Kubota D1803-CR-TIE4B-KEA-2 Installation Instructions Manual
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Kubota D1803-CR-TIE4B-KEA-2 Installation Instructions Manual

Carb/epa certified tier 4f engines
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Appendix 5
Kubota
Installation Instructions
CARB/EPA certified Tier 4f engines:
D1803-CR-TIE4B-KEA-1 (1J497-10000)
D1803-CR-TIE4B-KEA-2 (1J497-20000)
D1803-CR-TIE4BG-KEA-1 (1J478-10000)
V2403-CR-TIE4B-KEA-1 (1J498-10000)
V2403-CR-TIE4B-KEA-2 (1J498-20000)
V2403-CR-TIE4BG-KEA-1 (1J488-10000)
The instructions in this document supersede any other previous instructions provided by Kubota.
Kubota Emission-Related Installation Instructions
④
Document Number : KEA-STD-03-CRS-DOC-001-
Page No. 1

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Summary of Contents for Kubota D1803-CR-TIE4B-KEA-2

  • Page 1 CARB/EPA certified Tier 4f engines: D1803-CR-TIE4B-KEA-1 (1J497-10000) D1803-CR-TIE4B-KEA-2 (1J497-20000) D1803-CR-TIE4BG-KEA-1 (1J478-10000) V2403-CR-TIE4B-KEA-1 (1J498-10000) V2403-CR-TIE4B-KEA-2 (1J498-20000) V2403-CR-TIE4BG-KEA-1 (1J488-10000) The instructions in this document supersede any other previous instructions provided by Kubota. Kubota Emission-Related Installation Instructions ④ Document Number : KEA-STD-03-CRS-DOC-001- Page No. 1...

  • Page 2: Table Of Contents

    5. Engine Control System (Wire Harness / Display Panel)---------- page 48-50 6. Certification Labels ------------------------------------------------------- page 51 7. Application Review Requirements-------------------------------------- page 52 8. Installation Instructions Revision Log---------------------------------- page 53 Kubota Emission-Related Installation Instructions ④ Document Number : KEA-STD-03-CRS-DOC-001- Page No. 2...

  • Page 3: Important Notice

    Failing to follow these instructions when installing a certified engine in a piece of nonroad equipment violates federal law (40 CFR 1068.105(b)), and is subject to fines or other penalties as described in the Clean Air Act. Kubota Emission-Related Installation Instructions ④ Document Number : KEA-STD-03-CRS-DOC-001-...

  • Page 4: Objective Items

    Objective Items 1. Exhaust System Kubota supplies a certified diesel oxidation catalyst (DOC) assembly. FEA must use the Kubota supplied certified exhaust after treatment and assemble the exhaust system parts according to the instructions. No other exhaust after treatment is certified for use with these KEA standard engine models.

  • Page 5: Appendix

    6. Certification Labels Kubota installs the certification label on the cylinder head cover. If the final engine assembler installs the engine in a way that makes the engine’s emission control information label hard to read during normal engine maintenance, the final engine assembler must place a duplicate label on the equipment, as described in 40 CFR 1068.105.

  • Page 6: Exhaust System

    Exhaust system means the layout of all parts from the exhaust manifold to the exhaust exit. An example of exhaust system is shown below. No.4 : Tail Pipe No.1 : Diesel Oxidation Catalyst (DOC) No.3 : Bolt No.2 : Gasket Kubota Emission-Related Installation Instructions ④ Document Number : KEA-STD-03-CRS-DOC-001- Page No. 6...
  • Page 7 Appendix 5 1. Exhaust System Kubota supplies the following parts as shown below, these parts must be used in the exhaust system. FEA supplied parts must meet the installation instruction requirements. Kubota Part Name KBT Part No. Q'ty Engine Model...
  • Page 8 1-2-1. DOC Installation Options: A. Standard DOC Installation Position: The DOC is installed onto the top side of the flywheel housing at the Kubota production facility as the standard configuration. Kubota recommends to keep the DOC in this factory location.
  • Page 9 50 mm Hg Industrial V2403- CR- TIE4B- KEA- 2 1J498- 20000 50 mm Hg Industrial V2403- CR- TIE4BG- KEA- 1 1J488- 10000 40 mm Hg Back Pressure Measurement Location Kubota Emission-Related Installation Instructions ④ Document Number : KEA-STD-03-CRS-DOC-001- Page No. 9...
  • Page 10 1-2-1.B DOC Outlet Angle Adjustment Procedure (Option) 1. Kubota recommends to keep the DOC outlet angle in the standard position, but certain applications will require adjustment. 2. Adjusting the DOC outlet angle is acceptable to meet the installation requirements of the machine.
  • Page 11 Exhaust pipe insulation may be required and is recommended to meet this requirement. Muffler Flange Measurement Location for Exhaust Back Pressure Measurement Location for Exhaust Temperature (∆T) EXAMPLE REMOTE MOUNT DOC Kubota Emission-Related Installation Instructions ④ Document Number : KEA-STD-03-CRS-DOC-001- Page No. 11...
  • Page 12 F. Relocated DOC needs to be mounted without excessive strain/load on V-band clamps. G. It is strongly recommended to use the Kubota supplied DOC mounting brackets (shown below in blue). H. DOC inclination angle must follow the required installation angles defined in the next page.
  • Page 13 Please note the required installation angle limits below (viewed from DOC inlet side) II. Option #2: Incline the DOC up to +/-14 deg. Option #1 Option #2 D1803-CR-TIE4B-*** DOC Inlet Band Clamp V2403-CR-TIE4B-*** Base position Kubota Emission-Related Installation Instructions ④ Document Number : KEA-STD-03-CRS-DOC-001- Page No. 13...
  • Page 14 5. Intermediate Exhaust Pipe Vibration: for remote mounted DOC - Acceleration/Displacement must not exceed the limits prescribed in the application review form. - Vibration must be checked during the application review. Kubota Emission-Related Installation Instructions ④ Document Number : KEA-STD-03-CRS-DOC-001- Page No. 14...

  • Page 15: Exhaust System

    2. Confirm that water does not enter the exhaust system from the tail pipe outlet in all operating conditions. If water entry is possible, install a rain cover or similar device. Kubota Emission-Related Installation Instructions ④ Document Number : KEA-STD-03-CRS-DOC-001-...

  • Page 16: Intake System

    No.1 : Air Cleaner Assembly No.7 : Rain Cap / Pre-cleaner No.6 : Pre-Cleaner Hose No.4 : Air Inlet Hose No.2 : Mass Air Flow Sensor No.5 : Air Cleaner Bracket Kubota Emission-Related Installation Instructions ④ Document Number : KEA-STD-03-CRS-DOC-001- Page No. 16...
  • Page 17 Appendix 5 2. Intake System Kubota supplies the following parts as shown below, these parts MUST be used in the intake system. Kubota Part Name KBT Part No. Q'ty Engine Model Remarks supplied 1J497- 1101△ 7" Non- Rotatable A/ C (S/ N: <7HU* * * * ) D1803- CR- TIE4B- KEA- 1 1E690- 1101△...
  • Page 18 MAF sensor output. The next pages in this section illustrate the correct installation location for each air intake system. Mass Air Flow Sensor Kubota Emission-Related Installation Instructions ④ Document Number : KEA-STD-03-CRS-DOC-001- Page No. 18...
  • Page 19 Appendix 5 2. Intake System 2-2. Standard Intake System Layout 2-2-2. Standard Air Intake System Layout for D1803-CR-TIE4B-KEA-1 and D1803-CR-TIE4B-KEA-2 Models Incorrect air intake system layout will cause emission non-compliance. The standard air intake system layout is illustrated below. Kubota Emission-Related Installation Instructions ④...
  • Page 20 2-2. Standard Intake System Layout 2-2-3. Standard Air Intake System Layout for D1803-CR-TIE4BG-KEA-1 Incorrect air intake system layout will cause emission non-compliance. The standard air intake system layout is illustrated below. Kubota Emission-Related Installation Instructions ④ Document Number : KEA-STD-03-CRS-DOC-001- Page No. 20...
  • Page 21 2-2-4. Standard Air Intake System Layout for V2403-CR-TIE4B-KEA-1 and V2403-CR-TIE4B-KEA-2 Models Incorrect air intake system layout will cause emission non-compliance. The standard air intake system layout is illustrated below. Kubota Emission-Related Installation Instructions ④ Document Number : KEA-STD-03-CRS-DOC-001- Page No. 21...
  • Page 22 2-2. Standard Intake System Layout 2-2-5. Standard Air Intake System Layout for V2403-CR-TIE4BG-KEA-1 Incorrect air intake system layout will cause emission non-compliance. The standard air intake system layout is illustrated below. Kubota Emission-Related Installation Instructions ④ Document Number : KEA-STD-03-CRS-DOC-001- Page No. 22...
  • Page 23 In some cases the standard intake system layout may not fit within the OEM’s engine compartment due to interference or serviceability concerns. Kubota has added the intake system flexibility options to certain engine models to overcome these installation challenges. The intake system flexibility is only allowed on certain engine models and serial numbers. Please refer to the list in the below table to see if the intake system options are eligible for the engine being installed into the OEM equipment.
  • Page 24 Option #4: Rotate the air cleaner relative to the turbo charger inlet axis. Multiple combinations of option #1, 2, 3, and 4 are acceptable. See examples of a few variations on the next page. Up to 500 mm Kubota Emission-Related Installation Instructions ④ Document Number : KEA-STD-03-CRS-DOC-001-...
  • Page 25 Option #1: 90 deg. Option #2: 200 mm extension Option #2: No extension Option #2: 100 mm extension Option #3: 40 deg. Option #3: 50 deg. Option #3: 285 deg. Kubota Emission-Related Installation Instructions ④ Document Number : KEA-STD-03-CRS-DOC-001- Page No. 25...
  • Page 26 The air cleaner that is provided for the standard KEA engines with intake system flexibility has a rotatable inlet. It is acceptable to adjust the air cleaner inlet to angle (0-360 deg.) as illustrated below except for the limitations outlined in the following pages. Kubota Emission-Related Installation Instructions ④ Document Number : KEA-STD-03-CRS-DOC-001-...
  • Page 27 The extension pipe must be OEM procured and it must comply with the below requirements: A. The OEM must use the rubber coupling which is supplied by Kubota. B. The rubber coupling must fit tightly on the air cleaner and extension pipe in order to avoid dust in the intake system.
  • Page 28 I. The pipe must fall within the dimensions outlined in the below drawing. J. Pipe spec must follow ASTM A511, ASTM A519, or similar standards. FOR 7” Air Cleaner (2 3/8” OD) FOR 8” Air Cleaner (3 ½” OD) Kubota Emission-Related Installation Instructions ④ Document Number : KEA-STD-03-CRS-DOC-001- Page No. 28...
  • Page 29 Option #3: Rotate the air cleaner relative to the air cleaner outlet axis. It is acceptable to adjust the air cleaner installation to angle (0-360 degree) illustrated below except for the limitations outlined in the following pages. Kubota Emission-Related Installation Instructions ④ Document Number : KEA-STD-03-CRS-DOC-001- Page No. 29...
  • Page 30 It is acceptable to adjust the air cleaner installation to exactly 90 degrees as illustrated below. Other angles besides 90 degree are not permitted. Also, see other limitations outlined in the following pages for option #4. Kubota Emission-Related Installation Instructions ④...
  • Page 31 See below for air cleaner installation locations that are acceptable. These installations cause the mass air flow sensor to fall outside of the acceptable sensor performance range. Configuration NOTacceptable for D1803-CR-TIE4B-KEA-1, D1803-CR-TIE4B-KEA-2 AIR CLEANER INSTALLATION ANGLE (OPTION #3): Perpendicular to Crankshaft 0 +/- 45°...
  • Page 32 A. The exact combination of AC Inlet, AC Angle, and Heights in this table can be used as specified. B. Any other combination not listed in this table is not permitted. Acceptable Combinations for D1803-CR-TIE4B-KEA-1, D1803-CR-TIE4B-KEA-2 ACInlet ACAngle Height...
  • Page 33 Standard ( 0 mm Extension ) Extension = 250 mm Fixed Length Extension = 250 mm Fixed Length Extension = 500 mm Fixed Length Height ACAngle ACInlet (Option #2) (Option #3) (Option #1) Kubota Emission-Related Installation Instructions ④ Document Number : KEA-STD-03-CRS-DOC-001- Page No. 33...
  • Page 34 5. Air Cleaner Bracket: - The OEM is responsible to prepare the air cleaner mounting bracket if the air cleaner is moved from the standard position (intake system flexibility). Kubota Emission-Related Installation Instructions ④ Document Number : KEA-STD-03-CRS-DOC-001- Page No. 34...
  • Page 35 D1803- CR- TIE4B- KEA- 1 D1803- CR- TIE4B- KEA- 2 D1803- CR- TIE4BG- KEA- 1 V2403- CR- TIE4B- KEA- 1 V2403- CR- TIE4B- KEA- 2 V2403- CR- TIE4BG- KEA- 1 Kubota Emission-Related Installation Instructions ④ Document Number : KEA-STD-03-CRS-DOC-001- Page No. 35...

  • Page 36: Intake System

    2-8. Charge Air Cooler Installation Requirements The Kubota 03-CRS DOC engines require a charge air cooler. To prevent decreases of engine output performance and to maintain emission compliance, the charge air cooler must meet the following criteria. The charge air cooler pressure drop and temperature drop MUST be checked during the application review.

  • Page 37: Fuel System

    ① Lift Pump ⑧ Coupler Pre- ⑤ ⑥ ⑦ Assy Eye-bolt Supply ⑨ Fuel Cap Assy Pump ⑩ Clamp ⑪ T fitt ④ Water ② Check ③ Filter Separator Valve Kubota Emission-Related Installation Instructions ④ Document Number : KEA-STD-03-CRS-DOC-001- Page No. 37...
  • Page 38 Appendix 5 3. Fuel System Kubota has the parts shown in the previous drawing and recommends that these parts be used in the fuel system. FEA supplied parts must meet the installation instruction requirements. Kubota Part Name KBT Part No. Q'ty...
  • Page 39 The fuel supply lines, return hoses, and other loose components must be installed according to the guidelines shown on the following pages. Kubota Emission-Related Installation Instructions ④ Document Number : KEA-STD-03-CRS-DOC-001-...
  • Page 40 Review. Please note the expected values and measurement locations = Fuel Supply Design Target = Fuel Return Fuel Pressure < 20 kPa Design Target Fuel > -30 kPa Fuel < 75 ° C Kubota Emission-Related Installation Instructions ④ Document Number : KEA-STD-03-CRS-DOC-001- Page No. 40...
  • Page 41 1. Maximum vibration levels not to exceed 3G. 2. Pump can be mounted in horizontal or vertical orientation. 4. Do not mount Pump in high temperature environments which can create cavitation or vapor lock conditions. Kubota Emission-Related Installation Instructions ④ Document Number : KEA-STD-03-CRS-DOC-001-...
  • Page 42 Appendix 5 3. Fuel System 3-5. Fuel Filter and Water Separator Kubota supplies fuel filter (1J456-4301△ ). Fuel filter shall be installed between feed pump and injection pump. Supply Pump = Fuel Supply = Fuel Return M14x1.5 x 15mm ports for banjo...

  • Page 43: Fuel System

    - Temperature < 75 ° C @ the supply pump - Return pressure < 20 kPa @ the tank - Fuel Filter: - Filtration ≥ 98.7% at 3-5µm (per ISO 19438) Kubota Emission-Related Installation Instructions ④ Document Number : KEA-STD-03-CRS-DOC-001- Page No. 43...

  • Page 44: Engine Control Unit (Ecu)

    2-2. The ECU temperature must be checked during the application review. 2-3. The ECU vibration levels must be checked during the application review. 2-4. The ECU must be mounted within the installation angles shown below: Kubota Emission-Related Installation Instructions ④ Document Number : KEA-STD-03-CRS-DOC-001-...

This manual is also suitable for:

D1803-cr-tie4b-kea-1D1803-cr-tie4bg-kea-1V2403-cr-tie4b-kea-1V2403-cr-tie4b-kea-2V2403-cr-tie4bg-kea-1

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