Kubota D782-E3, D1005-E3, D902-E3, D1105-E3, D1105-TE3 Operator's Manual

ENGLISH

1J412-8911-1

MODELS

Z482-E3 · Z602-E3
D722-E3 · D782-E3 · D902-E3
D1005-E3 · D1105-E3
D1105-TE3 · D1305-E3

V1505-E3 · V1505-TE3 · D1005-E3BG

D1105-E3BG · V1505-E3BG

D1503-M-E3 · D1703-M-E3 · D1803-M-E3

V2003-M-E3 · V2203-M-E3 · V2403-M-E3 · V2403-M-T-E3

D1803-M-DI-E3 · V2403-M-DI-E3

V3600-E3 · V3600-T-E3 · V3300-E3BG · V3600-T-E3BG

1ABABAAAP15001ABAAAAAP1560

B-1554D-2357

ENGLISH

FOREWORD

SAFETY FIRST

FOREWORD

You are now the proud owner of a KUBOTA Engine. This engine is a
product of KUBOTA quality engineering and manufacturing. It is made
of fi ne materials and under a rigid quality control system. It will give you
long, satisfactory service. To obtain the best use of your engine, please
read this manual carefully. It will help you become familiar with the
operation of the engine and contains many helpful hints about engine
maintenance. It is KUBOTA's policy to utilize as quickly as possible every
advance in our research. The immediate use of new techniques in the
manufacture of products may cause some small parts of this manual to be
outdated. KUBOTA distributors and dealers will have the most up-to-date
information. Please do not hesitate to consult with them.

SAFETY FIRST

3

This symbol, the industry's "Safety Alert Symbol", is used throughout this
manual and on labels on the machine itself to warn of the possibility of
personal injury. Read these instructions carefully. It is essential that you
read the instructions and safety regulations before you attempt to assemble
or use this unit.

DANGER : Indicates an imminently hazardous situation which, if

3

not avoided, will result in death or serious injury.

WARNING : Indicates a potentially hazardous situation which, if not

3

CAUTION : Indicates a potentially hazardous situation which, if not

3

IMPORTANT : Indicates that equipment or property damage could

NOTE : Gives helpful information.

avoided, COULD result in death or serious injury.

avoided, MAY result in minor or moderate injury.

result if instructions are not followed.

CONTENTS

SAFE OPERATION ............................................................................................. 1

SERVICING OF THE ENGINE ................................................................................. 1

NAMES OF PARTS .................................................................................................. 2

PRE-OPERATION CHECK....................................................................................... 4

BREAK-IN ............................................................................................................. 4

DAILY CHECK ...................................................................................................... 4

OPERATING THE ENGINE ...................................................................................... 5

STARTING THE ENGINE (NORMAL) .................................................................. 5

COLD WEATHER STARTING .............................................................................. 7

STOPPING THE ENGINE ..................................................................................... 7

CHECKS DURING OPERATION .......................................................................... 8

Radiator cooling water (Coolant) ........................................................................................ 8

Oil pressure lamp................................................................................................................ 9

Fuel..................................................................................................................................... 9

Color of exhaust.................................................................................................................. 9

Immediately stop the engine if;........................................................................................... 9

REVERSED ENGINE REVOLUTION AND REMEDIES ....................................... 9

How to tell when the engine starts running backwards....................................................... 9

Remedies............................................................................................................................ 9

MAINTENANCE...................................................................................................... 10

SERVICE INTERVALS........................................................................................ 11

PERIODIC SERVICE .............................................................................................. 18

FUEL ................................................................................................................... 18

Fuel level check and refueling .......................................................................................... 18

Air bleeding the fuel system.............................................................................................. 19

Checking the fuel pipes .................................................................................................... 21

Cleaning the fuel filter pot................................................................................................. 22

Fuel filter cartridge replacement ....................................................................................... 23

ENGINE OIL........................................................................................................ 23

Checking oil level and adding engine oil........................................................................... 23

Changing engine oil.......................................................................................................... 25

Replacing the oil filter cartridge ........................................................................................ 26

RADIATOR.......................................................................................................... 27

Checking coolant level, adding coolant ............................................................................ 27

Changing coolant.............................................................................................................. 29

Remedies for quick decrease of coolant........................................................................... 30

Checking radiator hoses and clamp ................................................................................. 30

Precaution at overheating................................................................................................. 30

Cleaning radiator core (outside) ....................................................................................... 30

Anti-freeze ........................................................................................................................ 31

AIR CLEANER .................................................................................................... 32

Evacuator valve ................................................................................................................ 32

Dust indicator (optional).................................................................................................... 32

ENGLISH

CONTENTS

Evacuator valve ................................................................................................................ 33

Dust indicator (optional).................................................................................................... 33

Cleaning primary air filter element.................................................................................... 34

Evacuator valve ................................................................................................................ 34

For the air cleaner with a dust cup (optional).................................................................... 34

Dust indicator (optional).................................................................................................... 35

BATTERY............................................................................................................ 35

Battery charging................................................................................................................ 35

Direction for long term storage ......................................................................................... 36

ELECTRIC WIRING ............................................................................................ 37

FAN BELT ........................................................................................................... 37

Adjusting fan belt tension.................................................................................................. 37

CARRIAGE AND STORAGE .................................................................................. 38

ENGLISH

CARRIAGE.......................................................................................................... 38

STORAGE........................................................................................................... 38

TROUBLESHOOTING............................................................................................ 39

SPECIFICATIONS .................................................................................................. 41

WIRING DIAGRAMS .............................................................................................. 56

SAFE OPERATION

Careful operation is your best assurance against an accident. Read and understand this
section carefully before operating the engine. All operators, no matter how much
experience they may have, should read this and other related manuals before operating
the engine or any equipment attached to it. It is the owner's obligation to provide all
operators with this information and instruct them on safe operation.

Be sure to observe the following for safe operation.

1. OBSERVE SAFETY INSTRUCTIONS

A Read and understand carefully this "OPERATOR'S

MANUAL" and "LABELS ON THE ENGINE" before
attempting to start and operate the engine.

A Learn how to operate and work safely. Know your

equipment and its limitations. Always keep the engine in
good condition.

A Before allowing other people to use your engine, explain

how to operate and have them read this manual before
operation.

A DO NOT modify the engine. UNAUTHORIZED

MODIFICATIONS to the engine may impair the function
and/or safety and affect engine life. If the engine does
not perform properly, consult your local Kubota Engine
Distributor first.

1SAFE OPERATION

ENGLISH

2. WEAR SAFE CLOTHING AND PERSONAL PROTECTIVE EQUIPMENT (PPE)

A DO NOT wear loose, torn or bulky clothing around the

machine that may catch on working controls and
projections or into fans, pulleys and other moving parts
causing personal injury.

A Use additional safety items-PPE, e.g. hard hat, safety

protection, safety goggles, gloves, etc., as appropriate
or required.

A DO NOT operate the machine or any equipment

attached to it while under the influence of alcohol,
medication, or other drugs, or while fatigued.

A DO NOT wear radio or music headphones while

operating the engine.

2 SAFE OPERATION

3. CHECK BEFORE STARTING & OPERATING THE ENGINE

A Be sure to inspect the engine before operation. Do not

operate the engine if there is something wrong with it.
Repair it immediately.

A Ensure all guards and shields are in place before operating

the engine. Replace any that are damaged or missing.

A Check to see that you and others are a safe distance

from the engine before starting.

A Always keep the engine at least 3 feet (1 meter) away

from buildings and other facilities.

A DO NOT allow children or livestock to approach the

machine while the engine is running.

A DO NOT start the engine by shorting across starter

ENGLISH

terminals. The machine may start in gear and move. Do
not bypass or defeat any safety devices.

4. KEEP THE ENGINE AND SURROUNDINGS CLEAN

A Be sure to stop the engine before cleaning.
A Keep the engine clean and free of accumulated dirt, grease

and trash to avoid a fire. Store flammable fluids in proper
containers and cabinets away from sparks and heat.

A Check for and repair leaks immediately.
A DO NOT stop the engine without idling; Allow the engine

to cool down, first. Keep the engine idling for about 5
minutes before stopping unless there is a safety
problem that requires immediate shut down.

5.

SAFE HANDLING OF FUEL AND LUBRICANTS -KEEP AWAY FROM FIRE

A Always stop the engine before refueling and/or

lubricating.

A DO NOT smoke or allow flames or sparks in your work

area. Fuel is extremely flammable and explosive under
certain conditions.

A Refuel at a well ventilated and open place. When fuel

and/or lubricants are spilled, refuel after letting the
engine cool down.

A DO NOT mix gasoline or alcohol with diesel fuel. The

mixture can cause a fire or severe engine damage.

A Do not use unapproved containers e.g. buckets, bottles,

jars. Use approved fuel storage containers and
dispensers.

6. EXHAUST GASES & FIRE PREVENTION

A Engine exhaust fumes can be very harmful if allowed to

accumulate. Be sure to run the engine in a well
ventilated location and where there are no people or
livestock near the engine.

A The exhaust gas from the muffler is very hot. To prevent

a fire, do not expose dry grass, mowed grass, oil or any
other combustible materials to exhaust gas. Keep the
engine and muffler clean at all times.

A To avoid a fire, be alert for leaks of flammable

substances from hoses and lines. Be sure to check for
leaks from hoses or pipes, such as fuel and hydraulic
fluid by following the maintenance check list.

A To avoid a fire, do not short across power cables and

wires. Check to see that all power cables and wirings
are in good condition. Keep all electrical connections
clean. Bare wire or frayed insulation can cause a
dangerous electrical shock and personal injury.

7. ESCAPING FLUID

A Relieve all pressure in the air, the oil and the cooling

systems before disconnecting any lines, fittings or
related items.

A Be cautious of possible pressure relief when

disconnecting any device from a pressurized system
that utilizes pressure. DO NOT check for pressure leaks
with your hand. High pressure oil or fuel can cause
personal injury.

A Escaping fluid under pressure has sufficient force to

penetrate skin causing serious personal injury.

A Fluid escaping from pinholes may be invisible. Use a

piece of cardboard or wood to search for suspected
leaks: do not use hands and body. Use safety goggles
or other eye protection when checking for leaks.

A If injured by escaping fluid, see a medical doctor

immediately. This fluid can produce gangrene or severe
allergic reaction.

3SAFE OPERATION

ENGLISH

4 SAFE OPERATION

8. CAUTIONS AGAINST BURNS & BATTERY EXPLOSION

A To avoid burns, be cautious of hot components, e.g.

muffler, muffler cover, radiator, hoses, engine body,
coolants, engine oil, etc. during operation and after the
engine has been shut off.

A DO NOT remove the radiator cap while the engine is

running or immediately after stopping. Otherwise hot
water will spout out from the radiator. Wait until the
radiator is completely cool to the touch before removing
the cap. Wear safety goggles.

A Be sure to close the coolant drain valve, secure the

pressure cap, and fasten the pipe band before
operating. If these parts are taken off, or loosened, it will

ENGLISH

result in serious personal injury.

A The battery presents an explosive hazard. When the

battery is being charged, hydrogen and oxygen gases
are extremely explosive.

A DO NOT use or charge the battery if its fluid level is

below the LOWER mark.
Otherwise, the component parts may deteriorate earlier
than expected, which may shorten the service life or
cause an explosion. Immediately, add distilled water
until the fluid level is between the UPPER and LOWER
marks.

A Keep sparks and open flames away from the battery,

especially during charging. DO NOT strike a match near
the battery.

A DO NOT check the battery charge by placing a metal

object across the terminals. Use a voltmeter or
hydrometer.

A DO NOT charge a frozen battery. There is a risk of

explosion. When frozen, warm the battery up to at least
16°C (61°F).

9. KEEP HANDS AND BODY AWAY FROM ROTATING PARTS

A Be sure to stop the engine before checking or adjusting

the belt tension and cooling fan.

A Keep your hands and body away from rotating parts,

such as the cooling fan, V-belt, fan drive pulley or
flywheel. Contact with rotating parts can cause severe
personal injury.

A DO NOT run the engine without safety guards. Install

safety guards securely before operation.

10. ANTI-FREEZE & DISPOSAL OF FLUIDS

A Anti-freeze contains poison. Wear rubber gloves to

avoid personal injury. In case of contact with skin, wash
it off immediately.

A DO NOT mix different types of Anti-freeze. The mixture

can produce a chemical reaction causing harmful
substances. Use approved or genuine KUBOTA Anti­freeze.

A Be mindful of the environment and the ecology. Before

draining any fluids, determine the correct way to dispose
of them. Observe the relevant environmental protection
regulations when disposing of oil, fuel, coolant, brake
fluid, filters and batteries.

A When draining fluids from the engine, place a suitable

container underneath the engine body.

A DO NOT pour waste onto the ground, down a drain, or

into any water source. Dispose of waste fluids according
to environmental regulations.

5SAFE OPERATION

ENGLISH

6 SAFE OPERATION

11. CONDUCTING SAFETY CHECKS & MAINTENANCE

A When inspecting the engine or servicing, place the

engine on a large flat surface. DO NOT work on
anything that is supported ONLY by lift jacks or a hoist.
Always use blocks or the correct stands to support the
engine before servicing.

A Disconnect the battery from the engine before

conducting service. Put a "DO NOT OPERATE!" tag on
the key switch to avoid accidental starting.

A To avoid sparks from an accidental short circuit always

disconnect the battery's ground cable (-) first and
reconnect it last.

A Be sure to stop the engine and remove the key when

ENGLISH

conducting daily and periodic maintenance, service and
cleaning.

A Check or conduct maintenance after the engine,

coolant, muffler, or muffler cover have cooled off
completely.

A Always use the appropriate tools and fixtures. Verify that

they are in good condition before performing any service
work. Make sure you understand how to use them
before service.

A Use ONLY correct engine barring techniques for

manually rotating the engine. DO NOT attempt to rotate
the engine by pulling or prying on the cooling fan and V­belt. This practice can cause serious personal injury or
premature damage to the cooling fan and belt.

A Replace fuel pipes and lubricant pipes with their hose

clamps every 2 years or earlier whether they are
damaged or not. They are made of rubber and age
gradually.

A When servicing is performed together by two or more

persons, take care to perform all work safely.

A Keep a first aid kit and fire extinguisher handy at all

times.

12. WARNING AND CAUTION LABELS

Part No.19077-8724-1 or 16667-8724-1

(55mm in diameter) (37mm in diameter)

Part No.TA040-4957-1
Stay clear of engine
fan and fan belt

7SAFE OPERATION

ENGLISH

13. CARE OF WARNING AND CAUTION LABELS

1. Keep warning and caution labels clean and free from obstructing material.

2. Clean warning and caution labels with soap and water, dry with a soft cloth.

3. Replace damaged or missing warning and caution labels with new labels from your local
KUBOTA dealer.

4. If a component with warning and caution label(s) affixed is replaced with a new part, make
sure the new label(s) is (are) attached in the same location(s) as the replaced component.

5. Mount new warning and caution labels by applying to a clean dry surface and pressing any
bubbles to the outside edge.

SERVICING OF THE ENGINE

1SERVICING OF THE ENGINE

Your dealer is interested in your new engine and has the
desire to help you get the most value from it. After
reading this manual thoroughly, you will find that you
can do some of the regular maintenance yourself.
However, when in need of parts or major service, be
sure to see your KUBOTA dealer.
For service, contact the KUBOTA Dealership from
which you purchased your engine or your local
KUBOTA dealer.
When in need of parts, be prepared to give your dealer
the engine serial number.
Locate the serial number now and record them in the
space provided.

Type Serial No.

Engine

Date of Purchase

Name of Dealer

(To be filled in by purchaser)

[Z482-E3, Z602-E3, D722-E3, D782-E3, D902-E3]

[D1503-M-E3, D1703-M-E3, D1803-M-E3, V2003-M-E3,
V2203-M-E3, V2403-M-E3, V2403-M-T-E3, D1803-M-DI-E3,
V2403-M-DI-E3]

(1) Engine serial number

[V3600-E3, V3600-T-E3, V3300-E3BG, V3600-T-E3BG]

(1) Engine serial number

ENGLISH

(1) Engine serial number

[D1005-E3, D1105-E3, D1105-TE3, D1305-E3, V1505-E3,
V1505-TE3, D1005-E3BG, D1105-E3BG, V1505-E3BG]

(1) Engine serial number

2 NAMES OF PARTS

NAMES OF PARTS

[Z482-E3, Z602-E3, D722-E3, D782-E3, D902-E3]

ENGLISH

1ABAAAAAP157F 1ABAAAAAP158E

[D1005-E3, D1105-E3, D1105-TE3, D1305-E3, V1505-E3, V1505-TE3, D1005-E3BG, D1105-E3BG, V1505-E3BG]

1ABABAAAP149A

(1) Intake manifold
(2) Speed control lever
(3) Engine stop lever
(4) Injection pump
(5) Fuel feed pump
(6) Cooling fan
(7) Fan drive pulley
(8) Oil filter cartridge
(9) Water drain cock

(10) Oil filler plug
(11) Exhaust manifold
(12) Alternator
(13) Starter
(14) Oil level gauge
(15) Oil pressure switch
(16) Flywheel
(17) Oil drain plug
(18) Oil pan
(19) Engine hook

[D1503-M-E3, D1703-M-E3, D1803-M-E3, V2003-M-E3, V2203-M-E3, V2403-M-E3, V2403-M-T-E3, D1803-M-DI-E3,
V2403-M-DI-E3]

1ABACAAAP0020 1ABACAAAP0300

[V3600-E3, V3600-T-E3, V3300-E3BG, V3600-T-E3BG]

3NAMES OF PARTS

ENGLISH

B-1556 B-1543

(1) Intake manifold
(2) Speed control lever
(3) Engine stop lever
(4) Shut off solenoid
(5) Fuel feed pump
(6) Cooling fan
(7) Engine hook
(8) Oil filter cartridge
(9) Fuel filter

(10) Oil filler plug
(11) Exhaust manifold
(12) Alternator
(13) Starter
(14) Fan belt
(15) Oil pressure switch
(16) Flywheel
(17) Oil drain plug
(18) Oil pan

4 PRE-OPERATION CHECK

PRE-OPERATION CHECK

BREAK-IN

During the engine break-in period, observe the following by all means:

1. Change engine oil and oil filter cartridge after the first 50 hours of operation. (See "ENGINE OIL" in "PERIODIC
SERVICE" section.)

2. When ambient temperature is low, operate the machine after the engine has been completely warmed up.

DAILY CHECK

To prevent trouble from occurring, it is important to know the conditions of the engine well. Check it before starting.

CAUTION

To avoid personal injury:

ENGLISH

A Be sure to install shields and safeguards attached to the engine when operating.
A Stop the engine at a flat and wide space when checking.
A Keep dust or fuel away from the battery, wiring, muffler and engine to prevent a fire.

Check and clear them before operating everyday. Pay attention to the heat of the
exhaust pipe or exhaust gas so that it can not ignite trash.

Item Ref. page

1. Parts which had trouble in previous operation -

2. By walking around the machine (1) Oil or water leaks 23 to 31

(2) Engine oil level and contamination 23

(3) Amount of fuel 18

(4) Amount of coolant 27 to 31

(5) Dust in air cleaner dust cup 32

(6) Damaged parts and loosened bolts and nuts -

3. By inserting the key into the starter
switch

4. By starting the engine (1) Color of exhaust fumes 9

(1) Proper functions of meters and pilot lamps; no stains on

these parts

(2) Proper function of glow lamp timer -

(2) Unusual engine noise 9

(3) Engine start-up condition 5

(4) Slow-down and acceleration behavior 9

-

OPERATING THE ENGINE

5OPERATING THE ENGINE

STARTING THE ENGINE (NORMAL)

CAUTION

To avoid personal injury:
A Do not allow children to approach

the machine while the engine is
running.

A Be sure to install the machine on

which the engine is installed, on a
flat place.

A Do not run the engine on gradients.
A Do not run the engine in an enclosed

area. Exhaust gas can cause air
pollution and exhaust gas poisoning.

A Keep your hands away from rotating

parts (such as fan, pulley, belt,
flywheel etc.) during operation.

A Do not operate the machine while

under the influence of alcohol or
drugs.

A Do not wear loose, torn or bulky

clothing around the machine. It may
catch on moving parts or controls,
leading to the risk of accident. Use
additional safety items, e.g. hard
hat, safety boots or shoes, eye and
hearing protection, gloves, etc., as
appropriate or required.

A Do not wear radio or music

headphones while operating engine.

A Check to see if it is safe around the

engine before starting.

A Reinstall safeguards and shields

securely and clear all maintenance
tools when starting the engine after
maintenance.

1. Set the fuel lever to the "ON" position.

(1) Fuel lever (A) "ON"

2. Place the engine stop lever to the
"START" position.

3. Place the speed control lever at more
than half "OPERATION".

[Z482-E3, Z602-E3, D722-E3, D782-E3, D902-E3]

(B) "OFF"

ENGLISH

A Do not use ether or any starting fluid for starting the

engine, or a severe damage will occur.

A When starting the engine after a long storage (of

more than 3 months), first set the stop lever to the
"STOP" position and then activate the starter for
about 10 seconds to allow oil to reach every engine
part.

(1) Speed control lever (A) "OPERATION"

(B) "IDLING"

6 OPERATING THE ENGINE

[D1005-E3, D1105-E3, D1105-TE3, D1305-E3, V1505-E3,
V1505-TE3]

(1) Speed control lever

ENGLISH

(2) Engine stop lever

[D1503-M-E3, D1703-M-E3, D1803-M-E3, V2003-M-E3,
V2203-M-E3, V2403-M-E3, V2403-M-T-E3, D1803-M-DI-E3,

(A) "IDLING"
(B) "OPERATION"
(C) "START"
(D) "STOP"

V2403-M-DI-E3]

[V3600-E3, V3600-T-E3]

(1) Speed control lever
(2) Engine stop lever

(A) "IDLING"
(B) "OPERATION"
(C) "START"
(D) "STOP"

4. Insert the key into the key switch and
turn it "ON".

(1) Engine stop lever
(2) Speed control lever

(A) "STOP"
(B) "START"
(C) "IDLING"
(D) "OPERATION"

(A) "SWITCHED OFF"
(B) "OPERATION"
(C) "PREHEATING"
(D) "STARTING"

(A) "PREHEATING"
(B) "SWITCHED OFF"
(C) "OPERATION"
(D) "STARTING"

5. Turn the starter switch to the
"PREHEATING" position to allow the
glow lamp to redden.

(with lamp timer in use)

A The glow lamp goes out in about 5 seconds when

the lamp timer is up. Refer to this for pre-heating.
Even with the glow lamp off, the glow plug can be
pre-heated by turning the starter switch to the
"PREHEATING" position.

7OPERATING THE ENGINE

6. Turn the key to the "STARTING"
position and the engine should start.
Release the key immediately when the
engine starts.

7. Check to see that the oil pressure lamp
and charge lamp are off. If the lamps are
still on, immediately stop the engine,
and determine the cause.

(See "CHECKS DURING OPERATION" in
"OPERATING THE ENGINE" Section.)

A If the oil pressure lamp should be still on,

immediately stop the engine and check;

- if there is enough engine oil.

- if the engine oil has dirt in it.

- if the wiring is faulty.

8. Warm up the engine at medium speed
without load.

A If the glow lamp should redden too quickly or too

slowly, immediately ask your KUBOTA dealer to
check and repair it.

A If the engine does not catch or start at 10 seconds

after the starter switch is set at "STARTING"
position, wait for another 30 seconds and then begin
the engine starting sequence again. Do not allow the
starter motor to run continuously for more than 20
seconds.

COLD WEATHER STARTING

If the ambient temperature is below -5°C(23°F)* and the
engine is very cold, start it in the following manner:
Take steps (1) through (4) before.

5. Turn the key to the "PREHEATING"
position and keep it there for a certain
period mentioned below.

A Shown below are the standard preheating times for

various temperatures. This operation, however, is
not required, when the engine is warmed up.

Ambient

temperature

Above 10°C (50°F)

10°C (50°F) to

-5°C (23°F)

*Below -5°C (23°F)

Limit of
continuous use

Ordinary heat type

Approx. 5 seconds

Approx. 10 seconds

Preheating time

With glow lamp timer

NO NEED

See

20 seconds

A In case of installing standard glow lamp, glow lamp

goes off after about 6 seconds, when the starter
switch key is turned to preheating position. However
if necessary, keep the starter switch key at
preheating position for longer time, according to the
left recommendation.

6. Turn the key to the "STARTING"
position and the engine should start.

(If the engine fails to start after 10 seconds,
turn off the key for 5 to 30 seconds. Then
repeat steps (5) and (6).)

A Do not allow the starter motor to run continuously for

more than 20 seconds.

A Be sure to warm up the engine, not only in winter, but

also in warmer seasons. An insufficiently warmed-up
engine can shorten its service life.

A When there is fear of temperature dropping below

-15°C (5°F) detach the battery from the machine,
and keep it indoors in a safe area, to be reinstalled
just before the next operation.

STOPPING THE ENGINE

1. Return the speed control lever to low
idle, and run the engine under idling
conditions.

E3, D902-E3, D1005-E3, D1105-E3, D1105-TE3,
D1305-E3, V1505-E3, V1505-TE3, D1503-M-E3,
D1703-M-E3, D1803-M-E3, V2003-M-E3, V2203-M­E3, V2403-M-E3, V2403-M-T-E3, D1803-M-DI-E3,
V2403-M-DI-E3, V3600-E3, V3600-T-E3]

2. Set the engine stop lever to the "STOP"
position.

3. With the starter switch placed to the
"OFF" position, remove the key. (Be
sure to return the engine stop lever to
the "START" position to be ready for the
next start.)

[Z482-E3, Z602-E3, D722-E3, D782-

ENGLISH

8 OPERATING THE ENGINE

[Z482-E3, Z602-E3, D722-E3, D782-E3, D902-E3]

(1) Speed control lever
(2) Engine stop lever

ENGLISH

[D1005-E3, D1105-E3, D1105-TE3, D1305-E3, V1505-E3,
V1505-TE3]

(1) Speed control lever
(2) Engine stop lever

[D1503-M-E3, D1703-M-E3, D1803-M-E3, V2003-M-E3,
V2203-M-E3, V2403-M-E3, V2403-M-T-E3, D1803-M-DI-E3,
V2403-M-DI-E3]

(1) Engine stop lever
(2) Speed control lever

(A) "IDLING"
(B) "OPERATION"
(C) "START"
(D) "STOP"

(A) "IDLING"
(B) "OPERATION"
(C) "START"
(D) "STOP"

(A) "STOP"
(B) "START"
(C) "IDLING"
(D) "OPERATION"

[V3600-E3, V3600-T-E3]

(1) Speed control lever
(2) Engine stop lever

A If equipped with a turbo-charger, allow the engine to

idle for 5 minutes before shutting it off after a full load
operation.
Failure to do so may lead to turbo-charger trouble.

(A) "IDLING"
(B) "OPERATION"
(C) "START"
(D) "STOP"

CHECKS DURING OPERATION

While running, make the following checks to see that all
parts are working correctly.

BRadiator cooling water (Coolant)

WARNING

To avoid personal injury:
A Do not remove radiator cap until

coolant temperature is well below
its boiling point. Then loosen cap
slightly to the stop position, to
relieve any pressure, before
removing cap completely.

If the coolant temperature warning lamp lights up or if
steam or coolant does not stop squirting from the
radiator overflow pipe, turn off the load and keep the

engine idling (COOLING-DOWN) for at least 5
minutes to let it cool down gradually. Then stop the

engine and take the following inspection and servicing.

1. Check to see if the coolant runs short or if there is
any coolant leak;

2. Check to see if there is any obstacle around the
cooling air inlet or outlet;

3. Check to see if there is any dirt or dust between
radiator fins and tube;

4. Check to see if the fan belt is too loose;

5. Check to see if radiator water pipe is clogged; and

6. Check to see if anti-freeze is mixed to a 50/50% mix
of water and anti-freeze.

9OPERATING THE ENGINE

BOil pressure lamp

The lamp lights up to warn the operator that the engine
oil pressure has dropped below the prescribed level. If
this should happen during operation or should not go off
even after the engine is accelerated more than
1000rpm, immediately stop the engine and check the
following:

1. Engine oil level (See "ENGINE OIL" in "PERIODIC
SERVICE" Section.)

2. Lubricant system (See "ENGINE OIL" in "PERIODIC
SERVICE" Section.)

BFuel

CAUTION

To avoid personal injury:
A Fluid escaping from pinholes may

be invisible. Do not use hands to
search for suspected leaks; Use a
piece of cardboard or wood,
instead. If injured by escaping fluid,
see a medical doctor at once. This
fluid can produce gangrene or a
severe allergic reaction.

A Check any leaks from fuel pipes or

fuel injection pipes. Use eye
protection when checking for leaks.

Be careful not to empty the fuel tank. Otherwise air may
enter the fuel system, requiring fuel system bleeding.
(See "FUEL" in "PERIODIC SERVICE" Section.)

BColor of exhaust

While the engine is run within the rated output range:

A The color of exhaust remains colorless.
A If the output slightly exceeds the rated level, exhaust

may become a little colored with the output level kept
constant.

A If the engine is run continuously with dark exhaust

emission, it may lead to trouble with the engine.

REVERSED ENGINE REVOLUTION AND
REMEDIES

CAUTION

To avoid personal injury:
A Reversed engine operation can

make the machine reverse and run it
backwards. It may lead to serious
trouble.

A Reversed engine operation may

make exhaust gas gush out into the
intake side and ignite the air
cleaner; It could catch fire.

Reversed engine revolution must be stopped
immediately since engine oil circulation is cut quickly,
leading to serious trouble.

BHow to tell when the engine starts running

backwards

1. Lubricating oil pressure drops sharply. Oil pressure
warning light, if used, will light.

2. Since the intake and exhaust sides are reversed, the
sound of the engine changes, and exhaust gas will
come out of the air cleaner.

3. A louder knocking sound will be heard when the
engine starts running backwards.

BRemedies

1. Immediately set the engine stop lever to the "STOP"
position to stop the engine.

2. After stopping the engine, check the air cleaner,
intake rubber tube and then other parts and replace
parts as needed.

ENGLISH

BImmediately stop the engine if;

A The engine suddenly slows down or accelerates.
A Unusual noises are suddenly heard.
A Exhaust fumes suddenly become very dark.
A The oil pressure lamp or the water temperature

alarm lamp lights up.

10 MAINTENANCE

MAINTENANCE

CAUTION

To avoid personal injury:
A Be sure to conduct daily checks,

periodic maintenance, refueling or
cleaning on a level surface with the
engine shut off and remove the key.

A Before allowing other people to use

your engine, explain how to operate,
and have them read this manual

ENGLISH

before operation.

A When cleaning any parts, do not use

gasoline but use regular cleanser.

A Always use proper tools, that are in

good condition. Make sure you
understand how to use them, before
performing any service work.

A When installing, be sure to tighten

all bolts lest they should be loose.
Tighten the bolts by the specified
torque.

A Do not put any tools on the battery,

or battery terminals may short out.
Severe burns or fire could result.
Detach the battery from the engine
before maintenance.

A Do not touch muffler or exhaust

pipes while they are hot; Severe
burns could result.

11MAINTENANCE

SERVICE INTERVALS

Observe the following for service and maintenance.
The lubricating oil change intervals listed in the table below are for Classes CG-4, CH-4, CI-4 and CF lubricating oil of API
classification with a low-sulfur fuel in use. If the CG-4, CH-4 or CI-4 lubricating oil is used with a high-sulfur fuel, change
the lubricating oil at shorter intervals than recommended in the table below depending on the operating condition.

[Z482-E3, Z602-E3, D722-E3, D782-E3, D902-E3, D1005-E3, D1105-E3, D1105-TE3, D1305-E3, V1505-E3, V1505-TE3,
D1503-M-E3, D1703-M-E3, D1803-M-E3, V2003-M-E3, V2203-M-E3, V2403-M-E3, V2403-M-T-E3, D1803-M-DI-E3,
V2403-M-DI-E3]

Interval Item

Every 50 hours Check of fuel pipes and clamp bands 21 @

See

Changing engine oil (depending on the oil pan) 23 to 26

Cleaning of air cleaner element 32 *1 @

Cleaning of fuel filter 22

Every 100 hours

Check of battery electrolyte level 35, 36

Check of fan belt tightness 37

Draining water separator -

Check of radiator hoses and clamp bands 30

Every 200 hours

Replacing the oil filter cartridge
(depending on the oil pan)

Check of intake air line - @

Every 400 hours

Replacement of fuel filter cartridge 23 @

Cleaning of water separator -

Removal of sediment in fuel tank -

Every 500 hours

Cleaning of water jacket (radiator interior) 27 to 31

Replacement of fan belt 37

Every one or two
months

Recharging of battery 35, 36

Replacement of air cleaner element 32 *2 @

Every year

Check of damage in electric wiring and loose
connections

Every 800 hours Check of valve clearance 39

Every 1500 hours Check of fuel injection nozzle injection pressure - *3 @

Every 3000 hours

Check of turbo charger - *3 @

Check of injection pump - *3 @

Change of radiator coolant (L.L.C.) 29 to 31

Replacement of battery 35, 36

Every two years

Replacement of radiator hoses and clamp bands 30

Replacement of fuel pipes and clamp bands 21 *3 @

Replacement of intake air line - *4 @

Ref. page

26

-

ENGLISH

12 MAINTENANCE

[D1005-E3BG, D1105-E3BG, V1505-E3BG]

Interval Item

Ref. page

Every 50 hours Check of fuel pipes and clamp bands 21 @

Cleaning of air cleaner element 32 *1 @

Cleaning of fuel filter 22

Every 100 hours

Check of battery electrolyte level 35, 36

Check of fan belt tightness 37

Draining water separator -

Check of radiator hoses and clamp bands 30

Every 200 hours

Changing engine oil (depending on the oil pan) 23 to 26

Check of intake air line - @

ENGLISH

Every 400 hours

Replacing the oil filter cartridge 26

Replacement of fuel filter cartridge 23 @

Cleaning of water separator -

Removal of sediment in fuel tank -

Every 500 hours

Cleaning of water jacket (radiator interior) 27 to 31

Replacement of fan belt 37

Every one or two
months

Recharging of battery 35, 36

Replacement of air cleaner element 32 *2 @

Every year

Check of damage in electric wiring and loose
connections

-

Every 800 hours Check of valve clearance 39

Every 1500 hours Check of fuel injection nozzle injection pressure - *3 @

Every 3000 hours

Check of turbo charger - *3 @

Check of injection pump - *3 @

Change of radiator coolant (L.L.C.) 29 to 31

Replacement of battery 35, 36

Every two years

Replacement of radiator hoses and clamp bands 30

Replacement of fuel pipes and clamp bands 21 *3 @

Replacement of intake air line - *4 @