Kubota d722 e4 b diesel engine service repair manual
- 1. WORKSHOP MANUAL DIESEL ENGINE SM-E4B SERIES KiSC issued 01, 2013 A
- 2. TO THE READER This Workshop Manual tells the servicing personnel about the mechanism, servicing and maintenance of SM-E4B series. It contains 4 parts: "Information", "General", "Mechanism" and "Servicing". Information This section primarily contains information below. • Safety First • Specification • Performance Curve • Dimension General This section primarily contains information below. • Engine Identification • General Precautions • Maintenance Check List • Check and Maintenance • Special Tools Mechanism This section contains information on the structure and the function of the unit. Before you continue with the subsequent sections, make sure that you read this section. Refer to the latest version of Workshop Manual (Code No. 9Y021-01870 / 9Y021-18200) for the diesel engine / tractor mechanism that this workshop manual does not include. Servicing This section primarily contains information below. • Troubleshooting • Servicing Specifications • Tightening Torques • Checking, Disassembling and Servicing All illustrations, photographs and specifications contained in this manual are of the newest information available at the time of publication. KUBOTA reserves the right to change all information at any time without notice. Since this manual includes many models, information or illustrations and photographs can show more than one model. December, 2012 © KUBOTA Corporation 2012 KiSC issued 01, 2013 A
- 3. I INFORMATION KiSC issued 01, 2013 A
- 4. CONTENTS 1. SAFETY FIRST .............................................................................................................................. I-1 2. SPECIFICATIONS.......................................................................................................................... I-4 3. PERFORMANCE CURVES............................................................................................................ I-6 4. DIMENSIONS............................................................................................................................... I-11 INFORMATION KiSC issued 01, 2013 A
- 5. INFORMATIONSM-E4B SERIES, WSM I-1 1. SAFETY FIRST WSM000001INI0001US1 BEFORE YOU START SERVICE • Read all instructions and safety instructions in this manual and on your engine safety decals. • Clean the work area and engine. • Park the machine on a stable and level ground. • Let the temperature of the engine decrease before you start a job. • Stop the engine, then remove the key. • Disconnect the battery negative cable. • Hang a "DO NOT OPERATE" tag in the operator station. WSM000001INI0002US0 START SAFELY • Do not do the procedures below when you start the engine. – short across starter terminals – bypass the safety start switch • Do not make unauthorized modifications to the engine. This can cause damage and decrease the engine life. WSM000001INI0003US0 SAFETY FIRST • This symbol, the industry's "Safety Alert Symbol", is used throughout this manual and on labels on the machine itself to warn of the possibility of personal injury. Read these instructions carefully. • It is essential that you read the instructions and safety regulations before you try to repair or use this unit. 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. IMPORTANT • Indicates that equipment or property damage could result if instructions are not followed. NOTE • Gives helpful information. KiSC issued 01, 2013 A
- 6. INFORMATIONSM-E4B SERIES, WSM I-2 OPERATE SAFELY • Do not use the machine after you consume alcohol or medication or when you are tired. • Put on applicable clothing and safety equipment. • Use applicable tools only. Do not use alternative tools or parts. • When 2 or more persons do servicing, make sure that you do it safely. • Do not touch the hot parts or parts that turn when the engine operates. • Do not remove the radiator cap when the engine operates, or immediately after it stops. If not, hot water can spout out from the radiator. Only remove the radiator cap when it is at a sufficiently low temperature to touch with bare hands. Slowly loosen the cap to release the pressure before you remove it fully. • Released fluid (fuel or hydraulic oil) under pressure can cause damage to the skin and cause serious injury. Release the pressure before you disconnect hydraulic or fuel lines. Tighten all connections before you apply the pressure. • Do not open a fuel system under high pressure. The fluid under high pressure that stays in fuel lines can cause serious injury. Do not disconnect or repair the fuel lines, sensors, or any other components between the fuel pump and injectors on engines with a common rail fuel system under high pressure. • Put on an applicable ear protective device (earmuffs or earplugs) to prevent injury against loud noises. • Be careful about electric shock. The engine generates a high voltage of more than DC100 V in the ECU and is applied to the injector. WSM000001INI0004US0 PREVENT A FIRE • Fuel is very flammable and explosive under some conditions. Do not smoke or let flames or sparks in your work area. • To prevent sparks from an accidental short circuit, always disconnect the battery negative cable first and connect it last. • The battery gas can cause an explosion. Keep the sparks and open flame away from the top of battery, especially when you charge the battery. • Make sure that you do not spill fuel on the engine. WSM000001INI0005US1 KiSC issued 01, 2013 A
- 7. INFORMATIONSM-E4B SERIES, WSM I-3 KEEP A GOOD AIRFLOW IN THE WORK AREA • If the engine is in operation, make sure that the area has good airflow. Do not operate the engine in a closed area. The exhaust gas contains poisonous carbon monoxide. WSM000001INI0006US1 DISCARD FLUIDS CORRECTLY • Do not discard fluids on the ground, down the drain, into a stream, pond, or lake. Obey related environmental protection regulations when you discard oil, fuel, coolant, electrolyte and other dangerous waste. WSM000001INI0007US1 PREVENT ACID BURNS • Keep electrolyte away from your eyes, hands and clothing. Sulfuric acid in battery electrolyte is poisonous and it can burn your skin and clothing and cause blindness. If you spill electrolyte on yourself, clean yourself with water, and get medical aid immediately. WSM000001INI0008US1 PREPARE FOR EMERGENCIES • Keep a first aid kit and fire extinguisher ready at all times. • Keep the emergency contact telephone numbers near your telephone at all times. WSM000001INI0009US1 KiSC issued 01, 2013 A
- 8. INFORMATIONSM-E4B SERIES, WSM I-4 2. SPECIFICATIONS *The specification described above is of the standard engine of each model. *Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW Model Z482-E4B Z602-E4B Number of Cylinder 2 Type Vertical, Water-cooled, 4 cycle IDI diesel engine Bore × Stroke 67.0 × 68.0 mm (2.64 × 2.68 in.) 72.0 × 73.6 mm (2.83 × 2.90 in.) Total Displacement 479.0 cm3 (29.23 cu.in.) 599.0 cm3 (36.55 cu.in.) ISO Net Continuous 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) 3850 min-1 (rpm) Minimum Bare Idling Speed 1250 to 1350 min-1 (rpm) 1050 to 1150 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 0.33 rad (19 °) 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 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) 53.1 kg (117 lbs) 57.0 kg (125.7 lbs) KiSC issued 01, 2013 A
- 9. INFORMATIONSM-E4B SERIES, WSM I-5 *The specification described above is of the standard engine of each model. *Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW 9Y1210785INI0001US0 Model D722-E4B D782-E4B D902-E4B Number of Cylinder 3 Type Vertical, Water-cooled, 4 cycle IDI diesel engine Bore × Stroke 67.0 × 68.0 mm (2.64 × 2.68 in.) 67.0 × 73.6 mm (2.64 × 2.90 in.) 72.0 × 73.6 mm (2.83 × 2.90 in.) 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 12.2 kW / 3600 min-1 (rpm) (16.3 HP / 3600 min-1 (rpm)) 11.9 kW / 3200 min-1 (rpm) (16.0 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)) 14.4 kW / 3200 min-1 (rpm) (19.3 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) 3850 min-1 (rpm) Minimum Bare Idling Speed 1250 to 1350 min-1 (rpm) 1000 to 1100 min-1 (rpm) 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 0.35 rad (20 °) before T.D.C. 0.30 rad (17 °) before T.D.C. 0.331 rad (19 °) before T.D.C. Firing Order 1-2-3 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, 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. 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) 63.1 kg (139.1 lbs) 63.5 kg (140 lbs) 72.0 kg (159 lbs) KiSC issued 01, 2013 A
- 10. INFORMATIONSM-E4B SERIES, WSM I-6 3. PERFORMANCE CURVES Z482-E4B 9Y1210785INI0002US0 (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 01, 2013 A
- 11. INFORMATIONSM-E4B SERIES, WSM I-7 Z602-E4B 9Y1210785INI0003US0 (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 01, 2013 A
- 12. INFORMATIONSM-E4B SERIES, WSM I-8 D722-E4B 9Y1210785INI0004US0 (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 01, 2013 A
- 13. INFORMATIONSM-E4B SERIES, WSM I-9 D782-E4B 9Y1210785INI0005US0 (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 01, 2013 A
- 14. INFORMATIONSM-E4B SERIES, WSM I-10 D902-E4B 9Y1210785INI0006US0 (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 01, 2013 A
- 15. INFORMATIONSM-E4B SERIES, WSM I-11 4. DIMENSIONS Z482-E4B 9Y1210785INI0007US0 KiSC issued 01, 2013 A
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- 17. INFORMATIONSM-E4B SERIES, WSM I-12 Z602-E4B 9Y1210785INI0008US0 KiSC issued 01, 2013 A