIESEL ENGINE SM-E3B 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 – repair or replace fuel...
  • Page 63 DIESEL ENGINE SM-E3B SERIES WSM 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...
  • Page 64 DIESEL ENGINE SM-E3B SERIES WSM 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...

  • Page 65: Servicing Specifications

    DIESEL ENGINE SM-E3B 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-E3B 2.85 to 3.23 MPa 2.26 MPa D722-E3B 29.0 to 33.0 kgf/cm 23.0 kgf/cm...
  • Page 66 DIESEL ENGINE SM-E3B SERIES WSM 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 0.0017 in. 0.0059 in. Rocker Arm Shaft O.D. 10.473 to 10.484 mm –...
  • Page 67 DIESEL ENGINE SM-E3B SERIES WSM ENGINE BODY (Continued) Item Factory Specification Allowable Limit Idle Gear Shaft to Idle Gear Bushing Oil Clearance 0.020 to 0.084 mm 0.10 mm 0.00079 to 0.0033 in. 0.0039 in. Idle Gear Shaft O.D. 19.967 to 19.980 mm –...
  • Page 68 DIESEL ENGINE SM-E3B SERIES WSM 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 0.0020 in. 0.0059 in. Crankpin O.D. 33.959 to 33.975 mm – 1.3370 to 1.3375 in.
  • Page 69 DIESEL ENGINE SM-E3B SERIES WSM ENGINE BODY (Continued) Item Factory Specification Allowable Limit Cylinder Liner I.D. 67.000 to 67.019 mm 67.150 mm [Z482/D722/D782-E3B] 2.6378 to 2.6385 in. 2.6437 in. Cylinder Liner I.D. 72.000 to 72.019 mm 72.150 mm [Z602/D902-E3B] 2.8347 to 2.8353 in.
  • Page 70 DIESEL ENGINE SM-E3B SERIES WSM FUEL SYSTEM Item Factory Specification Allowable Limit Injection Pump Injection Timing [Z482/D722-E3B] (3600 min (rpm)) (Serial No. : below 7ZZ999) 0.3491 to 0.3839 rad – (20.00 to 22.00°) before T.D.C. (Serial No. : above 8A0001) 0.3535 to 0.3796 rad...
  • Page 71 DIESEL ENGINE SM-E3B SERIES WSM 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 1.10 in. 1.06 in. Difference O.D. Less than 0.05 mm 0.40 mm 0.002 in.

  • Page 72: Tightening Torques

    DIESEL ENGINE SM-E3B 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 73: Tightening Torques For Special Use Screws, Bolts And Nuts

    DIESEL ENGINE SM-E3B 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 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 74: Checking, Disassembling And Servicing

    DIESEL ENGINE SM-E3B 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 75 DIESEL ENGINE SM-E3B 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 76: Lubricating System

    DIESEL ENGINE SM-E3B 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 77 DIESEL ENGINE SM-E3B SERIES WSM 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.

  • Page 78: Fuel System

    DIESEL ENGINE SM-E3B SERIES WSM 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.
  • Page 79 DIESEL ENGINE SM-E3B SERIES WSM Z482/D722-E3B (3600 min (rpm) spec.) 0.3491 to 0.3839 rad Injection timing Factory spec. (20.00 to 22.00 °) before (Serial No. : below 7ZZ999) T.D.C. 0.3535 to 0.3796 rad Injection timing Factory spec. (20.25 to 21.75 °) before (Serial No.
  • Page 80 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 81 DIESEL ENGINE SM-E3B SERIES WSM 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 82: Electrical System

    DIESEL ENGINE SM-E3B 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 83 DIESEL ENGINE SM-E3B SERIES WSM 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 84 DIESEL ENGINE SM-E3B 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 85 DIESEL ENGINE SM-E3B 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 86 DIESEL ENGINE SM-E3B 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 MΩ meter.
  • Page 87 DIESEL ENGINE SM-E3B 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.
  • Page 88 DIESEL ENGINE SM-E3B 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 89: Disassembling And Assembling

    DIESEL ENGINE SM-E3B SERIES WSM [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.

  • Page 90: External Components

    DIESEL ENGINE SM-E3B SERIES WSM (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.
  • Page 91 DIESEL ENGINE SM-E3B SERIES WSM 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).
  • Page 92 DIESEL ENGINE SM-E3B 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 93 DIESEL ENGINE SM-E3B SERIES WSM Cylinder Head and Cylinder Head Gasket 1. Loosen the pipe clamps (1), and remove the water return pipe (2). 2. Remove the cylinder head screw in the order of (n or j) to (a). 3. Remove the cylinder head gasket.
  • Page 94 DIESEL ENGINE SM-E3B SERIES WSM Valves 1. Remove the valve caps (4). 2. Remove the valve spring collet (3), pushing the valve spring retainer (2) by valve spring replacer (1). 3. Remove the valve spring retainer (2), valve spring (5) and valve stem seal (6).
  • Page 95 DIESEL ENGINE SM-E3B 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 96: Gear Case And Timing Gears

    DIESEL ENGINE SM-E3B 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 97 DIESEL ENGINE SM-E3B SERIES WSM Injection Pump, Fuel Feed Pump and Speed Control Plate (for Energize to Run Type Engine Stop Solenoid) NOTE • Specific tool (1) : 1.2 mm (0.047 in.) diameter hard wire with its end hooked, overall length 200 mm (7.87 in.).
  • Page 98 DIESEL ENGINE SM-E3B SERIES WSM 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).
  • Page 99 DIESEL ENGINE SM-E3B 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 100 DIESEL ENGINE SM-E3B SERIES WSM 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 101 DIESEL ENGINE SM-E3B 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).
  • Page 102 DIESEL ENGINE SM-E3B 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 103: Piston And Connecting Rod

    DIESEL ENGINE SM-E3B 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 104 DIESEL ENGINE SM-E3B SERIES WSM Piston 1. Turn the flywheel and bring the piston to top dead center. 2. Draw out the piston upward by lightly tapping it from the bottom of the crankcase with the grip of a hammer.
  • Page 105 DIESEL ENGINE SM-E3B 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 106: Flywheel And Crankshaft

    DIESEL ENGINE SM-E3B 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 107 DIESEL ENGINE SM-E3B SERIES WSM Crankshaft Assembly For Z482-E3B, D722-E3B 1. Remove the main bearing case screw 2 (1). 2. Draw out all the crankshaft. For Z602-E3B 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 108 DIESEL ENGINE SM-E3B SERIES WSM Main Bearing Case Assembly (Z482-E3B, D722-E3B, D782-E3B) 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 109 DIESEL ENGINE SM-E3B SERIES WSM Main Bearing Case Assembly (Z602-E3B, D902-E3B) 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 110: Starter

    DIESEL ENGINE SM-E3B SERIES WSM (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...
  • Page 111 DIESEL ENGINE SM-E3B 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 112: Dynamo

    DIESEL ENGINE SM-E3B SERIES WSM (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).
  • Page 113 DIESEL ENGINE SM-E3B 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 W1224079 1.

  • Page 114: Servicing

    DIESEL ENGINE SM-E3B 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 115 DIESEL ENGINE SM-E3B 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 116 DIESEL ENGINE SM-E3B 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 117 DIESEL ENGINE SM-E3B 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 118 DIESEL ENGINE SM-E3B 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 119 DIESEL ENGINE SM-E3B 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 120: Timing Gears

    DIESEL ENGINE SM-E3B SERIES WSM (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 121 DIESEL ENGINE SM-E3B SERIES WSM 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 122: Piston And Connecting Rod

    DIESEL ENGINE SM-E3B SERIES WSM 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.
  • Page 123 DIESEL ENGINE SM-E3B SERIES WSM 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 124 DIESEL ENGINE SM-E3B SERIES WSM Piston Ring Gap 1. Insert the piston ring into the lower part of the cylinder (the least worn out part) with a piston ring compressor and piston. 2. Measure the ring gap with a feeler gauge.

  • Page 125: Crankshaft

    DIESEL ENGINE SM-E3B SERIES WSM (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 126 DIESEL ENGINE SM-E3B SERIES WSM 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 127 DIESEL ENGINE SM-E3B 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 DIESEL ENGINE SM-E3B SERIES WSM Oil Clearance between Crankshaft Journal and Crankshaft Bearing 1 (Continued) (Reference) • Undersize crankshaft bearing 1 Undersize Models Bearing Code Number Marking Z482-E3B D722-E3B 15861-23910 0.20 mm Crankshaft D782-E3B 020 US 0.0079 in. bearing 1 02...
  • Page 129 DIESEL ENGINE SM-E3B 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 DIESEL ENGINE SM-E3B SERIES WSM Oil Clearance between Crankshaft Journal and Crankshaft Bearing 2 and Crankshaft Bearing 3 (Continued) (Reference) • Undersize crankshaft bearing 2 and 3 (0.20 mm (0.0079 in.)) Models Bearing Code Number Marking Z482-E3B Crankshaft bearing 2 02...

  • Page 131: Cylinder

    DIESEL ENGINE SM-E3B SERIES WSM Replacing Crankshaft Sleeve (Z482-E3B, D722-E3B, D782-E3B) 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

    DIESEL ENGINE SM-E3B SERIES WSM Correcting Cylinder (Oversize) 1. When the cylinder is worn beyond the allowable limit, bore and hone it to the specified dimension. Z482-E3B 67.250 to 67.269 mm D722-E3B 2.6477 to 2.6483 in. Factory D782-E3B spec. Z602-E3B 72.250 to 72.269 mm...

  • Page 133: Starter

    DIESEL ENGINE SM-E3B SERIES WSM 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 134 DIESEL ENGINE SM-E3B 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 DIESEL ENGINE SM-E3B SERIES WSM 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 136: Alternator

    DIESEL ENGINE SM-E3B SERIES WSM 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 137 DIESEL ENGINE SM-E3B SERIES WSM 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.
  • 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 : ksos-pub@kubota.co.jp Printed in Japan 2011. 03, S, EI, EI, e Code No.9Y111-00133 KUBOTA Corporation 2007.

This manual is also suitable for:

Z482-e3bZ602-e3bD722-e3bD782-e3bD902-e3b

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