Kubota SM-E3B Series Instruction manual

SM-E3B SERIES
WORKSHOP MANUAL
DIESEL ENGINE
KiSC issued 03, 2011 A

TO THE READER
This Workshop Manual has been prepared to provide servicing personnel with
information on the mechanism, service and maintenance of SM-E3B series. It is divided
into three parts, “General”, “Mechanism” and “Servicing”.
QGeneral
Information on the engine identification, the general precautions, maintenance check
list, check and maintenance and special tools are described.
QMechanism
Information on the construction and function are included. This part should be
understood before proceeding with troubleshooting, disassembling and servicing.
Refer to Diesel Engine Mechanism Workshop Manual (Code No. 9Y021-01876) for
the one which has not been described to this workshop manual.
QServicing
Information on the troubleshooting, servicing specification lists, tightening torque,
checking and adjusting, disassembling and assembling, and servicing which cover
procedures, precautions, factory specifications and allowable limits.
All information illustrations and specifications contained in this manual are based on
the latest product information available at the time of publication.
The right is reserved to make changes in all information at any time without notice.
Due to covering many models of this manual, information or picture being used have
not been specified as one model.
March 2007
© KUBOTA Corporation 2007
KiSC issued 03, 2011 A

1
SM-E3B SERIES WSM SAFETY INSTRUCTIONS
SAFETY INSTRUCTIONS
BEFORE SERVICING AND REPAIRING
• Read all instructions and safety instructions in this
manual and on your engine safety decals.
• Clean the work area and engine.
• Park the machine on a firm and level ground.
• Allow the engine to cool before proceeding.
• Stop the engine, and remove the key.
• Disconnect the battery negative cable.
• Hang a “DO NOT OPERATE” tag in operator
station.
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 attempt to repair or use
this unit.
DANGER : Indicates an imminently hazardous situation which, if not avoided, will result in
death or serious injury.
WARNING : Indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION : Indicates a potentially hazardous situation which, if not avoided, may result in
minor or moderate injury.
QIMPORTANT : Indicates that equipment or property damage could result if instructions are not
followed.
QNOTE : Gives helpful information.
KiSC issued 03, 2011 A

2
SM-E3B SERIES WSM SAFETY INSTRUCTIONS
SAFETY STARTING
• Do not start the engine by shorting across starter
terminals or bypassing the safety start switch.
• Unauthorized modifications to the engine may impair
the function and / or safety and affect engine life.
SAFETY WORKING
• Do not work on the machine while under the influence
of alcohol, medication, or other substances or while
fatigued.
• Wear close fitting clothing and safety equipment
appropriate to the job.
• Use tools appropriate to the work. Makeshift tools,
parts, and procedures are not recommended.
• When servicing is performed together by two or more
persons, take care to perform all work safely.
• Do not touch the rotating or hot parts while the engine
is running.
• Never remove the radiator cap while the engine is
running, or immediately after stopping. Otherwise, hot
water will spout out from radiator. Only remove
radiator cap when cool enough to touch with bare
hands. Slowly loosen the cap to first stop to relieve
pressure before removing completely.
• Escaping fluid (fuel or hydraulic oil) under pressure
can penetrate the skin causing serious injury. Relieve
pressure before disconnecting hydraulic or fuel lines.
Tighten all connections before applying pressure.
• Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable
or uncomfortable loud noises.
• Do not open high-pressure fuel system.
High-pressure fluid remaining in fuel lines can cause
serious injury. Do not disconnect or attempt repair or
fuel lines, sensors, or any other components between
the high-pressure fuel pump and injectors on engines
with high pressure common rail fuel system.
• High voltage exceeding 100 V is generated in the
ECU, and is applied to the injector.
Pay sufficient caution to electric shock when
performing work activities.
KiSC issued 03, 2011 A

3
SM-E3B SERIES WSM SAFETY INSTRUCTIONS
AVOID FIRES
• Fuel is extremely flammable and explosive under
certain conditions. Do not smoke or allow flames or
sparks in your working area.
• To avoid sparks from an accidental short circuit,
always disconnect the battery negative cable first and
connect it last.
• Battery gas can explode. Keep sparks and open
flame away from the top of battery, especially when
charging the battery.
• Make sure that no fuel has been spilled on the engine.
VENTILATE WORK AREA
• If the engine must be running to do some work, make
sure the area is well ventilated. Never run the engine
in a closed area. The exhaust gas contains poisonous
carbon monoxide.
DISPOSE OF FLUIDS PROPERLY
• Do not pour fluids into the ground, down a drain, or
into a stream, pond, or lake. Observe relevant
environmental protection regulations when disposing
of oil, fuel, coolant, electrolyte and other harmful
waste.
PREVENT ACID BURNS
• Sulfuric acid in battery electrolyte is poisonous. It is
strong enough to burn skin, clothing and cause
blindness if splashed into eyes. Keep electrolyte
away from eyes, hands and clothing. If you spill
electrolyte on yourself, flush with water, and get
medical attention immediately.
KiSC issued 03, 2011 A

4
SM-E3B SERIES WSM SAFETY INSTRUCTIONS
PREPARE FOR EMERGENCIES
• Keep a first aid kit and fire extinguisher handy at all
times.
• Keep emergency numbers for doctors, ambulance
service, hospital and fire department near your
telephone.
KiSC issued 03, 2011 A

5
SM-E3B SERIES WSM SPECIFICATIONS
SPECIFICATIONS
* The specification described above is of the standard engine of each model.
* Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW
W10336300
Model Z482-E3B Z602-E3B
Number of Cylinders 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 cm3(29.23 cu.in.) 599.0 cm3(36.55 cu.in.)
ISO Net Continous 8.10 kW / 3600 min-1 (rpm)
(10.9 HP / 3600 min-1 (rpm))
10.1 kW / 3600 min-1 ( rpm)
(13.5 HP / 3600 min-1 (rpm))
ISO / SAE Net Intermittent 9.30 kW / 3600 min-1 (rpm)
(12.5 HP / 3600 min-1 (rpm))
11.6 kW / 3600 min-1 ( rpm)
(15.5 HP / 3600 min-1 (rpm))
SAE Gross Intermittent 9.90 kW / 3600 min-1 (rpm)
(13.3 HP / 3600 min-1 (rpm))
12.5 kW / 3600 min-1 ( rpm)
(16.8 HP / 3600 min-1 (rpm))
Maximum Bare Speed 3800 min-1 (rpm)
Minimum Bare Idling Speed 900 to 1000 min-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 0.37 rad (21 °) before T.D.C. 0.35 rad (20 °) before T.D.C.
Firing Order 1-2
Injection Pressure 13.73 MPa (140.0 kgf/cm2, 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, 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 Class CF lubricating oil as per API classification is recommended.
For details on recommended lubricating oils, see page G-6, 9
Lubricating Oil
Capacity
Oil Pan Depth
101 mm (3.98 in.) 2.1 L (0.55 U.S.gals) 2.5 L (0.66 U.S.gals)
Oil Pan Depth
121 mm (4.76 in.) 2.5 L (0.66 U.S.gals) –
Weight (Dry) kg (lbs) 53.1 (117) 60.0 (132)
KiSC issued 03, 2011 A

6
SM-E3B SERIES WSM SPECIFICATIONS
* The specification described above is of the standard engine of each model.
* Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW
W10304910
Model D722-E3B D782-E3B D902-E3B
Number of Cylinders 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.)
Total Displacement 719.0 cm3(43.88 cu.in.) 778.0 cm3(47.48 cu.in.) 898.0 cm3(54.80 cu.in.)
ISO Net Continuous 12.0 kW / 3600 min-1 (rpm)
(16.4 HP / 3600 min-1 (rpm))
11.7 kW / 3200 min-1 (rpm)
(15.7 HP / 3200 min-1 (rpm))
15.2 kW / 3600 min-1 (rpm)
(20.4 HP / 3600 min-1 (rpm))
ISO / SAE Net Intermittent 14.0 kW / 3600 min-1 (rpm)
(18.8 HP / 3600 min-1 (rpm))
13.5 kW / 3200 min-1 (rpm)
(18.1 HP / 3200 min-1 (rpm))
17.5 kW / 3600 min-1 (rpm)
(23.5 HP / 3600 min-1 (rpm))
SAE Gross Intermittent 14.9 kW / 3600 min-1 (rpm)
(20.0 HP / 3600 min-1 (rpm))
14.1 kW / 3200 min-1 (rpm)
(18.9 HP / 3200 min-1 (rpm))
18.5 kW / 3600 min-1 (rpm)
(24.8 HP / 3600 min-1 (rpm))
Maximum Bare Speed 3800 min-1 (rpm) 3450 min-1 (rpm) 3800 min-1 (rpm)
Minimum Bare Idling Speed 900 to 1000 min-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 0.37 rad (21 °) before T.D.C. 0.30 rad (17 °) before T.D.C. 0.35 rad (20 °) before T.D.C.
Firing Order 1-2-3
Injection Pressure 13.73 MPa (140.0 kgf/cm2, 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, 0.8 kW 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 Class CF lubricating oil as per API classification is recommended.
For details on recommended lubricating oils, see page G-6, 9
Lubricating Oil
Capacity
Oil Pan Depth
101 mm (3.98 in.) 3.2 L (0.85 U.S.gals) – 3.7 L (0.98 U.S.gals)
Oil Pan Depth
121 mm (4.76 in.) 3.8 L (1.0 U.S.gals) 3.6 L (0.95 U.S.gals) –
Weight (Dry) kg (lbs) 63.0 (139) 63.5 (140) 72.0 (159)
KiSC issued 03, 2011 A

7
SM-E3B SERIES WSM PERFORMANCE CURVES
PERFORMANCE CURVES
QZ482-E3B
(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.
KiSC issued 03, 2011 A

8
SM-E3B SERIES WSM PERFORMANCE CURVES
QZ602-E3B
(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.
KiSC issued 03, 2011 A

9
SM-E3B SERIES WSM PERFORMANCE CURVES
QD722-E3B
(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.
KiSC issued 03, 2011 A

10
SM-E3B SERIES WSM PERFORMANCE CURVES
QD782-E3B
(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.
KiSC issued 03, 2011 A

11
SM-E3B SERIES WSM PERFORMANCE CURVES
QD902-E3B
(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.
KiSC issued 03, 2011 A

12
SM-E3B SERIES WSM DIMENSIONS
DIMENSIONS
QZ482-E3B
KiSC issued 03, 2011 A

13
SM-E3B SERIES WSM DIMENSIONS
QZ602-E3B
KiSC issued 03, 2011 A

14
SM-E3B SERIES WSM DIMENSIONS
QD722-E3B
KiSC issued 03, 2011 A

15
SM-E3B SERIES WSM DIMENSIONS
QD782-E3B
KiSC issued 03, 2011 A

16
SM-E3B SERIES WSM DIMENSIONS
QD902-E3B
KiSC issued 03, 2011 A

CONTENTS
GENERAL
1. ENGINE IDENTIFICATION ............................................................................. G-1
[1] MODEL NAME AND ENGINE SERIAL NUMBER ................................ G-1
[2] E3B ENGINE............................................................................................. G-2
[3] CYLINDER NUMBER ............................................................................... G-2
2. GENERAL PRECAUTIONS ............................................................................ G-3
3. MAINTENANCE CHECK LIST ....................................................................... G-4
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 POINT OF EVERY 75 HOURS ............................................. G-12
[5] CHECK POINTS OF EVERY 100 HOURS ......................................... G-13
[6] CHECK POINT OF EVERY 150 HOURS ........................................... G-16
[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
KiSC issued 03, 2011 A

G-1
SM-E3B SERIES WSM G GENERAL
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.
QEngine Serial Number
The engine serial number is an identified number for the engine.
It is marked after the engine model number.
It indicates month and year of manufacture as follows.
•Year of manufacture
W1010477
•Month of manufacture
* Alphabetical letters “I” and “O” are not used.
e.g. D902 - 7 B A001
(a) (b)(c) (d)
W1011076
Alphabet or
Number Year Alphabet or Number Yea r
6 2006 H 2017
7 2007 J 2018
8 2008 K 2019
9 2009 L 2020
A 2010 M 2021
B 2011 N 2022
C 2012 P 2023
D 2013 R 2024
E 2014 S 2025
F 2015 T 2026
G 2016 V 2027
A : Engine Model Name and Serial
Number
Month Engine Lot Number
January A0001 ~ A9999 B0001 ~ BZ999
February C0001 ~ C9999 D0001 ~ DZ999
March E0001 ~ E9999 F0001 ~ FZ999
April G0001 ~ G9999 H0001 ~ HZ999
May J0001 ~ J9999 K0001 ~ KZ999
June L0001 ~ L9999 M0001 ~ MZ999
July N0001 ~ N9999 P0001 ~ PZ999
August Q0001 ~ Q9999 R0001 ~ RZ999
September S0001 ~ S9999 T0001 ~ TZ999
October U0001 ~ U9999 V0001 ~ VZ999
November W0001 ~ W9999 X0001 ~ XZ999
December Y0001 ~ Y9999 Z0001 ~ ZZ999
(a) Engine Model Name : D902
(b) Year : 7indicates 2007
(c) Month : Aor Bindicates January
(d) Lot number : (0001 ~ 9999 or A001 ~ Z999)
KiSC issued 03, 2011 A