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
• 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.
Working precautions.................................................................................................................................1-1
2. Preparing for emergencies .......................................................................................................................1-1
3. Working cautions ...................................................................................................................................... 1-2
4. Starting the machine safely ......................................................................................................................1-3
7. Avoiding high pressure fluid......................................................................................................................1-4
8. Avoiding hot exhaust ................................................................................................................................1-4
GENERAL WORKING PRECAUTIONS ............................................................................................................2-1
1. Tightening bolts and nuts..........................................................................................................................2-1
7. Handling the battery .................................................................................................................................2-3
11. Wiring color ............................................................................................................................................. 2-6
SPECIAL TOOLS............................................................................................................................................. 2-33
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
1.4 Checking fan belt ..............................................................................................................................3-7
2. Check points of initial 50 hours................................................................................................................. 3-7
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
2.3.1 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
2.8.1 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
2.19.1 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
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
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
7.8.1 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
8.8.3 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
9.9.1 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
1.1 Troubleshooting for 03 series engine..............................................................................................4-87
2. Service specifications ............................................................................................................................. 4-91
2.1 Service specifications for engine..................................................................................................... 4-91
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
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
a
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
• 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.
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.
• 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.
• 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.
• 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.
• 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.
You must identify the engine model name and serial
number before you start a job.
When you
tell your engine model name and serial number.
Engine serial number
The engine serial number is an identified number for
the engine.
It appears after the engine model name.
It shows the month and year of manufacture as below.
change. The timing or applicable date of the specific
Nonroad
Emission
regulations depends on the engine
output classification.
Over the past several years, Kubota has been
supplying diesel engines that comply with regulations in
the respective countries affected by Nonroad Emission
regulations. For Kubota Engines, E4B will be the
designation that identifies engine models affected by
the next emission phase.
When servicing or repairing ###-E4B series engines,
use only replacement parts for that specific E4B
engine, designated by the appropriate E4B Kubota
Parts List and perform all maintenance services listed
in the appropriate Kubota Operator's Manual or in the
appropriate E4B Kubota Workshop Manual. Use of
incorrect replacement parts or replacement parts from
other emission level engines (for example: E3B
engines), may result in emission levels out of
compliance with the original E4B design and EPA or
other applicable regulations. Please refer to the
emission label located on the engine head cover to
identify Output classification and Emission Control
Information. E4B engines are identified with "EF" at the
end of the Model designation, on the US EPA label.
Please note: E4B is not marked on the engine.
Example: Engine model name D1803-CR-E4-XXXX or
D1803-CR-TE4-XXXX
1.3 Cylinder number
2. Muffler full assembly
identification
2.1 Part number and serial number
(DPF)
Diesel particulate filter (hereinafter referred to as
the "DPF") muffler full assembly serial number
You
must keep the records of the filter comp (DPF) part
number and serial number (3) and catalyst (DOC) part
number and serial number (4) before you remove the
DPF for cleaning.
(1) DPF muffler assembly part
number and serial number
(2)
DPF muf
part number and serial number
fler full assembly
(3) Filter comp (DPF) part num-
ber and serial number
(4) Catalyst (DOC) part number
and serial number
You can see the cylinder numbers of Kubota diesel
engine in
the figure. The sequence of cylinder numbers
is No.1, No.2, No.3 and No.4 and it starts from the gear
case cover side.
Checking exhaust manifold (crack,
gas, leakage and mounting screw)
Replacing oil separator rubber
hose
Replacing rubber hose of differen-
*2
tial pressure sensor
Replacing intake hose (after air
flow sensor) and intercooler hose
Replacing EGR cooler hose○3-28
Replacing water hose○3-28
Replacing lubricant hose○3-28
Changing radiator coolant (L.L.C.)○3-28
Replacing radiator hose and clamp
bands
Replacing fuel hose and clamps○3-31
Replacing intake air line○3-31
Daily
Initial
50 hrs
Every
50 hrs
Every
250
hrs
400
hrs
Every
500
hrs
Every
1000
hrs
Every
1500
hrs
Every
3000
hrs
Every
1 year
○3-27
Reference
Every
2
years
○3-27
○3-28
○3-28
○3-30
page
NOTE
• When the
battery is used for less than 100 hours in a year, check its electrolyte yearly (for refillable
battery's only).
• The items above (*1 marked) are registered as emission related critical parts by KUBOTA in the U.S. EPA
nonroad emission regulation.
As the engine owner, you are responsible for the performance of the required maintenance on the engine
according to the above instruction.
Please see the warranty statement in detail.
• The items listed above other than *1 marked are not necessary to keep the emission-related warranty
valid.
• *2: Only for D1803-E4, -TE4, V2403-E4, -TE4
• Failure to perform the maintenance will cause problems that will significantly degrade the engine
performance.
CAUTION
• When changing or inspecting, be sure to level and stop the engine.
• Change the type of engine oil according to the ambient temperature.
When using oil of different brands from the previous one, be sure to drain all the previous oil before
•
adding the new engine oil.
• On DPF-equipped engines, part of the fuel may get mixed with engine oil during the regenerating process.
This may dilute the oil and increase its quantity.
If the oil rises above the oil level gauge upper limit, it means the oil has been diluted too much, resulting
in a trouble.
In such case, immediately change the oil for new one.
• If the interval of DPF regeneration becomes 5 hours or less, be sure to change the oil for new one.
Fuel
NOTE
The minimum recommended Fuel Cetane Rating is 45.
•
A
cetane rating greater than 50 is preferred, especially for ambient temperatures below −20 ℃ (−4 ℉) or
elevations above 1500 m (4921 ft).
• Diesel fuel specification type and sulfur content% (ppm) used, must be compliant with all applicable
emission regulations for the area in which the engine is operated.
• DO NOT USE Fuels that have sulfur content greater than 0.0015% (15 ppm).
• Diesel fuels specified to EN590 (0.001% (10 ppm) sulfur maximum) or ASTM D975 (0.0015% (15 ppm)
sulfur maximum) are recommended.
• No. 2-D is a distillate fuel of lower volatility for engines in industrial and heavy mobile service (SAE J313
JUN87).
• These engines utilize Interim Tier 4 standards, the use of ultra low sulfur fuel is mandatory for these
engines, when operated in US EPA regulated areas.
Therefore, please use No. 2-D S15 diesel fuel as an alternative to No. 2-D, and use No. 1-D S15 diesel fuel
as an alternative to No. 1-D for ambient temperature below −10 ℃ (14 ℉).
– SAE: Society of Automotive Engineers
– EN: European Norm
– ASTM: American Society of Testing and Materials
– US EPA: United States Environmental Protection Agency
– No. 1-D or No. 2-D, S15: Ultra Low Sulfur Diesel (ULSD)) 15 ppm or 0.0015 wt.%
IMPORTANT
• Be sure to use a strainer when filling the fuel tank, or dirt or sand in the fuel may cause trouble.
•
Do not operate the fuel tank level too low or completely out of fuel.
You may experience improper engine operating and/or a DTC (Diagnostic Trouble Code) error code may
be recorded in the Engine Control.
Additionally, fuel system bleeding may be necessary if air enters the fuel system.
Biodiesel fuel
[When the B7 blended fuel is used]
When the finally blended Biodiesel fuel is B7, make sure it conforms to the updated EN590 (European) standard.
Be also sure that the mineral oil diesel fuel, if used, conforms to the updated EN590 (European) standard and that the
B100 blend conforms to the updated EN14214 (European) standard.
[When the B5 blended fuel is used]
When the finally blended Biodiesel fuel is B5, make sure it conforms to the updated EN590 (European) standard.
Be also sure that the mineral oil diesel fuel, if used, conforms to the updated EN5950 (European) standard or the
ASTM D975 (U.S.) standard and that the B100 blend conforms to the updated EN 14214 (European) standard or the
ASTM D6751 (U.S.) standard.
Keep the fuel tank full whenever possible to prevent water vapor from accumulating inside the fuel tank.
ighten up the fuel tank filler cap to avoid the entry of moisture.
T
2. Routinely check the oil level before the operation.
Also strictly follow the specified oil change intervals.
3. Biodiesel fuels (BDF) during the supply process or in the machine easily deteriorate due to oxygen, water, heat
and other foreign substances.
With this in mind, take the following precautions.
• Do not leave those fuels in the fuel tank or a metallic drum longer than 3 month.
• Before storing the machine for a prolonged period, change such fuel for a conventional type of diesel fuel and
operate the machine for 30 minutes or longer to clean up the fuel system.
4. Bear it in mind that Biodiesel fuels have the characteristics below.
Referring to the servicing intervals specified in the Kubota products' Operator's Manuals, be sure to maintain and
clean up the fuel system, replace the fuel hose with new ones and take other necessary measures.
It is advisable to replace the fuel filter, fuel hose and clamp bands with new ones after half the specified
replacement intervals (Compared with the use of mineral oil diesel fuels, the filtration performance of fuel filters
gets degraded earlier than expected.).
• Biodiesel fuels easily induce the growth of microorganisms and foul themselves.
This may get the fuel system corroded and the fuel filter clogged.
• In cold weather, some problems may occur: the clog of the fuel line or fuel system, starting failure, and other
unforeseen troubles.
• Biodiesel fuels easily soak up moisture, which means that they may contain higher moisture content than
conventional diesel fuels.
5. Palm oil-based Biodiesel fuels are inferior in low-temperature fluidity to soy-based and rapeseed-based Biodiesel
fuels.
In cold season in particular, this may clog the fuel filter.
6. If Biodiesel fuels are spilt on a coated surface, the coating may get damaged.
Immediately wipe the spill off the surface.
diesel
engines, part of the fuel may get mixed with
engine oil during the regenerating process.
This may dilute the oil and increase its quantity.
If the oil rises above the dipstick upper limit, it
means the oil has been diluted too much,
resulting in a trouble.
In such case, immediately change the oil for
new one.
• When you use an oil of different brand or
viscosity from the previous, drain the remaining
oil.
Do not mix 2 different types of oil.
NOTE
• When you
that you put it in a level position.
If not, you cannot measure oil quantity
accurately.
• Make sure that you keep the oil level between
the upper and lower lines of the dipstick.
Too much oil can decrease the output or cause
too much blow-by gas.
On the closed breather type engine, the port
absorbs the mist and too much oil can cause oil
hammer.
But if the oil level is not sufficient, the moving
parts of engine can get a seizure.
• When Biodiesel
replace the fuel filter with a new one after half
the specified replacement intervals. (Compared
with the use of mineral oil diesel fuels, the
filtration performance of fuel filters gets
degraded earlier than expected.)
• Be sure to use a strainer when filling the fuel
tank, or dirt or sand in the fuel may cause
trouble.
• Do not operate the fuel tank level too low or
completely out of fuel.
You may experience improper engine operating
and/or a DTC (Diagnostic Trouble Code) error
code may be recorded in the Engine Control.
Additionally, fuel system bleeding may be
necessary if air enters the fuel system.
1. Make the engine level.
2. Make sure that the fuel level is above the lower limit
of the fuel level gauge.
NOTE
• If the
fuel level is too low, add fuel to the
upper limit.
fuel is used, it is advisable to
CHECK AND MAINTENANCE
1.Daily check points
(1) Radiator cap
2. Make sure that the coolant level is immediately
below the port.
NOTE
• This case is without reserve tank.
Make sure that the coolant level is between [FULL]
3.
(A) and [LOW] (B).
NOTE
• This case is with reserve tank (2).
1.3 Checking coolant level
CAUTION
• Do not
is hot.
Then loosen the cap slightly to release
unwanted pressure before you remove the cap
fully.
IMPORTANT
• When you
the engine coolant channels.
The engine releases the air when it shakes the
radiator upper and lower hoses.
• Make sure that you close the radiator cap
correctly.
If the cap is loose or incorrectly closed, coolant
can flow out and the engine can overheat.
• Do not use an anti-freeze and scale inhibitor at
the same time.
• Do not mix the different type or brand of L.L.C.
• When you add anti-freeze for the first time,
flush the water jacket and radiator interior
with clean, soft water several times.
• The brand of the anti-freeze and the ambient
temperature have an effect on the procedure
to mix water and anti-freeze.
Refer to the SAE J1034 standard, especially
to the SAE J814c.
• Mix the anti-freeze with clean, soft water,
and then fill into the radiator.
IMPORTANT
• Make sure that when you mix the anti-freeze
and water, the ratio of anti-freeze is less than
50%.
Anti-
freeze
volume
40%-24-11106223
50%-37-35108226
*At 1.01 × 100000 Pa (760 mmHg) pressure (atmospheric). Use
a radiator pressure cap that lets the pressure collect in the
cooling system to get a higher boiling point.
Freezing pointBoiling point
℃℉℃℉
*
6.5 Replacing fan belt
1. Remove the alternator (1).
2. Remove the fan belt (2).
NOTE
• The above
data is the industrial standards
that shows the minimum glycol content
necessary in the concentrated anti-freeze.
• When the coolant level decreases because
of evaporation, add clean, soft water only to
keep the anti-freeze mixing ratio less than
50%.
If there is a leakage, add anti-freeze and
clean, soft water in the specified mixing
ratio.
• The anti-freeze absorbs moisture. Keep new
anti-freeze in a tightly sealed container.
• Do not use the radiator cleaning agents after
you add anti-freeze to the coolant.
Anti-freeze contains an anti-corrosive agent,
which reacts with the radiator cleaning
agent to make sludge and cause damages to
the engine parts.
1. Check the
side of the turbine housing (1) for exhaust gas
leakage.
NOTE
• If you
nuts again or replace the gasket (2), (4), (6) with
a new one.
exhaust port (3) and the inlet port (5)
find a gas leakage, tighten the bolts and
NOTE
• If you
tighten the clamp or replace the hoses.
Radial clearance
1. Check the radial clearance between wheel and
housing.
NOTE
• If the wheel touches the housing, replace
the turbocharger assembly with a new one.
find loose connections or cracks,
(1) Turbine housing
(2) Gasket
(3)
Exhaust port
Compressor side
1. Check the
for air leakage.
NOTE
• If you
and / or the inlet hoses.
(7) Compressor cover
2. Replace
of the intake hose for loose connections or crack.
inlet hose of the compressor cover (7)
find an air leakage, change the clamp
the
inlet hose and check the suction side
(4) Gasket
(5) Inlet port
(6) Gasket
9.2 Cleaning DPF
IMPORTANT
• Since the
shock cannot be reused even if there is no
damage outwardly, replace it with a new one.
• Be sure to loosen the exhaust gas temperature
sensor tightening nut or the differential
pressure pipe tightening nut with crowfoot
wrench to prevent the damage of the sensor or
pipe.
If it is still hard to loosen, apply the lubricant
spray to threaded portion and soak it with
lubricant.
NOTE
• Always work
electric lift (including mobile lift).
• Put a product (engine) on a stable ground, and
set the parking brake.
• As the DPF muffler full assembly is hot just
after the engine shutdown, make sure to start
operation after it gets cool.
• Make sure not to let any foreign substances
enter the opening section during the operation.
• Make sure not to damage the DPF muffler full
assembly by falling or impact as it contains a
ceramic filter.
• Before removing the DPF muffler full assembly
from a product (engine), connect the diagnosis
tool (Diagmaster), check the failure history, and
save the project.
• Before
removing
the DPF for cleaning, keep the
records of the engine serial number, filter comp
(DPF) part number, filter comp (DPF) serial
number, catalyst (DOC) part number, catalyst
(DOC) serial number, and engine operating time,
which are required in preparing the DPF
cleaning order form.
• Since the engine operating time is recorded in
the engine ECU, check the operating time by
connecting the service tool (Diagmaster).
• When installing and removing the muffler full
assembly (DPF), make sure that the temperature
sensor, differential pressure sensor, and
differential pressure pipe do not make contact
with surrounding parts.
(13) Muffler full assembly (DPF)
mounting screw
(14) Muffler full assembly (DPF)
10. Loosen the Filter comp (DPF) bracket (15), (17) and
remove the Filter comp (DPF) (16).
Tools required
• Crowfoot wrench
1. Disconnect the harness of exhaust gas temperature
sensor from the connector (7), (8), (9) and the
harness of differential pressure sensor (10).
2. Remove the connector of exhaust gas temperature
sensor (7), (8), (9) from the bracket.
3. Remove the clamp (5).
4. Remove the tube (11), (12) from the differential
pressure pipe (1), (4).
• If the differential pressure tube is damaged
or cracked, replace it.
• When the differential pressure pipe (7), (12)
and exhaust gas temperature sensor (22),
(23), (24) is removed, wipe off the anti-seize
& lubricating compound, apply a anti-seize &
lubricating compound (Bostik, NEVER SEEZ,
Pure Nickel Special Grade), and then attach
them to their correct position.
• When replacing the differential pressure
pipe (7), (12) apply a anti-seize & lubricating
compound (Bostik, NEVER SEEZ, Pure
Nickel Special Grade), and then attach it to
its correct position.
• When replacing the exhaust gas temperature
sensor (22), (23), (24), check that it is coated
with anti-seize & lubricating compound, and
then attach it to its correct position.
• Tighten bolts and nuts to their specified
torque.
Also tighten the exhaust gas temperature
sensor tightening nut or the differential
pressure pipe tightening nut to the specified
torque with crowfoot wrench.
• After attaching the assembly, start the
engine and make sure that there are no gas
leaks.
• Reassemble the filter comp (DPF) (16) in the
correct direction.
there is no crack or loss of the
sealing part of the cell holes on both ends of the
filter (inlet side and outlet side).
NOTE
• If the
number of missing sealing parts more
than the service limit, the filter comp cannot
be reused even after cleaning.
Number for judgment of non-reusability of filter
Service limit
Number of missing sealing parts: 10 or more
3. Check whether there is no crack and loss of the
ceramics element.
NOTE
• If there
are any cracks or losses of the
ceramics element, the filter comp (DPF)
cannot be reused even if it is cleaned.
• If it is judged that the filter comp (DPF) is not
reusable, report the result of the evaluation
to the customer that requested the filter
cleaning, and replace the filter comp (DPF)
with a new one.
9.4 Judging reuse of DPF filter comp
after cleaning (Cleaning contractor)
ModelMeasurement total
D1803, V240316 blocks
(a) Serial number
NOTE
• If the
actual cell depth (D) is less than the
service limit, the DPF filter complete cannot
be reused.
• If the DPF filter complete is judged as nonreusable, report the result of the judgment to
the customer that requested the filter
cleaning via the service dealer, and replace
the DPF filter complete with a new one.
• Actual cell depth (D) = Cell depth (F) −
Accumulated ash depth (E)
Less than
85 mm
3.3 in.
Less than
102 mm
4.02 in.
Less than
119 mm
4.68 in.
Actual cell
depth (D)
(Average of
all measurement blocks)
Service limit
D1803-CR-E4
D1803-CRTE4
V2403-CR-E4
V2403-CRTE4
V2403-CRTE4BG
IMPORTANT
• After the
cleaning contractor has cleaned the
filter comp (DPF) (2), measure the quantity of
remaining ash in the following procedure, and
evaluate the reusability.
1. After having cleaned the filter comp (DPF) (2),
measure the actual cell depth (D) with a pin gauge
(1) in the each block shown in the figure.
NOTE
• One cell (The measurement point is not
specified) is measured in each block.
• Select a metal pin gauge (1) having a wire
size slightly thinner than the cell width.
Diameter
Pin gauge (1)
Length
0.60 to 0.80 mm
0.024 to 0.031 in.
150 mm
5.91 in.
• When the pin gauge (1) is inserted into the
hole, insert it by lightly tapping on the
cell
gauge end with a finger tip.
• If the pin gauge (1) is forcibly pushed in, the
pin pierces through the accumulated ash (C)
and it cannot be measured accurately.
So be careful not to push the pin forcibly.
9.5 Checking EGR system (with
Diagmaster)
(1) Active Test button
(2) Exhaust Gas Recirculation
(EGR) V
tion item
4. Select
alve ON/OFF Func-
the "#EGR Valve ON/OFF Function" (7) from
(3) Proceed button
the "select signal group" (8).
Select the "number of graph" (6).
5.
6. Click the [Start Active Test] button (4), then click
the [OK] button (5).
• If the actual position is not traced target
position, the EGR valve is abnormal so that
check it.
(9) Send Specified Active Test
Value button
Click the [Finish Active T
8.
button (10).
est]
NOTE
• If it
is determined that there is a failure,
check that the EGR valve gas passage and
coolant passage are not clogged.
• If it is determined that there is a failure,
clean any soot from the gas passage so that
it does not damage the EGR valve.
used
2. Remove
air cleaner primary element (3) and
secondary element (2).
(1) Air cleaner housing
(2) Secondary element
Primary element
(3)
3. Replace
new
air cleaner primary element (3) and
(4) Dust cup
(5) Evacuator valve
secondary element (2).
NOTE
• The air cleaner uses a dry element.
Never apply oil to it.
•
Do not operate the engine with filter element
removed.
4. Install the removed parts.
10.2 Checking DPF differential
pressure pipes and hoses
IMPORTANT
• Be sure
tightening nut with crowfoot wrench to prevent
the damage of the sensor or pipe.
If it is still hard to loosen, apply the lubricant
spray to threaded portion and soak it with
lubricant.
• Tighten bolts and nuts to their specified torque.
Also tighten the differential pressure pipe
tightening nut to the specified torque with
crowfoot wrench.
to loosen the differential pressure pipe
Tools required
• Crowfoot wrench
1. Check the DPF differential pressure pipe (2), (3) for
crack, gas leakage and loose mounting nut.
(10) Finish Active Test button
NOTE
• If you
differential pressure pipe.
10. Check points of every 1 year
• If you find a gas leakage, remove the DPF
differential pressure pipe and wipe off the
the anti-seize and lubricating compound
then tighten the DPF differential pressure
pipe to the specified torque.
NOTE
• When you
change the DPF differential
pressure pipe, apply the anti-seize and
lubricating compound (Bostik, NEVERSEEZ, Pure nickel special grade) to the DPF
differential pressure pipe.
3. Check the DPF differential pressure hose (1) for
crack, gas leakage.
NOTE
• If you find a crack or gas leakage, change
the DPF differential pressure hose.
(1) EGR pipe(2) EGR cooler
10.4 Checking intake air line
IMPORTANT
• To
prevent serious damage to the engine, keep
out dust in the intake air line.
1. Make sure that the intake air hose(s) (1) are
connected correctly or not.
2. Visually check for cracks gas leak and anything else
unusual.
3. If the clamp (2) is loose, apply oil to the threads and
tighten it again correctly.
(1) DPF differential pressure
hose
(2) DPF dif
ferential pressure
pipe
(3) DPF differential pressure
pipe
10.3 Checking EGR piping
1. Check the EGR cooler (2) and the EGR pipe (1) for
crack, gas leakage and loose mounting screw
NOTE
• If you
find a crack, replace the EGR cooler
(2) or EGR pipe (1) which has cracked.
• If you find a gas leakage, tighten the
mounting screw again or replace the gasket
with a new one.
• If you find a loose mounting screw, tighten
the mounting screw again.
.
NOTE
• You
must replace the intake air hose(s)
every 2 years.
Also replace the clamp (2) every 2 years and
tighten it correctly.
• When you add anti-freeze for the first time,
flush the water jacket and radiator interior
with clean, soft water several times.
• The brand of the anti-freeze and the ambient
temperature have an effect on the procedure
to mix water and anti-freeze.
Refer to the SAE J1034 standard, especially
to the SAE J814c.
• Mix the anti-freeze with clean, soft water,
and then fill into the radiator.
IMPORTANT
• Make sure that when you mix the anti-freeze
and water, the ratio of anti-freeze is less than
50%.
Anti-
freeze
volume
40%-24-11106223
50%-37-35108226
*At 1.01 × 100000 Pa (760 mmHg) pressure (atmospheric). Use
a radiator pressure cap that lets the pressure collect in the
cooling system to get a higher boiling point.
Freezing pointBoiling point
℃℉℃℉
*
11.9 Replacing radiator hose and
clamp bands
CAUTION
• Do not
is hot.
Then loosen the cap slightly to release
unwanted pressure before you remove the cap
fully.
1. Drain the coolant.
2. Loosen the clamp bands.
Remove the upper hose (1) and lower hose (2).
3.
remove the radiator cap when the engine
NOTE
• The above
data is the industrial standards
that shows the minimum glycol content
necessary in the concentrated anti-freeze.
• When the coolant level decreases because
of evaporation, add clean, soft water only to
keep the anti-freeze mixing ratio less than
50%.
If there is a leakage, add anti-freeze and
clean, soft water in the specified mixing
ratio.
• The anti-freeze absorbs moisture. Keep new
anti-freeze in a tightly sealed container.
• Do not use the radiator cleaning agents after
you add anti-freeze to the coolant.
Anti-freeze contains an anti-corrosive agent,
which reacts with the radiator cleaning
agent to make sludge and cause damages to
the engine parts.