Aixam Roadline, Scouty R User Manual
WORKSHOP MANUAL
KiSC issued 06, 2006 A
DIESEL ENGINE
SM-E2B SERIES
TO THE READER
KiSC issued 06, 2006 A
This Workshop Manual has been prepared to provide servicing personnel with
information on the mechanism, service and maintenance of SM-E2B 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.
■ Mechanism
Information on the construction and function are included. This part should be
understood before proceeding with troubleshooting, disassembling and servicing.
Refer to Diesel Engi ne Mechan ism W orksh op Man ual (C ode No. 9Y021-0 1870) for
the one which has not been described to this workshop manual.
■ Servicing
Information on the troubleshooting, servicing specification lists, tightening torque,
checking and adjusting, disassembling and assembling, and servicing which cover
procedures, precautions, factory specifications and allowable limits.
All information illustrations and specifications contained in this manual are based on
the latest product information available at the time of publication.
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.
© KUBOTA Corporation 2004
November 2004
SM-E2B SERIES, WSM
SAFETY FIRST
KiSC issued 06, 2006 A
SAFETY INSTRUCTIONS
SAFETY INSTRUCTIONS
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.
DANGER : Indicates an imminently hazardous situation which, if not avoided, will result in
death or serious injury.
WARNING : Indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION : Indicates a potentially hazardous situation which, if not avoided, may result in
minor or moderate injury.
■ IMPORTANT : Indicates that equipment or property damage could result if instructions are not
followed.
■ NOTE : Gives helpful information.
BEFORE SERVICING AND REPAIRING
• Read all instructions and safety instructions in this
manual and on your engine safety decals.
• Clean the work area and engine.
• Park the machine on a firm and level ground.
• Allow the engine to cool before proceeding.
• Stop the engine, and remove the key.
• Disconnect the battery negative cable.
• Hang a “DO NOT OPERATE” tag in operator
station.
1
SM-E2B SERIES, WS M
KiSC issued 06, 2006 A
SAFETY INSTRUCTIONS
SAFETY STARTING
• Do not start the engine by shorting across starter
terminals or bypassing the safety start switch.
• Unauthorized modifi catio ns to the engine may im pair
the function and / or safety and affect engine life.
SAFETY WORKING
• Do not work on the machine while under the influence
of alcohol, medication , or other substances or while
fatigued.
• Wear close fitting clothing and safety equipment
appropriate to the job.
• Use tools appropriate to the work. Makeshift tools,
parts, and procedures are not recommended.
• When servicing is performed together by two or more
persons, take care to perform all work safely.
• Do not touch the rotating or hot parts while the engine
is running.
• Never remove the radiator cap while the engine is
running, or immediately after stopping. Otherwise, hot
water will spout out from radiator. Only remove
radiator cap when cool enough to touch with bare
hands. Slowly loosen the cap to first stop to relieve
pressure before removing completely.
• Escaping fluid (fuel or hydraulic oil) un der pressure
can penetrate the skin causing serious injury. Relieve
pressure before disconnecting hydraulic or fuel lines.
Tighten all connections before applying pressure.
• Wear a suitable hearing protective device such as
earmuffs or earplugs to prote ct aga in st obj ec tio nab le
or uncomfortable loud noises.
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.
• Battery gas can explode. Keep sparks and open
flame away from the top of b attery, especially when
charging the battery.
• Make sure that no fuel has been spilled on the engine.
2
SM-E2B SERIES, WSM
KiSC issued 06, 2006 A
SAFETY INSTRUCTIONS
VENTILATE WORK AREA
• If the engine must be running to do some work, make
sure the area is well ventilated . Neve r run the eng ine
in a closed area. The exhaust gas contains poisonous
carbon monoxide.
DISPOSE OF FLUIDS PROPERLY
• Do not pour fluids into the ground, down a drain, or
into a stream, pond, or lake. Observe relevant
environmental prot ectio n regulati ons whe n disp osing
of oil, fuel, coolant, electrolyte and other harmful
waste.
PREVENT ACID BURNS
• Sulfuric acid in batte ry electrolyte is poisonou s. It is
strong enough to burn skin, clothing and cause
blindness if splashed into eyes. Keep electrolyte
away from eyes, hands and clothing. If you spill
electrolyte on yourself, flush with water, and get
medical attention immediately.
PREPARE FOR EMERGENCIES
• Keep a first aid kit and fire extingui sher handy at all
times.
• Keep emergency numbers for doctors, ambulance
service, hospital and fire department near your
telephone.
3
SM-E2B SERIES, WS M
KiSC issued 06, 2006 A
SPECIFICATIONS
SPECIFICATIONS
Model Z482-E2B Z602-E2B
Number of Cylinders 2
Type Vertical, Water-cooled, 4 cycle IDI diesel engine
Bore × Stroke mm (in.) 67 × 68 (2.64 × 2.68) 72 × 73.6 (2.83 × 2.90)
Total Displacement cm
ISO Net Continous
kW/min
ISO / SAE Net Intermitte n t
kW/min
SAE Gross Intermittent
kW/min
Maximum Bare Speed (min
Minimum Bare Idling Speed (min
Combustion Chamber Spherical type (E-TVCS)
Fuel Injection Pump Bosch MD type mini pump
Governor All speed mechanical governor
Direction of Rotation Counter-clockwise (viewed from flywheel side)
Injection Nozzle Bosch “Throttle” type
Injection Timing 0.35 rad (20 °) before T .D.C. 0.31 rad (18 °) before T.D.C. 0.35 rad (20 °) before T.D.C.
Firing Order 1-2
Injection Pressure 13.73 MPa (140 kgf/cm
Compression Ratio 23.5 : 1 24 : 1
Lubricating System Forced lubrication by trochoid pump
Oil Pressure Indicating Electrical type switch
Lubricating Filter Full flow paper filter (Cartridge type)
Cooling System Pressurized radiator, forced circulation with water pump (not included in the basic engine)
Starting System Electric Starting with Starter
Starting Motor 12 V, 0.8 kW 12 V, 1.0 kW
Starting Support Device By glow plug in combustion chamber
Battery 12 V, 28 AH equivalent 12 V, 36 AH equivalent
Charging Alternator 12 V, 150 W 12 V, 480 W
Fuel Diesel Fuel No.2-D (ASTM D975)
Lubricating Oil
Lubricating Oil
Capacity
Weight (Dry) kg (lbs) 53.1 (117.1) 57.0 (125.7)
* The specification described above is of the standard engine of each model.
* Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW
-1
(rpm) (HP/m in-1 (rpm))
-1
(rpm) (HP/m in-1 (rpm))
-1
(rpm) (HP/m in-1 (rpm))
Oil Pan Depth
101 mm (3.98 in.)
Oil Pan Depth
121 mm (4.76 in.)
3
(cu.in.) 479 (29.23) 599 (36.55)
8.1 / 3600 (10.9 / 3600) 8.8 / 3200 (11.8 / 3200) 10.1 / 3600 (13.5 / 3600)
9.3 / 3600 (12.5 / 3600) 10.1 / 3200 (13.5 / 3200) 11.6 / 3600 (15.5 / 3600)
9.9 / 3600 (13.3 / 3600) 10.8 / 3200 (14.5 / 3200) 12.5 / 3600 (16.8 / 3600)
-1
(rpm)) 3800 3450 3800
-1
(rpm)) 900 to 1000
2
, 1991 psi)
Class CF lubricating oil as per API classification is recommended.
If this class of lubricating oil is not available, preferably use Class CD or CE lubricating oil.
2.1 L (0.55 U.S.gals) 2.5 L (0.66 U.S.gals)
2.5 L (0.66 U.S.gals) –
For details on recommended lubricating oils, see page G-5, 8.
W10336300
4
SM-E2B SERIES, WSM
KiSC issued 06, 2006 A
SPECIFICATIONS
Model D662-E2B D722-E2B
Number of Cylinders 3
Type Vertical, Water-cooled, 4 cycle IDI diesel engine
Bore × Stroke mm (in.) 64 × 68 (2.52 × 2.68) 67 × 68 (2.64 × 2.68)
Total Displacement cm
ISO Net Continuous
kW/min
ISO / SAE Net Int e r mittent
kW/min
SAE Gross Intermittent
kW/min
-1
(rpm) (HP/min-1 (rpm))
-1
(rpm) (HP/min-1 (rpm))
-1
(rpm) (HP/min-1 (rpm))
Maximum Bare Speed (min
Minimum Bare Idling Speed (min
3
(cu.in.) 656 (40.03) 719 (43.88)
11.2 / 3600 (15.0 / 3600) 12.2 / 3600 (16.4 / 3600)
12.9 / 3600 (17.3 / 3600) 14.0 / 3600 (18.8 / 3600)
14.3 / 3600 (19.2 / 3600) 14.9 / 3600 (20.0 / 3600)
-1
(rpm)) 3800
-1
(rpm)) 900 to 1000
Combustion Chamber Spherical type (E-TVCS)
Fuel Injection Pump Bosch MD type mini pump
Governor All speed mechanical governor
Direction of Rotation Counter-clockwise (viewed from flywheel side)
Injection Nozzle Bosch “Throttle” type
Injection Timing 0.35 rad (20 °) before T.D.C.
Firing Order 1-2-3
Injection Pressure 13.73 MPa (140 kgf/cm
2
, 1991 psi)
Compression Ratio 23 : 1 23.5 : 1
Lubricating System Forced lubrication by trochoid pump
Oil Pressure Indicating Electrical type switch
Lubricating Filter Full flow paper filter (Cartridge type)
Cooling System Pressurized radiator, forced circulation with water pump (not included in the basic engine)
Starting System Electric Starting with Starter
Starting Motor 12 V, 0.8 kW
Starting Support Device By glow plug in combustion chamber
Battery 12 V, 36 AH equivalent
Charging Alternator 12 V, 150 W
Fuel Diesel Fuel No.2-D (ASTM D975)
Class CF lubricating oil as per API classification is recommended.
Lubricating Oil
If this class of lubricating oil is not available, preferably use Class CD or CE lubricating oil.
For details on recommended lubricating oils, see page G-5, 8.
Lubricating Oil
Capacity
Oil Pan Depth
101 mm (3.98 in.)
Oil Pan Depth
121 mm (4.76 in.)
3.2 L (0.85 U.S.gals)
3.8 L (1.00 U.S.gals)
Weight (Dry) kg (lbs) 63.7 (140.4) 63.1 (139.1)
* The specification described above is of the standard engine of each model.
* Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW
W10304910
5
SM-E2B SERIES, WS M
KiSC issued 06, 2006 A
SPECIFICATIONS
Model D782-E2B D902-E2B
Number of Cylinders 3
Type Vertical, Water-cooled, 4 cycle IDI diesel engine
Bore × Stroke mm (in.) 67 × 73.6 (2.64 × 2.90) 72 × 73.6 (2.83 × 2.90)
Total Displacement cm
ISO Net Continuous
kW/min
ISO / SAE Net Intermitte n t
kW/min
SAE Gross Intermittent
kW/min
-1
(rpm) (HP/m in-1 (rpm))
-1
(rpm) (HP/m in-1 (rpm))
-1
(rpm) (HP/m in-1 (rpm))
Maximum Bare Speed (min
Minimum Bare Idling Speed (min
3
(cu.in.) 778 (47.48) 898 (54.80)
11.7 / 3200 (15.7 / 3200) 13.4 / 3200 (18.0 / 3200) 15.2 / 3600 (20.4 / 3600)
13.5 / 3200 (18.1 / 3200) 15.4 / 3200 (20.6 / 3200) 17.5 / 3600 (23.5 / 3600)
14.1 / 3200 (18.9 / 3200) 16.1 / 3200 (21.6 / 3200) 18.5 / 3600 (24.8 / 3600)
-1
(rpm)) 3450 3800
-1
(rpm)) 900 to 1000
Combustion Chamber Spherical type (E-TVCS)
Fuel Injection Pump Bosch MD type mini pump
Governor All speed mechanical governor
Direction of Rotation Counter-clockwise (viewed from flywheel side)
Injection Nozzle Bosch “Throttle” type
Injection Timing 0.30 rad (17 °) before T .D.C. 0.31 rad (18 °) before T.D.C. 0.35 rad (20 °) before T.D.C.
Firing Order 1-2-3
Injection Pressure 13.73 MPa (140 kgf/cm
2
, 1991 psi)
Compression Ratio 24 : 1
Lubricating System Forced lubrication by trochoid pump
Oil Pressure Indicating Electrical type switch
Lubricating Filter Full flow paper filter (Cartridge type)
Cooling System Pressurized radiator, forced circulation with water pump (not included in the basic engine)
Starting System Electric Starting with Starter
Starting Motor 12 V, 1.0 kW 12 V, 1.2 kW
Starting Support Device By glow plug in combustion chamber
Battery 12 V, 36 AH equivalent 12 V, 52 AH equivalent
Charging Alternator 12 V, 150 W 12 V, 480 W
Fuel Diesel Fuel No.2-D (ASTM D975)
Class CF lubricating oil as per API classification is recommended.
Lubricating Oil
If this class of lubricating oil is not available, preferably use Class CD or CE lubricating oil.
For details on recommended lubricating oils, see page G-5, 8.
Lubricating Oil
Capacity
Oil Pan Depth
101 mm (3.98 in.)
Oil Pan Depth
121 mm (4.76 in.)
3.6 L (0.95 U.S.gals) –
– 3.7 L (0.98 U.S.gals)
Weight (Dry) kg (lbs) 63.5 (139.7) 72.0 (158.7)
* The specification described above is of the standard engine of each model.
* Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW
W10321290
6
SM-E2B SERIES, WSM
KiSC issued 06, 2006 A
PERFORMANCE CURVES
■ Z482-E2B
PERFORMANCE CURVES
(1) Brake Horsepower
(2) Engine Speed
(3) B.S.F.C.
(4) Torque
(5) Gross Intermittent Torque
(6) Net Intermittent Torque
(7) Net Continuous Torque
(8) Gross Interm ittent B.H.P.
(9) Net Intermittent B.H.P.
(10) Net Continuous B.H.P.
(11) Ne t In t e r mittent B.S.F.C.
(12) Gro ss Torque
(13) Overload Torque
(14) C ontinuous Torque
(15) Gross B.H.P.
(16) Overload B.H.P.
(17) Continuous B.H.P.
(18) Overload B.S.F.C.
7
SM-E2B SERIES, WS M
KiSC issued 06, 2006 A
■ Z602-E2B (3200 min-1 (rpm) spec.)
PERFORMANCE CURVES
(1) Brake Horsepower
(2) Engine Speed
(3) B.S.F.C.
(4) Torque
(5) Gross Intermittent Torque
(6) Net Intermittent Torque
(7) Net Continuous Torque
(8) Gros s Intermittent B.H.P.
(9) Net Intermittent B.H.P.
(10) Net Continuous B.H.P.
(11) Net Intermittent B.S.F.C.
(12) Gross Torque
(13) Overload Torque
(14) Continuous Torque
(15) Gross B.H.P.
(16) Overload B.H.P.
(17) Continuous B.H .P.
(18) Overload B.S. F.C.
8
SM-E2B SERIES, WSM
KiSC issued 06, 2006 A
■ Z602-E2B (3600 min-1 (rpm) spec.)
PERFORMANCE CURVES
(1) Brake Horsepower
(2) Engine Speed
(3) B.S.F.C.
(4) Torque
(5) Gross Intermittent T orque
(6) Net Intermittent Torque
(7) Gross Intermittent B.H.P .
(8) Net Intermittent B.H.P.
(9) N et Intermittent B.S.F.C.
(10) Gro ss Torque
(11) Overload Torque
(12) Gross B.H.P.
(13) Overload B.H.P.
(14) Overload B.S.F.C.
9
SM-E2B SERIES, WS M
KiSC issued 06, 2006 A
■ D662-E2B
PERFORMANCE CURVES
(1) Brake Horsepower
(2) Engine Speed
(3) B.S.F.C.
(4) Torque
(5) Gross Intermittent Torque
(6) Net Intermittent Torque
(7) Net Continuous Torque
(8) Gros s Intermittent B.H.P.
(9) Net Intermittent B.H.P.
(10) Net Continuous B.H.P.
(11) Net Intermittent B.S.F.C.
(12) Gross Torque
(13) Overload Torque
(14) Continuous Torque
(15) Gross B.H.P.
(16) Overload B.H.P.
(17) Continuous B.H .P.
(18) Overload B.S. F.C.
10
SM-E2B SERIES, WSM
KiSC issued 06, 2006 A
■ D722-E2B
PERFORMANCE CURVES
(1) Brake Horsepower
(2) Engine Speed
(3) B.S.F.C.
(4) Torque
(5) Gross Intermittent Torque
(6) Net Intermittent Torque
(7) Net Continuous Torque
(8) Gross Interm ittent B.H.P.
(9) Net Intermittent B.H.P.
(10) Net Continuous B.H.P.
(11) Ne t In t e r mittent B.S.F.C.
(12) Gro ss Torque
(13) Overload Torque
(14) C ontinuous Torque
(15) Gross B.H.P.
(16) Overload B.H.P.
(17) Continuous B.H.P.
(18) Overload B.S.F.C.
11
SM-E2B SERIES, WS M
KiSC issued 06, 2006 A
■ D782-E2B
PERFORMANCE CURVES
(1) Brake Horsepower
(2) Engine Speed
(3) B.S.F.C.
(4) Torque
(5) Gross Intermittent Torque
(6) Net Intermittent Torque
(7) Net Continuous Torque
(8) Gross Intermittent B.H.P.
(9) Net Intermittent B.H.P.
(10) Net Continuous B.H.P.
(11) Net Intermittent B.S.F.C.
(12) Gross Torque
(13) Overload Torque
(14) Gross B.H.P.
(15) Overload B.H.P.
(16) Overload B.S. F.C.
12
SM-E2B SERIES, WSM
KiSC issued 06, 2006 A
■ D902-E2B (3200 min-1 (rpm) spec.)
PERFORMANCE CURVES
(1) Brake Horsepower
(2) Engine Speed
(3) B.S.F.C.
(4) Torque
(5) Gross Intermittent Torque
(6) Net Intermittent Torque
(7) Net Continuous Torque
(8) Gross Interm ittent B.H.P.
(9) Net Intermittent B.H.P.
(10) Net Continuous B.H.P.
(11) Ne t In t e r mittent B.S.F.C.
(12) Gro ss Torque
(13) Overload Torque
(14) C ontinuous Torque
(15) Gross B.H.P.
(16) Overload B.H.P.
(17) Continuous B.H.P.
(18) Overload B.S.F.C.
13
SM-E2B SERIES, WS M
KiSC issued 06, 2006 A
■ D902-E2B (3600 min-1 (rpm) spec.)
PERFORMANCE CURVES
(1) Brake Horsepower
(2) Engine Speed
(3) B.S.F.C.
(4) Torque
(5) Gross Intermittent Torque
(6) Net Intermittent Torque
(7) Gross Intermittent B.H.P.
(8) Net Intermittent B.H.P.
(9) Net Intermittent B.S.F.C.
(10) Gross Torque
(11) Overload Torque
(12) Gross B.H.P.
(13) Overload B.H.P.
(14) Overload B.S. F.C.
14
SM-E2B SERIES, WSM
KiSC issued 06, 2006 A
DIMENSIONS
■ Z482-E2B
DIMENSIONS
15
SM-E2B SERIES, WS M
KiSC issued 06, 2006 A
■ Z602-E2B
DIMENSIONS
16
SM-E2B SERIES, WSM
KiSC issued 06, 2006 A
■ D662-E2B, D722-E2B
DIMENSIONS
17
SM-E2B SERIES, WS M
KiSC issued 06, 2006 A
■ D782-E2B
DIMENSIONS
18
SM-E2B SERIES, WSM
KiSC issued 06, 2006 A
■ D902-E2B
DIMENSIONS
19
GENERAL
KiSC issued 06, 2006 A
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........................................................................... G-6
[2] CHECK POINTS OF INITIAL 50 HOURS............................................. G-8
[3] CHECK POINT OF EVERY 50 HOURS ............................................. G-10
[4] CHECK POINT OF EVERY 75 HOURS ............................................. G-11
[5] CHECK POINTS OF EVERY 100 HOURS......................................... G-12
[6] CHECK POINT OF EVERY 150 HOURS ........................................... G-15
[7] CHECK POINTS OF EVERY 200 HOURS......................................... G-15
[8] CHECK POINTS OF EVERY 400 HOURS......................................... G-16
[9] CHECK POINTS OF EVERY 500 HOURS......................................... G-17
[10]CHECK POINTS OF EVERY 1 OR 2 MONTHS............................... G-19
[11]CHECK POINT OF EVERY YEAR....................................................... G-21
[12]CHECK POINT OF EVERY 800 HOURS ........................................... G-22
[13]CHECK POINTS OF EVERY 1500 HOURS....................................... G-23
[14]CHECK POINTS OF EVERY 3000 HOURS....................................... G-25
[15]CHECK POINTS OF EVERY 2 YEARS.............................................. G-28
5. SPECIAL TOOLS.......................................................................................... G-32
SM-E2B SERIES, WSM
KiSC issued 06, 2006 A
1. ENGINE IDENTIFICATION
[1] MODEL NAME AND ENGINE SERIAL NUMBER
When contacting th e manufacture, always specify y our 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.
It is marked after the engine model number.
It indicates month and year of manufacture as follows.
• Year of man uf acture
Alphabet or
Number
4 2004 G 2016
5 2005 H 2017
6 2006 J 2018
7 2007 K 2019
8 2008 L 2020
9 2009 M 2021
A 2010 N 2022
B 2011 P 2023
C 2012 R 2024
D 2013 S 2025
E 2014 T 2026
F 2015 V 2027
Year
Alphabet or
Number
G GENERAL
Year
A : Engine Model Name and Serial
Number
W1010477
G-1
SM-E2B SERIES, WS M
KiSC issued 06, 2006 A
G GENERAL
• Month of manufacture
Month
January A0001 ~ A9999 B0001 ~
February C0001 ~ C9999 D0001 ~
March E0001 ~ E9999 F0001 ~
April G0001 ~ G9999 H0001 ~
May J0001 ~ J9999 K0001 ~
June L0001 ~ L9999 M0001 ~
July N0001 ~ N9999 P0001 ~
August Q0001 ~ Q9999 R0001 ~
September S0001 ~ S9999 T0001 ~
October U0001 ~ U9999 V0001 ~
November W0001 ~ W9999 X0001 ~
December Y0001 ~ Y9999 Z0001 ~
0001 ~ 9999 10000 ~
Engine Serial Number
e.g. D902-5A0001
“5” indicates 2005 and “A” indicates January.
So, 5A indicates that the engine was manufactured in January,
2005.
W1011076
[2] E2B ENGINE
[ex. Model Name D902-E2B-XXXX]
The emission controls that have been put into effect in various countries to prevent air pollution will be stepped up.
The time to enforce the regulations differs depending on the engine output classifications.
Kubota has been supplyi ng the diesel engines conforming to the emission r egulations in respective countries.
Exhaust emissions regulations shift to the second stage. Kubota executed the improvement of the engine according
to this regulation.
In order to discriminate the engi nes con formi ng to Tier 1 / Phase 1 re quir eme nts and thos e confo rm in g to Tier 2 /
Phase 2 requirements , we have adopted E2B as a n ew model name for the engine s conforming Tier 2 / Ph ase 2
regulations.
In the after-sale serv ices f or S M-E2 B ser ies eng ine s, only us e the dedic ated parts f or E 2B m odels and carry out
the maintenance services accordingly.
[3] CYLINDER NUMBER
The cylinder numb ers of KUBOTA diese l engin e are de signa ted
as shown in the figure.
The sequence of cylinder numbers is give n as No.1, No.2 and
No.3 starting from the gear case side.
W1011077
G-2
SM-E2B SERIES, WSM
KiSC issued 06, 2006 A
2. GENERAL PRECAUTIONS
• During disasse mbly, care fully arrang e removed pa rts in a clean
area to prevent confusion later. Screws, bolts and nuts should be
replaced in their original position to prevent reassembly errors.
• When special tools are requir ed, use KUBOTA ge nuine special
tools. Special tools which are not frequently used should be
made according to the drawings provided.
• Before disassembling or servicing live wires, make sure to
always disconnect the grounding cable from the battery first.
• Remove oil and dirt from parts before measuring.
• Use only KUBOTA genuine parts for parts replacement to
maintain engine performance and to ensure safety.
• Gaskets and O-rings must be replaced during reassembly.
Apply grease to new O-rings or oil seals before assembling.
• When reassembling external or internal snap rings, position them
so that the sharp edge faces against the direction from which
force is applied.
• Be sure to perform run-i n the serviced or reassembled engine .
Do not attempt to give heavy load at once, or serious damage
may result to the engine.
(1) Grease
(2) Force
(3) Place the Sharp Edge against the
Direction of Force
G GENERAL
(A) External Snap Ring
(B) Internal Snap Ring
W1011734
G-3
SM-E2B SERIES, WS M
KiSC issued 06, 2006 A
G GENERAL
3. MAINTENANCE CHECK LIST
To maintain long-lasting and safe engine performance, make it a rule to carry out regular inspections by following
the table below.
Service Interval
Item
*Checking fuel hoses and clamp
bands
(1) Oil pan depth
(101 mm, 3.98 in.)
Changing
Engine oil
Checking fan belt tension and
damage
*Cleaning air cleaner element
(Replace the element after 6 times
cleaning)
Cleaning fuel filter (element type)
Checking battery electrolyte level
Replacing oil
filter cartridge
Checking radiator hoses and clamp
bands
*Checking intake air line ✩
*Replacing fuel filter ✩
Cleaning water jacket and radiator
interior
Replacing fan belt ✩
(2) Oil pan depth
(121 mm, 4.76 in.)
(3) Extended oil
pan depth
(101 mm, 3.98 in.)
(1) Oil pan depth
(101 mm, 3.98 in.)
(2) Oil pan depth
(121 mm, 4.76 in.)
(3) Extended oil
pan depth
(101 mm, 3.98 in.)
50
hrs75hrs
✩
★
✩
★
★
★
★
★
100
hrs
✩
✩
✩
✩
✩
✩
150
hrs
✩
200
hrs
✩
✩
✩
(1) This oil pan depth is optional for Z482-E2B, D662-E2B and D722-E2B.
(2) This oil pan depth is standard for Z482-E2B, D662-E2B, D722-E2B and D782-E2B.
(3) This oil pan depth is standard for Z602-E2B and D902-E2B.
★ Change engine oil and replace oil filter cartridge after the first 50 hours of operation.
* The items listed above (* m arked) are regis tered as emission r elated 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.
400
hrs
Every
500
hrs
✩
1 or 2
months1 year
800
hrs
1500
hrs
3000
hrs2 years
W1029462
G-4
SM-E2B SERIES, WSM
KiSC issued 06, 2006 A
Service Interval
Item
Recharging battery ✩
*Replacing air cleaner element ✩
Checking valve clearance ✩
*Checking injection nozzle condition ✩
*Checking injection timing ✩
*Checking injection pump ✩
*Replacing intake air line ✩
Replacing battery ✩
Replacing radiator hoses and clamp
bands
*Replacing fuel hoses and clamp
bands
Changing radiator coolant (L.L.C.) ✩
50
hrs75hrs
100
hrs
150
hrs
200
hrs
400
hrs
Every
500
hrs
1 or 2
months1 year
800
hrs
G GENERAL
1500
3000
hrs
hrs2 years
✩
✩
* The items listed above (* mark ed) are registered as emission re lated critical parts by KUBOT A 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.
W1014630
CAUTION
• When changing or inspecting, be sure to level and stop the engine.
■ NOTE
Lubricating Oil
With the emission control now in effect, the CF-4 and CG-4 lubricating oils have been developed for use of a lowsulfur fuel on- road vehicle engines. W hen an off-road vehicl e engine runs on a high -sulfur fuel, it is advi sable to
employ the CF, CD or CE lubricating oil with a high total base number. If the CF-4 or CG-4 lubricating oil is used with
a high-sulfur fuel, change the lubricating oil at shorter intervals.
• Lubricating oil recommended when a low-sulfur or high-sulfur fuel is employed.
Fuel
Lubricating
Low sulfur
(0.5 % ≥)
High sulfur Remarks
oil class
CF ❍❍TBN ≥ 10
CF-4 ❍ X
CG-4 ❍ X
❍ : Recommendable X : Not recommendable
W1035555
G-5
SM-E2B SERIES, WS M
IMPORTANT■
NOTE■
KiSC issued 06, 2006 A
4. CHECK AND MAIN TENANCE
[1] DAILY CHECK POINTS
Checking Engine Oil Level
1. Level the engine.
2. To check the oil level, draw ou t the dipstick (1), wipe it c lean,
reinsert it, and draw it out again.
Check to see that the oil level lies between the two notches.
3. If the level is too low, add new oil to the specified level.
• When using an oil of different maker or viscosity from the
previous, drain old oil. Never mix two different types of oil.
• Be sure to inspect the engine, locating it on a horizontal
place. If placed on gradien ts, accurately, oil quantity may
not be measured.
• Be sure to keep the oil level between upper and lower limits
of the dipstick. Too much oil may cause a drop in output or
excessive blow-by gas. On the closed breather type engine
in which mist is sucked through port, too much oil may
caused oil hammer. While too little oil, may seize the
engine’s rotating and sliding parts.
(1) Dipstick
G GENERAL
W1016222
G-6
SM-E2B SERIES, WSM
■
KiSC issued 06, 2006 A
G GENERAL
Checking and Replenish Coolant
1. Without recovery tank :
Remove the radiator ca p (1) and check to see th at the coolant
level is just below the port.
With recover y tank (2) :
Check to see that the coolant level lies between FULL (A) and
LOW (B).
2. If coolant level is too low, check the reason for decreasing
coolant.
(Case 1)
If coolant is decreasing by evaporation, replenish only fresh, soft
water.
(Case 2)
If coolant is decreasing by l eak, replenish coolant of the same
manufacture and type in the specified mixture ratio (fresh, sof t
water and L.L.C.). If the coolant brand cannot be identified, drain
out all of the remaining coolant and refill with a totally new brand
of coolant mix.
CAUTION
• Do not remove the radiator cap until coolant temperature is
below its boiling point. Then loosen the cap slightly to
relieve any excess pressure before removing the cap
completely.
IMPORTANT
• During filling the coolant, air must be vented from the engine
coolant passages. The air vents by jiggling the radiator
upper and lower hoses.
• Be sure to close the radiator cap securely. If the cap is loose
or improperly closed, coolant may leak out and the engine
could overheat.
• Do not use an antifreeze and scale inhibitor at the same time.
• Never mix the different type or brand of L.L.C..
(1) Radiator Cap
(2) Recovery Tank
A: FULL
B: LOW
W1035779
G-7
SM-E2B SERIES, WS M
■
KiSC issued 06, 2006 A
[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.
3. To drain the used oil, remove the dr ain pl ug (2) a t the bo ttom of
the engine and drain the oil completely.
4. Screw the drain plug (2).
5. Fill new oil up to upper line on the dipstick (1).
IMPORTANT
• When using an oil of different maker or viscosity from the
previous one, remove all of the old oil.
• Never mix two different types of oil.
• Engine oil should have properties of API classification CD/
CE/CF/CF-4/CG-4.
• Use the proper SAE Engine Oil according to ambient
temperature.
• Upon an oil change, be sure to replace the gasket with new
one.
Above 25 °C (77 °F)
0 °C to 25 °C (32 °F to 77 °F)
Below 0 °C (32 °F)
G GENERAL
SAE 30 or SAE 10W-30
SAE 10W-40
SAE 20 or SAE 10W-30
SAE 10W-40
SAE 10W or SAE 10W-30
SAE 10W-40
Oil pan depth
Models
*Z482-E2B
*D662-E2B
*D722-E2B
D782-E2B –
Z602-E2B
D902-E2B
* 101 mm (3.98 in.) oil pan depth is optional.
Drain plug with
Tightening
torque
(1) Dipstick (2) Drain Plug
copper gasket
Drain plug with
rubber coated
gasket
101 mm (3.98 in.) 121 mm (4.76 in.)
0.55 U.S.gals
0.85 U.S.gals
0.66 U.S.gals
0.98 U.S.gals
M12 × 1.25
M22 × 1.5
M22 × 1.5
Engine oil capacity
2.1 L
3.2 L
2.5 L
3.7 L
2.5 L
0.66 U.S.gals
3.8 L
1.00 U.S.gals
3.6 L
0.95 U.S.gals
–
–
32.4 to 37.3 N·m
3.3 to 3.8 kgf·m
23.9 to 27.5 ft-lbs
63.7 to 73.5 N·m
6.5 to 7.5 kgf·m
47.0 to 54.2 ft-lbs
44.1 to 53.9 N·m
4.5 to 5.5 kgf·m
32.5 to 39.8 ft-lbs
W1016604
G-8
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