Kubota V2607-CR-E4, D1803-CR-TE4, V3307-CR-TE4, V2607-CR-TE4, V3800-CR-TE4 Workshop Manual
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WORKSHOP MANUAL
KiSC issued 09, 2013 A
DIESEL ENGINE
DIESEL PARTICULATE FILTER
HANDLING MANUAL
TO THE READER
KiSC issued 09, 2013 A
This Workshop Manual tells the servicing personnel about the servicing and maintenance of the
Diesel Particulate Filter. It contains 2 parts: "Information" and "Servicing".
Information
This section contains information below.
• Safety First
Servicing
This section contains information below.
•Servicing
All illustrations, photographs and specifications contained in this manual are of the newest
information available at the time of publication.
Click this mark to open the attached file.
KUBOTA reserves the right to change all information at any time without notice.
Since this manual includes many models, information or illustrations and photographs can show
more than one model.
August, 2012
© KUBOTA Corporation 2012
Record of Revisions
KiSC issued 09, 2013 A
For pdf, use search function {Search word} to find the all revised locations.
Last digit
of the
Code No.
Issue
month
Main Revised Point and Corrective Measures {Search word}
2 2013.09 • Correction of Workshop Manual
The following are the changes from 9Y121-07331 to 9Y121-07332.
1. Information for V6108 was deleted.
2. Information for 03-CR-E4 was added.
3. Information for 07-CR-E4 was added.
Reference
Page
All pages
I INFORMATION
KiSC issued 09, 2013 A
INFORMATION
KiSC issued 09, 2013 A
CONTENTS
1. SAFETY FIRST .............................................................................................................................. I-1
DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM
SAFETY FIRST
DANGER
WARNING
CAUTION
IMPORTANT
NOTE
KiSC issued 09, 2013 A
INFORMATION
1. SAFETY FIRST
• This symbol, the industry's "Safety Alert Symbol", is used throughout this manual and on labels on the
machine itself to warn of the possibility of personal injury. Read these instructions carefully.
• It is essential that you read the instructions and safety regulations before you attempt to repair or use
this unit.
• Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
• Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
• Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate
injury.
• Indicates that equipment or property damage could result if instructions are not followed.
• Gives helpful information.
BEFORE YOU START SERVICE
• Read all instructions and safety instructions in this
manual and on your engine safety decals.
• Clean the work area and engine.
• Park the machine on a stable and level ground.
• Let the temperature of the engine decrease before
you start a job.
• Stop the engine, then remove the key.
• Disconnect the battery negative cable.
• Hang a "DO NOT OPERATE" tag in the operator
station.
START SAFELY
• Do not do the procedures below when you start the
engine.
– short across starter terminals
– bypass the safety start switch
• Do not make unauthorized modifications to the
engine. This can cause damage and decrease the
engine life.
I-1
DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM
KiSC issued 09, 2013 A
INFORMATION
OPERATE SAFELY
• Do not use the machine after you consume alcohol
or medication or when you are tired.
• Put on applicable clothing and safety equipment.
• Use applicable tools only. Do not use alternative
tools or parts.
• When 2 or more persons do servicing, make sure
that you do it safely.
• Do not touch the hot parts or parts that turn when the
engine operates.
• Do not remove the radiator cap when the engine
operates, or immediately after it stops. If not, hot
water can spout out from the radiator. Only remove
the radiator cap when it is at a sufficiently low
temperature to touch with bare hands. Slowly loosen
the cap to release the pressure before you remove it
fully.
• Released fluid (fuel or hydraulic oil) under pressure
can cause damage to the skin and cause serious
injury. Release the pressure before you disconnect
hydraulic or fuel lines. Tighten all connections before
you apply the pressure.
• Do not open a fuel system under high pressure.
The fluid under high pressure that stays in fuel lines
can cause serious injury. Do not disconnect or repair
the fuel lines, sensors, or any other components
between the fuel pump and injectors on engines with
a common rail fuel system under high pressure.
• Put on an applicable ear protective device (earmuffs
or earplugs) to prevent injury against loud noises.
• Be careful about electric shock. The engine
generates a high voltage of more than DC100 V in
the ECU and is applied to the injector.
PREVENT A FIRE
• Fuel is very flammable and explosive under some
conditions. Do not smoke or let flames or sparks in
your work area.
• To prevent sparks from an accidental short circuit,
always disconnect the battery negative cable first
and connect it last.
• The battery gas can cause an explosion. Keep the
sparks and open flame away from the top of battery,
especially when you charge the battery.
• Make sure that you do not spill fuel on the engine.
I-2
DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM
KiSC issued 09, 2013 A
INFORMATION
KEEP A GOOD AIRFLOW IN THE WORK AREA
• If the engine is in operation, make sure that the area
has good airflow. Do not operate the engine in a
closed area. The exhaust gas contains poisonous
carbon monoxide.
DISCARD FLUIDS CORRECTLY
• Do not discard fluids on the ground, down the drain,
into a stream, pond, or lake. Obey related
environmental protection regulations when you
discard oil, fuel, coolant, electrolyte and other
dangerous waste.
PREVENT ACID BURNS
• Keep electrolyte away from your eyes, hands and
clothing. Sulfuric acid in battery electrolyte is
poisonous and it can burn your skin and clothing and
cause blindness. If you spill electrolyte on yourself,
clean yourself with water, and get medical aid
immediately.
PREPARE FOR EMERGENCIES
• Keep a first aid kit and fire extinguisher ready at all
times.
• Keep the emergency contact telephone numbers
near your telephone at all times.
I-3
1 ENGINE
KiSC issued 09, 2013 A
SERVICING
KiSC issued 09, 2013 A
CONTENTS
1. FUNCTION OF DIESEL PARTICULATE FILTER (DPF).............................................................1-S1
2. DPF REGENERATION AND DPF CLEANING............................................................................1-S2
3. DPF MAINTENANCE FLOW ....................................................................................................... 1-S3
[1] CLEANING & RETURN FLOW .............................................................................................1-S4
[2] DPF EXCHANGE FLOW .......................................................................................................1-S5
4. DPF CLEANING PROCEDURE ..................................................................................................1-S6
[1] TO ENSURE SAFETY AND GOOD PERFORMANCE IN DPF CLEANING PROCEDURE .1-S6
[2] SEPARATION OF DPF MUFFLER FULL ASSY ...................................................................1-S7
(1) D1803-CR-E4, D1803-CR-TE4, V2403-CR-E4, V2403-CR-TE4 ....................................1-S8
(2) V2607-CR-E4 ..................................................................................................................1-S9
(3) V2607-CR-TE4, V3307-CR-TE4 ................................................................................... 1-S10
(4) V3800-CR-TE4, V3800-CR-TIE4, V3800-CR-TE4C, V3800-CR-TIE4C .......................1-S11
[3] DISASSEMBLY OF DPF MUFFLER FULL ASSEMBLY .....................................................1-S12
(1) D1803-CR-E4, D1803-CR-TE4, V2403-CR-E4, V2403-CR-TE4 ..................................1-S12
(2) V2607-CR-E4 ................................................................................................................1-S13
(3) V2607-CR-TE4, V3307-CR-TE4 ................................................................................... 1-S13
(4) V3800-CR-TE4, V3800-CR-TIE4, V3800-CR-TE4C, V3800-CR-TIE4C .......................1-S14
[4] JUDGMENT OF REUSE OF DPF FILTER COMPLETE BEFORE CLEANING.................. 1-S15
[5] PREPARATION OF "AFTER-TREATMENT DEVICE EXCHANGE REPORT FORM" .......1-S15
[6] PREPARATION OF "DPF CLEANING ORDER FORM" .....................................................1-S16
[7] PACKING, DELIVERING, AND HANDLING STANDARD OF DPF FILTER COMPLETE
.............................................................................................................................................1-S17
[8] DPF CLEANING METHOD, RESPONSIBLE FOR CLEANING CONTRACTOR (REFERENCE)
.............................................................................................................................................1-S18
[9] JUDGMENT OF REUSE OF DPF FILTER COMPLETE AFTER CLEANING, RESPONSIBLE
FOR CLEANING CONTRACTOR ....................................................................................... 1-S19
[10]ASSEMBLY OF DPF MUFFLER FULL ASSEMBLY ...........................................................1-S22
(1) D1803-CR-E4, D1803-CR-TE4, V2403-CR-E4, V2403-CR-TE4 ..................................1-S22
(2) V2607-CR-E4 ................................................................................................................1-S24
(3) V2607-CR-TE4, V3307-CR-TE4 ................................................................................... 1-S26
(4) V3800-CR-TE4, V3800-CR-TIE4, V3800-CR-TE4C, V3800-CR-TIE4C .......................1-S28
[11]MOUNTING OF DPF MUFFLER FULL ASSEMBLY........................................................... 1-S30
(1) D1803-CR-E4, D1803-CR-TE4, V2403-CR-E4, V2403-CR-TE4 ..................................1-S30
(2) V2607-CR-E4 ................................................................................................................1-S31
(3) V2607-CR-TE4, V3307-CR-TE4 ................................................................................... 1-S32
(4) V3800-CR-TE4, V3800-CR-TIE4, V3800-CR-TE4C, V3800-CR-TIE4C .......................1-S33
[12]RESETTING BY USING DIAGNOSIS TOOL ......................................................................1-S34
(1) In Case of Scheduled Maintenance for Every 3,000 Hours of Operation, or In
Case of Heavy Soot Accumulation (P-Code:P3008, J1939:3701-0) ............................. 1-S34
(2) In Case of Excessive Regeneration Frequency (P-Code:P3024, J1939:523602-0) .....1-S36
[13]EXECUTION CONDITION FOR MANUAL REGENERATION ............................................1-S38
[14]ATTACHED FORM..............................................................................................................1-S39
(1) After-Treatment Device Exchange Report Form ........................................................... 1-S39
...
(2) DPF Cleaning Order Form
..........................................................................................1-S40
DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM
KiSC issued 09, 2013 A
1. FUNCTION OF DIESEL PARTICULATE FILTER (DPF)
The Diesel Particulate Filter (hereinafter referred to as the
"DPF") is a filter to capture fine particles (soot and ash) contained in
the exhaust gas of a diesel engine.
The ash content is mainly metallic additives contained in burnt
lubricating oil.
The filter has a honeycomb structure with adjacent cell holes
alternately closed.
In addition, by alternately closing the inlet side and the outlet
side of the exhaust gas, the thin ceramics wall is used as a filter.
As shown in the figure, fine particles in the exhaust gas are
captured when they pass through this thin wall, and the exhaust gas
is discharged as clean gas.
ENGINE
1-S1
DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM
KiSC issued 09, 2013 A
2. DPF REGENERATION AND DPF CLEANING
As mentioned above, the filter is a device to capture fine particles.
The filter is clogged with the increase of the engine operating time.
When this occurs, the filter is "regenerated" by burning and removing soot.
However, since ash cannot be removed by the regeneration of the filter, there is a need for "cleaning" of the filter
by removing ash at regular intervals by a cleaning contractor using specialized equipment.
1. DPF Regeneration
The engine has the DPF regeneration mode described below (function to burn and remove deposited soot).
(a) Automatic regeneration
(b) Parked regeneration
Manual regeneration with a diagnosis
(c)
tool (Diagmaster)
2. Cleaning of ash based on maintenance intervals
Since ash deposited in the filter cannot be removed by regeneration, periodical cleaning is required.
There is a need to clean the filter at the pre-determined maintenance intervals (3,000 hours) by a cleaning
contractor using the specialized equipment by removing the DPF filter complete from the DPF muffler full assy.
3. Cleaning of heavy soot and ash accumulation on filter
a) In the case of cleaning request due to heavy soot accumulation
b) In the case of cleaning request due to increase the frequency of regeneration
In this case, there is a need to clean the filter by a cleaning contractor using the specialized equipment by
removing the DPF filter complete from the DPF muffler full assy.
Regeneration by automatic control is performed using post injection.
The operation of the product can be continued.
If regeneration cannot be carried out depending on the situation of the work, the operation of
the installed product is stopped to carry out regeneration.
Such regeneration is performed as urgent measures in the event of abnormal soot deposition.
ENGINE
1-S2
DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM
KiSC issued 09, 2013 A
ENGINE
3. DPF MAINTENANCE FLOW
When the following condition happened, DPF need to have cleaning or exchange.There are two types of
maintenance flow as "Clean & Return" and "Exchange". Please execute the correct maintenance according to
distributor's instructions.
(1) Every 3,000 hours of operation (Scheduled maintenance)
(2) Cleaning request due to heavy soot accumulation (P-Code:P3008, J1939:3701-0)
(3) Cleaning request due to increase the frequency of regeneration (P-Code:P3024, J1939:523602-0)
1-S3
DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM
KiSC issued 09, 2013 A
[1] CLEANING & RETURN FLOW
ENGINE
1-S4
DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM
KiSC issued 09, 2013 A
[2] DPF EXCHANGE FLOW
ENGINE
1-S5
DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM
IMPORTANT
KiSC issued 09, 2013 A
ENGINE
4. DPF CLEANING PROCEDURE
[1] TO ENSURE SAFETY AND GOOD PERFORMANCE IN DPF
CLEANING PROCEDURE
(1) Always work in the workshop equipped with a electric hoist (including mobile hoist).
(2) Put a product (engine) on a stable ground, and set the parking brake.
(3) As the DPF muffler full assy is hot just after the engine shutdown, make sure to start operation after it gets cool.
(4) Make sure not to let any foreign substances enter the opening section during the operation.
(5) Make sure not to damage the DPF muffler full assy by falling or impact as it contains a ceramic filter.
• Since the DPF that was dropped or given a shock cannot be reused even if there is no damage outwardly,
replace it with a new one.
1-S6
DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM
KiSC issued 09, 2013 A
[2] SEPARATION OF DPF MUFFLER FULL ASSY
Follow the procedures below to separate DPF muffler full assy from a product (engine).
Prior Arrangement for Installation and Removal of DPF
1. Before removing the DPF muffler full assy from a product
(engine), connect the diagnosis tool (Diagmaster), check the
failure history (DTC), and save to the "Project" on the
Diagmaster.
Before removing the DPF for cleaning, keep the records of the
engine serial number, DPF filter complete part number, DPF
filter complete serial number, and engine operating time, which
are required in preparing the DPF cleaning order form.
Record the engine operating time by checking the “Hourmeter”
on the data monitor of the diagnosis tool (Diagmaster).
ENGINE
(1) Engine Serial Number
(2) DPF Filter Complete Part Number /
DPF Filter Complete Serial Number
1-S7
(a) CAN Communication Connector
(For Servicing)
[A] D1803-CR-E4, D1803-CR-TE4,
V2403-CR-E4, V2403-CR-TE4
[B] V2607-CR-E4, V2607-CR-TE4,
V3307-CR-TE4
[C] V3800-CR-TE4, V3800-CR-TIE4,
V3800-CR-TE4C,
V3800-CR-TIE4C
[D] D1803-CR-E4, D1803-CR-TE4,
V2403-CR-E4, V2403-CR-TE4,
V2607-CR-E4
[E] V2607-CR-TE4, V3307-CR-TE4
[F] V3800-CR-TE4, V3800-CR-TIE4,
V3800-CR-TE4C,
V3800-CR-TIE4C
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