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

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Page 1

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

Page 2

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

Page 3

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)

Page 4

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

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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

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

Page 6

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

Page 7

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

Page 8

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

Page 9

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

Page 10

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

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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

Page 12

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

Page 13

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

Page 14

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

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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

Page 15

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

Page 16

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

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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

Page 17

1. SAFETY

KiSC issued 12, 2018 A

Page 18

SAFETY FIRST

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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.

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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

Page 20

SAFETY FIRST

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1-3

KiSC issued 12, 2018 A

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.

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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

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KiSC issued 12, 2018 A

• 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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1. SAFETY

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KiSC issued 12, 2018 A

SAFETY FIRST

Page 24

2. GENERAL

KiSC issued 12, 2018 A

Page 25

GENERAL WORKING PRECAUTIONS

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KiSC issued 12, 2018 A

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

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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

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GENERAL WORKING PRECAUTIONS

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KiSC issued 12, 2018 A

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.

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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.

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GENERAL WORKING PRECAUTIONS

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KiSC issued 12, 2018 A

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

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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

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KiSC issued 12, 2018 A

1. Engine identification 2. GENERAL

GENERAL MACHINE INFORMATION

1. Engine identification

1.1 Engine model name and engine serial number

(1) Engine model name and se-

rial number

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.

Engine series

get in touch with the manufacturer, always

Number or alphabet Series

1 05 (include: WG)

2 V3 (include: WG)

3 08

4 SM (include: WG)

5 Air cooled gasoline

6 GZ, OC, AC, EA, E

7 03 (include: WG)

8 07

A EA, RK

B 03 (KET production)

C V3, 07 (KEW production)

Production year

Alphabet or number Year

1 2001

2 2002

3 2003

4 2004

5 2005

6 2006

7 2007

8 2008

9 2009

A 2010

B 2011

C 2012

D 2013

E 2014

F 2015

G 2016

H 2017

J 2018

K 2019

L 2020

M 2021

N 2022

P 2023

R 2024

S 2025

T 2026

V 2027

* Alphabetical letters "I" and "O" are not used.

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2. GENERAL

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KiSC issued 12, 2018 A

GENERAL MACHINE INFORMATION

1. Engine identification

Production month and lot number

Month Engine lot number

January A0001～A9999 B0001～

February C0001～C9999 D0001～

March E0001～E9999 F0001～

April G0001～G9999 H0001～

May J0001～J9999 K0001～

June L0001～L9999 M0001～

July N0001～N9999 P0001～

August Q0001～Q9999 R0001～

September S0001～S9999 T0001～

October U0001～U9999 V0001～

November W0001～W9999 X0001～

December Y0001～Y9999 Z0001～

* Alphabetical letters "I" and "O" are not used.

Example of model name and engine serial number

1.2 E4B engine

(a) D1803: Engine model name (b) 7: Engine series (03 series)

C: Production year (2012)

ber)

(e) 1237: Lot number (0001～

9999 or A001～Z999)

(1) EU regulation engine output

classification category

Category (1)

K From 19 to 37 kW STAGE IIIB

Category (2)

Engine output

classification

From 37 to less than 56 kW

From 56 to less than 75 kW

From 75 to less than 130 kW

Engine output

classification

Less than 19 kW Tier 4

From 19 to less than 56 kW

From 56 to less than 75 kW

From 75 to less than 130 kW

(2) "E4B" engines are identified

with "EF" at the end of the Model designation, on the US EPA label. "E4B" designates some In-

ier 4 / Tier 4 models,

terim T depending on engine output classification.

EU regulation

STAGE IIIB

EPA regulation

Interim Tier 4

The emission controls previously implemented in various

countries

to prevent air pollution will be stepped

up as Nonroad Emission Standards continue to

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GENERAL MACHINE INFORMATION

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KiSC issued 12, 2018 A

1. Engine identification 2. GENERAL

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.

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GENERAL MACHINE INFORMATION

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KiSC issued 12, 2018 A

2. GENERAL

3. Specifications

3.1 Specification for D1803-CR-E4, TE4

Model D1803-CR-E4 D1803-CR-TE4

Number of cylinder 3

Engine type Vertical, water-cooled, 4-cycle diesel

Bore × Stroke 87 × 102.4 mm (3.43 × 4.031 in.)

Total displacement 1826 cm3 (11

SAE gross continuous

SAE gross intermittent

Maximum bare speed 2900 min-1 (rpm)

Minimum bare idling speed

Combustion chamber Reentrant type (Direct injection)

Fuel supply pump

Governor system

Injector

Fuel supply timing

Fuel injection pressure

Direction of rotation Counter-clockwise (Viewed from flywheel side)

Firing order 1-2-3

Compression ratio 18.1

Lubricating system Forced lubrication by trochoid pump

Oil pressure indicating Electrical type switch

Lubricating filter Full flow paper filter (Cartridge type)

Cooling system Pressurized radiator, forced circulation with water pump

Starting system Electric starting with starter

Starter motor 12 V, 1.4 kW

Starting support device By glow plug in combustion chamber

EGR External EGR (EGR cooler + Electric EGR valve + Reed valve)

Battery 12 V, 88 AH (105E41R) equivalent

Charging alternator 12 V, 480 W

Fuel Diesel fuel No. 2-D S15, see page 3-1.

Lubricating oil (API classification)

Lubricating oil capacity 7.0 L (1.8 U.S.gals, 1.5 Imp.gals)

Weight (Dry) 185 kg (408 lbs) 196 kg (432 lbs)

24.3 kW / 2700 min-1 (rpm)

(32.6 HP / 2700 min-1 (rpm))

28.0 kW / 2700 min-1 (rpm)

(37.5 HP / 2700 min-1 (rpm))

800 min-1 (rpm)

BOSCH common rail system

Class CJ-4 lubricating oil as per API classification is recommended.

For details on recommended lubricating oils, see page 3-1.

1.4 cu.in.)

32.1 kW / 2700 min-1 (rpm)

(43.0 HP / 2700 min-1 (rpm))

37.0 kW / 2700 min-1 (rpm)

(49.6 HP / 2700 min-1 (rpm))

3. Specifications

NOTE

• The specification described above is of the standard engine of each model. Conversion formula: HP = 0.746 kW, PS = 0.7355 kW.

•

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KiSC issued 12, 2018 A

3. Specifications 2. GENERAL

3.2 Specification for V2403-CR-E4, TE4

Model V2403-CR-E4 V2403-CR-TE4

Number of cylinder 4

Engine type Vertical, water-cooled, 4-cycle diesel

Bore × Stroke 87 × 102.4 mm (3.43 × 4.031 in.)

Total displacement 2434 cm3 (148.5 cu.in.)

SAE gross continuous

SAE gross intermittent

Maximum bare speed 2900 min-1 (rpm)

Minimum bare idling speed

Combustion chamber Reentrant type (Direct injection)

Fuel supply pump

Governor system

Injector

Fuel supply timing

Fuel injection pressure

Direction of rotation Counter-clockwise (V

Firing order 1-3-4-2

Compression ratio 18.1

Lubricating system Forced lubrication by trochoid pump

Oil pressure indicating Electrical type switch

Lubricating filter Full flow paper filter (Cartridge type)

Cooling system Pressurized radiator, forced circulation with water pump

Starting system Electric starting with starter

Starter motor 12 V, 2.0 kW

Starting support device By glow plug in combustion chamber

EGR External EGR (EGR cooler + Electric EGR valve + Reed valve)

Battery 12 V, 92 AH (130E41R) equivalent

Charging alternator 12 V, 480 W

Fuel Diesel fuel No. 2-D S15, see page 3-1.

Lubricating oil (API classification)

Lubricating oil capacity 9.5 L (2.5 U.S.gals, 2.1 Imp.gals)

Weight (Dry) 221 kg (487 lbs) 233 kg (514 lbs)

32.4 kW / 2700 min-1 (rpm)

(43.4 HP / 2700 min-1 (rpm))

37.4 kW / 2700 min-1 (rpm)

(50.2 HP / 2700 min-1 (rpm))

800 min-1 (rpm)

BOSCH common rail system

iewed from flywheel side)

Class CJ-4 lubricating oil as per API classification is recommended.

For details on recommended lubricating oils, see page 3-1.

42.1 kW / 2700 min-1 (rpm)

(56.5 HP / 2700 min-1 (rpm))

48.6 kW / 2700 min-1 (rpm)

(65.2 HP / 2700 min-1 (rpm))

NOTE

• The specification described above is of the standard engine of each model. Conversion formula: HP = 0.746 kW, PS = 0.7355 kW.

•

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GENERAL MACHINE INFORMATION

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KiSC issued 12, 2018 A

2. GENERAL

3. Specifications

3.3 Specification for D1803-CR-TIE4, V2403-CR-TIE4

Model D1803-CR-TIE4 (DOC only) V2403-CR-TIE4 (DOC only)

Number of cylinder 3 4

Engine type Vertical, water-cooled, 4-cycle diesel

Bore × Stroke 87 × 102.4 mm (3.43 × 4.031 in.)

Total displacement 1826 cm3 (11

SAE gross continuous

SAE gross intermittent

Maximum bare speed 2900 min-1 (rpm)

Minimum bare idling speed

Combustion chamber Reentrant type (Direct injection)

Fuel supply pump

Governor system

Injector

Fuel supply timing

Fuel injection pressure

Direction of rotation Counter-clockwise (Viewed from flywheel side)

Firing order 1-2-3 1-3-4-2

Compression ratio 16.0

Lubricating system Forced lubrication by trochoid pump

Oil pressure indicating Electrical type switch

Lubricating filter Full flow paper filter (Cartridge type)

Cooling system Pressurized radiator, forced circulation with water pump

Starting system Electric starting with starter

Starter motor 12 V, 1.4 kW 12 V, 2.0 kW

Starting support device By glow plug in combustion chamber

EGR External EGR (EGR cooler + Electric EGR valve + Reed valve)

Battery 12 V, 88 AH (105E41R) equivalent 12 V, 92 AH (130E41R) equivalent

Charging alternator 12 V, 480 W

Fuel Diesel fuel No. 2-D S15, see page 3-1.

Lubricating oil (API classification)

Lubricating oil capacity 7.0 L (1.8 U.S.gals, 1.5 Imp.gals) 9.5 L (2.5 U.S.gals, 2.1 Imp.gals)

Weight (Dry) 195 kg (430 lbs) 232 kg (511 lbs)

32.1 kW / 2700 min-1 (rpm)

(43.0 HP / 2700 min-1 (rpm))

37.0 kW / 2700 min-1 (rpm)

(49.6 HP / 2700 min-1 (rpm))

1.4 cu.in.) 2434 cm3 (148.5 cu.in.)

42.1 kW / 2700 min-1 (rpm)

(56.5 HP / 2700 min-1 (rpm))

48.6 kW / 2700 min-1 (rpm)

(65.2 HP / 2700 min-1 (rpm))

800 min-1 (rpm)

BOSCH common rail system

Class CJ-4 lubricating oil as per API classification is recommended.

For details on recommended lubricating oils, see page 3-1.

NOTE

• The specification described above is of the standard engine of each model. Conversion formula: HP = 0.746 kW, PS = 0.7355 kW.

•

Page 37

GENERAL MACHINE INFORMATION

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

2-13

KiSC issued 12, 2018 A

3. Specifications 2. GENERAL

3.4 Specification for V2403-CR-TE4BG

Model V2403-CR-TE4BG

Number of cylinder 4

Engine type Vertical, water-cooled, 4-cycle diesel

Bore × Stroke 87 × 102.4 mm (3.43 × 4.031 in.)

Total displacement 2434 cm3 (148.5 cu.in.)

SAE gross continuous

SAE gross intermittent

Maximum bare speed 2000 min-1 (rpm)

Minimum bare idling speed 2000 min-1 (rpm)

Combustion chamber Reentrant type (Direct injection)

Fuel supply pump

Governor system

Injector

Fuel supply timing

Fuel injection pressure

Direction of rotation Counter-clockwise (Viewed from flywheel side)

Firing order 1-3-4-2

Compression ratio 18.1

Lubricating system Forced lubrication by trochoid pump

Oil pressure indicating Electrical type switch

Lubricating filter Full flow paper filter (Cartridge type)

Cooling system Pressurized radiator, forced circulation with water pump

Starting system Electric starting with starter

Starter motor 12 V, 2.0 kW

Starting support device By glow plug in combustion chamber

EGR External EGR (EGR cooler + Electric EGR valve + Reed valve)

Battery 12 V, 92 AH (130E41R) equivalent

Charging alternator 12 V, 720 W

Fuel Diesel fuel No. 2-D S15, see page 3-1.

Lubricating oil (API classification)

Lubricating oil capacity 9.5 L (2.5 U.S.gals, 2.1 Imp.gals)

Weight (Dry) 230 kg (507 lbs)

Class CJ-4 lubricating oil as per API classification is recommended.

For details on recommended lubricating oils, see page 3-1

31.7 kW / 1800 min-1 (rpm)

(42.6 HP / 1800 min-1 (rpm))

36.5 kW / 1800 min-1 (rpm)

(48.9 HP / 1800 min-1 (rpm))

BOSCH common rail system

NOTE

• The specification described above is of the standard engine of each model. Conversion formula: HP = 0.746 kW, PS = 0.7355 kW.

•

Page 38

2. GENERAL

2-14

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. Performance curves

4.1 Performance curve for D1803-CR-E4

D1803-CR-E4

GENERAL MACHINE INFORMATION

4. Performance curves

(1) Torque (2) Brake specific fuel consump-

tion (B.S.F

.C.)

(3) Engine speed (4) Brake horsepower (5) Gross intermittent torque

(6) Gross intermittent brake

horsepower

(7) Gross intermittent B.S.F.C.

Page 39

GENERAL MACHINE INFORMATION

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

2-15

KiSC issued 12, 2018 A

4. Performance curves 2. GENERAL

4.2 Performance curve for D1803-CR-TE4

D1803-CR-TE4

(1) Torque (2) Brake specific fuel consump-

tion (B.S.F

.C.)

(3) Engine speed (4) Brake horsepower (5) Gross intermittent torque

(6) Gross intermittent brake

horsepower

(7) Gross intermittent B.S.F.C.

Page 40

2. GENERAL

2-16

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

4.3 Performance curve for D1803-CR-TIE4

D1803-CR-TIE4

GENERAL MACHINE INFORMATION

4. Performance curves

(1) Torque (2) Brake specific fuel consump-

tion (B.S.F

.C.)

(3) Engine speed (4) Brake horsepower (5) Gross intermittent torque

(6) Gross intermittent brake

horsepower

(7) Gross intermittent B.S.F.C.

Page 41

GENERAL MACHINE INFORMATION

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

2-17

KiSC issued 12, 2018 A

4. Performance curves 2. GENERAL

4.4 Performance curve for V2403-CR-E4

V2403-CR-E4

(1) Torque (2) Brake specific fuel consump-

tion (B.S.F

.C.)

(3) Engine speed (4) Brake horsepower (5) Gross intermittent torque

(6) Gross intermittent brake

horsepower

(7) Gross intermittent B.S.F.C.

Page 42

2. GENERAL

2-18

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

4.5 Performance curve for V2403-CR-TE4

V2403-CR-TE4

GENERAL MACHINE INFORMATION

4. Performance curves

(1) Torque (2) Brake specific fuel consump-

tion (B.S.F

.C.)

(3) Engine speed (4) Brake horsepower (5) Gross intermittent torque

(6) Gross intermittent brake

horsepower

(7) Gross intermittent B.S.F.C.

Page 43

GENERAL MACHINE INFORMATION

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

2-19

KiSC issued 12, 2018 A

4. Performance curves 2. GENERAL

4.6 Performance curve for V2403-CR-TIE4

V2403-CR-TIE4

(1) Torque (2) Brake specific fuel consump-

tion (B.S.F

.C.)

(3) Engine speed (4) Brake horsepower (5) Gross intermittent torque

(6) Gross intermittent brake

horsepower

(7) Gross intermittent B.S.F.C.

Page 44

2. GENERAL

2-20

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

5. Dimensions

5.1 Dimensions

GENERAL MACHINE INFORMATION

5. Dimensions

D1803-CR-E4 D1803-CR-TE4 D1803-CR-TIE4

A 744 mm (29.3 in.) 744 mm (29.3 in.) 758 mm (29.8 in.)

B 507 mm (20.0 in.) 513 mm (20.2 in.) 513 mm (20.2 in.)

C 721 mm (28.4 in.) 735 mm (28.9 in.) 744 mm (29.3 in.)

V2403-CR-E4

A 869 mm (34.2 in.) 869 mm (34.2 in.) 854 mm (33.6 in.)

B 517 mm (20.4 in.) 517 mm (20.4 in.) 517 mm (20.4 in.)

C 721 mm (28.4 in.) 735 mm (28.9 in.) 744 mm (29.3 in.)

V2403-CR-TE4

V2403-CR-TE4BG

V2403-CR-TIE4

Page 45

GENERAL MACHINE INFORMA

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

2-21

KiSC issued 12, 2018 A

TION

6. Wiring diagram 2. GENERAL

6. Wiring diagram

6.1 Engine intermediate harness (Engine side harness)

(1) － CAN and EGR

(2) CN202 Coolant temperature sensor

(3) CN204 Crankshaft position sensor

(4) CN205 Camshaft position sensor

(5) CN206 Rail pressure sensor

(6) CN207 Oil pressure switch

(7) CN208 Boost pressure sensor

(8) CN209 Suction control valve (SCV)

(9) CN210 Intake throttle valve

(10) － Shield cable

NOTE

• The figure shows the pin arrangement of the connector housing viewed from wire side, not mating side.

Page 46

2. GENERAL

2-22

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

GENERAL MACHINE INFORMA

6. Wiring diagram

TION

(11) － CAN and EGR

(12) CN223 EGR valve

(13) CN224 / CN225 CAN tool

(14) CN226 Resistance connector (120 Ω)

(15) － Shield cable

NOTE

• The figure shows the pin arrangement of the connector housing viewed from wire side, not mating side.

Page 47

GENERAL MACHINE INFORMA

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

2-23

KiSC issued 12, 2018 A

TION

6. Wiring diagram 2. GENERAL

6.2 Injector intermediate harness (Engine side harness)

(1) CN305 Pin plated terminal

(2) － Shield cable

(3) CN301 Injector 1

(4) CN302 Injector 4

(5) CN303 Injector 3

(6) CN304 Injector 2

* Injector 4 is equipped only V2403 model.

NOTE

• The figure shows the pin arrangement of the connector housing viewed from wire side, not mating side.

Page 48

GENERAL MACHINE INFORMATION

2-24

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. GENERAL

6.3 Engine ECU intermediate harness (OEM side harness)

6. Wiring diagram

(1) CN501 Engine ECU (1)

(2) CN502 Engine ECU (2)

(3) CN503 Engine ECU joint connector 1

(4) － Power unit

(5) －

(6) － Engine

(7) － Injector

Diesel Particulate Filter (Hereinafter referred to as the "DPF")

Page 49

GENERAL MACHINE INFORMATION

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

2-25

KiSC issued 12, 2018 A

6. Wiring diagram 2. GENERAL

NOTE

• The figure shows the pin arrangement of the connector housing viewed from wire side, not mating side.

(8) － Power unit

(9) CN401 Accel sensor

(10) CN408 Alternator

(11) CN402 Starter relay

(12) CN403 Starter

(13) CN404 Connector

(14) CN405 Connector

(15) CN413 Main relay

(16) － Glow

(17) CN416 Glow relay

(18) CN414 Connector

(19) CN415 Connector

(20) － Fuel feed pump

(21) － Battery unit

(22) － Battery

(23) － Key switch

(24) － Speed sensor

(25) － CAN for vehicle

(Continued)

Page 50

GENERAL MACHINE INFORMA

2-26

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. GENERAL

(26) CN407 CAN connector cap

(27) － Shield cable

6. Wiring diagram

NOTE

• The figure shows the pin arrangement of the connector housing viewed from wire side, not mating side.

TION

(28) － Diesel particulate filter (DPF)

(29) CN101 Exhaust gas temperature sensor (T2)

(30) CN102 Exhaust gas temperature sensor (T1)

(31) CN103 Exhaust gas temperature sensor (T0)

(32) CN104 Differential pressure sensor (ΔP)

(33) CN105 Air flow sensor

NOTE

• The figure shows the pin arrangement of the connector housing viewed from wire side, not mating side.

Page 51

GENERAL MACHINE INFORMATION

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

2-27

KiSC issued 12, 2018 A

6. Wiring diagram 2. GENERAL

(34) － Engine

(35) － Shield cable

NOTE

• The figure shows the pin arrangement of the connector housing viewed from wire side, not mating side.

Page 52

2. GENERAL

2-28

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

GENERAL MACHINE INFORMA

6. Wiring diagram

TION

(36) － Injector

(37) － Shield cable

NOTE

• The figure shows the pin arrangement of the connector housing viewed from wire side, not mating side.

Page 53

GENERAL MACHINE INFORMATION

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

2-29

KiSC issued 12, 2018 A

6. Wiring diagram 2. GENERAL

6.4 System wiring diagram for D1803-CR-E4, D1803-CR-TE4, V2403-CR-E4, V2403-CR-TE4, V2403-CR-TE4BG

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

(1) Main relay (13) Injector 1 (25) Rail pressure sensor

(2) Fuel feed pump (14) Injector 4

(3) CAN1 connector (for service) (15) Injector 3 (27) Stop switch

(4) CAN2 connector (for vehicle) (16) Injector 2 (28) Parked regeneration switch

(5) EGR valve (17) Crankshaft position sensor (29) Parking switch

(6) Starter (18) Camshaft position sensor (30) Regeneration inhibit switch

(26) Boost pressure sensor

(Continued)

Page 54

GENERAL MACHINE INFORMA

2-30

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. GENERAL

(7) Air flow sensor (19) Accel sensor 1 (31) Neutral switch

(8) Intake throttle valve (20) Accel sensor 2 (32)

(9) Starter relay (21) Vehicle speed sensor (33)

(10) Battery (22) Differential pressure sensor (ΔP) (34)

(11) Glow relay (23) Suction control valve (SCV)

(12) Glow heater (24) Coolant temperature sensor

* Injector 4 is equipped only V2403 model.

Exhaust gas temperature sensor (T0)

Exhaust gas temperature sensor (T1)

Exhaust gas temperature sensor (T2)

TION

6. Wiring diagram

Page 55

GENERAL MACHINE INFORMATION

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

2-31

KiSC issued 12, 2018 A

6. Wiring diagram 2. GENERAL

6.5 System wiring diagram for D1803-CR-TIE4, V2403-CR-TIE4

D1803-CR-TIE4, V2403-CR-TIE4

(1) Main relay (10) Glow relay (19) Accel sensor 2

(2) Fuel feed pump (11) Glow heater (20) Suction control valve (SCV)

(3) CAN1 connector (for service) (12) Injector 1 (21) Coolant temperature sensor

(4) CAN2 connector (for vehicle) (13) Injector 4

(5) EGR valve (14) Injector 3 (23) Boost pressure sensor

(6) Starter (15) Injector 2 (24) Stop switch

(7) Air flow sensor (16) Crankshaft position sensor (25) Neutral switch

(8) Starter relay (17) Camshaft position sensor

(22) Rail pressure sensor

(Continued)

Page 56

2. GENERAL

2-32

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

(9) Battery (18) Accel sensor 1

* Injector 4 is equipped only V2403 model.

GENERAL MACHINE INFORMA

6. Wiring diagram

TION

Page 57

SPECIAL TOOLS

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

2-33

KiSC issued 12, 2018 A

1. Diesel engine compression tester 2. GENERAL

SPECIAL TOOLS

1. Diesel engine compression tester

Use for measuring the diesel engine compression.

Code No.

07909-30208 (Assembly)

(1) Gauge

Page 58

2. GENERAL

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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

2. Compression tester adapter K

Use for check compression pressure through glow plug hole.

NOTE

• This special tool is not provided, so make it referring to the figure.

A 3 mm dia. (0.1 in. dia.) through hole

B 16 mm dia. 18 mm thread (0.63 in. dia. 0.70 in. thread) (Special screw)

C M10 × 1.25

D 8.00 to 8.20 mm dia. (0.315 to 0.322 in. dia.)

E 118° to 120° (2.06 to 2.09 rad)

F 4.8 to 5.2 mm dia. (0.19 to 0.20 in. dia.)

G 17 mm (0.67 in.)

H 10 mm (0.39 in.)

I 41 mm (1.6 in.)

J 15 mm (0.59 in.)

K 49 mm (1.9 in.)

L 10 mm (0.39 in.)

M 15 mm (0.59 in.)

N 10 mm (0.39 in.)

O 100 mm (3.94 in.)

P 125 mm (4.92 in.)

C0.3 Chamfer 0.3 mm (Chamfer 0.01 in.)

Material SS400

SPECIAL TOOLS

2. Compression tester adapter K

Page 59

SPECIAL TOOLS

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

2-35

KiSC issued 12, 2018 A

3. Oil pressure tester 2. GENERAL

3. Oil pressure tester

Use for measuring the engine oil pressure.

(1) Gauge (2) Cable

Threaded joint

(3) (4) Adapter 1

(5) Adapter 2 (6) Adapter 3 (7) Adapter 4 (8) Adapter 5

4. Valve guide replacing tool

Use for press out and press fit the valve guide.

NOTE

• This

special

referring to the figure.

tool is not provided, so make it

A 225 mm (8.86 in.)

B 70 mm (2.8 in.)

C 45 mm (1.8 in.)

D 20 mm dia. (0.79 in. dia.)

G 25 mm dia. (0.98 in. dia.)

I 5 mm (0.2 in.)

J 20 mm dia. (0.79 in. dia.)

L 8.90 to 9.10 mm (0.351 to 0.358 in.)

C1 Chamfer 1.0 mm (0.039 in.)

C2 Chamfer 2.0 mm (0.079 in.)

C0.3 Chamfer 0.3 mm (0.01 in.)

Material SS400

12.7 to 12.9 mm dia. (0.500 to 0.507 in. dia.)

7.50 to 7.60 mm dia. (0.296 to 0.299 in. dia.)

7.70 to 8.00 mm dia. (0.304 to 0.314 in. dia.)

13.5 to 13.8 mm dia. (0.532 to 0.543 in. dia.)

5. Bushing replacing tools

Use for press out and press fit the bushing.

NOTE

• This special

tool is not provided, so make it

referring to the figure.

Page 60

2. GENERAL

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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

SPECIAL TOOLS

6. Flywheel stopper

For small end bushing

A 162 mm (6.38 in.)

B 35 mm (1.4 in.)

C 27 mm (1.1 in.)

D 35 mm dia. (1.4 in. dia.)

Material SS400

27.90 to 27.95 mm dia. (1.099 to 1.100 in. dia.)

25.00 to 25.01 mm dia. (0.9843 to

0.9846 in. dia.)

For idle gear bushing

A 175 mm (6.89 in.)

B 40 mm (1.6 in.)

C 38 mm (1.5 in.)

D 45 mm dia. (1.8 in. dia.)

Material SS400

41.90 to 41.95 mm dia. (1.650 to 1.651 in. dia.)

37.950 to 37.970 mm dia. (1.4941 to

1.4948 in. dia.)

A 140 mm (5.51 in.)

B 80 mm (3.1 in.)

C 49.3 mm (1.94 in.)

D 49.3 mm (1.94 in.)

E 23.8 mm (0.937 in.)

F 23.8 mm (0.937 in.)

G 11 mm dia. (0.43 in. dia.)

H 56.5 mm (2.22 in.)

I 56.5 mm (2.22 in.)

J 8 mm (0.3 in.)

Material SS400

7. Crankshaft bearing 1 replacing tool

Use for press out and press fit the crankshaft bearing 1.

NOTE

• This special referring to the figure.

tool is not provided, so make it

6. Flywheel stopper

Use for loosening and tightening the flywheel screw.

NOTE

• This

special

make it by referring to the figure.

tool is not provided, therefore

Page 61

SPECIAL TOOLS

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

2-37

KiSC issued 12, 2018 A

8. Auxiliary socket for fixing crankshaft sleeve 2. GENERAL

[1] Extracting tool

A 135 mm (5.31 in.)

B 72 mm (2.83 in.)

C R40 mm (R1.57 in.)

D 10 mm (0.39 in.)

E 20 mm (0.79 in.)

F 20 mm dia. (0.79 in. dia.)

Material SS400

64.80 to 64.90 mm dia. (2.552 to 2.555 in. dia.)

59.80 to 59.90 mm dia. (2.355 to 2.358 in. dia.)

[2] Inserting tool

A 130 mm (5.12 in.)

B 72 mm (2.83 in.)

C R40 mm (R1.57 in.)

D 9 mm (0.35 in.)

E 4 mm (0.16 in.)

F 20 mm (0.79 in.)

G 20 mm dia. (0.79 in. dia.)

H 68 mm dia. (2.68 in. dia.)

Material SS400

59.80 to 59.90 mm dia. (2.355 to 2.358 in. dia.)

64.80 to 64.90 mm dia. (2.552 to 2.555 in. dia.)

8. Auxiliary socket for fixing crankshaft sleeve

Use for fixing the crankshaft sleeve of the diesel engine.

NOTE

• The special them referring to the figure.

tools are not provided, so make

Page 62

2. GENERAL

2-38

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) Stopper (2)

Sleeve guide

A 80.0 mm (3.15 in.)

B 60.10 to 60.30 mm (2.367 to 2.374 in.)

C 80.0 mm dia. (3.15 in. dia.)

D 85.0 mm dia. (3.35 in. dia.)

F 26.30 to 26.40 mm (1.036 to 1.039 in.)

G 25.85 to 25.90 mm (1.018 to 1.019 in.)

H 15.0 mm (0.591 in.)

I 5.0 mm (0.20 in.)

J 42.0 mm (1.65 in.)

K 30.50 to 30.60 mm (1.201 to 1.204 in.)

L 23.0 mm (0.906 in.)

M 20.0 mm (0.787 in.)

N 2.0 mm (0.079 in.)

P 30.0 mm dia. (1.18 in. dia.)

Q 5.0 mm dia. (0.20 in. dia.)

R 0.09 rad (5°)

S 25.0 mm dia. (0.984 in. dia.)

T 60.0 mm dia. (2.36 in. dia.)

V 10.0 mm (0.394 in.)

W 0.04 mm dia. (0.002 in. dia.)

X 140 mm (5.51 in.)

Y 120 mm (4.72 in.)

Auxiliary socket for pushing

(3)

60.10 to 60.30 mm dia. (2.367 to

2.374 in. dia.)

31.911 to 31.950 mm dia. (1.2564 to

1.2578 in. dia.)

79.80 to 79.85 mm dia. (3.142 to 3.143 in. dia.)

(Continued)

SPECIAL TOOLS

9. Injection top correction jig

Z 110 mm (4.33 in.)

a 50.0 mm (1.97 in.)

b 39.90 to 40.00 mm (1.571 to 1.574 in.)

c 25.0 mm (0.984 in.)

d 90.0 mm dia. (3.54 in. dia.)

e 81.0 mm dia. (3.19 in. dia.)

g 30.0 mm dia. (1.18 in. dia.)

h 5.0 mm dia. (0.20 in. dia.)

i 70.0 mm (2.76 in.)

j 50.0 mm (1.97 in.)

k 40.0 mm dia. (1.57 in. dia.)

C1 Chamfer 1.0 mm (0.039 in.)

C5 Chamfer 5.0 mm (0.20 in.)

C0.3 Chamfer 0.3 mm (0.01 in.)

R1 1.0 mm radius (0.039 in. radius)

R2 2.0 mm radius (0.079 in. radius)

R10 10.0 mm radius (0.394 in. radius)

Material S43C

80.10 to 80.15 mm dia. (3.154 to 3.155 in. dia.)

9. Injection top correction jig

Use for detect and position the sensor in top dead center position.

NOTE

• This special referring to the figure.

tool is not provided, so make it

Page 63

SPECIAL TOOLS

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

2-39

KiSC issued 12, 2018 A

A 60 mm (2.4 in.)

B 45 mm (1.8 in.)

C 37.3 mm (1.47 in.)

D 35 mm (1.4 in.)

E 12 mm dia. (0.47 in. dia.)

F 10 mm dia. (0.39 in. dia.)

H 1.0 rad (60°)

C1 Chamfer 1.0 mm (0.039 in.)

Material SS400

2. GENERAL

20.34 to 20.50 mm dia. (0.8008 to

0.8070 in. dia.)

Page 64

2. GENERAL

2-40

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KiSC issued 12, 2018 A

10. Bearing case cover oil seal replacing tool

Use for install bearing case cover oil seal. This special tool is not provided, so make it referring to the figure.

SPECIAL TOOLS

A 42 mm dia. (1.7 in. dia.)

B 32.000 to 32.025 mm dia. (1.2599 to 1.2608 in. dia.)

C 116 mm dia. (4.57 in. dia.)

D 3 mm dia. (0.1 in. dia.)

E 88 mm (3.5 in.)

F 12 mm (0.47 in.)

G 88 mm (3.5 in.)

H 92 mm (3.6 in.)

(Continued)

Page 65

SPECIAL TOOLS

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

2-41

KiSC issued 12, 2018 A

2. GENERAL

I 100 mm (3.94 in.)

J M8 × Pitch 1.25

K 0.70 rad (40°)

L 129 mm dia. (5.08 in. dia.)

M 31.950 to 31.975 mm dia. (1.2579 to 1.2588 in. dia.)

N 22 mm dia. (0.87 in. dia.)

O 145 mm dia. (5.71 in. dia.)

P 90 mm (3.5 in.)

Q 12 mm (0.47 in.)

C0.3 Chamfer 0.3 mm (0.01 in.)

C1 Chamfer 1.0 mm (0.039 in.)

C2 Chamfer 2.0 mm (0.079 in.)

C4 Chamfer 4.0 mm (0.16 in.)

Material SS400

Page 66

2. GENERAL

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KiSC issued 12, 2018 A

SPECIAL TOOLS

Page 67

3. MAINTENANCE

KiSC issued 12, 2018 A

Page 68

MAINTENANCE CHECK LIST

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3-1

KiSC issued 12, 2018 A

3. MAINTENANCE

MAINTENANCE CHECK LIST

To make sure that the engine operates safely for a long time, refer to the table below to do regular inspections.

Service interval

Inspection item

Checking engine oil level ○ 3-5

Checking fuel level ○ 3-6

Checking coolant level ○ 3-6

Checking fan belt ○ 3-7

Changing engine oil ○ ○ 3-7

Replacing oil filter cartridge ○ ○ 3-8

Checking fuel hoses and clamp bands

Checking and draining water separator (Type 1)

Cleaning of air cleaner element (replace the element after 6-times cleaning)

Adjusting fan belt tension ○ 3-10

Checking radiator hose and clamp bands

Checking intake air line ○ ○ 3-1

Replacing fuel filter cartridge ○ 3-12

Cleaning water separator (Type 1) ○ 3-13

Cleaning fuel tank interior ○ －

Cleaning water jacket and radiator interior

Replacing fan belt ○ ○ 3-15

Replacing water separator filter (Type2)

Checking valve clearance ○ 3-16

Checking injector (with Diagmas-

ter)

Checking EGR cooler ○ 3-18

*1 Replacing oil separator element ○ 3-19

Checking positive crankcase venti-

lation (PCV) valve

*1 Checking turbocharger ○ 3-20

Cleaning DPF ○ 3-20

Checking EGR system (with Diag-

master)

Replacing air cleaner element ○ 3-25

Checking DPF differential pressure

pipes and hoses

Checking EGR piping ○ 3-26

Daily

Initial

50 hrs

Every

○ 3-8

○ 3-9

Every

250

400

hrs

○ 3-9

○ 3-10

Every 500 hrs

○ 3-13

○ ○ 3-13

1000

hrs

Every

1500

hrs

○ 3-17

○ 3-19

Every

3000

1 year

hrs

○ 3-24

○ 3-25

Every

years

Reference

(Continued)

page

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3. MAINTENANCE

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KiSC issued 12, 2018 A

Service interval

Every

Inspection item

Checking exhaust manifold (crack, gas, leakage and mounting screw)

Replacing oil separator rubber hose

Replacing rubber hose of differen-

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

years

○ 3-27

○ 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.

NOTE

Changing interval of engine oil.

•

Models Interval

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

API service classification: above CJ-4 grade Ambient temperature: below 35 ℃

(95 ℉)

Engine oil

NOTE

• Refer to

the following table for the suitable American Petroleum Institute (API) classification of engine oil

according to the engine type and the Fuel Type.

Every 400 Hrs or 1 year whichever comes first

Initial 50 Hrs

Page 70

3. MAINTENANCE

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3-3

KiSC issued 12, 2018 A

Fuel type

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

Ultra low sulfur fuel Sulfur content <0.0015% (15 ppm)

Engine oil classification (API classification)

CJ-4

• Engine oil should be API classification CJ-4.

• 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.

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3. MAINTENANCE

3-4

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KiSC issued 12, 2018 A

Precautions in handling Biodiesel fuels

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.

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.

Page 72

CHECK AND MAINTENANCE

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

3-5

KiSC issued 12, 2018 A

1.Daily check points 3. MAINTENANCE

CHECK AND MAINTENANCE

1. Daily check points

1.1 Checking engine oil level

IMPORTANT

• On

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.

particulate filter (DPF) equipped

check the engine oil level, make sure

(1) Dipstick

3. Make

sure that the oil level is between the upper

line (a) and lower line (b).

D1803-CR-E4 D1803-CR-TE4 D1803-CRTIE4

Engine oil capacity

V2403-CR-E4 V2403-CR-TE4 V2403-CRTE4BG V2403-CRTIE4

7.0 L

1.8 U.S.gals

1.5 Imp.gals

9.5 L

2.5 U.S.gals

2.1 Imp.gals

Above 25 ℃ (77 ℉)

℃ to 25 ℃ (32 ℉ to 77 ℉)

Below 0 ℃ (32 ℉)

1. Make the engine level.

2. Pull out

the dipstick (1) and clean it. Put in and pull

it out again.

SAE 30 or SAE 10W-30, SAE 15W-40

SAE 20 or SAE 10W-30, SAE 15W-40

SAE10W or SAE 10W-30, SAE 15W-40

(a) Upper line (b) Lower line

NOTE

• If the upper line (a).

level is too low, add new oil to the

Page 73

3. MAINTENANCE

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KiSC issued 12, 2018 A

1.2 Checking fuel level

IMPORTANT

• 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.

1. Remove the radiator cap (1).

remove the radiator cap when the engine

add the coolant, release the air from

(2) Reserve tank (A) FULL

(B)

LOW

Page 74

CHECK AND MAINTENANCE

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

3-7

KiSC issued 12, 2018 A

1.Daily check points 3. MAINTENANCE

1.4 Checking fan belt

1. Check that pulley groove or not.

• If it is, replace it.

the fan belt is worn out and sunk in the

NOTE

• If the

measurement is out of the service specifications, loosen the alternator mounting screws and adjust its position.

2. Check points of initial 50 hours

2.1 Changing engine oil

CAUTION

• Make sure change the engine oil.

IMPORTANT

• When you viscosity from the previous, drain the remaining oil.

• Do not mix 2 different types of oil.

• Engine oil must have the properties of API classification CJ-4. Use the correct SAE Engine Oil by reference to the ambient temperature.

that you stop the engine before you

use an oil of different brand or

(A) OK (B) Wear

2. Push

the belt halfway between the fan drive pulley

alternator pulley at a specified force to measure

and the deflection (1).

10.0 to 12.0 mm

0.394 to 0.472 in. in. (Under load of 98 N (10 kgf, 22.1 lbf))

Deflection (1)

Service specification

Above 25 ℃ (77 ℉)

℃ to 25 ℃ (32 ℉ to 77 ℉)

Below 0 ℃ (32 ℉)

SAE 30 or SAE 10W-30, SAE 15W-40

SAE 20 or SAE 10W-30, SAE 15W-40

SAE10W or SAE 10W-30, SAE 15W-40

1. Start and warm-up the engine for approximately 5 minutes.

Put an oil pan below the engine.

3. Remove the drain plug (1) at the bottom of the engine and drain the oil fully.

(1) Drain plug

4. Tighten the drain plug (1).

(1) Deflection

Tightening torque

Drain plug (1)

32.4 to 37.2 N⋅m

3.31 to 3.79 kgf⋅m

23.9 to 27.4 lbf⋅ft

Page 75

3. MAINTENANCE

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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

5. Fill new oil until the upper line on the dipstick (2).

CHECK AND MAINTENANCE

2.Check points of initial 50 hours

Engine oil capacity

(2) Dipstick

D1803-CR-E4 D1803-CR-TE4 D1803-CRTIE4

V2403-CR-E4 V2403-CR-TE4 V2403-CRTE4BG V2403-CRTIE4

7.0 L

1.8 U.S.gals

1.5 Imp.gals

9.5 L

2.5 U.S.gals

2.1 Imp.gals

2.2 Replacing oil filter cartridge

(1) Oil filter cartridge

2. Apply a thin layer of oil on the new cartridge gasket.

3. Install the new cartridge by hand.

NOTE

• Do not

tighten too much because it can

cause deformation of the rubber gasket.

4. Make sure that the engine oil does not flow through the seal and read the oil level on the dipstick.

5. Fill the engine oil until the specified level.

NOTE

you

• After

replace the cartridge, the engine

oil usually decrease by a small level.

CAUTION

• Make sure that you stop the engine before you replace the oil filter cartridge.

IMPORTANT

• To

Tools required

• Filter wrench

1. Remove the

prevent serious damage to the engine, replacement element must be highly efficient. Use only a Kubota genuine filter or its equivalent.

oil filter cartridge (1) with the filter

wrench.

3. Check point of every 50 hours

3.1 Checking fuel hoses and clamp bands

1. Check the fuel hose (1) and clamp (2) are damaged or not.

If the fuel hose (1) or clamp (2) is damaged, replace it.

Page 76

CHECK AND MAINTENANCE

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3-9

KiSC issued 12, 2018 A

3.Check point of every 50 hours 3. MAINTENANCE

3. If

the clamp (2) is loose, apply oil to the threads and

tighten it again correctly

NOTE

• Replace the clamp (2) in a 2 years interval.

• After replace the fuel hose (1) and the clamp (2), bleed the fuel system.

fuel hose (1) together with the

(1) Fuel hose (2) Clamp

3.2 Checking and draining water separator (T

Check if water and dirt contained in fuel precipitate inside the water separator

2. When such foreign substances are precipitated, set the water separator handle (1) to the close (A) position.

3. Loosen the top screw (4) first and then the bottom valve (3) to let the foreign substances out of the separator.

4. Loosen and remove the cup (5) properly, and clean its inside with diesel fuel.

5. Tighten up the cup (5) properly.

6. Finally be sure to air-bleed the fuel system.

ype 1)

(1) Water separator handle (2) Specified line

Bottom valve

(3) (4) Top screw

(5) Cup (6) Float (A) Close

4. Check points of every 250 hours

4.1 Cleaning air cleaner primary element

NOTE

• Replace the primary element (3) once a year or every 6th cleaning.

• The air cleaner uses a dry element, never apply oil.

• Do not operate the engine with filter element removed.

• Do not touch the secondary element (2) except in cases where replacing is required.

1. Remove the dust cup (4).

2. Remove the primary element (3).

IMPORTANT

• As water goes up. When the float (6) has reached the specified line (2), immediately drain the water separator.

• In reattaching the water separator, be careful to keep off dust and dirt.

• Be sure to air-bleed the fuel system before operating engine.

is accumulated, the red float (6)

Page 77

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KiSC issued 12, 2018 A

MAINTENANCE

CHECK AND MAINTENANCE

4.Check points of every 250 hours

3. Clean

the inner side of the primary element (3) by

clean dry compressed air

Pressure of compressed air

(1) Air cleaner housing (2)

Secondary element Primary element

(3)

4. Install the removed parts.

Less than 205 kPa

2.1 kgf/cm 30 psi

(4) Dust cup (5) Evacuator valve

(A) OK (B) Wear

2. Push the belt halfway between the fan drive pulley and alternator pulley at a specified force to measure the deflection (1).

10.0 to 12.0 mm

0.394 to 0.472 in. in. (under load of 98 N (10 kgf, 22.1 lbf))

Deflection (1)

Service specification

4.2 Adjusting fan belt tension

1. Check pulley groove or not.

that the fan belt is worn out and sunk in the

If it is, replace it.

•

(1) Deflection

NOTE

• If the

measurement is out of the service specifications, loosen the alternator mounting screws and adjust its position.

4.3 Checking radiator hose and clamp bands

1. Check that the radiator hoses (1), (2) are connected correctly or not.

Page 78

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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

3-11

KiSC issued 12, 2018 A

4.Check points of every 250 hours 3. MAINTENANCE

2. Check

the radiator hoses (1), (2) and clamp are

damaged or not.

If the radiator hose (1), (2) or clamp is

• damaged, replace it.

(1) Upper hose (2) Lower hose

3. If the clamp is loose, apply oil to the threads and tighten it again correctly

NOTE

• You

must replace the radiator hose(s) every 2 years. Also replace the clamp every 2 years and tighten it correctly.

4.4 Checking intake air line

IMPORTANT

• To

prevent serious damage to the engine, keep

out dust in the intake air line.

(1) Intake air hose (2) Clamp

5. Check points of every 400 hours

5.1 Changing engine oil

CAUTION

• Make sure that you stop the engine before you change the engine oil.

IMPORTANT

• When you viscosity from the previous, drain the remaining oil.

• Do not mix 2 different types of oil.

• Engine oil must have the properties of API classification CJ-4. Use the correct SAE Engine Oil by reference to the ambient temperature.

use an oil of different brand or

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.

NOTE

• You

must replace the intake air hose(s) every 2 years. Also replace the clamp (2) every 2 years and tighten it correctly.

Above 25 ℃ (77 ℉)

℃ to 25 ℃ (32 ℉ to 77 ℉)

Below 0 ℃ (32 ℉)

SAE 30 or SAE 10W-30, SAE 15W-40

SAE 20 or SAE 10W-30, SAE 15W-40

SAE10W or SAE 10W-30, SAE 15W-40

1. Start and warm-up the engine for approximately 5 minutes.

Put an oil pan below the engine.

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KiSC issued 12, 2018 A

CHECK AND MAINTENANCE

5.Check points of every 400 hours

3. Remove

drain plug (1) at the bottom of the

the

engine and drain the oil fully.

(1) Drain plug

4. Tighten the drain plug (1).

Tightening torque

Drain plug (1)

32.4 to 37.2 N⋅m

3.31 to 3.79 kgf⋅m

23.9 to 27.4 lbf⋅ft

5. Fill new oil until the upper line on the dipstick (2).

IMPORTANT

• To

prevent serious damage to the engine, replacement element must be highly efficient. Use only a Kubota genuine filter or its equivalent.

Tools required

• Filter wrench

1. Remove the oil filter cartridge (1) with the filter wrench.

Engine oil capacity

(2) Dipstick

D1803-CR-E4 D1803-CR-TE4 D1803-CRTIE4

V2403-CR-E4 V2403-CR-TE4 V2403-CRTE4BG V2403-CRTIE4

7.0 L

1.8 U.S.gals

1.5 Imp.gals

9.5 L

2.5 U.S.gals

2.1 Imp.gals

(1) Oil filter cartridge

2. Apply a thin layer of oil on the new cartridge gasket.

3. Install the new cartridge by hand.

NOTE

• Do not

tighten too much because it can

cause deformation of the rubber gasket.

4. Make sure that the engine oil does not flow through the seal and read the oil level on the dipstick.

5. Fill the engine oil until the specified level.

NOTE

• After you

replace the cartridge, the engine

oil usually decrease by a small level.

6. Check points of every 500

hours

6.1 Replacing fuel filter cartridge

Tools required

• Filter wrench

5.2 Replacing oil filter cartridge

CAUTION

• Make sure replace the oil filter cartridge.

that you stop the engine before you

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3-13

KiSC issued 12, 2018 A

6.Check points of every 500 hours 3. MAINTENANCE

1. Remove wrench.

(1) Fuel filter cartridge

2. Apply a thin layer of fuel to the surface of the new filter cartridge gasket before you put it on.

Tighten the new cartridge by hand.

4. Open the fuel valve and bleed the fuel system.

5. Operate the engine for a while and check if there is not the fuel leakage from the filter.

fuel filter cartridge (1) with filter

the

6.3 Replacing water separator filter (Type 2)

IMPORTANT

• Replace the prevent wear of the supply pump or the injector, due to dirt in the fuel.

NOTE

• Replace the one every 500 hours or 1 year.

Tools required

• Filter wrench

1. Remove the old water separator filter (1) with a filter wrench.

water separator filter periodically to

water separator filter with a new

6.2 Cleaning water separator (Type

1. Turn the water separator handle (1) to the close position (A).

Drain fuel and water from bottom valve (3).

3. Remove and flush the cup (5) if the float (6) goes up with water, or the cup (3) has the dust.

(1) Water separator handle (2) Specified line (3) Bottom valve (4) Top screw

(5) Cup (6) Float (A) Close

(1) Water separator filter

2. Apply a thin layer of oil on the new water separator filter

3. Tighten the new water separator filter by hand.

4. Operate the engine for a while and check if there is not the fuel leakage from the filter.

6.4 Cleaning water jacket and

radiator interior

CAUTION

• Do not is hot. Then loosen the cap slightly to release unwanted pressure before you remove the cap fully.

IMPORTANT

• Do not start the engine without coolant. Use clean and soft water with anti-freeze to fill

• the radiator and reserve tank.

• Make sure that when you mix the anti-freeze and water, the ratio of anti-freeze is less than 50%.

remove the radiator cap when the engine

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KiSC issued 12, 2018 A

CHECK AND MAINTENANCE

6.Check points of every 500 hours

• Make correctly

sure that you close the radiator cap

. If the cap is loose or incorrectly closed, coolant can flow out and the engine can overheat.

1. Stop the engine and let the coolant temperature decreases.

2. Remove the radiator cap (1) to drain the coolant fully.

(1) Radiator cap

3. Open the drain valve (2) and remove the EGR cooler hose (3).

6. Obey the directions of the cleaner instruction.

7. After you

flush, fill with clean water and anti-freeze

until the coolant level is immediately below the port.

8. Install the radiator cap (1) correctly.

9. Fill with the coolant until the [FULL] (A) mark on the

reserve tank (4).

(4) Reserve tank (A) FULL

(B)

LOW

10. Start and operate the engine for a few minutes. 1

Stop the engine and let the coolant temperature

1. decreases.

(2) Drain valve (3) EGR cooler hose

4. After you drained all coolant, close the drain valve (2) and install the EGR cooler hose (3).

Fill with clean water and cooling system cleaner.

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KiSC issued 12, 2018 A

6.Check points of every 500 hours 3. MAINTENANCE

12. Check (4) and add coolant if necessary

the coolant level of radiator and reserve tank

Anti-freeze

NOTE

• There are

2 types of anti-freeze available:

use the permanent type (PT) for this engine.

• 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 -11 106 223

50% -37 -35 108 226

* 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 point Boiling 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) Alternator (2) Fan belt

3. Replace the fan belt (2) with a new one.

4. Install the alternator (1).

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3. MAINTENANCE

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KiSC issued 12, 2018 A

CHECK AND MAINTENANCE

7.Check point of every 1000 hours

5. Adjust drive

the tension of belt halfway between the fan

pulley and alternator pulley at a specified

force to measure the deflection (3).

10.0 to 12.0 mm

0.394 to 0.472 in. in. (under load of 98 N (10 kgf, 22.1 lbf))

Deflection (3)

(3) Deflection

Service specification

NOTE

• If the measurement is out of the service specifications, loosen the alternator mounting screws and adjust its position.

4. Make sure that the No.1 piston comes to the compression or overlap top dead center

7. Check point of every 1000 hours

7.1 Checking valve clearance

IMPORTANT

• You must check and adjust the valve clearance when the engine is cold.

Tools required

• Feeler gauge

1. Remove the air cleaner and muffler.

2. Remove the cylinder head cover

3. Align the [1TC] mark (2) line on the flywheel and

projection (1) on the housing.

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3-17

KiSC issued 12, 2018 A

8.Check points of every 1500 hours 3. MAINTENANCE

5. Check mark

the subsequent valve clearance (5) at the

[1TC] with a feeler gauge.

NOTE

• If the

clearance (5) is out of the service specifications, adjust with the adjusting screw (3).

• Tighten the lock nut (4) of the adjusting screw.

Valve clearance (5) (cold)

Adjustable cylinder loca-

tion of piston

When No. 1 piston is at compression top dead center.

When No. 1 piston is at overlap position.

Service specification

Intake

1 ☆

2 ☆ ☆

3 ☆ ☆

4 －－

2 ☆ ☆

3 ☆ ☆

4 －－ ☆ ☆

0.18 to 0.22 mm

0.0071 to 0.0086 in.

Valve arrangement

3 cylinder 4 cylinder

Ex-

haust

Intake

☆ ☆ ☆

Ex-

haust

8. Check points of every 1500 hours

8.1 Checking injector (with Diagmaster)

Tools required

• Laptop computer (Diagmaster (software) installed)

•

Interface (DST-i)

1. Connect the diagnosis tool.

2. Start "Diagmaster", then click the [Active Test]

button (1) from the project window.

3. Select the "#1, 2, 3 and 4 Cylinder Injector Injection

Stop" item (2), then click the [proceed] button (3).

(1) Active Test button (2) #1, 2, 3 and 4 Cylinder Injec-

tor Injection Stop item

(3)

Proceed button

(3) Adjusting screw (4) Lock nut

6. Install the removed parts.

Tightening torque

Cylinder head cover screw

Valve clearance

(5)

6.86 to 11.3 N⋅m

0.700 to 1.15 kgf⋅m

5.06 to 8.33 lbf⋅ft

4. Select

the "#Cylinder Injector Injection Stop" (7)

from the "select signal group" (8). Select the "number of graph" (6).

6. Click the [Start Active Test] button (4), then click the [OK] button (5).

(4) Start Active Test button (5) OK button (6)

Number of graph

(7) #Cylinder Injector Injection

Stop

(8) Select signal group

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3. MAINTENANCE

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KiSC issued 12, 2018 A

CHECK AND MAINTENANCE

8.Check points of every 1500 hours

7. Click

the [Send

Specified Active Test Value]

button (9).

NOTE

• Confirm that

the each injectors are injecting

normally.

• If it is injecting normally, the engine vibration and noise will increase and engine speed will fluctuate when the injector is stopped.

(9) Send Specified Active Test

Value button

8.2 Checking EGR cooler

Exhaust gas passage

1. Block the EGR cooler exhaust gas outlet (2). Attach an air hose to the EGR cooler exhaust gas

2. inlet (1) and then submerge it in a water tank.

3. Check that the coolant passage is full of water.

4. Apply the specified amount of air pressure (a) to the air hose side.

EGR cooler leakage test pressure

Service specification

Exhaust gas passage

290 kPa

3.0 kgf/cm 43 psi

Click the [Finish Active T

button (10).

est]

NOTE

• If it

is determined that there is a failure,

check for a plug in the injection pipe.

• If the injector pipe is normal, this may be an injector failure so replace the injector using the procedure for replacing injectors.

(10) Finish Active Test button

(1) Exhaust gas inlet (2) Exhaust gas outlet

Air pressure

(a)

5. Check that there are no air leaks in any of the EGR cooler parts.

NOTE

• If there are air leaks, replace the EGR cooler.

6. Install the removed parts.

Coolant passage

1. Block the

EGR cooler exhaust gas inlet (1), EGR cooler exhaust gas outlet (2), and the coolant outlet (3).

2. Attach an air hose to the EGR cooler coolant inlet (4), and then submerge it in a water tank.

3. Apply the specified amount of air pressure (a) to the air hose side.

EGR cooler leakage test pressure

Service specification

Coolant passage

250 kPa

2.5 kgf/cm 36 psi

7.56 Replacing injector on page 4-191

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KiSC issued 12, 2018 A

8.Check points of every 1500 hours 3. MAINTENANCE

(1) Exhaust gas inlet (2) Exhaust gas outlet

Coolant outlet

(3)

(4) Coolant inlet (a) Air pressure

4. Check that there are no air leaks in any of the EGR cooler parts.

NOTE

• If there are air leaks, replace the EGR cooler

5. Install the removed parts.

8.3 Replacing oil separator element

CAUTION

• Be sure the oil separator element.

1. Remove the cover (1).

2. Remove the (2).

to stop the engine before replacement

oil separator element (3) and O-ring

(1) Cover (2) O-ring

Element

(3)

(4) Body

2. Look into the hole leading to the PCV valve of the oil

separator body (4) inside, and then check if there

is no crack, break or abnormal sediment in the PCV

valve.

3. Check the oil separator assembly for crack, oil leakage and loose connections.

NOTE

• If you

find a crack or oil leakage, replace the

oil separator assembly with a new one.

• If you find loose connections, tighten the clamp or replace the hoses.

(1) Cover (2) O-ring (3) Element

3. Replace

oil separator element (3) and O-ring (2)

the

(4) Body

with a new one.

8.4 Checking positive crankcase ventilation (PCV) valve

1. Remove the cover (1) and element (3).

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3. MAINTENANCE

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KiSC issued 12, 2018 A

CHECK AND MAINTENANCE

9.Check points of every 3000 hours

9. Check points of every 3000 hours

9.1 Checking turbocharger

Turbine side

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

DPF that was dropped or given a

in the workshop equipped with a

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KiSC issued 12, 2018 A

9.Check points of every 3000 hours 3. MAINTENANCE

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).

5. Remove the differential sensor (3).

6. Remove the differential sensor bracket (2).

7. Remove the 4 screws of muffler flange (6).

(15) Filter comp (DPF) bracket (16) Filter comp (DPF)

(17)

Filter comp (DPF) bracket

(1) Differential pressure pipe

ferential pressure sensor

(2) Dif

bracket (3) Differential pressure sensor (4) Differential pressure pipe (5) Clamp (6) Muffler flange (7) Connector of exhaust gas

temperature sensor (T2)

8. Remove the

muffler full assembly (DPF) mounting

(8) Connector of exhaust gas

temperature sensor (T1)

(9) Connector of exhaust gas

temperature sensor (T0)

(10) Differential pressure sensor

connector (11) Tube (12) Tube

screws (13).

9. Remove the muffler full assembly (DPF) (14).

11. Pack

the filter comp (DPF) (16) and send it to a

cleaning contractor

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KiSC issued 12, 2018 A

CHECK AND MAINTENANCE

9.Check points of every 3000 hours

12. Install

the removed parts and cleaned filter comp

(DPF) (16).

NOTE

• Replace the

gaskets (19), (20) with new

ones.

• 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.

(1) Differential pressure pipe

ferential pressure pipe

(4) Dif (15) Filter comp (DPF) bracket (16) Filter comp (DPF) (17) Filter comp (DPF) bracket (18) Body (DPF outlet) (19) Gasket (20) Gasket

(21) Catalyst (DOC) (22) Exhaust gas temperature

sensor (T0)

(23) Exhaust gas temperature

sensor (T1)

(24) Exhaust gas temperature

sensor (T2)

7.58 Replacing DPF on page 4-196

9.3 Judging reuse of DPF filter comp before cleaning (Service dealer)

IMPORTANT

• Before ordering the procedures below to make a Judgment on whether the separated filter comp (DPF) is reusable.

to a cleaning contractor, follow

Tightening torque

Filter comp (DPF) bracket (15), (17)

Exhaust gas temperature sensor (22), (23), (24)

Differential pressure pipe (1), (4)

16 to 20 N⋅m

1.7 to 2.0 kgf⋅m 12 to 14 lbf⋅ft

25.0 to 35.0 N⋅m

2.55 to 3.56 kgf⋅m

18.5 to 25.8 lbf⋅ft

16.0 to 23.0 N⋅m

1.64 to 2.34 kgf⋅m

11.8 to 16.9 lbf⋅ft

1. Check to see that the surface of the removed filter comp (DPF) on the exhaust gas outlet side is not darkened.

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KiSC issued 12, 2018 A

9.Check points of every 3000 hours 3. MAINTENANCE

2. Check

whether

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)

Model Measurement total

D1803, V2403 16 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.

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KiSC issued 12, 2018 A

CHECK AND MAINTENANCE

9.Check points of every 3000 hours

(1) Pin gauge (2) Filter comp (DPF)

Exhaust gas inlet side

(A) (B) Exhaust gas outlet side (C) Accumulated ash

(D) Actual cell depth (E) Accumulated ash depth (F) Cell depth

• 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).

6. Click the [Start Active Test] button (4), then click the [OK] button (5).

Tools required

• Laptop computer (Diagmaster (software) installed)

•

Interface (DST-i)

1. Connect the diagnosis tool.

2. Start "Diagmaster", then click the [Active Test]

(4) Start Active Test button (5) OK button

Number of graph

(6) (7) #EGR Valve ON/OFF Func-

tion

button (1) from the project window.

3. Select the "Exhaust Gas Recirculation (EGR) Valve ON/OFF Function" item (2), then click the [proceed] button (3).

(8) Select signal group

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7. Click

the [Send

Specified Active Test Value]

button (9).

NOTE

• If the

actual position is traced target

position, the EGR valve is normal.

• 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

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

10.1 Replacing air cleaner element

anti-seize & lubricating compound.

1. Remove the dust cup (4).

find a crack, change the DPF

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10.Check points of every 1 year

2. Apply again,

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.

(1) Intake air hose (2) Clamp

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10.5 Checking exhaust manifold

1. Check the leakage and loose mounting screw.

NOTE

• If manifold.

• 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.

exhaust manifold for crack, exhaust gas

you

find a crack, change the exhaust

10.6 Replacing water separator filter (Type 2)

IMPORTANT

• Replace the prevent wear of the supply pump or the injector, due to dirt in the fuel.

NOTE

• Replace the one every 500 hours or 1 year.

water separator filter periodically to

water separator filter with a new

2. Remove the fan belt (2).

(1) Alternator (2) Fan belt

3. Replace the fan belt (2) with a new one.

4. Install the alternator (1).

Adjust the tension of belt halfway between the fan drive pulley and alternator pulley at a specified force to measure the deflection (3).

10.0 to 12.0 mm

0.394 to 0.472 in. in. (under load of 98 N (10 kgf, 22.1 lbf))

Deflection (3)

Service specification

Tools required

• Filter wrench

1. Remove the wrench.

(1) Water separator filter

2. Apply a thin layer of oil on the new water separator filter

3. Tighten the new water separator filter by hand.

4. Operate the engine for a while and check if there is not the fuel leakage from the filter.

old water separator filter (1) with a filter

11. Check points of every 2

years

(3) Deflection

NOTE

• If the specifications, loosen the alternator mounting screws and adjust its position.

measurement is out of the service

11.2 Replacing oil separator rubber hose

1. Loosen the rubber hose (3), (5).

clamp (1), (2), (4) and remove the

11.1 Replacing fan belt

1. Remove the alternator (1).

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KiSC issued 12, 2018 A

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11.Check points of every 2 years

2. Replace (4) with new ones.

(1) Clamp (2) Clamp

Rubber hose

(3)

3. Tighten the clamp (1), (2), (4) correctly.

rubber hose (3), (5) and clamp (1), (2),

the

(4) Clamp (5) Rubber hose

11.3 Replacing rubber hose of

differential pressure sensor

1. Loosen hose (1), (3).

2. Replace the rubber hose (1), (3) and clamp (2), (4) with new ones.

clamp (2), (4) and remove the rubber

the

11.5 Replacing EGR cooler hose

1. Loosen the clamp (1) and remove the hose (2).

Replace the hose (2) with new ones.

(1) Clamp (2) Hose

3. Tighten the clamp (1) correctly.

11.6 Replacing water hose

1. Loosen the clamp and remove the hose.

Replace the hose with new ones. Tighten the clamp correctly.

11.7 Replacing lubricant hose

(1) Rubber hose (2) Clamp (3) Rubber hose

3. Tighten the clamp (2), (4) correctly.

(4) Clamp

11.4 Replacing intake hose (after air

flow sensor) and intercooler hose

1. Loosen the clamp and remove the hose.

Replace the hose and clamp with new ones. Tighten the clamp correctly.

1. Loosen the clamp and remove the hose.

2. Replace the hose with new ones.

Tighten the clamp correctly.

11.8 Changing radiator coolant

CAUTION

• Do not is hot. Then loosen the cap slightly to release unwanted pressure before you remove the cap fully.

IMPORTANT

• Do not start the engine without coolant. Use clean and soft water with anti-freeze to fill

• the radiator and reserve tank.

• Make sure that when you mix the anti-freeze and water, the ratio of anti-freeze is less than 50%.

• 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.

remove the radiator cap when the engine

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1. Stop

the engine and let the coolant temperature

decreases. Remove the radiator cap (1) to drain the coolant

2. fully.

(1) Radiator cap

3. Open the drain valve (2) and remove the EGR cooler hose (3).

9. Fill with the coolant until the [FULL] (A) mark on the

reserve tank (4).

(4) Reserve tank (A) FULL

(B)

LOW

10. Start and operate the engine for a few minutes. 1

Stop the engine and let the coolant temperature

1. decreases.

(2) Drain valve (3) EGR cooler hose

4. After

you drained all coolant, close the drain valve

(2) and install the EGR cooler hose (3). Fill with clean water and cooling system cleaner.

6. Obey the directions of the cleaner instruction.

7. After you flush, fill with clean water and anti-freeze until the coolant level is immediately below the port.

8. Install the radiator cap (1) correctly.

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11.Check points of every 2 years

12. Check (4) and add coolant if necessary

the coolant level of radiator and reserve tank

Anti-freeze

NOTE

• There are

2 types of anti-freeze available:

use the permanent type (PT) for this engine.

• 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 -11 106 223

50% -37 -35 108 226

* 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 point Boiling 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).

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.

• The anti-freeze absorbs moisture. Keep new anti-freeze in a tightly sealed container.

(1) Upper hose (2) Lower hose

4. Replace

upper / lower hose (1), (2) and clamp

the

bands with new ones.

5. Tighten the clamp bands correctly.

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11.10 Replacing fuel hose and clamps

1. Loosen the clamp (2) and remove the fuel hose (1).

(1) Fuel hose (2) Clamp

2. Replace ones.

3. Tighten the clamp (2) correctly.

4. After you replace the fuel hose and the clamp, bleed the fuel system.

fuel hose (1) and clamp (2) with new

the

11.11 Replacing intake air line

IMPORTANT

prevent serious damage to the engine, keep

• To out dust in the intake air line.

1. Loosen the clamp (2).

2. Remove the intake air hose (1) and clamp (2).

(1) Intake air hose (2) Clamp

3. Replace new ones.

4. Tighten the clamp (2) correctly.

intake air hose (1) and clamp (2) with

the

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11.Check points of every 2 years

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4. ENGINE

KiSC issued 12, 2018 A

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

GENERAL MACHINE INFORMATION

1. Engine identification

1.1 Engine model name and engine serial number

1.2 E4B engine

1.3 Cylinder number

2. Muffler full assembly identification

2.1 Part number and serial number (DPF)

3. Specifications

3.1 Specification for D1803-CR-E4, TE4

3.2 Specification for V2403-CR-E4, TE4

3.3 Specification for D1803-CR-TIE4, V2403-CR-TIE4

3.4 Specification for V2403-CR-TE4BG

4. Performance curves

4.1 Performance curve for D1803-CR-E4

4.2 Performance curve for D1803-CR-TE4

4.3 Performance curve for D1803-CR-TIE4

4.4 Performance curve for V2403-CR-E4

4.5 Performance curve for V2403-CR-TE4

4.6 Performance curve for V2403-CR-TIE4

5. Dimensions

5.1 Dimensions

6. Wiring diagram

6.1 Engine intermediate harness (Engine side harness)

6.2 Injector intermediate harness (Engine side harness)

6.3 Engine ECU intermediate harness (OEM side harness)

6.4 System wiring diagram for D1803-CR-E4, D1803-CR-TE4, V2403-CR-E4, V2403-CR-TE4, V2403-CR-TE4BG

6.5 System wiring diagram for D1803-CR-TIE4, V2403-CR-TIE4

SPECIAL TOOLS

1. Diesel engine compression tester

2. Compression tester adapter K

3. Oil pressure tester

4. Valve guide replacing tool

5. Bushing replacing tools

6. Flywheel stopper

7. Crankshaft bearing 1 replacing tool

8. Auxiliary socket for fixing crankshaft sleeve

9. Injection top correction jig

10. Bearing case cover oil seal replacing tool

3. MAINTENANCE

MAINTENANCE CHECK LIST

CHECK AND MAINTENANCE

1. Daily check points

1.1 Checking engine oil level

1.2 Checking fuel level

1.3 Checking coolant level

1.4 Checking fan belt

2. Check points of initial 50 hours

2.1 Changing engine oil

2.2 Replacing oil filter cartridge

3. Check point of every 50 hours

3.1 Checking fuel hoses and clamp bands

4. Check points of every 250 hours

4.1 Cleaning air cleaner primary element