Kubota V2403-CR-TE4BG Manuals

Manuals and User Guides for Kubota V2403-CR-TE4BG. We have 2 Kubota V2403-CR-TE4BG manuals available for free PDF download: Workshop Manual, Operator's Manual

Kubota V2403-CR-TE4BG Workshop Manual

Kubota V2403-CR-TE4BG Workshop Manual (309 pages)

Brand: Kubota | Category: Engine | Size: 24 MB

Table of Contents

Table of Contents

5
- Safety
  
  17
  - Safety First
    18
    
    Preparing for Emergencies
    18
    
    Working Precautions
    18
    
    Working Cautions
    19
    
    Preventing Fires
    20
    
    Starting the Machine Safely
    20
    
    Avoiding High Pressure Fluid
    21
    
    Avoiding Hot Exhaust
    21
    
    Cleaning Exhaust Filter
    21
    
    Preventing Acid Burns
    21
- General
  
  24
- Maintenance
  
  67
Maintenance Check List

68
- Inspection Item
  
  69
- Every 250 Hrs Every 400 Hrs
  
  69
- Initial
  
  69
  - Check and Maintenance
    72
    
    Checking Engine Oil Level
    72
    
    Daily Check Points
    72
    
    Checking Coolant Level
    73
    
    Checking Fuel Level
    73
    
    Changing Engine Oil
    74
    
    Check Points of Initial 50 Hours
    74
    
    Checking Fan Belt
    74
    
    Bands
    75
    
    Check Point of Every 50 Hours
    75
    
    Checking Fuel Hoses and Clamp
    75
    
    Checking Fuel Hoses and Clamp Bands
    75
    
    Replacing Oil Filter Cartridge
    75
    
    Check Points of Every 250 Hours
    76
    
    Checking and Draining Water Separator (Type 1)
    76
    
    Cleaning Air Cleaner Primary Element
    76
    
    Cleaning of Air Cleaner Element
    76
    
    Adjusting Fan Belt Tension
    77
    
    Checking Radiator Hose and Clamp Bands
    77
    
    Changing Engine Oil
    78
    
    Check Points of Every 400 Hours
    78
    
    Checking Intake Air Line
    78
    
    Check Points of Every 500 Hours
    79
    
    Replacing Fuel Filter Cartridge
    79
    
    Replacing Oil Filter Cartridge
    79
    
    (Type2)
    80
    
    Cleaning Water Jacket and Radiator Interior
    80
    
    Cleaning Water Separator (Type 1)
    80
    
    Replacing Water Separator Filter
    80
    
    Replacing Water Separator Filter (Type 2)
    80
    
    Replacing Fan Belt
    82
    
    Check Point of Every 1000 Hours
    83
    
    Checking Valve Clearance
    83
    
    Check Points of Every 1500 Hours
    84
    
    Checking Injector (with Diagmas- Ter)
    84
    
    Checking Injector (with Diagmaster)
    84
    
    Checking EGR Cooler
    85
    
    Checking Positive Crankcase Venti- Lation (PCV) Valve
    86
    
    Checking Positive Crankcase Ventilation (PCV) Valve
    86
    
    Replacing Oil Separator Element
    86
    
    Check Points of Every 3000 Hours
    87
    
    Checking Turbocharger
    87
    
    Cleaning DPF
    87
    
    Judging Reuse of DPF Filter Comp before Cleaning (Service Dealer)
    89
    
    Judging Reuse of DPF Filter Comp after Cleaning (Cleaning Contractor)
    90
    
    Checking EGR System (with Diag- Master)
    91
    
    Checking EGR System (with Diagmaster)
    91
    
    Check Points of Every 1 Year
    92
    
    Checking DPF Differential Pressure Pipes and Hoses
    92
    
    Replacing Air Cleaner Element
    92
    
    Checking EGR Piping
    93
    
    Checking Intake Air Line
    93
    
    Check Points of Every 2 Years
    94
    
    Checking Exhaust Manifold
    94
    
    Replacing Fan Belt
    94
    
    Replacing Oil Separator Rubber Hose
    94
    
    Replacing Water Separator Filter (Type 2)
    94
    
    Changing Radiator Coolant
    95
    
    Replacing EGR Cooler Hose
    95
    
    Replacing Intake Hose (after Air Flow Sensor) and Intercooler Hose
    95
    
    Replacing Lubricant Hose
    95
    
    Replacing Rubber Hose of Differential Pressure Sensor
    95
    
    Replacing Water Hose
    95
    
    Replacing Radiator Hose and Clamp Bands
    97
    
    Replacing Fuel Hose and Clamps
    98
    
    Replacing Intake Air Line
    98
- Daily 50 Hrs
  
  69
- Hrs
  
  69
- Every 1500 Hrs
  
  69
- Every 3000 1 Year
  
  69
- Engine
  
  100
  - Mechanism
    101
    
    Feature of Combustion (E-CDIS)
    101
    
    Flow of Combustion (E-CDIS)
    101
    
    General (Introduction)
    101
    
    Structure of Combustion (Center Direct Injection System (E-CDIS))
    101
    
    Control of Combustion (E-CDIS)
    102
    
    Engine Body
    103
    
    Structure of Engine Body
    103
    
    Crankcase
    104
    
    Cylinder Head
    104
    
    Feature of Engine Body
    104
    
    Function of Crankcase
    104
    
    Function of Cylinder Head
    104
    
    Outline of Crankcase
    104
    
    Outline of Cylinder Head
    104
    
    Specification of Crankcase
    104
    
    Structure of Crankcase
    104
    
    Structure of Cylinder Head
    104
    
    Breather
    105
    
    Cylinder Head Cover
    105
    
    Function of Breather
    105
    
    Function of Cylinder Head Cover
    105
    
    Oil Separator
    105
    
    Outline of Breather
    105
    
    Outline of Cylinder Head Cover
    105
    
    Outline of Oil Separator
    105
    
    Structure of Breather
    105
    
    Structure of Cylinder Head Cover
    105
    
    Function of Oil Separator
    106
    
    Function of Piston
    106
    
    Outline of Piston
    106
    
    Piston
    106
    
    Specification of Piston
    106
    
    Structure of Oil Separator
    106
    
    Structure of Piston
    106
    
    Connecting Rod
    107
    
    Function of Piston Ring
    107
    
    Outline of Connecting Rod
    107
    
    Outline of Piston Ring
    107
    
    Piston Ring
    107
    
    Specification of Piston Ring
    107
    
    Structure of Connecting Rod
    107
    
    Structure of Piston Ring
    107
    
    Function of Connecting Rod
    108
  - Crankshaft
    108
    
    Function of Crankshaft
    108
    
    Outline of Crankshaft
    108
    
    Specification of Crankshaft
    108
    
    Structure of Crankshaft
    108
  - Main Bearing Case
    108
    
    Function of Main Bearing Case
    108
    
    Outline of Main Bearing Case
    108
    
    Structure of Main Bearing Case
    108
  - Flywheel
    109
    
    Function of Flywheel
    109
    
    Outline of Flywheel
    109
    
    Specification of Flywheel
    109
    
    Structure of Flywheel
    109
  - Rocker Arm
    109
    
    Outline of Rocker Arm
    109
    
    Structure of Rocker Arm
    109
    
    Function of Rocker Arm
    110
  - Camshaft
    110
    
    Function of Camshaft
    110
    
    Outline of Camshaft
    110
    
    Specification of Camshaft
    110
    
    Structure of Camshaft
    110
  - Valve
    110
    
    Function of Valve
    110
    
    Outline of Valve
    110
    
    Structure of Valve
    110
  - Tappet
    111
    
    Function of Tappet
    111
    
    Outline of Tappet
    111
    
    Structure of Tappet
    111
  - Push Rod
    111
    
    Outline of Push Rod
    111
    
    Structure of Push Rod
    111
    
    Function of Push Rod
    112
  - Timing Gears
    112
    
    Function of Timing Gears
    112
    
    Outline of Timing Gears
    112
    
    Structure of Timing Gears
    112
  - Fuel System
    113
    
    Structure of Common Rail System (CRS) Engine
    113
    
    Feature of Common Rail System (CRS) Engine
    114
    
    Flow of Common Rail System (CRS) Engine
    115
    
    Control of Common Rail System (CRS) Engine
    117
    
    Fuel Tank
    117
    
    Function of Fuel Tank
    117
    
    Outline of Fuel Tank
    117
    
    Outline of Water Separator
    117
    
    Specification of Fuel Tank
    117
    
    Structure of Fuel Tank
    117
    
    Structure of Water Separator (Type1)
    117
    
    Structure of Water Separator (Type2)
    117
    
    Water Separator
    117
    
    Function of Water Separator
    118
    
    Specification of Water Separator (Type2)
    118
  - Electromagnetic Fuel Feed Pump
    118
    
    Function of Electromagnetic Fuel Feed Pump
    118
    
    Outline of Electromagnetic Fuel Feed Pump
    118
    
    Specification of Electromagnetic Fuel Feed Pump
    118
    
    Structure of Electromagnetic Fuel Feed Pump
    118
  - Fuel Feed Pump
    119
    
    Function of Fuel Feed Pump
    119
    
    Outline of Fuel Feed Pump
    119
    
    Specification of Fuel Feed Pump
    119
    
    Structure of Fuel Feed Pump
    119
  - Fuel Filter
    120
    
    Function of Fuel Filter
    120
    
    Outline of Fuel Filter
    120
    
    Specification of Fuel Filter
    120
    
    Structure of Fuel Filter
    120
  - Supply Pump
    120
    
    Outline of Supply Pump
    120
    
    Structure of Supply Pump
    120
    
    Function of Supply Pump
    121
    
    Specification of Supply Pump
    123
  - Injection Pipe
    123
    
    Outline of Injection Pipe
    123
    
    Structure of Injection Pipe
    123
    
    Function of Injection Pipe
    124
  - Rail Assembly
    124
    
    Function of Rail Assembly
    124
    
    Outline of Rail Assembly
    124
    
    Structure of Rail Assembly
    124
    
    Specification of Rail Assembly
    125
  - Injector
    126
    
    Outline of Injector
    126
    
    Structure of Injector
    126
    
    Function of Injector
    127
    
    Specification of Injector
    129
  - Overflow Pipe
    129
    
    Function of Overflow Pipe
    129
    
    Outline of Overflow Pipe
    129
    
    Structure of Overflow Pipe
    129
  - Check Valve
    129
    
    Function of Check Valve
    129
    
    Outline of Check Valve
    129
    
    Specification of Check Valve
    129
    
    Structure of Check Valve
    129
    
    Function of Fuel Cooler
    130
    
    Structure of Fuel Cooler
    130
  - Engine ECU
    130
    
    Function of Engine ECU
    130
    
    Outline of Engine ECU
    130
    
    Specification of Engine ECU
    130
    
    Structure of Engine ECU
    130
  - Crankshaft Position Sensor
    131
    
    Function of Crankshaft Position Sensor
    131
    
    Outline of Crankshaft Position Sensor
    131
    
    Specification of Crankshaft Position Sensor
    131
    
    Structure of Crankshaft Position Sensor
    131
  - Camshaft Position Sensor
    132
    
    Function of Camshaft Position Sensor
    132
    
    Outline of Camshaft Position Sensor
    132
    
    Specification of Camshaft Position Sensor
    132
    
    Structure of Camshaft Position Sensor
    132
    
    Coolant Temperature Sensor
    133
    
    Function of Coolant Temperature Sensor
    133
    
    Outline of Coolant Temperature Sensor
    133
    
    Structure of Coolant Temperature Sensor
    133
    
    Atmosphere Pressure Sensor
    134
    
    Boost Pressure Sensor
    134
    
    Function of Atmosphere Pressure Sensor
    134
    
    Function of Boost Pressure Sensor
    134
    
    Outline of Atmosphere Pressure Sensor
    134
    
    Outline of Boost Pressure Sensor
    134
    
    Specification of Boost Pressure Sensor
    134
    
    Structure of Atmosphere Pressure Sensor
    134
    
    Structure of Boost Pressure Sensor
    134
    
    Fuel Camshaft
    135
    
    Function of Fuel Camshaft
    135
    
    Outline of Fuel Camshaft
    135
    
    Structure of Fuel Camshaft
    135
  - Intake and Exhaust System
    136
    
    Structure of Intake and Exhaust System
    136
    
    Feature of Intake and Exhaust System
    137
    
    Flow of Intake and Exhaust System
    138
    
    Air Cleaner
    140
    
    Control of Intake and Exhaust System
    140
    
    Function of Air Cleaner
    140
    
    Function of Pre-Cleaner
    140
    
    Outline of Air Cleaner
    140
    
    Outline of Pre-Cleaner
    140
    
    Pre-Cleaner
    140
    
    Specification of Pre-Cleaner
    140
    
    Structure of Air Cleaner
    140
    
    Structure of Pre-Cleaner
    140
    
    Function of Intercooler
    141
    
    Function of Turbocharger
    141
    
    Intercooler
    141
    
    Outline of Intercooler
    141
    
    Specification of Intercooler
    141
    
    Specification of Turbocharger
    141
    
    Structure of Intercooler
    141
    
    Structure of Turbocharger
    141
    
    Exhaust Manifold
    142
    
    Function of Glow Plug
    142
    
    Function of Intake Manifold
    142
    
    Glow Plug
    142
    
    Intake Manifold
    142
    
    Outline of Glow Plug
    142
    
    Outline of Intake Manifold
    142
    
    Specification of Glow Plug
    142
    
    Structure of Glow Plug
    142
    
    Structure of Intake Manifold
    142
    
    Function of Exhaust Manifold
    143
    
    Exhaust Gas Recirculation (EGR) System
    144
    
    Structure of EGR System
    144
    
    Feature of EGR System
    145
    
    Flow of EGR System
    146
    
    Control of EGR System
    147
    
    EGR Cooler
    147
    
    EGR Valve
    147
    
    Function of EGR Cooler
    147
    
    Outline of EGR Cooler
    147
    
    Outline of EGR Valve
    147
    
    Specification of EGR Cooler
    147
    
    Structure of EGR Cooler
    147
    
    Structure of EGR Valve
    148
    
    Function of EGR Valve
    150
    
    Function of Reed Valve
    150
    
    Outline of Reed Valve
    150
    
    Reed Valve
    150
    
    Specification of EGR Valve
    150
    
    Structure of Reed Valve
    150
    
    Lubricating System
    151
    
    Structure of Lubricating System
    151
    
    Feature of Lubricating System
    152
    
    Flow of Lubricating System
    153
    
    Function of Oil Pan
    155
    
    Function of Oil Strainer
    155
    
    Oil Pan
    155
    
    Oil Strainer
    155
    
    Outline of Oil Pan
    155
    
    Outline of Oil Strainer
    155
    
    Specification of Oil Pan
    155
    
    Specification of Oil Strainer
    155
    
    Structure of Oil Pan
    155
    
    Structure of Oil Strainer
    155
    
    Function of Oil Pump
    156
    
    Oil Pump
    156
    
    Outline of Oil Pump
    156
    
    Outline of Relief Valve
    156
    
    Relief Valve
    156
    
    Specification of Oil Pump
    156
    
    Structure of Oil Pump
    156
    
    Structure of Relief Valve
    156
    
    Function of Oil Filter
    157
    
    Function of Relief Valve
    157
    
    Oil Cooler
    157
    
    Oil Filter
    157
    
    Outline of Oil Cooler
    157
    
    Outline of Oil Filter
    157
    
    Specification of Oil Filter
    157
    
    Structure of Oil Cooler
    157
    
    Structure of Oil Filter
    157
    
    Function of Oil Cooler
    158
    
    Function of Oil Pressure Switch
    158
    
    Oil Pressure Switch
    158
    
    Outline of Oil Pressure Switch
    158
    
    Specification of Oil Cooler
    158
    
    Structure of Oil Pressure Switch
    158
    
    Specification of Oil Pressure Switch
    159
  - Cooling System
    160
    
    Structure of Cooling System
    160
    
    Control of Cooling System (Bottom By-Pass System)
    161
    
    Feature of Cooling System
    161
    
    Flow of Cooling System (Bottom By-Pass System)
    161
    
    Outline of Water Pump
    161
    
    Structure of Water Pump
    161
    
    Water Pump
    161
    
    Function of Thermostat
    162
    
    Function of Water Pump
    162
    
    Outline of Thermostat
    162
    
    Specification of Thermostat
    162
    
    Structure of Thermostat
    162
    
    Thermostat
    162
    
    Function of Radiator
    163
    
    Outline of Radiator
    163
    
    Outline of Radiator Cap
    163
    
    Radiator
    163
    
    Radiator Cap
    163
    
    Specification of Radiator
    163
    
    Structure of Radiator
    163
    
    Structure of Radiator Cap
    163
    
    Cooling Fan
    164
    
    Function of Cooling Fan
    164
    
    Function of Radiator Cap
    164
    
    Outline of Cooling Fan
    164
    
    Specification of Cooling Fan
    164
    
    Specification of Radiator Cap
    164
    
    Structure of Cooling Fan
    164
    
    Fan Belt
    165
    
    Function of Fan Belt
    165
    
    Function of Reserve Tank
    165
    
    Outline of Fan Belt
    165
    
    Outline of Reserve Tank
    165
    
    Reserve Tank
    165
    
    Structure of Fan Belt
    165
    
    Structure of Reserve Tank
    165
  - Electrical System
    166
    
    Structure of Electrical System
    166
    
    Feature of Electrical System
    167
    
    Flow of Electrical System
    168
    
    Battery
    170
    
    Control of Electrical System
    170
    
    Function of Battery
    170
    
    Key Switch
    170
    
    Outline of Battery
    170
    
    Outline of Key Switch
    170
    
    Specification of Battery
    170
    
    Structure of Battery
    170
    
    Structure of Key Switch
    170
    
    Function of Key Switch
    171
    
    Function of Starter (Planetary Gear Reduction Type)
    171
    
    Outline of Starter (Planetary Gear Reduction Type)
    171
    
    Specification of Key Switch
    171
    
    Starter (Planetary Gear Reduction Type)
    171
    
    Structure of Starter (Planetary Gear Reduction Type)
    171
    
    Alternator
    172
    
    Function of Alternator
    172
    
    Outline of Alternator
    172
    
    Specification of Starter (Planetary Gear Reduction Type)
    172
    
    Structure of Alternator
    172
    
    Specification of Alternator
    174
    
    Aftertreatment System
    175
    
    Feature of Diesel Particulate Filter (DPF) System
    175
    
    Flow of Diesel Particulate Filter (DPF) System
    175
    
    Structure of Diesel Particulate Filter (DPF) System
    175
    
    Control of Diesel Particulate Filter (DPF) System
    176
    
    Feature of Diesel Oxidation Catalyst (DOC) System
    178
    
    Flow of Diesel Oxidation Catalyst (DOC) System
    178
    
    Structure of Diesel Oxidation Catalyst (DOC) System
    178
    
    Diesel Oxidation Catalyst (DOC)
    179
    
    Diesel Particulate Filter (DPF)
    179
    
    Function of Diesel Oxidation Catalyst (DOC)
    179
    
    Outline of Diesel Oxidation Catalyst (DOC)
    179
    
    Outline of Diesel Particulate Filter (DPF)
    179
    
    Structure of Diesel Oxidation Catalyst (DOC)
    179
    
    Structure of Diesel Particulate Filter (DPF)
    179
    
    Air Flow Sensor
    180
    
    Function of Air Flow Sensor
    180
    
    Function of Diesel Particulate Filter (DPF)
    180
    
    Outline of Air Flow Sensor
    180
    
    Structure of Air Flow Sensor
    180
    
    Exhaust Gas Temperature Sensor
    181
    
    Outline of Exhaust Gas Temperature Sensor
    181
    
    Specification of Air Flow Sensor
    181
    
    Structure of Exhaust Gas Temperature Sensor
    181
    
    Function of Exhaust Gas Temperature Sensor
    182
    
    Specification of Exhaust Gas Temperature Sensor
    182
    
    Differential Pressure Sensor
    183
    
    Function of Differential Pressure Sensor
    183
    
    Outline of Differential Pressure Sensor
    183
    
    Specification of Differential Pressure Sensor
    183
    
    Structure of Differential Pressure Sensor
    183
    
    Function of Intake Throttle Valve
    184
    
    Intake Throttle Valve
    184
    
    Outline of Intake Throttle Valve
    184
    
    Specification of Intake Throttle Valve
    184
    
    Structure of Intake Throttle Valve
    184
    
    Servicing
    187
    
    Troubleshooting
    187
    
    Troubleshooting for 03 Series Engine
    187
    
    Service Specifications
    191
    
    Service Specifications for Engine
    191
    
    Tightening Torques
    196
    
    Tightening Torques of Screws, Bolts and Nuts for General Use
    196
    
    Tightening Torques of Screws, Bolts and Nuts for Special Use
    196
    
    Adjusting Valve Clearance
    198
    
    Checking and Adjusting
    198
    
    Checking Compression Pressure of Cylinder
    198
    
    Checking Engine Oil Pressure
    199
    
    Checking Fan Belt Damage and Wear
    200
    
    Checking Fan Belt Tension
    200
    
    Checking Radiator Cap Air Leakage
    200
    
    Checking Opening Temperature of Thermostat Valve
    201
    
    Checking Radiator Water Leakage
    201
    
    Checking Battery Specific Gravity
    202
    
    Checking Battery Voltage
    202
    
    Checking Starter Motor
    203
    
    Checking Magnetic Switch of Starter
    204
    
    Checking Alternator on Unit
    205
    
    Checking Magnetic Switch Continuity
    205
    
    Checking Air Leakage of Turbocharger Compressor Side
    206
    
    Checking Exhaust Gas Leakage of Turbocharger Turbine Side
    206
    
    Checking Glow Plug Continuity
    206
    
    Checking Injector
    207
    
    Checking Radial Clearance of Turbocharger
    207
    
    Checking Suction Control Valve (SCV)
    207
    
    Checking Boost Pressure Sensor
    208
    
    Checking Rail Pressure Sensor
    208
    
    Checking Camshaft Position Sensor
    209
    
    Checking Coolant Temperature Sensor
    209
    
    Checking Crankshaft Position Sensor
    209
    
    Checking Air Flow Sensor
    210
    
    Checking EGR System
    210
    
    Checking Exhaust Gas Temperature Sensor
    211
    
    Selecting Cylinder Head Gasket
    211
    
    Measuring Angular Deviation between Crankshaft T.D.C. and Crankshaft Position Sensor
    212
    
    Adjusting Air Gap between Crankshaft Position Sensor and Flywheel
    214
    
    Adjusting Air Gap between Camshaft Position Sensor and Pulsar Gear
    215
  - Disassembling
    215
    
    Draining Coolant
    215
    
    Draining Engine Oil
    215
    
    Removing CRS Intermediate Harness
    216
    
    Removing External Components
    216
    
    Removing Muffler Full Assembly
    217
    
    Disassembling DPF Assembly
    218
    
    Removing EGR Cooler
    219
    
    Removing Turbocharger
    219
    
    Removing Common Rail
    220
    
    Removing EGR Valve
    220
    
    Removing Intake Throttle Valve
    220
    
    Removing Sensors
    221
    
    Removing Cylinder Head Cover
    222
    
    Removing Glow Plug
    222
    
    Removing Injector
    222
    
    Removing Cylinder Head
    223
    
    Removing Rocker Arm Assembly
    223
    
    Removing Suction Control Valve (SCV)
    224
    
    Removing Tappet
    224
    
    Removing Thermostat Assembly
    224
    
    Removing Valve
    224
    
    Removing Oil Cooler
    225
    
    Removing Supply Pump
    225
    
    Removing Crankshaft Oil Slinger
    226
    
    Removing Fan Drive Pulley
    226
    
    Removing Gear Case Cover
    226
    
    Removing Water Pump
    226
    
    Removing Fuel Camshaft Assembly
    227
    
    Removing Idle Gear
    227
    
    Removing Camshaft with Cam Gear
    228
    
    Removing Crank Gear
    228
    
    Removing Oil Pump
    228
    
    Removing Oil Pan and Oil Strainer
    229
    
    Removing Piston
    229
    
    Removing Piston Ring
    229
    
    Disassembling Piston Assembly
    230
    
    Removing Flywheel
    230
    
    Removing Bearing Case Cover
    231
    
    Removing Crankshaft (for 3 Cylinders)
    231
    
    Removing Flywheel Housing
    231
    
    Removing Crankshaft (for 4 Cylinders)
    232
    
    Disassembling Alternator
    233
    
    Disassembling Starter
    233
    
    Removing Main Bearing Case
    233
    
    Assembling
    234
    
    Assembling Alternator
    234
    
    Assembling Starter
    236
    
    Installing Main Bearing Case
    237
    
    Installing Crankshaft (for 3 Cylinders)
    238
    
    Installing Crankshaft (for 4 Cylinders)
    238
    
    Installing Bearing Case Cover
    239
    
    Installing Flywheel
    239
    
    Installing Flywheel Housing
    239
    
    Assembling Piston Assembly
    240
    
    Installing Piston
    241
    
    Installing Piston Ring
    241
    
    Installing Oil Strainer and Oil Pan
    243
    
    Installing Camshaft with Cam Gear
    244
    
    Installing Crank Gear
    244
    
    Installing Oil Pump
    244
    
    Installing Fuel Camshaft with Supply Pump Gear
    245
    
    Installing Idle Gear
    245
    
    Installing Crankshaft Oil Slinger
    246
    
    Installing Fan Drive Pulley
    246
    
    Installing Gear Case Cover
    246
    
    Installing Oil Cooler
    247
    
    Installing Water Pump
    247
    
    Installing Suction Control Valve (SCV)
    248
    
    Installing Supply Pump
    248
    
    Installing Cylinder Head
    249
    
    Installing Tappet
    249
    
    Installing Thermostat Assembly
    249
    
    Installing Valve
    249
    
    Installing Injector
    251
    
    Installing Rocker Arm Assembly
    251
    
    Installing Glow Plug
    252
    
    Installing Cylinder Head Cover
    253
    
    Installing Sensors
    253
    
    Installing Common Rail
    254
    
    Installing EGR Valve
    255
    
    Installing Intake Throttle Valve
    255
    
    Installing Turbocharger Assembly
    255
    
    Assembling DPF Assembly
    256
    
    Installing EGR Cooler
    256
    
    Installing Muffler Full Assembly
    257
    
    Installing CRS Intermediate Harness
    259
    
    Installing External Components
    261
    
    Filling Coolant
    262
    
    Filling Engine Oil
    262
    
    Servicing
    262
  - Checking Cylinder Head Top Clearance
    262
  - Checking Cylinder Head Surface Flatness
    263
  - Checking Cylinder Head Flaw
    263
  - Checking Valve Recessing
    264
  - Adjusting Valve Lapping
    264
  - Checking Clearance between Valve Stem and Valve Guide
    265
  - Replacing Valve Guide
    265
  - Adjusting Valve Angle
    266
  - Adjusting Valve Seat
    266
  - Checking Free Length of Valve Spring
    267
  - Checking Tilt of Valve Spring
    267
  - Checking Set Load of Valve Spring
    268
  - Checking Oil Clearance between Rocker Arm and Rocker Arm Shaft
    268
  - Checking Push Rod Alignment
    269
  - Checking Oil Clearance between Tappet and Tappet Guide Bore
    269
  - Checking Timing Gear Backlash
    269
  - Checking Side Clearance of Idle Gear
    270
  - Checking Side Clearance of Camshaft
    270
  - Checking Camshaft Alignment
    271
  - Replacing Idle Gear Bushing
    271
  - Checking Cam Height
    272
  - Checking Oil Clearance between Camshaft Journal and Crankcase Bore
    272
  - Checking Oil Clearance between Idle Gear Shaft and Idle Gear Bushing
    273
  - Checking Piston Pin Bore I.D
    273
  - Checking Oil Clearance between Piston Pin and Small End Bushing
    273
  - Replacing Small End Bushing
    274
  - Checking Connecting Rod Alignment
    275
  - Checking Piston Ring Gap
    275
  - Checking Clearance between Piston Ring and Ring Groove
    276
  - Checking Side Clearance of Crankshaft
    277
  - Checking Crankshaft Alignment
    278
  - Checking Oil Clearance between Crankpin and Crankpin Bearing
    279
  - Checking Oil Clearance between Crankshaft Journal and Crankshaft Bearing 1
    279
  - Replacing Crankshaft Sleeve
    280
  - Replacing Crankshaft Bearing 1
    280
  - Checking Oil Clearance between Crankshaft Journal and Crankshaft Bearing 2
    281
  - Replacing Bearing Case Cover Oil Seal
    282
  - Checking Cylinder Wear
    283
  - Adjusting Cylinder Correction (over Size)
    283
  - Checking Clearance between Inner Rotor and Outer Rotor
    284
  - Checking Clearance between Outer Rotor and Pump Body
    284
  - Checking Clearance between Rotor and Cover
    285
  - Checking Commutator and Mica of Starter
    285
  - Checking Brush Wear of Starter
    286
  - Checking Brush Holder of Starter
    287
  - Checking Field Coil of Starter
    288
  - Checking Bearing of Alternator
    288
  - Checking Stator of Alternator
    288
  - Checking Rotor of Alternator
    289
  - Checking Slip Ring of Alternator
    289
  - Checking Brush Wear of Alternator
    290
  - Checking Rectifier
    290
  - Checking IC Regulator
    290
  - Replacing Injector
    291
  - Replacing Engine ECU
    293
  - Replacing DPF
    296

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Kubota V2403-CR-TE4BG Operator's Manual

Kubota V2403-CR-TE4BG Operator's Manual (50 pages)

Brand: Kubota | Category: Engine | Size: 11 MB

Table of Contents

Table of Contents
5
Safe Operation
13
Servicing the Engine
13
Names of Parts
14
Pre-Operation Check
18
Break-In
18
Daily Check
18
Operating the Engine
19
Starting the Engine (Normal)
19
Cold Weather Starting
20
Stopping the Engine
20
Checks During Operation
20
Radiator Cooling Water (Coolant)
20
Oil Pressure Lamp
21
Charge Lamp
21
Fuel
21
Color of Exhaust
21
Immediately Stop the Engine if
21
Air Flow Sensor
21
Air Cleaner-Mounted Type
21
Inlet Hose Pipe-Mounted Type
21
Precautions on Generator-Equipped Engine
21
Maintenance
22
Service Intervals
23
Water Separator
27
Daily Checks
27
Checking Engine Oil Level
27
Checking Fuel Level and Refueling
29
Checking Coolant Level
29
Biodiesel Fuel (BDF)
29
Antifreeze
31
Checking Fan Belt
32
For the Air Cleaner with a Dust Cup (Optional)
32
Dust Indicator (Optional)
32
Regular Checks and Maintenance Work
33
Every 50 Service Hours
33
Checking Fuel Pipes and Clamp Bands
33
Draining Water Separator
33
Every 250 Service Hours
34
Cleaning Air Cleaner Element
34
Adjusting Fan Belt Tension
34
Checking Intake Air Line
36
Every 250 Hours or 6 Months
36
Checking Radiator Hoses and Clamp Bands
36
Precaution at Overheating
36
EVERY 400 or 500 SERVICE HOURS
37
Changing Engine Oil
37
Replacing Oil Filter Cartridge
37
Every 500 Service Hours
38
Replacing Fuel Filter Cartridge
38
Replacing Oil Filter Cartridge
38
Cleaning Water Separator (Type 1)
38
Removing Sediment in Fuel Tank
38
Cleaning Fuel Tank Interior
38
Cleaning Water Jacket (Radiator Interior)
38
Replacing Fan Belt
38
Every 500 Service Hours or 1 Year
39
Changing Engine Oil
39
Replacing Water Separator Filter (Type 2)
39
Every 500 Service Hours or 2 Years
39
Replacing Fan Belt
39
Every 1000 Service Hours
39
Checking Valve Clearance
39
Every 1500 Service Hours
40
Checking Injector Tip
40
Checking EGR Cooler
40
Changing Oil Separator Element
40
Checking PCV Valve (Positive Crankcase Ventilation Valve)
40
Every 3000 Service Hours
40
Checking Turbo Charger
40
Checking EGR System
40
Annual Servicing
41
Replacing Air Cleaner Element
41
Checking EGR Piping
41
Checking Intake Air Line
41
Checking Exhaust Manifold for Cracks or Gas Leak and for Looseness or Damage
41
Biennial Servicing
41
Replacing Rubber Piping Related Oil Separator
41
Replacing Intake Air Line and Suction Air Pressure Takeout Rubber Piping
41
Replacing Boost Sensor Pressure Rubber Piping
41
Replacing EGR Cooler Rubber Piping
41
Replacing Radiator Hoses and Clamp Bands
42
Replacing Fuel Pipes and Clamp Bands
42
Replacing Intake Air Line
42
Service as Required
42
Draining Water Separator (Type 2)
42
Carriage and Storage
43
Carriage
43
Storage
43
Troubleshooting
44
Specifications
46

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