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Kubota D1803-CR-E4 User Manual

Kubota D1803-CR-E4
309 pages
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WORKSHOP MANUAL
DIESEL ENGINE
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

Table of Contents

Questions and Answers:

Kubota D1803-CR-E4 Specifications

General IconGeneral
Engine ModelD1803-CR-E4
Displacement1.8 L
Number of cylinders3
FuelDiesel
Fuel SystemDirect Injection
AspirationNaturally Aspirated
Cooling SystemWater-cooled
TypeVertical, water-cooled 4-cycle diesel engine
Lubrication SystemForced lubrication
Starting SystemElectric starter
Dry Weight200 kg
Emission StandardEU Stage V

Summary

RECORD OF REVISIONS

SPECIAL TOOLS

Diesel engine compression tester

Tool for measuring diesel engine compression.

Compression tester adapter K

Adapter for compression tester to use with glow plug holes.

Oil pressure tester

Tool for measuring engine oil pressure.

Valve guide replacing tool

Tool for pressing out and fitting valve guides.

Bushing replacing tools

Tools for pressing out and fitting bushings.

Flywheel stopper

Tool for loosening and tightening flywheel screws.

Crankshaft bearing 1 replacing tool

Tool for pressing out and fitting crankshaft bearing 1.

Auxiliary socket for fixing crankshaft sleeve

Tool for fixing the crankshaft sleeve.

Injection top correction jig

Tool for detecting and positioning the sensor in top dead center.

Bearing case cover oil seal replacing tool

Tool for installing bearing case cover oil seals.

SAFETY

General Safety Precautions

Covers working precautions, emergency prep, cautions, starting safely, and hazard avoidance.

Starting the machine safely

Procedures and warnings for safely starting the engine.

Preventing fires

Guidelines to prevent fire hazards related to fuel and batteries.

Preventing acid burns

Warnings and precautions regarding sulfuric acid from batteries.

Avoiding high pressure fluid

Warnings about high-pressure fluid hazards and injury prevention.

Avoiding hot exhaust

Precautions regarding hot exhaust gases and engine components.

Cleaning exhaust filter

Instructions for cleaning the exhaust filter.

GENERAL

General Working Precautions

Guidelines for servicing, cleaning, battery handling, tool usage, and parts.

Engine Identification

Information on identifying engine model name, serial number, and series codes.

Specifications

Technical specifications for various engine models including power, displacement, and basic engine parameters.

Performance Curves

Graphs illustrating engine performance characteristics like torque, horsepower, and fuel consumption.

Dimensions

Provides overall physical dimensions for different engine models.

Wiring Diagrams

Detailed electrical system diagrams and component connections for engine control.

MECHANISM

1. General (Introduction)

Overview of combustion features and systems like E-CDIS.

2. Engine body

Describes the main components of the engine body, including crankcase, cylinder head, pistons, and crankshaft.

3. Fuel system

Explains the common rail system (CRS) structure, flow, control, fuel tank, and components like pumps and injectors.

4. Intake and exhaust system

Details the components and flow of the intake, exhaust, turbocharger, intercooler, and EGR systems.

5. Exhaust gas recirculation (EGR) system

Explains the purpose, structure, and control of the EGR system, including coolers and valves.

6. Lubricating system

Covers the structure, features, flow, and components of the engine's oil system, including pump, filter, and cooler.

7. Cooling system

Details the radiator, water pump, thermostat, fan, and reserve tank structure, function, and control.

8. Electrical system

Outlines the starting, charging, battery, key switch, starter, and alternator systems.

9. Aftertreatment system

Describes the DPF, DOC systems, sensors, and regeneration control.

MAINTENANCE

MAINTENANCE CHECK LIST

A comprehensive table outlining inspection items and their service intervals for regular maintenance.

Daily check points

Procedures for daily checks including engine oil, fuel, and coolant levels.

Check points of initial 50 hours

Maintenance tasks required after the initial 50 hours of operation, like oil change.

Check points of every 50 hours

Maintenance tasks required every 50 hours, such as checking fuel hoses and water separators.

Check points of every 250 hours

Maintenance tasks required every 250 hours, including air cleaner cleaning and belt tension checks.

Check points of every 400 hours

Maintenance tasks required every 400 hours, primarily engine oil changes.

Check points of every 500 hours

Maintenance tasks required every 500 hours, such as filter replacements and coolant system checks.

Check points of every 1 year

Maintenance tasks to be performed annually, including manifold checks and hose replacements.

Check points of every 2 years

Maintenance tasks required every two years, such as replacing belts and hoses.

SERVICING

1. Troubleshooting

Identifies common engine symptoms, probable causes, and recommended solutions with reference pages.

2. Service specifications

Provides detailed service and limit specifications for engine components like cylinder head, valves, and bearings.

3. Tightening torques

Lists specified tightening torques for various screws, bolts, and nuts used in engine assembly.

4. Checking and adjusting

Step-by-step procedures for checking and adjusting engine parameters like compression, valve clearance, and oil pressure.

5. Disassembling

Detailed instructions and illustrations for disassembling engine components and systems.

6. Assembling

Step-by-step instructions and illustrations for reassembling engine components and systems.

7. Servicing

Procedures for checking and adjusting critical engine components like cylinder head and valve train.

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