Aixam Roadline, Scouty R User Manual

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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.

November 2004

SM-E2B SERIES, WSM

SAFETY FIRST

KiSC issued 06, 2006 A

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.

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.

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.

SM-E2B SERIES, WS M

KiSC issued 06, 2006 A

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.)

(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

, 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

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

(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

, 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

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

(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

, 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

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.

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.

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.

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.

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.

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.

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.

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.

SM-E2B SERIES, WSM

KiSC issued 06, 2006 A

DIMENSIONS

■ Z482-E2B

DIMENSIONS

SM-E2B SERIES, WS M

KiSC issued 06, 2006 A

■ Z602-E2B

DIMENSIONS

SM-E2B SERIES, WSM

KiSC issued 06, 2006 A

■ D662-E2B, D722-E2B

DIMENSIONS

SM-E2B SERIES, WS M

KiSC issued 06, 2006 A

■ D782-E2B

DIMENSIONS

SM-E2B SERIES, WSM

KiSC issued 06, 2006 A

■ D902-E2B

DIMENSIONS

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.)

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.) ✩

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

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

SM-E2B SERIES, WSM

■

NOTE■

KiSC issued 06, 2006 A

G GENERAL

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.

3. To install the new cartridge, screw it in by hand. Over tightening may cause deformation of rubber gasket.

4. After the new cartridge has been replaced, the engine oil normally decrease a li ttle . Thus see that the eng ine oil does not leak through the s eal and be sure to read the oil l evel on the dipstick. 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.

• The oil pan of 101 mm (3.98 in.) depth is optional for Z482E2B, D662-E2B and D722-E2B. This service interval is every 150 hours.

(1) Engine Oil Filter Cartridge [a] Standard Type

[b] One-side Maintenance Type

W1017137

G-9

SM-E2B SERIES, WS M

■

KiSC issued 06, 2006 A

[3] CHECK POINT OF EVERY 50 HOURS

Checking Fuel Hose

1. If the clamp ( 2) is loose, apply oil to the thr eads and securely retighten it.

2. The fuel hose (1) is made of rubber and ages regardl ess of the period service. Change the fuel hose together with the clamp every two years.

3. However, if the fuel hose and clamp are found to be damaged or deteriorate earlier than two years, then change or remedy.

4. After the fuel hose and the clamp have been changed, bleed the fuel system.

CAUTION

• Stop the engine when attempting the check and change prescribed above.

(When bleeding fuel system)

1. Fill the tank with fuel and open the cock (4). ([B] only.)

2. Loosen the air vent plug (3) of the fuel filter a few turns.

3. Screw back the plug when bubbles do not come up any more.

4. Open the air vent cock (5) on top of the fuel injection pump.

5. If equipped electrical fuel feed pump, turn the key to AC posit io n and pump the fuel up for 10 to 15 seconds. If equipped mechanical fuel feed pump, set the stop lever on stop position and crank the engine for 10 to 15 seconds.

6. Close securely the air vent cock after air bleeding.

NOTE

• Always keep the air vent cock on the fuel injection pump closed except when air is vented, or it may cause the engine to stop.

(1) Fuel Hose (2) Clamp (3) Air Vent Plug (4) Fuel Cock (5) Air Vent Cock

G GENERAL

[A] Cartridge Type [B] Element Type

W1035921

G-10

SM-E2B SERIES, WSM

■

KiSC issued 06, 2006 A

[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.

2. Place an oil pan underneath the engine.

3. To drain the used o il, remo ve the drain pl ug (2) at the b ottom o f 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

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

W1017177

G-11

SM-E2B SERIES, WS M

■

KiSC issued 06, 2006 A

[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.

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

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

W1017548

G-12

SM-E2B SERIES, WSM

NOTE■

KiSC issued 06, 2006 A

G GENERAL

Fan Belt Tension

1. Measur e t he d efl ecti on (A), depressing the belt halfway between the fan drive pulley a nd altern ator pulley at specifie d 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.

Deflection (A) Factory spec.

(A) Deflection

7.0 to 9.0 mm

0.28 to 0.35 in.

W1208957

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. If the fan belt is n early worn out and deeply s unk in the pulley groove, replace it.

(A) Good (B) Bad

W1209480

Cleaning Air Cleaner Element

1. Remove the air cleaner element.

2. Use clean dry compressed air on the inside of the element. Pressure of compressed air must be under 205 kPa (2.1 kgf/cm 30 psi). Maintain reasonable distance between the nozzle and the filter.

• The air cleaner uses a dry element. Never apply oil to it.

• Do not run the engine with filter element removed.

• Change the element once a year or every 6th cleaning.

W1045746

G-13

SM-E2B SERIES, WS M

IMPORTANT■

KiSC issued 06, 2006 A

G GENERAL

Cleaning Fuel Filter (Element Type only)

1. Close the fuel cock (3).

2. Unscrew the retainin g ring (6) and remov e the fil ter cup (5 ), and rinse the inside with kerosene.

3. Take out the element (4) and dip it in the kerosene to rinse.

4. After cleaning, reassemble the fuel filter, keeping out dust and dirt.

5. Bleed the fuel system.

• If dust and dirt enter the fuel, the fuel injection pump and injection nozzle will wear quickly. To prev ent this, be sure to clean the fuel filter cup (5) periodically.

(1) Cock Body (2) Air Vent Plug (3) Fuel Cock

(4) Filter Element (5) Filter Cup (6) Retaining Ring

W1046058

Checking Battery Electrolyte Level

1. Check the battery electr ol yt e lev el.

2. If the level is below than lower level line (2), and the distilled water to pour level of each cell.

(1) Upper Level Line (2) Lower Level Line

W1047154

G-14

SM-E2B SERIES, WSM

■

IMPORTANT■

KiSC issued 06, 2006 A

[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.

2. Apply a slight coat of oil onto the new cartridge gasket.

3. To install the new cartridge, screw it in by hand. Over tightening may cause deformation of rubber gasket.

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

G GENERAL

[b] One-side Maintenance Type

W1018457

[7] CHECK POINTS OF EVERY 200 HOURS

Replacing Oil Filter Cartridge (for Standard 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.

2. Apply a slight coat of oil onto the new cartridge gasket.

3. To install the new cartridge, screw it in by hand. Over tightening may cause deformation of rubber gasket.

• 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

[b] One-side Maintenance Type

W1018643

G-15

SM-E2B SERIES, WS M

IMPORTANT■

KiSC issued 06, 2006 A

G GENERAL

Checking Radiator Hoses and Clamp Bands

1. Check to see i f the radiator hoses are pr operly fixed every 2 00 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.

3. The water hose is m ade of rubber and tens to age . It must be replaced every two year s. Al so r eplace th e cla mp and tighten it securely.

(1) Upper Hose (2) Lower Hose

W1029518

Checking Intake Air Line

1. Check to see if the intake a ir hose(s) and th e breather hose (3) are properly fixed every 200 hours of operation.

2. If the clamp is loose, apply oil to the threads and retighten it securely.

3. The intake air hose(s) and the breather hose are made of rubber and tends to age. It must be change d every two years. Also change the clamp and tighten it securely.

• To prevent serious damage to the engine, keep out any dust inside the intake air line.

(1) Intake Air Hose (2) Clamp

(3) Breather Hose

W1029631

[8] CHECK POINTS OF EVERY 400 HOURS

Replacing Fuel Filter Cartridge (Cartridge Type)

Water and dust in fuel are collected in the filter cartridge. S o,

change the filter cartridge every 400 hours service.

1. Remove the used filter cartridge with filter wrench.

2. Apply a thin film of fuel to the surface of new filter cartridge gasket before scr ewing on.

3. Then tighten enough by hand.

4. Loosen the air vent plug to let the air out.

5. Start engine and check for fuel leakage.

(1) Fuel Filter Cartridge

Replacing Fuel Filter Element (Element Type)

1. Close the fuel cock (3).

2. Unscrew the retainin g ring (6) and remov e the fil ter cup (5 ), and rinse the inside with kerosene.

3. Replace the filter element (4).

4. Reassemble the fuel filter, keeping out dust and dirt.

5. Bleed the fuel system.

(1) Cock Body (2) Air Vent Plug (3) Fuel Cock

W1050548

(4) Filter Element (5) Filter Cup (6) Retaining Ring

W1050583

G-16

SM-E2B SERIES, WSM

■

KiSC issued 06, 2006 A

[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.

1. Stop the engine and let cool down.

2. To drain the coolant, open the radiator drain plug (2) and remove the radiator cap ( 1). Then radi ator cap ( 1) must be r emoved to completely drain the coolant. And open the drain cock (3).

3. After all coolant is drained, close the drain plug.

4. Fill with clean water and cooling system cleaner.

5. Follow directions of the cleaner instruction.

6. After flushing, fill with clean water and anti-freeze until the coolant level is just below the port. Install the radiator cap (1) securely.

7. Fill with coolant up to “FULL” (A) mark on the recovery tank (4).

8. Start and operate the engine for few minutes.

9. Stop the engine and let cool. Check coolant level of radiator and recovery tank (4) and add coolant if necessary.

IMPORTANT

• Do not start engine without coolant.

• Use clean, fresh, soft water and anti-freeze to fill the radiator and recovery tank.

• When the an ti-fr eeze is mi xed wit h fresh, soft wat er, th e antifreeze mixing ratio must be less than 50 %.

• Securely tighten radiator cap. If the cap is loose or improperly fitted, water may leak out and the engine could overheat.

(1) Radiator Cap (2) Drain Plug (3) Drain Cock (4) Recovery Tank

G GENERAL

A : Full B : Low

W1038102

G-17

SM-E2B SERIES, WS M

IMPORTANT■

NOTE■

KiSC issued 06, 2006 A

G GENERAL

Anti-Freeze

• There are two types of anti- freeze availabl e: use the perman ent 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.

• The procedure for mixing water and anti-freeze differs according to the maker of the anti-freeze and the ambient temperature. Basically, it should be referred to SAE J1034 standard, more specifically also to SAE J814c.

• Mix the anti-fr eeze with fresh, soft water, and then fill into the radiator.

• When the anti-freeze is mixed with fresh, soft water, the antifreeze mixing ratio must be less than 50 %.

Vol %

anti-freeze

40 –24 –11.2 106 222.8 50 –37 –34.6 108 226.4

Freezing point Boiling point*

°C °F °C °F

* At 1.013 × 100000 Pa (760 mm Hg) pr es sure (atm os phe ric ). A

higher boiling point is obtained by using a radiator pressure cap which permits the development of pressure within the cooling system.

• The above data represents industrial standards that necessitate a minimum g lycol content in the concentrated anti-freeze.

• When the coolant level drops due to evaporation, add fresh, soft water only to keep the anti-freeze mixing ratio less than 50 %. In case of leakage, add anti-freeze and fresh, soft water in the specified mixing ratio.

• Anti-freeze abs or bs moisture. Keep unused an ti- f reeze in a tightly sealed container.

• Do not use radiator cleaning agents when anti-freeze has been added to the coolant. (Anti-freeze contains an anti-corrosive agent, which will react with the radiator cleaning agent forming sludge which will affect the engine parts.)

W1039218

Replacing Fan Belt

1. Remove the alternator.

2. Remove the fan belt (1).

3. Replace new fan belt.

4. Install the alternator.

5. Check the fan belt tension.

Deflection (A) Factory spec.

7.0 to 9.0 mm / 98 N

0.28 to 0.35 in. / 98 N (10 kgf, 22 lbs)

(1) Fan Belt (A) Deflection

W1052220

G-18

SM-E2B SERIES, WSM

KiSC issued 06, 2006 A

[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.

• When charging battery, remove battery vent plugs.

• When disconnecting the cable from the battery, start with the negative terminal first. When connecting the cable to th e battery, start with the positive terminal first.

• Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.

1) Slow Charging

1. Add distilled water if the electrolyte level is low. When charging, the amount of electrolyte should be slightly lower than the specified level to prevent overflow.

2. Connect the battery to the charging unit, following the manufacture’s instruc tions.

3. As the electrolyte generates gas while c harg ing, remo ve al l por t caps.

4. The electrolyte temperature must not exceed 40 °C (104 °F) during charging. If it exceed 40 °C (104 °F), de crease the char ging ampe rage or stop charging for a while.

5. When charging several batteries in series, charging at the rate of the smallest battery in the line.

2) Quick Charging

1. Determine the proper charging current and charging time with the tester attached to the quick charger.

2. Determine the proper charging current as 1/1 of the battery capacity. If the battery capacity exceeds 50 Ah, consider 50 A as the maximum.

■ Precaution for Operating a Quick Charger

• Operating with a quick charger differs according to the type. Consult the instruction manual and use accordingly.

G GENERAL

W1052658

G-19

SM-E2B SERIES, WS M

NOTE■

KiSC issued 06, 2006 A

G GENERAL

Battery Specific Gravity

1. Check the s pecific gravity of the electr olyte in each cell with a hydrometer.

2. When the electrolyte temperature differs from that at which the hydrometer was cali brated, correct the specific gravity reading following the formula mention ed in (Reference).

3. If the sp ecific gravity i s less than 1 .215 (after it is corrected for temperature), charge or replace the battery.

4. If the specific grav it y di ffe rs between any two cells by more th an

0.05, replace the battery.

• Hold the hydrometer tube vertical without removing it from the electrolyte.

• Do not suck too much electrolyte into the tube.

• Allow the float to move freely and hold the hydrometer at eye level.

• The hydrometer reading must be taken at the highest electrolyte level.

(Reference)

• Specific gravity slightly varies with temperature. To be exact, the specific gravity decreases by 0.0007 with an increase of 1 °C (0.0004 with an inc rease of 1 ° F) in temp erature, and incr eases by 0.0007 with a decreases of 1 °C (0.0004 with a decrease of 1 °F). Therefore, using 20 °C (68 °F) as a reference, the specific gravity reading must be corrected by the following formula :

- Specific gravity at 20 °C = Measured value + 0.0007 ×

(electrolyte temperature : 20 °C)

- Specific gravity at 68 °F = Measured value + 0.0004 ×

(electrolyte temperature : 68 °F)

Specific Gravity State of Charge

1.260 Sp. Gr. 100 % Charged

1.230 Sp. Gr. 75 % Charged

1.200 Sp. Gr. 50 % Charged

1.170 Sp. Gr. 25 % Charged

1.140 Sp. Gr. Very Little Useful Capacity

1.110 Sp. Gr. Discharged

At an electrolyte temperature of 20 °C (68 °F)

(a) Good (b) Bad

W1012763

G-20

SM-E2B SERIES, WSM

NOTE■

KiSC issued 06, 2006 A

[11] CHECK POINT OF EVERY YEAR

Replacing Air Cleaner Element

1. Remove used air cleaner element.

2. Replace new air cleaner element.

• The air cleaner uses a dry element. Never apply oil to it.

• Do not run the engine with filter element removed.

G GENERAL

W1020554

G-21

SM-E2B SERIES, WS M

IMPORTANT■

■

KiSC issued 06, 2006 A

[12] CHECK POINT OF EVERY 800 HOURS

Checking Valve Clearance

• 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. 1 piston comes to the compression top dead center.

3. Check the following valve clearance marked with “★” using a feeler gauge.

4. If the clearance is not within the factory specifications, adjust with the adjusting screw.

5. Then turn the flywheel 6.28 rad (360 °), and align the “1TC” mark (2) on the flywheel and alignment mark (3) on the rear en d pl ate so that the No. 1 piston comes to the overlap position.

6. Check the following valve clearance marked with “✩” using a feeler gauge.

7. If the clearance is not within the factory specifications, adjust with the adjusting screw.

Number of cylinders Valve arrangement

Adjustable cylinder location of piston

No. 1 ★★★★ No. 2 ✩★✩★ No. 3 – – ★✩

★ : When No. 1 piston is at the compression top dead center position. ✩ : When No. 1 piston is at the overlap position.

Intake and exhaust valve clearance (cold)

Intake

valve

Factory spec.

Z482-E2B Z602-E2B

Exhaust

G GENERAL

D662-E2B D722-E2B D782-E2B D902-E2B

Intake

valve

0.145 to 0.185 mm

0.00571 to 0.00728 in.

Exhaust

valve

NOTE

• The sequence of cylinder numbers is given as No. 1, No. 2 and No. 3 starting from the gear case side.

• After adjusting the valve clearance, secure the adjusting screw with the lock nut.

(1) Cylinder Head Cover (2) “1TC” Mark (3) Alignment Mark

A : Gear Case Side [a] Z482-E2B, Z602-E2B [b] D662-E2B, D722-E2B,

D782-E2B, D902-E2B

W10113200

G-22

SM-E2B SERIES, WSM

KiSC issued 06, 2006 A

G GENERAL

[13] CHECK POINTS OF EVERY 1500 HOURS

CAUTION

• Check the injection pressure and condition after confirming that th ere is no body stand ing in the dir ection the fume goes.

• If the fume from the nozzle directly contacts the human body, c ells may be destroyed and blood poisoning may be caused.

Nozzle Spraying Condition

1. Set the injection noz zle to a no zzle tester , and check the nozz le spraying condition.

2. If the spraying condition is defective, replace the nozzle piece.

(a) Good (b) Bad

W10411400

Fuel Injection Pressure

1. Set the injection nozzle to a nozzle tester.

2. Slowly move the tester handle to measure the pressure at which fuel begins jetting out from the nozzle.

3. If the measurement is not within the factory specifications, replace the adjusting washer (1) in the nozzle holder to adjust it.

(Reference)

• Pressure variation with 0.025 mm (0.0010 in.) difference of adjusting washer thickness. Approx. 588 kPa (6.0 kgf/cm

Fuel injection pressure Factory spec.

, 85 psi)

13.73 to 14.71 MPa 140 to 150 kgf/cm 1991 to 2134 psi

(1) Adjusting Washer

W10182100

Nozzle Valve Seat Tightness

1. Set the injection nozzle to a nozzle tester.

2. Raise the fuel pressure, and k eep at 12.75 MPa (130 kgf/cm 1849 psi) for 10 seconds.

3. If any fuel leak is found, replace the nozzle piece.

No fuel leak at

Valve seat tightness Factory spec.

12.75 MPa 130 kgf/cm 1849 psi

W10412730

G-23

SM-E2B SERIES, WS M

KiSC issued 06, 2006 A

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.

• After assembl ing the nozzle, be sur e to adjust the f uel injection pressure.

34.3 to 39.2 N·m

Tightening torque

Nozzle holder

Overflow pipe retaining nut

Nozzle holder assembly

3.5 to 4.0 kgf·m

25.3 to 28.9 ft-lbs

19.6 to 24.5 N·m

2.0 to 2.5 kgf·m

14.5 to 18.1 ft-lbs

49.0 to 68.6 N·m

5.0 to 7.0 kgf·m

36.2 to 50.6 ft-lbs

(1) Nozzle Holder (2) Adjusting Washer (3) Nozzle Spring (4) Push Rod

(5) Distance Piece (6) Nozzle Piece (7) Nozzle Retaining Nut

W1018491

G-24

SM-E2B SERIES, WSM

KiSC issued 06, 2006 A

[14] CHECK POINTS OF EVERY 3000 HOURS

Injection Timing

1. Remove the injection pipes.

2. Remove the engine stop solenoid.

3. Turn the flywheel co unterclockwise (viewed from flywheel side) until the fuel fills up to the hole of the delivery valve holder (3) for No. 1 cylinder.

4. After the fuel fills up to the hole of the delivery valve holder for No. 1 cylinder, turn back (clockwise) the flywheel around 1.57 rad (90 °).

5. Turn the flywheel counterclockwise to set at around 0.44 rad (25 °) before T.D.C..

6. Slowly turn the flywheel counterclockwise and stop turning when the fuel begins to come up, to get the present injection timing.

7. Check to see the degree on flywheel. The flywheel has mark “1TC” , “10” and “20” for the cran k angle before the top dead center of No. 1 cylinder.

8. Check to see if the timing angle on the flywheel is aligned with the alignment mark (2).

9. If injection timing is out of adj ustment, readjust the timing with shims.

Z482/D662/D722-E2B (3600 min

Injection timing Factory spec.

D782-E2B (3200 min

Injection timing Factory spec.

Z602/D902-E2B (3200 min

Injection timing Factory spec.

Z602/D902-E2B (3600 min

Injection timing Factory spec.

(1) Timing Line (2) Alignment Mark (3) Delivery Valve Holder (4) Shim (Soft Metal Gasket Shim)

-1

(rpm) spec.)

-1

(rpm) spec.)

-1

(rpm) spec.)

G GENERAL

-1

(rpm) spec.)

0.33 to 0.37 rad (19 to 21 °) before T.D.C.

0.28 to 0.31 rad (16 to 18 °) before T.D.C.

0.30 to 0.33 rad (17 to 19 °) before T.D.C.

0.33 to 0.37 rad (19 to 21 °) before T.D.C.

(5) Two-holes : 0.20 mm (0.0079 in.) (6) One-hole : 0.25 mm (0.0098 in.) (7) Without hole : 0.30 mm (0.0118 in.)

W1023147

G-25

SM-E2B SERIES, WS M

NOTE■

KiSC issued 06, 2006 A

G GENERAL

Injection Timing (Continued)

• The sealant is applied to both sides of the shims (soft meta l gasket shim). 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.) and 0.30 mm (0.0118 in.). Combine these shims for adjustments.

• Addition or reduction of shim (0.05 mm, 0.0020 in.) delays or advances the injection timing by approx. 0.0087 rad (0.5 °).

• In disassembling and replacing the injection pump, be sure to use the same number of new shims with the same thickness.

• 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

Rated Speed Specification

-1

(rpm))

(min 3600 to 3301

3300 to 3001

3000 to 2501

2500 to 2001

Under 2000

Z482-E2B D662-E2B D722-E2B

0.33 to 0.37 rad (19 to 21 °)

0.31 to 0.35 rad (18 to 20 °)

0.30 to 0.33 rad (17 to 19 °)

0.26 to 0.30 rad (15 to 17 °)

0.23 to 0.26 rad (13 to 15 °)

D782-E2B

–

0.28 to 0.31 rad (16 to 18 °)

0.24 to 0.28 rad (14 to 16 °)

0.23 to 0.26 rad (13 to 15 °)

Z602-E2B D902-E2B

0.33 to 0.37 rad (19 to 21 °)

0.30 to 0.33 rad (17 to 19 °)

0.28 to 0.31 rad (16 to 18 °)

0.24 to 0.28 rad (14 to 16 °)

0.23 to 0.26 rad (13 to 15 °)

W1022861

G-26

SM-E2B SERIES, WSM

NOTE■

KiSC issued 06, 2006 A

G GENERAL

Checking Injection Pump (Fuel Tightness of Pump Element)

1. Remove the engine stop solenoid.

2. Remove the injection pipes and glow plugs.

3. Install the injection pump pressure tester to the injection pump.

4. Install the injection nozzle (2) jetted with the proper injection pressure to the injec ti on pu mp p re ssur e te st er (1). ( Ref er to the photo.)

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. Remove the engine stop solenoid.

2. Remove the injection pipes and glow plugs.

3. Set a pressure tester to the fuel injection pump.

4. Install the injection nozzle (2) jetted with the proper injection pressure to the injection pump pressure tester (1).

5. Run the starter to increase the pressure.

6. Stop the starter when the fuel jets from the injection nozzle. After that, turn the flywheel by hands and raise the pressure to approx.

13.73 MPa (140 kgf/cm

, 1991 psi).

7. Now turn the flywheel back about half a turn (to keep the plunger free). Maintain the flywheel at thi s position and clock the time taken for the pressure to drop from 13.73 to 12.75 MPa (from 140

to 130 kgf/cm

, from 1991 to 1849 psi).

8. Measure the time needed to decrease the pressure from 13.73 to

12.75 MPa (140 to 130 kgf/cm

, 1991 to 1849 psi).

9. If the measurement is less than allowable limit, replace the pump with new one or repair with a Kub ota-authorized pump service shop.

Fuel tightness of pump element

Fuel tightness of delivery valve

Allowable limit

Factory spec.

Allowable limit

13.73 MPa 140 kgf/cm 1991 psi

10 seconds

13.73 → 12.75 MPa 140 → 130 kgf/cm 1991 → 1849 psi

5 seconds

13.73 → 12.75 MPa 140 → 130 kgf/cm 1991 → 1849 psi

• Never try to disassemble the injectio n pump ass embly. For repairs, you are strongly requested to contact a Kubotaauthorized pump service shop.

(1) Injection Pump Pressure Tester (2) Injection Nozzle

(3) Protection Cover for Jetted Fuel

W1022357

G-27

SM-E2B SERIES, WS M

NOTE■

KiSC issued 06, 2006 A

[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. Tighten the clamp (2).

• To prevent serious damage to the engine, keep out any dust inside the intake air line.

(1) Intake Air Hose (2) Clamp

Replacing Battery

CAUTION

• When charging battery, remove battery vent plugs.

• When disconnecting the cable from the battery, start with the negative terminal first. When connecting the cable to the battery, start with the positive terminal first.

• Never check battery charge by placing a metal object across the posts.

1. Disconnect the negative terminal and positive terminal.

2. Remove the battery holder.

3. Remove the used battery.

4. Replace the new battery.

5. Tighten the battery holder.

6. Connect the positive terminal.

7. Connect the negative terminal.

Replacing Radiator Hoses and Clamp Bands

G GENERAL

W1023867

W1023996

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. Drain the coolant.

2. Loosen the clamp bands.

3. Remove the upper hose (1) and lower hose (2).

4. Replace new upper / lower hose (1), (2) and clamp bands.

5. Tighten the clamp bands.

6. Fill with clean wa ter and anti-fre eze unti l the co olan t leve l is ju st below the port. Install the radiator cap securely.

(1) Upper Hose (2) Lower Hose

W1024178

G-28

SM-E2B SERIES, WSM

■

KiSC issued 06, 2006 A

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.

(When bleeding fuel system)

1. Fill the tank with fuel and open the cock (4).

2. Loosen the air vent plug (3) of the fuel filter a few turns.

3. Screw back the plug when bubbles do not come up any more.

4. Open the air vent cock on top of the fuel injection pump.

5. If equipped electrical fuel feed pump, turn the key to AC position and pump the fuel up for 10 to 15 seconds. If equipped mechanical fuel feed pump, set the stop lever on stop position and crank the engine for 10 to 15 seconds.

6. Close securely the air vent cock after air bleeding.

NOTE

• Always keep the air vent cock on the fuel injection pump closed except when air is vented, or it may cause the engine to stop.

(1) Fuel Hose (2) Clamp (3) Air Vent Plug (4) Fuel Cock

[A] Cartridge Type [B] Element Type

W1024305

G-29

SM-E2B SERIES, WS M

■

KiSC issued 06, 2006 A

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. Stop the engine and let cool down.

2. To drain the coolant, open the radiator drain plug (2) and remove the radiator cap (1). Then ra diator cap (1 ) must be re moved to completely drain the coolant. And open the drain cock (3).

3. After all coolant is drained, close the dr ain plug.

4. Fill with clean water and cooling system cleaner.

5. Follow directions of the cleaner instruction.

6. After flushing, fill with clean water and anti-freeze until the coolant level is just below the port. Install the radiator cap (1) securely.

7. Fill with coolant up to “FULL” (A) mark on the recovery tank (4).

8. Start and operate the engine for few minutes.

9. Stop the engine and let cool. Check coolant level of radiator and recovery tank (4) and add coolant if necessary.

IMPORTANT

• Do not start engine without coolant.

• Use clean, fresh, soft water and anti-freeze to fill the radiator and recovery tank.

• When the anti-freeze is mixed with fresh, soft water, the antifreeze mixing ratio must be less than 50 %.

• Securely tighten radiator cap. If the cap is loose or improperly fitted, water may leak out and the engine could overheat.

(1) Radiator Cap (2) Drain Plug (3) Drain Cock (4) Recovery Tank

A : Full B : Low

W1028063

G-30

SM-E2B SERIES, WSM

IMPORTANT■

NOTE■

KiSC issued 06, 2006 A

G GENERAL

Changing Radiator Coolant (L.L.C.) (Continued) (Anti-freeze)

• There are two types of anti- freeze availab le: use the perma nent 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.

• Mix the anti-freeze with fresh, soft water, and then fill into the radiator.

• When the an ti-fr eeze is mi xed wit h fresh, soft wat er, th e antifreeze mixing ratio must be less than 50 %.

Vol %

anti-freeze

40 –24 –11.2 106 222.8 50 –37 –34.6 108 226.4

Freezing point Boiling point*

°C °F °C °F

* At 1.013 × 100000 Pa (760 mmHg) pres su r e (atmos ph er ic) . A

higher boiling point is obtained by using a radiator pressure cap which permits the development of pressure within the cooling system.

• The above data represents industrial standards that necessitate a minimum glyc ol content in the concentrated anti-freeze.

• Anti-freeze absorb s moist ure. Kee p un used a nti-f re ez e in a tightly sealed container.

W1024852

G-31

SM-E2B SERIES, WS M

KiSC issued 06, 2006 A

5. SPECIAL TOOLS

G GENERAL

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.

(1) Gauge (2) L Joint (3) Adaptor A (4) Adaptor B (5) Adaptor C (6) Adaptor E

(7) Adaptor F (8) Adaptor G

(9) Adaptor H (10) Adaptor I (11) Adaptor J

W1024200

Diesel Engine Compression Tester (for Glow Plug)

Code No: 07909-39081 (Assembly) 07909-31301 (L)

07909-31291 (K) 07909-31311 (M)

Application: Use to measure diesel engine compression and

diagnosis of need for major overhaul.

(1) Gauge (2) Hose Assembly (3) L Joint

(4) Adaptor K (5) Adaptor L (6) Adaptor M

W1025289

Oil Pressure Tester

Code No: 07916-32032 Application: Use to measure lubricating oil pressure.

(1) Gauge (2) Cable (3) Threaded Joint (4) Adaptor 1

(5) Adaptor 2 (6) Adaptor 3 (7) Adaptor 4 (8) Adaptor 5

W1024318

G-32

SM-E2B SERIES, WSM

NOTE■

KiSC issued 06, 2006 A

• 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

B PF 1/2 C Copper gasket D Flange (Mateiral Steel)

E Hex. nut 27 mm (1.06 in.) across the plat

F Adhesive application G Fillet welding on the enter circumference H Retaining nut

I 17 mm dia. (0.67 in. dia.)

J 8 mm dia. (0.31 in. dia.) K 1.0 mm (0.039 in.)

L 17 mm dia. (0.67 in. dia.) M 6.10 to 6.20 mm dia. (0.2402 to 0.2441 in. dia.) N 8 mm (0.31 in.) O 4 mm (0.16 in.)

P 11.97 to 11.99 mm dia. (0.4713 to 0.4720 in. dia.) Q PF 1/2 R 23 mm (0.91 in.)

S 17 mm (0.67 in.)

T 4 mm (0.16 in.) U 12.00 to 12.02 mm dia. (0.4724 to 0.4732 in. dia.)

V 100 mm (3.94 in.) W M12 × P1.5

X 5 mm (0.20 in.)

, 4267 psi)

Valve Guide Replacing Tool

Application: Use to press out and press fit the valve guide.

A 220 mm (8.66 in.) B 80 mm (3.15 in.) C 40 mm (1.58 in.) D 20 mm dia. (0.79 in. dia.)

E 9.96 to 9.98 mm dia. (0.3921 to 0.3929 in. dia.)

F 5.5 to 5.7 mm dia. (0.2165 to 0.2244 in. dia.) G 25 mm dia. (0.98 in. dia.) H 6.0 to 6.1 mm dia. (0.236 to 0.240 in. dia.)

I 5 mm (0.197 in.)

J 18 mm dia. (0.71 in. dia.) K 10.6 to 10.7 mm dia. (0.417 to 0.421 in. dia.)

L 6.9 to 7.1 mm (0.272 to 0.280 in.)

C1 Chamfer 1.0 mm (0.039 in.) C2 Chamfer 2.0 mm (0.079 in.)

C0.3 Chamfer 0.3 mm (0.012 in.)

G GENERAL

W10252400

W10250170

G-33

SM-E2B SERIES, WS M

KiSC issued 06, 2006 A

G GENERAL

Bushing Replacing Tool

Application: Use to press out and press fit the bushing.

1. For small end bushing

A 145 mm (5.71 in.) B 20 mm (0.79 in.) C 100 mm (3.94 in.) D 19.90 to 19.95 mm dia. (0.7835 to 0.7854 in. dia.) E 21.90 to 21.95 mm dia. (0.8622 to 0.8642 in. dia.)

F 25 mm dia. (0.98 in. dia.) C1 Chamfer 1.0 mm (0.039 in.) C2 Chamfer 2.0 mm (0.079 in.)

C0.3 Chamfer 0.3 mm (0.012 in.)

a 6.3 μm (248 μin.)

b 6.3 μm (248 μin.)

2. For idle gear bushing

A 150 mm (5.91 in.) B 23 mm (0.91 in.) C 100 mm (3.94 in.) D 19.90 to 19.95 mm dia. (0.7835 to 0.7854 in. dia.) E 21.90 to 21.95 mm dia. (0.8622 to 0.8642 in. dia.)

F 25 mm dia. (0.98 in. dia.) C1 Chamfer 1.0 mm (0.039 in.) C2 Chamfer 2.0 mm (0.079 in.)

C0.3 Chamfer 0.3 mm (0.012 in.)

a 6.3 μm (248 μin.)

b 6.3 μm (248 μin.)

W12358870

Flywheel Stopper

Application: Use to loosen and tighten the flywheel screw.

A 20 mm (0.79 in.) B 15 mm (0.59 in.) C 10 mm dia. (0.39 in. dia.) D 30 mm (1.18 in.) E 8 mm (0.31 in.)

F 200 mm (7.87 in.)

W10259480

G-34

SM-E2B SERIES, WSM

KiSC issued 06, 2006 A

G GENERAL

Crankshaft Bearing 1 Replacing Tool

Application: Use to press out and press fit the crankshaft bearing 1.

[Press Out]

A 135 mm (5.31 in.) B 72 mm (2.83 in.) C 40 mm radius (1.57 in. radius) D 10 mm (0.39 in.)

E 22 mm (0.87 in.)

F 20 mm dia. (0.79 in. dia.) G 47.90 to 47.95 mm dia. (1.8858 to 1.8878 in. dia.) H 43.90 to 43.95 mm dia. (1.7283 to 1.7303 in. dia.)

C1 Chamfer 1.0 mm (0.039 in.) C2 Chamfer 2.0 mm (0.079 in.)

C0.3 Chamfer 0.3 mm (0.012 in.)

[Press Fit] for Z482/D662/D722/D782-E2B

A 130 mm (5.12 in.) B 72 mm (2.83 in.) C 40 mm radius (1.57 in. radius) D 9 mm (0.35 in.)

E 24 mm (0.95 in.)

F 20 mm dia. (0.79 in. dia.) G 68 mm dia. (2.68 in. dia.) H 39.90 to 39.95 mm dia. (1.5709 to 1.5728 in. dia.)

C1 Chamfer 1.0 mm (0.039 in.) C2 Chamfer 2.0 mm (0.079 in.)

C0.3 Chamfer 0.3 mm (0.012 in.)

[Press Fit] for Z602/D902-E2B

A 130 mm (5.12 in.) B 72 mm (2.83 in.) C 40 mm radius (1.57 in. radius) D 9 mm (0.35 in.)

E 24 mm (0.95 in.)

F 20 mm dia. (0.79 in. dia.) G 68 mm dia. (2.68 in. dia.) H 43.90 to 43.95 mm dia. (1.7283 to 1.7303 in. dia.)

C1 Chamfer 1.0 mm (0.039 in.) C2 Chamfer 2.0 mm (0.079 in.)

C0.3 Chamfer 0.3 mm (0.012 in.)

W10261390

G-35

SM-E2B SERIES, WS M

KiSC issued 06, 2006 A

G GENERAL

Crank Sleeve Setter (for Z482/D662/D72 2/D7 82-E 2B)

Application: Use to fix the crankshaft sleeve.

(1) Auxiliary Socket for Pushing

A 130 mm (5.12 in.) B 112 mm (4.41 in.) C 107 mm (4.21 in.) D 82 mm (3.23 in.) E 72 mm (2.83 in.)

F 67 mm (2.64 in.) G 47 mm (1.85 in.) H 37.0 to 37.2 mm (1.457 to 1.465 in.)

I 17 mm (0.67 in.)

J 5 mm dia. (0.20 in. dia.) K 52 mm dia. (2.05 in. dia.)

L 40 mm dia. (1.57 in. dia.) M 10 mm (0.39 in.) N 33 mm (1.30 in.) O 20 mm dia. (0.79 in. dia.) P 40 mm dia. (1.57 in. dia.) Q 63.10 to 63.15 mm dia. (2.484 to 2.486 in. dia.) R 64 mm dia. (2.52 in. dia.) S 75 mm dia. (2.95 in. dia.)

C0.3 Chamfer 0.3 mm (0.01 in.)

C1 Chamfer 1 mm (0.04 in.) C5 Chamfer 5 mm (0.2 in.)

(2) Sleeve Guide

A 42 mm (1.65 in.) B 12 mm (0.47 in.) C 30 mm (1.18 in.) D M10 × Pitch 1.25 E 2 mm (0.08 in.)

F 10 mm (0.39 in.) G 2.0 mm (0.08 in.) H 17.90 to 17.95 mm dia. (0.700 to 0.707 in. dia.)

I 8 mm dia. (0.31 in. dia.)

J 1.8 mm (0.07 in.) K 0.09 rad (5 °)

C0.5 Chamfer 0.5 mm (0.02 in.)

W1026961

G-36

MECHANISM

KiSC issued 06, 2006 A

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

SM-E2B SERIES, WSM

KiSC issued 06, 2006 A

1. ENGINE BODY

[1] HALF-FLOATING HEAD COVER

[2] CLOSED BREATHER

DIESEL ENGINE

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.

(1) Cylinder Head Cover (2) Rubber Packing

W1013327

Closed breather system has been adopted to prevent the release of blow-by gas into the atmosphere.

After its oil content is filtered by oil shield (4), the blowby gas is fed back to the intake manifold through breather valve (3) to be used for re-combustion.

(1) Cylinder Head Cover (2) Breather Hose (3) Breather Valve

(4) Oil Shield (5) Rubber Packing

W1012956

M-1

SM-E2B SERIES, WS M

KiSC issued 06, 2006 A

[3] PISTON (Z602-E2B, D902-E2B)

DIESEL ENGINE

Piston’s skirt is coated with molybdenum disulfied★, which reduces the piston slap noise and thus the entire operating noise.

[4] OIL PAN (Z602-E2B, D902-E2B)

★Molybdenum disulfide (MoS

The molybdenum disulfide (1) serves as a solid lubricant, like a Graphite or Tefl on. This mater ial helps resist metal wears even with little lube oil.

(1) Molybdenum Disulfide

W1013114

The oil pan is extended under the gear case. Therefore, the height of the engine can be lowered more than so far while securing a necessary amount of oil.

(1) Cylinder Block (2) Gear Case

(3) Oil Pan

W1013041

M-2

SM-E2B SERIES, WSM

KiSC issued 06, 2006 A

2. COOLING SYSTEM

[1] COOLING FIN (Z602-E2B, D902-E2B)

gear case. wind generated by the cooling fan.

(1) Cooling Fin

DIESEL ENGINE

The cooling fin is set up around the oil passage in the Therefore, the tempe ra tur e o f oil is de cr ea se d by the

W1013135

M-3

SERVICING

KiSC issued 06, 2006 A

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

(4) Fuel System........................................................................................S-17

(5) Electrical System ................................................................................S-21

[2] DISASSEMBLING AND ASSEMBLING..................................................S-28

(1) Draining Engine Oil and Coolant.........................................................S-28

(2) External Components .........................................................................S-29

(3) Cylinder Head, Valves and Oil Pan.....................................................S-29

(4) Gear Case and Timing Gears.............................................................S-35

(5) Piston and Connecting Rod ................................................................S-42

(6) Flywheel and Crankshaft ....................................................................S-45

(7) Starter .................................................................................................S-49

(8) Dynamo...............................................................................................S-51

(9) Alternator ............................................................................................S-52

[3] SERVICING ..............................................................................................S-53

(1) Cylinder Head and Valves ..................................................................S-53

(2) Timing Gears ......................................................................................S-59

(3) Piston and Connecting Rod ................................................................S-61

(4) Crankshaft...........................................................................................S-64

(5) Cylinder...............................................................................................S-70

(6) Oil Pump .............................................................................................S-71

(7) Starter .................................................................................................S-72

(8) Alternator ............................................................................................S-75

SM-E2B SERIES, WSM

KiSC issued 06, 2006 A

1. TROUBLESHOOTING

DIESEL ENGINE

Symptom Probable Cause Solution

Engine Does Not Start

Starter Does Not Run Battery discharged Charge G-19

Engine Revolution Is Not Smooth

No fuel Replenish fuel G-10 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 G-10 Fuel filter clogged Replace G-16 Excessively high viscosity of fuel or engine oil at

low temperature Fuel with low cetane number Use specified fuel 4 Fuel leak due to loose injection pipe retaining nut T ighten retaining nut S-29 Incorrect injection timing Adjust S-17, 18 Fuel camshaft worn Replace S-41 Injection nozzle clogged Clean or replace S-20, 21 Injection pump malfunctioning Repair or replace S-19, 35,

Seizure of crankshaft, camshaft, piston, cylinder or bearing

Compression leak from cylinder Replace head

Improper valve timing Correct or replace

Piston ring and cylinder worn Replace S-43, 44,

Excessive valve clearance Adjust S-14 Stop solenoid malfunctioning Replace S-26, 27,

Starter malfunctioning Repair or replace S-29,

Wiring disconnected Connect – Fuel filter clogged or dirty Replace G-16 Air cleaner clogged Clean or replace G-13, 16,

Fuel leak due to loose injection pipe retaining nut T ighten retaining nut S-29 Injection pump malfunctioning Repair or replace S-19, 35,

Incorrect nozzle injection pressure Adjust S-20 Injection nozzle stuck or clogged Repair or replace S-20, 21 Governor malfunctioni ng Repair S-41

Use specified fuel or

engine oil

Repair or replace S-40 to 48

gasket, tighten

cylinder head screw,

glow plug and nozzle

holder

timing gear

Reference Page

–

4, G-8

36, 37

S-64 to 71

S-30, 31,

S-40

29, 36

72 to 75

36, 37

W1014322

S-1

SM-E2B SERIES, WS M

KiSC issued 06, 2006 A

DIESEL ENGINE

Symptom Probable Cause Solution

Either White or Blue Exhaust Gas Is Observed

Excessive engine oil Reduce to specified

level

Piston ring and cylinder worn or stuck Repair or replace S-43, 44,

Reference Page

G-6

Incorrect injection timing Adjust S-17, 18

Either Black or Dark Gray Exhaust Gas Is Observed

Overload Reduce the load – Low grade fuel used Use specified fuel 4 Fuel filter clogged Replace G-16 Air cleaner clogged Clean or replace G-13, 16,

Deficient nozzle injection Repair or replace

S-20, 21

nozzle

Deficient Output Incorrect injection timing Adjust S-17, 18

Engine’s moving parts seem to be seizing Repair or replace – Injection pump malfunctioning Repair or replace S-19, 35,

36, 37

Deficient nozzle injection Repair or replace

S-20, 21

nozzle

Compression leak Chec k the

S-13 compression pressure and repair

Excessive Lubricant Oil Consumption

Piston ring’s gap facing the same directio n Shift ring gap

direction

S-43

Oil ring worn or stuck Replace S-43, 44 Piston ring groove worn Replace piston S-43, 44,

Valve stem and valve guide worn Replace S-33, 54,

Crankshaft bearing and crank pin bearing worn Replace S-47, 48,

65 to 69

Oil leaking due to defective seals or packing Replace –

Fuel Mixed into Lubricant Oil

Injection pump’s plunger worn Repair or replace S-19, 35,

36, 37

Deficient nozzle injection Repair or replace

S-20, 21

nozzle

Injection pump broken Replace S-35, 36,

Water Mixed into Lubricant Oil

Head gasket defective Replace S-32 Cylinder block or cylinder head flawed Replace S-32, 54

W1014322

S-2

SM-E2B SERIES, WSM

KiSC issued 06, 2006 A

DIESEL ENGINE

Symptom Probable Cause Solution

Reference Page

Low Oil Pressure Engine oil insufficient Replenish G-6

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 Excessive oil clearance of crankpin bearing Replace S-42, 65 Excessive oil clearance of rocker arm Replace S-31, 57 Oil passage clogged Clean – Different type of oil Use specified type of

G-8

oil

Oil pump defective Replace S-41, 71,

High Oil Pressure Different type of oil Use specified type of

G-8

oil

Relief valve defective Replace –

Engine Overheated Engine oil insufficient Replenish G-6

Fan belt broken or elongated Replace or adjust G-13 Coolant insufficient Replenish G-17, 18 Radiator net and radiator fin clogged with dust Clean – Inside of radiator corroded Clean or replace G-17 Coolant flow route corroded Clean or replace G-17, 18 Radiator cap defective Replace – Overload running Reduce the load – Head gasket defective Replace S-32 Incorrect injection timing Adjust S-17, 18 Unsuitable fuel used Use specified fuel 4

Battery Quickly Discharged

Battery electrolyte insufficient Replenish distilled

water and charge

Fan belt slips Adjust belt tension or

G-14

G-13

replace Wiring disconnected Connect – Rectifier defective Replace S-52, 76 Alternator defective Replace S-29, 52 Battery defective Replace G-28

W1014322

S-3

SM-E2B SERIES, WS M

KiSC issued 06, 2006 A

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-E2B D662-E2B D722-E2B D782-E2B

2.84 to 3.24 MPa

29.0 to 33.0 kgf/cm 412 to 469 psi

DIESEL ENGINE

–

2.26 MPa

23.0 kgf/cm

327 psi

Z602-E2B D902-E2B

3.53 to 4.02 MPa

36.0 to 41.0 kgf/cm 512 to 583 psi

Difference among Cylinders

–

Top Clearance 0.50 to 0.70 mm

2.55 MPa

26.0 kgf/cm 370 psi

10 % or less

–

0.0197 to 0.0276 in.

Cylinder Head Surface Flatness – 0.05 mm

0.0020 in.

Valve Recessing Intake and Exhaust −0.10 to 0.10 mm

−0.0039 to 0.0039 in.

Valve Stem to Valve Guide

Clearance

0.030 to 0.057 mm

0.00118 to 0.00224 in.

Valve Stem

O.D.

5.968 to 5.980 mm

0.30 mm

0.0118 in.

0.10 mm

0.0039 in. –

0.23496 to 0.23543 in.

Valve Guide

I.D.

6.010 to 6.025 mm

–

0.23661 to 0.23720 in.

Valve Face Angle 0.785 rad

–

45 °

Valve Seat Angle

0.785 rad

–

45 °

Valve Spring Free Length

Width

Tilt

Setting Load / Setting Length

S-4

2.12 mm

0.0835 in.

31.3 to 31.8 mm

1.232 to 1.252 in. –

64.7 N / 27.0 mm

6.6 kgf / 27.0 mm

14.6 lbs / 1.063 in.

–

28.4 mm

1.118 in.

1.2 mm

0.047 in.

54.9 N / 27.0 mm

5.6 kgf / 27.0 mm

12.3 lbs / 1.063 in.

W10138740

SM-E2B SERIES, WSM

KiSC issued 06, 2006 A

ENGINE BODY (Continued)

Rocker Arm Shaft to Rocker Arm

DIESEL ENGINE

Item Factory Specification Allowable Limit

Oil Clearance

0.016 to 0.045 mm

0.00063 to 0.00177 in.

0.15 mm

0.0059 in.

Rocker Arm Shaft

O.D.

10.473 to 10.484 mm

–

0.41232 to 0.41276 in.

Rocker Arm

I.D.

10.500 to 10.518 mm

–

0.41339 to 0.41410 in.

Push Rod Alignment – 0.25 mm

0.0098 in.

Tappet to Tappet Guide

Tappet

Oil Clearance

O.D.

0.016 to 0.052 mm

0.00063 to 0.00205 in.

17.966 to 17.984 mm

0.10 mm

0.0039 in. –

0.70732 to 0.70803 in.

Tappet Guide

I.D.

18.000 to 18.018 mm

–

0.70866 to 0.70937 in.

Timing Gear

Crank Gear to Idle Gear

Idle Gear to Cam Gear

Idle Gear to Injection Pump Gear

Backlash

0.043 to 0.124 mm

0.00169 to 0.00488 in.

0.047 to 0.123 mm

0.00185 to 0.00484 in.

0.046 to 0.124 mm

0.00181 to 0.00488 in.

0.15 mm

0.0059 in.

0.15 mm

0.0059 in.

0.15 mm

0.0059 in.

Crank Gear to Oil Pump Drive Gear

Backlash

0.041 to 0.123 mm

0.00161 to 0.00484 in.

Idle Gear Side Clearance 0.20 to 0.51 mm

0.0079 to 0.0201 in.

Camshaft Side Clearance

0.15 to 0.31 mm

0.0059 to 0.0122 in.

Alignment

Cam Height Intake and

Exhaust

Camshaft Journal to Cylinder Block Bore

Oil Clearance

0.050 to 0.091 mm

–

26.88 mm

1.0583 in.

0.00197 to 0.00358 in.

Camshaft Journal

O.D.

32.934 to 32.950 mm

1.29661 to 1.29724 in.

Cylinder Block Bore

I.D.

33.000 to 33.025 mm

1.29921 to 1.30020 in.

0.15 mm

0.0059 in.

0.80 mm

0.0315 in.

0.50 mm

0.0197 in.

0.01 mm

0.0004 in.

26.83 mm

1.0563 in.

0.15 mm

0.0059 in. –

–

W1013874

S-5

SM-E2B SERIES, WS M

KiSC issued 06, 2006 A

ENGINE BODY (Continued)

Item Factory Specification Allowable Limit

Idle Gear Shaft to Idle Gear Bushing

Oil Clearance

0.020 to 0.084 mm

0.00079 to 0.00331 in.

DIESEL ENGINE

0.10 mm

0.0039 in.

Idle Gear Shaft

O.D.

19.967 to 19.980 mm

0.78610 to 0.78661 in.

Idle Gear Bushing

I.D.

20.000 to 20.051 mm

0.78740 to 0.78941 in.

Piston Pin Bore I.D. 20.000 to 20.013 mm

0.78740 to 0.78791 in.

Piston Pin to Small End Bushing

Oil Clearance

0.014 to 0.038 mm

0.00055 to 0.00150 in.

Piston Pin

O.D.

20.002 to 20.011 mm

0.78748 to 0.78783 in.

Small End Bushin g

I.D.

20.025 to 20.040 mm

0.78839 to 0.78897 in.

Piston Pin to Small End Bushing (Spare Parts)

Small End Bushin g

Oil Clearance

I.D.

0.015 to 0.075 mm

0.00059 to 0.00295 in.

20.026 to 20.077 mm

0.78843 to 0.79043 in.

Piston Ring Gap

[Z482-E2B] [D662-E2B] [D722-E2B] [D782-E2B]

Top Ring 0.15 to 0.30 mm

0.0059 to 0.0118 in.

Second Ring 0.30 to 0.45 mm

0.0118 to 0.0177 in.

Oil Ring 0.15 to 0.30 mm

0.0059 to 0.0118 in.

Piston Ring Gap

[Z602-E2B] [D902-E2B]

Top Ring 0.20 to 0.35 mm

0.0079 to 0.0138 in.

Second Ring 0.35 to 0.50 mm

0.0138 to 0.0197 in.

Oil Ring 0.20 to 0.35 mm

0.0079 to 0.0138 in.

Piston Ring to Piston Ring Groove

Second Ring

Clearance

0.090 to 0.120 mm

0.00354 to 0.00472 in.

–

20.05 mm

0.7894 in.

0.10 mm

0.0039 in. –

–

0.15 mm

0.0059 in. –

1.20 mm

0.0472 in.

1.20 mm

0.0472 in.

1.20 mm

0.0472 in.

1.25 mm

0.0492 in.

1.25 mm

0.0492 in.

1.25 mm

0.0492 in.

0.15 mm

0.0059 in.

Oil Ring

Connecting Rod Alignment – 0.05 mm

Crankshaft Side Clearance 0.15 to 0.31 mm

Clearance

0.04 to 0.08 mm

0.0016 to 0.0031 in.

0.15 mm

0.0059 in.

0.0020 in.

0.50 mm

0.0059 to 0.0122 in.

0.0197 in.

Alignment – 0.02 mm

0.0008 in.

W10138740

S-6

SM-E2B SERIES, WSM

KiSC issued 06, 2006 A

ENGINE BODY (Continued)

Crankpin to Crankpin Bearing

DIESEL ENGINE

Item Factory Specification Allowable Limit

Oil Clearance

0.020 to 0.051 mm

0.00079 to 0.00201 in.

0.15 mm

0.0059 in.

Crankpin

Crankpin Bearing

Crankshaft Journal to Crankshaft Bearing 1 [Z482/D662/D722/D782-E2B]

Crankshaft Journal

Crankshaft Bearing 1

Crankshaft Journal to Crankshaft Bearing 1 [Z602/D902-E2B]

Crankshaft Journal

Crankshaft Bearing 1

Crankshaft Journal to Crankshaft Bearing 2 (Flywheel Side)

O.D.

I.D.

Oil Clearance

O.D.

I.D.

Oil Clearance

O.D.

I.D.

Oil Clearance

33.959 to 33.975 mm

1.33697 to 1.33760 in.

33.995 to 34.010 mm

1.33839 to 1.33898 in.

0.034 to 0.106 mm

0.00134 to 0.00417 in.

39.934 to 39.950 mm

1.57221 to 1.57284 in.

39.984 to 40.040 mm

1.57417 to 1.57638 in.

0.034 to 0.106 mm

0.00134 to 0.00417 in.

43.934 to 43.950 mm

1.72968 to 1.73031 in.

43.984 to 44.040 mm

1.73165 to 1.73386 in.

0.028 to 0.059 mm

0.00110 to 0.00232 in.

–

0.20 mm

0.0079 in. –

–

0.20 mm

0.0079 in. –

–

0.20 mm

0.0079 in.

Crankshaft Journal

Crankshaft Bearing 2

Crankshaft Journal to Crankshaft Bearing 3 (Intermediate)

[Z482/D662/D722/D782-E2B]

Crankshaft Journal

Crankshaft Bearing 3

Crankshaft Journal to Crankshaft Bearing 3 (Intermediate) [Z602/D902-E2B]

Crankshaft Journal

Crankshaft Bearing 3

O.D.

I.D.

Oil Clearance

O.D.

I.D.

Oil Clearance

O.D.

I.D.

43.934 to 43.950 mm

1.72968 to 1.73031 in.

43.978 to 43.993 mm

1.73142 to 1.73201 in.

0.028 to 0.059 mm

0.00110 to 0.00232 in.

39.934 to 39.950 mm

1.57221 to 1.57284 in.

39.978 to 39.993 mm

1.57394 to 1.57453 in.

0.028 to 0.059 mm

0.00110 to 0.00232 in.

43.934 to 43.950 mm

1.72968 to 1.73031 in.

43.978 to 43.993 mm

1.73142 to 1.73201 in.

–

0.20 mm

0.0079 in.

–

0.20 mm

0.0079 in. –

–

W10138740

S-7

SM-E2B SERIES, WS M

KiSC issued 06, 2006 A

ENGINE BODY (Continued)

Item Factory Specification Allowable Limit

Cylinder Liner

I.D. 64.000 to 64.019 mm

[D662-E2B]

Cylinder Liner

I.D. 67.000 to 67.019 mm

[Z482/D722/D782-E2B]

Cylinder Liner

I.D. 72.000 to 72.019 mm

[Z602/D902-E2B]

Cylinder Liner

I.D. 64.250 to 64.269 mm

[Oversize : 0.25 mm (0.0098 in.)]

[D662-E2B]

Cylinder Liner

I.D. 67.250 to 67.269 mm

[Oversize : 0.25 mm (0.0098 in.)]

[Z482/D722/D782-E2B]

Cylinder Liner

I.D. 72.250 to 72.269 mm

[Oversize : 0.25 mm (0.0098 in.)]

[Z602/D902-E2B]

LUBRICATING SYSTEM

Engine Oil Pressure At Idle Speed

2.51968 to 2.52043 in.

2.63779 to 2.63854 in.

2.83464 to 2.83539 in.

2.52953 to 2.53027 in.

2.64764 to 2.64839 in.

2.84449 to 2.84524 in.

More than 49 kPa

0.5 kgf/cm

7 psi

DIESEL ENGINE

64.150 mm

2.52559 in.

67.150 mm

2.64370 in.

72.150 mm

2.84055 in.

64.400 mm

2.53543 in.

67.400 mm

2.65354 in.

72.400 mm

2.85040 in.

W10138740

–

At Rated Speed

196 to 441 kPa

2.0 to 4.5 kgf/cm 28 to 64 psi

Inner Rotor to Outer Rotor Clearance 0.03 to 0.14 mm

0.0012 to 0.0055 in.

Outer Rotor to Pump Body Clearance 0.07 to 0.15 mm

0.0028 to 0.0059 in.

Inner Rotor to Cover Clearance 0.075 to 0.135 mm

0.00295 to 0.00531 in.

1.5 kgf/cm

21 psi

–

W10139730

147 kPa

S-8

SM-E2B SERIES, WSM

KiSC issued 06, 2006 A

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

Temperature

69.5 to 72.5 °C

157.1 to 162.5 °F

(At Beginning)

DIESEL ENGINE

–

Valve Opening Temperature

85 °C

185 °F

–

(Opened Completely)

Radiator Cap Pressure Falling

Time

10 seconds or more

88 → 59 kPa

0.9 → 0.6 kgf/cm

–

13 → 9 psi

Radiator Water Leakage

Test Pressure

No leak at specified

pressure

–

157 kPa

1.6 kgf/cm

23 psi

W10135990

FUEL SYSTEM

Item Factory Specification Allowable Limit

Injection Pump

[Z482/D662/D722-E2B]

Injection Timing

-1

(3600 min

(rpm))

0.33 to 0.37 rad (19 to 21°)

–

before T.D.C.

Injection Pump

[D782-E2B]

Injection Timing (3200 min

-1

(rpm))

0.28 to 0.31 rad (16 to 18°)

–

before T.D.C.

Injection Pump

[Z602/D902-E2B]

Injection Timing (3200 min

-1

(rpm))

0.30 to 0.33 rad (17 to 19°)

–

before T.D.C.

Injection Pump

[Z602/D902-E2B]

Injection Timing (3600 min

-1

(rpm))

0.33 to 0.37 rad (19 to 21°)

–

before T.D.C.

Pump Element Fuel Tightness – 13.73 MPa

140 kgf/cm

1991 psi

Delivery Valve Fuel Tightness 10 seconds

13.73 → 12.75 MPa 140 → 130 kgf/cm

1991 → 1849 psi

Injection Nozzle Injection Pressure 13.73 to 14.71 MPa

140 to 150 kgf/cm

5 seconds

13.73 → 12.75 MPa 140 → 130 kgf/cm

1991 → 1849 psi

–

1991 to 2134 psi

Injection Nozzle Valve Seat Valve Seat

Tightness

When the pressure is

12.75 MPa

(130 kgf/cm

, 1849 psi),

–

the valve seat must be

fuel tightness.

W10139730

S-9

SM-E2B SERIES, WS M

KiSC issued 06, 2006 A

DIESEL ENGINE

ELECTRICAL SYSTEM

Item Factory Specification Allowable Limit

Glow Plug Resistance Approx. 0.9 Ω – Starter (Electromagnetic Drive Type)

Commutator

O.D.

28.0 mm

1.102 in.

27.0 mm

1.063 in.

Difference

Mica

Brush

Starter (Planetary Gear Reduction Type)

Commutator

Difference

Mica

Brush

Dynamo

No-load

O.D.

Undercut

Length

O.D.

Undercut

Length

Output Voltage

Less than 0.05 mm

0.0002 in.

0.50 to 0.80 mm

0.0197 to 0.0315 in.

16.0 mm

0.630 in.

30.0 mm

1.181 in.

Less than 0.02 mm

0.0008 in.

0.50 to 0.80 mm

0.0197 to 0.0315 in.

14.0 mm

0.551 in.

AC20V or more at

5200 min

-1

(rpm)

0.4 mm

0.016 in.

0.20 mm

0.0079 in.

10.5 mm

0.413 in.

29.0 mm

1.142 in.

0.05 mm

0.0020 in.

0.20 mm

0.0079 in.

9.0 mm

0.354 in.

–

Regulating

Alternator

Stator Rotor Slip Ring

Brush

Output Voltage

Resistance Resistance O.D.

Length

14 to 15 V at

-1

5200 min

(rpm)

Less than 1.0 Ω

2.9 Ω

14.4 mm

0.567 in.

10.5 mm

0.413 in.

–

– –

14.0 mm

0.551 in.

8.4 mm

0.331 in.

W1013973

S-10

SM-E2B SERIES, WSM

KiSC issued 06, 2006 A

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.

Grade

Nominal Unit Diameter

M6 7.9 to 9.3 0.80 to 0.95 5.8 to 6.9 9.8 to 11.3 1.00 to 1.15 7.23 to 8.32

M8 17.7 to 20.6 1.8 to 2.1 13.0 to 15.2 23.5 to 27.5 2.4 to 2.8 17.4 to 20.3 M10 39.2 to 45.1 4.0 to 4.6 28.9 to 33.3 48.1 to 55.9 4.9 to 5.7 35.4 to 41.2 M12 62.8 to 72.6 6.4 to 7.4 46.3 to 53.5 77.5 to 90.2 7.9 to 9.2 57.1 to 66.5

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

Punched number Screw and bolt material grade

None or 4 Standard screw and bolt SS41, S20C

7 Special screw and bolt S43C, S48C (Refined)

Standard Screw and Bolt

N·m kgf·m ft-lbs N·m kgf·m ft-lbs

Special Screw and Bolt

W10371750

W1012705

S-11

SM-E2B SERIES, WS M

■

KiSC issued 06, 2006 A

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. The pitch is the nominal distance in mm between two threads.

Item Size x Pitch N·m kgf·m ft-lbs

*Cylinder head cover screw M6 x 1 6.86 to 11.3 0.7 to 1.15 5.1 to 8.3 Injection pipe retaining nut M12 x 1.5 24.5 to 34.3 2.5 to 3.5 18.1 to 25.3 Overflow pipe retaining nut M12 x 1.5 19.6 to 24.5 2.0 to 2.5 14.5 to 18.1 Nozzle holder assembly M20 x 1.5 49.0 to 68.6 5.0 to 7.0 36.2 to 50.6 Glow plug M8 x 1 7.8 to 14.7 0.8 to 1.5 5.8 to 10.8 *Rocker arm bracket nut M6 x 1 9.8 to 11.3 1.00 to 1.15 7.2 to 8.3 *Cylinder head screw M8 x 1.25 37.3 to 42.2 3.8 to 4.3 27.5 to 31.1 *Fan drive pulley screw M12 x 1.5 117.7 to 127.5 12.0 to 13.0 86.8 to 94.0 *Idle gear shaft mounting screw M6 x 1 9.8 to 11.3 1.00 to 1.15 7.2 to 8.3 Oil pump mounting screw M8 x 1.25 17.7 to 21.6 1.80 to 2.20 13.0 to 15.9 *Connecting rod screw M7 x 0.75 26.5 to 30.4 2.7 to 3.1 19.5 to 22.4 *Flywheel screw M10 x 1.25 53.9 to 58.8 5.5 to 6.0 39.8 to 43.4 Bearing case cover mounting screw M6 x 1 9.8 to 11.3 1.00 to 1.15 7.2 to 8.3 *Main bearing case screw 2 M7 x 1 26.5 to 30.4 2.7 to 3.1 19.5 to 22.4 *Main bearing case screw 1 M6 x 1 12.7 to 15.7 1.3 to 1.6 9.4 to 11.6 Oil pressure switch PT 1/8 14.7 to 19.6 1.5 to 2.0 10.8 to 14.5 Nozzle holder – 34.3 to 39.2 3.5 to 4.0 25.3 to 28.9 Starter’s terminal B mounting nut

(Electromagnetic drive type) Starter’s terminal B mounting nut

(Planetary gear reduction type) Dynamo’s pulley nut M10 x 1.25 39.2 to 44.1 4.0 to 4.5 28.9 to 32.5 Alternator’s pulley nut – 58.3 to 78.9 5.95 to 8.05 43.0 to 58.2 Drain plug with copper gasket M12 x 1.25 32.4 to 37.3 3.3 to 3.8 23.9 to 27.5 Drain plug with copper gasket M22 x 1.5 63.7 to 73.5 6.5 to 7.5 47.0 to 54.2 Drain plug with rubber coated gasket M22 x 1.5 44.1 to 53.9 4.5 to 5.5 32.5 to 39.8

M8 7.8 to 9.8 0.8 to 1.0 5.8 to 7.2

M8 5.9 to 11.8 0.6 to 1.2 4.3 to 8.7

W1013236

S-12

SM-E2B SERIES, WSM

NOTE■

KiSC issued 06, 2006 A

DIESEL ENGINE

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.

[b] Glow Plug Hole Adaptor Setting :

Remove the air cleaner, th e mu ffl er, the b re ath er tube , the head cover and all glow plugs.

4. [a] Nozzle Hole Adaptor Setting : Set a compression tester (Code No. 07909-30208) with the adaptor (Adaptor H, code No. 07909-31231) to the nozzle hole.

[b] Glow Plug Hole Adaptor Setting :

Set a compression tester (Code No. 07909-30208) with the adaptor (Adaptor L, code No. 07909-31301) to the glow plug hole.

5. After making sure that th e stop lever is set at the stop position (non-injection), ru n the engine with the starter and measure the compression pressure.

6. Repeat steps 4 and 5 for each cylinder.

7. If the measurement is below the allowable limi t, apply a small amount of oil to the cylinder wall through the gl ow plug hole (or nozzle hole) and measure the compression pressure again.

8. If the compression pressur e is still less than the all owable limit, check the top clearance, valve clearance and cylinder head.

9. If the compressio n pressure incre ases after applying oil, check the cylinder wall and piston rings.

• 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 D662-E2B

Factory spec.

Compression pressure

Allowable limit

[a] Nozzle Hole Adaptor Setting [b] Glow Plug Hole Adaptor Setting

D722-E2B D782-E2B

Z602-E2B D902-E2B

Z482-E2B D662-E2B D722-E2B D782-E2B

Z602-E2B D902-E2B

2.84 to 3.24 MPa 29 to 33 kgf/cm 412 to 469 psi

3.53 to 4.02 MPa 36 to 41 kgf/cm 512 to 583 psi

2.26 MPa 23 kgf/cm 327 psi

2.55 MPa 26 kgf/cm 370 psi

W10178940

S-13

SM-E2B SERIES, WS M

IMPORTANT■

NOTE■

KiSC issued 06, 2006 A

DIESEL ENGINE

Checking Valve Clearance

• 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. 1 piston comes to the compression top dead center.

3. Check the following valve clearance marked with “★” using a feeler gauge.

4. If the clearance is not within the factory specifications, adjust with the adjusting screw.

5. Then turn the flywheel 6.28 rad (360 °), and align the “1TC” mark (2) on the flywheel and alignment mark (3) on the rear en d pl ate so that the No. 1 piston comes to the overlap position.

6. Check the following valve clearance marked with “✩” using a feeler gauge.

7. If the clearance is not within the factory specifications, adjust with the adjusting screw.

Number of cylinders Valve arrangement

Adjustable cylinder location of piston

No. 1 ★★★★ No. 2 ✩★✩★ No. 3 – – ★✩

★ : When No. 1 piston is at the compression top dead center position. ✩ : When No. 1 piston is at the overlap position.

Intake and exhaust valve clearance (cold)

Factory spec.

Z482-E2B Z602-E2B

Intake

valve

Exhaust

valve

0.145 to 0.185 mm

0.00571 to 0.00728 in.

D662-E2B D722-E2B D782-E2B D902-E2B

Intake

valve

Exhaust

valve

• The sequence of cylinder numbers is given as No. 1, No. 2 and No. 3 starting from the gear case side.

• After adjusting the valve clearance, secure the adjusting screw with the lock nut.

(1) Cylinder Head Cover (2) “1TC” Mark (3) Alignment Mark

A : Gear Case Side [a] Z482-E2B, Z602-E2B [b] D662-E2B, D722-E2B,

D782-E2B, D902-E2B

W10172470

S-14

SM-E2B SERIES, WSM

KiSC issued 06, 2006 A

(2) Lubricating System

DIESEL ENGINE

Engine Oil Pressure

1. Remove the engine o il pressure s witch, and set an oil pressure tester. (Code No. : 07916-32032.)

2. Start the engine. After warm ing up, m easure the oil pres sure of both idling and rated speeds.

3. If the oil pressure is less than the allowable limit, check the following.

• Engine oil insufficient

• Oil pump defective

• Oil strainer clogged

• Oil filter cartridge clogged

• Oil gallery clogged

• Excessive oil clearance

• Foreign matter in the relief valve

More than 49 kPa

0.5 kgf/cm 7 psi

196 to 441 kPa

2.0 to 4.5 kgf/cm 28 to 64 psi

147 kPa

1.5 kgf/cm 21 psi

Engine oil pressure

At idle speed

At rated speed

Factory spec.

Allowable limit

(When reassembling)

• After checking the engine oil pressure, tighten the engine oil pressure switch to the specified torque.

Tightening torque Oil pressure switch

14.7 to 19.6 N·m

1.5 to 2.0 kgf·m

10.8 to 14.5 ft-lbs W10349520

(3) Cooling System

Fan Belt Tension

1. Measure the defl ecti on (A), depressing the belt halfway between the fan drive pulley a nd altern ator pulley at specifie d 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.

Deflection (A) Factory spec.

(A) Deflection

7.0 to 9.0 mm

0.28 to 0.35 in.

W10356670

S-15

SM-E2B SERIES, WS M

KiSC issued 06, 2006 A

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. If the fan be lt is nearly worn out and deeply sunk in the pul ley groove, replace it.

(A) Good (B) Bad

W1016443

CAUTION

• When removing the radiator cap, wait at least ten minutes after the engine has stopped and cooled down. Otherwise, hot water may gush out, scalding nearby people.

Radiator Cap Air Leakage

1. Set a radiator tester (1) and an adaptor (2) on the radiator cap.

2. Apply the specifi ed pressure (88 kPa, 0.9 kgf/c m

, 13 psi), and measure the time f or th e pres su re to fa ll to 5 9 kP a (0.6 k gf/c m 9 psi).

3. If the meas urement is les s th an t he fa ct o ry s pe cification, r e pl a ce the radiator cap.

More than 10 seconds for pressure fall from

Pressure falling time Factory spec.

(1) Radiator Tester (2) Adaptor

88 to 59 kPa (from 0.9 to 0.6 kgf/cm from 13 to 9 psi)

W1054156

Radiator Water Leakage

1. Pour a specified amount of water into the radiator.

2. Set a radiator tester (1) and an adaptor (2) and raise the water pressure to the specified pressure.

3. Check the radiator for water leaks.

4. For water leak from the pinhole, repair with the radiator cement. When water leak is excessive, replace the radiator.

Radiator water leakage test pressure

Factory spec.

157 kPa

1.6 kgf/cm 23 psi

(1) Radiator Tester (2) Adaptor

W1016903

S-16

SM-E2B SERIES, WSM

KiSC issued 06, 2006 A

(4) Fuel System

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. Continue heating and read the temperature when the valve opens approx. 8 mm (0.315 in.).

4. If the measurement is not within the factory specifications, replace the thermostat.

Thermostat’s valve opening temperature

Temperature at which thermostat completely opens

Factory spec.

69.5 to 72.5 °C

157.1 to 162.5 °F 85 °C

185 °F

W1035849

Injection Timing

1. Remove the injection pipes.

2. Remove the engine stop solenoid.

3. Turn the flywheel co unterclockwise (viewed from flywheel side) until the fuel fills up to the hole of the delivery valve holder (3) for No. 1 cylinder.

4. After the fuel fills up to the hole of the delivery valve holder for No. 1 cylinder, turn back (clockwise) the flywheel around 1.57 rad (90 °).

5. Turn the flywheel counterclockwise to set at around 0.44 rad (25 °) before T.D.C..

6. Slowly turn the flywheel counterclockwise and stop turning when the fuel begins to come up, to get the present injection timing.

7. Check to see the degree on flywheel. The flywheel has mark “1TC” , “10” and “20” for the cran k angle before the top dead center of No. 1 cylinder.

8. Check to see if the timing angle on the flywheel is aligned with the alignment mark (2).

9. If injection timing is out of adj ustment, readjust the timing with shims.

-1

Z482/D662/D722-E2B (3600 min

Injection timing Factory spec.

D782-E2B (3200 min

Injection timing Factory spec.

Z602/D902-E2B (3200 min

Injection timing Factory spec.

Z602/D902-E2B (3600 min

Injection timing Factory spec.

(1) Timing Line (2) Alignment Mark (3) Delivery Valve Holder (4) Shim (Soft Metal Gasket Shim)

-1

(rpm) spec.)

-1

(rpm) spec.)

0.33 to 0.37 rad (19 to 21 °) before T.D.C.

0.28 to 0.31 rad (16 to 18 °) before T.D.C.

(rpm) spec.)

0.30 to 0.33 rad (17 to 19 °) before T.D.C.

(rpm) spec.)

0.33 to 0.37 rad (19 to 21 °) before T.D.C.

(5) Two-holes : 0.20 mm (0.0079 in.) (6) One-hole : 0.25 mm (0.0098 in.) (7) Without hole : 0.30 mm (0.0118 in.)

W1018724

S-17

SM-E2B SERIES, WS M

NOTE■

KiSC issued 06, 2006 A

DIESEL ENGINE

Injection Timing (Continued)

• The sealant is applied to both sides of the shims (soft meta l gasket shim). 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.) and 0.30 mm (0.0118 in.). Combine these shims for adjustments.

• Addition or reduction of shim (0.05 mm, 0.0020 in.) delays or advances the injection timing by approx. 0.0087 rad (0.5 °).

• In disassembling and replacing the injection pump, be sure to use the same number of new shims with the same thickness.

• 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

Rated Speed Specification

-1

(rpm))

(min 3600 to 3301

3300 to 3001

3000 to 2501

2500 to 2001

Under 2000

Z482-E2B D662-E2B D722-E2B

0.33 to 0.37 rad (19 to 21 °)

0.31 to 0.35 rad (18 to 20 °)

0.30 to 0.33 rad (17 to 19 °)

0.26 to 0.30 rad (15 to 17 °)

0.23 to 0.26 rad (13 to 15 °)

D782-E2B

–

0.28 to 0.31 rad (16 to 18 °)

0.24 to 0.28 rad (14 to 16 °)

0.23 to 0.26 rad (13 to 15 °)

Z602-E2B D902-E2B

0.33 to 0.37 rad (19 to 21 °)

0.30 to 0.33 rad (17 to 19 °)

0.28 to 0.31 rad (16 to 18 °)

0.24 to 0.28 rad (14 to 16 °)

0.23 to 0.26 rad (13 to 15 °)

W1018986

S-18

SM-E2B SERIES, WSM

NOTE■

KiSC issued 06, 2006 A

DIESEL ENGINE

Fuel Tightness of Pump Element

1. Remove the engine stop solenoid.

2. Remove the injection pipes and glow plugs.

3. Install the injection pump pressure tester to the injection pump.

4. Install the injection nozzle (2) jetted with the proper injection pressure to the injec ti on pu mp p re ssur e te st er (1). ( Ref er to the photo.)

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 pump element

Allowable limit

13.73 MPa 140 kgf/cm 1991 psi

• Never try to disassemble the injectio n pump ass embly. For repairs, you are strongly requested to contact a Kubotaauthorized pump service shop.

(1) Injection Pump Pressure Tester (2) Injection Nozzle

(3) Protection Cover for Jetted Fuel

W1017430

Fuel Tightness of Delivery Valve

1. Remove the engine stop solenoid.

2. Remove the injection pipes and glow plugs.

3. Set a pressure tester to the fuel injection pump.

4. Install the injection nozzle (2) jetted with the proper injection pressure to the injection pump pressure tester (1).

5. Run the starter to increase the pressure.

6. Stop the starter when the fuel jets from the injection nozzle. After that, turn the flywheel by hands and raise the pressure to approx.

13.73 MPa (140 kgf/cm

, 1991 psi).

7. Now turn the flywheel back about half a turn (to keep the plunger free). Maintain the flywheel at thi s position and clock the time taken for the pressure to drop from 13.73 to 12.75 MPa (from 140 to 130 kgf/cm

8. Measure the time needed to decrease the pressure from 13.73 to

12.75 MPa (140 to 130 kgf/cm

, from 1991 to 1849 psi).

, 1991 to 1849 psi).

9. If the measurement is less than allowable limit, replace the pump with new one or repair with a Kub ota-authorized pump service shop.

10 seconds

Factory spec.

Fuel tightness of delivery valve

Allowable limit

13.73 → 12.75 MPa 140 → 130 kgf/cm 1991 → 1849 psi

5 seconds

13.73 → 12.75 MPa 140 → 130 kgf/cm 1991 → 1849 psi

• Never try to disassemble the injectio n pump ass embly. For repairs, you are strongly requested to contact a Kubotaauthorized pump service shop.

(1) Injection Pump Pressure Tester (2) Injection Nozzle

(3) Protection Cover for Jetted Fuel

W1017786

S-19

SM-E2B SERIES, WS M

KiSC issued 06, 2006 A

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 poisonin g may be caused.

Nozzle Spraying Condition

1. Set the injection no zzle to a nozz le tester, a nd check th e nozz le spraying condition.

2. If the spraying condition is defective, replace the nozzle piece.

(a) Good (b) Bad

W10181310

Fuel Injection Pressure

1. Set the injection nozzle to a nozzle tester.

2. Slowly move the tester handle to measure the pressure at which fuel begins jetting out from the nozzle.

3. If the measurement is not within the factory specifications, replace the adjusting washer (1) in the nozzle holder to adjust it.

(Reference)

• Pressure variation with 0.025 mm (0.0010 in.) difference of adjusting washer thickness.

Approx. 588 kPa (6.0 kgf/cm

Fuel injection pressure Factory spec.

, 85 psi)

13.73 to 14.71 MPa 140 to 150 kgf/cm 1991 to 2134 psi

(1) Adjusting Washer

W10182100

Nozzle Valve Seat Tightness

1. Set the injection nozzle to a nozzle tester.

2. Raise the fuel pres sure, and keep at 12.75 MPa (130 k gf/cm 1849 psi) for 10 seconds.

3. If any fuel leak is found, replace the nozzle piece.

No fuel leak at

Valve seat tightness Factory spec.

12.75 MPa 130 kgf/cm 1849 psi

W10183690

S-20

SM-E2B SERIES, WSM

IMPORTANT■

KiSC issued 06, 2006 A

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.

• After assemblin g the nozzle, be sure to adjust the fuel injection pressure.

34.3 to 39.2 N·m

Tightening torque

Nozzle holder

Overflow pipe retaining nut

Nozzle holder assembly

3.5 to 4.0 kgf·m

25.3 to 28.9 ft-lbs

19.6 to 24.5 N·m

2.0 to 2.5 kgf·m

14.5 to 18.1 ft-lbs

49.0 to 68.6 N·m

5.0 to 7.0 kgf·m

36.2 to 50.6 ft-lbs

(1) Nozzle Holder (2) Adjusting Washer (3) Nozzle Spring (4) Push Rod

(5) Distance Piece (6) Nozzle Piece (7) Nozzle Retaining Nut

W1018491

(5) Electrical System

CAUTION

• To avoid accident al short circuit, be sure to attach the posi tive cable to the pos itive terminal before the negative cable is attached to the negative terminal.

• Never remove the battery cap while the engine is running.

• Keep electrolyte away from eyes, hands and clothes. If you are spattered with it, wash it away completely with water immediately.

• Keep open sparks and flames away from the battery at all times. Hydrogen gas mixed with oxygen becomes very explosive.

• If the machine is to be operated for a short time without battery (using a slave battery for starting), use additional current (lights) while engine is running and insulate terminal of battery. If this advice is disregarded, damage to alternator and regulator may result.

Battery Voltage

1. Stop the engine.

2. Measure the voltage with a circuit tester between the battery terminals.

3. If the battery voltage is le ss th an th e fac tory sp ec ifi ca tio n, c heck the battery specific gravity and recharge the battery.

Battery voltage Factory spec. More than 12 V

(1) Positive Terminal (2) Negative Terminal

W10125620

S-21

SM-E2B SERIES, WS M

NOTE■

KiSC issued 06, 2006 A

DIESEL ENGINE

Battery Specific Gravity

1. Check the s pecific gravity of the electr olyte in each cell with a hydrometer.

2. When the electrolyte temperature differs from that at which the hydrometer was cali brated, correct the specific gravity reading following the formula mention ed in (Reference).

3. If the sp ecific gravity i s less than 1 .215 (after it is corrected for temperature), charge or replace the battery.

4. If the specific grav it y di ffe rs between any two cells by more th an

0.05, replace the battery.

• Hold the hydrometer tube vertical without removing it from the electrolyte.

• Do not suck too much electrolyte into the tube.

• Allow the float to move freely and hold the hydrometer at eye level.

• The hydrometer reading must be taken at the highest electrolyte level.

(Reference)

- Specific gravity at 20 °C = Measured value + 0.0007 ×

(electrolyte temperature : 20 °C)

- Specific gravity at 68 °F = Measured value + 0.0004 ×

(electrolyte temperature : 68 °F)

Specific Gravity State of Charge

1.260 Sp. Gr. 100 % Charged

1.230 Sp. Gr. 75 % Charged

1.200 Sp. Gr. 50 % Charged

1.170 Sp. Gr. 25 % Charged

1.140 Sp. Gr. Very Little Useful Capacity

1.110 Sp. Gr. Discharged

At an electrolyte temperature of 20 °C (68 °F)

(a) Good (b) Bad

W1019017

S-22

SM-E2B SERIES, WSM

■

NOTE■

KiSC issued 06, 2006 A

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. Disconnect the leads from the starter B terminal.

4. Remove the starter from the engine.

5. Connect a jumper lead from the starter C terminal (1) to the battery positive terminal (2).

6. Connect a jumper lead mom entarily between the starter’ s body and the battery negative terminal (3).

7. If the motor does not run, starter is failure. Repair or replace the starter.

NOTE

• B terminal : It is the terminal which connects the cable from the battery to the starter.

• C terminal : It is the terminal which connects the cable from the motor to the magnet switch.

(1) C Terminal (2) Positive Terminal (3) Negative Terminal

[A] Electromagnetic Drive Type [B] P lanetary Gear Reduction Type

W1019297

Magnetic Switch Test

1. Disconnect the battery negative cable from the battery.

2. Disconnect the battery positive cable from the battery.

3. Disconnect the leads from the starter B terminal.

4. Remove the starter from the engine.

5. Connect a jumper lead from the starter S terminal (1) to the battery positive terminal (2).

6. Connect a jumper lead mom entarily between the starter’ s body and the battery negative terminal (3).

7. If the pinion gear does not pop out, the magnetic switch is failure. Repair or replace the starter.

• B terminal : It is the terminal which connects the cable from the battery to the starter.

• S terminal : It is the terminal which conn ects the cab le fro m the starter switch to the magnet switch.

(1) S Terminal (2) Positive Terminal (3) Negative Terminal

[A] Electromagnetic Drive Type [B] P lanetary Gear Reduction Type

0000010743E

S-23

SM-E2B SERIES, WS M

KiSC issued 06, 2006 A

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 cont inuous or if a certain value is indicated, replace the magnet switch.

(1) C Terminal (2) B Terminal

[A] Electromagnetic Drive Type [B] Planetary Gear Reduction Type

0000010771E

No-load Dynamo Output

1. Disconnect the lead wires from the dynamo.

2. Start the engine and operate the dynamo at the specified speed.

3. Measure the output voltage with a volt meter. If the measurement is not within the specified values, replace the dynamo.

No-load output voltage Factory spec.

AC 20 V or more at 5200 min

-1

(rpm)

W1021164

S-24

SM-E2B SERIES, WSM

NOTE■

KiSC issued 06, 2006 A

DIESEL ENGINE

Continuity across Regulator’s Terminals

1. Measure with a circuit tester according to the list below.

• For this test, use only Analog Meter and do not use a high voltage tester such as a MΩ meter.

• This check sheet shows the results of the t est conducted b y using the “Sanwa-made te ster SP-10 and SP-15D” (Analog Meter).

• Use of other testers t han those above may show different measured results. Ω shall be used as the unit for the measuring range.

• The judgement should be as below table. “ON” if the indicator moves, otherwise “OFF”.

■ Check Table (★ : ON, ✩ : OFF)

Tester + Terminal Tester − Terminal

Blue ✩✩✩ ✩ ★

Black ✩✩✩✩✩

Code

colors

(1) Blue (2) Black (3) Blue

Blue ✩✩ ✩ ✩★

Green ✩✩✩ ✩✩

Yellow ★★★✩ ★

Red ✩✩✩✩ ✩

Blue Black Blue Green Yellow Red

Code colors

(4) Green (5) Yellow (6) Red

W1021509

Regulating Voltage

1. Complete the charging circuit with a fully charged battery and operate the dynamo at the specified speed.

2. Measure the output voltage with a volt meter.

3. If the measurement is not within the specified values, replace the dynamo.

Regulating output voltage

Factory spec.

14 to 15 V at 5200 min

-1

(rpm)

W1022299

S-25

SM-E2B SERIES, WS M

NOTE■

KiSC issued 06, 2006 A

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.

• Prepare full charged battery for the test.

• Be careful not to touch the rotating engine parts while engine is running. Keep safety distance from the engine rotating parts.

1. Start the engine.

2. When the engin e is operating measure the v ol tag e be tween two battery terminals. If the voltag e is between 13.8 V and 14.8 V, the alternator is operating normally.

3. If the results of alternator on unit test are not within the specifications, disassemble the alternator and check the each component part for finding out the failure. See the “DISASSEMBLING AN D ASSE MB LI NG ” and “S ERVI C IN G” f or alternator.

Regulating voltage at no load

Factory spec.

13.8 to 14.8 V at 25 °C (77 °F)

0000010745E

Glow Plug Lead Terminal Voltage

1. Turn the ke y switch to the “GLOW (or PREHEAT)” position, and measure the voltage with a circuit tester between the lead terminal and the engine body.

2. If the voltage d iffe r s fro m the bat ter y v olta ge, the wi r ing ha rn ess or main switch is faulty.

Main switch key at

Voltage

GLOW (or PREHEAT)

Approx. battery voltage

0000010725E

Glow Plug Continuity

1. Remove the glow plug.

2. Measure the resistance with a circuit tester between the glow plug terminal and the glow plug housing.

3. If the factory specification is not indicated, glow plug is faulty.

Resistance Factory spec. Approx. 0.9 Ω

0000010726E

Engine Stop Solenoid Test (Energize to Stop Type)

1. Disconnect the 1P connector from the engine stop solenoid.

2. Remove the engine stop solenoid from the engine.

3. Connect the jumper leads from the battery positive terminal to the 1P connector, and from the battery negative terminal to the engine stop solenoid body.

4. If the soleno id plunge r is not a ttracted, the en gine s top s olenoid is faulty.

(1) Battery (12 V)

W1019658

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NOTE■

KiSC issued 06, 2006 A

DIESEL ENGINE

Engine Stop Solenoid Test (Energize to Run Type)

1. Disconnect the 3P conn ector (3) from the eng ine stop solen oid (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).

4. Connect the jumper leads from the holding coil terminal (5) to the switch (8), and from switch (8) to the battery positive terminal (10).

5. Connect the jumper leads from the ground terminal (4) to the battery negative terminal (9).

6. When the switch (7) i s tur n o n, the plunger pull i nto the so len oid body and then the plunger co mes out within approximately 1.2 seconds.

7. Turn on the switch (8) then turn on the switch (7), the plunger pull into the solenoid bo dy and it keep s in holdi ng positi on after tu rn off the switch (7),

8. If the plunger is not attracted, the engine stop solenoid is faulty.

• This solenoid as sembly inc ludes r everse polar ity pr otected pulling coil timer module (2) to prevent solenoid burnout due to engine over crank or misadjustment of linkage by limiting the pull coil ON time.

Pull coil energized time F ac tory spec. 0.52 to 1.20 seconds

(1) Engine Stop Solenoid (2) Pulling Coil Timer Module (3) 3P Connector (4) Ground Terminal (5) Holding Coil Terminal

(6) Pulling Coil Terminal (7) Switch for Pulling Coil (8) Switch for Holding Coil (9) Battery Negative Terminal

(10) Batte ry Positive Terminal

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IMPORTANT■

KiSC issued 06, 2006 A

[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. After draining, screw in the drain plug.

(When refilling)

• Fill the engine oil up to the upper line on the dipstick (1).

• Never mix two different types of oil.

• Use the proper SAE Engine Oil according to ambient temperature.

(1) Dipstick (2) Drain Plug

DIESEL ENGINE

(3) Oil Inlet Plug

W1023464

Draining Coolant

CAUTION

• Never remove rad iator cap while operating or immedi ately after stopping. Otherwise, hot water will spout out from the radiator. Wait for more than ten minutes to cool the radiator, before opening the cap.

1. Prepare a bucket. Open the coolant drain cock.

(1) Coolant Drain Cock

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SM-E2B SERIES, WSM

IMPORTANT■

KiSC issued 06, 2006 A

(2) External Components

DIESEL ENGINE

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. Remove the starter.

(When reassembling)

• Check to see that there are no cracks on the belt surface.

• Keep the engine stop lever (7) to touch the stopper (6). Tighten the engine stop solenoid mounting screw (4) so that there be no gap between the engine stop lever and the engine stop solenoid plunger (5).

• After reassembling the fan belt, be sure to adjust the fan belt tension.

• Do not confuse the direction of the fan.

(1) Engine Stop Solenoid (2) Cooling Fan (3) Fan Belt (4) Engine Stop Solenoid Mounting

Screw

(5) Plunger

(6) Stopper (7) Engine Stop Lever

A : 0 m m ( 0 in .)

W1023769

(3) Cylinder Head, Valves and Oil Pan

Cylinder Head Cover

1. Disconnect the breather hose (1).

2. Remove the cylinder head cover screws (2).

3. Remove the cylinder head cover (3).

(When reassembling)

• Check to see if the cylinder head cover gasket is not defective.

Tightening torque Cylinder head cover screw

(1) Breather Hose (2) Cylinder Head Cover Screws

(3) Cylinder Head Cover

6.86 to 11.3 N·m

0.7 to 1.15 kgf·m

5.1 to 8.3 ft-lbs

W1028468

Injection Pipes

1. Loosen the screws to the pipe clamp (2).

2. Detach the injection pipes (1).

(When reassembling)

• Sent compressed air into the pipes to blow out dust. Then, reassemble the pipes in the reverse order.

Tightening torque Injection pipe retaining nut

(1) Injection Pipe (2) Pipe Clamp

24.5 to 34.3 N·m

2.5 to 3.5 kgf·m

18.1 to 25.3 ft-lbs

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SM-E2B SERIES, WS M

IMPORTANT■

KiSC issued 06, 2006 A

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. Remove the glow plugs (3).

(When reassembling)

• Replace the copper gasket and heat seal with new one.

19.6 to 24.5 N·m

Tightening torque

Overflow pipe retaining nut

Nozzle holder assembly

Glow plug

2.0 to 2.5 kgf·m

14.5 to 18.1 ft-lbs

49.0 to 68.6 N·m

5.0 to 7.0 kgf·m

36.2 to 50.6 ft-lbs

7.8 to 14.7 N·m

0.8 to 1.5 kgf·m

5.8 to 10.8 ft-lbs

(1) Overflow Pipe (2) Lead (3) Glow Plug

(4) Nozzle Holder Assembly (5) Copper Gasket (6) Heat Seal

W1024604

Nozzle Heat Seal Service Removal Procedure

• Use a plus (phillips head) screw driver (1) that has a diameter which is bigger than the heat seal hole (Approx. 6 mm (1/4 in.)).

1. Drive screw driver (1) lightly into the heat seal hole.

2. Turn screw driver three or four times each way.

3. While turnin g the screw driver, slowly pul l the heat seal (4) out together with the injection nozzle gasket (3).

4. If the heat seal drops, repeat the above procedure.

(When reassembling)

• Heat seal and injection nozzle gasket must be changed when the injection nozzle is removed for cleaning or for service.

(1) Plus Screw Driver (2) Injection Nozzle

(3) Injection Nozzle Gasket (4) Heat Seal

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SM-E2B SERIES, WSM

IMPORTANT■

KiSC issued 06, 2006 A

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.

• After installing the rocker arm, be sure to a djust the valve clearance.

9.8 to 11.3 N·m

Tightening torque Rocker arm bracket screw

1.00 to 1.15 kgf·m

7.2 to 8.3 ft-lbs

(1) Rocker Arm Assembly (2) Rocker Arm Bracket Screws

(3) Push Rod (4) Tappet

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SM-E2B SERIES, WS M

KiSC issued 06, 2006 A

DIESEL ENGINE

Cylinder Head

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. Lift up the cylinder head to detach.

4. Remove the cylinder head gasket and O-ring (3).

(When reassembling)

• Replace the cylinder head gasket with a new one.

• Securely fit the O-ring (3) to the pipe pin.

• Tighten the cylinder head screws after applying sufficient oil.

• Tighten the cylinder head screws in order of (a) to (n or j).

• Tighten them uniformly, or the head may deform in the long run.

• Retighten the cylin der head screws after runni ng the engine for 30 minutes.

37.3 to 42.2 N·m

Tightening torque Cylinder head screw

3.8 to 4.3 kgf·m

27.5 to 31.1 ft-lbs

(1) Pipe Clamp (2) Water Return Pipe (3) O-ring

A : Gear Case Side (n or j) to (a) : To Loosen (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 the rm os tat cov er m oun tin g s crew s ( 1), and re mov e the thermostat cover (2).

2. Remove the thermostat assembly (4).

(When reassembling)

• Apply a liquid gasket (Three Bond 1215 or equivalent) only at the thermostat cover side of the gasket (3).

(1) Thermostat Cover Mounting Screw (2) Thermostat Cover

(3) Thermostat Cover Gasket (4) Thermostat Assembly

W10363950

S-32

SM-E2B SERIES, WSM

IMPORTANT■

KiSC issued 06, 2006 A

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.

• Do not change the combination of tappet and tappet guide.

(1) Tappet

W10209700

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 sp ring re tainer ( 2), va lve spr ing (5 ) and val ve stem seal (6).

4. Remove the valve (7).

(When reassembling)

• Wash the valve st em and valve guide hole, a nd app ly en gi ne o il sufficiently.

• After installing the valve spring collets, lightly tap the stem to assure proper fit with a plastic hammer.

• Don’t change the combination of valve and valve guide.

(1) Valve Spring Replacer (2) Valve Spring Retainer (3) Valve Spring Collet (4) Valve Cap

(5) Valve Spring (6) Valve Stem Seal (7) Valve

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SM-E2B SERIES, WS M

IMPORTANT■

KiSC issued 06, 2006 A

DIESEL ENGINE

Oil Pan and Oil Strainer

1. Remove the oil pan mounting screws (2).

2. Remove the o il p an (1) by lightly tappi ng the rim o f the pan wi th a wooden hammer.

3. Remove the oil strainer (3).

(When reassembling)

• After cleaning the oil strainer, check to see that the filter mesh in clean, and install it.

• Visually check the O-ring (4), apply engine oil, and install it.

• Securely fit the O-ring to the oil strainer.

• To avoid uneven tighte ning, tighten oil pan mountin g 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-E 2B, D782-E2B, D902-E2B

• Using the hole (5) numbered “3”, install the oil strainer by mounting screw

• Scrape off the old adhesive completely. Wipe th e sealing surface clean using waste cloth soaked with gasoline. Now apply new adhesive 3 to 5 mm (0.12 to 0.20 in.) thick all over the contact surface. Apply t he adhesive also on the cent er of the flange as well as on the inner wall of each bolt hole.

• Cut the nozzle of the “liquid gasket” (Three Bond 1207D or equivalent) container at its second notch. Apply “liquid gasket” about 3 to 5 mm (0.12 to 0.20 in.) thick. Within 20 minutes after the application of fluid sealant, reassemble the components. Wait then for about 30 minutes, and pour oil in the crankcase.

(1) Oil Pan (2) Oil Pan Mounting Screw (3) Oil Strainer (4) O-ring (5) Hole Numbered “3” (6) Hole Numbered “2”

[a] Z482-E2B, Z602-E2B [b] D662-E2B, D722-E2B,

D782-E2B, D902-E2B

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NOTE■

KiSC issued 06, 2006 A

(4) Gear Case and Timing Gears

DIESEL ENGINE

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. Remove the screws and separate the speed control p late (2), taking care not to damage the governor spring (4).

3. Disconnect the governor spring (4) and remove the speed control plate (2).

4. Remove the fuel feed pump (3).

(When reassembling)

• Hook the gover nor spring (4) to the governor lev er (5) first and install the speed control plate (2).

• Be sure to place the copper washers underneath two screws (8). (Two screws (8) in the upper of the speed control plate (2).)

• Position the slot (7) on the fork lever just under the slot (6) on the crankcase.

• Insert the injection pump (1) so that the control rod (10) should be pushed by the idling adju sting spring (9) at its end and th e pin (11) on the rod engages with the sl ot (7) on the fork lever (as shown in the photo).

• The sealant is applied to both sides of the soft metal gasket shim. The liquid gasket is not required for assembling.

• Addition or reduction of shim (0.05 mm, 0.0020 in.) delays or advances the injection timing by approx. 0.0087 rad (0.5 °).

• In disassembling and replacing, be sure to use the same number of new gasket shims with the same thickness.

(1) Injection Pump (2) Speed Control Plate (3) Fuel Feed Pump (4) Governor Spring (5) Governor Lever (6) Slot (Crankcase Side)

(7) Slot (Fork Lever Side) (8) Screw and Copper Washer

(9) Idling Adjusting Spring (10) Control Rod (11) Pin

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SM-E2B SERIES, WS M

NOTE■

KiSC issued 06, 2006 A

DIESEL ENGINE

Injection Pump, Fuel Feed Pump and Speed Control Plate (for Energize to Run Type Engine Stop Solenoid)

• 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.

1. Remove the socket head screws (3), and remove the engine stop solenoid (4).

2. Remove the screws and separate the speed control plate (6), taking care not to damage the governor spring (7).

3. Disconnect the governor spring (7) and remove the speed control plate (6) using the specific tool (1).

4. Remove the fuel feed pump (2).

5. Disconnect the start spring (8) from the bracket (9) using the specific tool (1).

6. Remove the socket head screws and nuts, and remove the injection pump (5).

(1) Specific Tool (2) Fuel Feed Pump (3) Socket Head Screw (4) Engine Stop Solenoid (5) Injection Pump

(6) Speed Control Plate (7) Governor Spring (8) Start Spring (9) Bracket

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S-36

SM-E2B SERIES, WSM

NOTE■

KiSC issued 06, 2006 A

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. Put the specific to ol (7) through the fork lever hole of cyl inder block (9) and hook the start spring (6).

4. Keep this spring slightly extended an d install the inj ection pump (4). Make sure the control rod (8) should be pushed by the idling adjusting spring (1) and the pin (5 ) on th e rod enga ges with the fork lever (2).

5. Hook the start spring (6) to the bracket (3) using the specific tool (7).

6. Hook the governor springs (small and large) (14) to the governor lever (13) using the specific tool (7) and install the speed control plate (11). Be sure to place the copper washers underneath two screws (12) in the upper of the speed control plate.

7. Install the engine stop solenoid rod (15) to the guide hole of cylinder block (10) and fix the engine stop solenoid (16) with socket head screws.

• Be careful not to stretch the start spring (6) too long. Otherwise it may get deformed permanently.

• Make sure the start spring (6) is tight on the bracket (3).

• The sealant is applied to both sides of the soft metal gasket shim. The liquid gasket is not required for assembling.

• Addition or reduction of shim (0.05 mm, 0.0020 in.) delays or advances the injection timing by approx. 0.0087 rad (0.5 °).

• In disassembling and replacing, be sure to use the same number of new gasket shims with the same thickness.

(1) Idling Adjusting Spring (2) Fork Lever (3) Bracket (4) Injection Pump (5) Injection Pump Control Rack Pin (6) Start Spring (7) Specific Tool (8) Injection Pump Control Rod

(9) Fork Lever Hole of Cylinder Block

(10) Guide Hole of Cylinder Block

(11) Speed Control Plate (12) Screw and Copper Washer (13) Governor Lever (14) Governor Spring (15) Engine Stop Solenoid Rod (16) Engine Stop Solenoid

W1028534

S-37

Aixam Roadline, Scouty R User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

TO THE READER

GENERAL

MECHANISM

SERVICING