Service Manual

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SM-E2B SERIES

WORKSHOP MANUAL

DIESEL ENGINE

KiSC issued 06, 2006 A

Summary of content (142 pages)

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WORKSHOP MANUAL DIESEL ENGINE SM-E2B SERIES KiSC issued 06, 2006 A
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TO THE READER This Workshop Manual has been prepared to provide servicing personnel with information on the mechanism, service and maintenance of SM-E2B series. It is divided into three parts, “General”, “Mechanism” and “Servicing”. ■ General Information on the engine identification, the general precautions, maintenance check list, check and maintenance and special tools are described. ■ Mechanism Information on the construction and function are included.
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SAFETY INSTRUCTIONS SM-E2B SERIES, WSM SAFETY INSTRUCTIONS 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.
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SAFETY INSTRUCTIONS SM-E2B SERIES, WSM 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.
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SAFETY INSTRUCTIONS SM-E2B SERIES, WSM 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.
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SPECIFICATIONS SM-E2B SERIES, WSM SPECIFICATIONS Model Z482-E2B Z602-E2B Number of Cylinders 2 Type Vertical, Water-cooled, 4 cycle IDI diesel engine Bore × Stroke mm (in.) cm3 Total Displacement (cu.in.) 67 × 68 (2.64 × 2.68) 72 × 73.6 (2.83 × 2.90) 479 (29.23) 599 (36.55) ISO Net Continous kW/min-1 (rpm) (HP/min-1 (rpm)) 8.1 / 3600 (10.9 / 3600) 8.8 / 3200 (11.8 / 3200) 10.1 / 3600 (13.5 / 3600) ISO / SAE Net Intermittent kW/min-1 (rpm) (HP/min-1 (rpm)) 9.3 / 3600 (12.5 / 3600) 10.
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SPECIFICATIONS SM-E2B SERIES, WSM Model D662-E2B D722-E2B Number of Cylinders 3 Type Vertical, Water-cooled, 4 cycle IDI diesel engine Bore × Stroke mm (in.) Total Displacement 3 cm (cu.in.) 64 × 68 (2.52 × 2.68) 67 × 68 (2.64 × 2.68) 656 (40.03) 719 (43.88) ISO Net Continuous kW/min-1 (rpm) (HP/min-1 (rpm)) 11.2 / 3600 (15.0 / 3600) 12.2 / 3600 (16.4 / 3600) ISO / SAE Net Intermittent kW/min-1 (rpm) (HP/min-1 (rpm)) 12.9 / 3600 (17.3 / 3600) 14.0 / 3600 (18.
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SPECIFICATIONS SM-E2B SERIES, WSM Model D782-E2B D902-E2B Number of Cylinders 3 Type Vertical, Water-cooled, 4 cycle IDI diesel engine Bore × Stroke mm (in.) Total Displacement 3 cm (cu.in.) 67 × 73.6 (2.64 × 2.90) 72 × 73.6 (2.83 × 2.90) 778 (47.48) 898 (54.80) ISO Net Continuous kW/min-1 (rpm) (HP/min-1 (rpm)) 11.7 / 3200 (15.7 / 3200) 13.4 / 3200 (18.0 / 3200) 15.2 / 3600 (20.4 / 3600) ISO / SAE Net Intermittent kW/min-1 (rpm) (HP/min-1 (rpm)) 13.5 / 3200 (18.1 / 3200) 15.
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PERFORMANCE CURVES SM-E2B SERIES, WSM PERFORMANCE CURVES ■ Z482-E2B (1) (2) (3) (4) (5) Brake Horsepower Engine Speed B.S.F.C. Torque Gross Intermittent Torque (6) (7) (8) (9) (10) Net Intermittent Torque Net Continuous Torque Gross Intermittent B.H.P. Net Intermittent B.H.P. Net Continuous B.H.P. (11) (12) (13) (14) Net Intermittent B.S.F.C. Gross Torque Overload Torque Continuous Torque (15) (16) (17) (18) Gross B.H.P. Overload B.H.P. Continuous B.H.P. Overload B.S.F.C.
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PERFORMANCE CURVES SM-E2B SERIES, WSM ■ Z602-E2B (3200 min-1 (rpm) spec.) (1) (2) (3) (4) (5) Brake Horsepower Engine Speed B.S.F.C. Torque Gross Intermittent Torque (6) (7) (8) (9) (10) Net Intermittent Torque Net Continuous Torque Gross Intermittent B.H.P. Net Intermittent B.H.P. Net Continuous B.H.P. (11) (12) (13) (14) Net Intermittent B.S.F.C. Gross Torque Overload Torque Continuous Torque (15) (16) (17) (18) Gross B.H.P. Overload B.H.P. Continuous B.H.P. Overload B.S.F.C.
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PERFORMANCE CURVES SM-E2B SERIES, WSM ■ Z602-E2B (3600 min-1 (rpm) spec.) (1) (2) (3) (4) Brake Horsepower Engine Speed B.S.F.C. Torque (5) (6) (7) (8) Gross Intermittent Torque Net Intermittent Torque Gross Intermittent B.H.P. 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.
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PERFORMANCE CURVES SM-E2B SERIES, WSM ■ D662-E2B (1) (2) (3) (4) (5) Brake Horsepower Engine Speed B.S.F.C. Torque Gross Intermittent Torque (6) (7) (8) (9) (10) Net Intermittent Torque Net Continuous Torque Gross Intermittent B.H.P. Net Intermittent B.H.P. Net Continuous B.H.P. (11) (12) (13) (14) Net Intermittent B.S.F.C. Gross Torque Overload Torque Continuous Torque (15) (16) (17) (18) Gross B.H.P. Overload B.H.P. Continuous B.H.P. Overload B.S.F.C.
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PERFORMANCE CURVES SM-E2B SERIES, WSM ■ D722-E2B (1) (2) (3) (4) (5) Brake Horsepower Engine Speed B.S.F.C. Torque Gross Intermittent Torque (6) (7) (8) (9) (10) Net Intermittent Torque Net Continuous Torque Gross Intermittent B.H.P. Net Intermittent B.H.P. Net Continuous B.H.P. (11) (12) (13) (14) Net Intermittent B.S.F.C. Gross Torque Overload Torque Continuous Torque (15) (16) (17) (18) Gross B.H.P. Overload B.H.P. Continuous B.H.P. Overload B.S.F.C.
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PERFORMANCE CURVES SM-E2B SERIES, WSM ■ D782-E2B (1) (2) (3) (4) Brake Horsepower Engine Speed B.S.F.C. Torque (5) (6) (7) (8) Gross Intermittent Torque Net Intermittent Torque Net Continuous Torque Gross Intermittent B.H.P. (9) (10) (11) (12) Net Intermittent B.H.P. Net Continuous B.H.P. Net Intermittent B.S.F.C. Gross Torque (13) (14) (15) (16) Overload Torque Gross B.H.P. Overload B.H.P. Overload B.S.F.C.
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PERFORMANCE CURVES SM-E2B SERIES, WSM ■ D902-E2B (3200 min-1 (rpm) spec.) (1) (2) (3) (4) (5) Brake Horsepower Engine Speed B.S.F.C. Torque Gross Intermittent Torque (6) (7) (8) (9) (10) Net Intermittent Torque Net Continuous Torque Gross Intermittent B.H.P. Net Intermittent B.H.P. Net Continuous B.H.P. (11) (12) (13) (14) Net Intermittent B.S.F.C. Gross Torque Overload Torque Continuous Torque (15) (16) (17) (18) Gross B.H.P. Overload B.H.P. Continuous B.H.P. Overload B.S.F.C.
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PERFORMANCE CURVES SM-E2B SERIES, WSM ■ D902-E2B (3600 min-1 (rpm) spec.) (1) (2) (3) (4) Brake Horsepower Engine Speed B.S.F.C. Torque (5) (6) (7) (8) Gross Intermittent Torque Net Intermittent Torque Gross Intermittent B.H.P. 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.
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DIMENSIONS SM-E2B SERIES, WSM DIMENSIONS ■ Z482-E2B KiSC issued 06, 2006 A 15
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DIMENSIONS SM-E2B SERIES, WSM ■ Z602-E2B KiSC issued 06, 2006 A 16
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DIMENSIONS SM-E2B SERIES, WSM ■ D662-E2B, D722-E2B KiSC issued 06, 2006 A 17
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DIMENSIONS SM-E2B SERIES, WSM ■ D782-E2B KiSC issued 06, 2006 A 18
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DIMENSIONS SM-E2B SERIES, WSM ■ D902-E2B KiSC issued 06, 2006 A 19
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GENERAL CONTENTS 1. ENGINE IDENTIFICATION ............................................................................. G-1 [1] MODEL NAME AND ENGINE SERIAL NUMBER ................................ G-1 [2] E2B ENGINE............................................................................................. G-2 [3] CYLINDER NUMBER ............................................................................... G-2 2. GENERAL PRECAUTIONS ........................................................................
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G GENERAL SM-E2B SERIES, WSM 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. ■ Engine Serial Number The engine serial number is an identified number for the engine. It is marked after the engine model number. It indicates month and year of manufacture as follows.
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G GENERAL SM-E2B SERIES, WSM • Month of manufacture Month Engine Serial Number 0001 ~ 9999 10000 ~ 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 ~ e.g.
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G GENERAL SM-E2B SERIES, WSM 2. GENERAL PRECAUTIONS • During disassembly, carefully arrange removed parts in a clean area to prevent confusion later. Screws, bolts and nuts should be replaced in their original position to prevent reassembly errors. • When special tools are required, use KUBOTA genuine special tools. Special tools which are not frequently used should be made according to the drawings provided.
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G GENERAL SM-E2B SERIES, WSM 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. Item *Checking fuel hoses and clamp bands (1) Oil pan depth (101 mm, 3.98 in.) (2) Oil pan depth Changing (121 mm, 4.76 in.) Engine oil (3) Extended oil pan depth (101 mm, 3.98 in.
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G GENERAL SM-E2B SERIES, WSM Item 50 hrs 75 hrs 100 hrs 150 hrs 200 hrs Service Interval Every 400 500 1 or 2 hrs hrs months 1 year 800 hrs 1500 hrs 3000 hrs 2 years ✩ 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
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G GENERAL SM-E2B SERIES, WSM 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. ■ IMPORTANT • When using an oil of different maker or viscosity from the previous, drain old oil. Never mix two different types of oil.
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G GENERAL SM-E2B SERIES, WSM Checking and Replenish Coolant 1. Without recovery tank : 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.
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G GENERAL SM-E2B SERIES, WSM [2] CHECK POINTS OF INITIAL 50 HOURS Changing Engine Oil • 1. 2. 3. 4. 5. ■ • • • • • CAUTION Be sure to stop engine before changing engine oil. Start and warm up the engine for approx. 5 minutes. Place an oil pan underneath the engine. To drain the used oil, remove the drain plug (2) at the bottom of the engine and drain the oil completely. Screw the drain plug (2). Fill new oil up to upper line on the dipstick (1).
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G GENERAL SM-E2B SERIES, WSM Replacing Oil Filter Cartridge • 1. 2. 3. 4. ■ • ■ • CAUTION Be sure to stop the engine before changing filter cartridge. Remove the oil filter cartridge (1) with the filter wrench. Apply a slight coat of oil onto the new cartridge gasket. To install the new cartridge, screw it in by hand. Over tightening may cause deformation of rubber gasket. After the new cartridge has been replaced, the engine oil normally decrease a little.
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G GENERAL SM-E2B SERIES, WSM [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.
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G GENERAL SM-E2B SERIES, WSM [4] CHECK POINT OF EVERY 75 HOURS Changing Engine Oil (for Optional Depth Oil Pans) • 1. 2. 3. 4. 5. ■ • • • • • CAUTION Be sure to stop engine before changing engine oil. Start and warm up the engine for approx. 5 minutes. Place an oil pan underneath the engine. To drain the used oil, remove the drain plug (2) at the bottom of the engine and drain the oil completely. Screw the drain plug (2). Fill new oil up to upper line on the dipstick (1).
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G GENERAL SM-E2B SERIES, WSM [5] CHECK POINTS OF EVERY 100 HOURS Changing Engine Oil (for Standard Depth Oil Pans) • 1. 2. 3. 4. 5. ■ • • • • • CAUTION Be sure to stop engine before changing engine oil. Start and warm up the engine for approx. 5 minutes. Place an oil pan underneath the engine. To drain the used oil, remove the drain plug (2) at the bottom of the engine and drain the oil completely. Screw the drain plug (2). Fill new oil up to upper line on the dipstick (1).
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G GENERAL SM-E2B SERIES, WSM 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 lbs). 2. If the measurement is not within the factory specifications, loosen the alternator mounting screws and relocate the alternator to adjust. Deflection (A) Factory spec. 7.0 to 9.0 mm 0.28 to 0.35 in. (A) Deflection W1208957 Fan Belt Damage and Wear 1. Check the fan belt for damage. 2.
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G GENERAL SM-E2B SERIES, WSM 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. ■ IMPORTANT • If dust and dirt enter the fuel, the fuel injection pump and injection nozzle will wear quickly.
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G GENERAL SM-E2B SERIES, WSM [6] CHECK POINT OF EVERY 150 HOURS Replacing Oil Filter Cartridge (for Optional Depth Oil Pans) CAUTION Be sure to stop the engine before changing filter cartridge. Remove the oil filter cartridge (1) with the filter wrench. Apply a slight coat of oil onto the new cartridge gasket. 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.
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G GENERAL SM-E2B SERIES, WSM 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 W1029518 Checking Intake Air Line 1.
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G GENERAL SM-E2B SERIES, WSM [9] CHECK POINTS OF EVERY 500 HOURS Cleaning Water Jacket and Radiator Interior CAUTION • Do not remove the radiator cap when the engine is hot. Then loosen cap slightly to the stop to relieve any excess pressure before removing cap completely. 1. Stop the engine and let cool down. 2. To drain the coolant, open the radiator drain plug (2) and remove the radiator cap (1). Then radiator cap (1) must be removed to completely drain the coolant. And open the drain cock (3). 3.
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G GENERAL SM-E2B SERIES, WSM 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.
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G GENERAL SM-E2B SERIES, WSM [10] CHECK POINTS OF EVERY 1 OR 2 MONTHS Recharging CAUTION • When the battery is being activated, hydrogen and oxygen gases in the battery are extremely explosive. Keep open sparks and flames away from the battery at all times, especially when charging the battery. • When charging battery, remove battery vent plugs. • When disconnecting the cable from the battery, start with the negative terminal first.
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G GENERAL SM-E2B SERIES, WSM Battery Specific Gravity 1. Check the specific gravity of the electrolyte in each cell with a hydrometer. 2. When the electrolyte temperature differs from that at which the hydrometer was calibrated, correct the specific gravity reading following the formula mentioned in (Reference). 3. If the specific gravity is less than 1.215 (after it is corrected for temperature), charge or replace the battery. 4. If the specific gravity differs between any two cells by more than 0.
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G GENERAL SM-E2B SERIES, WSM [11] CHECK POINT OF EVERY YEAR Replacing Air Cleaner Element 1. Remove used air cleaner element. 2. Replace new air cleaner element. ■ NOTE • The air cleaner uses a dry element. Never apply oil to it. • Do not run the engine with filter element removed.
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G GENERAL SM-E2B SERIES, WSM [12] CHECK POINT OF EVERY 800 HOURS Checking Valve Clearance ■ IMPORTANT • 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.
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G GENERAL SM-E2B SERIES, WSM [13] CHECK POINTS OF EVERY 1500 HOURS CAUTION • 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. 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.
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G GENERAL SM-E2B SERIES, WSM 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. Tightening torque (1) (2) (3) (4) Nozzle Holder Adjusting Washer Nozzle Spring Push Rod Nozzle holder 34.3 to 39.2 N·m 3.5 to 4.0 kgf·m 25.3 to 28.
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G GENERAL SM-E2B SERIES, WSM [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 1.57 rad (90 °). 5. Turn the flywheel counterclockwise to set at around 0.
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G GENERAL SM-E2B SERIES, WSM Injection Timing (Continued) ■ NOTE • The sealant is applied to both sides of the shims (soft metal gasket shim). The liquid gasket is not required for assembling. • Shims are available in thickness of 0.20 mm (0.0079 in.), 0.25 mm (0.0098 in.) and 0.30 mm (0.0118 in.). Combine these shims for adjustments. • Addition or reduction of shim (0.05 mm, 0.0020 in.) delays or advances the injection timing by approx. 0.0087 rad (0.5 °).
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G GENERAL SM-E2B SERIES, WSM 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.
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G GENERAL SM-E2B SERIES, WSM [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). ■ NOTE • To prevent serious damage to the engine, keep out any dust inside the intake air line.
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G GENERAL SM-E2B SERIES, WSM Replacing Fuel Hoses and Clamp Bands 1. Loosen the clamp (2) and remove the fuel hose (1). 2. Replace new fuel hose (1) and new clamp (2). 3. Tighten the clamp (2). CAUTION • Stop the engine when attempting the check and change prescribed above. (When bleeding fuel system) 1. Fill the tank with fuel and open the cock (4). 2. Loosen the air vent plug (3) of the fuel filter a few turns. 3. Screw back the plug when bubbles do not come up any more. 4.
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G GENERAL SM-E2B SERIES, WSM Cleaning Water Jacket and Radiator Interior • 1. 2. 3. 4. 5. 6. 7. 8. 9. ■ • • • • (1) (2) (3) (4) CAUTION Do not remove the radiator cap when the engine is hot. Then loosen cap slightly to the stop to relieve any excess pressure before removing cap completely. Stop the engine and let cool down. 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.
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G GENERAL SM-E2B SERIES, WSM Changing Radiator Coolant (L.L.C.) (Continued) (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.
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G GENERAL SM-E2B SERIES, WSM 5. SPECIAL TOOLS Diesel Engine Compression Tester (for Injection Nozzle) Code No: 07909-30208 (Assembly) 07909-31251 (G) 07909-30934 (A to F) 07909-31271 (I) 07909-31211 (E and F) 07909-31281 (J) 07909-31231 (H) Application: Use to measure diesel engine compression and diagnosis of need for major overhaul.
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G GENERAL SM-E2B SERIES, WSM ■ NOTE • 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. A Pressure gauge full scale : More than 29.4 MPa (300 kgf/cm2, 4267 psi) B PF 1/2 C Copper gasket D Flange (Mateiral Steel) E Hex. nut 27 mm (1.06 in.) across the plat F Adhesive application G Fillet welding on the enter circumference H Retaining nut I 17 mm dia. (0.67 in. dia.
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G GENERAL SM-E2B SERIES, WSM Bushing Replacing Tool Application: Use to press out and press fit the bushing. 1. For small end bushing A 145 mm (5.71 in.) B 20 mm (0.79 in.) C 100 mm (3.94 in.) D 19.90 to 19.95 mm dia. (0.7835 to 0.7854 in. dia.) E 21.90 to 21.95 mm dia. (0.8622 to 0.8642 in. dia.) F 25 mm dia. (0.98 in. dia.) C1 Chamfer 1.0 mm (0.039 in.) C2 Chamfer 2.0 mm (0.079 in.) C0.3 Chamfer 0.3 mm (0.012 in.) a 6.3 μm (248 μin.) b 6.3 μm (248 μin.) 2.
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G GENERAL SM-E2B SERIES, WSM Crankshaft Bearing 1 Replacing Tool Application: Use to press out and press fit the crankshaft bearing 1. [Press Out] A 135 mm (5.31 in.) B 72 mm (2.83 in.) C 40 mm radius (1.57 in. radius) D 10 mm (0.39 in.) E 22 mm (0.87 in.) F 20 mm dia. (0.79 in. dia.) G 47.90 to 47.95 mm dia. (1.8858 to 1.8878 in. dia.) H 43.90 to 43.95 mm dia. (1.7283 to 1.7303 in. dia.) C1 Chamfer 1.0 mm (0.039 in.) C2 Chamfer 2.0 mm (0.079 in.) C0.3 Chamfer 0.3 mm (0.012 in.
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G GENERAL SM-E2B SERIES, WSM Crank Sleeve Setter (for Z482/D662/D722/D782-E2B) Application: Use to fix the crankshaft sleeve. (1) Auxiliary Socket for Pushing A 130 mm (5.12 in.) B 112 mm (4.41 in.) C 107 mm (4.21 in.) D 82 mm (3.23 in.) E 72 mm (2.83 in.) F 67 mm (2.64 in.) G 47 mm (1.85 in.) H 37.0 to 37.2 mm (1.457 to 1.465 in.) I 17 mm (0.67 in.) J 5 mm dia. (0.20 in. dia.) K 52 mm dia. (2.05 in. dia.) L 40 mm dia. (1.57 in. dia.) M 10 mm (0.39 in.) N 33 mm (1.30 in.
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MECHANISM CONTENTS 1. ENGINE BODY ............................................................................................... M-1 [1] HALF-FLOATING HEAD COVER ............................................................ M-1 [2] CLOSED BREATHER............................................................................... M-1 [3] PISTON (Z602-E2B, D902-E2B)............................................................... M-2 [4] OIL PAN (Z602-E2B, D902-E2B)..................................................
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DIESEL ENGINE SM-E2B SERIES, WSM 1. ENGINE BODY [1] HALF-FLOATING HEAD COVER The rubber packing is fitted in to maintain the cylinder head cover 0.5 mm (0.02 in.) or so off the cylinder head. This arrangement helps reduce noise coming from the cylinder head. (1) Cylinder Head Cover (2) Rubber Packing W1013327 [2] CLOSED BREATHER Closed breather system has been adopted to prevent the release of blow-by gas into the atmosphere.
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DIESEL ENGINE SM-E2B SERIES, WSM [3] PISTON (Z602-E2B, D902-E2B) Piston’s skirt is coated with molybdenum disulfied★, which reduces the piston slap noise and thus the entire operating noise. ★Molybdenum disulfide (MoS2) 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 W1013114 [4] OIL PAN (Z602-E2B, D902-E2B) The oil pan is extended under the gear case.
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DIESEL ENGINE SM-E2B SERIES, WSM 2. COOLING SYSTEM [1] COOLING FIN (Z602-E2B, D902-E2B) 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.
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SERVICING CONTENTS 1. TROUBLESHOOTING ......................................................................................S-1 2. SERVICING SPECIFICATIONS ......................................................................S-4 3. TIGHTENING TORQUES ..............................................................................S-11 [1] TIGHTENING TORQUES FOR GENERAL USE SCREWS, BOLTS AND NUTS...............................................................................................
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DIESEL ENGINE SM-E2B SERIES, WSM 1.
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DIESEL ENGINE SM-E2B SERIES, WSM Symptom Either White or Blue Exhaust Gas Is Observed Either Black or Dark Gray Exhaust Gas Is Observed Deficient Output Excessive Lubricant Oil Consumption Fuel Mixed into Lubricant Oil Water Mixed into Lubricant Oil Probable Cause Solution Reference Page Excessive engine oil Reduce to specified level G-6 Piston ring and cylinder worn or stuck Repair or replace S-43, 44, 63 Incorrect injection timing Adjust S-17, 18 Overload Reduce the load – Low grade
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DIESEL ENGINE SM-E2B SERIES, WSM Symptom Low Oil Pressure High Oil Pressure Engine Overheated Battery Quickly Discharged Probable Cause Reference Page Solution Engine oil insufficient Replenish G-6 Oil strainer clogged Clean S-34 Relief valve stuck with dirt Clean – Relief valve spring weaken or broken Replace – Excessive oil clearance of crankshaft bearing Replace S-47, 48, 66 to 69 Excessive oil clearance of crankpin bearing Replace S-42, 65 Excessive oil clearance of rocker arm
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DIESEL ENGINE SM-E2B SERIES, WSM 2. SERVICING SPECIFICATIONS ENGINE BODY Item Factory Specification Allowable Limit 0.145 to 0.185 mm 0.00571 to 0.00728 in. – Z482-E2B D662-E2B D722-E2B D782-E2B 2.84 to 3.24 MPa 29.0 to 33.0 kgf/cm2 412 to 469 psi 2.26 MPa 23.0 kgf/cm2 327 psi Z602-E2B D902-E2B 3.53 to 4.02 MPa 36.0 to 41.0 kgf/cm2 512 to 583 psi 2.55 MPa 26.0 kgf/cm2 370 psi – 10 % or less 0.50 to 0.70 mm 0.0197 to 0.0276 in. – – 0.05 mm 0.0020 in.
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DIESEL ENGINE SM-E2B SERIES, WSM ENGINE BODY (Continued) Item Factory Specification Allowable Limit Oil Clearance 0.016 to 0.045 mm 0.00063 to 0.00177 in. 0.15 mm 0.0059 in. Rocker Arm Shaft O.D. 10.473 to 10.484 mm 0.41232 to 0.41276 in. – Rocker Arm I.D. 10.500 to 10.518 mm 0.41339 to 0.41410 in. – – 0.25 mm 0.0098 in. Rocker Arm Shaft to Rocker Arm Push Rod Alignment Tappet to Tappet Guide Oil Clearance 0.016 to 0.052 mm 0.00063 to 0.00205 in. 0.10 mm 0.0039 in. Tappet O.D. 17.
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DIESEL ENGINE SM-E2B SERIES, WSM ENGINE BODY (Continued) Item Factory Specification Allowable Limit Oil Clearance 0.020 to 0.084 mm 0.00079 to 0.00331 in. 0.10 mm 0.0039 in. Idle Gear Shaft O.D. 19.967 to 19.980 mm 0.78610 to 0.78661 in. – Idle Gear Bushing I.D. 20.000 to 20.051 mm 0.78740 to 0.78941 in. – Piston Pin Bore I.D. 20.000 to 20.013 mm 0.78740 to 0.78791 in. 20.05 mm 0.7894 in. Piston Pin to Small End Bushing Oil Clearance 0.014 to 0.038 mm 0.00055 to 0.00150 in. 0.10 mm 0.
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DIESEL ENGINE SM-E2B SERIES, WSM ENGINE BODY (Continued) Item Factory Specification Allowable Limit Oil Clearance 0.020 to 0.051 mm 0.00079 to 0.00201 in. 0.15 mm 0.0059 in. Crankpin O.D. 33.959 to 33.975 mm 1.33697 to 1.33760 in. – Crankpin Bearing I.D. 33.995 to 34.010 mm 1.33839 to 1.33898 in. – Oil Clearance 0.034 to 0.106 mm 0.00134 to 0.00417 in. 0.20 mm 0.0079 in. Crankshaft Journal O.D. 39.934 to 39.950 mm 1.57221 to 1.57284 in. – Crankshaft Bearing 1 I.D. 39.984 to 40.
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DIESEL ENGINE SM-E2B SERIES, WSM ENGINE BODY (Continued) Item Factory Specification Allowable Limit Cylinder Liner [D662-E2B] I.D. 64.000 to 64.019 mm 2.51968 to 2.52043 in. 64.150 mm 2.52559 in. Cylinder Liner [Z482/D722/D782-E2B] I.D. 67.000 to 67.019 mm 2.63779 to 2.63854 in. 67.150 mm 2.64370 in. Cylinder Liner [Z602/D902-E2B] I.D. 72.000 to 72.019 mm 2.83464 to 2.83539 in. 72.150 mm 2.84055 in. Cylinder Liner [Oversize : 0.25 mm (0.0098 in.)] [D662-E2B] I.D. 64.250 to 64.269 mm 2.
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DIESEL ENGINE SM-E2B SERIES, WSM COOLING SYSTEM Item Factory Specification Allowable Limit 7.0 to 9.0 mm / 98 N 0.28 to 0.35 in. / 98 N (10 kgf, 22 lbs) – Fan Belt Tension Thermostat Valve Opening Temperature (At Beginning) 69.5 to 72.5 °C 157.1 to 162.5 °F – Valve Opening Temperature (Opened Completely) 85 °C 185 °F – Radiator Cap Pressure Falling Time 10 seconds or more 88 → 59 kPa 0.9 → 0.
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DIESEL ENGINE SM-E2B SERIES, WSM ELECTRICAL SYSTEM Item Factory Specification Allowable Limit Approx. 0.9 Ω – Glow Plug Resistance Starter (Electromagnetic Drive Type) Commutator O.D. 28.0 mm 1.102 in. 27.0 mm 1.063 in. Difference O.D. Less than 0.05 mm 0.0002 in. 0.4 mm 0.016 in. Mica Undercut 0.50 to 0.80 mm 0.0197 to 0.0315 in. 0.20 mm 0.0079 in. Brush Length 16.0 mm 0.630 in. 10.5 mm 0.413 in. O.D. 30.0 mm 1.181 in. 29.0 mm 1.142 in. Difference O.D. Less than 0.02 mm 0.
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DIESEL ENGINE SM-E2B SERIES, WSM 3. TIGHTENING TORQUES Screws, bolts and nuts must be tightened to the specified torque using a torque wrench, several screws, bolts and nuts such as those used on the cylinder head must be tightened in proper sequence and the proper torque. [1] TIGHTENING TORQUES FOR GENERAL USE SCREWS, BOLTS AND NUTS When the tightening torques are not specified, tighten the screws, bolts and nuts according to the table below.
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DIESEL ENGINE SM-E2B SERIES, WSM [2] TIGHTENING TORQUES FOR SPECIAL USE SCREWS, BOLTS AND NUTS ■ NOTE • For “*” marked screws, bolts and nuts on the table, apply engine oil to their threads and seats before tightening. • The letter “M” in Size x Pitch means that the screw, bolt or nut dimension stands for metric. The size is the nominal outside diameter in mm of the threads. The pitch is the nominal distance in mm between two threads.
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DIESEL ENGINE SM-E2B SERIES, WSM 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.
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DIESEL ENGINE SM-E2B SERIES, WSM Checking Valve Clearance ■ IMPORTANT • 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.
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DIESEL ENGINE SM-E2B SERIES, WSM (2) Lubricating System 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.
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DIESEL ENGINE SM-E2B SERIES, WSM 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 W1016443 CAUTION • When removing the radiator cap, wait at least ten minutes after the engine has stopped and cooled down. Otherwise, hot water may gush out, scalding nearby people.
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DIESEL ENGINE SM-E2B SERIES, WSM Thermostat Valve Opening Temperature 1. Suspend the thermostat in the water by a string with its end inserted between the valve and seat. 2. Heating the water gradually, read the temperature when the valve opens and leaves the string. 3. Continue heating and read the temperature when the valve opens approx. 8 mm (0.315 in.). 4. If the measurement is not within the factory specifications, replace the thermostat. Thermostat’s valve opening temperature Factory spec. 69.
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DIESEL ENGINE SM-E2B SERIES, WSM Injection Timing (Continued) ■ NOTE • The sealant is applied to both sides of the shims (soft metal gasket shim). The liquid gasket is not required for assembling. • Shims are available in thickness of 0.20 mm (0.0079 in.), 0.25 mm (0.0098 in.) and 0.30 mm (0.0118 in.). Combine these shims for adjustments. • Addition or reduction of shim (0.05 mm, 0.0020 in.) delays or advances the injection timing by approx. 0.0087 rad (0.5 °).
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DIESEL ENGINE SM-E2B SERIES, WSM 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.
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DIESEL ENGINE SM-E2B SERIES, WSM CAUTION • Check the nozzle injection pressure and condition after confirming that there is nobody standing in the direction the fume goes. • If the fume from the nozzle directly contacts the human body, cells may be destroyed and blood poisoning may be caused. 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.
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DIESEL ENGINE SM-E2B SERIES, WSM 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. Tightening torque (1) (2) (3) (4) Nozzle Holder Adjusting Washer Nozzle Spring Push Rod Nozzle holder 34.3 to 39.2 N·m 3.5 to 4.0 kgf·m 25.3 to 28.
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DIESEL ENGINE SM-E2B SERIES, WSM Battery Specific Gravity 1. Check the specific gravity of the electrolyte in each cell with a hydrometer. 2. When the electrolyte temperature differs from that at which the hydrometer was calibrated, correct the specific gravity reading following the formula mentioned in (Reference). 3. If the specific gravity is less than 1.215 (after it is corrected for temperature), charge or replace the battery. 4. If the specific gravity differs between any two cells by more than 0.
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DIESEL ENGINE SM-E2B SERIES, WSM Motor Test • 1. 2. 3. 4. 5. 6. 7. ■ • • CAUTION Secure the starter to prevent it from jumping up and down while testing the motor. Disconnect the battery negative cable from the battery. Disconnect the battery positive cable from the battery. Disconnect the leads from the starter B terminal. Remove the starter from the engine. Connect a jumper lead from the starter C terminal (1) to the battery positive terminal (2).
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DIESEL ENGINE SM-E2B SERIES, WSM 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 0000010771E No-load Dynamo Output 1. Disconnect the lead wires from the dynamo. 2. Start the engine and operate the dynamo at the specified speed.
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DIESEL ENGINE SM-E2B SERIES, WSM Continuity across Regulator’s Terminals 1. Measure with a circuit tester according to the list below. ■ NOTE • For this test, use only Analog Meter and do not use a high voltage tester such as a MΩ meter. • This check sheet shows the results of the 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.
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DIESEL ENGINE SM-E2B SERIES, WSM 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. ■ NOTE • 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.
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DIESEL ENGINE SM-E2B SERIES, WSM 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.
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DIESEL ENGINE SM-E2B SERIES, WSM [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). ■ IMPORTANT • Never mix two different types of oil. • Use the proper SAE Engine Oil according to ambient temperature.
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DIESEL ENGINE SM-E2B SERIES, WSM (2) External Components 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. ■ IMPORTANT • Keep the engine stop lever (7) to touch the stopper (6).
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DIESEL ENGINE SM-E2B SERIES, WSM 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. Tightening torque (1) Overflow Pipe (2) Lead (3) Glow Plug Overflow pipe retaining nut 19.6 to 24.5 N·m 2.0 to 2.5 kgf·m 14.5 to 18.
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DIESEL ENGINE SM-E2B SERIES, WSM 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. ■ IMPORTANT • After installing the rocker arm, be sure to adjust the valve clearance. Tightening torque Rocker arm bracket screw (1) Rocker Arm Assembly (2) Rocker Arm Bracket Screws 9.8 to 11.
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DIESEL ENGINE SM-E2B SERIES, WSM Cylinder Head 1. Loosen the pipe clamps (1), and remove the water return pipe (2). 2. Remove the cylinder head screw in the order of (n or j) to (a). 3. Lift up the cylinder head to detach. 4. Remove the cylinder head gasket and O-ring (3). (When reassembling) • Replace the cylinder head gasket with a new one. • Securely fit the O-ring (3) to the pipe pin. • Tighten the cylinder head screws after applying sufficient oil.
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SM-E2B SERIES, WSM DIESEL ENGINE Water Pump Assembly 1. Loosen the alternator mounting screws, and remove the fan belt. 2. Remove the fan and fan pulley. 3. Remove the water pump assembly from the gear case cover. 4. Remove the water pump flange (1). 5. Press out the water pump shaft (2) with the impeller (6) on it. 6. Remove the impeller from the water pump shaft. 7. Remove the mechanical seal (5).
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SM-E2B SERIES, WSM DIESEL ENGINE THIS PAGE INTENTIONALLY LEFT BLANK. S-32b - rev.
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DIESEL ENGINE SM-E2B SERIES, WSM 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. ■ IMPORTANT • Do not change the combination of tappet and tappet guide. (1) Tappet W10209700 Valves 1. Remove the valve caps (4). 2.
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DIESEL ENGINE SM-E2B SERIES, WSM 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.
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DIESEL ENGINE SM-E2B SERIES, WSM (4) Gear Case and Timing Gears 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).
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DIESEL ENGINE SM-E2B SERIES, WSM Injection Pump, Fuel Feed Pump and Speed Control Plate (for Energize to Run Type Engine Stop Solenoid) ■ NOTE • Specific tool (1) : 1.2 mm diameter hard wire with its end hooked, overall length 200 mm (7.87 in.). The tip of wire is bent like the hook to hang governor springs. 1. Remove the socket head screws (3), and remove the engine stop solenoid (4). 2. Remove the screws and separate the speed control plate (6), taking care not to damage the governor spring (7). 3.
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DIESEL ENGINE SM-E2B SERIES, WSM Injection Pump, Fuel Feed Pump and Speed Control Plate (for Energize to Run Type Engine Stop Solenoid) (Continued) (When reassembling) 1. Move the fork lever (2) to the gear case side. 2. Hook the start spring (6) to the injection pump control rack pin (5). 3. Put the specific tool (7) through the fork lever hole of cylinder block (9) and hook the start spring (6). 4. Keep this spring slightly extended and install the injection pump (4).
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DIESEL ENGINE SM-E2B SERIES, WSM Fan Drive Pulley 1. Secure the flywheel to keep it from turning. 2. Remove the fan drive pulley screw. 3. Draw out the fan drive pulley with a puller. (When reassembling) • Install the pulley to crankshaft, aligning the mark (1) on them. • Apply engine oil to the fan drive pulley retaining screw. And tighten it. Tightening torque Fan drive pulley screw 117.7 to 127.5 N·m 12.0 to 13.0 kgf·m 86.8 to 94.
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DIESEL ENGINE SM-E2B SERIES, WSM Gear Case 1. Disconnect the start spring (2) from the fork lever 1 (3). 2. Remove the screw (1) of inside the gear case and outside screws. 3. Remove the gear case (4). (When reassembling) • Apply a liquid gasket (Three Bond 1215 or equivalent) to both sides of the gear case gasket. • Be sure to set three O-rings inside the gear case.
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DIESEL ENGINE SM-E2B SERIES, WSM Idle Gear 1. Remove the external snap ring (3), the collar (2) and the idle gear (1). 2. Remove the idle gear shaft mounting screws (4). 3. Remove the idle gear shaft (5) (if necessary). (When reassembling) • Apply engine oil to the idle gear shaft mounting screw (4). And tighten them. • Install the idle gear, aligning the mark (6) on the gears referring to the photo.
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DIESEL ENGINE SM-E2B SERIES, WSM Fuel Camshaft 1. Remove the retaining plate (6). 2. Remove the fork lever holder mounting screws (8), then draw out the injection pump gear (1) and fuel camshaft (7) with the governor fork assembly. (When reassembling) • Hook the governor spring (5) to the fork lever 2 (4) before installing the fork lever assembly to the crankcase.
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DIESEL ENGINE SM-E2B SERIES, WSM (5) Piston and Connecting Rod Connecting Rod Cap 1. Remove the connecting rod caps (1) using a bihexagonal 8 mm socket. (When reassembling) • Align the marks (a) with each other. (Face the marks toward the injection pump.) • Apply engine oil to the connecting rod screws and lightly screw it in by hand, then tighten it to the specified torque. If the connecting rod screw won’t be screwed in smoothly, clean the threads.
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DIESEL ENGINE SM-E2B SERIES, WSM Piston 1. Turn the flywheel and bring the piston to top dead center. 2. Draw out the piston upward by lightly tapping it from the bottom of the crankcase with the grip of a hammer. 3. Draw out the other pistons after the same method as above. (When reassembling) • Before inserting the piston into the cylinder, apply enough engine oil to the cylinder. • When inserting the piston into the cylinder, face the mark on the connecting rod to the injection pump.
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DIESEL ENGINE SM-E2B SERIES, WSM Piston Ring and Connecting Rod 1. Remove the piston rings using a piston ring tool. 2. Remove the piston pin (7), and separate the connecting rod (6) from the piston (5). (When reassembling) • When installing the ring, assemble the rings so that the manufacturer’s mark (12) near the gap faces the top of the piston. • When installing the oil ring onto the piston, place the expander joint (10) on the opposite side of the oil ring gap (11).
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DIESEL ENGINE SM-E2B SERIES, WSM (6) Flywheel and Crankshaft Flywheel 1. Secure the flywheel to keep it from turning using a flywheel stopper. (Refer to “SPECIAL TOOLS”.) 2. Remove all flywheel screws (1) and then remove the flywheel (2). (When reassembling) • Set the No. 1 crankpin at the top dead center (T.D.C.). • Align the “1TC” mark (a) on the outer surface of the flywheel horizontally with the alignment mark (b) on the rear end plate.
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DIESEL ENGINE SM-E2B SERIES, WSM Crankshaft Assembly For Z482-E2B, D662-E2B, D722-E2B 1. Remove the main bearing case screw 2 (1). 2. Draw out all the crankshaft. For Z602-E2B 1. Remove the main bearing case screw 2 (1). 2. Turn the crankshaft to set the crankpin of the cylinder to the horizontal directions (right or left). Then draw out all the crankshaft, holding the crankpins to the horizontal directions. For D782-E2B, D902-E2B 1. Remove the main bearing case screw 2 (1). 2.
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DIESEL ENGINE SM-E2B SERIES, WSM Main Bearing Case Assembly (Z482-E2B, D662-E2B, D722-E2B, D782-E2B) 1. Remove the two main bearing case screws 1 (4), and remove the main bearing case assembly 1 (1), being careful with crankshaft bearing 3 (5). 2. Remove the main bearing case assembly 2 (2) and the main bearing case assembly (3) as above. Keep in mind, however, that the thrust bearing (7) is installed in the main bearing case assembly (3).
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DIESEL ENGINE SM-E2B SERIES, WSM Main Bearing Case Assembly (Z602-E2B, D902-E2B) 1. Remove the two main bearing case screws 1 (4), and remove the main bearing case assembly 1 (1), being careful with crankshaft bearing 3 (5) (9). 2. Remove the main bearing case assembly 2 (2) and the main bearing case assembly (3) as above. Keep in mind, however, that the thrust bearing (8) is installed in the main bearing case assembly (3). (When reassembling) • Clean the oil passage in the main bearing cases.
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DIESEL ENGINE SM-E2B SERIES, WSM (7) Starter ■ Electromagnetic Drive Type (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22) Solenoid Switch Mounting Nut Starter Drive Housing Drive Lever Gasket Solenoid Switch B Terminal Nut C Terminal Nut Snap RIng Overrunning Clutch Armature Brush Spring Connecting Lead Rear End Frame Gasket Brake Spring Brake Shoe End Frame Cap Screw Yoke Brush Brush Holder Through Bolt W1037593 1.
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DIESEL ENGINE SM-E2B SERIES, WSM ■ Planetary Gear Reduction Type (1) Magnetic Switch Mounting Nut (2) Housing (3) Magnetic Switch (4) B Terminal Nut (5) C Terminal Nut (6) Drive Lever (7) Shaft Assembly (8) Overrunning Clutch (9) Connecting Lead (10) Mounting Screw (11) Armature (12) Yoke (13) Brush Holder (14) Rear End Frame (15) Through Bolt W1222714 1. Unscrew the C terminal nut (5), and disconnect the connecting lead (9). 2.
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DIESEL ENGINE SM-E2B SERIES, WSM (8) Dynamo (1) (2) (3) (4) (5) (6) (7) (8) Shaft Pulley Rotor Collar Bearing Stator Plate Bearing W1036558 1. Remove the nut and separate the plate (7). 2. Tap out the shaft (1) from the rotor (3). 3. Unscrew the screws and remove the stator (6). (When reassembling) • Take care the direction of the collar (4), the flat side should face to the pulley side Tightening torque Pulley nut 39.2 to 44.1 N·m 4.0 to 4.5 kgf·m 28.9 to 32.
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DIESEL ENGINE SM-E2B SERIES, WSM (9) Alternator (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) Pulley Drive End Frame Stator Bearing Retainer Plate Rotor Bearing Rear End Frame Rectifier IC Regulator Brush Holder Rear End Cover W1224079 1. Remove the pulley (1). 2. Remove the rear end cover (12). 3. Remove the brush holder (11). 4. Remove the IC regulator (10). 5. Remove the four screws holding the stator lead wires. 6. Remove the rectifier (9). 7. Remove the rear end frame (8). 8.
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DIESEL ENGINE SM-E2B SERIES, WSM [3] SERVICING (1) Cylinder Head and Valves Top Clearance 1. Remove the cylinder head. (Do not attempt to remove the cylinder head gasket.) 2. Move the piston up and stick a strip of fuse [1.5 mm dia. (0.059 in. dia.), 5 to 7 mm long (0.197 to 0.276 in. long)] on the piston head at three positions with grease so as to avoid the intake and exhaust valves and the combustion chamber ports. 3.
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DIESEL ENGINE SM-E2B SERIES, WSM Cylinder Head Flaw 1. Prepare an air spray red check. 2. Clean the surface of the cylinder head with detergent (2). 3. Spray the cylinder head surface with the red permeative liquid (1). Leave it five to ten minutes after spraying. 4. Wash away the read permeative liquid on the cylinder head surface with the detergent (2). 5. Spray the cylinder head surface with white developer (3). 6. If flawed, it can be identified as red marks.
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DIESEL ENGINE SM-E2B SERIES, WSM Replacing Valve Guide (When removing) 1. Press out the used valve guide using a valve guide replacing tool. (Refer to “SPECIAL TOOLS”.) (When installing) 1. Clean a new valve guide and valve guide bore, and apply engine oil to them. 2. Press in a new valve guide using a valve guide replacing tool. 3. Ream precisely the I.D. of the valve guide to the specified dimension. Valve guide I.D. (Intake and exhaust) Factory spec. 6.010 to 6.025 mm 0.23661 to 0.23720 in.
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DIESEL ENGINE SM-E2B SERIES, WSM Correcting Valve and Valve Seat ■ NOTE • Before correcting the valve and seat, check the valve stem and the I.D. of valve guide section, and repair them if necessary. • After correcting the valve seat, be sure to check the valve recessing. 1) Correcting Valve 1. Correct the valve with a valve refacer. Valve face angle Factory spec. 0.785 rad 45 ° 2) Correcting Valve Seat 1. Slightly correct the seat surface with a 0.785 rad (45 °) valve seat cutter. 2.
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DIESEL ENGINE SM-E2B SERIES, WSM Free Length and Tilt of Valve Spring 1. Measure the free length (B) of valve spring with vernier calipers. If the measurement is less than the allowable limit, replace it. 2. Put the valve spring on a surface plate, place a square on the side of the valve spring. 3. Check to see if the entire side is in contact with the square. Rotate the valve spring and measure the maximum tilt (A). If the measurement exceeds the allowable limit, replace it. 4.
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DIESEL ENGINE SM-E2B SERIES, WSM Push Rod Alignment 1. Place the push rod on V blocks. 2. Measure the push rod alignment. 3. If the measurement exceeds the allowable limit, replace the push rod. Push rod alignment Allowable limit 0.25 mm 0.0098 in. W11220210 Oil Clearance between Tappet and Tappet Guide Bore 1. Measure the tappet O.D. with an outside micrometer. 2. Measure the I.D. of the tappet guide bore with a cylinder gauge, and calculate the oil clearance. 3.
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DIESEL ENGINE SM-E2B SERIES, WSM (2) Timing Gears Timing Gear Backlash 1. Set a dial indicator (lever type) with its tip on the gear tooth. 2. Move the gear to measure the backlash, holding its mating gear. 3. If the backlash exceeds the allowable limit, check the oil clearance of the shaft and the gear. 4. If the oil clearance is proper, replace the gear. Factory spec. 0.043 to 0.124 mm 0.00169 to 0.00488 in. Allowable limit 0.15 mm 0.0059 in. Factory spec. 0.047 to 0.123 mm 0.00185 to 0.00484 in.
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DIESEL ENGINE SM-E2B SERIES, WSM Camshaft Alignment 1. Support the camshaft with V blocks on the surface plate at both end journals. 2. Set a dial indicator with its tip on the intermediate journal. 3. Measure the camshaft alignment. 4. If the measurement exceeds the allowable limit, replace the camshaft. Camshaft alignment Allowable limit 0.01 mm 0.0004 in. W11312720 Cam Height 1. Measure the height of the cam at its highest point with an outside micrometer. 2.
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DIESEL ENGINE SM-E2B SERIES, WSM Oil Clearance between Idle Gear Shaft and Idle Gear Bushing 1. Measure the idle gear shaft O.D. with an outside micrometer. 2. Measure the idle gear bushing I.D. with an inside micrometer, and calculate the oil clearance. 3. If the oil clearance exceeds the allowable limit, replace the bushing. 4. If it still exceeds the allowable limit, replace the idle gear shaft. Oil clearance between idle gear shaft and idle gear bushing Factory spec. 0.020 to 0.084 mm 0.00079 to 0.
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DIESEL ENGINE SM-E2B SERIES, WSM Oil Clearance between Piton Pin and Small End Bushing 1. Measure the piston pin O.D. where it contacts the bushing with an outside micrometer. 2. Measure the small end bushing I.D. with an inside micrometer, and calculate the oil clearance. 3. If the oil clearance exceeds the allowable limit, replace the bushing. If it still exceeds the allowable limit, replace the piston pin. Oil clearance between piston pin and small end bushing Factory spec. 0.014 to 0.038 mm 0.
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DIESEL ENGINE SM-E2B SERIES, WSM Piston Ring Gap 1. Insert the piston ring into the lower part of the cylinder (the least worn out part) with a piston ring compressor and piston. 2. Measure the ring gap with a feeler gauge. 3. If the measurement exceeds the allowable limit, replace the piston ring. Top ring Piston ring gap [Z482-E2B] [D662-E2B] [D722-E2B] [D782-E2B] Second ring Oil ring Top ring Piston ring gap [Z602-E2B] [D902-E2B] Second ring Oil ring Factory spec. 0.15 to 0.30 mm 0.0059 to 0.
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DIESEL ENGINE SM-E2B SERIES, WSM (4) Crankshaft Crankshaft Side Clearance 1. Set a dial indicator with its tip on the end of the crankshaft. 2. Measure the side clearance by moving the crankshaft to the front and rear. 3. If the measurement exceeds the allowable limit, replace the thrust bearings. 4. If the same size bearing is useless because of the crankshaft journal wear, replace it with an oversize one referring to the table and figure. Crankshaft side clearance Factory spec. 0.15 to 0.31 mm 0.
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DIESEL ENGINE SM-E2B SERIES, WSM Oil Clearance between Crankpin and Crankpin Bearing 1. Clean the crankpin and crankpin bearing. 2. Put a strip of plastigage on the center of the crankpin. 3. Install the connecting rod cap and tighten the connecting rod screws to the specified torque, and remove the cap again. 4. Measure the amount of the flattening with the scale, and get the oil clearance. 5. If the oil clearance exceeds the allowable limit, replace the crankpin bearing. 6.
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DIESEL ENGINE SM-E2B SERIES, WSM Oil Clearance between Crankshaft Journal and Crankshaft Bearing 1 1. Measure the O.D. of the crankshaft front journal with an outside micrometer. 2. Measure the I.D. of the crankshaft bearing 1 with an inside micrometer, and calculate the oil clearance. 3. If the oil clearance exceeds the allowable limit, replace the crankshaft bearing 1. 4.
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DIESEL ENGINE SM-E2B SERIES, WSM Oil Clearance between Crankshaft Journal and Crankshaft Bearing 1 (Continued) (Reference) • Undersize crankshaft bearing 1 Undersize Models Z482-E2B D662-E2B D722-E2B D782-E2B 0.2 mm 0.008 in. Bearing Crankshaft bearing 1 02 Z602-E2B D902-E2B Z482-E2B D662-E2B D722-E2B D782-E2B 0.4 mm 0.016 in.
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DIESEL ENGINE SM-E2B SERIES, WSM Oil Clearance between Crankshaft Journal and Crankshaft Bearing 2 and Crankshaft Bearing 3 1. Put a strip of plastigage on the center of the journal. 2. Install the bearing case and tighten the bearing case screws 1 to the specified torque, and remove the bearing case again. 3. Measure the amount of the flattening with the scale, and get the oil clearance. 4. If the oil clearance exceeds the allowable limit, replace the crankshaft bearing 2 (crankshaft bearing 3). 5.
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DIESEL ENGINE SM-E2B SERIES, WSM Oil Clearance between Crankshaft Journal and Crankshaft Bearing 2 and Crankshaft Bearing 3 (Continued) (Reference) • Undersize crankshaft bearing 2 and 3 (0.2 mm (0.008 in.)) Models Bearing Code Number Z482-E2B D662-E2B D722-E2B D782-E2B Crankshaft bearing 2 02 15694-23930 Crankshaft bearing 3 02 15861-23860 Z602-E2B D902-E2B Crankshaft bearing 2 02 1G460-23930 Crankshaft bearing 3 02 1G460-23940 Marking 020 US • Undersize crankshaft bearing 2 and 3 (0.
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DIESEL ENGINE SM-E2B SERIES, WSM Replacing Crankshaft Sleeve (Z482-E2B, D662-E2B, D722-E2B, D782-E2B) 1. Remove the used crankshaft sleeve (2). 2. Set the sleeve guide (3) to the crankshaft (1). 3. Heat a new sleeve to a temperature between 150 and 200 °C (302 and 392 °F), and fix the sleeve to the crankshaft as shown in figure. 4. Press fit the sleeve using the auxiliary socket for pushing (4). (Refer to “SPECIAL TOOLS”.) ■ NOTE • Mount the sleeve with its largely chamfered surface facing outward.
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DIESEL ENGINE SM-E2B SERIES, WSM Correcting Cylinder (Oversize) 1. When the cylinder is worn beyond the allowable limit, bore and hone it to the specified dimension. Factory spec. Cylinder liner I.D. Allowable limit Finishing D662-E2B 64.250 to 64.269 mm 2.52953 to 2.53027 in. Z482-E2B D722-E2B D782-E2B 67.250 to 67.269 mm 2.64764 to 2.64839 in. Z602-E2B D902-E2B 72.250 to 72.269 mm 2.84449 to 2.84524 in. D662-E2B 64.400 mm 2.53543 in. Z482-E2B D722-E2B D782-E2B 67.400 mm 2.65354 in.
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DIESEL ENGINE SM-E2B SERIES, WSM Clearance between Rotor and Cover 1. Put a strip of plastigage onto the rotor face with grease. 2. Install the cover and tighten the screws. 3. Remove the cover carefully, and measure the amount of the flattening with the scale and get the clearance. 4. If the clearance exceeds the factory specifications, replace oil pump rotor assembly. Clearance between rotor and cover Factory spec. 0.075 to 0.135 mm 0.00295 to 0.00531 in. W10382660 (7) Starter Overrunning Clutch 1.
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DIESEL ENGINE SM-E2B SERIES, WSM Commutator and Mica 1. Check the contact of the commutator for wear, and grind the commutator with emery paper if it is slightly worn. 2. Measure the commutator O.D. with an outside micrometer at several points. 3. If the minimum O.D. is less than the allowable limit, replace the armature. 4. If the difference of the O.D.'s exceeds the allowable limit, correct the commutator on a lathe to the factory specification. 5. Measure the mica undercut. 6.
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DIESEL ENGINE SM-E2B SERIES, WSM Brush Wear 1. If the connect face of the brush is dirty or dusty, clean it with emery paper. 2. Measure the brush length (A) with vernier caliper. 3. If the length is than the allowable limit, replace the yoke assembly and brush holder. Factory spec. Brush length A Allowable limit Electromagnetic drive type 16.0 mm 0.630 in. Planetary gear reduction type 14.0 mm 0.551 in. Electromagnetic drive type 10.5 mm 0.413 in. Planetary gear reduction type 9.0 mm 0.354 in.
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DIESEL ENGINE SM-E2B SERIES, WSM Field Coil 1. Check the continuity across the lead (1) and brush (2) with a circuit tester. 2. If it dose not conduct, replace the yoke assembly. 3. Check the continuity across the brush (2) and yoke (3) with a circuit tester. 4. If it conducts, replace the yoke assembly. (1) Lead (2) Bush (3) Yoke W1156968 (8) Alternator Bearing 1. Check the bearing for smooth rotation. 2. If it does not rotate smoothly, replace it. W1019790 Stator 1.
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DIESEL ENGINE SM-E2B SERIES, WSM Slip Ring 1. Check the slip ring for score. 2. If scored, correct with an emery paper or on a lathe. 3. Measure the O.D. of slip ring with vernier calipers. 4. If the measurement is less than the allowable limit, replace it. Factory spec. 14.4 mm 0.567 in. Allowable limit 14.0 mm 0.551 in. Slip ring O.D. W1020208 Brush Wear 1. Measure the brush length with vernier calipers. 2. If the measurement is less than allowable limit, replace it. 3.
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EDITOR: KUBOTA FARM & INDUSTRIAL MACHINERY SERVICE, LTD. 64, ISHIZU-KITAMACHI, SAKAI-KU, SAKAI-CITY, OSAKA, 590-0823, JAPAN PHONE : (81)72-241-1129 FAX : (81)72-245-2484 E-mail : ksos-pub@kubota.co.jp KUBOTA Corporation Printed in Japan 2006. 02, S, EI, EI, e 2004. 11, S, EI, EI, e Code No.