KUBOTA D902-E4 Operator's Manual

OPERATOR'S MANUAL
KUBOTA DIESEL ENGINE

MANUEL DE L'OPERATEUR
MOTEUR DIESEL DE KUBOTA
BEDIENUNGSANLEITUNG
Z482 E-4·Z602 E-4·D722 E-4·D782 E-4·D902 E-4·D902 T

KUBOTA DIESEL MOTOR
U.S.A. : KUBOTA ENGINE AMERICA CORPORATION
505 Schelter Road, Lincolnshire, Illinois 60069 U.S.A.
MANUALE DELL'OPERATORE
Canada
Telephone : (847)955-2500
: KUBOTA CANADA LTD.
5900 14th Avenue, Markham, Ontario, L3S 4K4, Canada
Telephone : (905)294-7477
KUBOTA MOTORE DIESEL
France : KUBOTA EUROPE S.A.S
MANUAL DE INSTRUCCIONES
19-25, Rue Jules Vercruysse, Z.I. BP88, 95101 Ar enteuil Cedex, France
Telephone : (33)1-3426-3434
Italy : KUBOTA EUROPE S.A.S Italy Branch
Via Grandi, 29 20068 Peschiera Borrome (MI) Italy
Telephone : (39)02-51650377
Germany : KUBOTA (DEUTSCHLAND) GmbH
Senefelder Str. 3-5 63110 Rod au /Nieder-Roden, Germany
KUBOTA DIESEL MOTOR
Telephone : (49)6106-873-0
U.K. : KUBOTA (U.K.) LTD.
Dormer Road, Thame, Oxfordshire, OX9 3UN, U.K.
Telephone : (44)1844-214500
Australia : KUBOTA AUSTRALIA PTY LTD.
25-29 Permas Way, Tru anina, VIC 3029, Australia
Telephone : (61)-3-9394-4400
Z482-E4 · Z602-E4
Malaysia : KUBOTA MALAYSIA SDN. BHD.
Lot 766, Jalan Suban 4, off Persiaran Suban Sun ai Pena a Industrial Park,
D722-E4 · D782-E4
47500 Suban Jaya
Telephone : (60)-3-7890-3533
Philippines : KUBOTA PHILIPPINES, INC.
D902-E4· D902-T-E4
232 Quirino Hi hway, Baesa, Quezon City 1106, Philippines
Telephone : (63)2-422-3500
Indonesia : P.T. KUBOTA INDONESIA
Taman Industri Bukit Semaran Baru(BSB) Blok D.1 Kav.8, Kel. Jatibaran -
Kec.Mijen, Semaran , Indonesia
Telephone : (62)-24-7472849
Japan : KUBOTA Corporation

En ine Export Dept.
2-47, Shikitsuhi ashi 1-chome, Naniwa-ku, Osaka, Japan 556-8601
Telephone : (81)6-6648-2155 Fax : (81)6-6648-3521
-- E-4
1ABAAAAAP1560
Code No. 1J090-8916-7
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MANUEL A LIRE ET A CONSERVER
DIESE ANLEITUNG BITTE SORGFÄLTIG DURCHLESEN
UND GRIFFBEREIT AUFBEWAHREN
PRINTED IN JAPAN
© KUBOTA Corporation 2012
LEGGETE E CONSERVATE QUESTO MANUALE
LEAN Y CONSERVEN ESTE MANUAL
1906-0631
California Proposition 65
WARNING
Engine exhaust, some of its constituents,
certain vehicle components and fluids,
contain or emit chemicals known to the
State of California to cause cancer and birth
defects or other reproductive harm.
Z482-E4/Z602-E4
D722-E4/D782-E4
D902-E4/D902-T-E4
AY. K. 8-47. 70. K
1906-0631
OPERATOR'S MANUAL
KUBOTA
DIESEL ENGINE
MODELS Z482-E4 · Z602-E4
D722-E4 · D782-E4
D902-E4· D902-T-E4
1ABAAAAAP1560
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1906-0631
Engine FOREWORD(E).fm 1 ページ２０１１年２月９日水曜日午前８時４９分
ENGLISH
FOREWORD
You are now the proud owner of a KUBOTA Engine. This engine is a
product of KUBOTA quality engineering and manufacturing. It is made
of fine materials and under a rigid quality control system. It will give
you long, satisfactory service. To obtain the best use of your engine,
please read this manual carefully. It will help you become familiar with
the operation of the engine and contains many helpful hints about
engine maintenance. It is KUBOTA's policy to utilize as quickly as
possible every advance in our research. The immediate use of new
techniques in the manufacture of products may cause some small
parts of this manual to be outdated. KUBOTA distributors and dealers
will have the most up-to-date information. Please do not hesitate to
consult with them.
SAFETY FIRST
This symbol, the industry's "Safety Alert Symbol", is used throughout
this manual and on labels on the machine itself to warn of the
possibility of personal injury. Read these instructions carefully. It is
essential that you read the instructions and safety regulations before
you attempt to assemble or use this unit.
DANGER : Indicates an imminently hazardous situation which,

if 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.

E.book Page 1 Wednesday, October 7, 2020 7:17 PM
ENGLISH
CONTENTS
SAFE OPERATION ..................................................................................................1
SERVICING OF THE ENGINE ....................................................................................1
NAMES OF PARTS .....................................................................................................2
PRE-OPERATION CHECK ..........................................................................................3
BREAK-IN.................................................................................................................3
DAILY CHECK..........................................................................................................3
OPERATING THE ENGINE .........................................................................................4
STARTING THE ENGINE(NORMAL).......................................................................4
COLD WEATHER STARTING .................................................................................5
STOPPING THE ENGINE ........................................................................................6
CHECKS DURING OPERATION .............................................................................6
Radiator Cooling water(Coolant) ...................................................................................... 6
Oil pressure lamp ............................................................................................................. 6
Fuel .................................................................................................................................. 6
Color of exhaust ............................................................................................................... 6
Immediately stop the engine if;......................................................................................... 6
REVERSED ENGINE REVOLUTION AND REMEDIES ..........................................7
How to tell when the engine starts running backwards .................................................... 7
Remedies ......................................................................................................................... 7
EMISSION CONTROL SYSTEM..............................................................................7
PRECAUTIONS ON GENERATOR-EQUIPPED ENGINE .......................................7
MAINTENANCE ...........................................................................................................8
SERVICE INTERVALS .............................................................................................9
PERIODIC SERVICE .................................................................................................12
FUEL ......................................................................................................................12
Fuel level check and refueling........................................................................................ 12
Air bleeding the fuel system ........................................................................................... 13
Checking the fuel pipes .................................................................................................. 13
Cleaning the fuel filter pot............................................................................................... 14
ENGINE OIL ...........................................................................................................14
Checking level and adding engine oil ............................................................................. 14
Changing engine oil........................................................................................................ 15
Replacing the oil filter cartridge ...................................................................................... 16
RADIATOR .............................................................................................................16
Checking coolant level, adding coolant .......................................................................... 16
Changing coolant ........................................................................................................... 17
Checking radiator hoses and clamp bands .................................................................... 18
Precaution at overheating .............................................................................................. 18
Cleaning radiator core (outside) ..................................................................................... 18
Cleaning the radiator (inside) ......................................................................................... 18
Anti-freeze ...................................................................................................................... 18
AIR CLEANER........................................................................................................19
ELECTRIC WIRING ...............................................................................................20
FAN BELT ..............................................................................................................20
Adjusting Fan Belt Tension ............................................................................................ 20
TURBO-CHARGER ................................................................................................20
CARRIAGE AND STORAGE .....................................................................................21
CONTENTS
ENGLISH
CARRIAGE .............................................................................................................21
STORAGE ..............................................................................................................21
TROUBLESHOOTING ...............................................................................................22
SPECIFICATIONS .....................................................................................................24
WIRING DIAGRAMS..................................................................................................27
SAFE OPERATION 1
ENGLISH
SAFE OPERATION
Careful operation is your best assurance against an accident. Read and understand this
section carefully before operating the engine. All operators, no matter how much
experience they may have, should read this and other related manuals before operating
the engine or any equipment attached to it. It is the owner's obligation to provide all
operators with this information and instruct them on safe operation.
Be sure to observe the following for safe operation.
1. OBSERVE SAFETY INSTRUCTIONS

A Read and understand carefully this "OPERATOR'S
MANUAL" and "LABELS ON THE ENGINE" before
attempting to start and operate the engine.
A Learn how to operate and work safely. Know your
equipment and its limitations. Always keep the engine in
good condition.
A Before allowing other people to use your engine, explain
how to operate and have them read this manual before
operation.
A DO NOT modify the engine. UNAUTHORIZED
MODIFICATIONS to the engine may impair the function
and/or safety and affect engine life. If the engine does not
perform properly, consult your local Kubota Engine
Distributor first.
2. WEAR SAFE CLOTHING AND PERSONAL PROTECTIVE EQUIPMENT (PPE)

A DO NOT wear loose, torn or bulky clothing around the
machine that may catch on working controls and
projections or into fans, pulleys and other moving parts
causing personal injury.
A Use additional safety items-PPE, e.g. hard hat, safety
protection, safety goggles, gloves, etc., as appropriate or
required.
A DO NOT operate the machine or any equipment attached
to it while under the influence of alcohol, medication, or
other drugs, or while fatigued.
A DO NOT wear radio or music headphones while
operating the engine.
2 SAFE OPERATION
ENGLISH
3. CHECK BEFORE STARTING & OPERATING THE ENGINE

A Be sure to inspect the engine before operation. Do not
operate the engine if there is something wrong with it.
Repair it immediately.
A Ensure all guards and shields are in place before
operating the engine. Replace any that are damaged or
missing.
A Check to see that you and others are a safe distance
from the engine before starting.
A Always keep the engine at least 3 feet (1 meter) away
from buildings and other facilities.
A DO NOT allow children or livestock to approach the
machine while the engine is running.
A DO NOT start the engine by shorting across starter
terminals. The machine may start in gear and move. Do
not bypass or defeat any safety devices.
4. KEEP THE ENGINE AND SURROUNDINGS CLEAN

A Be sure to stop the engine before cleaning.
A Keep the engine clean and free of accumulated dirt,
grease and trash to avoid a fire. Store flammable fluids in
proper containers and cabinets away from sparks and
heat.
A Check for and repair leaks immediately.
A DO NOT stop the engine without idling; Allow the engine
to cool down, first. Keep the engine idling for about 5
minutes before stopping unless there is a safety problem
that requires immediate shut down.
5. SAFE HANDLING OF FUEL AND LUBRICANTS -KEEP AWAY FROM FIRE

A Always stop the engine before refueling and/or
lubricating.
A DO NOT smoke or allow flames or sparks in your work
area. Fuel is extremely flammable and explosive under
certain conditions.
A Refuel at a well ventilated and open place. When fuel
and/or lubricants are spilled, refuel after letting the
engine cool down.
A DO NOT mix gasoline or alcohol with diesel fuel. The
mixture can cause a fire or severe engine damage.
A Do not use unapproved containers e.g. buckets, bottles,
jars. Use approved fuel storage containers and
dispensers.
SAFE OPERATION 3
ENGLISH
6. EXHAUST GASES & FIRE PREVENTION
A Engine exhaust fumes can be very harmful if allowed to
accumulate. Be sure to run the engine in a well ventilated
location and where there are no people or livestock near
the engine.
A The exhaust gas from the muffler is very hot. To prevent
a fire, do not expose dry grass, mowed grass, oil or any
other combustible materials to exhaust gas. Keep the
engine and muffler clean at all times.
A To avoid a fire, be alert for leaks of flammable
substances from hoses and lines. Be sure to check for
leaks from hoses or pipes, such as fuel and hydraulic
fluid by following the maintenance check list.
A To avoid a fire, do not short across power cables and
wires. Check to see that all power cables and wirings are
in good condition. Keep all electrical connections clean.
Bare wire or frayed insulation can cause a dangerous
electrical shock and personal injury.
7. ESCAPING FLUID
A Relieve all pressure in the air, the oil and the cooling
systems before disconnecting any lines, fittings or
related items.
A Be cautious of possible pressure relief when
disconnecting any device from a pressurized system that
utilizes pressure. DO NOT check for pressure leaks with
your hand. High pressure oil or fuel can cause personal
injury.
A Escaping fluid under pressure has sufficient force to
penetrate skin causing serious personal injury.
A Fluid escaping from pinholes may be invisible. Use a
piece of cardboard or wood to search for suspected
leaks: do not use hands and body. Use safety goggles or
other eye protection when checking for leaks.
A If injured by escaping fluid, see a medical doctor
immediately. This fluid can produce gangrene or severe
allergic reaction.
4 SAFE OPERATION
ENGLISH
8. CAUTIONS AGAINST BURNS & BATTERY EXPLOSION

A To avoid burns, be cautious of hot components, e.g.
muffler, muffler cover, radiator, hoses, engine body,
coolants, engine oil, etc. during operation and after the
engine has been shut off.
A DO NOT remove the radiator cap while the engine is
running or immediately after stopping. Otherwise hot
water will spout out from the radiator. Wait until the
radiator is completely cool to the touch before removing
the cap. Wear safety goggles.
A Be sure to close the coolant drain valve, secure the
pressure cap, and fasten the pipe band before operating.
If these parts are taken off, or loosened, it will result in
serious personal injury.
A The battery presents an explosive hazard. When the
battery is being charged, hydrogen and oxygen gases
are extremely explosive.
A DO NOT use or charge the battery if its fluid level is below
the LOWER mark.
Otherwise, the component parts may deteriorate earlier
than expected, which may shorten the service life or
cause an explosion. Immediately, add distilled water until
the fluid level is between the UPPER and LOWER marks.
A Keep sparks and open flames away from the battery,
especially during charging. DO NOT strike a match near
the battery.
A DO NOT check the battery charge by placing a metal
object across the terminals. Use a voltmeter or
hydrometer.
A DO NOT charge a frozen battery. There is a risk of
explosion. When frozen, warm the battery up to at least
16 C (61 F).
9. KEEP HANDS AND BODY AWAY FROM ROTATING PARTS

A Be sure to stop the engine before checking or adjusting
the belt tension and cooling fan.
A Keep your hands and body away from rotating parts,
such as the cooling fan, V-belt, fan drive pulley or
flywheel. Contact with rotating parts can cause severe
personal injury.
A DO NOT run the engine without safety guards. Install
safety guards securely before operation.
SAFE OPERATION 5
ENGLISH
10. ANTI-FREEZE & DISPOSAL OF FLUIDS
A Anti-freeze contains poison. Wear rubber gloves to avoid
personal injury. In case of contact with skin, wash it off
immediately.
A DO NOT mix different types of Anti-freeze. The mixture
can produce a chemical reaction causing harmful
substances. Use approved or genuine KUBOTA Anti-
freeze.
A Be mindful of the environment and the ecology. Before
draining any fluids, determine the correct way to dispose
of them. Observe the relevant environmental protection
regulations when disposing of oil, fuel, coolant, brake
fluid, filters and batteries.
A When draining fluids from the engine, place a suitable
container underneath the engine body.
A DO NOT pour waste onto the ground, down a drain, or
into any water source. Dispose of waste fluids according
to environmental regulations.
11. CONDUCTING SAFETY CHECKS & MAINTENANCE

A When inspecting the engine or servicing, place the
engine on a large flat surface. DO NOT work on anything
that is supported ONLY by lift jacks or a hoist. Always use
blocks or the correct stands to support the engine before
servicing.
A Disconnect the battery from the engine before
conducting service. Put a "DO NOT OPERATE!" tag on
the key switch to avoid accidental starting.
A To avoid sparks from an accidental short circuit always
disconnect the battery's ground cable (-) first and
reconnect it last.
A Be sure to stop the engine and remove the key when
conducting daily and periodic maintenance, service and
cleaning.
A Check or conduct maintenance after the engine, coolant,
muffler, or muffler cover have cooled off completely.
A Always use the appropriate tools and fixtures. Verify that
they are in good condition before performing any service
work. Make sure you understand how to use them before
service.
A Use ONLY correct engine barring techniques for
manually rotating the engine. DO NOT attempt to rotate
the engine by pulling or prying on the cooling fan and V-
belt. This practice can cause serious personal injury or
premature damage to the cooling fan and belt.
6 SAFE OPERATION
ENGLISH
A Replace fuel pipes and lubricant pipes with their hose

clamps every 2 years or earlier whether they are
damaged or not. They are made of rubber and age
gradually.
A When servicing is performed together by two or more
persons, take care to perform all work safely.
A Keep a first aid kit and fire extinguisher handy at all times.
12. WARNING AND CAUTION LABELS

Part No.19077-8724-1 or 16667-8724-1 Part No.TA040-4957-1
(55mm in diameter) (37mm in diameter) Do not get your hands close
to engine fan and fan belt.
13. CARE OF WARNING AND CAUTION LABELS

1. Keep warning and caution labels clean and free from obstructing material.
2. Clean warning and caution labels with soap and water, dry with a soft cloth.
3. Replace damaged or missing warning and caution labels with new labels from your local
KUBOTA dealer.
4. If a component with warning and caution label(s) affixed is replaced with a new part, make
sure the new label(s) is (are) attached in the same location(s) as the replaced component.
5. Mount new warning and caution labels by applying to a clean dry surface and pressing any
bubbles to the outside edge.
SERVICING OF THE ENGINE 1
ENGLISH
SERVICING OF THE ENGINE
Your dealer is interested in your new engine and has the
desire to help you get the most value from it. After reading
this manual thoroughly, you will find that you can do some
of the regular maintenance yourself.
However, when in need of parts or major service, be sure
to see your KUBOTA dealer.
For service, contact the KUBOTA Dealership from which
you purchased your engine or your local KUBOTA dealer.
When in need of parts, be prepared to give your dealer
the engine serial number.
Locate the serial number now and record them in the
space provided.
Type Serial No.

(1) Engine serial number
Engine
Date of Purchase
Name of Dealer
(To be filled in by purchaser)
2 NAMES OF PARTS
ENGLISH
NAMES OF PARTS
(1) Intake manifold (10) Oil filler plug

(2) Speed control lever (11) Exhaust manifold
(3) Engine stop lever (12) Alternator
(4) Injection pump (13) Starter
(5) Fuel feed pump (14) Oil level gauge
(6) Cooling fan (15) Oil pressure switch
(7) Fan drive pulley (16) Flywheel
(8) Oil filter cartridge (17) Oil drain plug
(9) Water drain cock (18) Oil pan
(19) Turbo-charger (D902-T-E4)
PRE-OPERATION CHECK 3
ENGLISH
PRE-OPERATION CHECK
BREAK-IN
During the engine break-in period, observe the following by all means:
1. Change engine oil and oil filter cartridge after the first 50 hours of operation. (See "ENGINE OIL" in "PERIODIC
SERVICE" section.)
2. When ambient temperature is low, operate the machine after the engine has been completely warmed up.
DAILY CHECK
To prevent trouble from occurring, it is important to know the conditions of the engine well. Check it before starting.
To avoid personal injury or death:

A Be sure to install shields and safeguards attached to the engine when operating.
A Stop the engine at a flat and wide space when checking.
A Keep dust or fuel away from the battery, wiring, muffler and engine to prevent a fire.
Check and clear them before operating everyday. Pay attention to the heat of the
exhaust pipe or exhaust gas so that it can not ignite trash.
Item Ref. page
1. Parts which had trouble in previous operation -
2. By walking around the machine (1) Oil or water leaks 14 to 16
(2) Engine oil level and contamination 14
(3) Amount of fuel 12
(4) Amount of coolant 16
(5) Dust in air cleaner 19
(6) Damaged parts and loosened bolts and nuts -
3. By inserting the key into the (1) Proper functions of meters and pilot lamps; no stains on
-
starter switch these parts
(2) Proper function of glow lamp timer -
4. By starting the engine (1) Color of exhaust fumes 6
(2) Unusual engine noise 6
(3) Engine start-up condition 5
(4) Slow-down and acceleration behavior 6
4 OPERATING THE ENGINE

ENGLISH
OPERATING THE ENGINE

STARTING THE ENGINE(NORMAL) 1. Set the fuel lever to the "ON" position.

A Do not allow children to approach the
machine while the engine is running.
A Be sure to install the machine on
which the engine is installed, on a flat
place.
A Do not run the engine on gradients.
A Do not run the engine in an enclosed
area. Exhaust gas can cause air
pollution and exhaust gas poisoning.
A Keep your hands away from rotating
parts (such as fan, pulley, belt,
flywheel etc.) during operation. (1) Fuel lever (A) "ON"
(B) "OFF"
A Do not operate the machine while
under the influence of alcohol or
drugs. 2. Place the engine stop lever in the
A Do not wear loose, torn or bulky "START" position.
clothing around the machine. It may 3. Place the speed control lever at more
catch on moving parts or controls, than half "OPERATION"
leading to the risk of accident. Use
additional safety items, e.g. hard hat,
safety boots or shoes, eye and
hearing protection, gloves, etc., as
appropriate or required.
A Do not wear radio or music
headphones while operating engine.
A Check to see if it is safe around the
engine before starting.
A Reinstall safeguards and shields
securely and clear all maintenance
tools when starting the engine after
maintenance.
(1) Speed Control lever (A) "OPERATION"
(B) "IDLING"
A Do not use ether or any starting fluid for starting the
engine, or a severe damage will occur.
A When starting the engine after a long storage (of more
than 3 months), first set the stop lever to the "STOP"
position and then activate the starter for about 10
seconds to allow oil to reach every engine part.
OPERATING THE ENGINE 5
ENGLISH
4. Insert the key into the key switch and
COLD WEATHER STARTING
If the ambient temperature is below* -5 C(23 F) and the
turn it to the "OPERATION" position. engine is very cold, start it in the following manner:
Take steps (1) through (4) left.
5. Turn the key to the "PREHEATING"

position and keep it there for a certain
period mentioned below.
A Shown below are the standard preheating times for

various temperatures. This operation, however, is not
required, when the engine is warmed up.
Preheating time
Ambient
temperature With glow lamp
Ordinary heat type
timer
Above 10 C (50 F) NO NEED
(A) "OFF" SWITCHED OFF
(B) "ON" OPERATION 10 C (50 F) to Approx.
(C) "GL" PREHEATING -5 C (23 F) 5 seconds
(D) "ST" STARTING
Approx. See NOTE:
*Below -5 C (23 F)
10 seconds
5. Turn the starter switch to the
Limit of
"PREHEATING" position to allow the 20 seconds
continuous use
glow lamp to redden.
6. Turn the key to the "STARTING"
A In case of installing standard glow lamp, glow lamp
position and the engine should start.
goes off after about 6 seconds, when the starter
Release the key immediately when the switch key is turned to the "PREHEATING" position.
engine starts. However if necessary, keep the starter switch key at
7. Check to see that the oil pressure lamp the "PREHEATING" position for longer time,
and charge lamp are off. If the lamps according to the left recommendation.
are still on, immediately stop the
engine, and determine the cause. 6. Turn the key to the "STARTING"
(See "CHECKS DURING OPERATION" in
position and the engine should start.
(If the engine fails to start after 10 seconds, turn off
"OPERATING THE ENGINE" section.)
the key for 5 to 30 seconds. Then repeat steps (5)
and (6).)
A If the oil pressure lamp should be still on, immediately
stop the engine and check;
- if there is enough engine oil. A Do not allow the starter motor to run continuously for
- if the engine oil has dirt in it. more than 20 seconds.
- if the wiring is faulty. A Be sure to warm up the engine, not only in winter, but
also in warmer seasons. An insufficiently warmed-up
8. Warm up the engine at medium speed engine can shorten its service life.
without load. A When there is fear of temperature dropping below
-15 C (5 F) detach the battery from the machine, and
keep it indoors in a safe area, to be reinstalled just
A If the glow lamp should redden too quickly or too before the next operation.
slowly, immediately ask your KUBOTA dealer to
check and repair it.
A If the engine does not catch or start at 10 seconds
after the starter switch is set at "STARTING" position,
wait for another 30 seconds and then begin the engine
starting sequence again. Do not allow the starter
motor to run continuously for more than 20 seconds.
6 OPERATING THE ENGINE

ENGLISH
STOPPING THE ENGINE If the coolant temperature warning lamp lights up or if

steam or coolant does not stop squirting from the radiator
overflow pipe, turn off the load and keep the engine
1. Return the speed control lever to low idling (COOLING-DOWN) for at least 5 minutes to let it
idle, and run the engine under idling cool down gradually. Then stop the engine and take the
conditions. following inspection and servicing.
1. Check to see if the coolant runs short or if there is any
coolant leak;
A Allow the engine to idle for 5 minutes before shutting 2. Check to see if there is any obstacle around the
it off after a full load operation. cooling air inlet or outlet;
Failure to do so may lead to turbo-charger trouble. 3. Check to see if there is any dirt or dust between
radiator fin and tube;
2. Set the engine stop lever to the "STOP" 4. Check to see if the fan belt is too loose; and
position. 5. Check to see if radiator water pipe is clogged.
3. With the starter switch placed to the BOil pressure lamp

"SWITCHED OFF" position, remove the The lamp lights up to warn the operator that the engine oil
key. (Be sure to return the engine stop pressure has dropped below the prescribed level. If this
lever to the "START" position to be should happen during operation or should not go off even
ready for the next start.) after the engine is accelerated more than 1000rpm,
immediately stop the engine and check the following:
1. Engine oil level (See "ENGINE OIL" in "PERIODIC
SERVICE" section.)
BFuel

A Fluid escaping from pinholes may be
invisible. Do not use hands to search
for suspected leaks; Use a piece of
cardboard or wood, instead. If
injured by escaping fluid, see a
medical doctor at once. This fluid can
(1) Speed control lever (A) "IDLING" produce gangrene or a severe
(2) Engine stop lever (B) "OPERATION" allergic reaction.
(C) "START"
(D) "STOP"
A Check any leaks from fuel pipes or
fuel injection pipes. Use eye
protection when checking for leaks.
CHECKS DURING OPERATION
While running, make the following checks to see that all Be careful not to empty the fuel tank. Otherwise air may
parts are working correctly. enter the fuel system, requiring fuel system bleeding.
(See "FUEL" in "PERIODIC SERVICE" section.)
BRadiator Cooling water(Coolant)
BColor of exhaust
While the engine is run within the rated output range:
A The color of exhaust remains colorless.
A If the output slightly exceeds the rated level, exhaust
A Do not remove radiator cap until may become a little colored with the output level kept
coolant temperature is well below its constant.
boiling point. Then loosen cap A If the engine is run continuously with dark exhaust
slightly to the stop position, to emission, it may lead to trouble with the engine.
relieve any pressure, before
removing cap completely. BImmediately stop the engine if;
A The engine suddenly slows down or accelerates.
A Unusual noises are suddenly heard.
A Exhaust fumes suddenly become very dark.
A The oil pressure lamp or the water temperature alarm
lamp lights up.
OPERATING THE ENGINE 7
ENGLISH
REVERSED ENGINE REVOLUTION AND PRECAUTIONS ON GENERATOR-
REMEDIES EQUIPPED ENGINE
To avoid personal injury or death: To avoid personal injury or death:

A Reversed engine operation can make If the engine is kept running under no
the machine reverse and run it load or light load (load factor below
backwards. It may lead to serious 30%), unburnt fuel or carbon builds up
trouble. in the exhaust system. As a result, the
A Reversed engine operation may engine may get damaged or cause a
make exhaust gas gush out into the fire.
intake side and ignite the air cleaner; Run the engine under enough load at
It could catch fire. regular intervals to remove unburnt fuel
and carbon deposits.
Reversed engine revolution must be stopped immediately
since engine oil circulation is cut quickly, leading to A Before doing the load operation,
serious trouble. make sure there is nothing
flammable around the engine.
BHow to tell when the engine starts running A Do not put a load all at once on the
backwards engine, but gradually.
1. Lubricating oil pressure drops sharply. Oil pressure A If by any chance, spark rises out of
warning light, if used, will light. the muffler outlet, DO NOT GET THE
2. Since the intake and exhaust sides are reversed, the
sound of the engine changes, and exhaust gas will ENGINE UNLOADED, BUT
come out of the air cleaner. INTERRUPT IT IMMEDIATELY.
3. A louder knocking sound will be heard when the
engine starts running backwards.
BRemedies
1. Immediately set the engine stop lever to the "STOP"
position to stop the engine.
2. After stopping the engine, check the air cleaner, intake
rubber tube and other parts, and then replace parts as
needed.
EMISSION CONTROL SYSTEM

A Operate, use and maintain the engine, including the
emission control system in accordance with the
instructions provided to the end users, so that the
engine’s emissions performance is kept within the
requirements applicable to the engine's category.
A Do not deliberately tamper, or misuse, the engine
emission control system, especially with regard to
deactivating or not maintaining an exhaust gas
recirculation (EGR) system or a reagent dosing
system.
A When a warning indicator lights up, the engine is
experiencing trouble, which may also cause problems
in the emission control system. Take prompt action
and rectify any incorrect operation, use, or
maintenance of the emission control system in
accordance with the rectification measures. (See
"TROUBLESHOOTING" or, where applicable,
"OPERATOR WARNING AND INDUCEMENT".
8 MAINTENANCE
ENGLISH
MAINTENANCE

A Be sure to conduct daily checks,
periodic maintenance, refueling or
cleaning on a level surface with the
engine shut off and remove the key.
A Before allowing other people to use
your engine, explain how to operate,
and have them read this manual
before operation.
A When cleaning any parts, do not use
gasoline but use regular cleanser.
A Always use proper tools, that are in
good condition. Make sure you
understand how to use them, before
performing any service work.
A When installing, be sure to tighten all
bolts lest they should be loose.
Tighten the bolts by the specified
torque.
A Do not put any tools on the battery,
or battery terminals may short out.
Severe burns or fire could result.
Detach the battery from the engine
before maintenance.
A Do not touch muffler or exhaust
pipes while they are hot; Severe
burns could result.
MAINTENANCE 9
ENGLISH
SERVICE INTERVALS
Observe the following for service and maintenance.
Ref.
Interval Item
page
Every 50 hours Check of fuel pipes and clamp bands 13 @
See NOTE Change of engine oil (depending on the oil pan) 14,15
Cleaning of air cleaner element 19 *1 @
Cleaning of fuel filter 14
Every 100 hours
Check of fan belt tightness 20
Draining water separator -
Replacement of oil filter cartridge (depending on the
16
Every 200 hours oil pan)
Check of intake air line - @
Every 200 hours of
operation or six Check of radiator hoses and clamp bands 18
months
Replacement of fuel filter element 14 @
Every 400 hours
Cleaning of water separator in fuel tank -
Cleaning of water jacket (radiator interior) -
Every 500 hours
Replacement of fan belt 20
Every year or every
6 cleanings of air Replacement of air cleaner element 19 *2 @
cleaner element
Every 800 hours Check of valve clearance - *3
Every 1500 hours Check of fuel injection nozzle injection pressure - *3 @
Check of injection pump - *3 @
Every 3000 hours
Check of turbo-charger (D902-T-E4) 20
Replacement of radiator hoses and clamp bands 18
Replacement of fuel pipes and clamps 13 *3 @
Every two years
Change of radiator coolant (L.L.C.) 16
Replacement of intake air line - *4 @
10 MAINTENANCE
ENGLISH
A The jobs indicated by must be done after the first 50 hours of operation.
*1 Air cleaner should be cleaned more often in dusty conditions than in normal conditions.
*2 After 6 times of cleaning.
*3 Consult your local KUBOTA Dealer for this service.
*4 Replace only if necessary.
A The items listed above (@ marked) are registered as emission related critical parts by KUBOTA in the U.S. EPA
nonroad emission regulation. As the engine owner, you are responsible for the performance of the required
maintenance on the engine according to the above instruction.
Please see the Warranty Statement in detail.
A Changing interval of Engine oil and oil filter cartridge.

*Oil pan depth
*101 mm 121 mm
(3.98 in.) (4.76 in.)
50 Hrs (Initial)
Z602-E4 Engine oil
D902-E4 100 Hrs -
D902-T-E4
Oil filter cartridge 200 Hrs
50 Hrs (Initial)
Z482-E4 Engine oil
75 Hrs 100 Hrs
D722-E4
Oil filter cartridge 150 Hrs 200 Hrs
50 Hrs (Initial)
Engine oil
D782-E4 - 100 Hrs
Oil filter cartridge 200 Hrs
* 101 mm (3.98 in.) oil pan depth is optional for Z482-E4 and D722-E4.
**Standard replacement interval
A American Petroleum Institute (API) classification: above CF-4 grade
A Ambient temperature: below 35 C (95 F)
MAINTENANCE 11
ENGLISH
Lubricating oil
With strict emission control regulations now in effect, the CF-4 and CG-4 engine oils have been developed for use with
low sulfur fuels, for On-Highway vehicle engines. When a Non-Road engine runs on high sulfur fuel, it is advisable to
use a "CF or better" classification engine oil with a high Total Base Number (a minimum TBN of 10 is recommended).
A Lubricating oil recommended when a low-sulfur or high-sulfur fuel is employed.
: Recommendable X : Not recommendable
Lubricating **Fuel
Remarks
oil classification Low-sulfur High-sulfur
CF *TBN 10
CF-4 X
CG-4 X
CH-4 X
CI-4 X
*TBN: Total Base Number

**Fuel
A Diesel Fuel Specification Type and Sulfur Content % (ppm) used, must be compliant with all applicable emission
regulations for the area in which the engine is operated.
A Use of diesel fuel with sulfur content less than 0.10 % (1000 ppm) is strongly recommended.
A If high-sulfur fuel (sulfur content 0.50 % (5000 ppm) to 1.0 % (10000 ppm)) is used as a diesel fuel, change the engine
oil and oil filter at shorter intervals. (approximately half).
A DO NOT USE Fuels that have sulfur content greater than 1.0 % (10000 ppm).
A Since KUBOTA diesel engines of less than 56 kW (75 hp) utilize EPA Tier 4 and Interim Tier 4 standards, the use of
ultra low sulfur fuel is mandatory for these engines, when operated in US EPA regulated areas. Therefore, please use
No.2-D S15 diesel fuel as an alternative to No.2-D, and use No.1-D S15 diesel fuel as an alternative to No.1-D for
ambient temperatures below -10 C (14 F).
No.1-D or No.2-D, S15 : Ultra Low Sulfur Diesel (ULSD) 15 ppm or 0.0015 wt.%
A If the engine is to be operated within the European Union on diesel or non-road gas-oil, a fuel with sulfur content not
greater than 10 mg/kg (20 mg/kg at point of final distribution), a cetane number not less than 45 and a fatty acid methyl
ester (FAME) content not greater than 7 % volume per volume (v/v) shall be used.
A Oil used in the engine should have API classification and Proper SAE Engine
Oil according to the ambient temperatures as shown below:
Above 25 (77 ) 10W-30 or 10W-40 or 15W-40
-10 to 25 (14 to 77 ) 10W-30 or 10W-40 or 15W-40
Below -10 (14 ) 10W-30 or 10W-40
A Recommended API classification

Refer to the following table for the suitable American Petroleum Institute (API) classification of engine oil according to
the engine type (with internal EGR, external EGR or non-EGR) and the Fuel Type Used : (Ultra Low Sulfur or High
Sulfur Fuels).
Engine oil classification (API classification)
Fuel type Engines with non-EGR
Engines with external EGR
Engines with internal EGR
High Sulfur Fuel CF
[0.05 % (500 ppm) (If the "CF-4, CG-4, CH-4 or CI-4" engine oil is used
---
Sulfur Content < with a high-sulfur fuel, change the engine oil at
0.50 % (5000 ppm)] shorter intervals. (approximately half))
Ultra Low Sulfur Fuel CF or CI-4

[Sulfur Content < CF, CF-4, CG-4, CH-4 or CI-4 (Class CF-4, CG-4 and CH-4 engine, oils
0.0015 % (15 ppm)] cannot be used on EGR type engines.)
EGR: Exhaust Gas Re-circulation

12 PERIODIC SERVICE
ENGLISH
PERIODIC SERVICE
FUEL Sulfur, Copper
Cetane
Fuel is flammable and can be dangerous. You should weight Strip
Number
% Corrosion
handle fuel with care.
Max Max Min
0.50 No. 3 40
A Do not mix gasoline or alcohol with A Cetane Rating : The minimum recommended Fuel
diesel fuel. This mixture can cause Cetane Rating is 45. A cetane rating greater than 50
an explosion. is preferred, especially for ambient temperatures
below -20 (-4 ) or elevations above 1500 m (5000
A Be careful not to spill fuel during
ft).
refueling. If fuel should spill, wipe it A Diesel Fuel Specification Type and Sulfur Content %
off at once, or it may cause a fire. (ppm) used, must be compliant with all applicable
A Do not fail to stop the engine before emission regulations for the area in which the engine
refueling. Keep the engine away from is operated.
A Use of diesel fuel with sulfur content less than 0.10 %
the fire. (1000 ppm) is strongly recommended.
A Be sure to stop the engine while A If high-sulfur fuel (sulfur content 0.50 % (5000 ppm) to
refueling or bleeding and when 1.0 % (10000 ppm)) is used as a diesel fuel, change
cleaning or changing fuel filter or fuel the engine oil and oil filter at shorter intervals.
(approximately half).
pipes. Do not smoke when working
A DO NOT USE Fuels that have sulfur content greater
around the battery or when refueling. than 1.0 % (10000 ppm).
A Check the fuel systems at a well A Diesel fuels specified to EN 590 or ASTM D975 are
ventilated and wide place. recommended.
A When fuel and lubricant are spilled, A No.2-D is a distillate fuel of lower volatility for engines
in industrial and heavy mobile service.
refuel after letting the engine cool off. (SAE J313 JUN87)
A Always keep spilled fuel and A Since KUBOTA diesel engines of less than 56 kW (75
lubricant away from engine. hp) utilize EPA Tier 4 and Interim Tier 4 standards, the
use of ultra low sulfur fuel is mandatory for these
BFuel level check and refueling engines, when operated in US EPA regulated areas.
Therefore, please use No.2-D S15 diesel fuel as an
1. Check to see that the fuel level is above the lower limit
alternative to No.2-D, and use No.1-D S15 diesel fuel
of the fuel level gauge.
as an alternative to No.1-D for ambient temperatures
2. If the fuel is too low, add fuel to the upper limit. Do not
below -10 (14 ).
overfill.
1) SAE : Society of Automotive Engineers
Carbon 2) EN : European Norm
Water and 3) ASTM : American Society of Testing and Materials
Flash Point, Residue on, Ash,
Sediment, 4) US EPA : United States Environmental Protection
10 percent weight
volume Agency
( ) Residuum, %
% 5) No.1-D or No.2-D, S15 : Ultra Low Sulfur Diesel
%
(ULSD) 15 ppm or 0.0015 wt.%
Min Max Max Max
52
0.05 0.35 0.01
(125)
Distillation Viscosity
Viscosity
Temperatures, Kinematic
Saybolt,
( ) cSt or
SUS at
90% mm /s at
37.8 (100 )
Point 40
Min Max Min Max Min Max
282 338
1.9 4.1 32.6 40.1
(540) (640)
PERIODIC SERVICE 13
ENGLISH
A Be sure to use a strainer when filling the fuel tank, or
BChecking the fuel pipes
dirt or sand in the fuel may cause trouble in the fuel
injection pump.
A For fuel, always use diesel fuel. You are required not
to use alternative fuel, because its quality is unknown To avoid personal injury or death:
or it may be inferior in quality. Kerosene, which is very A Check or replace the fuel pipes after
low in cetane rating, adversely affects the engine. stopping the engine. Broken fuel
Diesel fuel differs in grades depending on the
temperature. pipes can cause fires.
A Be careful not to let the fuel tank become empty, or air
can enter the fuel system, necessitating bleeding Check the fuel pipes every 50 hours of operation. When if;
before next engine start. 1. If the clamp band is loose, apply oil to the screw of the
band, and tighten the band securely.
2. If the fuel pipes, made of rubber, become worn out,
BAir bleeding the fuel system
replace them and clamp bands every 2 years.
3. If the fuel pipes and clamp bands are found worn or
damaged before 2 years' pass, replace or repair them
To avoid personal injury or death: at once.
A Do not bleed a hot engine as this 4. After replacement of the pipes and bands, air-bleed
could cause fuel to spill onto a hot the fuel system.
exhaust manifold creating a danger
of fire. A When the fuel pipes are not installed, plug them at
both ends with clean cloth or paper to prevent dirt from
Air bleeding of the fuel system is required if; entering. Dirt in the pipes can cause fuel injection
A after the fuel filter and pipes have been detached and pump malfunction.
refitted;
A after the fuel tank has become empty; or
A before the engine is to be used after a long storage.
[PROCEDURE]
1. Fill the fuel tank to the fullest extent. Open the fuel
filter lever.
2. Loosen air vent plug of the fuel filter a few turns.
3. Screw back the plug when bubbles do not come up
any more.
4. Open the air vent plug on top of the fuel injection
pump.
5. Retighten the plug when bubbles do not come up any
more.
(1) Clamp band

(2) Fuel pipe
(1) Fuel filter lever (A) "ON"

(2) Air vent plug (B) "OFF"
(3) Fuel filter pot
14 PERIODIC SERVICE
ENGLISH
ENGINE OIL
BCleaning the fuel filter pot
Every 100 hours of operation, clean the fuel filter in a
clean place to prevent dust intrusion.
1. Close the fuel filter lever.
A Be sure to stop the engine before
checking and changing the engine
oil and the oil filter cartridge.
A Do not touch muffler or exhaust
pipes while they are hot; Severe
burns could result. Always stop the
engine and allow it to cool before
conducting inspections,
maintenance, or for a cleaning
procedure.
A Contact with engine oil can damage
your skin. Put on gloves when using
engine oil. If you come in contact
(1) Fuel filter lever (A) "OFF" with engine oil, wash it off
(2) Fuel filter pot (B) "ON" immediately.
2. Remove the top cap, and rinse the inside with diesel
fuel. A Be sure to inspect the engine, locating it on a
3. Take out the element, and rinse it with diesel fuel. horizontal place. If placed on gradients accurately, oil
4. After cleaning, reinstall the fuel filter, keeping out of quantity may not be measured.
dust and dirt. A Be sure to keep the oil level between upper and lower
5. Air-bleed the injection pump. limits of the oil gauge. Too much oil may cause a drop
in output or excessive blow-by gas. On the closed
breather type engine in which mist is sucked through
A Entrance of dust and dirt can cause a malfunction of port, too much oil may cause oil hammer. While too
the fuel injection pump and the injection nozzle. Wash little oil, may seize the engine's rotating and sliding
the fuel filter cup periodically. parts. (The closed breather is an option.)
BChecking level and adding engine oil

1. Check the engine oil level before starting or more than
5 minutes after stopping the engine.
2. Remove the oil level gauge, wipe it clean and reinstall
it.
3. Take the oil level gauge out again, and check the oil
level.
(1) O ring
(2) Filter element
(3) Spring
(4) Filter bowl
(5) Screw ring
(1) Oil filler plug [Lower end of oil level gauge]

(2) Oil level gauge (A):Engine oil level within this
range is proper.
PERIODIC SERVICE 15
ENGLISH
4. If the oil level is too low, remove the oil filler plug, and
add new oil to the prescribed level. BChanging engine oil
5. After adding oil, wait more than 5 minutes and check
the oil level again. It takes same time for the oil to
come down to the oil pan.
Engine oil quantity A Be sure to stop the engine before
Oil pan depth draining engine oil.
Models A When draining engine oil, place
*101 mm (3.98 in.) 121 mm (4.76 in.)
some container underneath the
2.1 L 2.5 L engine and dispose it according to
Z482-E4
(0.55 U.S.gals.) (0.66 U.S.gals.)
local regulations.
3.2 L 3.8 L A Do not drain oil after running the
D722-E4
(0.84 U.S.gals.) (1.0 U.S.gals.)
engine. Allow engine to cool down
D782-E4 -
3.6 L sufficiently.
(0.95 U.S.gals.)
2.5 L 1. Change oil after the initial 50 hours of operation and
Z602-E4 - every 100 hours thereafter.
(0.66 U.S.gals.)
2. Remove the drain plug at the bottom of the engine,
D902-E4 3.7 L and drain all the old oil. Drain oil easier and completely
-
D902-T-E4 (0.98 U.S.gals.) while the engine is hot.
*101 mm (3.98 in.) oil pan depth is optional.
Oil quantities shown are for standard oil pans.
A Engine oil should be MIL-L-2104C or have properties

of API classification CF or higher.
Change the type of engine oil according to the
ambient temperature.
Above 25 C (77 F) 10W-30 or 10W-40 or 15W-40
-10 C to 25 C
10W-30 or 10W-40 or 15W-40
(14 F to 77 F)
Below -10 C (14 F) 10W-30 or 10W-40
(1) Oil drain plug
A When using oil different from the previous one, be
sure to drain all the previous oil before adding the new 3. Add new engine oil up to the upper limit of the oil level
engine oil. gauge.
A Use of the following oil not only disallows the engine
from performing well in low temperatures until it
warms up sufficiently but may also lead to excessive
engine wear or engine seizure.
A Oil with a viscosity higher than 10W-30
A Oil not recommended by KUBOTA
16 PERIODIC SERVICE
ENGLISH
RADIATOR
BReplacing the oil filter cartridge Coolant will last for one day's work if filled all the way up
before operation start. Make it a rule to check the coolant
level before every operation.
A Be sure to stop the engine before
changing the oil filter cartridge. To avoid personal injury or death:
A Allow engine to cool down A Do not stop the engine suddenly,
sufficiently, oil can be hot and cause stop it after about 5 minutes of
burns. unloaded idling.
A Work only after letting the engine and
1. Replace the oil filter cartridge after the initial 50 hours radiator cool off completely (more
of operation and every 200 hours thereafter. than 30 minutes after it has been
2. Remove the old oil filter cartridge with a filter wrench.
3. Apply a film of oil to the gasket for the new cartridge.
stopped).
4. Screw in the cartridge by hand. When the gasket A Do not remove the radiator cap while
contacts the seal surface, tighten the cartridge enough coolant is hot. When cool to the
by hand. Because, if you tighten the cartridge with touch, rotate cap to the first stop to
wrench, it will be tightened too much.
allow excess pressure to escape.
Then remove cap completely.
If overheats should occur, steam
may gush out from the radiator or
recovery tank; Severe burns could
result.
BChecking coolant level, adding coolant

1. Remove the radiator cap, after the engine has
completely cooled, and check to see that coolant
reaches the supply port.
(1) Oil filter cartridge

Remove with a filter wrench
(Tighten with your hand)
5. After the new cartridge has been replaced, the engine

oil level normally decreases a little. Thus, run the
engine for a while and check oil leaks through the seal
before checking the engine oil level. Add oil if
necessary.
A Wipe off any oil sticking to the machine completely.

(1) Radiator pressure cap
PERIODIC SERVICE 17
ENGLISH
2. If the radiator is provided with a recovery tank, check
the coolant level of the recovery tank. When it is A If the radiator cap has to be removed, follow the
between the "FULL" and "LOW" marks, the coolant caution and securely retighten the cap.
will last for one day's work. A If coolant should be leak, consult your local KUBOTA
dealer.
A Make sure that muddy or sea water does not enter the
radiator.
A Use clean, fresh water and 50% anti-freeze to fill the
recovery tank.
A Do not refill recovery tank with coolant over the
"FULL" level mark.
A Be sure to close the radiator cap securely. If the cap is
loose or improperly closed, coolant may leak out and
decrease quickly.
BChanging coolant
1. To drain coolant, always open both drain cocks and
simultaneously open the radiator cap as well. With the
radiator cap kept closed, a complete drain of water is
(1) Recovery tank (A) "FULL" impossible.
(B) "LOW" 2. Remove the overflow pipe of the radiator pressure cap
to drain the recovery tank.
3. When the coolant level drops due to evaporation, add 3. Prescribed coolant volume (U.S.gallons)
water only up to the full level.
4. Check to see that two drain cocks; one is at the Models Quantity
crankcase side and the other is at the lower part of the
Z482-E4, Z602-E4 2.8 L (0.74 U.S.gals.)
radiator as figures below.
D722-E4, D782-E4,
3.1 L (0.82 U.S.gals.)
D902-E4, D902-T-E4
A Coolant quantities shown are for standard radiators.
4. An improperly tightened radiator cap or a gap between

the cap and the seat quickens loss of coolant.
5. Coolant (Radiator cleaner and anti-freeze)
Season Coolant
Pure water and anti-freeze
All seasons (See "Anti-freeze" in
"RADIATOR" section.)
(1) Coolant drain cock

18 PERIODIC SERVICE
ENGLISH
BCleaning the radiator (inside)

BChecking radiator hoses and clamp 1. Clean up the coolant line inside in the following cases.
bands A As per the SERVICE INTERVALS list.
A When changing the coolant.
2. Use a radiator cleaning agent. This helps washaway
scale deposits.
A Be sure to check radiator hoses and BAnti-freeze
clamp bands periodically. If radiator
hose is damaged or coolant leaks,
overheats or severe burns could To avoid personal injury or death:
occur. A When using anti-freeze, put on some
protection such as rubber gloves
Check to see if radiator hoses are properly fixed every
(Anti-freeze contains poison.).
200 hours of operation or 6 months, whichever comes
first.
A If should drink anti-freeze, throw up
1. If hose clamps are loose or water leaks, tighten hose at once and take medical attention.
clamp securely. A When anti-freeze comes in contact
2. Replace hoses and tighten hose clamps securely, if with the skin or clothing, wash it off
radiator hoses are swollen, hardened or cracked. immediately.
Replace hoses and hose clamps every 2 years or earlier,
A Do not mix different types of anti-
if checked and found that hoses are swollen, hardened or
cracked.
freeze. The mixture can produce
chemical reaction causing harmful
BPrecaution at overheating substances.
The event that the coolant temperature is nearly or more A Anti-freeze is extremely flammable
than the boiling point is called "OVERHEATING". and explosive under certain
While running, make the following checks to see that all conditions. Keep fire and children
parts are working correctly. If anything is unusual, away from anti-freeze.
inspect it, referring to the relevant description in. A When draining fluids from the
"MAINTENANCE" and "PERIODIC SERVICE" section. engine, place some container
C Coolant underneath the engine body.
If the coolant temperature warning lamp lights up or if A Do not pour waste onto the grounds,
steam or coolant does not stop squirting from the radiator down a drain, or into any water
overflow pipe, turn off the load and keep the engine source.
idling (COOLING-DOWN) for at least 5 minutes to let it A Also, observe the relevant
cool down gradually. Then stop the engine and take the
environmental protection
following inspection and servicing.
1. Check to see if the coolant runs short or if there is any
regulations when disposing of anti-
coolant leak; freeze.
2. Check to see if there is any obstacle around the
cooling air inlet or outlet; Always use a 50/50 mix of long-life coolant and clean soft
3. Check to see if there is any dirt or dust between water in KUBOTA engines.
radiator fins and tube; Contact KUBOTA concerning coolant for extreme
4. Check to see if the fan belt is too loose; and conditions.
5. Check to see if radiator water pipe is clogged. 1. Long-life coolant (hereafter LLC) comes in several
types. Use ethylene glycol (EG) type for this engine.
2. Before employing LLC-mixed cooling water, flush the
BCleaning radiator core (outside) radiator with fresh water. Repeat this procedure 2 or 3
If dust is between the fin and tube, wash it away with times to clean up the radiator and engine block from
running water. inside.
3. Mixing the LLC
Premix 50% LLC with 50% clean soft water. When
A Do not clean radiator with firm tools such as spatulas mixing, stir it up well, and then fill into the radiator.
or screwdrivers. They may damage specified fin or 4. The procedure for the mixing of water and anti-freeze
tube. It can cause coolant leaks or decrease cooling differs according to the make of the anti-freeze. Refer
performance. to SAE J1034 standard, more specifically also to SAE
J814c.
PERIODIC SERVICE 19
ENGLISH
Vol % Freezing Point Boiling Point * AIR CLEANER
As the element of the air cleaner employed on this engine
Anti-freeze
is a dry type, never apply oil to it.
50 -37 -34 108 226 1. Open the evacuator valve once a week under ordinary
conditions-or daily when used in a dusty place-to get
*At 1.013 x 10 Pa (760 mmHg) pressure rid of large particles of dust and dirt.
(atmospheric). A higher boiling point is obtained by 2. Wipe the inside air cleaner clean with cloth or the like
using a radiator pressure cap which permits the if it is dirty or wet.
development of pressure within the cooling system. 3. Avoid touching the element except when cleaning.
4. When dry dust adheres to the element, blow
5. Adding the LLC compressed air from the inside turning the element.
(1) Add only water if the coolant level reduces in the Pressure of compressed air must be under 205 kPa
cooling system by evaporation. (2.1 kgf/cm , 30 psi).
(2) If there is a coolant leak, add the LLC of the same 5. Replace the element every year or every six
manufacturer and type in the same coolant cleanings.
percentage.
*Never add any long-life coolant of different
manufacturer. (Different brands may have different
additive components, and the engine may fail to
perform as specified.)
6. When the LLC is mixed, do not employ any radiator
cleaning agent. The LLC contains anti-corrosive
agent. If mixed with the cleaning agent, sludge may
build up, adversely affecting the engine parts.
7. Kubota's genuine long-life coolant has a service life of
2 years. Be sure to change the coolant every 2 years.
A The above data represent industry standards that

necessitate minimum glycol content in the
(1) Air cleaner body
concentrated anti-freeze.
(2) Element
(3) Cover
(4) Evacuator valve
(5) "TOP" mark
A Make sure the hooking clip for cover for the element is
tight enough. If it is loose, dust and dirt may be
sucked, wearing down the cylinder liner and piston
ring earlier and thereby resulting in poor power output.
20 PERIODIC SERVICE
ENGLISH
ELECTRIC WIRING FAN BELT

BAdjusting Fan Belt Tension
C Shorting of electric cable or wiring
may cause a fire.
A Be sure to stop the engine and
A Check to see if electric cables and
remove the key before checking the
wiring are swollen, hardened or
belt tension.
cracked.
A Be sure to reinstall the detached
A Keep dust and water away from all
safety shield after maintenance or
power connections.
checking.
Loose wiring terminal parts, make
bad connections. Be sure to repair Proper fan belt
A deflection of between 7 to 9 mm
them before starting the engine. (0.28 to 0.35 in.) when the belt is
tension
pressed in the middle of the span.
Damaged wiring reduces the capacity of electrical parts.
Change or repair damaged wiring immediately. 1. Stop the engine and remove the key.
2. Apply moderate thumb pressure to belt between the
pulleys.
1. Use automobile low voltage wiring cables for this
3. If tension is incorrect, loosen the alternator mounting
wiring harness.
bolts and, using a lever placed between the alternator
2. Use fuse and slow blow fuse as wiring protection.
and the engine block, pull the alternator out until the
3. Generally, available current of each fuse and size of
deflection of the belt falls within acceptable limits.
wire in this drawing are recommendable value showed
4. Replace fan belt if it is damaged.
by Kubota, use suitable size fuses and wires for each
machine to consideration to wiring setting and
connection with another lines.
A If belt is loosen or damaged and the fan is damaged,
4. Install slow blow fuse near by battery, and install fuse
it could result in overheats or insufficient charging.
box near by key switch.
Correct or replace belt.
5. Do not connect any parts which may cause induction
current like motors to AC line.
6. Use heatproof cables, if room temperature around
wire harness become over 75 (167 ).
7. Remove painting at connecting position before
installation of each cable to any parts.
(1) Fan belt (A) 7 to 9 mm (0.28 to 0.35 in.)

(2) Bolt and nut (under load of 10 kgf (22.1 lbs))
TURBO-CHARGER
Consult your local KUBOTA Dealer for this service.
CARRIAGE AND STORAGE 21
ENGLISH
CARRIAGE AND STORAGE
CARRIAGE STORAGE
To avoid personal injury or death: To avoid personal injury or death:

A Fix the engine securely not to fall A Do not clean the machine with engine
during operation. running.
A Do not stand near or under the A To avoid the danger of exhaust fume
engine while carrying it. poisoning, do not operate the engine
A The engine is heavy. In handling it, in a closed building without proper
be very alert not to get your hands ventilation.
and body caught in. A When storing the engine just after
running, let the engine cool off.
1. Use carrier such as crane when carrying the engine,
or hurt your waist and yourself. Support the engine Before storing the engine for more than a few months,
securely with rope not to fall while carrying it. remove any dirt on the machine, and:
2. When lifting the engine, put the hook securely to metal 1. Drain the coolant in the radiator. Open the cock at the
fittings attached to the engine. Use strong hook and bottom of the radiator, and remove the pressure cap
fittings enough to hang the engine. to drain water completely. Leave the cock open. Hang
a note written "No water" on the pressure cap. Since
water may freeze when the temperature drops below
0 C (32 F), it is very important that no water is left in
the machine.
A When using anti-freeze, it is not necessary to take

step (1) above.
2. Remove dirty engine oil, fill with new oil and run the
engine for about 5 minutes to let the oil penetrate to all
the parts.
3. Check all the bolts and nuts, and tighten if necessary.
4. Remove the battery from the engine, adjust the
electrolyte level, and recharge it. Store the battery in a
dry and dark place.
5. When the engine is not used for a long period of time,
run it for about 5 minutes under no load every 2 to 3
months to keep it free from rust. If the engine is stored
without any running, moisture in the air may condense
into dew over the sliding parts of the engine, resulting
in rust there.
6. If you forget to run the engine for longer than 5 to 6
months, apply enough engine oil to the valve guide
and valve stem seal and make sure the valve works
smoothly before starting the engine.
7. Store the engine in a flat place and remove the key
from engine.
8. Do not store the engine in a place where has
flammable materials such as dry grass or straw.
9. When covering the engine for storage, let engine and
muffler cool off completely.
10. Operate the engine after checking and repairing
damaged wirings or pipes, and clearing flammable
materials carried by mouse.
22 TROUBLESHOOTING
ENGLISH
TROUBLESHOOTING
If the engine does not function properly, use the following chart to identify and correct the cause.
B When it is difficult to start the engine B When engine suddenly stops

Cause Countermeasures Cause Countermeasures
* Check the fuel tank and fuel filter. * Check the fuel tank and refill the fuel, if
* Remove water, dirt and other necessary.
Lack of fuel
impurities. * Also check the fuel system for air or
Fuel is thick and
* As all fuel will be filtered by the filter, if leaks.
doesn't flow.
there should be water or other foreign
* If necessary, replace with a new
matters on the filter, clean the filter Bad nozzle
nozzle.
with kerosene.
Moving parts are * Check amount of engine oil with oil
* If air is in the fuel filter or injection
overheated due to level gauge.
lines, the fuel pump will not work
shortage of * Check lubricating oil system.
properly.
lubrication oil or * At every 2 times of oil change, oil filter
* To attain proper fuel injection
Air or water mixed improper cartridge should be replaced.
pressure, check carefully for loosened
in fuel system lubrication.
fuel line coupling, loose cap nut, etc.
* Loosen air vent screws stop fuel filter
and fuel injection pump to eliminate all B When color of exhaust is especially bad
the air in the fuel system.
Cause Countermeasures
Engine oil becomes
thick in cold * Change grade of oil according to the Fuel is of extremely * Select good quality fuel.
weather and engine weather (temperature.) poor quality. Use No. 2-D diesel fuel only.
cranks slow. Nozzle is bad. * If necessary, replace with new nozzle.
* Charge battery.
Battery is
* In winter, always remove battery from
discharged and the
machine, charge fully and keep
B When engine must be stopped immediately
engine will not
indoors. Install in machine at time of Cause Countermeasures
crank.
use.
Color of exhaust
* Check the fuel injection system,
suddenly turns
especially the fuel injection nozzle.
B When output is insufficient dark.
Cause Countermeasures Bearing parts are

* Check the lubricating system.
overheated.
Fuel is insufficient. * Check fuel system.
* Check the lubricating system.
* Check lubricating oil system. * Check the function of the relieve valve
* Check to see if lubricating oil filter is Oil lamp lights up
in the lubricating system.
Overheating of working properly. during operation.
* Check pressure switch.
moving parts * Filter element deposited with * Check filter base gasket.
impurities would cause poor
lubrication. Change element.
* Clean the element every 100 hours of
Air cleaner is dirty
operation.
* Do not use poor quality fuel as it will
Injection pump cause wear of the pump. Only use No.
wear 2-D diesel fuel. (See "FUEL" in
"PERIODIC SERVICE" section.)
A If the cause of trouble can not be found, contact your KUBOTA dealer.
TROUBLESHOOTING 23
ENGLISH
B When engine overheats
Cause Countermeasures
Engine oil * Check oil level. Replenish oil as
insufficient required.
Fan belt broken or
* Change belt or adjust belt tension.
elongated
Coolant insufficient * Replenish coolant.
Excessive
* Add water only or change to coolant
concentration of
with the specified mixing ratio.
antifreeze
Radiator net or
radiator fin clogged * Clean net or fin carefully.
with dust
Inside of radiator or
coolant flow route * Clean or replace radiator and parts.
corroded
Fan or radiator or
radiator cap * Replace defective parts.
defective
Thermostat * Check thermostat and replace if
defective necessary.
Temperature gauge * Check temperature with thermometer
or sensor defective and replace if necessary.
Overload running * Reduce load.
Head gasket
defective or water * Replace parts.
leakage
Unsuitable fuel
* Use the specified fuel.
used
24 SPECIFICATIONS
ENGLISH
SPECIFICATIONS
Model Z482-E4 Z602-E4
Type Vertical, water-cooled, 4-cycle diesel engine
Number of cylinders 2
Bore and stroke 67 x 68 72 x 73.6
mm (in.) (2.64 x 2.68) (2.83 x 2.90)
Total displacement 0.479 0.599
L (cu.in.) (29.23) (36.55)
Combustion chamber Spherical Type (ETVCS)
SAE NET Intermittent kW / rpm 9.3 / 3600 11.6 / 3600
H.P. (SAEJ1349) (HP / rpm) (12.5 / 3600) (15.6 / 3600)
SAE NET Continuous kW / rpm 8.1 / 3600 10.1 / 3600
H.P. (SAEJ1349) (HP / rpm) (10.8 / 3600) (13.5 / 3600)
Maximum bare speed rpm 3800 3850
Minimum bare idling speed rpm 1250 to 1350 1050 to 1150
Order of firing 1-2
Direction of rotation Counter-clockwise (viewed from flywheel side)
Injection pump Bosch MD Type mini pump
Injection pressure 13.73 MPa, 1991 psi (140 kgf/cm )
Injection timing (Before T.D.C.) 0.331 rad (19 ) 0.331 rad (19 )
Compression ratio 23.5 : 1 24 : 1
Fuel Diesel Fuel No.2-D
Lubricant (API classification) above CF
Dimension mm (in.) 351 x 389 x 520 385 x 421 x 544
(length x width x height) (13.82 x 15.31 x 20.47) (15.16 x 16.57 x 21.42)
Dry weight
53.1 (117.1) 57.0 (125.7)
(BB Spec.) kg (lbs.)
Starting system Cell starter (with glow plug)
Starting motor 12 V, 0.8 kW 12 V, 1.0 kW
Charging generator 12 V, 150 W 12 V, 480 W
Recommended battery capacity
12 V, 28 AH, equivalent 12 V, 36 AH, equivalent
(5Hr capacity)
EU engine family name HKBXL.778KCB HKBXL.898KCB
CO2 Emission data g/kWh
1019.8 1047.4
Non-road steady-state test cycle
A Specifications are subject to change without notice.

A The battery capacity is indicated in 5-hour ratio.
A This CO2 measurement results from testing over a fixed test cycle under laboratory conditions a(n) (parent) engine
representative of the engine type (engine family) and shall not imply or express any guarantee of the performance of
a particular engine.
SPECIFICATIONS 25
ENGLISH
Model D722-E4 D782-E4 D902-E4
Bore and stroke 67 x 68 67 x 73.6 72 x 73.6
mm (in.) (2.64 x 2.68) (2.64 x 2.90) (2.83 x 2.90)
Total displacement 0.719 0.778 0.898
L (cu.in.) (43.88) (47.46) (54.80)
SAE NET Intermittent kW / rpm 14.0 / 3600 13.7 / 3200 17.5 / 3600
H.P. (SAEJ1349) (HP / rpm) (18.8 / 3600) (18.4 / 3200) (23.5 / 3600)
SAE NET Continuous kW / rpm 12.2 / 3600 11.9 / 3200 15.2 / 3600
H.P. (SAEJ1349) (HP / rpm) (16.3 / 3600) (16.0 / 3200) (20.4 / 3600)
Maximum bare speed rpm 3800 3450 3850
Minimum bare idling speed rpm 1250 to 1350 1000 to 1100 900 to 1000
Order of firing 1-2-3
Injection timing (Before T.D.C.) 0.35 rad (20 ) 0.296 rad (17 ) 0.331 rad (19 )
Compression ratio 23.5 : 1 24 : 1
453 x 425 x 544
Dimension mm (in.) 426 x 389 x 520
(17.83 x 16.73 x
(length x width x height) (16.77 x 15.31 x 20.47)
21.42)
Dry weight
63.1 (139.1) 63.5 (140.0) 72.0 (158.7)
Starting motor 12 V, 0.8 kW 12 V, 1.2 kW
Charging generator 12 V, 150 W 12 V, 480 W
Recommended battery capacity 12 V, 52 AH,
12 V, 36 AH, equivalent
(5Hr capacity) equivalent
EU engine family name HKBXL.778KCB HKBXL.778KCB HKBXL.898KCB
1019.8 1019.8 1047.4

26 SPECIFICATIONS
ENGLISH
Model D902-T-E4
Bore and stroke 72 x 73.6
mm (in.) (2.83 x 2.90)
Total displacement 0.898
L (cu.in.) (54.80)
SAE NET Intermittent kW / rpm 17.7 / 3200
H.P. (SAEJ1349) (HP / rpm) (23.7 / 3200)
SAE NET Continuous kW / rpm 16.1 / 3200
H.P. (SAEJ1349) (HP / rpm) (21.6 / 3200)
Maximum bare speed rpm 3530
Minimum bare idling speed rpm 1300 to 1400
Order of firing 1-2-3
Injection timing (Before T.D.C.) 0.323 rad (18.5 )
Compression ratio 23 : 1
Dimension mm (in.) 453 x 425 x 544
(length x width x height) (17.83 x 16.73 x 21.42)
Dry weight
75.0 (165.4)
Starting motor 12 V, 1.2 kW
Charging generator 12 V, 480 W
Recommended battery capacity
12 V, 55 AH, equivalent
(5Hr capacity)
EU engine family name LKBXL.898KAB
921.2

WIRING DIAGRAMS 27
ENGLISH
WIRING DIAGRAMS
28 WIRING DIAGRAMS
ENGLISH
WIRING DIAGRAMS 29
ENGLISH
30 WIRING DIAGRAMS
ENGLISH

KUBOTA D902-E4 Operator's Manual

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OPERATOR'S MANUAL

KUBOTA DIESEL ENGINE

Z482 E-4·Z602 E-4·D722 E-4·D782 E-4·D902 E-4·D902 T

Japan : KUBOTA Corporation

READ AND SAVE THIS BOOK

READ AND SAVE THIS BOOK

DANGER : Indicates an imminently hazardous situation which,

WARNING : Indicates a potentially hazardous situation which,

CAUTION : Indicates a potentially hazardous situation which,

IMPORTANT : Indicates that equipment or property damage

NOTE : Gives helpful information.

Be sure to observe the following for safe operation.

1. OBSERVE SAFETY INSTRUCTIONS

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

3. CHECK BEFORE STARTING & OPERATING THE ENGINE

4. KEEP THE ENGINE AND SURROUNDINGS CLEAN

5. SAFE HANDLING OF FUEL AND LUBRICANTS -KEEP AWAY FROM FIRE

8. CAUTIONS AGAINST BURNS & BATTERY EXPLOSION

9. KEEP HANDS AND BODY AWAY FROM ROTATING PARTS

11. CONDUCTING SAFETY CHECKS & MAINTENANCE

A Replace fuel pipes and lubricant pipes with their hose

12. WARNING AND CAUTION LABELS

13. CARE OF WARNING AND CAUTION LABELS

SERVICING OF THE ENGINE 1

Type Serial No.

(1) Intake manifold (10) Oil filler plug

To avoid personal injury or death:

4 OPERATING THE ENGINE

OPERATING THE ENGINE

To avoid personal injury or death:

OPERATING THE ENGINE 5

5. Turn the key to the "PREHEATING"

A Shown below are the standard preheating times for

6 OPERATING THE ENGINE

STOPPING THE ENGINE If the coolant temperature warning lamp lights up or if

3. With the starter switch placed to the BOil pressure lamp

To avoid personal injury or death:

OPERATING THE ENGINE 7

To avoid personal injury or death: To avoid personal injury or death:

EMISSION CONTROL SYSTEM

To avoid personal injury or death:

A Changing interval of Engine oil and oil filter cartridge.

*TBN: Total Base Number

A Recommended API classification

Ultra Low Sulfur Fuel CF or CI-4

EGR: Exhaust Gas Re-circulation

(1) Clamp band

(1) Fuel filter lever (A) "ON"

BChecking level and adding engine oil

(1) Oil filler plug [Lower end of oil level gauge]

Oil quantities shown are for standard oil pans.

A Engine oil should be MIL-L-2104C or have properties

BChecking coolant level, adding coolant

(1) Oil filter cartridge

5. After the new cartridge has been replaced, the engine

A Wipe off any oil sticking to the machine completely.

A Coolant quantities shown are for standard radiators.

4. An improperly tightened radiator cap or a gap between

(1) Coolant drain cock

BCleaning the radiator (inside)