Wsm 05-E2B SERIES Especificações

WORKSHOP MANUALDIESEL ENGINESM-E4B SERIESKiSC issued 01, 2013 A

INFORMATIONSM-E4B SERIES, WSMI-63. PERFORMANCE CURVESZ482-E4B9Y1210785INI0002US0(1) Brake Horsepower(2) Engine Speed(3) B.S.F.C.(4) Torque(5) Gross In

ENGINESM-E4B SERIES, WSM1-S36(Continued)NOTE• Specific tool (1) :1.2 mm (0.047 in.) diameter hard wire with its end hooked,overall length 200 mm (7.87

ENGINESM-E4B SERIES, WSM1-S37(Continued)(When reassembling)1. Move the fork lever (2) to the gear case side.2. Hook the start spring (6) to the inject

ENGINESM-E4B SERIES, WSM1-S38Fan Drive Pulley1. Secure the flywheel to keep it from turning.2. Remove the fan drive pulley screw.3. Draw out the fan d

ENGINESM-E4B SERIES, WSM1-S39Idle Gear1. Remove the external snap ring (3), the collar (2) and the idlegear (1).2. Remove the idle gear shaft mounting

ENGINESM-E4B SERIES, WSM1-S40Fuel Camshaft1. Remove the retaining plate (6).2. Remove the fork lever holder mounting screws (8), then drawout the inje

ENGINESM-E4B SERIES, WSM1-S41(5) Piston and Connecting RodConnecting Rod Cap1. Remove the connecting rod caps (1) using a bihexagonal 8 mmsocket.(Whe

ENGINESM-E4B SERIES, WSM1-S42Piston Ring and Connecting Rod1. Remove the piston rings using a piston ring tool.2. Remove the piston pin (7), and separ

ENGINESM-E4B SERIES, WSM1-S43(6) Flywheel and CrankshaftFlywheel1. Secure the flywheel to keep it from turning using a flywheelstopper. (Refer to &quo

ENGINESM-E4B SERIES, WSM1-S44Crankshaft AssemblyFor Z482-E4B, D722-E4B1. Remove the main bearing case screw 2 (1).2. Draw out all the crankshaft.For Z

ENGINESM-E4B SERIES, WSM1-S45Main Bearing Case Assembly (Z482-E4B, D722-E4B, D782-E4B)1. Remove the two main bearing case screws 1 (4), and removethe

INFORMATIONSM-E4B SERIES, WSMI-7Z602-E4B9Y1210785INI0003US0(1) Brake Horsepower(2) Engine Speed(3) B.S.F.C.(4) Torque(5) Gross Intermittent Torque(6)

ENGINESM-E4B SERIES, WSM1-S46Main Bearing Case Assembly (Z602-E4B, D902-E4B)1. Remove the two main bearing case screws 1 (4), and removethe main beari

ENGINESM-E4B SERIES, WSM1-S47(7) StarterElectromagnetic Drive Type1. Unscrew the C terminal nut (7), and disconnect the connecting lead (12).2. Unscre

ENGINESM-E4B SERIES, WSM1-S48Planetary Gear Reduction Type1. Unscrew the C terminal nut (5), and disconnect the connecting lead (9).2. Unscrew the mag

ENGINESM-E4B SERIES, WSM1-S49(8) Dynamo1. Remove the nut and separate the plate (7).2. Tap out the shaft (1) from the rotor (3).3. Unscrew the screws

ENGINESM-E4B SERIES, WSM1-S50(9) Alternator1. Remove the pulley (1).2. Remove the rear end cover (12).3. Remove the brush holder (11).4. Remove the IC

ENGINESM-E4B SERIES, WSM1-S51[3] SERVICING(1) Cylinder Head and ValvesTop Clearance1. Remove the cylinder head.2. With the piston at TDC, use grease

ENGINESM-E4B SERIES, WSM1-S52Cylinder Head Flaw1. Prepare an air spray red check.2. Clean the surface of the cylinder head with detergent (2).3. Spray

ENGINESM-E4B SERIES, WSM1-S53Replacing Valve Guide(When removing)1. Press out the used valve guide using a valve guide replacingtool. (Refer to "

ENGINESM-E4B SERIES, WSM1-S54Correcting Valve and Valve SeatNOTE• Before correcting the valve and seat, check the valve stemand the I.D. of valve guid

ENGINESM-E4B SERIES, WSM1-S55Free Length and Tilt of Valve Spring1. Measure the free length (B) of valve spring with vernier calipers.If the measureme

INFORMATIONSM-E4B SERIES, WSMI-8D722-E4B9Y1210785INI0004US0(1) Brake Horsepower(2) Engine Speed(3) B.S.F.C.(4) Torque(5) Gross Intermittent Torque(6)

ENGINESM-E4B SERIES, WSM1-S56Push Rod Alignment1. Place the push rod on V blocks.2. Measure the push rod alignment.3. If the measurement exceeds the a

ENGINESM-E4B SERIES, WSM1-S57Idle Gear Side Clearance1. Set a dial indicator with its tip on the idle gear.2. Measure the side clearance by moving the

ENGINESM-E4B SERIES, WSM1-S58Oil Clearance of Camshaft Journal1. Measure the camshaft journal O.D. with an outside micrometer.2. Measure the cylinder

ENGINESM-E4B SERIES, WSM1-S59(3) Piston and Connecting RodPiston Pin Bore I.D.1. Measure the piston pin bore I.D. in both the horizontal andvertical

ENGINESM-E4B SERIES, WSM1-S60Connecting Rod AlignmentNOTE• Since the I.D. of the connecting rod small end bushing isthe basis of this check, check bus

ENGINESM-E4B SERIES, WSM1-S61Clearance between Piston Ring and Piston Ring Groove1. Clean the rings and the ring grooves, and install each ring in its

ENGINESM-E4B SERIES, WSM1-S62Crankshaft Alignment1. Support the crankshaft with V blocks on the surface plate atboth end journals.2. Set a dial indica

ENGINESM-E4B SERIES, WSM1-S63Oil Clearance between Crankshaft Journal and CrankshaftBearing 11. Measure the O.D. of the crankshaft front journal with

ENGINESM-E4B SERIES, WSM1-S64(Continued)(Reference)• Undersize crankshaft bearing 1• Undersize dimensions of crankshaft journal9Y1210785ENS0092US0Repl

ENGINESM-E4B SERIES, WSM1-S65Oil Clearance between Crankshaft Journal and CrankshaftBearing 2 and Crankshaft Bearing 31. Put a strip of plastigage on

INFORMATIONSM-E4B SERIES, WSMI-9D782-E4B9Y1210785INI0005US0(1) Brake Horsepower(2) Engine Speed(3) B.S.F.C.(4) Torque(5) Gross Intermittent Torque(6)

ENGINESM-E4B SERIES, WSM1-S66(Continued)(Reference)• Undersize crankshaft bearing 2 and 3• Undersize crankshaft bearing 2 and 3• Undersize dimensions

ENGINESM-E4B SERIES, WSM1-S67Replacing Crankshaft Sleeve (Z482-E4B, D722-E4B, D782-E4B)1. Remove the used crankshaft sleeve (2).2. Set the sleeve guid

ENGINESM-E4B SERIES, WSM1-S68Correcting Cylinder (Oversize)1. When the cylinder is worn beyond the allowable limit, bore andhone it to the specified d

ENGINESM-E4B SERIES, WSM1-S69(7) StarterOverrunning Clutch1. Check the pinion and if worn or damage, replace the clutchassembly.2. Check that the pini

ENGINESM-E4B SERIES, WSM1-S70Commutator and Mica1. Check the contact of the commutator for wear, and grind thecommutator with emery paper if it is sli

ENGINESM-E4B SERIES, WSM1-S71Brush Holder1. Check the continuity across the brush holder and the holdersupport with a circuit tester.2. If it conducts

ENGINESM-E4B SERIES, WSM1-S72(8) AlternatorBearing1. Check the bearing for smooth rotation.2. If it does not rotate smoothly, replace it.9Y1210785ENS0

ENGINESM-E4B SERIES, WSM1-S73Rectifier1. Check the continuity across each diode of rectifier withresistance range of circuit tester.2. The rectifier i

EDITOR:KUBOTA FARM & INDUSTRIAL MACHINERY SERVICE, LTD.64, ISHIZU-KITAMACHI, SAKAI-KU, SAKAI-CITY, OSAKA, 590-0823, JAPANPHONE : (81)72-241-1129FA

INFORMATIONSM-E4B SERIES, WSMI-10D902-E4B9Y1210785INI0006US0(1) Brake Horsepower(2) Engine Speed(3) B.S.F.C.(4) Torque(5) Gross Intermittent Torque(6)

INFORMATIONSM-E4B SERIES, WSMI-114. DIMENSIONSZ482-E4B9Y1210785INI0007US0KiSC issued 01, 2013 A

INFORMATIONSM-E4B SERIES, WSMI-12Z602-E4B9Y1210785INI0008US0KiSC issued 01, 2013 A

INFORMATIONSM-E4B SERIES, WSMI-13D722-E4B9Y1210785INI0009US0KiSC issued 01, 2013 A

INFORMATIONSM-E4B SERIES, WSMI-14D782-E4B9Y1210785INI0010US0KiSC issued 01, 2013 A

INFORMATIONSM-E4B SERIES, WSMI-15D902-E4B9Y1210785INI0011US0KiSC issued 01, 2013 A

TO THE READERThis Workshop Manual tells the servicing personnel about the mechanism, servicing andmaintenance of SM-E4B series. It contains 4 parts: &

G GENERALKiSC issued 01, 2013 A

CONTENTS1. ENGINE IDENTIFICATION ... G-1[1] MOD

GENERALSM-E4B SERIES, WSMG-11. ENGINE IDENTIFICATION[1] MODEL NAME AND ENGINE SERIAL NUMBERWhen contacting the manufacture, always specify your engin

GENERALSM-E4B SERIES, WSMG-2(Continued)Production Month and Lot Number* Alphabetical letters "I" and "O" are not used.e.g. D902(a)

GENERALSM-E4B SERIES, WSMG-3[2] E4B ENGINE[Example : Engine Model Name D902-E4B-XXXX]The emission controls previously implemented in various countries

GENERALSM-E4B SERIES, WSMG-42. GENERAL PRECAUTION• When you disassemble, carefully put the parts in a clean areato make it easy to find the parts. You

GENERALSM-E4B SERIES, WSMG-53. MAINTENANCE CHECK LISTTo maintain long-lasting and safe engine performance, make it a rule to carry out regular inspec

GENERALSM-E4B SERIES, WSMG-6NOTEEngine Oil :• Refer to the following table for the suitable American Petroleum Institute (API) classification of engin

GENERALSM-E4B SERIES, WSMG-74. CHECK AND MAINTENANCE[1] DAILY CHECK POINTSChecking Engine Oil Level1. Level the engine.2. To check the oil level, dr

GENERALSM-E4B SERIES, WSMG-8Checking and Replenish Coolant1. Without recovery tank (2) :Remove the radiator cap (1) and check to see that the coolantl

I INFORMATIONKiSC issued 01, 2013 A

GENERALSM-E4B SERIES, WSMG-9[2] CHECK POINTS OF INITIAL 50 HOURSChanging Engine Oil CAUTION• Be sure to stop engine before changing engine oil.1. Sta

GENERALSM-E4B SERIES, WSMG-10Replacing Oil Filter Cartridge CAUTION• Be sure to stop the engine before changing filter cartridge.1. Remove the oil fil

GENERALSM-E4B SERIES, WSMG-11[3] CHECK POINT OF EVERY 50 HOURSChecking Fuel Hose1. If the clamp (2) is loose, apply oil to the threads and securelyre

GENERALSM-E4B SERIES, WSMG-12[4] CHECK POINTS OF EVERY 75 HOURSChanging Engine Oil (for Optional Depth Oil Pans) CAUTION• Be sure to stop engine befo

GENERALSM-E4B SERIES, WSMG-13[5] CHECK POINTS OF EVERY 100 HOURSChanging Engine Oil (for Standard Depth Oil Pans) CAUTION• Be sure to stop engine bef

GENERALSM-E4B SERIES, WSMG-14Fan Belt Tension1. Measure the deflection (A), depressing the belt halfwaybetween the fan drive pulley and alternator pul

GENERALSM-E4B SERIES, WSMG-15Cleaning Fuel Filter (Element Type only)1. Close the fuel cock (3).2. Unscrew the retaining ring (6) and remove the filte

GENERALSM-E4B SERIES, WSMG-16[7] CHECK POINTS OF EVERY 200 HOURSReplacing Oil Filter Cartridge (for Standard Depth Oil Pans) CAUTION• Be sure to stop

GENERALSM-E4B SERIES, WSMG-17[8] CHECK POINTS OF EVERY 400 HOURSReplacing Fuel Filter Cartridge (Cartridge Type)Water and dust in fuel are collected

GENERALSM-E4B SERIES, WSMG-18[9] CHECK POINTS OF EVERY 500 HOURSCleaning Water Jacket and Radiator Interior CAUTION• Do not remove the radiator cap w

CONTENTS1. SAFETY FIRST ...

GENERALSM-E4B SERIES, WSMG-19Anti-Freeze• There are two types of anti-freeze available: use the permanenttype (PT) for this engine.• Before adding ant

GENERALSM-E4B SERIES, WSMG-20[10] CHECK POINTS OF EVERY 1 OR 2 MONTHSRecharging CAUTION• When the battery is being activated, hydrogen and oxygengases

GENERALSM-E4B SERIES, WSMG-21Battery Specific Gravity CAUTION• If battery acid (dilute sulfuric acid) gets on you it couldcause blindness or burns, or

GENERALSM-E4B SERIES, WSMG-22[11] CHECK POINT OF EVERY YEARReplacing Air Cleaner Element1. Remove used air cleaner element.2. Replace new air cleaner

GENERALSM-E4B SERIES, WSMG-23[12] CHECK POINT OF EVERY 800 HOURSChecking Valve ClearanceIMPORTANT• Valve clearance must be checked and adjusted whenen

GENERALSM-E4B SERIES, WSMG-24[13] CHECK POINTS OF EVERY 1500 HOURS CAUTION• Check the injection pressure and condition after confirming that there is

GENERALSM-E4B SERIES, WSMG-25Nozzle Holder1. Secure the nozzle retaining nut (7) with a vise.2. Remove the nozzle holder (1), and take out parts insid

GENERALSM-E4B SERIES, WSMG-26[14] CHECK POINTS OF EVERY 3000 HOURSInjection Timing1. Remove the injection pipes.2. Remove the engine stop solenoid.3.

GENERALSM-E4B SERIES, WSMG-27(Continued)NOTE• The liquid gasket is not required for assembling.• Shims are available in thickness of 0.20 mm (0.0079 i

GENERALSM-E4B SERIES, WSMG-28Checking Injection Pump(Fuel Tightness of Pump Element)1. Remove the engine stop solenoid.2. Remove the injection pipes a

INFORMATIONSM-E4B SERIES, WSMI-11. SAFETY FIRSTWSM000001INI0001US1BEFORE YOU START SERVICE• Read all instructions and safety instructions in thismanua

GENERALSM-E4B SERIES, WSMG-29[15] CHECK POINTS OF EVERY 2 YEARSReplacing Intake Air Line1. Loosen the clamp (2).2. Remove the intake air hose (1) and

GENERALSM-E4B SERIES, WSMG-30Replacing Fuel Hoses and Clamp Bands1. Loosen the clamp (2) and remove the fuel hose (1).2. Replace new fuel hose (1) and

GENERALSM-E4B SERIES, WSMG-31Cleaning Water Jacket and Radiator Interior CAUTION• Do not remove the radiator cap when the engine is hot.Then loosen ca

GENERALSM-E4B SERIES, WSMG-32(Continued)(Anti-freeze)• There are two types of anti-freeze available: use the permanenttype (PT) for this engine.• Befo

GENERALSM-E4B SERIES, WSMG-335. SPECIAL TOOLSDiesel Engine Compression Tester (for Injection Nozzle)Code No.• 07909-30208 (Assembly)• 07909-30934 (A t

GENERALSM-E4B SERIES, WSMG-34NOTE• The following special tools are not provided, so make them referring to the figure.9Y1210785GEG0043US0Injection Pum

GENERALSM-E4B SERIES, WSMG-35Valve Guide Replacing ToolApplication• Use to press out and press fit the valve guide.9Y1210785GEG0045US0Bushing Replacin

GENERALSM-E4B SERIES, WSMG-36Flywheel StopperApplication• Use to loosen and tighten the flywheel screw.9Y1210785GEG0047US0Crankshaft Bearing 1 Replaci

GENERALSM-E4B SERIES, WSMG-37Crank Sleeve Setter (for Z482/D722-E4B, D782-E4B)Application• Use to fix the crankshaft sleeve.(1) Auxiliary Socket for P

1 ENGINEKiSC issued 01, 2013 A

INFORMATIONSM-E4B SERIES, WSMI-2OPERATE SAFELY• Do not use the machine after you consume alcoholor medication or when you are tired.• Put on applicabl

CONTENTS1. ENGINE BODY... 1-M1

ENGINESM-E4B SERIES, WSM1-M11. ENGINE BODY[1] HALF-FLOATING HEAD COVERThe rubber packing is fitted in to maintain thecylinder head cover 0.5 mm (0.02

ENGINESM-E4B SERIES, WSM1-M2[3] PISTON (Z602-E4B, D782-E4B, D902-E4B)Piston's skirt is coated with molybdenumdisulfide*, which reduces the piston

ENGINESM-E4B SERIES, WSM1-M32. COOLING SYSTEM[1] COOLING FIN (Z602-E4B, D902-E4B)The cooling fin is set up around the oil passage in thegear case.The

CONTENTS1. TROUBLESHOOTING...1-S12. SERV

ENGINESM-E4B SERIES, WSM1-S11. TROUBLESHOOTINGSymptom Probable Cause SolutionReference PageEngine Does Not StartNo fuel Replenish fuel G-11Air in the

ENGINESM-E4B SERIES, WSM1-S2Engine Revolution Is Not SmoothFuel filter clogged or dirty Replace G-17Air cleaner clogged Clean or replace G-14Fuel leak

ENGINESM-E4B SERIES, WSM1-S39Y1210785ENS0001US0Water Mixed into Lubricant OilHead gasket defective Replace 1-S32Cylinder block or cylinder head flawed

ENGINESM-E4B SERIES, WSM1-S42. SERVICING SPECIFICATIONSENGINE BODYItem Factory Specification Allowable LimitValve Clearance (Cold) 0.145 to 0.185 mm0.

ENGINESM-E4B SERIES, WSM1-S5Exhaust Valve Timing[Z602/D902-E4B]OpenClose0.87 rad (50 °)before B.D.C.0.26 rad (15 °)after T.D.C.––Valve Spring (Intake

INFORMATIONSM-E4B SERIES, WSMI-3KEEP A GOOD AIRFLOW IN THE WORK AREA• If the engine is in operation, make sure that the areahas good airflow. Do not o

ENGINESM-E4B SERIES, WSM1-S6Cam Height[Z482/D722/D782-E4B][Z482/D722/D782-E4B][Z602/D902-E4B]IntakeExhaustIntake and Exhaust26.88 mm1.058 in.25.88 mm1

ENGINESM-E4B SERIES, WSM1-S7Piston Ring to Piston Ring Groove• Second Ring• Oil RingClearanceClearance0.0900 to 0.120 mm0.00355 to 0.00472 in.0.040 to

ENGINESM-E4B SERIES, WSM1-S8Crankshaft Journal to Crankshaft Bearing 3 (Intermediate)[Z602/D902-E4B]• Crankshaft Journal• Crankshaft Bearing 3Oil Clea

ENGINESM-E4B SERIES, WSM1-S9LUBRICATING SYSTEMCOOLING SYSTEMItem Factory Specification Allowable LimitEngine Oil Pressure At Idle SpeedAt Rated SpeedM

ENGINESM-E4B SERIES, WSM1-S10FUEL SYSTEMItem Factory Specification Allowable LimitInjection Pump[Z482/D602-E4B]Injection Timing(3600 min-1(rpm))0.3186

ENGINESM-E4B SERIES, WSM1-S11ELECTRICAL SYSTEM9Y1210785ENS0002US0Item Factory Specification Allowable LimitGlow Plug Resistance Approx. 1.1 Ω –Starter

ENGINESM-E4B SERIES, WSM1-S123. TIGHTENING TORQUESScrews, bolts and nuts must be tightened to the specified torque using a torque wrench, several scre

ENGINESM-E4B SERIES, WSM1-S13[2] TIGHTENING TORQUES FOR SPECIAL USE SCREWS, BOLTS AND NUTSNOTE• For "*" marked screws, bolts and nuts on th

ENGINESM-E4B SERIES, WSM1-S144. CHECKING, DISASSEMBLING AND SERVICING[1] CHECKING AND ADJUSTING(1) Engine BodyCompression Pressure1. Run the engine

ENGINESM-E4B SERIES, WSM1-S15Checking Valve ClearanceIMPORTANT• Valve clearance must be checked and adjusted whenengine is cold.1. Remove the cylinder

INFORMATIONSM-E4B SERIES, WSMI-42. SPECIFICATIONS*The specification described above is of the standard engine of each model.*Conversion Formula : HP =

ENGINESM-E4B SERIES, WSM1-S16(2) Lubricating SystemEngine Oil Pressure1. Remove the engine oil pressure switch, and set an oil pressuretester. (Code N

ENGINESM-E4B SERIES, WSM1-S17(3) Cooling SystemFan Belt Tension1. Measure the deflection (A), depressing the belt halfwaybetween the fan drive pulley

ENGINESM-E4B SERIES, WSM1-S18 CAUTION• When removing the radiator cap, wait at least ten minutes after the engine has stopped and cooled down.Otherwis

ENGINESM-E4B SERIES, WSM1-S19(4) Fuel SystemInjection Timing1. Remove the injection pipes.2. Remove the engine stop solenoid.3. Turn the flywheel coun

ENGINESM-E4B SERIES, WSM1-S20(Continued)NOTE• The liquid gasket is not required for assembling.• Shims are available in thickness of 0.20 mm (0.0079 i

ENGINESM-E4B SERIES, WSM1-S21Fuel Tightness of Pump Element1. Remove the engine stop solenoid.2. Remove the injection pipes and glow plugs.3. Install

ENGINESM-E4B SERIES, WSM1-S22 CAUTION• Check the injection pressure and condition after confirming that there is nobody standing in the directionthe f

ENGINESM-E4B SERIES, WSM1-S23Nozzle Holder1. Secure the nozzle retaining nut (7) with a vise.2. Remove the nozzle holder (1), and take out parts insid

ENGINESM-E4B SERIES, WSM1-S24Battery Specific Gravity CAUTION• If battery acid (dilute sulfuric acid) gets on you it couldcause blindness or burns, or

ENGINESM-E4B SERIES, WSM1-S25Motor Test CAUTION• Secure the starter to prevent it from jumping up and downwhile testing the motor.1. Disconnect the ba

INFORMATIONSM-E4B SERIES, WSMI-5*The specification described above is of the standard engine of each model.*Conversion Formula : HP = 0.746 kW, PS = 0

ENGINESM-E4B SERIES, WSM1-S26Magnet Switch Continuity Test1. Check the continuity across the C terminal (1) and the Bterminal (2) with a circuit teste

ENGINESM-E4B SERIES, WSM1-S27Continuity across Regulator's Terminals1. Measure with a circuit tester according to the list below.NOTE• For this t

ENGINESM-E4B SERIES, WSM1-S28Alternator on Unit Test(Before testing)• Before alternator on unit test, check the battery terminalconnections, circuit c

ENGINESM-E4B SERIES, WSM1-S29Engine Stop Solenoid Test (Energize to Run Type)1. Disconnect the 3P connector (3) from the engine stop solenoid(1) wirin

ENGINESM-E4B SERIES, WSM1-S30Draining Coolant CAUTION• Never remove radiator cap while operating or immediatelyafter stopping. Otherwise, hot water wi

ENGINESM-E4B SERIES, WSM1-S31Injection Pipes1. Loosen the screws to the pipe clamp (2).2. Detach the injection pipes (1).(When reassembling)• Sent com

ENGINESM-E4B SERIES, WSM1-S32Rocker Arm and Push Rod1. Remove the rocker arm bracket screws (2).2. Detach the rocker arm assembly (1).3. Remove the pu

ENGINESM-E4B SERIES, WSM1-S33Tappets1. Remove the tappets (1) from the crankcase.(When reassembling)• Visually check the contact between tappets and c

ENGINESM-E4B SERIES, WSM1-S34Oil Pan and Oil Strainer1. Remove the oil pan mounting screws (2).2. Remove the oil pan (1) by lightly tapping the rim of

ENGINESM-E4B SERIES, WSM1-S35(4) Gear Case and Timing GearsInjection Pump, Fuel Feed Pump and Speed Control Plate(for Energize to Stop Type Engine St