Kubota D1803-CR-E4 Workshop Manual
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Kubota D1803-CR-E4 Workshop Manual

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WORKSHOP MANUAL
DIESEL ENGINE
DIESEL PARTICULATE FILTER
HANDLING MANUAL
KiSC issued 09, 2013 A

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  • Page 1 WORKSHOP MANUAL DIESEL ENGINE DIESEL PARTICULATE FILTER HANDLING MANUAL KiSC issued 09, 2013 A...
  • Page 2 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.
  • Page 3 Record of Revisions For pdf, use search function {Search word} to find the all revised locations. Last digit Issue Reference of the Main Revised Point and Corrective Measures {Search word} month Page Code No. 2013.09 • Correction of Workshop Manual The following are the changes from 9Y121-07331 to 9Y121-07332.
  • Page 4 INFORMATION KiSC issued 09, 2013 A...
  • Page 5 INFORMATION CONTENTS 1. SAFETY FIRST ..........................I-1 KiSC issued 09, 2013 A...
  • Page 6 INFORMATION DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM 1. SAFETY FIRST 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. •...
  • Page 7 INFORMATION DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM 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.
  • Page 8 INFORMATION DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM 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.
  • Page 9 ENGINE KiSC issued 09, 2013 A...

  • Page 10: Table Of Contents

    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...

  • Page 11: Function Of Diesel Particulate Filter (Dpf)

    ENGINE DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM 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.

  • Page 12: Dpf Regeneration And Dpf Cleaning

    ENGINE DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM 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"...

  • Page 13: Dpf Maintenance Flow

    ENGINE DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM 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.

  • Page 14: Cleaning & Return Flow

    ENGINE DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM [1] CLEANING & RETURN FLOW 1-S4 KiSC issued 09, 2013 A...

  • Page 15: Dpf Exchange Flow

    ENGINE DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM [2] DPF EXCHANGE FLOW 1-S5 KiSC issued 09, 2013 A...

  • Page 16: Dpf Cleaning Procedure

    ENGINE DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM 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.

  • Page 17: Separation Of Dpf Muffler Full Assy

    (Diagmaster). (1) Engine Serial Number (a) CAN Communication Connector (2) DPF Filter Complete Part Number / (For Servicing) DPF Filter Complete Serial Number [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,...

  • Page 18: D1803-Cr-E4, D1803-Cr-Te4, V2403-Cr-E4, V2403-Cr-Te4

    ENGINE DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM (1) D1803-CR-E4, D1803-CR-TE4, V2403-CR-E4, V2403-CR-TE4 Connector of Exhaust Temperature Sensor and Differential Pressure Sensor 1. Disconnect the connectors of exhaust temperature sensor (6), (7), (8) and differential pressure sensor (2) from wiring harness.

  • Page 19: V2607-Cr-E4

    ENGINE DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM (2) V2607-CR-E4 Connector of Exhaust Temperature Sensor 1. Disconnect the connectors of exhaust temperature sensor (9), (10), (11) and differential pressure sensor (13) from wiring harness. 2. Remove the connectors of exhaust temperature sensor (9), (10), (11) from the bracket.

  • Page 20: V2607-Cr-Te4, V3307-Cr-Te4

    ENGINE DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM (3) V2607-CR-TE4, V3307-CR-TE4 Connector of Exhaust Temperature Sensor 1. Disconnect the connectors of exhaust temperature sensor (7), (8), (9) and differential pressure sensor (11) from wiring harness. 2. Remove the connectors of exhaust temperature sensor (7), (8), (9) from the bracket.

  • Page 21: V3800-Cr-Te4, V3800-Cr-Tie4, V3800-Cr-Te4C, V3800-Cr-Tie4C

    ENGINE DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM (4) V3800-CR-TE4, V3800-CR-TIE4, V3800-CR-TE4C, V3800-CR-TIE4C Connector of Exhaust Temperature Sensor 1. Disconnect the connectors of exhaust temperature sensor (2), (3), (4) and differential pressure sensor (1) from wiring harness. 2. Remove the connectors of exhaust temperature sensor (2), (3), (4) from the bracket.

  • Page 22: Disassembly Of Dpf Muffler Full Assembly

    • 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. (1) D1803-CR-E4, D1803-CR-TE4, V2403-CR-E4, V2403-CR-TE4 DPF Filter Complete 1. Remove the DPF mounting clamp band (2).

  • Page 23: V2607-Cr-E4

    ENGINE DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM (2) V2607-CR-E4 Differential Pressure Sensor and DPF Filter Complete 1. Remove the tube (5) from the differential pressure pipe (2). 2. Remove the tube (6) from the differential pressure pipe (3). 3. Remove the differential pressure sensor (7). 4.

  • Page 24: V3800-Cr-Te4, V3800-Cr-Tie4, V3800-Cr-Te4C, V3800-Cr-Tie4C

    ENGINE DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM (4) V3800-CR-TE4, V3800-CR-TIE4, V3800-CR-TE4C, V3800-CR-TIE4C Differential Pressure Sensor and DPF Filter Complete 1. Remove the tube (3) from the differential pressure pipe (10). 2. Remove the tube (4) from the differential pressure pipe (6). 3.

  • Page 25: Judgment Of Reuse Of Dpf Filter Complete Before Cleaning

    KUBOTA sales company. Preparation of "After-Treatment Device Exchange Report Form" 1. Fill out the attached form (After-Treatment Device Exchange Report Form). 2. Send the report form to a service representative of KUBOTA sales company. 1-S15 KiSC issued 09, 2013 A...

  • Page 26: Preparation Of "Dpf Cleaning Order Form

    ENGINE DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM [6] PREPARATION OF "DPF CLEANING ORDER FORM" Preparation of "DPF Cleaning Order Form" 1. Fill out the attached form (DPF Cleaning Order Form). 2. Enclose the form when sending DPF filter complete to a cleaning contractor.

  • Page 27: Packing, Delivering, And Handling Standard Of Dpf Filter Complete

    ENGINE DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM [7] PACKING, DELIVERING, AND HANDLING STANDARD OF DPF FILTER COMPLETE Follow the below procedures to pack the separated DPF filter complete and to send it to a cleaning contractor. [Packing and delivering] (1) Refer to the example of packaging, cover and seal the DPF filter complete with a plastic bag so that soot and ash are not scattered in the air, and pack it in a cardboard box having cushioning material in it.

  • Page 28: Dpf Cleaning Method, Responsible For Cleaning Contractor (Reference)

    ENGINE DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM [8] DPF CLEANING METHOD, RESPONSIBLE FOR CLEANING CONTRACTOR (REFERENCE) NOTE • DPF cleaning must be carried out by authorized cleaning contractor. (1) Workers should wear a mask and goggles, and other required protective equipments according to local relevant regulations whenever cleaning DPF.

  • Page 29: Judgment Of Reuse Of Dpf Filter Complete After Cleaning, Responsible For Cleaning Contractor

    ENGINE DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM [9] JUDGMENT OF REUSE OF DPF FILTER COMPLETE AFTER CLEANING, RESPONSIBLE FOR CLEANING CONTRACTOR IMPORTANT • After the cleaning contractor has cleaned the DPF filter complete, measure the quantity of remaining ash in the following procedure, and evaluate the reusability. 1-S19 KiSC issued 09, 2013 A...
  • Page 30 (2) DPF Filter Complete (C) Accumulated Ash (D) 150 mm (5.91 in.) (a) Serial No. (E) Actual Cell Depth (F) Accumulated Ash Depth (G) Cell Depth [A] D1803-CR-E4, D1803-CR-TE4, V2403-CR-E4, V2403-CR-TE4 [B] V2607-CR-E4 [C] V2607-CR-TE4, V3307-CR-TE4 [D] V3800-CR-TE4, V3800-CR-TIE4, V3800-CR-TE4C, V3800-CR-TIE4C...
  • Page 31 (2) DPF Filter Complete (C) Accumulated Ash (D) 150 mm (5.91 in.) (a) Serial No. (E) Actual Cell Depth (F) Accumulated Ash Depth (G) Cell Depth [A] D1803-CR-E4, D1803-CR-TE4, V2403-CR-E4, V2403-CR-TE4 [B] V2607-CR-E4 [C] V2607-CR-TE4, V3307-CR-TE4 [D] V3800-CR-TE4, V3800-CR-TIE4, V3800-CR-TE4C, V3800-CR-TIE4C...

  • Page 32: Assembly Of Dpf Muffler Full Assembly

    ENGINE DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM [10] ASSEMBLY OF DPF MUFFLER FULL ASSEMBLY (1) D1803-CR-E4, D1803-CR-TE4, V2403-CR-E4, V2403-CR-TE4 IMPORTANT • Visually check if there is no damage (ceramic crack or damage) with the cleaned and returned DPF filter complete.
  • Page 33 ENGINE DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM Differential Pressure Pipe (In the event of need for replacement) When the differential pressure pipe is removed or has to be replaced because it is damaged, follow the procedure given below. 1. Clean the screw parts and apply anti seize agent (NEVER SEEZ made by Bostik, Grade: Pure nickel special grade).

  • Page 34: V2607-Cr-E4

    ENGINE DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM (2) V2607-CR-E4 IMPORTANT • Visually check if there is no damage (ceramic crack or damage) with the cleaned and returned DPF filter complete. DOC Catalyst Complete, DPF Filter Complete and DPF Outlet Body 1.
  • Page 35 ENGINE DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM Differential Pressure Pipe (In the event of need for replacement) When the differential pressure pipe is removed or has to be replaced because it is damaged, follow the procedure given below. 1. Clean the screw parts and apply anti seize agent (NEVER SEEZ made by Bostik, Grade: Pure nickel special grade).

  • Page 36: V2607-Cr-Te4, V3307-Cr-Te4

    ENGINE DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM (3) V2607-CR-TE4, V3307-CR-TE4 IMPORTANT • Visually check if there is no damage (ceramic crack or damage) with the cleaned and returned DPF filter complete. DOC Catalyst Complete, DPF Filter Complete and DPF Outlet Body 1.
  • Page 37 ENGINE DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM Differential Pressure Pipe (In the event of need for replacement) When the differential pressure pipe is removed or has to be replaced because it is damaged, follow the procedure given below. 1. Clean the screw parts and apply anti seize agent (NEVER SEEZ made by Bostik, Grade: Pure nickel special grade).

  • Page 38: V3800-Cr-Te4, V3800-Cr-Tie4, V3800-Cr-Te4C, V3800-Cr-Tie4C

    ENGINE DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM (4) V3800-CR-TE4, V3800-CR-TIE4, V3800-CR-TE4C, V3800-CR-TIE4C IMPORTANT • Visually check if there is no damage (ceramic crack or damage) with the cleaned and returned DPF filter complete. DOC Catalyst Complete, DPF Filter Complete and DPF Outlet Body 1.
  • Page 39 ENGINE DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM Differential Pressure Pipe (In the event of need for replacement) When the differential pressure pipe is removed or has to be replaced because it is damaged, follow the procedure given below. 1. Clean the screw parts and apply anti seize agent (NEVER SEEZ made by Bostik, Grade: Pure nickel special grade).

  • Page 40: Mounting Of Dpf Muffler Full Assembly

    Follow the below procedures to mount DPF muffler full assy to a product (engine). After mounting it, start up an engine and check gas leak. (1) D1803-CR-E4, D1803-CR-TE4, V2403-CR-E4, V2403-CR-TE4 Mounting of DPF Muffler Full Assembly 1. Assemble the DPF muffler full assembly (DPF) (1) with the muffler full assembly (DPF) mounting screw (2) and the screw of muffler flange.

  • Page 41: V2607-Cr-E4

    ENGINE DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM (2) V2607-CR-E4 Mounting of Muffler Full Assembly (DPF) 1. Assemble the muffler full assembly (DPF) (1) with the muffler full assembly (DPF) mounting screw (2) and the screw of muffler flange. 49.0 to 55.9 N·m Muffler full assembly (DPF) 5.00 to 5.70 kgf·m mounting screw...

  • Page 42: V2607-Cr-Te4, V3307-Cr-Te4

    ENGINE DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM (3) V2607-CR-TE4, V3307-CR-TE4 Mounting of DPF Muffler Full Assy 1. Assemble the muffler full assembly (DPF) (1) with the muffler full assembly (DPF) mounting screw (2) and the screw of muffler flange. 49.0 to 55.9 N·m Muffler full assembly (DPF) 5.00 to 5.70 kgf·m mounting screw...

  • Page 43: V3800-Cr-Te4, V3800-Cr-Tie4, V3800-Cr-Te4C, V3800-Cr-Tie4C

    ENGINE DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM (4) V3800-CR-TE4, V3800-CR-TIE4, V3800-CR-TE4C, V3800-CR-TIE4C Mounting of Muffler Full Assembly (DPF) 1. Set the chain sling by using shackle at two places (a) and (b) as shown in the photograph. 2. Lift the muffler full assembly (DPF) (1), and guide it to the installation position.

  • Page 44: Resetting By Using Diagnosis Tool

    ENGINE DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM [12] RESETTING BY USING DIAGNOSIS TOOL IMPORTANT • The engine ECU memorizes the quantity of soot and ash deposited in the DPF. So, the value needs to be reset by the "DPF Soot Load Reset", "DPF Regeneration Interval Time Reset" in the utility functions of the diagnosis tool (Diagmaster) immediately after the cleaning and replacement of the filter.
  • Page 45 ENGINE DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM Step2 1. Execute the request by the "DPF Manual Regeneration Request Function" in the utility functions of the diagnosis tool, and give the command to execute on the application side. (When the execution button is not on the application side, ECU on the application side receives the request signal and gives command to execute.) Step3...

  • Page 46: In Case Of Excessive Regeneration Frequency (P-Code:p3024, J1939:523602-0)

    ENGINE DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM (2) In Case of Excessive Regeneration Frequency (P-Code:P3024, J1939:523602-0) Step1 1. Reset the value by the "DPF Regeneration Interval Time Reset" in the utility functions of the diagnosis tool. 1-S36 KiSC issued 09, 2013 A...
  • Page 47 ENGINE DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM Step2 1. Reset the value by "DPF Soot Load Reset" in the utility functions of the diagnosis tool. 1-S37 KiSC issued 09, 2013 A...

  • Page 48: Execution Condition For Manual Regeneration

    ENGINE DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM Step3 1. Execute the request by the "DPF Manual Regeneration Request Function" in the utility functions of the diagnosis tool, and give the command to execute on the application side. (When the execution button is not on the application side, ECU on the application side receives the request signal and gives command to execute.) Step4...

  • Page 49: Attached Form

    ENGINE DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM [14] ATTACHED FORM (1) After-Treatment Device Exchange Report Form 1-S39 KiSC issued 09, 2013 A...

  • Page 50: Dpf Cleaning Order Form

    ENGINE DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM (2) DPF Cleaning Order Form 1-S40 KiSC issued 09, 2013 A...
  • Page 51 ENGINE DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM 1-S41 KiSC issued 09, 2013 A...
  • Page 52 ENGINE DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM 1-S42 KiSC issued 09, 2013 A...
  • Page 53 ENGINE DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM 1-S43 KiSC issued 09, 2013 A...
  • Page 54 ENGINE DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM 1-S44 KiSC issued 09, 2013 A...
  • Page 55 EDITOR : KUBOTA FARM & INDUSTRIAL MACHINERY SERVICE, LTD. 64, ISHIZU-KITAMACHI, SAKAI-KU, SAKAI-CITY, OSAKA, 590-0823, JAPAN PHONE : ( 81 ) 72-241-1129 : ( 81 ) 72-245-2484 E-mail : ks_g.ksos-pub@kubota.com Printed in Japan 2013. 09, S, EI, EI, engusa Code No.9Y111-07332 2012.

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