Kubota SM-E4B Workshop Manual

WORKSHOP MANUAL

KiSC issued 01, 2013 A

DIESEL ENGINE

SM-E4B SERIES

TO THE READER

KiSC issued 01, 2013 A

This Workshop Manual tells the servicing personnel about the mechanism, servicing and

maintenance of SM-E4B series. It contains 4 parts: "Information", "General", "Mechanism" and
"Servicing".

Q Information

This section primarily contains information below.

• Safety First

• Specification

• Performance Curve

• Dimension

Q General

This section primarily contains information below.

• Engine Identification

• General Precautions

• Maintenance Check List

• Check and Maintenance

• Special Tools

Q Mechanism

This section contains information on the structure and the function of the unit. Before you continue

with the subsequent sections, make sure that you read this section.

Refer to the latest version of Workshop Manual (Code No. 9Y021-01870 / 9Y021-18200) for the

diesel engine / tractor mechanism that this workshop manual does not include.

Q Servicing

This section primarily contains information below.

• Troubleshooting

• Servicing Specifications

• Tightening Torques

• Checking, Disassembling and Servicing

All illustrations, photographs and specifications contained in this manual are of the newest

information available at the time of publication.

KUBOTA reserves the right to change all information at any time without notice.
Since this manual includes many models, information or illustrations and photographs can show

more than one model.

December, 2012

© KUBOTA Corporation 2012

I INFORMATION

KiSC issued 01, 2013 A

INFORMATION

KiSC issued 01, 2013 A

CONTENTS

1. SAFETY FIRST .............................................................................................................................. I-1

2. SPECIFICATIONS.......................................................................................................................... I-4

3. PERFORMANCE CURVES ............................................................................................................I-6

4. DIMENSIONS ............................................................................................................................... I-11

SM-E4B SERIES, WSM

SAFETY FIRST

DANGER

WARNING

CAUTION

IMPORTANT

NOTE

KiSC issued 01, 2013 A

INFORMATION

1. SAFETY FIRST

• This symbol, the industry's "Safety Alert Symbol", is used throughout this manual and on labels on the
machine itself to warn of the possibility of personal injury. Read these instructions carefully.

• It is essential that you read the instructions and safety regulations before you try to repair or use this
unit.

• Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

• Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

• Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate
injury.

• Indicates that equipment or property damage could result if instructions are not followed.

• Gives helpful information.

WSM000001INI0001US1

BEFORE YOU START SERVICE

• 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 stable and level ground.

• Let the temperature of the engine decrease before
you start a job.

• Stop the engine, then remove the key.

• Disconnect the battery negative cable.

• Hang a "DO NOT OPERATE" tag in the operator
station.

WSM000001INI0002US0

START SAFELY

• Do not do the procedures below when you start the
engine.
– short across starter terminals
– bypass the safety start switch

• Do not make unauthorized modifications to the
engine. This can cause damage and decrease the
engine life.

WSM000001INI0003US0

I-1

SM-E4B SERIES, WSM

KiSC issued 01, 2013 A

INFORMATION

OPERATE SAFELY

• Do not use the machine after you consume alcohol
or medication or when you are tired.

• Put on applicable clothing and safety equipment.

• Use applicable tools only. Do not use alternative
tools or parts.

• When 2 or more persons do servicing, make sure
that you do it safely.

• Do not touch the hot parts or parts that turn when the
engine operates.

• Do not remove the radiator cap when the engine
operates, or immediately after it stops. If not, hot
water can spout out from the radiator. Only remove
the radiator cap when it is at a sufficiently low
temperature to touch with bare hands. Slowly loosen
the cap to release the pressure before you remove it
fully.

• Released fluid (fuel or hydraulic oil) under pressure
can cause damage to the skin and cause serious
injury. Release the pressure before you disconnect
hydraulic or fuel lines. Tighten all connections before
you apply the pressure.

• Do not open a fuel system under high pressure.
The fluid under high pressure that stays in fuel lines
can cause serious injury. Do not disconnect or repair
the fuel lines, sensors, or any other components
between the fuel pump and injectors on engines with
a common rail fuel system under high pressure.

• Put on an applicable ear protective device (earmuffs
or earplugs) to prevent injury against loud noises.

• Be careful about electric shock. The engine
generates a high voltage of more than DC100 V in
the ECU and is applied to the injector.

WSM000001INI0004US0

PREVENT A FIRE

• Fuel is very flammable and explosive under some
conditions. Do not smoke or let flames or sparks in
your work area.

• To prevent sparks from an accidental short circuit,
always disconnect the battery negative cable first
and connect it last.

• The battery gas can cause an explosion. Keep the
sparks and open flame away from the top of battery,
especially when you charge the battery.

• Make sure that you do not spill fuel on the engine.

WSM000001INI0005US1

I-2

SM-E4B SERIES, WSM

KiSC issued 01, 2013 A

INFORMATION

KEEP A GOOD AIRFLOW IN THE WORK AREA

• If the engine is in operation, make sure that the area
has good airflow. Do not operate the engine in a
closed area. The exhaust gas contains poisonous
carbon monoxide.

WSM000001INI0006US1

DISCARD FLUIDS CORRECTLY

• Do not discard fluids on the ground, down the drain,
into a stream, pond, or lake. Obey related
environmental protection regulations when you
discard oil, fuel, coolant, electrolyte and other
dangerous waste.

WSM000001INI0007US1

PREVENT ACID BURNS

• Keep electrolyte away from your eyes, hands and
clothing. Sulfuric acid in battery electrolyte is
poisonous and it can burn your skin and clothing and
cause blindness. If you spill electrolyte on yourself,
clean yourself with water, and get medical aid
immediately.

WSM000001INI0008US1

PREPARE FOR EMERGENCIES

• Keep a first aid kit and fire extinguisher ready at all
times.

• Keep the emergency contact telephone numbers
near your telephone at all times.

WSM000001INI0009US1

I-3

SM-E4B SERIES, WSM

KiSC issued 01, 2013 A

INFORMATION

2. SPECIFICATIONS

Model Z482-E4B Z602-E4B

Number of Cylinder 2

Type Vertical, Water-cooled, 4 cycle IDI diesel engine

Bore × Stroke 67.0 × 68.0 mm (2.64 × 2.68 in.) 72.0 × 73.6 mm (2.83 × 2.90 in.)

Total Displacement 479.0 cm

ISO Net Continuous

ISO / SAE Net Intermittent

SAE Gross Intermittent

8.10 kW / 3600 min

(10.9 HP / 3600 min

9.30 kW / 3600 min

(12.5 HP / 3600 min

9.90 kW / 3600 min

(13.3 HP / 3600 min

Maximum Bare Speed 3800 min

Minimum Bare Idling Speed 1250 to 1350 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 0.33 rad (19 °) before T.D.C.

Firing Order 1-2

Injection Pressure 13.73 MPa (140.0 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

EGR None

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

Oil Pan Depth

Lubricating Oil
Capacity

101 mm (3.98 in.)

Oil Pan Depth
121 mm (4.76 in.)

Weight (Dry) 53.1 kg (117 lbs) 57.0 kg (125.7 lbs)

*The specification described above is of the standard engine of each model.
*Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW

3

(29.23 cu.in.) 599.0 cm3 (36.55 cu.in.)

-1

(rpm)

-1

(rpm))

-1

(rpm)

-1

(rpm))

-1

(rpm)

-1

(rpm))

-1

(rpm) 3850 min-1 (rpm)

-1

(rpm) 1050 to 1150 min-1 (rpm)

10.1 kW / 3600 min

(13.5 HP / 3600 min

11.6 kW / 3600 min

(15.5 HP / 3600 min

12.5 kW / 3600 min

(16.8 HP / 3600 min

2

, 1991 psi)

-1

(rpm)

-1

(rpm))

-1

(rpm)

-1

(rpm))

-1

(rpm)

-1

(rpm))

Class CF lubricating oil as per API classification is recommended.

For details on recommended lubricating oils, see page G-6

2.1 L (0.55 U.S.gals) 2.5 L (0.66 U.S.gals)

2.5 L (0.66 U.S.gals) –

I-4

SM-E4B SERIES, WSM

KiSC issued 01, 2013 A

INFORMATION

Model D722-E4B D782-E4B D902-E4B

Number of Cylinder 3

Type Vertical, Water-cooled, 4 cycle IDI diesel engine

Bore × Stroke 67.0 × 68.0 mm (2.64 × 2.68 in.) 67.0 × 73.6 mm (2.64 × 2.90 in.) 72.0 × 73.6 mm (2.83 × 2.90 in.)

3

Total Displacement 719.0 cm

ISO Net Continuous

ISO / SAE Net Intermittent

SAE Gross Intermittent

12.2 kW / 3600 min

(16.3 HP / 3600 min

14.0 kW / 3600 min

(18.8 HP / 3600 min

14.9 kW / 3600 min

(20.0 HP / 3600 min

Maximum Bare Speed 3800 min

Minimum Bare Idling Speed 1250 to 1350 min

(43.88 cu.in.) 778.0 cm3 (47.48 cu.in.) 898.0 cm3 (54.80 cu.in.)

-1

(rpm)

-1

(rpm))

-1

(rpm)

-1

(rpm))

-1

(rpm)

-1

(rpm))

-1

(rpm) 3450 min-1 (rpm) 3850 min-1 (rpm)

-1

(rpm) 1000 to 1100 min-1 (rpm) 900 to 1000 min-1 (rpm)

11.9 kW / 3200 min

(16.0 HP / 3200 min

13.5 kW / 3200 min

(18.1 HP / 3200 min

14.4 kW / 3200 min

(19.3 HP / 3200 min

-1

(rpm)

-1

(rpm))

-1

(rpm)

-1

(rpm))

-1

(rpm)

-1

(rpm))

15.2 kW / 3600 min

(20.4 HP / 3600 min

17.5 kW / 3600 min

(23.5 HP / 3600 min

18.5 kW / 3600 min

(24.8 HP / 3600 min

-1

(rpm)

-1

(rpm))

-1

(rpm)

-1

(rpm))

-1

(rpm)

-1

(rpm))

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. 0.30 rad (17 °) before T.D.C. 0.331 rad (19 °) before T.D.C.

Firing Order 1-2-3

2

Injection Pressure 13.73 MPa (140.0 kgf/cm

, 1991 psi)

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, 1.0 kW 12 V, 1.2 kW

Starting Support Device By glow plug in combustion chamber

EGR None

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)

Lubricating Oil

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) – 3.7 L (0.98 U.S.gals)

3.8 L (1.0 U.S.gals) 3.6 L (0.95 U.S.gals) –

Class CF lubricating oil as per API classification is recommended.

For details on recommended lubricating oils, see page G-6.

Weight (Dry) 63.1 kg (139.1 lbs) 63.5 kg (140 lbs) 72.0 kg (159 lbs)

*The specification described above is of the standard engine of each model.
*Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW

9Y1210785INI0001US0

I-5

SM-E4B SERIES, WSM

KiSC issued 01, 2013 A

3. PERFORMANCE CURVES

Z482-E4B

INFORMATION

(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) Continuous Torque

(15) Gross B.H.P.
(16) Overload B.H.P.
(17) Continuous B.H.P.
(18) Overload B.S.F.C.

9Y1210785INI0002US0

I-6

SM-E4B SERIES, WSM

KiSC issued 01, 2013 A

Z602-E4B

INFORMATION

(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.

9Y1210785INI0003US0

I-7

SM-E4B SERIES, WSM

KiSC issued 01, 2013 A

D722-E4B

INFORMATION

(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) Continuous Torque

(15) Gross B.H.P.
(16) Overload B.H.P.
(17) Continuous B.H.P.
(18) Overload B.S.F.C.

9Y1210785INI0004US0

I-8

SM-E4B SERIES, WSM

KiSC issued 01, 2013 A

D782-E4B

INFORMATION

(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.

9Y1210785INI0005US0

I-9

SM-E4B SERIES, WSM

KiSC issued 01, 2013 A

D902-E4B

INFORMATION

(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.

9Y1210785INI0006US0

I-10

SM-E4B SERIES, WSM

KiSC issued 01, 2013 A

4. DIMENSIONS

Z482-E4B

INFORMATION

9Y1210785INI0007US0

I-11

SM-E4B SERIES, WSM

KiSC issued 01, 2013 A

Z602-E4B

INFORMATION

9Y1210785INI0008US0

I-12

SM-E4B SERIES, WSM

KiSC issued 01, 2013 A

D722-E4B

INFORMATION

9Y1210785INI0009US0

I-13

SM-E4B SERIES, WSM

KiSC issued 01, 2013 A

D782-E4B

INFORMATION

9Y1210785INI0010US0

I-14

SM-E4B SERIES, WSM

KiSC issued 01, 2013 A

D902-E4B

INFORMATION

9Y1210785INI0011US0

I-15

G GENERAL

KiSC issued 01, 2013 A

GENERAL

KiSC issued 01, 2013 A

CONTENTS

1. ENGINE IDENTIFICATION .......................................................................................................... G-1

[1] MODEL NAME AND ENGINE SERIAL NUMBER.................................................................. G-1

[2] E4B ENGINE .......................................................................................................................... G-3

[3] CYLINDER NUMBER ............................................................................................................. G-3

2. GENERAL PRECAUTION ............................................................................................................G-4

3. MAINTENANCE CHECK LIST ..................................................................................................... G-5

4. CHECK AND MAINTENANCE ..................................................................................................... G-7

[1] DAILY CHECK POINTS ......................................................................................................... G-7

[2] CHECK POINTS OF INITIAL 50 HOURS .............................................................................. G-9

[3] CHECK POINT OF EVERY 50 HOURS ............................................................................... G-11

[4] CHECK POINTS OF EVERY 75 HOURS ............................................................................ G-12

[5] CHECK POINTS OF EVERY 100 HOURS .......................................................................... G-13

[6] CHECK POINTS OF EVERY 150 HOURS .......................................................................... G-15

[7] CHECK POINTS OF EVERY 200 HOURS .......................................................................... G-16

[8] CHECK POINTS OF EVERY 400 HOURS .......................................................................... G-17

[9] CHECK POINTS OF EVERY 500 HOURS .......................................................................... G-18

[10]CHECK POINTS OF EVERY 1 OR 2 MONTHS .................................................................. G-20

[11]CHECK POINT OF EVERY YEAR ....................................................................................... G-22

[12]CHECK POINT OF EVERY 800 HOURS ............................................................................. G-23

[13]CHECK POINTS OF EVERY 1500 HOURS ........................................................................ G-24

[14]CHECK POINTS OF EVERY 3000 HOURS ........................................................................ G-26

[15]CHECK POINTS OF EVERY 2 YEARS ............................................................................... G-29

....

5. SPECIAL TOOLS ...................................................................................................................

G-33

SM-E4B SERIES, WSM

KiSC issued 01, 2013 A

1. ENGINE IDENTIFICATION

[1] MODEL NAME AND ENGINE SERIAL NUMBER

When contacting the manufacture, always specify your engine

model name and serial number.

The engine model and its serial number need to be identified

before the engine can be serviced or parts replaced.

Q Engine Serial Number

The engine serial number is an identification number.
It is marked after the engine model name.
It indicates the engine series, the production year and month,

and the lot number.

Engine Series

Number or

Alphabet

1 05 (include: WG) 6

2V3703

308807

4 SM (include: WG) A EA, RK

5

Series

Air Cooled

Gasoline

Number or

Alphabet

B

GENERAL

Series

GZ, OC, AC, EA,

E

03 (KET

Production)

Production Year

Alphabet or

Number

1 2001 F 2015

2 2002 G 2016

3 2003 H 2017

4 2004 J 2018

5 2005 K 2019

6 2006 L 2020

7 2007 M 2021

8 2008 N 2022

9 2009 P 2023

A 2010 R 2024

B 2011 S 2025

C 2012 T 2026

D 2013 V 2027

E 2014

(1) Engine Model Name and Serial

Number

Year

Alphabet or

Number

Yea r

(To be continued)

G-1

SM-E4B SERIES, WSM

KiSC issued 01, 2013 A

(Continued)

Production Month and Lot Number

Month Engine Lot Number

January A0001 ~ A9999 B0001 ~

February C0001 ~ C9999 D0001 ~

March E0001 ~ E9999 F0001 ~

April G0001 ~ G9999 H0001 ~

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 ~

* Alphabetical letters "I" and "O" are not used.

(a)

e.g. D902

(a) D902: Engine Model Name
(b) 4: Engine Series (SM series)
(c) C: Production Year (2012)
(d) W: Production Month (November)
(e) 1237: Lot Number: (0001 ~ 9999 or A001 ~ Z999)

(b)C(c)W(d)

- 4

(e)

1237

GENERAL

9Y1210785GEG0001US0

G-2

SM-E4B SERIES, WSM

KiSC issued 01, 2013 A

GENERAL

[2] E4B ENGINE

[Example : Engine Model Name D902-E4B-XXXX]

The emission controls previously implemented in various countries to prevent air pollution will be stepped up as
Non-Road Emission Standards continue to change. The timing or applicable date of the specific Non-Road Emission
regulations depends on the engine output classification.

Over the past several years, KUBOTA has been supplying diesel engines that comply with regulations in the
respective countries affected by Non-Road Emission regulations. For KUBOTA Engines, E4B will be the designation
that identifies engine models affected by the next emission phase (See the table below).

When servicing or repairing ###-E4B series engines, use only replacement parts for that specific E4B engine,
designated by the appropriate E4B KUBOTA Parts List and perform all maintenance services listed in the appropriate
KUBOTA Operator's Manual or in the appropriate E4B KUBOTA Workshop Manual. Use of incorrect replacement
parts or replacement parts from other emission level engines (for example: E2B engines), may result in emission
levels out of compliance with the original E4B design and EPA or other applicable regulations. Please refer to the
emission label located on the engine head cover to identify Output classification and Emission Control Information.
E4B engines are identified with "EF" at the end of the Model designation, on the US EPA label. Please note : E4B is
not marked on the engine.

Category (1) Engine output classification EPA regulation

EF Less than 19 kW Tier 4

(1) "E4B" engines are identified with "EF" at the end of the Model designation, on

the US EPA label.
"E4B" designates Tier 4, depending on engine output classification.

9Y1210785GEG0002US0

[3] CYLINDER NUMBER

The cylinder numbers of KUBOTA diesel engine are designated

as shown in the figure.

The sequence of cylinder numbers is given as No.1, No.2 and

No.3 starting from the gear case side.

9Y1210785GEG0003US0

G-3

SM-E4B SERIES, WSM

KiSC issued 01, 2013 A

2. GENERAL PRECAUTION

• When you disassemble, carefully put the parts in a clean area
to make it easy to find the parts. You must install the screws,
bolts and nuts in their initial position to prevent the reassembly
errors.

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

• Before you disassemble or repair machine, make sure that you
always disconnect the ground cable from the battery first.

• Remove oil and dirt from parts before you measure.

• Use only KUBOTA genuine parts for replacement to keep the
machine performance and to make sure of safety.

• You must replace the gaskets and O-rings when you assemble
again. Apply grease (1) to new O-rings or oil seals before you
assemble.

• When you assemble the external or internal snap rings, make
sure that the sharp edge (3) faces against the direction from
which force (2) is applied.

• Make sure that you try to operate the engine after you repair or
assemble it. Do not try to give a heavy load immediately, if not,
you can cause serious damage to the engine.

(1) Grease
(2) Force
(3) Sharp Edge

GENERAL

(A) External Snap Ring
(B) Internal Snap Ring

WSM000001GEG0091US0

G-4

SM-E4B SERIES, WSM

CAUTION

KiSC issued 01, 2013 A

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

50 hrs 75 hrs

*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 ,

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.) ,

(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.)

,

+,

+,

+,

+,

+,

+,

100
hrs

,

150
hrs

200
hrs

,

• (1) : This oil pan depth is optional for Z482-E4B and D722-E4B.

• (2) : This oil pan depth is standard for Z482-E4B, D722-E4B and D782-E4B.

• (3) : This oil pan depth is standard for Z602-E4B and D902-E4B.

• + : Change engine oil and replace oil filter cartridge after the first 50 hours of operation.

• * : The items listed above (* marked) are registered as emission related critical parts by KUBOTA in the U.S. EPA
nonroad emission regulation. As the engine owner, you are responsible for the performance of the required
maintenance on the engine according to the above instruction.

400
hrs

Every

500

hrs

,

1 or 2

months

1 year

800
hrs

1500

hrs

3000

hrs2 years

,

,

• When changing or inspecting, be sure to level and stop the engine.

9Y1210785GEG0004US0

G-5

SM-E4B SERIES, WSM

NOTE

KiSC issued 01, 2013 A

GENERAL

Engine Oil :

• Refer to the following table for the suitable American Petroleum Institute (API) classification of engine oil
according to the engine type (with internal EGR, external EGR or non-EGR) and the Fuel Type Used :
(Low Sulfur, Ultra Low Sulfur or High Sulfur Fuels).

Engine oil classification (API classification)

Fuel Type

High Sulfur Fuel
[0.05 % (500 ppm) ≤
Sulfur Content <

0.50 % (5000 ppm)]

CF

(If the "CF-4, CG-4, CH-4, or CI-4" engine
oil is used with a high-sulfur fuel, change
the engine oil at shorter intervals.
(approximately half))

Engines with non-EGR

Engines with internal EGR

Engines with external EGR

–

Low Sulfur Fuel
[Sulfur Content <

0.05 % (500 ppm)] or

Ultra Low Sulfur Fuel
[Sulfur Content <

CF, CF-4, CG-4, CH-4 or CI-4

CF or CI-4

(Class CF-4, CG-4 and CH-4 engine oils
cannot be used on EGR type engines.)

0.0015 % (15 ppm)]

EGR : Exhaust Gas Re-circulation

• CJ-4 classification oil is intended for use in engines equipped with DPF (Diesel Particulate Filter) and is
Not Recommended for use in KUBOTA E3 specification engines.

• Oil used in the engine should have API classification and Proper SAE Engine Oil Viscosity according to
the ambient temperatures where the engine is operated.

• With strict emission control regulations now in effect, the CF-4 and CG-4 engine oils have been developed
for use with low sulfur fuels, for On-Highway vehicle engines. When a Non-Road engine runs on high
sulfur fuel, it is advisable to use a "CF or better" classification engine oil with a high Total Base Number
(a minimum TBN of 10 is recommended).

Fuel :

• Cetane Rating : The minimum recommended Fuel Cetane Rating is 45. A cetane rating greater than 50 is
preferred, especially for ambient temperatures below −20 °C (−4 °F) or elevations above 1500 m (5000 ft).

• Diesel Fuel Specification Type and Sulfur Content % (ppm) used, must be compliant with all applicable
emission regulations for the area in which the engine is operated.

• Use of diesel fuel with sulfur content less than 0.10 % (1000 ppm) is strongly recommended.

• If high-sulfur fuel (sulfur content 0.50 % (5000 ppm) to 1.0 % (10000 ppm)) is used as a diesel fuel, change
the engine oil and oil filter at shorter intervals. (approximately half)

• DO NOT USE Fuels that have sulfur content greater than 1.0 % (10000 ppm).

• Diesel fuels specified to EN 590 or ASTM D975 are recommended.

• No.2-D is a distillate fuel of lower volatility for engines in industrial and heavy mobile service. (SAE J313
JUN87)

• Since KUBOTA diesel engines of less than 56 kW (75 hp) utilize EPA Tier 4 and Interim Tier 4 standards,
the use of low sulfur fuel or ultra low sulfur fuel is mandatory for these engines, when operated in US EPA
regulated areas. Therefore, please use No.2-D S500 or S15 diesel fuel as an alternative to No.2-D, and use
No.1-D S500 or S15 diesel fuel as an alternative to No.1-D for ambient temperatures below −10 °C (14 °F).

1) SAE : Society of Automotive Engineers

2) EN : European Norm

3) ASTM : American Society of Testing and Materials

4) US EPA : United States Environmental Protection Agency

5) No.1-D or No.2-D, S500 : Low Sulfur Diesel (LSD) less than 500 ppm or 0.05 wt.%
No.1-D or No.2-D, S15 : Ultra Low Sulfur Diesel (ULSD) 15 ppm or 0.0015 wt.%

9Y1210785GEG0005US0

G-6

SM-E4B SERIES, WSM

IMPORTANT

NOTE

KiSC issued 01, 2013 A

4. CHECK AND MAINTENANCE

[1] DAILY CHECK POINTS

Checking Engine Oil Level

1. Level the engine.

2. To check the oil level, draw out the dipstick (1), wipe it clean,
reinsert it, and draw it out again.
Check to see that the oil level lies between the two notches.

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 gradients, 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

GENERAL

9Y1210785GEG0006US0

G-7

SM-E4B SERIES, WSM

CAUTION

IMPORTANT

KiSC issued 01, 2013 A

GENERAL

Checking and Replenish Coolant

1. Without recovery tank (2) :
Remove the radiator cap (1) and check to see that the coolant
level is just below the port.
With recovery tank (2) :
Check to see that the coolant level lies between FULL "A" and
LOW "B".

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 leak, replenish coolant of the same

manufacture and type in the specified mixture ratio (fresh, soft 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.

• 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.

• 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

9Y1210785GEG0007US0

G-8

SM-E4B SERIES, WSM

CAUTION

IMPORTANT

KiSC issued 01, 2013 A

[2] CHECK POINTS OF INITIAL 50 HOURS

Changing Engine Oil

• 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 drain plug (2) at the bottom 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).

• 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 CF
(See page G-6).

• 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) SAE 30 or SAE 10W-30, SAE 10W-40

0 °C to 25 °C (32 °F to 77 °F) SAE 20 or SAE 10W-30, SAE 10W-40

Below 0 °C (32 °F)

GENERAL

SAE 10W or SAE 10W-30,
SAE 10W-40

Model

101 mm (3.98 in.) 121 mm (4.76 in.)

*Z482-E4B

*D722-E4B

D782-E4B –

Z602-E4B

D902-E4B

*101 mm (3.98 in.) oil pan depth is optional.

Drain plug with

Tightening
torque

copper gasket

Drain plug with
rubber coated
gasket

2.1 L

0.55 U.S.gals

3.2 L

0.85 U.S.gals

2.5 L

0.66 U.S.gals

3.7 L

0.98 U.S.gals

M12 × 1.25

M22 × 1.5

M22 × 1.5

Engine oil capacity

Oil pan depth

2.5 L

0.66 U.S.gals

3.8 L

1.0 U.S.gals

3.6 L

0.95 U.S.gals

–

–

33 to 37 N·m

3.3 to 3.8 kgf·m
24 to 27 lbf·ft

64 to 73 N·m

6.5 to 7.5 kgf·m
47 to 54 lbf·ft

45 to 53 N·m

4.5 to 5.5 kgf·m
33 to 39 lbf·ft

(1) Dipstick (2) Drain Plug

9Y1210785GEG0008US0

G-9

SM-E4B SERIES, WSM

CAUTION

IMPORTANT

NOTE

KiSC issued 01, 2013 A

GENERAL

Replacing Oil Filter Cartridge

• 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 little. Thus see that the engine oil does not
leak through the seal and be sure to read the oil level on the
dipstick. Then, replenish the engine oil up to the specified level.

• 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
Z482-E4B and D722-E4B. This service interval is every 150
hours.

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

[b] One-side Maintenance Type

9Y1210785GEG0009US0

G-10

SM-E4B SERIES, WSM

CAUTION

NOTE

KiSC issued 01, 2013 A

[3] CHECK POINT OF EVERY 50 HOURS

Checking Fuel Hose

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

2. The fuel hose (1) is made of rubber and ages regardless of the
period service.
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.

• 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 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.

GENERAL

• 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

[A] Cartridge Type
[B] Element Type

9Y1210785GEG0010US0

G-11

SM-E4B SERIES, WSM

CAUTION

IMPORTANT

KiSC issued 01, 2013 A

[4] CHECK POINTS OF EVERY 75 HOURS

Changing Engine Oil (for Optional Depth Oil Pans)

• 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 drain plug (2) at the bottom 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).

• 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 CF
(See page G-6).

• 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) SAE 30 or SAE 10W-30, SAE 10W-40

0 °C to 25 °C (32 °F to 77 °F) SAE 20 or SAE 10W-30, SAE 10W-40

Below 0 °C (32 °F)

GENERAL

SAE 10W or SAE 10W-30
SAE 10W-40

Model

101 mm (3.98 in.) 121 mm (4.76 in.)

*Z482-E4B

*D722-E4B

D782-E4B –

Z602-E4B

D902-E4B

*101 mm (3.98 in.) oil pan depth is optional.

Drain plug with

Tightening
torque

copper gasket

Drain plug with
rubber coated
gasket

2.1 L

0.55 U.S.gals

3.2 L

0.85 U.S.gals

2.5 L

0.66 U.S.gals

3.7 L

0.98 U.S.gals

M12 × 1.25

M22 × 1.5

M22 × 1.5

Engine oil capacity

Oil pan depth

2.5 L

0.66 U.S.gals

3.8 L

1.0 U.S.gals

3.6 L

0.95 U.S.gals

–

–

33 to 37 N·m

3.3 to 3.8 kgf·m
24 to 27 lbf·ft

64 to 73 N·m

6.5 to 7.5 kgf·m
47 to 54 lbf·ft

45 to 53 N·m

4.5 to 5.5 kgf·m
33 to 39 lbf·ft

(1) Dipstick (2) Drain Plug

9Y1210785GEG0011US0

G-12

SM-E4B SERIES, WSM

CAUTION

IMPORTANT

KiSC issued 01, 2013 A

[5] CHECK POINTS OF EVERY 100 HOURS

Changing Engine Oil (for Standard Depth Oil Pans)

• 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 drain plug (2) at the bottom 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).

• 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 CF
(See page G-6).

• 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) SAE 30 or SAE 10W-30, SAE 10W-40

0 °C to 25 °C (32 °F to 77 °F) SAE 20 or SAE 10W-30, SAE 10W-40

Below 0 °C (32 °F)

GENERAL

SAE 10W or SAE 10W-30
SAE 10W-40

Model

101 mm (3.98 in.) 121 mm (4.76 in.)

*Z482-E4B

*D722-E4B

D782-E4B –

Z602-E4B

D902-E4B

*101 mm (3.98 in.) oil pan depth is optional.

Drain plug with

Tightening
torque

copper gasket

Drain plug with
rubber coated
gasket

2.1 L

0.55 U.S.gals

3.2 L

0.85 U.S.gals

2.5 L

0.66 U.S.gals

3.7 L

0.98 U.S.gals

M12 × 1.25

M22 × 1.5

M22 × 1.5

Engine oil capacity

Oil pan depth

2.5 L

0.66 U.S.gals

3.8 L

1.0 U.S.gals

3.6 L

0.95 U.S.gals

–

–

33 to 37 N·m

3.3 to 3.8 kgf·m
24 to 27 lbf·ft

64 to 73 N·m

6.5 to 7.5 kgf·m
47 to 54 lbf·ft

45 to 53 N·m

4.5 to 5.5 kgf·m
33 to 39 lbf·ft

(1) Dipstick (2) Drain Plug

9Y1210785GEG0012US0

G-13

SM-E4B SERIES, WSM

NOTE

KiSC issued 01, 2013 A

GENERAL

Fan Belt Tension

1. Measure the deflection (A), depressing the belt halfway

between the fan drive pulley and alternator pulley at specified
force 98 N (10 kgf, 22 lbf).

2. If the measurement is not within the factory specifications,
loosen the alternator mounting screws and relocate the
alternator to adjust.

Deflection (A) Factory specification

(A) Deflection

7.0 to 9.0 mm

0.28 to 0.35 in.

9Y1210785GEG0013US0

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 nearly worn out and deeply sunk in the pulley
groove, replace it.

(A) Good (B) Bad

9Y1210785GEG0014US0

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

2

, 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.

9Y1210785GEG0015US0

G-14

SM-E4B SERIES, WSM

IMPORTANT

CAUTION

IMPORTANT

KiSC issued 01, 2013 A

GENERAL

Cleaning Fuel Filter (Element Type only)

1. Close the fuel cock (3).

2. Unscrew the retaining ring (6) and remove the filter cup (5), and
rinse the inside with kerosene.

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

4. 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 prevent 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

9Y1210785GEG0016US0

Checking Battery Electrolyte Level

1. Check the battery electrolyte level.

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

9Y1210785GEG0017US0

[6] CHECK POINTS OF EVERY 150 HOURS

Replacing Oil Filter Cartridge (for Optional Depth Oil Pans)

• 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 little. Thus see that the engine oil does not
leak through the seal and be sure to read the oil level on the
dipstick. Then, replenish the engine oil up to the specified level.

• 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

9Y1210785GEG0018US0

G-15

SM-E4B SERIES, WSM

CAUTION

IMPORTANT

IMPORTANT

KiSC issued 01, 2013 A

[7] CHECK POINTS OF EVERY 200 HOURS

Replacing Oil Filter Cartridge (for Standard Depth Oil Pans)

• 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 little. Thus see that the engine oil does not
leak through the seal and be sure to read the oil level on the
dipstick. Then, replenish the engine oil up to the specified level.

• 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

GENERAL

[b] One-side Maintenance Type

9Y1210785GEG0019US0

Checking Radiator Hoses and Clamp Bands

1. Check to see if the radiator hoses are properly fixed every 200
hours of operation or every six months, whichever comes first.

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

3. The water hose is made of rubber and tens to age. It must be
replaced every two years. Also replace the clamp and tighten it
securely.

(1) Upper Hose (2) Lower Hose

9Y1210785GEG0020US0

Checking Intake Air Line

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

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

3. The intake air hose(s) (1) and the breather hose (3) are made of
rubber and tends to age. It must be changed every two years.
Also change the clamp (2) 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

9Y1210785GEG0021US0

G-16

SM-E4B SERIES, WSM

KiSC issued 01, 2013 A

[8] CHECK POINTS OF EVERY 400 HOURS

Replacing Fuel Filter Cartridge (Cartridge Type)

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

change the filter cartridge every 400 hours service.

1. Remove the used filter cartridge with filter wrench.

2. Apply a thin film of fuel to the surface of new filter cartridge
gasket before screwing 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 retaining ring (6) and remove the filter 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

GENERAL

9Y1210785GEG0022US0

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

9Y1210785GEG0023US0

G-17

SM-E4B SERIES, WSM

CAUTION

IMPORTANT

KiSC issued 01, 2013 A

[9] CHECK POINTS OF EVERY 500 HOURS

Cleaning Water Jacket and Radiator Interior

• 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 radiator cap (1) must be
removed 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.

GENERAL

• 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
anti-freeze 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

9Y1210785GEG0024US0

G-18

SM-E4B SERIES, WSM

IMPORTANT

NOTE

KiSC issued 01, 2013 A

GENERAL

Anti-Freeze

• There are two types of anti-freeze available: use the permanent
type (PT) for this engine.

• Before adding anti-freeze for the first time, clean the radiator
interior by pouring fresh, soft water and draining it a few times.

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

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

Vol %

anti-freeze

40 –24 –11 106 223

50 –37 –35 108 226

* At 1.013 × 100000 Pa (760 mmHg) pressure (atmospheric). A higher boiling point
is obtained by using a radiator pressure cap which permits the development of
pressure within the cooling system.

Freezing point Boiling point*

°C °F °C °F

• The above data represents industrial standards that
necessitate a minimum glycol 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 absorbs moisture. Keep unused anti-freeze 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.)

9Y1210785GEG0025US0

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.

7.0 to 9.0 mm / 98 N

Deflection (A) Factory specification

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

(1) Fan Belt (A) Deflection

9Y1210785GEG0026US0

G-19

SM-E4B SERIES, WSM

CAUTION

KiSC issued 01, 2013 A

[10] CHECK POINTS OF EVERY 1 OR 2 MONTHS

Recharging

• 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
the 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 instructions.

3. As the electrolyte generates gas while charging, remove all port
caps.

4. The electrolyte temperature must not exceed 40 °C (104 °F)
during charging.
If it exceed 40 °C (104 °F), decrease the charging amperage 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.

Q Precaution for Operating a Quick Charger

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

GENERAL

9Y1210785GEG0027US0

G-20

SM-E4B SERIES, WSM

CAUTION

NOTE

KiSC issued 01, 2013 A

GENERAL

Battery Specific Gravity

• If battery acid (dilute sulfuric acid) gets on you it could
cause blindness or burns, or could cause corrosion of
machinery and tools so please be careful when handling.

• Wear safety glasses and rubber gloves when performing
battery maintenance and inspection (measuring specific
gravity, replenishing water, or charging).

• If the gas that is generated is ignited by an ignition source,
it may explode so be very careful with sparks and fire.

• Keep your body and face as far away from the battery as
you can when performing maintenance and inspection.

• Do not allow people who do not know how to handle a
battery or who do not sufficiently understand the danger
perform inspection or maintenance.

(Measurement items)
Q Zero adjustment

1. Open the cover and drip water on the prism surface using the
included rod.

2. Close the cover.

3. Aim in a direction that is bright, look into the lens, and adjust the
focus until the gradations can be seen clearly.

4. If the boundary line is not on the gradation baseline (0 position),
turn the adjustment screw until it matches.

5. When zero adjustment is complete, wipe the prism and cover
surface with a soft cloth or tissue paper.

Q Measurement of test fluid

1. Open the cover and drip test fluid on the prism surface using the
included rod.

2. Close the cover.

3. Aim in a direction that is bright, look into the lens and read the
gradation of the blue boundary line.

4. When the measurement is complete, wipe the prism and cover
surface with a soft cloth or tissue paper.

(Reference)

Electrolyte specific gravity and amount of discharge.
Use the following table as a reference.

(A) Electrolyte Specific Gravity
(B) Discharge

(C) Good
(D) Charging is necessary.

Temperature conversion of electrolyte specific gravity

• Battery electrolyte specific gravity changes based on
temperature.

• Insert the value identified on a specific gravity meter into
the following conversion equation for temperature
correction to learn an accurate specific gravity value.
(Standard temperature assumed to be 20 °C (68 °F))

= Dt + 0.0007 (t - 20)

D

20

= specific gravity value converted to standard

D

20

temperature of 20 °C (68 °F)

= measured specific gravity value at the electrolyte

D

t

temperature t °C

9Y1210785GEG0028US0

G-21

SM-E4B SERIES, WSM

NOTE

KiSC issued 01, 2013 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.

GENERAL

9Y1210785GEG0029US0

G-22

SM-E4B SERIES, WSM

IMPORTANT

NOTE

KiSC issued 01, 2013 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 end
plate 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.

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)

Number of cylinders Valve arrangement

Z482-E4B
Z602-E4B

Intake

valve

Factory specification

Exhaust

valve

0.145 to 0.185 mm

0.00571 to 0.00728 in.

Intake

valve

GENERAL

D722-E4B
D782-E4B
D902-E4B

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-E4B, Z602-E4B
[b] D722-E4B, D782-E4B, D902-E4B

9Y1210785GEG0030US0

G-23

SM-E4B SERIES, WSM

CAUTION

KiSC issued 01, 2013 A

GENERAL

[13] CHECK POINTS OF EVERY 1500 HOURS

• Check the injection pressure and condition after confirming that there is nobody standing in the direction
the fume goes.

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

9Y1210785GEG0031US0

Nozzle Spraying Condition

1. Set the injection nozzle to a nozzle tester, and check the nozzle
spraying condition.

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

(a) Good (b) Bad

9Y1210785GEG0032US0

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 (0.00098 in.) difference of
adjusting washer thickness.
Approx. 590 kPa (6.0 kgf/cm

Fuel injection pressure Factory specification

2

, 85 psi)

13.73 to 14.70 MPa

140.0 to 150.0 kgf/cm
1992 to 2133 psi

2

(1) Adjusting Washer

9Y1210785GEG0033US0

Nozzle Valve Seat Tightness

1. Set the injection nozzle to a nozzle tester.

2. Raise the fuel pressure, and keep at 12.75 MPa (130.0 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 specification

12.75 MPa

130.0 kgf/cm
1849 psi

9Y1210785GEG0034US0

2

2

,

G-24

SM-E4B SERIES, WSM

KiSC issued 01, 2013 A

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 assembling the nozzle, be sure to adjust the fuel injection
pressure.

35 to 39 N·m

3.5 to 4.0 kgf·m
26 to 28 lbf·ft

20 to 24 N·m

2.0 to 2.5 kgf·m
15 to 18 lbf·ft

49 to 68 N·m

5.0 to 7.0 kgf·m
37 to 50 lbf·ft

Tightening torque

Nozzle holder

Overflow pipe retaining nut

Nozzle holder assembly

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

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

9Y1210785GEG0035US0

G-25

SM-E4B SERIES, WSM

KiSC issued 01, 2013 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 counterclockwise (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 1.6 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 crank
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 adjustment, readjust the timing with
shims.

Z482/D602-E4B (3600 min

Injection timing Factory specification

D722-E4B (3200 min

Injection timing Factory specification

D782-E4B (3200 min

Injection timing Factory specification

D902-E4B (3600 min

Injection timing Factory specification

-1

(rpm) spec.)

-1

(rpm) spec.)

-1

(rpm) spec.)

-1

(rpm) spec.)

GENERAL

0.3186 to 0.3447 rad
(18.25 to 19.75 °) before
T. D. C .

0.3360 to 0.3621 rad
(19.25 to 20.75 °) before
T. D. C .

0.2837 to 0.3097 rad
(16.25 to 17.75 °) before
T. D. C .

0.3186 to 0.3447 rad
(18.25 to 19.75 °) before
T. D. C .

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

G-26

(5) Two-holes : 0.20 mm (0.0079 in.)

Two-holes : 0.175 mm (0.00689 in.)
(6) One-hole : 0.25 mm (0.0098 in.)
(7) Without hole : 0.30 mm (0.012 in.)
(8) Three-holes : 0.35 mm (0.014 in.)

(To be continued)

SM-E4B SERIES, WSM

NOTE

KiSC issued 01, 2013 A

(Continued)

GENERAL

• The liquid gasket is not required for assembling.

• Shims are available in thickness of 0.20 mm (0.0079 in.),

0.25 mm (0.0098 in.), 0.30 mm (0.012 in.), 0.35 mm (0.014 in.)
and 0.175 mm (0.00689 in.). Combine these shims for
adjustments.

• Addition or reduction of shim (0.025 mm, 0.00098 in.)
delays or advances the injection timing by approx.

0.0044 rad (0.25 °).

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

• The 0.175 mm (0.00689 in.) thick shim is coated only on the
lower face. Therefore, do not use the 0.175 mm (0.00689 in.)
thick shim as the top shim of the combination (injection
pump side), because this can cause oil leakage.

• Refer to figure of the shim to check the thickness of the
shims.

• The injection timing might be changed by the application.

9Y1210785GEG0036US0

G-27

SM-E4B SERIES, WSM

NOTE

KiSC issued 01, 2013 A

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 injection pump pressure tester (1). (Refer 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 (140.0 kgf/cm

2

, 1991 psi).

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

140.0 to 130.0 kgf/cm

2

, from 1991 to 1849 psi).

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

2

to 12.75 MPa (140.0 to 130.0 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 KUBOTA-authorized pump
service shop.

Fuel tightness of pump
element

Fuel tightness of delivery
valve

Allowable limit

Factory specification

Allowable limit

13.73 MPa

140.0 kgf/cm
1991 psi

10 seconds

13.73 → 12.75 MPa

140.0 → 130.0 kgf/cm
1991 → 1849 psi

5 seconds

13.73 → 12.75 MPa

140.0 → 130.0 kgf/cm
1991 → 1849 psi

2

2

2

• Never try to disassemble the injection pump assembly. For
repairs, you are strongly requested to contact a
KUBOTA-authorized pump service shop.

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

(3) Protection Cover for Jetted Fuel

9Y1210785GEG0037US0

G-28

SM-E4B SERIES, WSM

NOTE

CAUTION

CAUTION

KiSC issued 01, 2013 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

• 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
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

GENERAL

9Y1210785GEG0038US0

9Y1210785GEG0039US0

• 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 water and anti-freeze until the coolant level is just
below the port. Install the radiator cap securely.

(1) Upper Hose (2) Lower Hose

9Y1210785GEG0040US0

G-29

SM-E4B SERIES, WSM

CAUTION

NOTE

KiSC issued 01, 2013 A

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).

• 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 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.

• 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

9Y1210785GEG0041US0

G-30

SM-E4B SERIES, WSM

CAUTION

IMPORTANT

KiSC issued 01, 2013 A

GENERAL

Cleaning Water Jacket and Radiator Interior

• 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 radiator cap (1) must be
removed 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.

• 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
anti-freeze 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

(To be continued)

G-31

SM-E4B SERIES, WSM

IMPORTANT

NOTE

KiSC issued 01, 2013 A

(Continued)

GENERAL

(Anti-freeze)

• There are two types of anti-freeze available: use the permanent
type (PT) for this engine.

• Before adding anti-freeze for the first time, clean the radiator
interior by pouring fresh, soft water and draining it a few times.

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

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

Vol %

anti-freeze

40 –24 –11 106 223

50 –37 –35 108 226

* At 1.013 × 100000 Pa (760 mmHg) pressure (atmospheric). A higher boiling point
is obtained by using a radiator pressure cap which permits the development of
pressure within the cooling system.

Freezing point Boiling point*

°C °F °C °F

• The above data represents industrial standards that
necessitate a minimum glycol 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 absorbs moisture. Keep unused anti-freeze 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.)

9Y1210785GEG0042US0

G-32

SM-E4B SERIES, WSM

KiSC issued 01, 2013 A

5. SPECIAL TOOLS

GENERAL

Diesel Engine Compression Tester (for Injection Nozzle)

Code No.

• 07909-30208 (Assembly)

• 07909-30934 (A to F)

• 07909-31211 (E and F)

• 07909-31231 (H)

• 07909-31251 (G)

• 07909-31271 (I)

• 07909-31281 (J)

Application

• Use to measure diesel engine compression and diagnostics 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

WSM000001GEG0014US0

Diesel Engine Compression Tester (for Glow Plug)

Code No.

• 07909-39081 (Assembly)

• 07909-31291 (K)

• 07909-31301 (L)

• 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

WSM000001GEG0096US0

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

WSM000001GEG0015US0

G-33

SM-E4B SERIES, WSM

NOTE

KiSC issued 01, 2013 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

A

(300 kgf/cm

B PF 1/2

C Copper gasket

D Flange (Material Steel)

E Hex. nut 27 mm (1.1 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 8.0 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. (0.241 to 0.244 in. dia.)

N 8.0 mm (0.31 in.)

O 4.0 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 4.0 mm (0.16 in.)

U 12.00 to 12.02 mm dia. (0.4725 to 0.4732 in. dia.)

V 100 mm (3.94 in.)

W M12 × P1.5

X 5.0 mm (0.20 in.)

2

, 4270 psi)

GENERAL

9Y1210785GEG0043US0

9Y1210785GEG0044US0

G-34

SM-E4B SERIES, WSM

KiSC issued 01, 2013 A

GENERAL

Valve Guide Replacing Tool

Application

• Use to press out and press fit the valve guide.

A 220 mm (8.66 in.)

B 80 mm (3.1 in.)

C 40 mm (1.6 in.)

D 20 mm dia. (0.79 in. dia.)

E 9.960 to 9.980 mm dia. (0.3922 to 0.3929 in. dia.)

F 5.50 to 5.70 mm dia. (0.217 to 0.224 in. dia.)

G 25 mm dia. (0.98 in. dia.)

H 6.00 to 6.10 mm dia. (0.237 to 0.240 in. dia.)

I 5.0 mm (0.20 in.)

J 18 mm dia. (0.71 in. dia.)

K 10.6 to 10.7 mm dia. (0.418 to 0.421 in. dia.)

L 6.90 to 7.10 mm (0.272 to 0.279 in.)

C1 Chamfer 1.0 mm (0.039 in.)

C2 Chamfer 2.0 mm (0.079 in.)

C0.3 Chamfer 0.3 mm (0.01 in.)

9Y1210785GEG0045US0

Bushing Replacing Tool

Application

• Use to press out and press fit the bushing.

Q 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 0.8641 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 (0.01 in.)

a 6.3 μm (250 μin.)

b 6.3 μm (250 μin.)

Q 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 0.8641 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 (0.01 in.)

a 6.3 μm (250 μin.)

b 6.3 μm (250 μin.)

9Y1210785GEG0046US0

G-35

SM-E4B SERIES, WSM

KiSC issued 01, 2013 A

GENERAL

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 (1.2 in.)

E 8.0 mm (0.31 in.)

F 200 mm (7.87 in.)

9Y1210785GEG0047US0

Crankshaft Bearing 1 Replacing Tool

Application

• Use to press out and press fit the crankshaft bearing 1.

Q Press Out

A 135 mm (5.31 in.)

B 72 mm (2.8 in.)

C 40 mm radius (1.6 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. (1.886 to 1.887 in. dia.)

H 43.90 to 43.95 mm dia. (1.729 to 1.730 in. dia.)

C1 Chamfer 1.0 mm (0.039 in.)

C2 Chamfer 2.0 mm (0.079 in.)

C0.3 Chamfer 0.3 mm (0.01 in.)

Q Press Fit for Z482/D722-E4B, D782-E4B

A 130 mm (5.12 in.)

B 72 mm (2.8 in.)

C 40 mm radius (1.6 in. radius)

D 9.0 mm (0.35 in.)

E 24 mm (0.94 in.)

F 20 mm dia. (0.79 in. dia.)

G 68 mm dia. (2.7 in. dia.)

H 39.90 to 39.95 mm dia. (1.571 to 1.572 in. dia.)

C1 Chamfer 1.0 mm (0.039 in.)

C2 Chamfer 2.0 mm (0.079 in.)

C0.3 Chamfer 0.3 mm (0.01 in.)

Q Press Fit for Z602/D902-E4B

A 130 mm (5.12 in.)

B 72 mm (2.8 in.)

C 40 mm radius (1.6 in. radius)

D 9.0 mm (0.35 in.)

E 24 mm (0.94 in.)

F 20 mm dia. (0.79 in. dia.)

G 68 mm dia. (2.7 in. dia.)

H 43.90 to 43.95 mm dia. (1.729 to 1.730 in. dia.)

C1 Chamfer 1.0 mm (0.039 in.)

C2 Chamfer 2.0 mm (0.079 in.)

C0.3 Chamfer 0.3 mm (0.01 in.)

9Y1210785GEG0048US0

G-36

SM-E4B SERIES, WSM

KiSC issued 01, 2013 A

GENERAL

Crank Sleeve Setter (for Z482/D722-E4B, D782-E4B)

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 (3.2 in.)

E 72 mm (2.8 in.)

F 67 mm (2.6 in.)

G 47 mm (1.8 in.)

H 37.00 to 37.20 mm (1.457 to 1.464 in.)

I 17 mm (0.67 in.)

J 5.0 mm dia. (0.20 in. dia.)

K 52 mm dia. (2.0 in. dia.)

L 40 mm dia. (1.6 in. dia.)

M 10 mm (0.39 in.)

N 33 mm (1.3 in.)

O 20 mm dia. (0.79 in. dia.)

P 40 mm dia. (1.6 in. dia.)

Q 63.10 to 63.15 mm dia. (2.485 to 2.486 in. dia.)

R 64 mm dia. (2.5 in. dia.)

S 75 mm dia. (3.0 in. dia.)

C0.3 Chamfer 0.3 mm (0.01 in.)

C1 Chamfer 1.0 mm (0.039 in.)

C5 Chamfer 5.0 mm (0.20 in.)

(2) Sleeve Guide

A 42 mm (1.7 in.)

B 12 mm (0.47 in.)

C 30 mm (1.2 in.)

D M10 × Pitch 1.25

E 2.0 mm (0.079 in.)

F 10 mm (0.39 in.)

G 2.0 mm (0.079 in.)

H 17.90 to 17.95 mm dia. (0.7048 to 0.7066 in. dia.)

I 8.0 mm dia. (0.31 in. dia.)

J 1.8 mm (0.071 in.)

K 0.09 rad (5 °)

C0.5 Chamfer 0.5 mm (0.02 in.)

9Y1210785GEG0049US0

G-37

1 ENGINE

KiSC issued 01, 2013 A

MECHANISM

KiSC issued 01, 2013 A

CONTENTS

1. ENGINE BODY ........................................................................................................................... 1-M1

[1] HALF-FLOATING HEAD COVER ........................................................................................ 1-M1

[2] CLOSED BREATHER .......................................................................................................... 1-M1

[3] PISTON (Z602-E4B, D782-E4B, D902-E4B) ....................................................................... 1-M2

[4] OIL PAN (Z602-E4B, D902-E4B) ......................................................................................... 1-M2

2. COOLING SYSTEM ................................................................................................................... 1-M3

[1] COOLING FIN (Z602-E4B, D902-E4B) ................................................................................ 1-M3

SM-E4B SERIES, WSM

KiSC issued 01, 2013 A

1. ENGINE BODY

[1] HALF-FLOATING HEAD COVER

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.

[2] CLOSED BREATHER

prevent the release of blow-by gas into the atmosphere.

blow-by gas is fed back to the intake manifold through
breather valve (3) to be used for re-combustion.

ENGINE

The rubber packing is fitted in to maintain the

(1) Cylinder Head Cover (2) Rubber Packing

9Y1210785ENM0001US0

Closed breather system has been adopted to

After its oil content is filtered by oil shield (4), the

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

(4) Oil Shield
(5) Rubber Packing

9Y1210785ENM0002US0

1-M1

SM-E4B SERIES, WSM

KiSC issued 01, 2013 A

[3] PISTON (Z602-E4B, D782-E4B, D902-E4B)

Piston's skirt is coated with molybdenum

disulfide*, which reduces the piston slap noise and thus

the entire operating noise.

ENGINE

[4] OIL PAN (Z602-E4B, D902-E4B)

*Molybdenum disulfide (MoS

)

2

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

(1) Molybdenum Disulfide

9Y1210785ENM0003US0

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

9Y1210785ENM0004US0

1-M2

SM-E4B SERIES, WSM

KiSC issued 01, 2013 A

2. COOLING SYSTEM

[1] COOLING FIN (Z602-E4B, D902-E4B)

The cooling fin is set up around the oil passage in the

gear case.

Therefore, the temperature of oil is decreased by the

wind generated by the cooling fan.

(1) Cooling Fin

ENGINE

9Y1210785ENM0005US0

1-M3

SERVICING

KiSC issued 01, 2013 A

CONTENTS

1. TROUBLESHOOTING.................................................................................................................1-S1

2. SERVICING SPECIFICATIONS ..................................................................................................1-S4

3. TIGHTENING TORQUES .......................................................................................................... 1-S12

[1] TIGHTENING TORQUES FOR GENERAL USE SCREWS, BOLTS AND NUTS...............1-S12

[2] TIGHTENING TORQUES FOR SPECIAL USE SCREWS, BOLTS AND NUTS................. 1-S13

4. CHECKING, DISASSEMBLING AND SERVICING ...................................................................1-S14

[1] CHECKING AND ADJUSTING............................................................................................ 1-S14

(1) Engine Body ..................................................................................................................1-S14

(2) Lubricating System ........................................................................................................1-S16

(3) Cooling System .............................................................................................................1-S17

(4) Fuel System...................................................................................................................1-S19

(5) Electrical System ...........................................................................................................1-S23

[2] DISASSEMBLING AND ASSEMBLING ..............................................................................1-S29

(1) Draining Engine Oil and Coolant ...................................................................................1-S29

(2) External Components ....................................................................................................1-S30

(3) Cylinder Head, Valves and Oil Pan ...............................................................................1-S30

(4) Gear Case and Timing Gears........................................................................................1-S35

(5) Piston and Connecting Rod...........................................................................................1-S41

(6) Flywheel and Crankshaft ...............................................................................................1-S43

(7) Starter............................................................................................................................1-S47

(8) Dynamo .........................................................................................................................1-S49

(9) Alternator.......................................................................................................................1-S50

[3] SERVICING .........................................................................................................................1-S51

(1) Cylinder Head and Valves ............................................................................................. 1-S51

(2) Timing Gears .................................................................................................................1-S56

(3) Piston and Connecting Rod...........................................................................................1-S59

(4) Crankshaft .....................................................................................................................1-S61

(5) Cylinder .........................................................................................................................1-S67

(6) Oil Pump........................................................................................................................1-S68

(7) Starter............................................................................................................................1-S69

(8) Alternator.......................................................................................................................1-S72

SM-E4B SERIES, WSM

KiSC issued 01, 2013 A

1. TROUBLESHOOTING

ENGINE

Symptom Probable Cause Solution

Engine Does Not
Start

Starter Does Not Run Battery discharged Charge 1-S23,

No fuel Replenish fuel G-11

Air in the fuel system Bleed G-11

Water in the fuel system Change fuel and

repair or replace fuel
system

Fuel hose clogged Clean or replace G-11

Fuel filter clogged Replace G-17

Excessively high viscosity of fuel or engine oil at
low temperature

Fuel with low cetane number Use specified fuel I-4,

Fuel leak due to loose injection pipe retaining nut Tighten retaining nut 1-S31

Incorrect injection timing Adjust I-4,

Fuel camshaft worn Replace 1-S57

Injection nozzle clogged Clean or replace 1-S22

Injection pump malfunctioning Repair or replace G-28,

Seizure of crankshaft, camshaft, piston, cylinder
or bearing

Compression leak from cylinder Replace head gasket,

Improper valve timing Correct or replace

Piston ring and cylinder worn Replace 1-S60,

Excessive valve clearance Adjust G-23

Stop solenoid malfunctioning Replace 1-S28,

Starter malfunctioning Repair or replace 1-S25,

Wiring disconnected Connect –

Use specified fuel or
engine oil

Repair or replace 1-S39,

tighten cylinder head
screw, glow plug and
nozzle holder

timing gear

Reference

Page

G-11

I-4,

G-6

G-6

G-26

1-S21

1-S41,

1-S43

1-S14,

1-S32

1-S39

1-S61,

1-S67

1-S29

1-S24

1-S26

1-S1

SM-E4B SERIES, WSM

KiSC issued 01, 2013 A

ENGINE

Symptom Probable Cause Solution

Engine Revolution Is
Not Smooth

Fuel filter clogged or dirty Replace G-17

Air cleaner clogged Clean or replace G-14

Reference

Page

Fuel leak due to loose injection pipe retaining nut Tighten retaining nut 1-S31

Injection pump malfunctioning Repair or replace G-28,

1-S21

Incorrect nozzle injection pressure Adjust G-24

Injection nozzle stuck or clogged Repair or replace G-24

Governor malfunctioning Repair 1-S45

Either White or Blue
Exhaust Gas Is
Observed

Excessive engine oil Reduce to specified

level

I-4,

G-7,

G-9

Piston ring and cylinder worn or stuck Repair or replace 1-S60,

1-S61

Incorrect injection timing Adjust I-4,

G-26

Either Black or Dark
Gray Exhaust Gas Is
Observed

Overload Reduce the load I-4

Low grade fuel used Use specified fuel I-4,

G-6

Fuel filter clogged Replace G-17

Air cleaner clogged Clean or replace G-14

Deficient nozzle injection Repair or replace

G-24

nozzle

Deficient Output Incorrect injection timing Adjust I-4,

G-26

Engine's moving parts seem to be seizing Repair or replace 1-S39,

1-S45

Injection pump malfunctioning Repair or replace G-28,

1-S21

Deficient nozzle injection Repair or replace

G-28

nozzle

Compression leak Check the

compression

1-S14,

1-S32

pressure and repair

Excessive Lubricant
Oil Consumption

Piston ring's gap facing the same direction Shift ring gap

direction

1-S41

Oil ring worn or stuck Replace 1-S42

Piston ring groove worn Replace piston 1-S61

Valve stem and valve guide worn Replace 1-S52

Crankshaft bearing and crank pin bearing worn Replace 1-S61,

1-S63

Oil leaking due to defective seals or packing Replace 1-S67

Fuel Mixed into
Lubricant Oil

Injection pump's plunger worn Repair or replace G-28

Deficient nozzle injection Repair or replace

G-24

nozzle

Injection pump broken Replace G-28

1-S2

SM-E4B SERIES, WSM

KiSC issued 01, 2013 A

ENGINE

Symptom Probable Cause Solution

Water Mixed into
Lubricant Oil

Head gasket defective Replace 1-S32

Cylinder block or cylinder head flawed Replace 1-S51

Reference

Page

Low Oil Pressure Engine oil insufficient Replenish I-4,

G-7

Oil strainer clogged Clean 1-S34

Relief valve stuck with dirt Clean –

Relief valve spring weaken or broken Replace –

Excessive oil clearance of crankshaft bearing Replace 1-S63

Excessive oil clearance of crankpin bearing Replace 1-S62

Excessive oil clearance of rocker arm Replace 1-S55

Oil passage clogged Clean –

Different type of oil Use specified type of

oil

I-4,

G-6

Oil pump defective Replace 1-S40

High Oil Pressure Different type of oil Use specified type of

oil

I-4,

G-6

Relief valve defective Replace –

Engine Overheated Engine oil insufficient Replenish I-4,

G-7

Fan belt broken or elongated Replace or adjust G-14

Coolant insufficient Replenish G-8,

G-19

Radiator net and radiator fin clogged with dust Clean –

Inside of radiator corroded Clean or replace –

Coolant flow route corroded Clean or replace –

Radiator cap defective Replace 1-S18

Overload running Reduce the load –

Head gasket defective Replace 1-S32

Incorrect injection timing Adjust I-4,

G-26

Unsuitable fuel used Use specified fuel I-4,

G-6

Battery Quickly
Discharged

Battery electrolyte insufficient Replenish distilled

water and charge

Fan belt slips Adjust belt tension or

G-15

G-19

replace

Wiring disconnected Connect –

Rectifier defective Replace 1-S73

Alternator defective Replace 1-S72

Battery defective Replace G-21

9Y1210785ENS0001US0

1-S3

SM-E4B SERIES, WSM

KiSC issued 01, 2013 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-E4B
D722-E4B
D782-E4B

2.85 to 3.23 MPa

29.0 to 33.0 kgf/cm
413 to 469 psi

ENGINE

–

2

2.26 MPa

23.0 kgf/cm

2

327 psi

Z602-E4B
D902-E4B

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

2.55 MPa

26.0 kgf/cm
370 psi

10 % or less

–

0.020 to 0.027 in.

Cylinder Head Surface Flatness – 0.05 mm

0.002 in.

Valve Recessing (Intake and Exhaust) −0.10 to 0.10 mm

−0.0039 to 0.0039 in.

Valve Stem to Valve Guide
(Intake and Exhaust)

• Valve Stem

Clearance

O.D.

0.030 to 0.057 mm

0.0012 to 0.0022 in.

5.968 to 5.980 mm

0.30 mm

0.012 in.

0.10 mm

0.0039 in.

–

0.2350 to 0.2354 in.

• Valve Guide

I.D.

6.010 to 6.025 mm

–

0.2367 to 0.2372 in.

Valve Face (Intake and Exhaust) Angle 0.79 rad

–

45 °

Valve Seat (Intake and Exhaust) Angle

0.79 rad

–

45 °

2

Intake Valve Timing

[Z482/D722/D782-E4B]

Exhaust Valve Timing

[Z482/D722/D782-E4B]

Intake Valve Timing

[Z602/D902-E4B]

Width

Open

Close

Open

Close

Open

Close

1-S4

2.12 mm

0.0835 in.

0.445 rad (25.5 °)
before T.D.C.

0.881 rad (50.5 °)

after B.D.C.

0.969 rad (55.5 °)

before B.D.C.

0.201 rad (11.5 °)

after T.D.C.

0.35 rad (20 °)
before T.D.C.

0.79 rad (45 °)

after B.D.C.

–

–

–

–

–

–

–

SM-E4B SERIES, WSM

KiSC issued 01, 2013 A

Exhaust Valve Timing

[Z602/D902-E4B]

ENGINE

Item Factory Specification Allowable Limit

Open

0.87 rad (50 °)

–

before B.D.C.

Close

0.26 rad (15 °)

–

after T.D.C.

Valve Spring (Intake and Exhaust) Tilt

–

1.2 mm

0.047 in.

Rocker Arm Shaft to Rocker Arm

• Rocker Arm Shaft

Free Length

Setting Load /
Setting Length

Oil Clearance

O.D.

31.3 to 31.8 mm

1.24 to 1.25 in.

65 N / 27.0 mm

6.6 kgf / 27.0 mm
15 lbf / 1.06 in.

0.016 to 0.045 mm

0.00063 to 0.0017 in.

10.473 to 10.484 mm

28.4 mm

1.12 in.

55 N / 27.0 mm

5.6 kgf / 27.0 mm
12 lbf / 1.06 in.

0.15 mm

0.0059 in.

–

0.41233 to 0.41275 in.

• Rocker Arm

I.D.

10.500 to 10.518 mm

–

0.41339 to 0.41409 in.

Push Rod Alignment – 0.25 mm

0.0098 in.

Tappet to Tappet Bore

Oil Clearance

0.016 to 0.052 mm

0.00063 to 0.0020 in.

0.10 mm

0.0039 in.

• Tappet

O.D.

17.966 to 17.984 mm

0.70733 to 0.70803 in.

• Tappet Bore

I.D.

18.000 to 18.018 mm

0.70867 to 0.70937 in.

Timing Gear

• Crank Gear to Idle Gear

Backlash

0.0430 to 0.124 mm

0.00170 to 0.00488 in.

• Idle Gear to Cam Gear

Backlash

0.0470 to 0.123 mm

0.00185 to 0.00484 in.

• Idle Gear to Injection Pump Gear

Backlash

0.0460 to 0.124 mm

0.00182 to 0.00488 in.

• Crank Gear to Oil Pump Drive Gear

Backlash

0.0410 to 0.123 mm

0.00162 to 0.00484 in.

Idle Gear Side Clearance 0.20 to 0.51 mm

0.0079 to 0.020 in.

Camshaft Side Clearance

0.15 to 0.31 mm

0.0059 to 0.012 in.

Alignment

–

–

–

0.15 mm

0.0059 in.

0.15 mm

0.0059 in.

0.15 mm

0.0059 in.

0.15 mm

0.0059 in.

0.80 mm

0.031 in.

0.50 mm

0.020 in.

0.01 mm

0.0004 in.

1-S5

SM-E4B SERIES, WSM

KiSC issued 01, 2013 A

Cam Height

[Z482/D722/D782-E4B]

ENGINE

Item Factory Specification Allowable Limit

Intake

26.88 mm

1.058 in.

26.83 mm

1.056 in.

[Z482/D722/D782-E4B]

Exhaust

25.88 mm

1.019 in.

[Z602/D902-E4B]

Intake and Exhaust

26.88 mm

1.058 in.

Camshaft Journal to Cylinder Block Bore

Oil Clearance

0.050 to 0.091 mm

0.0020 to 0.0035 in.

• Camshaft Journal

O.D.

32.934 to 32.950 mm

1.2967 to 1.2972 in.

• Cylinder Block Bore

I.D.

33.000 to 33.025 mm

1.2993 to 1.3001 in.

Idle Gear Shaft to Idle Gear Bushing

Oil Clearance

0.020 to 0.084 mm

0.00079 to 0.0033 in.

• Idle Gear Shaft

O.D.

19.967 to 19.980 mm

0.78611 to 0.78661 in.

• Idle Gear Bushing

I.D.

20.000 to 20.051 mm

0.78740 to 0.78940 in.

Piston Pin Bore I.D. 20.000 to 20.013 mm

0.78741 to 0.78791 in.

Piston Pin to Small End Bushing

Oil Clearance

0.014 to 0.038 mm

0.00056 to 0.0014 in.

25.83 mm

1.017 in.

26.83 mm

1.056 in.

0.15 mm

0.0059 in.

–

–

0.10 mm

0.0039 in.

–

–

20.05 mm

0.7894 in.

0.10 mm

0.0039 in.

•Piston Pin

• Small End Bushing

Piston Pin to Small End Bushing
(Spare Parts)

• Small End Bushing

Piston Ring Gap

[Z482/D722/D782-E4B]

Piston Ring Gap

[Z602/D902-E4B]

O.D.

I.D.

Oil Clearance

I.D.

Top Ring

Second Ring

Oil Ring

Top Ring

Second Ring

20.002 to 20.011 mm

0.78748 to 0.78783 in.

20.025 to 20.040 mm

0.78839 to 0.78897 in.

0.015 to 0.075 mm

0.00059 to 0.0029 in.

20.026 to 20.077 mm

0.78843 to 0.79043 in.

0.12 to 0.27 mm

0.0047 to 0.010 in.

0.30 to 0.45 mm

0.012 to 0.017 in.

0.15 to 0.35 mm

0.0059 to 0.013 in.

0.15 to 0.30 mm

0.0059 to 0.011 in.

0.35 to 0.50 mm

0.014 to 0.019 in.

–

–

0.15 mm

0.0059 in.

–

1.15 mm

0.0453 in.

1.20 mm

0.0472 in.

1.20 mm

0.0472 in.

25 m

1.

m

0.0472 in.

1.25 mm

0.0492 in.

Oil Ring

1-S6

0.15 to 0.35 mm

0.0059 to 0.013 in.

1.20 mm

0.0472 in.

SM-E4B SERIES, WSM

KiSC issued 01, 2013 A

ENGINE

tem Factory S

I

pecification Allowable Limit

Piston Ring to Piston Ring Groove

• Second Ring

• Oil Ring

Clearance

Clearance

0.0900 to 0.120 mm

0.00355 to 0.00472 in.

0.040 to 0.080 mm

0.0016 to 0.0031 in.

0.15 mm

0.0059 in.

0.15 mm

0.0059 in.

Connecting Rod Alignment – 0.05 mm

0.002 in.

Crankshaft Side Clearance

Alignment

0.15 to 0.35 mm

0.0059 to 0.012 in.

–

0.50 mm

0.020 in.

0.02 mm

0.0008 in.

Crank Pin to Crank Pin Bearing

•Crank Pin

Oil Clearance

O.D.

0.020 to 0.051 mm

0.00079 to 0.0020 in.

33.959 to 33.975 mm

0.15 mm

0.0059 in.

–

1.3370 to 1.3375 in.

• Crankpin Bearing

O.D.

33.995 to 34.010 mm

–

1.3384 to 1.3389 in.

Crankshaft Journal to Crankshaft Bearing 1

[Z482/D722/D782-E4B]

Oil Clearance

0.0340 to 0.106 mm

0.00134 to 0.00417 in.

0.20 mm

0.0079 in.

• Crankshaft Journal

• Crankshaft Bearing 1

Crankshaft Journal to Crankshaft Bearing 1

[Z602/D902-E4B]

• Crankshaft Journal

• Crankshaft Bearing 1

Crankshaft Journal to Crankshaft Bearing 2
(Flywheel Side)

• Crankshaft Journal

• Crankshaft Bearing 2

Crankshaft Journal to Crankshaft Bearing 3
(Intermediate)

[Z482/D722/D782-E4B]

• Crankshaft Journal

O.D.

I.D.

Oil Clearance

O.D.

I.D.

Oil Clearance

O.D.

I.D.

Oil Clearance

O.D.

39.934 to 39.950 mm

1.5722 to 1.5728 in.

39.984 to 40.040 mm

1.5742 to 1.5763 in.

0.0340 to 0.106 mm

0.00134 to 0.00417 in.

43.934 to 43.950 mm

1.7297 to 1.7303 in.

43.984 to 44.040 mm

1.7317 to 1.7338 in.

0.028 to 0.059 mm

0.0011 to 0.0023 in.

43.934 to 43.950 mm

1.7297 to 1.7303 in.

43.978 to 43.993 mm

1.7315 to 1.7320 in.

0.028 to 0.059 mm

0.0011 to 0.0023 in.

39.934 to 39.950 mm

1.5722 to 1.5728 in.

–

–

0.20 mm

0.0079 in.

–

–

0.20 mm

0.0079 in.

–

–

0.20 mm

0.0079 in.

–

• Crankshaft Bearing 3

I.D.

1-S7

39.978 to 39.993 mm

1.5740 to 1.5745 in.

–

SM-E4B SERIES, WSM

KiSC issued 01, 2013 A

Item Factory Specification Allowable Limit

Crankshaft Journal to Crankshaft Bearing 3
(Intermediate)

[Z602/D902-E4B]

• Crankshaft Journal

Oil Clearance

O.D.

0.028 to 0.059 mm

0.0011 to 0.0023 in.

43.934 to 43.950 mm

1.7297 to 1.7303 in.

ENGINE

0.20 mm

0.0079 in.

–

• Crankshaft Bearing 3

Cylinder Liner

[Z482/D722/D782-E4B]

Cylinder Liner

[Z602/D902-E4B]

Cylinder Liner
[Oversize : 0.25 mm (0.0098 in.)]

[Z482/D722/D782-E4B]

Cylinder Liner
[Oversize : 0.25 mm (0.0098 in.)]

[Z602/D902-E4B]

I.D.

43.978 to 43.993 mm

1.7315 to 1.7320 in.

I.D. 67.000 to 67.019 mm

2.6378 to 2.6385 in.

I.D. 72.000 to 72.019 mm

2.8347 to 2.8353 in.

I.D. 67.250 to 67.269 mm

2.6477 to 2.6483 in.

I.D. 72.250 to 72.269 mm

2.8445 to 2.8452 in.

–

67.150 mm

2.6437 in.

72.150 mm

2.8406 in.

67.400 mm

2.6535 in.

72.400 mm

2.8504 in.

1-S8

SM-E4B SERIES, WSM

KiSC issued 01, 2013 A

LUBRICATING SYSTEM

Item Factory Specification Allowable Limit

Engine Oil Pressure At Idle Speed

More than

49 kPa

0.50 kgf/cm

7.1 psi

ENGINE

–

2

At Rated Speed

197 to 441 kPa

2.00 to 4.50 kgf/cm

28.5 to 64.0 psi

Inner Rotor to Outer Rotor Clearance 0.030 to 0.14 mm

0.0012 to 0.0055 in.

Outer Rotor to Pump Body Clearance 0.070 to 0.15 mm

0.0028 to 0.0059 in.

Inner Rotor to Cover Clearance 0.0750 to 0.135 mm

0.00296 to 0.00531 in.

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 lbf)

Thermostat Valve Opening

Temperature

69.5 to 72.5 °C

157.1 to 162.5 °F

(At Beginning)

Valve Opening
Temperature

85 °C

185 °F
(Opened
Completely)

Radiator Cap Pressure Falling

Time

10 seconds or more

88 → 59 kPa

0.90 → 0.60 kgf/cm
13 → 8.5 psi

Radiator Water Leakage

Test Pressure

No leak at specified

pressure

2

147 kPa

1.50 kgf/cm

2

21.3 psi

–

–

–

–

–

–

–

2

–

1-S9

SM-E4B SERIES, WSM

KiSC issued 01, 2013 A

FUEL SYSTEM

Item Factory Specification Allowable Limit

Injection Pump

[Z482/D602-E4B]

Injection Timing
(3600 min

-1

(rpm))

0.3186 to 0.3447 rad
(18.25 to 19.75 °)

–

before T.D.C.

Injection Pump

[D722-E4B]

Injection Timing
(3200 min

-1

(rpm))

0.3360 to 0.3621 rad
(19.25 to 20.75 °)

–

before T.D.C.

Injection Pump

[D782-E4B]

Injection Timing
(3200 min

-1

(rpm))

0.2837 to 0.3097 rad
(16.25 to 17.75 °)

–

before T.D.C.

Injection Pump

[D902-E4B]

Injection Timing
(3600 min

-1

(rpm))

0.3186 to 0.3447 rad
(18.25 to 19.75 °)

–

before T.D.C.

Pump Element Fuel Tightness – 13.73 MPa

140.0 kgf/cm
1991 psi

Delivery Valve Fuel Tightness 10 seconds

13.73 → 12.75 MPa

140.0 → 130.0 kgf/cm
1991 → 1849 psi

2

5 seconds

13.73 → 12.75 MPa

140.0 →

130.0 kgf/cm

1991 → 1849 psi

Injection Nozzle Injection Pressure 13.73 to 14.70 MPa

140.0 to 150.0 kgf/cm

2

–

1992 to 2133 psi

Injection Nozzle Valve Seat Valve Seat

Tightness

When the pressure is

12.75 MPa

(130.0 kgf/cm

2

,

–

1849 psi), the valve seat

must be fuel tightness

ENGINE

2

2

1-S10

SM-E4B SERIES, WSM

KiSC issued 01, 2013 A

ELECTRICAL SYSTEM

Item Factory Specification Allowable Limit

Glow Plug Resistance Approx. 1.1 Ω –

Starter (Electromagnetic Drive Type)

• Commutator

O.D.

28.0 mm

1.10 in.

27.0 mm

1.06 in.

ENGINE

• Difference

•Mica

•Brush

Starter (Planetary Gear Reduction Type)

• Commutator

• Difference

•Mica

•Brush

Dynamo

• No-load

O.D.

Undercut

Length

O.D.

O.D.

Undercut

Length

Output Voltage

Less than

0.05 mm

0.002 in.

0.50 to 0.80 mm

0.020 to 0.031 in.

16.0 mm

0.630 in.

30.0 mm

1.18 in.

Less than

0.02 mm

0.0008 in.

0.50 to 0.80 mm

0.020 to 0.031 in.

14.0 mm

0.551 in.

AC20V or more at

5200 min

-1

(rpm)

0.40 mm

0.016 in.

0.20 mm

0.0079 in.

10.5 mm

0.413 in.

29.0 mm

1.14 in.

0.05 mm

0.002 in.

0.20 mm

0.0079 in.

9.0 mm

0.35 in.

–

• Regulating

Alternator

• Stator

• Rotor

• Slip Ring

•Brush

Output Voltage

Resistance

Resistance

O.D.

Length

14 to 15 V at

5200 min

-1

(rpm)

Less than 1.0 Ω

2.9 Ω

14.4 mm

0.567 in.

10.0 mm

0.394 in.

–

–

–

14.0 mm

0.551 in.

8.4 mm

0.33 in.

9Y1210785ENS0002US0

1-S11

SM-E4B SERIES, WSM

KiSC issued 01, 2013 A

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.

9Y1210785ENS0003US0

[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.

Indication on

top of bolt

Unit N·m kgf·m lbf·ft N·m kgf·m lbf·ft

M6 7.9 to 9.3 0.80 to 0.95 5.8 to 6.8 9.81 to 11.2 1.00 to 1.15 7.24 to 8.31

M8 18 to 20 1.8 to 2.1 13 to 15 24 to 27 2.4 to 2.8 18 to 20

M10 40 to 45 4.0 to 4.6 29 to 33 48 to 55 4.9 to 5.7 36 to 41

M12 63 to 72 6.4 to 7.4 47 to 53 78 to 90 7.9 to 9.2 58 to 66

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)

No-grade or 4T 7T

9Y1210785ENS0004US0

1-S12

SM-E4B SERIES, WSM

NOTE

KiSC issued 01, 2013 A

ENGINE

[2] TIGHTENING TORQUES FOR SPECIAL USE SCREWS, BOLTS

AND NUTS

• For "*" marked screws, bolts and nuts on the table, apply engine oil to their threads and seats before
tightening.

• The letter "M" in Size × Pitch means that the screw, bolt or nut dimension stands for metric. The size is
the nominal outside diameter in mm of the threads. The pitch is the nominal distance in mm between two
threads.

Item

*Cylinder head cover screw M6 × 1 9.81 to 11.2 1.00 to 1.15 7.24 to 8.31

Injection pipe retaining nut M12 × 1.5 25 to 34 2.5 to 3.5 18 to 25

Overflow pipe retaining nut M12 × 1.5 20 to 24 2.0 to 2.5 15 to 18

Nozzle holder assembly M20 × 1.5 49 to 68 5.0 to 7.0 37 to 50

Glow plug M8 × 1 7.9 to 14 0.80 to 1.5 5.8 to 10

*Rocker arm bracket nut M6 × 1 9.81 to 11.2 1.00 to 1.15 7.24 to 8.31

*Cylinder head screw M8 × 1.25 38 to 42 3.8 to 4.3 28 to 31

*Fan drive pulley screw M12 × 1.5 118 to 127 12.0 to 13.0 86.8 to 94.0

*Idle gear shaft mounting screw M6 × 1 9.81 to 11.2 1.00 to 1.15 7.24 to 8.31

Oil pump mounting screw M8 × 1.25 17.7 to 21.5 1.80 to 2.20 13.1 to 15.9

*Connecting rod screw M7 × 0.75 27 to 30 2.7 to 3.1 20 to 22

*Flywheel screw M10 × 1.25 54 to 58 5.5 to 6.0 40 to 43

Bearing case cover mounting screw M6 × 1 9.81 to 11.2 1.00 to 1.15 7.24 to 8.31

*Main bearing case screw 2 M7 × 1 27 to 30 2.7 to 3.1 20 to 22

*Main bearing case screw 1 M6 × 1 13 to 15 1.3 to 1.6 9.4 to 11

Oil pressure switch PT 1/8 15 to 19 1.5 to 2.0 11 to 14

Nozzle holder – 35 to 39 3.5 to 4.0 26 to 28

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

Starter's terminal B mounting nut
(Planetary gear reduction type)

Dynamo's pulley nut M10 × 1.25 40 to 44 4.0 to 4.5 29 to 32

Alternator's pulley nut – 58.4 to 78.9 5.95 to 8.05 43.1 to 58.2

Drain plug with copper gasket M12 × 1.25 33 to 37 3.3 to 3.8 24 to 27

Drain plug with copper gasket M22 × 1.5 64 to 73 6.5 to 7.5 47 to 54

Drain plug with rubber coated gasket M22 × 1.5 45 to 53 4.5 to 5.5 33 to 39

Dimension ×

Pitch

M8 7.9 to 9.8 0.80 to 1.0 5.8 to 7.2

M8 5.9 to 11 0.60 to 1.2 4.4 to 8.6

N·m kgf·m lbf·ft

9Y1210785ENS0005US0

1-S13

SM-E4B SERIES, WSM

NOTE

KiSC issued 01, 2013 A

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, the muffler, the breather 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 the stop lever is set at the stop position
(non-injection), run 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 limit, apply a small
amount of oil to the cylinder wall through the glow plug hole (or
nozzle hole) and measure the compression pressure again.

8. If the compression pressure is still less than the allowable limit,
check the top clearance, valve clearance and cylinder head.

9. If the compression pressure increases 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 %.

Factory

Z482-E4B
D722-E4B
D782-E4B

Compression
pressure

Z602-E4B
D902-E4B

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

specifica­tion

Allowable
limit

Factory
specifica­tion

Allowable
limit

2.85 to 3.23 MPa

29.0 to 33.0 kgf/cm
413 to 469 psi

2.26 MPa

23.0 kgf/cm
327 psi

3.53 to 4.02 MPa

36.0 to 41.0 kgf/cm
512 to 583 psi

2.55 MPa

26.0 kgf/cm
370 psi

9Y1210785ENS0006US0

2

2

2

2

1-S14

SM-E4B SERIES, WSM

IMPORTANT

NOTE

KiSC issued 01, 2013 A

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 end
plate 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 specification

Z482-E4B
Z602-E4B

Intake

valve

Exhaust

valve

0.145 to 0.185 mm

0.00571 to 0.00728 in.

D722-E4B
D782-E4B
D902-E4B

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-E4B, Z602-E4B
[b] D722-E4B, D782-E4B, D902-E4B

9Y1210785GEG0030US0

1-S15

SM-E4B SERIES, WSM

KiSC issued 01, 2013 A

(2) Lubricating System

ENGINE

Engine Oil Pressure

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

2. Start the engine. After warming up, measure the oil pressure of
both idling and rated speeds.

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

0.50 kgf/cm

7.1 psi

197 to 441 kPa

2.00 to 4.50 kgf/cm

28.5 to 64.0 psi

147 kPa

1.50 kgf/cm

21.3 psi

2

2

2

Engine oil pressure

At idle
speed

At rated
speed

Factory
specifica­tion

Factory
specifica­tion

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

15 to 19 N·m

1.5 to 2.0 kgf·m
11 to 14 lbf·ft

9Y1210785ENS0007US0

1-S16

SM-E4B SERIES, WSM

KiSC issued 01, 2013 A

(3) Cooling System

ENGINE

Fan Belt Tension

1. Measure the deflection (A), depressing the belt halfway

between the fan drive pulley and alternator pulley at specified
force 98 N (10 kgf, 22 lbf).

2. If the measurement is not within the factory specifications,
loosen the alternator mounting screws and relocate the
alternator to adjust.

Deflection (A) Factory specification

(A) Deflection

7.0 to 9.0 mm

0.28 to 0.35 in.

9Y1210785GEG0013US0

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 nearly worn out and deeply sunk in the pulley
groove, replace it.

(A) Good (B) Bad

9Y1210785GEG0014US0

1-S17

SM-E4B SERIES, WSM

CAUTION

NOTE

KiSC issued 01, 2013 A

ENGINE

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

9Y1210785ENS0008US0

Radiator Cap Air Leakage

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

2. Apply the specified pressure of 88 kPa (0.90 kgf/cm
and measure the time for the pressure to fall to 59 kPa
(0.60 kgf/cm

2

, 8.5 psi).

2

, 13 psi),

3. If the measurement is less than the factory specification,
replace the radiator cap.

More than 10 seconds for
pressure fall

Pressure falling time Factory specification

(1) Radiator Tester (2) Adaptor

88 → 59 kPa
(0.90 → 0.60 kgf/cm
13 → 8.5 psi)

9Y1210785ENS0009US0

2

,

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, replace the radiator or repair
with the radiator cement. When water leak is excessive, replace
the radiator.

Radiator water leakage
test pressure

Factory specification

No leak at specified
pressure

• The pressure of the leak test is different from each radiator
specification.
Thus, do the leak test, refer to the test pressure of each
radiator specification.

(1) Radiator Tester (2) Adaptor

9Y1210785ENS0010US0

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. 8.0 mm (0.31 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 specification

Factory specification

69.5 to 72.5 °C

157.1 to 162.5 °F

85 °C
185 °F

9Y1210785ENS0011US0

1-S18

SM-E4B SERIES, WSM

KiSC issued 01, 2013 A

(4) Fuel System

ENGINE

Injection Timing

1. Remove the injection pipes.

2. Remove the engine stop solenoid.

3. Turn the flywheel counterclockwise (viewed from flywheel side)
until the fuel fills up to the hole of the delivery valve holder (3)
for No. 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 1.6 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 crank
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 adjustment, readjust the timing with
shims.

Z482/D602-E4B (3600 min

Injection timing Factory specification

D722-E4B (3200 min

Injection timing Factory specification

D782-E4B (3200 min

Injection timing Factory specification

D902-E4B (3600 min

Injection timing Factory specification

-1

(rpm) spec.)

-1

(rpm) spec.)

-1

(rpm) spec.)

-1

(rpm) spec.)

0.3186 to 0.3447 rad
(18.25 to 19.75 °) before
T.D.C.

0.3360 to 0.3621 rad
(19.25 to 20.75 °) before
T.D.C.

0.2837 to 0.3097 rad
(16.25 to 17.75 °) before
T.D.C.

0.3186 to 0.3447 rad
(18.25 to 19.75 °) before
T.D.C.

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

1-S19

(5) Two-holes : 0.20 mm (0.0079 in.)

Two-holes : 0.175 mm (0.00689 in.)
(6) One-hole : 0.25 mm (0.0098 in.)
(7) Without hole : 0.30 mm (0.012 in.)
(8) Three-holes : 0.35 mm (0.014 in.)

(To be continued)

SM-E4B SERIES, WSM

NOTE

KiSC issued 01, 2013 A

(Continued)

ENGINE

• The liquid gasket is not required for assembling.

• Shims are available in thickness of 0.20 mm (0.0079 in.),

0.25 mm (0.0098 in.), 0.30 mm (0.012 in.), 0.35 mm (0.014 in.)
and 0.175 mm (0.00689 in.). Combine these shims for
adjustments.

• Addition or reduction of shim (0.025 mm, 0.00098 in.)
delays or advances the injection timing by approx.

0.0044 rad (0.25 °).

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

• The 0.175 mm (0.00689 in.) thick shim is coated only on the
lower face. Therefore, do not use the 0.175 mm (0.00689 in.)
thick shim as the top shim of the combination (injection
pump side), because this can cause oil leakage.

• Refer to figure of the shim to check the thickness of the
shims.

• The injection timing might be changed by the application.

9Y1210785GEG0036US0

1-S20

SM-E4B SERIES, WSM

NOTE

NOTE

KiSC issued 01, 2013 A

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 injection pump pressure tester (1). (Refer 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

140.0 kgf/cm
1991 psi

2

• Never try to disassemble the injection pump assembly. For
repairs, you are strongly requested to contact a
KUBOTA-authorized pump service shop.

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

(3) Protection Cover for Jetted Fuel

9Y1210785ENS0012US0

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 (140.0 kgf/cm

2

, 1991 psi).

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

140.0 to 130.0 kgf/cm

8. Measure the time needed to decrease the pressure from 13.73
to 12.75 MPa (from 140.0 to 130.0 kgf/cm

2

, from 1991 to 1849 psi).

2

, from 1991 to 1849

psi).

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

10 seconds

Factory specification

Fuel tightness of delivery
valve

Allowable limit

13.73 → 12.75 MPa

140.0 → 130.0 kgf/cm
1991 → 1849 psi

5 seconds

13.73 → 12.75 MPa

140.0 → 130.0 kgf/cm
1991 → 1849 psi

2

2

• Never try to disassemble the injection pump assembly. For
repairs, you are strongly requested to contact a
KUBOTA-authorized pump service shop.

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

(3) Protection Cover for Jetted Fuel

9Y1210785ENS0013US0

1-S21

SM-E4B SERIES, WSM

CAUTION

KiSC issued 01, 2013 A

ENGINE

• Check the injection pressure and condition after confirming that there is nobody standing in the direction
the fume goes.

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

9Y1210785GEG0031US0

Nozzle Spraying Condition

1. Set the injection nozzle to a nozzle tester, and check the nozzle
spraying condition.

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

(a) Good (b) Bad

9Y1210785GEG0032US0

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 (0.00098 in.) difference of
adjusting washer thickness.
Approx. 590 kPa (6.0 kgf/cm

Fuel injection pressure Factory specification

2

, 85 psi)

13.73 to 14.70 MPa

140.0 to 150.0 kgf/cm
1992 to 2133 psi

2

(1) Adjusting Washer

9Y1210785GEG0033US0

Nozzle Valve Seat Tightness

1. Set the injection nozzle to a nozzle tester.

2. Raise the fuel pressure, and keep at 12.75 MPa (130.0 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 specification

12.75 MPa

130.0 kgf/cm
1849 psi

9Y1210785GEG0034US0

2

2

,

1-S22

SM-E4B SERIES, WSM

CAUTION

IMPORTANT

KiSC issued 01, 2013 A

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 assembling the nozzle, be sure to adjust the fuel injection
pressure.

35 to 39 N·m

3.5 to 4.0 kgf·m
26 to 28 lbf·ft

20 to 24 N·m

2.0 to 2.5 kgf·m
15 to 18 lbf·ft

49 to 68 N·m

5.0 to 7.0 kgf·m
37 to 50 lbf·ft

Tightening torque

Nozzle holder

Overflow pipe retaining nut

Nozzle holder assembly

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

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

9Y1210785GEG0035US0

(5) Electrical System

• To avoid accidental short circuit, be sure to attach the positive cable to the positive 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.

9Y1210785ENS0014US0

Battery Voltage

1. Stop the engine.

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

3. If the battery voltage is less than the factory specification, check
the battery specific gravity and recharge the battery.

Battery voltage Factory specification More than 12 V

(1) Positive Terminal (2) Negative Terminal

9Y1210785ENS0015US0

1-S23

SM-E4B SERIES, WSM

CAUTION

NOTE

KiSC issued 01, 2013 A

ENGINE

Battery Specific Gravity

• If battery acid (dilute sulfuric acid) gets on you it could
cause blindness or burns, or could cause corrosion of
machinery and tools so please be careful when handling.

• Wear safety glasses and rubber gloves when performing
battery maintenance and inspection (measuring specific
gravity, replenishing water, or charging).

• If the gas that is generated is ignited by an ignition source,
it may explode so be very careful with sparks and fire.

• Keep your body and face as far away from the battery as
you can when performing maintenance and inspection.

• Do not allow people who do not know how to handle a
battery or who do not sufficiently understand the danger
perform inspection or maintenance.

(Measurement items)
Q Zero adjustment

1. Open the cover and drip water on the prism surface using the
included rod.

2. Close the cover.

3. Aim in a direction that is bright, look into the lens, and adjust the
focus until the gradations can be seen clearly.

4. If the boundary line is not on the gradation baseline (0 position),
turn the adjustment screw until it matches.

5. When zero adjustment is complete, wipe the prism and cover
surface with a soft cloth or tissue paper.

Q Measurement of test fluid

1. Open the cover and drip test fluid on the prism surface using the
included rod.

2. Close the cover.

3. Aim in a direction that is bright, look into the lens and read the
gradation of the blue boundary line.

4. When the measurement is complete, wipe the prism and cover
surface with a soft cloth or tissue paper.

(Reference)

Electrolyte specific gravity and amount of discharge.
Use the following table as a reference.

(A) Electrolyte Specific Gravity
(B) Discharge

(C) Good
(D) Charging is necessary.

Temperature conversion of electrolyte specific gravity

• Battery electrolyte specific gravity changes based on
temperature.

• Insert the value identified on a specific gravity meter into
the following conversion equation for temperature
correction to learn an accurate specific gravity value.
(Standard temperature assumed to be 20 °C (68 °F))

= Dt + 0.0007 (t - 20)

D

20

= specific gravity value converted to standard

D

20

temperature of 20 °C (68 °F)

= measured specific gravity value at the electrolyte

D

t

temperature t °C

9Y1210785GEG0028US0

1-S24

SM-E4B SERIES, WSM

CAUTION

NOTE

NOTE

KiSC issued 01, 2013 A

ENGINE

Motor Test

• 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 momentarily 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.

• 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] Planetary Gear Reduction Type

9Y1210785ENS0016US0

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 momentarily 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 connects the cable from
the starter switch to the magnet switch.

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

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

9Y1210785ENS0017US0

1-S25

SM-E4B SERIES, WSM

KiSC issued 01, 2013 A

ENGINE

Magnet Switch Continuity Test

1. Check the continuity across the C terminal (1) and the B

terminal (2) with a circuit tester, pushing in the plunger.

2. If not continuous or if a certain value is indicated, replace the
magnet switch.

(1) C Terminal
(2) B Terminal

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

9Y1210785ENS0018US0

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 specification

AC 20 V or more at
5200 min

-1

(rpm)

9Y1210785ENS0019US0

1-S26

SM-E4B SERIES, WSM

NOTE

KiSC issued 01, 2013 A

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 M Ω meter.

• This check sheet shows the results of the test conducted
by using the "Sanwa-made tester SP-10 and SP-15D"
(Analog Meter).

• Use of other testers than 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)

Code colors (Tester + Terminal)

Blue Black Blue Green Yellow Red

Blue ,,,,+

Code
colors
(Tester

−

Ter min
al)

Black ,,,,,

Blue ,, ,,+

Green ,,, ,,

Yellow +++, +

Red ,,,,,

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

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

9Y1210785ENS0020US0

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 specification

14 to 15 V at
5200 min

-1

(rpm)

9Y1210785ENS0021US0

1-S27

SM-E4B SERIES, WSM

NOTE

KiSC issued 01, 2013 A

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 engine is operating measure the voltage between two
battery terminals. If the voltage 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 AND ASSEMBLING" and "SERVICING" for
alternator.

Regulating voltage at no
load

Factory specification

13.8 to 14.8 V at
25 °C (77 °F)

9Y1210785ENS0022US0

Glow Plug Lead Terminal Voltage

1. Turn the key 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 differs from the battery voltage, the wiring harness
or main switch is faulty.

Voltage

Main switch key at GLOW
(or PREHEAT)

Approx. battery voltage

9Y1210785ENS0023US0

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 specification Approx. 1.1 Ω

9Y1210785ENS0024US0

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

(1) Battery (12 V)

9Y1210785ENS0025US0

1-S28

SM-E4B SERIES, WSM

NOTE

IMPORTANT

KiSC issued 01, 2013 A

ENGINE

Engine Stop Solenoid Test (Energize to Run Type)

1. Disconnect the 3P connector (3) from the engine stop solenoid

(1) wiring harness.

2. Remove the engine stop solenoid (1) from the engine.

3. Connect the jumper leads from the pulling coil terminal (6) to the
switch (7), and from switch (7) to the battery positive terminal
(10).

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) is turn on, the plunger pull into the solenoid
body and then the plunger comes out within approximately 1.2
seconds.

7. Turn on the switch (8) then turn on the switch (7), the plunger
pull into the solenoid body and it keeps in holding position after
turn off the switch (7).

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

• This solenoid assembly includes reverse polarity protected
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 Factory specification 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

[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

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

9Y1210785ENS0026US0

(3) Oil Inlet Plug

9Y1210785ENS0027US0

1-S29

SM-E4B SERIES, WSM

CAUTION

IMPORTANT

KiSC issued 01, 2013 A

(2) External Components

ENGINE

Draining Coolant

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

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

(1) Coolant Drain Cock

9Y1210785ENS0028US0

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 mm (0 in.)

9Y1210785ENS0029US0

(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

9.81 to 11.2 N·m

1.00 to 1.15 kgf·m

7.24 to 8.31 lbf·ft

(3) Cylinder Head Cover

9Y1210785ENS0030US0

1-S30

SM-E4B SERIES, WSM

IMPORTANT

KiSC issued 01, 2013 A

ENGINE

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

25 to 34 N·m

2.5 to 3.5 kgf·m
18 to 25 lbf·ft

9Y1210785ENS0031US0

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.

20 to 24 N·m

Tightening torque

Overflow pipe retaining nut

Nozzle holder assembly

Glow plug

2.0 to 2.5 kgf·m
15 to 18 lbf·ft

49 to 68 N·m

5.0 to 7.0 kgf·m
37 to 50 lbf·ft

7.9 to 14 N·m

0.80 to 1.5 kgf·m

5.8 to 10 lbf·ft

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

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

9Y1210785ENS0032US0

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.

6.0 mm (0.24 in.)).

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

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

3. While turning the screw driver, slowly pull 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

9Y1210785ENS0033US0

1-S31

SM-E4B SERIES, WSM

IMPORTANT

NOTE

KiSC issued 01, 2013 A

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 adjust the valve
clearance.

9.81 to 11.2 N·m

Tightening torque Rocker arm bracket screw

1.00 to 1.15 kgf·m

7.24 to 8.31 lbf·ft

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

(3) Push Rod
(4) Tappet

9Y1210785ENS0034US0

Cylinder Head and Cylinder Head Gasket

1. Loosen the pipe clamps (1), and remove the water return pipe
(2).

2. Remove the cylinder head screw in the order of (n or j) to (a).

3. Remove the cylinder head gasket.

(When reassembling)

• Replace the cylinder head gasket with a new one.

• When mounting the gasket, set it to the pin pipe holes. Take
care not to mount it reversely.

• The cylinder head should be free of scratches and dust.

• Install the cylinder head, using care not to damage the gasket.

• After applying engine oil to the thread of screws, tighten them in
several steps and specified sequence (a) to (n or j).

• Do not use O-ring on the pin pipe.

• It is not necessary to retighten the cylinder head screw and
to readjust valve clearance after engine warmed up.

38 to 42 N·m

Tightening torque Cylinder head screw

3.8 to 4.3 kgf·m
28 to 31 lbf·ft

(1) Pipe Clamp
(2) Water Return Pipe
(3) Pin Pipe

1-S32

A : Gear Case Side
(n or j) to (a) :To Loosen
(a) to (n or j) :To Tighten
[a] Z482-E4B, Z602-E4B
[b] D722-E4B, D782-E4B, D902-E4B

9Y1210785ENS0035US0

SM-E4B SERIES, WSM

IMPORTANT

IMPORTANT

KiSC issued 01, 2013 A

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

9Y1210785ENS0036US0

Valves

1. Remove the valve caps (4).

2. Remove the valve spring collet (3), pushing the valve spring
retainer (2) by valve spring replacer (1).

3. Remove the valve spring retainer (2), valve spring (5) and valve
stem seal (6).

4. Remove the valve (7).

(When reassembling)

• Wash the valve stem and valve guide hole, and apply engine oil
sufficiently.

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

• Do not 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

9Y1210785ENS0037US0

Thermostat Assembly

1. Remove the thermostat cover mounting screws (1), and remove
the thermostat cover (2).

2. Remove the thermostat assembly (4).

(When reassembling)

• Replace the gasket (3) with a new one.

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

(3) Thermostat Cover Gasket
(4) Thermostat Assembly

9Y1210785ENS0038US0

Water Pump Assembly (If necessary)

1. Loosen the alternator mounting screws, and remove the fan
belt.

2. Remove the fan and fan pulley.

3. Remove the water pump assembly (1) from the gear case cover
(3).

(When reassembling)

• Replace the gasket (2) with a new one.

(1) Water Pump Assembly
(2) Water Pump Gasket

(3) Gear Case Cover

9Y1210785ENS0039US0

1-S33

SM-E4B SERIES, WSM

IMPORTANT

KiSC issued 01, 2013 A

ENGINE

Oil Pan and Oil Strainer

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

2. Remove the oil pan (1) by lightly tapping the rim of the pan with
a wooden hammer.

3. Remove the oil strainer (3).

(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 tightening, tighten oil pan mounting screws in
diagonal order form the center.

For Z482-E4B, Z602-E4B

• Using the hole (6) numbered "2", install the oil strainer by
mounting screw.

For D722-E4B, D782-E4B, D902-E4B

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

• Scrape off the old adhesive completely. Wipe the sealing
surface clean using waste cloth soaked with gasoline. Now
apply new adhesive 3.0 to 5.0 mm (0.12 to 0.19 in.) thick all
over the contact surface. Apply the adhesive also on the
center 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 3.0 to 5.0 mm (0.12 to 0.19 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-E4B, Z602-E4B
[b] D722-E4B, D782-E4B, D902-E4B

9Y1210785ENS0040US0

1-S34

SM-E4B SERIES, WSM

NOTE

KiSC issued 01, 2013 A

(4) Gear Case and Timing Gears

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 plate (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 governor spring (4) to the governor lever (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 adjusting spring (9) at its end and the
pin (11) on the rod engages with the slot (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, 0.002 in.) delays or
advances the injection timing by approx. 0.009 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

(To be continued)

1-S35

SM-E4B SERIES, WSM

NOTE

KiSC issued 01, 2013 A

(Continued)

ENGINE

• Specific tool (1) :

1.2 mm (0.047 in.) diameter hard wire with its end hooked,
overall length 200 mm (7.87 in.).
The tip of wire is bent like the hook to hang governor
springs.

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

(To be continued)

1-S36