Kubota D1803-CR-E4, D1803-CR-TE4, D1803-CR-TIE4, V2403-CR-TE4, V2403-CR-TE4BG Workshop Manual

...

WORKSHOP MANUAL

KiSC issued 12, 2018 A

DIESEL ENGINE

D1803-CR-E4,D1803-CR-TE4,

D1803-CR-TIE4,V2403-CR-E4,

V2403-CR-TE4,

V2403-CR-TE4BG,

V2403-CR-TIE4

TO THE READER

KiSC issued 12, 2018 A

This workshop manual provides safety information for service activity, general information such as specifications and dimensions of the machine, mechanisms and structure descriptions of the machine, and service procedures.

Safety

This section contains safety service descriptions and safety label information.

General

This section contains general instructions, tightening torques, general machine information and special tools.

Maintenance

This section contains information for the recommended oil and general maintenance procedures.

Each section basically consists of mechanism and servicing.

Mechanism

part

Mechanism or component parts. This part should become prehended before proceeding with troubleshooting, disassembling, assembling, and servicing works.

Servicing

Servicing part contains information and procedures for maintenance, troubleshooting and repair works. The reader should follow these instructions in order to satisfy any servicing work safely, correctly and quickly.

In this WSM, service specifications and service limits are defined as followings.

Service specifications:

Specification which corresponds to new machine's ex-factory. It is based on quality standard, drawings, or actual measurements conducted by Kubota. This value is used to determine whether there is a problem with the machine in the event of a troubleshooting. However, it is necessary to consider degradation due to wear, based on the operating time of the machine, application or maintenance condition.

Service limits:

Service limit is a value corresponding to the recommended performance limit by taking long term-use wear into account. When the service limit is reached, the machine is required to have proper repair, overhaul or replacement in order to keep safe and adequate performance.

All of the illustrations, photographs, specifications, and other information in this manual were created based on the latest model at the time of publication. The parts names used in this manual are unified into names representing the functions of the parts. Therefore, it does not necessarily correspond to the names used in other materials (parts list, operators manual etc.) and the name on the label / identification plates on the product. Kubota reserves the right to change all information at any time without notice.

contains information and explanations for the structure, functions, and specifications of the machine

February 2013

RECORD OF REVISIONS

D1803-CR-E4,D1803-CR-TE4,D1803-CR-TIE4,V2403-CR-E4,V2403-CR-TE4,V2403-CR-TE4BG,V2403-CR-TIE4

KiSC issued 12, 2018 A

Main revised contents and corrective measures are described in a table. Find the main revised point and corrective measure through the reference page.

Last digit

of the Code

No.

1 2013.07 Rail pressure sensor

2 2013.12 Thermostat

3 2014.06 Oil separator

4 2014.09 Oil separator

5 2014.11 D1803-CR-TIE4

6 2017.04 SCV Added the information about disassembling and assembling. 4-124

Month of Revision

Part name Main revised point and corrective measure

EGR valve lift sensor Common rail and injection pipes

alve guide

Rail Diesel particulate filter (DPF) Air cleaner and others Crankshaft position sensor Fuel camshaft Pistons Flywheel Main bearing case assembly

Positive crankcase ventilation (PCV) valve Starter Alternator Glow plug

Pressure limiter valve V2403-CR-TE4BG

V2403-CR-TIE4

Correction point

• 2. SPECIFICA

• 3. PERFORMANCE CURVES

• 4. MAINTENANCE CHECK LIST – Cleaning water jacket and radiator interior – Changing radiator coolant (L.L.C.)

• Mechanism – Rail pressure sensor – EGR valve lift sensor

• Servicing – Adjusting valve clearance – Common rail and injection pipes – Replacing valve guide – Measuring angular deviation between crankshaft TDC

and crankshaft position sensor detected TDC

Correction point

• 2. SPECIFICATIONS

• Model name and engine serial number

• Checking valve clearance

• Judging reuse of DPF filter comp after cleaning (Cleaning

contractor)

• Checking DPF differential pressure pipes and hoses

• Thermostat

• Rail

• Function of diesel particulate filter (DPF)

• TROUBLESHOOTING

• Adjusting valve clearance

• Disassembling and assembling – Air cleaner and others – Filter comp (DPF) (If necessary) – Crankshaft position sensor – Fuel camshaft – Pistons – Flywheel – Main bearing case assembly

Correction point

• MAINTENANCE CHECK LIST

•

Check and maintenance

– Replacing oil separator element – Checking positive crankcase ventilation (PCV) valve

• Checking and servicing – Checking starter motor – Checking magnetic switch of starter – Checking magnetic switch continuity – Checking alternator on unit – Checking glow plug continuity

Correction the picture Correction the information Added the information of V2403-CR-TE4BG

Added the model about D1803-CR-TIE4 and V2403-CR-TIE4 These models are equipped DOC only instead of DPF.

TIONS

Reference

page

2-10 2-14

3-1 3-13 3-28 4-24 4-98

4-112

2-10 3-16 3-23 4-87

3-1 3-19 3-19

4-103 4-104 4-105 4-105 4-106

4-6

－

4-148

(Continued)

Last digit

D1803-CR-E4,D1803-CR-TE4,D1803-CR-TIE4,V2403-CR-E4,V2403-CR-TE4,V2403-CR-TE4BG,V2403-CR-TIE4

KiSC issued 12, 2018 A

of the Code

No.

7 2018.12 Mechanism

Month of

Revision

Part name Main revised point and corrective measure

Servicing

Added the information about all mechanism section. Added the follow information about checking and adjusting.

• Checking injector

•

Checking suction control valve (SCV)

• Checking sensors

• Adjusting air gap between crank/camshaft position sensor and flywheel/pulsar gear

Separate disassembling and assembling Added follow servicing information.

• Replacing injector

• Replacing engine ECU

• Replacing DPF

Change notification about fan drive pulley mounting nut tightening torque

Reference

page

4-96 4-107 4-107 4-114 4-115 4-191 4-193 4-196

D1803-CR-E4,D1803-CR-TE4,D1803-CR-TIE4,V2403-CR-E4,V2403-CR-TE4,V2403-CR-TE4BG,V2403-CR-TIE4

iii

KiSC issued 12, 2018 A

1. SAFETY

SAFETY FIRST

Working precautions.................................................................................................................................1-1

2. Preparing for emergencies .......................................................................................................................1-1

3. Working cautions ...................................................................................................................................... 1-2

4. Starting the machine safely ......................................................................................................................1-3

5. Preventing fires......................................................................................................................................... 1-3

6. Preventing acid burns...............................................................................................................................1-4

7. Avoiding high pressure fluid......................................................................................................................1-4

8. Avoiding hot exhaust ................................................................................................................................1-4

9. Cleaning exhaust filter .............................................................................................................................. 1-4

2. GENERAL

GENERAL WORKING PRECAUTIONS ............................................................................................................2-1

1. Tightening bolts and nuts..........................................................................................................................2-1

2. Applying thread-locking fluid..................................................................................................................... 2-1

3. Installing circlips .......................................................................................................................................2-1

4. Handling liquid gasket ..............................................................................................................................2-2

5. Replacing O-rings.....................................................................................................................................2-2

6. Replacing oil seals.................................................................................................................................... 2-2

7. Handling the battery .................................................................................................................................2-3

8. Handling electrical wiring..........................................................................................................................2-3

9. Handling fuses..........................................................................................................................................2-4

10. Handling connectors...............................................................................................................................2-5

11. Wiring color ............................................................................................................................................. 2-6

12. Dispose fluids correctly........................................................................................................................... 2-6

GENERAL MACHINE INFORMATION ..............................................................................................................2-7

1. Engine identification .................................................................................................................................2-7

1.1 Engine model name and engine serial number................................................................................. 2-7

1.2 E4B engine........................................................................................................................................ 2-8

1.3 Cylinder number................................................................................................................................2-9

2. Muffler full assembly identification............................................................................................................2-9

2.1 Part number and serial number (DPF) .............................................................................................. 2-9

3. Specifications .........................................................................................................................................2-10

3.1 Specification for D1803-CR-E4, TE4 ..............................................................................................2-10

3.2 Specification for V2403-CR-E4, TE4............................................................................................... 2-11

3.3 Specification for D1803-CR-TIE4, V2403-CR-TIE4 ........................................................................2-12

3.4 Specification for V2403-CR-TE4BG................................................................................................2-13

4. Performance curves ...............................................................................................................................2-14

4.1 Performance curve for D1803-CR-E4 ............................................................................................. 2-14

4.2 Performance curve for D1803-CR-TE4...........................................................................................2-15

4.3 Performance curve for D1803-CR-TIE4..........................................................................................2-16

4.4 Performance curve for V2403-CR-E4 .............................................................................................2-17

4.5 Performance curve for V2403-CR-TE4 ........................................................................................... 2-18

4.6 Performance curve for V2403-CR-TIE4 .......................................................................................... 2-19

5. Dimensions.............................................................................................................................................2-20

5.1 Dimensions .....................................................................................................................................2-20

6. Wiring diagram .......................................................................................................................................2-21

6.1 Engine intermediate harness (Engine side harness) ......................................................................2-21

6.2 Injector intermediate harness (Engine side harness)......................................................................2-23

6.3 Engine ECU intermediate harness (OEM side harness).................................................................2-24

6.4 System wiring diagram for D1803-CR-E4, D1803-CR-TE4, V2403-CR-E4, V2403-CR-TE4,

6.5 System wiring diagram for D1803-CR-TIE4, V2403-CR-TIE4 ........................................................2-31

..................................................................................................................................................1-1

V2403-CR-TE4BG ..........................................................................................................................2-29

SPECIAL TOOLS............................................................................................................................................. 2-33

D1803-CR-E4,D1803-CR-TE4,D1803-CR-TIE4,V2403-CR-E4,V2403-CR-TE4,V2403-CR-TE4BG,V2403-CR-TIE4

KiSC issued 12, 2018 A

1. Diesel engine compression tester

2. Compression tester adapter K

..........................................................................................................2-33

................................................................................................................2-34

3. Oil pressure tester ..................................................................................................................................2-35

4. Valve guide replacing tool.......................................................................................................................2-35

5. Bushing replacing tools ..........................................................................................................................2-35

6. Flywheel stopper ....................................................................................................................................2-36

7. Crankshaft bearing 1 replacing tool........................................................................................................2-36

8. Auxiliary socket for fixing crankshaft sleeve ........................................................................................... 2-37

9. Injection top correction jig.......................................................................................................................2-38

10. Bearing case cover oil seal replacing tool ............................................................................................2-40

3. MAINTENANCE

MAINTENANCE CHECK LIST........................................................................................................................... 3-1

CHECK AND MAINTENANCE........................................................................................................................... 3-5

1. Daily check points..................................................................................................................................... 3-5

1.1 Checking engine oil level ..................................................................................................................3-5

1.2 Checking fuel level ............................................................................................................................ 3-6

1.3 Checking coolant level ......................................................................................................................3-6

1.4 Checking fan belt ..............................................................................................................................3-7

2. Check points of initial 50 hours................................................................................................................. 3-7

2.1 Changing engine oil ..........................................................................................................................3-7

2.2 Replacing oil filter cartridge...............................................................................................................3-8

3. Check point of every 50 hours..................................................................................................................3-8

3.1 Checking fuel hoses and clamp bands .............................................................................................3-8

3.2 Checking and draining water separator (Type 1) .............................................................................. 3-9

4. Check points of every 250 hours .............................................................................................................. 3-9

4.1 Cleaning air cleaner primary element ...............................................................................................3-9

4.2 Adjusting fan belt tension ................................................................................................................ 3-10

4.3 Checking radiator hose and clamp bands.......................................................................................3-10

4.4 Checking intake air line ................................................................................................................... 3-11

5. Check points of every 400 hours ............................................................................................................ 3-11

5.1 Changing engine oil ........................................................................................................................ 3-11

5.2 Replacing oil filter cartridge.............................................................................................................3-12

6. Check points of every 500 hours ............................................................................................................ 3-12

6.1 Replacing fuel filter cartridge........................................................................................................... 3-12

6.2 Cleaning water separator (Type 1).................................................................................................. 3-13

6.3 Replacing water separator filter (Type 2) ........................................................................................ 3-13

6.4 Cleaning water jacket and radiator interior...................................................................................... 3-13

6.5 Replacing fan belt ...........................................................................................................................3-15

7. Check point of every 1000 hours............................................................................................................3-16

7.1 Checking valve clearance ...............................................................................................................3-16

8. Check points of every 1500 hours .......................................................................................................... 3-17

8.1 Checking injector (with Diagmaster) ...............................................................................................3-17

8.2 Checking EGR cooler...................................................................................................................... 3-18

8.3 Replacing oil separator element...................................................................................................... 3-19

8.4 Checking positive crankcase ventilation (PCV) valve .....................................................................3-19

9. Check points of every 3000 hours .......................................................................................................... 3-20

9.1 Checking turbocharger....................................................................................................................3-20

9.2 Cleaning DPF..................................................................................................................................3-20

9.3 Judging reuse of DPF filter comp before cleaning (Service dealer)................................................3-22

9.4 Judging reuse of DPF filter comp after cleaning (Cleaning contractor)........................................... 3-23

9.5 Checking EGR system (with Diagmaster).......................................................................................3-24

10. Check points of every 1 year ................................................................................................................ 3-25

10.1 Replacing air cleaner element....................................................................................................... 3-25

10.2 Checking DPF differential pressure pipes and hoses ...................................................................3-25

10.3 Checking EGR piping....................................................................................................................3-26

10.4 Checking intake air line ................................................................................................................. 3-26

10.5 Checking exhaust manifold ........................................................................................................... 3-27

D1803-CR-E4,D1803-CR-TE4,D1803-CR-TIE4,V2403-CR-E4,V2403-CR-TE4,V2403-CR-TE4BG,V2403-CR-TIE4

KiSC issued 12, 2018 A

10.6 Replacing water separator filter (T

......................................................................................3-27

ype 2)

11. Check points of every 2 years............................................................................................................... 3-27

11.1 Replacing fan belt..........................................................................................................................3-27

11.2 Replacing oil separator rubber hose.............................................................................................. 3-27

11.3 Replacing rubber hose of differential pressure sensor .................................................................. 3-28

11.4 Replacing intake hose (after air flow sensor) and intercooler hose...............................................3-28

11.5 Replacing EGR cooler hose ..........................................................................................................3-28

11.6 Replacing water hose .................................................................................................................... 3-28

11.7 Replacing lubricant hose ...............................................................................................................3-28

11.8 Changing radiator coolant .............................................................................................................3-28

11.9 Replacing radiator hose and clamp bands ....................................................................................3-30

11.10 Replacing fuel hose and clamps.................................................................................................. 3-31

11.11 Replacing intake air line............................................................................................................... 3-31

4. ENGINE

MECHANISM ..................................................................................................................................................... 4-1

1. General (Introduction)............................................................................................................................... 4-1

1.1 Feature of combustion (E-CDIS).......................................................................................................4-1

1.2 Structure of combustion (Center direct injection system (E-CDIS)) .................................................. 4-1

1.3 Flow of combustion (E-CDIS)............................................................................................................ 4-1

1.4 Control of combustion (E-CDIS)........................................................................................................ 4-2

2. Engine body.............................................................................................................................................. 4-3

2.1 Structure of engine body ................................................................................................................... 4-3

2.2 Feature of engine body .....................................................................................................................4-4

2.3 Crankcase ......................................................................................................................................... 4-4

2.3.1 Outline of crankcase ................................................................................................................. 4-4

2.3.2 Structure of crankcase..............................................................................................................4-4

2.3.3 Function of crankcase............................................................................................................... 4-4

2.3.4 Specification of crankcase ........................................................................................................ 4-4

2.4 Cylinder head .................................................................................................................................... 4-4

2.4.1 Outline of cylinder head ............................................................................................................ 4-4

2.4.2 Structure of cylinder head.........................................................................................................4-4

2.4.3 Function of cylinder head.......................................................................................................... 4-4

2.5 Cylinder head cover ..........................................................................................................................4-5

2.5.1 Outline of cylinder head cover ..................................................................................................4-5

2.5.2 Structure of cylinder head cover ............................................................................................... 4-5

2.5.3 Function of cylinder head cover................................................................................................4-5

2.6 Breather ............................................................................................................................................4-5

2.6.1 Outline of breather .................................................................................................................... 4-5

2.6.2 Structure of breather.................................................................................................................4-5

2.6.3 Function of breather.................................................................................................................. 4-5

2.7 Oil separator...................................................................................................................................... 4-5

2.7.1 Outline of oil separator.............................................................................................................. 4-5

2.7.2 Structure of oil separator ..........................................................................................................4-6

2.7.3 Function of oil separator ...........................................................................................................4-6

2.8 Piston ................................................................................................................................................4-6

2.8.1 Outline of piston........................................................................................................................4-6

2.8.2 Structure of piston..................................................................................................................... 4-6

2.8.3 Function of piston .....................................................................................................................4-6

2.8.4 Specification of piston...............................................................................................................4-6

2.9 Piston ring .........................................................................................................................................4-7

2.9.1 Outline of piston ring.................................................................................................................4-7

2.9.2 Structure of piston ring.............................................................................................................. 4-7

2.9.3 Function of piston ring ..............................................................................................................4-7

2.9.4 Specification of piston ring........................................................................................................4-7

2.10 Connecting rod................................................................................................................................4-7

2.10.1 Outline of connecting rod........................................................................................................4-7

2.10.2 Structure of connecting rod..................................................................................................... 4-7

D1803-CR-E4,D1803-CR-TE4,D1803-CR-TIE4,V2403-CR-E4,V2403-CR-TE4,V2403-CR-TE4BG,V2403-CR-TIE4

KiSC issued 12, 2018 A

2.10.3 Function of connecting rod

1 Crankshaft .......................................................................................................................................4-8

2.1

.....................................................................................................4-8

2.11.1 Outline of crankshaft ...............................................................................................................4-8

2.11.2 Structure of crankshaft ............................................................................................................ 4-8

2.11.3 Function of crankshaft.............................................................................................................4-8

2.11.4 Specification of crankshaft ......................................................................................................4-8

2.12 Main bearing case...........................................................................................................................4-8

2.12.1 Outline of main bearing case .................................................................................................. 4-8

2.12.2 Structure of main bearing case...............................................................................................4-8

2.12.3 Function of main bearing case................................................................................................ 4-8

2.13 Flywheel .......................................................................................................................................... 4-9

2.13.1 Outline of flywheel ..................................................................................................................4-9

2.13.2 Structure of flywheel ...............................................................................................................4-9

2.13.3 Function of flywheel ................................................................................................................ 4-9

2.13.4 Specification of flywheel .........................................................................................................4-9

2.14 Rocker arm...................................................................................................................................... 4-9

2.14.1 Outline of rocker arm ..............................................................................................................4-9

2.14.2 Structure of rocker arm ........................................................................................................... 4-9

2.14.3 Function of rocker arm..........................................................................................................4-10

2.15 Camshaft.......................................................................................................................................4-10

2.15.1 Outline of camshaft...............................................................................................................4-10

2.15.2 Structure of camshaft............................................................................................................ 4-10

2.15.3 Function of camshaft ............................................................................................................4-10

2.15.4 Specification of camshaft......................................................................................................4-10

2.16 Valve..............................................................................................................................................4-10

2.16.1 Outline of valve ..................................................................................................................... 4-10

2.16.2 Structure of valve..................................................................................................................4-10

2.16.3 Function of valve................................................................................................................... 4-10

2.16.4 Specification of valve ............................................................................................................ 4-10

2.17 Tappet ........................................................................................................................................... 4-11

2.17.1 Outline of tappet ................................................................................................................... 4-11

2.17.2 Structure of tappet ................................................................................................................4-11

2.17.3 Function of tappet ................................................................................................................. 4-11

2.18 Push rod........................................................................................................................................ 4-11

2.18.1 Outline of push rod ............................................................................................................... 4-11

2.18.2 Structure of push rod ............................................................................................................ 4-11

2.18.3 Function of push rod ............................................................................................................. 4-12

2.19 Timing gears..................................................................................................................................4-12

2.19.1 Outline of timing gears..........................................................................................................4-12

2.19.2 Structure of timing gears....................................................................................................... 4-12

2.19.3 Function of timing gears .......................................................................................................4-12

3. Fuel system ............................................................................................................................................4-13

3.1 Structure of common rail system (CRS) engine..............................................................................4-13

3.2 Feature of common rail system (CRS) engine ................................................................................ 4-14

3.3 Flow of common rail system (CRS) engine.....................................................................................4-15

3.4 Control of common rail system (CRS) engine.................................................................................4-17

3.5 Fuel tank .........................................................................................................................................4-17

3.5.1 Outline of fuel tank..................................................................................................................4-17

3.5.2 Structure of fuel tank............................................................................................................... 4-17

3.5.3 Function of fuel tank ...............................................................................................................4-17

3.5.4 Specification of fuel tank.........................................................................................................4-17

3.6 Water separator...............................................................................................................................4-17

3.6.1 Outline of water separator ......................................................................................................4-17

3.6.2 Structure of water separator (Type1)......................................................................................4-17

3.6.3 Structure of water separator (Type2)......................................................................................4-17

3.6.4 Function of water separator .................................................................................................... 4-18

3.6.5 Specification of water separator (Type2) ................................................................................ 4-18

3.7 Electromagnetic fuel feed pump...................................................................................................... 4-18

D1803-CR-E4,D1803-CR-TE4,D1803-CR-TIE4,V2403-CR-E4,V2403-CR-TE4,V2403-CR-TE4BG,V2403-CR-TIE4

vii

KiSC issued 12, 2018 A

3.7.1 Outline of electromagnetic fuel feed pump

3.7.2 Structure of electromagnetic fuel feed pump

.............................................................................4-18

..........................................................................4-18

3.7.3 Function of electromagnetic fuel feed pump...........................................................................4-18

3.7.4 Specification of electromagnetic fuel feed pump ....................................................................4-18

3.8 Fuel feed pump ...............................................................................................................................4-19

3.8.1 Outline of fuel feed pump........................................................................................................ 4-19

3.8.2 Structure of fuel feed pump ....................................................................................................4-19

3.8.3 Function of fuel feed pump .....................................................................................................4-19

3.8.4 Specification of fuel feed pump............................................................................................... 4-19

3.9 Fuel filter .........................................................................................................................................4-20

3.9.1 Outline of fuel filter..................................................................................................................4-20

3.9.2 Structure of fuel filter............................................................................................................... 4-20

3.9.3 Function of fuel filter ...............................................................................................................4-20

3.9.4 Specification of fuel filter.........................................................................................................4-20

3.10 Supply pump .................................................................................................................................4-20

3.10.1 Outline of supply pump ......................................................................................................... 4-20

3.10.2 Structure of supply pump......................................................................................................4-20

3.10.3 Function of supply pump....................................................................................................... 4-21

3.10.4 Specification of supply pump ................................................................................................ 4-23

3.11 Injection pipe .................................................................................................................................4-23

3.11.1 Outline of injection pipe.........................................................................................................4-23

3.11.2 Structure of injection pipe...................................................................................................... 4-23

3.11.3 Function of injection pipe ......................................................................................................4-24

3.12 Rail assembly................................................................................................................................4-24

3.12.1 Outline of rail assembly ........................................................................................................4-24

3.12.2 Structure of rail assembly .....................................................................................................4-24

3.12.3 Function of rail assembly ...................................................................................................... 4-24

3.12.4 Specification of rail assembly ...............................................................................................4-25

3.13 Injector ..........................................................................................................................................4-26

3.13.1 Outline of injector..................................................................................................................4-26

3.13.2 Structure of injector............................................................................................................... 4-26

3.13.3 Function of injector ...............................................................................................................4-27

3.13.4 Specification of injector.........................................................................................................4-29

3.14 Overflow pipe ................................................................................................................................4-29

3.14.1 Outline of overflow pipe ........................................................................................................4-29

3.14.2 Structure of overflow pipe ..................................................................................................... 4-29

3.14.3 Function of overflow pipe......................................................................................................4-29

3.15 Check valve................................................................................................................................... 4-29

3.15.1 Outline of check valve........................................................................................................... 4-29

3.15.2 Structure of check valve .......................................................................................................4-29

3.15.3 Function of check valve ........................................................................................................4-29

3.15.4 Specification of check valve.................................................................................................. 4-29

3.16 Fuel cooler ....................................................................................................................................4-29

3.16.1 Outline of fuel cooler.............................................................................................................4-29

3.16.2 Structure of fuel cooler.......................................................................................................... 4-30

3.16.3 Function of fuel cooler ..........................................................................................................4-30

3.17 Engine ECU ..................................................................................................................................4-30

3.17.1 Outline of engine ECU .......................................................................................................... 4-30

3.17.2 Structure of engine ECU.......................................................................................................4-30

3.17.3 Function of engine ECU........................................................................................................ 4-30

3.17.4 Specification of engine ECU ................................................................................................. 4-30

3.18 Crankshaft position sensor............................................................................................................ 4-31

3.18.1 Outline of crankshaft position sensor.................................................................................... 4-31

3.18.2 Structure of crankshaft position sensor ................................................................................4-31

3.18.3 Function of crankshaft position sensor .................................................................................4-31

3.18.4 Specification of crankshaft position sensor........................................................................... 4-31

3.19 Camshaft position sensor.............................................................................................................. 4-32

3.19.1 Outline of camshaft position sensor...................................................................................... 4-32

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D1803-CR-E4,D1803-CR-TE4,D1803-CR-TIE4,V2403-CR-E4,V2403-CR-TE4,V2403-CR-TE4BG,V2403-CR-TIE4

KiSC issued 12, 2018 A

3.19.2 Structure of camshaft position sensor

3.19.3 Function of camshaft position sensor

..................................................................................4-32

...................................................................................4-32

3.19.4 Specification of camshaft position sensor............................................................................. 4-32

3.20 Coolant temperature sensor.......................................................................................................... 4-33

3.20.1 Outline of coolant temperature sensor.................................................................................. 4-33

3.20.2 Structure of coolant temperature sensor ..............................................................................4-33

3.20.3 Function of coolant temperature sensor ...............................................................................4-33

3.20.4 Specification of coolant temperature sensor......................................................................... 4-33

3.21 Boost pressure sensor ..................................................................................................................4-34

3.21.1 Outline of boost pressure sensor..........................................................................................4-34

3.21.2 Structure of boost pressure sensor....................................................................................... 4-34

3.21.3 Function of boost pressure sensor .......................................................................................4-34

3.21.4 Specification of boost pressure sensor.................................................................................4-34

3.22 Atmosphere pressure sensor ........................................................................................................ 4-34

3.22.1 Outline of atmosphere pressure sensor................................................................................ 4-34

3.22.2 Structure of atmosphere pressure sensor ............................................................................4-34

3.22.3 Function of atmosphere pressure sensor .............................................................................4-34

3.23 Fuel camshaft................................................................................................................................ 4-35

3.23.1 Outline of fuel camshaft ........................................................................................................ 4-35

3.23.2 Structure of fuel camshaft.....................................................................................................4-35

3.23.3 Function of fuel camshaft...................................................................................................... 4-35

4. Intake and exhaust system.....................................................................................................................4-36

4.1 Structure of intake and exhaust system .......................................................................................... 4-36

4.2 Feature of intake and exhaust system ............................................................................................4-37

4.3 Flow of intake and exhaust system ................................................................................................. 4-38

4.4 Control of intake and exhaust system ............................................................................................. 4-40

4.5 Pre-cleaner...................................................................................................................................... 4-40

4.5.1 Outline of pre-cleaner .............................................................................................................4-40

4.5.2 Structure of pre-cleaner .......................................................................................................... 4-40

4.5.3 Function of pre-cleaner...........................................................................................................4-40

4.5.4 Specification of pre-cleaner ....................................................................................................4-40

4.6 Air cleaner ....................................................................................................................................... 4-40

4.6.1 Outline of air cleaner............................................................................................................... 4-40

4.6.2 Structure of air cleaner ...........................................................................................................4-40

4.6.3 Function of air cleaner ............................................................................................................4-40

4.6.4 Specification of air cleaner...................................................................................................... 4-40

4.7 Turbocharger................................................................................................................................... 4-40

4.7.1 Outline of turbocharger ........................................................................................................... 4-40

4.7.2 Structure of turbocharger........................................................................................................4-41

4.7.3 Function of turbocharger......................................................................................................... 4-41

4.7.4 Specification of turbocharger .................................................................................................. 4-41

4.8 Intercooler .......................................................................................................................................4-41

4.8.1 Outline of intercooler............................................................................................................... 4-41

4.8.2 Structure of intercooler ...........................................................................................................4-41

4.8.3 Function of intercooler ............................................................................................................4-41

4.8.4 Specification of intercooler...................................................................................................... 4-41

4.9 Glow plug ........................................................................................................................................4-42

4.9.1 Outline of glow plug ................................................................................................................4-42

4.9.2 Structure of glow plug ............................................................................................................. 4-42

4.9.3 Function of glow plug..............................................................................................................4-42

4.9.4 Specification of glow plug .......................................................................................................4-42

4.10 Intake manifold..............................................................................................................................4-42

4.10.1 Outline of intake manifold .....................................................................................................4-42

4.10.2 Structure of intake manifold .................................................................................................. 4-42

4.10.3 Function of intake manifold...................................................................................................4-42

4.11 Exhaust manifold ........................................................................................................................... 4-42

4.11.1 Outline of exhaust manifold................................................................................................... 4-42

4.11.2 Structure of exhaust manifold ...............................................................................................4-42

D1803-CR-E4,D1803-CR-TE4,D1803-CR-TIE4,V2403-CR-E4,V2403-CR-TE4,V2403-CR-TE4BG,V2403-CR-TIE4

KiSC issued 12, 2018 A

4.1

1.3 Function of exhaust manifold

................................................................................................4-43

5. Exhaust gas recirculation (EGR) system................................................................................................4-44

5.1 Structure of EGR system ................................................................................................................4-44

5.2 Feature of EGR system................................................................................................................... 4-45

5.3 Flow of EGR system........................................................................................................................4-46

5.4 Control of EGR system ...................................................................................................................4-47

5.5 EGR cooler...................................................................................................................................... 4-47

5.5.1 Outline of EGR cooler.............................................................................................................4-47

5.5.2 Structure of EGR cooler.......................................................................................................... 4-47

5.5.3 Function of EGR cooler ..........................................................................................................4-47

5.5.4 Specification of EGR cooler....................................................................................................4-47

5.6 EGR valve ....................................................................................................................................... 4-47

5.6.1 Outline of EGR valve ..............................................................................................................4-47

5.6.2 Structure of EGR valve ........................................................................................................... 4-48

5.6.3 Function of EGR valve............................................................................................................4-50

5.6.4 Specification of EGR valve .....................................................................................................4-50

5.7 Reed valve ......................................................................................................................................4-50

5.7.1 Outline of reed valve...............................................................................................................4-50

5.7.2 Structure of reed valve............................................................................................................ 4-50

5.7.3 Function of reed valve ............................................................................................................4-50

6. Lubricating system.................................................................................................................................. 4-51

6.1 Structure of lubricating system........................................................................................................4-51

6.2 Feature of lubricating system .......................................................................................................... 4-52

6.3 Flow of lubricating system...............................................................................................................4-53

6.4 Oil pan.............................................................................................................................................4-55

6.4.1 Outline of oil pan.....................................................................................................................4-55

6.4.2 Structure of oil pan.................................................................................................................. 4-55

6.4.3 Function of oil pan ..................................................................................................................4-55

6.4.4 Specification of oil pan............................................................................................................4-55

6.5 Oil strainer.......................................................................................................................................4-55

6.5.1 Outline of oil strainer...............................................................................................................4-55

6.5.2 Structure of oil strainer............................................................................................................ 4-55

6.5.3 Function of oil strainer ............................................................................................................4-55

6.5.4 Specification of oil strainer......................................................................................................4-55

6.6 Oil pump..........................................................................................................................................4-56

6.6.1 Outline of oil pump..................................................................................................................4-56

6.6.2 Structure of oil pump............................................................................................................... 4-56

6.6.3 Function of oil pump ...............................................................................................................4-56

6.6.4 Specification of oil pump.........................................................................................................4-56

6.7 Relief valve...................................................................................................................................... 4-56

6.7.1 Outline of relief valve ..............................................................................................................4-56

6.7.2 Structure of relief valve ........................................................................................................... 4-56

6.7.3 Function of relief valve............................................................................................................4-57

6.8 Oil filter ............................................................................................................................................ 4-57

6.8.1 Outline of oil filter .................................................................................................................... 4-57

6.8.2 Structure of oil filter.................................................................................................................4-57

6.8.3 Function of oil filter.................................................................................................................. 4-57

6.8.4 Specification of oil filter ........................................................................................................... 4-57

6.9 Oil cooler ......................................................................................................................................... 4-57

6.9.1 Outline of oil cooler ................................................................................................................. 4-57

6.9.2 Structure of oil cooler..............................................................................................................4-57

6.9.3 Function of oil cooler............................................................................................................... 4-58

6.9.4 Specification of oil cooler ........................................................................................................ 4-58

6.10 Oil pressure switch........................................................................................................................4-58

6.10.1 Outline of oil pressure switch................................................................................................4-58

6.10.2 Structure of oil pressure switch............................................................................................. 4-58

6.10.3 Function of oil pressure switch .............................................................................................4-58

6.10.4 Specification of oil pressure switch.......................................................................................4-59

D1803-CR-E4,D1803-CR-TE4,D1803-CR-TIE4,V2403-CR-E4,V2403-CR-TE4,V2403-CR-TE4BG,V2403-CR-TIE4

KiSC issued 12, 2018 A

7. Cooling system

7.1 Structure of cooling system

.......................................................................................................................................4-60

.............................................................................................................4-60

7.2 Feature of cooling system ............................................................................................................... 4-61

7.3 Flow of cooling system (Bottom by-pass system) ........................................................................... 4-61

7.4 Control of cooling system (Bottom by-pass system) ....................................................................... 4-61

7.5 Water pump..................................................................................................................................... 4-61

7.5.1 Outline of water pump............................................................................................................. 4-61

7.5.2 Structure of water pump .........................................................................................................4-61

7.5.3 Function of water pump ..........................................................................................................4-62

7.6 Thermostat ...................................................................................................................................... 4-62

7.6.1 Outline of thermostat ..............................................................................................................4-62

7.6.2 Structure of thermostat ...........................................................................................................4-62

7.6.3 Function of thermostat ............................................................................................................ 4-62

7.6.4 Specification of thermostat .....................................................................................................4-62

7.7 Radiator........................................................................................................................................... 4-63

7.7.1 Outline of radiator ...................................................................................................................4-63

7.7.2 Structure of radiator ................................................................................................................ 4-63

7.7.3 Function of radiator.................................................................................................................4-63

7.7.4 Specification of radiator ..........................................................................................................4-63

7.8 Radiator cap....................................................................................................................................4-63

7.8.1 Outline of radiator cap ............................................................................................................4-63

7.8.2 Structure of radiator cap .........................................................................................................4-63

7.8.3 Function of radiator cap .......................................................................................................... 4-64

7.8.4 Specification of radiator cap ...................................................................................................4-64

7.9 Cooling fan ...................................................................................................................................... 4-64

7.9.1 Outline of cooling fan .............................................................................................................. 4-64

7.9.2 Structure of cooling fan...........................................................................................................4-64

7.9.3 Function of cooling fan............................................................................................................ 4-64

7.9.4 Specification of cooling fan ..................................................................................................... 4-64

7.10 Reserve tank ................................................................................................................................. 4-65

7.10.1 Outline of reserve tank.......................................................................................................... 4-65

7.10.2 Structure of reserve tank ......................................................................................................4-65

7.10.3 Function of reserve tank .......................................................................................................4-65

7.11 Fan belt..........................................................................................................................................4-65

7.11.1 Outline of fan belt .................................................................................................................. 4-65

7.11.2 Structure of fan belt...............................................................................................................4-65

7.11.3 Function of fan belt................................................................................................................4-65

8. Electrical system..................................................................................................................................... 4-66

8.1 Structure of electrical system .......................................................................................................... 4-66

8.2 Feature of electrical system ............................................................................................................4-67

8.3 Flow of electrical system ................................................................................................................. 4-68

8.4 Control of electrical system ............................................................................................................. 4-70

8.5 Battery.............................................................................................................................................4-70

8.5.1 Outline of battery ....................................................................................................................4-70

8.5.2 Structure of battery .................................................................................................................4-70

8.5.3 Function of battery .................................................................................................................. 4-70

8.5.4 Specification of battery ...........................................................................................................4-70

8.6 Key switch ....................................................................................................................................... 4-70

8.6.1 Outline of key switch...............................................................................................................4-70

8.6.2 Structure of key switch............................................................................................................ 4-70

8.6.3 Function of key switch ............................................................................................................4-71

8.6.4 Specification of key switch......................................................................................................4-71

8.7 Starter (Planetary gear reduction type) ........................................................................................... 4-71

8.7.1 Outline of starter (planetary gear reduction type) ...................................................................4-71

8.7.2 Structure of starter (planetary gear reduction type) ................................................................ 4-71

8.7.3 Function of starter (planetary gear reduction type).................................................................4-71

8.7.4 Specification of starter (planetary gear reduction type) ..........................................................4-72

8.8 Alternator......................................................................................................................................... 4-72

D1803-CR-E4,D1803-CR-TE4,D1803-CR-TIE4,V2403-CR-E4,V2403-CR-TE4,V2403-CR-TE4BG,V2403-CR-TIE4

KiSC issued 12, 2018 A

8.8.1 Outline of alternator

8.8.2 Structure of alternator

................................................................................................................4-72

.............................................................................................................4-72

8.8.3 Function of alternator..............................................................................................................4-72

8.8.4 Specification of alternator .......................................................................................................4-74

9. Aftertreatment system ............................................................................................................................4-75

9.1 Structure of diesel particulate filter (DPF) system...........................................................................4-75

9.2 Feature of diesel particulate filter (DPF) system ............................................................................. 4-75

9.3 Flow of diesel particulate filter (DPF) system..................................................................................4-75

9.4 Control of diesel particulate filter (DPF) system..............................................................................4-76

9.5 Structure of diesel oxidation catalyst (DOC) system.......................................................................4-78

9.6 Feature of diesel oxidation catalyst (DOC) system ......................................................................... 4-78

9.7 Flow of diesel oxidation catalyst (DOC) system..............................................................................4-78

9.8 Diesel oxidation catalyst (DOC) ......................................................................................................4-79

9.8.1 Outline of diesel oxidation catalyst (DOC) .............................................................................. 4-79

9.8.2 Structure of diesel oxidation catalyst (DOC)...........................................................................4-79

9.8.3 Function of diesel oxidation catalyst (DOC)............................................................................ 4-79

9.9 Diesel particulate filter (DPF) ..........................................................................................................4-79

9.9.1 Outline of diesel particulate filter (DPF) .................................................................................. 4-79

9.9.2 Structure of diesel particulate filter (DPF)...............................................................................4-79

9.9.3 Function of diesel particulate filter (DPF)................................................................................ 4-80

9.10 Air flow sensor............................................................................................................................... 4-80

9.10.1 Outline of air flow sensor ......................................................................................................4-80

9.10.2 Structure of air flow sensor ................................................................................................... 4-80

9.10.3 Function of air flow sensor....................................................................................................4-80

9.10.4 Specification of air flow sensor .............................................................................................4-81

9.11 Exhaust gas temperature sensor................................................................................................... 4-81

9.11.1 Outline of exhaust gas temperature sensor ..........................................................................4-81

9.11.2 Structure of exhaust gas temperature sensor ....................................................................... 4-81

9.11.3 Function of exhaust gas temperature sensor........................................................................4-82

9.11.4 Specification of exhaust gas temperature sensor .................................................................4-82

9.12 Differential pressure sensor ..........................................................................................................4-83

9.12.1 Outline of differential pressure sensor .................................................................................. 4-83

9.12.2 Structure of differential pressure sensor...............................................................................4-83

9.12.3 Function of differential pressure sensor................................................................................ 4-83

9.12.4 Specification of differential pressure sensor ......................................................................... 4-83

9.13 Intake throttle valve ....................................................................................................................... 4-84

9.13.1 Outline of intake throttle valve ..............................................................................................4-84

9.13.2 Structure of intake throttle valve ...........................................................................................4-84

9.13.3 Function of intake throttle valve ............................................................................................ 4-84

9.13.4 Specification of intake throttle valve .....................................................................................4-84

SERVICING .....................................................................................................................................................4-87

1. Troubleshooting......................................................................................................................................4-87

1.1 Troubleshooting for 03 series engine..............................................................................................4-87

2. Service specifications ............................................................................................................................. 4-91

2.1 Service specifications for engine..................................................................................................... 4-91

3. Tightening torques..................................................................................................................................4-96

3.1 Tightening torques of screws, bolts and nuts for general use.........................................................4-96

3.2 Tightening torques of screws, bolts and nuts for special use.......................................................... 4-96

4. Checking and adjusting ..........................................................................................................................4-98

4.1 Checking compression pressure of cylinder ...................................................................................4-98

4.2 Adjusting valve clearance ...............................................................................................................4-98

4.3 Checking engine oil pressure..........................................................................................................4-99

4.4 Checking fan belt tension..............................................................................................................4-100

4.5 Checking fan belt damage and wear............................................................................................. 4-100

4.6 Checking radiator cap air leakage................................................................................................. 4-100

4.7 Checking radiator water leakage................................................................................................... 4-101

4.8 Checking opening temperature of thermostat valve...................................................................... 4-101

4.9 Checking battery voltage............................................................................................................... 4-102

xii

D1803-CR-E4,D1803-CR-TE4,D1803-CR-TIE4,V2403-CR-E4,V2403-CR-TE4,V2403-CR-TE4BG,V2403-CR-TIE4

KiSC issued 12, 2018 A

4.10 Checking battery specific gravity

.................................................................................................4-

102

4.11 Checking starter motor ................................................................................................................4-103

4.12 Checking magnetic switch of starter ...........................................................................................4-104

4.13 Checking magnetic switch continuity ..........................................................................................4-105

4.14 Checking alternator on unit .........................................................................................................4-105

4.15 Checking glow plug continuity.....................................................................................................4-106

4.16 Checking exhaust gas leakage of turbocharger turbine side ......................................................4-106

4.17 Checking air leakage of turbocharger compressor side..............................................................4-106

4.18 Checking radial clearance of turbocharger .................................................................................4-107

4.19 Checking injector......................................................................................................................... 4-107

4.20 Checking suction control valve (SCV).........................................................................................4-107

4.21 Checking rail pressure sensor..................................................................................................... 4-108

4.22 Checking boost pressure sensor................................................................................................. 4-108

4.23 Checking crankshaft position sensor ..........................................................................................4-109

4.24 Checking camshaft position sensor ............................................................................................4-109

4.25 Checking coolant temperature sensor ........................................................................................4-109

4.26 Checking EGR system ................................................................................................................ 4-110

4.27 Checking air flow sensor ............................................................................................................. 4-110

4.28 Checking exhaust gas temperature sensor................................................................................. 4-111

4.29 Selecting cylinder head gasket ................................................................................................... 4-111

4.30 Measuring angular deviation between crankshaft T.D.C. and crankshaft position sensor

detected T.D.C. ........................................................................................................................... 4-112

4.31 Adjusting air gap between crankshaft position sensor and flywheel ........................................... 4-114

4.32 Adjusting air gap between camshaft position sensor and pulsar gear ........................................ 4-115

5. Disassembling ......................................................................................................................................4-115

5.1 Draining engine oil ........................................................................................................................ 4-115

5.2 Draining coolant ............................................................................................................................4-115

5.3 Removing CRS intermediate harness........................................................................................... 4-116

5.4 Removing external components.................................................................................................... 4-116

5.5 Removing muffler full assembly .................................................................................................... 4-117

5.6 Disassembling DPF assembly ...................................................................................................... 4-118

5.7 Removing EGR cooler .................................................................................................................. 4-119

5.8 Removing turbocharger................................................................................................................. 4-119

5.9 Removing intake throttle valve ...................................................................................................... 4-120

5.10 Removing EGR valve..................................................................................................................4-120

5.11 Removing common rail................................................................................................................4-120

5.12 Removing sensors ......................................................................................................................4-121

5.13 Removing cylinder head cover....................................................................................................4-122

5.14 Removing glow plug....................................................................................................................4-122

5.15 Removing injector .......................................................................................................................4-122

5.16 Removing rocker arm assembly.................................................................................................. 4-123

5.17 Removing cylinder head.............................................................................................................. 4-123

5.18 Removing tappet ......................................................................................................................... 4-124

5.19 Removing valve........................................................................................................................... 4-124

5.20 Removing thermostat assembly..................................................................................................4-124

5.21 Removing suction control valve (SCV)........................................................................................ 4-124

5.22 Removing supply pump............................................................................................................... 4-125

5.23 Removing oil cooler..................................................................................................................... 4-125

5.24 Removing water pump ................................................................................................................4-126

5.25 Removing fan drive pulley...........................................................................................................4-126

5.26 Removing gear case cover .........................................................................................................4-126

5.27 Removing crankshaft oil slinger ..................................................................................................4-126

5.28 Removing idle gear .....................................................................................................................4-127

5.29 Removing fuel camshaft assembly .............................................................................................4-127

5.30 Removing camshaft with cam gear ............................................................................................. 4-128

5.31 Removing oil pump .....................................................................................................................4-128

5.32 Removing crank gear .................................................................................................................. 4-128

5.33 Removing oil pan and oil strainer................................................................................................4-129

D1803-CR-E4,D1803-CR-TE4,D1803-CR-TIE4,V2403-CR-E4,V2403-CR-TE4,V2403-CR-TE4BG,V2403-CR-TIE4

xiii

KiSC issued 12, 2018 A

5.34 Removing piston

.........................................................................................................................4-

129

5.35 Removing piston ring ..................................................................................................................4-129

5.36 Disassembling piston assembly .................................................................................................. 4-130

5.37 Removing flywheel ...................................................................................................................... 4-130

5.38 Removing flywheel housing ........................................................................................................4-131

5.39 Removing bearing case cover..................................................................................................... 4-131

5.40 Removing crankshaft (for 3 cylinders)......................................................................................... 4-131

5.41 Removing crankshaft (for 4 cylinders)......................................................................................... 4-132

5.42 Removing main bearing case...................................................................................................... 4-133

5.43 Disassembling starter.................................................................................................................. 4-133

5.44 Disassembling alternator............................................................................................................. 4-133

6. Assembling ........................................................................................................................................... 4-134

6.1 Assembling alternator ...................................................................................................................4-134

6.2 Assembling starter ........................................................................................................................4-136

6.3 Installing main bearing case.......................................................................................................... 4-137

6.4 Installing crankshaft (for 3 cylinders)............................................................................................. 4-138

6.5 Installing crankshaft (for 4 cylinders)............................................................................................. 4-138

6.6 Installing bearing case cover......................................................................................................... 4-139

6.7 Installing flywheel housing ............................................................................................................4-139

6.8 Installing flywheel .......................................................................................................................... 4-139

6.9 Assembling piston assembly.........................................................................................................4-140

6.10 Installing piston ring ....................................................................................................................4-141

6.11 Installing piston............................................................................................................................4-141

6.12 Installing oil strainer and oil pan..................................................................................................4-143

6.13 Installing crank gear .................................................................................................................... 4-144

6.14 Installing oil pump .......................................................................................................................4-144

6.15 Installing camshaft with cam gear ............................................................................................... 4-144

6.16 Installing fuel camshaft with supply pump gear........................................................................... 4-145

6.17 Installing idle gear .......................................................................................................................4-145

6.18 Installing crankshaft oil slinger ....................................................................................................4-146

6.19 Installing gear case cover ...........................................................................................................4-146

6.20 Installing fan drive pulley.............................................................................................................4-146

6.21 Installing water pump ..................................................................................................................4-147

6.22 Installing oil cooler....................................................................................................................... 4-147

6.23 Installing supply pump................................................................................................................. 4-148

6.24 Installing suction control valve (SCV).......................................................................................... 4-148

6.25 Installing thermostat assembly....................................................................................................4-149

6.26 Installing valve............................................................................................................................. 4-149

6.27 Installing tappet ........................................................................................................................... 4-149

6.28 Installing cylinder head................................................................................................................ 4-149

6.29 Installing rocker arm assembly.................................................................................................... 4-151

6.30 Installing injector .........................................................................................................................4-151

6.31 Installing glow plug......................................................................................................................4-152

6.32 Installing cylinder head cover......................................................................................................4-153

6.33 Installing sensors ........................................................................................................................4-153

6.34 Installing common rail .................................................................................................................4-154

6.35 Installing EGR valve....................................................................................................................4-155

6.36 Installing intake throttle valve ...................................................................................................... 4-155

6.37 Installing turbocharger assembly ................................................................................................4-155

6.38 Installing EGR cooler ..................................................................................................................4-156

6.39 Assembling DPF assembly .........................................................................................................4-156

6.40 Installing muffler full assembly ....................................................................................................4-157

6.41 Installing CRS intermediate harness...........................................................................................4-159

6.42 Installing external components.................................................................................................... 4-161

6.43 Filling coolant ..............................................................................................................................4-162

6.44 Filling engine oil ..........................................................................................................................4-162

7. Servicing...............................................................................................................................................4-162

7.1 Checking cylinder head top clearance ..........................................................................................4-162

xiv

D1803-CR-E4,D1803-CR-TE4,D1803-CR-TIE4,V2403-CR-E4,V2403-CR-TE4,V2403-CR-TE4BG,V2403-CR-TIE4

KiSC issued 12, 2018 A

7.2 Checking cylinder head surface flatness

.......................................................................................4-

163

7.3 Checking cylinder head flaw .........................................................................................................4-163

7.4 Checking valve recessing .............................................................................................................4-164

7.5 Adjusting valve lapping .................................................................................................................4-164

7.6 Checking clearance between valve stem and valve guide............................................................ 4-165

7.7 Replacing valve guide ................................................................................................................... 4-165

7.8 Adjusting valve angle ....................................................................................................................4-166

7.9 Adjusting valve seat ......................................................................................................................4-166

7.10 Checking free length of valve spring ........................................................................................... 4-167

7.11 Checking tilt of valve spring.........................................................................................................4-167

7.12 Checking set load of valve spring ...............................................................................................4-168

7.13 Checking oil clearance between rocker arm and rocker arm shaft .............................................4-168

7.14 Checking push rod alignment...................................................................................................... 4-169

7.15 Checking oil clearance between tappet and tappet guide bore ..................................................4-169

7.16 Checking timing gear backlash ...................................................................................................4-169

7.17 Checking side clearance of idle gear ..........................................................................................4-170

7.18 Checking side clearance of camshaft .........................................................................................4-170

7.19 Checking camshaft alignment ..................................................................................................... 4-171

7.20 Replacing idle gear bushing........................................................................................................4-171

7.21 Checking cam height................................................................................................................... 4-172

7.22 Checking oil clearance between camshaft journal and crankcase bore .....................................4-172

7.23 Checking oil clearance between idle gear shaft and idle gear bushing ......................................4-173

7.24 Checking piston pin bore I.D. ...................................................................................................... 4-173

7.25 Checking oil clearance between piston pin and small end bushing ............................................ 4-173

7.26 Replacing small end bushing ......................................................................................................4-174

7.27 Checking connecting rod alignment ............................................................................................ 4-175

7.28 Checking piston ring gap............................................................................................................. 4-175

7.29 Checking clearance between piston ring and ring groove ..........................................................4-176

7.30 Checking side clearance of crankshaft .......................................................................................4-177

7.31 Checking crankshaft alignment ................................................................................................... 4-178

7.32 Checking oil clearance between crankpin and crankpin bearing ................................................4-179

7.33 Checking oil clearance between crankshaft journal and crankshaft bearing 1 ...........................4-179

7.34 Replacing crankshaft sleeve .......................................................................................................4-180

7.35 Replacing crankshaft bearing 1................................................................................................... 4-181

7.36 Checking oil clearance between crankshaft journal and crankshaft bearing 2 ...........................4-181

7.37 Replacing bearing case cover oil seal......................................................................................... 4-182

7.38 Checking cylinder wear ............................................................................................................... 4-183

7.39 Adjusting cylinder correction (over size) .....................................................................................4-183

7.40 Checking clearance between inner rotor and outer rotor ............................................................ 4-184

7.41 Checking clearance between outer rotor and pump body........................................................... 4-184

7.42 Checking clearance between rotor and cover.............................................................................4-185

7.43 Checking overrunning clutch of starter........................................................................................ 4-185

7.44 Checking commutator and mica of starter ..................................................................................4-185

7.45 Checking brush wear of starter ...................................................................................................4-186

7.46 Checking brush holder of starter ................................................................................................. 4-187

7.47 Checking armature coil of starter ................................................................................................4-187

7.48 Checking field coil of starter ........................................................................................................ 4-188

7.49 Checking bearing of alternator .................................................................................................... 4-188

7.50 Checking stator of alternator ....................................................................................................... 4-188

7.51 Checking rotor of alternator......................................................................................................... 4-189

7.52 Checking slip ring of alternator.................................................................................................... 4-189

7.53 Checking brush wear of alternator ..............................................................................................4-190

7.54 Checking rectifier ........................................................................................................................4-190

7.55 Checking IC regulator .................................................................................................................4-190

7.56 Replacing injector........................................................................................................................ 4-191

7.57 Replacing engine ECU................................................................................................................4-193

7.58 Replacing DPF ............................................................................................................................ 4-196

1. SAFETY

KiSC issued 12, 2018 A

SAFETY FIRST

D1803-CR-E4,D1803-CR-TE4,D1803-CR-TIE4,V2403-CR-E4,V2403-CR-TE4,V2403-CR-TE4BG,V2403-CR-TIE4

1-1

KiSC issued 12, 2018 A

1. Working precautions 1. SAFETY

SAFETY FIRST

This symbol, the industry's "Safety Alert Symbol", is used throughout 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.

this manual and on labels on the

DANGER

• Indicates an which, if not avoided, will result in death or serious injury.

imminently hazardous situation

WARNING

• Indicates which, if not avoided, could result in death or serious injury.

potentially hazardous situation

CAUTION

• Indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury.

• Stop the engine and remove the key when leaving the operator's seat for cleaning, maintenance, and servicing.

• Hang a DO NOT OPERATE tag near the operator's seat.

• Do not use worn or cracked tools. Use tools in a proper way with enough strength.

• In regards to the facility which is used in the work shop, follow each safety instruction.

IMPORTANT

• Indicates that could result if instructions are not followed.

NOTE

• Gives helpful information.

1. W

orking precautions

• Understand all in this manual.

• Park the machine on a stable and level ground then lower the attachment to check the machine safely.

equipment or property damage

safety instructions and safety labels

2. Preparing for emergencies

• Keep a first aid kit and fire extinguisher ready at all times. Keep emergency numbers near your telephone at

• all times.

1. SAFETY

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KiSC issued 12, 2018 A

3. Working cautions

• Wear a uniform suited for service working. Do not wear

loose clothes as they could get caught on the

control lever.

• Wear the proper protective equipment when checking the machine. For example helmet, eye protector and protective shoes.

• Do not check the machine after you have consumed alcohol or drugs or when you are tired.

SAFETY FIRST

3. Working cautions

• Make sure you have the support of the 3 points with both

hands holding the handle and one foot at the

step when getting on and off the machine.

• Park the machine on a stable and level ground. Keep hazardous materials.

• Make sure to ventilate the work area in cases of working indoors.

• Do not allow third parties to come near the machine.

• Keep the machine clean. Remove dirt, debris, and oil attached to the machine.

the machine away from obstacles and

• Confirm the pressure when opening the radiator cap.

• Release residual pressure in the hydraulic circuit before removing the hydraulic components.

• Pay attention when releasing pressure in hydraulic circuit, the machine or attachment might move unexpectedly.

• When working under the machine, make sure the machine does not move back and forth.

• When working under the machine, provide secure support for the machine.

• When using a garage jack, always use with a rigid rack to prevent the machine from falling.

coolant temperature and release

SAFETY FIRST

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4. Starting the machine safely 1. SAFETY

4. Starting the machine safely

• Do not do the following work when staring the engine.

–

Short across starter terminals.

– Bypass the safety start switch.

• Confirm if it is safe around the machine from the operator's seat before starting the engine.

• Do not start the engine unless seating in the operator's seat.

• Make sure that the pilot levers are in neutral before starting the engine.

5. Preventing fires

• Lock the covers before starting the machine.

• Keep away from rotating and moving objects.

•

Keep tools and waste cloth away from rotating and moving objects.

• Keep fire (welding sparks, grinding sparks, cigarettes) away from the fuel. Wipe the fuel off when spilled.

•

• Keep fire (welding sparks, grinding sparks, cigarettes) away from the battery. The battery produces oxygen and hydrogen gas that are flammable.

• Make sure to disconnect the negative (-) terminal first when disconnecting the battery cable.

• Make sure to connect the positive (+) terminal first when connecting the battery cable.

• Follow notes on handling diesel particulate filter (DPF).

• Do not make a short-circuit.

• Do not splash the hydraulic oil on the exhaust components.

1. SAFETY

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KiSC issued 12, 2018 A

SAFETY FIRST

6. Preventing acid burns

• Keep the electrolyte away from your eyes, hands, and

clothes. Sulfuric acid in the battery electrolyte is poisonous: it can cause blindness and strong enough to burn your skin and clothing. If you spill electrolyte on yourself, clean yourself with water and get a medical aid immediately.

7. Avoiding high pressure fluid

8. Avoiding hot exhaust

• Avoid skin exposure and contact with hot exhaust gas or components.

•

Exhaust gas and components are extremely hot during operation.

• Keep away from high pressure fluids bursting from a

hose or pipe. The fluid can penetrate your skin

and cause serious injuries.

• Get a medical aid immediately if the accident occurs.

• Do not work immediately after stopping the engine. The

engine, muffler, radiator, and hydraulic

components are extremely hot.

• Do not remove caps and plugs soon after stopping the engine. The temperature and pressure of the coolant, hydraulic oil, and fuel are still high.

9. Cleaning exhaust filter

SAFETY FIRST

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• A

void skin exposure and contact with hot exhaust

or components. Exhaust gas and components

gas are extremely hot during regeneration of diesel particulate filter (DPF).

1. SAFETY

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KiSC issued 12, 2018 A

SAFETY FIRST

2. GENERAL

KiSC issued 12, 2018 A

GENERAL WORKING PRECAUTIONS

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1. Tightening bolts and nuts 2. GENERAL

GENERAL WORKING PRECAUTIONS

NOTE

– Tighten the bolts and nuts alternately from

top to bottom and left to right so the torque is distributed evenly.

– Gradually tighten the bolts and nuts two or

three times.

2. Applying thread-locking fluid

1. Clean and dry the location where a thread-locking fluid

will be applied with a solvent to remove

moisture, oil, and dirt.

2. Apply the thread-locking fluid to the tip of the bolt.

• When servicing, observe the safety regulations in the operator's manual and workshop manual. Clean the machine before maintenance.

•

• Before working, remove the negative (-) terminal from the battery or turn off the battery isolator switch.

• Disassemble the machine at a clean location.

• Whenever a special tool is required, use the special tool that Kubota recommends. Or, craft the special tools according to the illustrations in this manual.

• Use genuine Kubota parts to ensure safety and machine performance.

3. If the threads are large, apply the thread-locking fluid all around the bolt hole.

1. Tightening bolts and nuts

(A) Alternately (B) Diagonally

• T

ighten the bolts and nuts with their specified

torque.

outside

(A) Bolt hole (bolts, nuts) (B) Screw hole

3. Installing circlips

(3)

(1) Circlip

Rounded side

(2)

Angular side

2. GENERAL

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KiSC issued 12, 2018 A

GENERAL WORKING PRECAUTIONS

4. Handling liquid gasket

5. Replacing O-rings

(4) Side that receives force (5) Force

External circlip

(A) (B) Internal circlip

• When installing the circlip, assemble the circlip's angular

side (3) toward the side that receives force

(4) as shown in the figure.

4. Handling liquid gasket

(1) Application route (2)

Bolt hole Dowel pin

(3) (A) Correct (B) Incorrect

(a) 3.0 to 3.5 mm (0.12 to

0.13 in.)

(b) 3.0 to 5.0 mm (0.12 to

0.19 in.)

(1) O-ring groove (2) O-ring

(3)

Burr

1. Remove the burr and clean the O-ring groove.

2. Lubricate

O-ring. Do not apply any grease to

the

the floating seal.

3. Put the O-ring in the groove.

NOTE

• Do not twist the O-ring.

•

Remove the burr to avoid damage on the Oring caused by the burr.

6. Replacing oil seals

• Use the specified liquid gasket.

• When using

liquid gasket, fully remove the old

gasket and grease or oil.

• When applying liquid gasket, apply it on the joint surface with a thickness of 3.0 to 5.0 mm (0.12 to

0.13 in.) without making any gaps.

• When applying liquid gasket near the bolt hole (2), apply it in the inner side.

• If there is a risk of oil leakage or if the hole goes all the way through when applying liquid gasket near the dowel pin (3) hole, apply it in the inner side. If there is no concern of oil leakage, apply it on the

(1) Packing (2)

Metal ring Spring

(3) (4) Seal lip

1. Do

not face the lip of the oil seal in the wrong

direction.

Face the main lip toward the material to

be sealed.

2. Use a press to install the oil seal until firmly fixed to the boss.

outer side.

• Reassemble within 15 minutes after applying; wait for 30 minutes or more then fill with oil.

NOTE

• In cases

when installing an oil seal without a press, place a wooden board on the seal and gently tap the board with a hammer; install the oil seal straightly and evenly.

(5) Grease (6) Dust lip (A) Air side (B) Oil side

GENERAL WORKING PRECAUTIONS

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7. Handling the battery 2. GENERAL

3. Grease the seal lip and dust lip.

NOTE

• If the

seal has a dust lip, grease the gap

between the lips.

• After oil seals are replaced, grease the moving parts around the lip to prevent the dry surfaces from wearing against each other during engine start up.

7. Handling the battery

CAUTION

• When removing negative (-) terminal first.

• When installing battery cables, connect positive (+) terminal first.

battery cables, disconnect

• Tighten the electrical terminals securely.

(A) Correct (B) Incorrect: loose bolt

• Check the

electrical terminal protection and clamping conditions before connecting the battery cable.

(1) Battery negative (-) terminal (2) Battery positive (+) terminal

• Do not install any battery with a capacity (Ah) other than is specified.

• Securely attach the terminal covers on the cables when connecting the cables to the battery terminal posts. There is a danger of short-circuiting if the tip of the cables attached to the battery terminal post is exposed.

• Do not allow dirt and dust to collect on the battery.

• Apply grease thinly to the battery terminal posts to prevent corrosion.

8. Handling electrical wiring

CAUTION

• Do not come in contact with other components.

• Do not clamp the electrical wiring to fuel hoses.

• If the electrical wiring is damaged, repair it with an insulating tape or rat-proof tape, or replace the wiring with a new one.

• Do not alter the electrical device and wiring.

put an unprotected electrical wiring to

(1) Covered completely with a

protection cover

• Keep the wiring away from hazardous positions such as rotating parts or high-temperature sections.

(2) Hazardous position (3) Wiring position: poor

Wiring position: good

(4)

• Repair

replace damaged or old wiring

(5) Hazardous position

immediately.

2. GENERAL

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KiSC issued 12, 2018 A

GENERAL WORKING PRECAUTIONS

9. Handling fuses

(6) Insulating tape (C) Damaged

(D)

Torn

• Install the grommet securely.

(7) Grommet (A)

Correct

• Clamp the

electrical wiring securely. Do not

Incorrect: poor installation

(B)

damage the electrical wiring by the clamp.

(12) Electrical wiring (13) Clamp

Correct

(A)

(B) Incorrect

• Do not pinch the electrical wiring when installing parts.

(14) Electrical wiring (B) Incorrect

9. Handling fuses

• Always use fuses of the specified capacity.

• Do not use steel or copper wiring instead of fuse.

•

Do not install work light or radio without auxiliary power line.

• Do not install auxiliaries to the fuses. The fuses may blow.

(8) Clamp: clamped spirally (9) Electrical wiring (10)

Clamp

• Clamp

the electrical wiring correctly. Do not slack,

(11) Welding point

twist, and pull. In cases of connecting the electrical wiring to

• moving or vibrating locations, make sure to clamp the electrical wiring loosely.

GENERAL WORKING PRECAUTIONS

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10. Handling connectors 2. GENERAL

• If

the terminal is rusted, remove rust with

sandpaper

(1) Fuse (2) Fusible link

Slow blow fuse

(3)

10. Handling connectors

• When disconnecting the locking connectors, be to disengage the lock before disconnecting.

sure There are two kinds of locks: one requires pressing and the other requires pulling.

(A) Press

• Pull the connector body securely when

disconnecting the connectors.

•

Do not pull the wire harness to separate.

(1) Missing terminal (2) Bent terminal

Sandpaper

(3)

• Cover terminals

the female bullet terminals and male bullet

securely with the waterproof plastic

(4) Rust

covers.

• Make sure that the bullet terminals are secure and connected securely to the tip.

(B) Correct (C) Incorrect

• Cover the female connectors and male connectors securely with the waterproof plastic covers.

(B) Correct (C) Incorrect

(5) Cover (B) Correct

• Make sure the terminal condition of the connectors is not bent, rusty, and so on.

(C)

Incorrect

2. GENERAL

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KiSC issued 12, 2018 A

GENERAL WORKING PRECAUTIONS

11. Wiring color

(1) Wire color (2) Stripe

• Wire colors are specified in the color codes.

• This symbol of "/" shows color with stripe(s).

iring Colors Color code

Black B

Brown BR, Br

Green G

Gray GY, GR

Blue L

Light green LG, Lg

Orange OR, O

Pink P

Purple PU, V, Pu

Red R

Sky blue SB, Sb

White W

Yellow Y

(An example)

W/R:

Red stripe on white color

12. Dispose fluids correctly

• Do not dispose fluids on the ground, down the drain, environmental protection regulations when you dispose of oil, fuel, coolant, electrolyte, and other dangerous materials.

into a stream, pond, or lake. Obey related

+ 279 hidden pages

Kubota D1803-CR-E4, D1803-CR-TE4, D1803-CR-TIE4, V2403-CR-TE4, V2403-CR-TE4BG Workshop Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

CONTENTS

1. SAFETY

SAFETY FIRST

1. Working precautions 1. SAFETY

2. Preparing for emergencies

3. Working cautions

4. Starting the machine safely

5. Preventing fires

6. Preventing acid burns

7. Avoiding high pressure fluid

8. Avoiding hot exhaust

9. Cleaning exhaust filter

2. GENERAL

GENERAL WORKING PRECAUTIONS

2. Applying thread-locking fluid

1. Tightening bolts and nuts

3. Installing circlips

4. Handling liquid gasket

5. Replacing O-rings

6. Replacing oil seals

7. Handling the battery

8. Handling electrical wiring

9. Handling fuses

10. Handling connectors

11. Wiring color

12. Dispose fluids correctly