EasyManua.ls Logo

Kubota V2403-CR-E4 User Manual

Kubota V2403-CR-E4
309 pages
To Next Page IconTo Next Page
To Next Page IconTo Next Page
Page #1 background imageLoading...
Page #1 background image
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 V2403-CR-E4 Specifications

General IconGeneral
BrandKubota
ModelV2403-CR-E4
CategoryEngine
LanguageEnglish

Summary

SAFETY

SAFETY FIRST

Industry's 'Safety Alert Symbol' usage and importance of reading instructions and safety regulations.

1. Working precautions

Basic safety practices for servicing, including machine preparation and engine shutdown.

2. Preparing for emergencies

Recommendations for keeping first aid kits, fire extinguishers, and emergency numbers accessible.

3. Working cautions

Guidelines on appropriate work attire, protective equipment, and avoiding hazardous conditions.

4. Starting the machine safely

Steps and warnings to ensure safe engine starting procedures.

5. Preventing fires

Measures to prevent fires, focusing on fuel, batteries, and electrical shorts.

6. Preventing acid burns

Safety precautions regarding battery electrolyte (sulfuric acid) to prevent burns and eye damage.

7. Avoiding high pressure fluid

Warning about the danger of high-pressure fluid penetration and injury.

8. Avoiding hot exhaust

Precautions for avoiding contact with hot exhaust gas and components.

GENERAL

GENERAL WORKING PRECAUTIONS

General guidelines for safe and proper machine servicing procedures.

7. Handling the battery

Safety and handling procedures for battery removal, installation, and maintenance.

8. Handling electrical wiring

Guidelines for safe handling of electrical wiring, including protection and repair.

GENERAL MACHINE INFORMATION

Information related to general machine characteristics and identification.

1. Engine identification

Details on identifying engine model name and serial number.

3. Specifications

Technical specifications for various engine models.

6. Wiring diagram

Diagrams illustrating the electrical system's wiring.

6.1 Engine intermediate harness (Engine side harness)

Details the wiring harness connecting engine components.

6.5 System wiring diagram for D1803-CR-TIE4, V2403-CR-TIE4

Complete system wiring diagram for specific engine models.

MAINTENANCE

MAINTENANCE CHECK LIST

Table outlining regular inspection items and their service intervals.

Daily check points

List of daily checks for engine maintenance.

Check points of initial 50 hours

Maintenance checks required after the first 50 hours of operation.

Check point of every 50 hours

Maintenance checks to be performed every 50 operating hours.

Check point of every 1000 hours

Maintenance checks to be performed every 1000 operating hours.

8.1 Checking injector (with Diagmaster)

Procedure for checking injectors using Diagmaster software.

9. Check points of every 3000 hours

Maintenance checks to be performed every 3000 operating hours.

9.1 Checking turbocharger

Procedures for checking the turbocharger for gas leakage and radial clearance.

9.2 Cleaning DPF

Instructions for cleaning the Diesel Particulate Filter (DPF).

9.5 Checking EGR system (with Diagmaster)

Procedure for checking the EGR system using Diagmaster.

10. Check points of every 1 year

Maintenance checks to be performed annually.

ENGINE

3. Fuel system

Explanation of the common rail system (CRS) fuel system.

3.1 Structure of common rail system (CRS) engine

Diagram and description of the CRS fuel system structure.

3.2 Feature of common rail system (CRS) engine

Explains the characteristics and control of the CRS engine.

3.3 Flow of common rail system (CRS) engine

Diagram illustrating the fuel flow in the CRS system.

Fuel flow

Diagram and description of fuel flow through the system components.

3.4 Control of common rail system (CRS) engine

Details engine ECU control functions for the CRS system.

3.13 Injector

Covers injector outline, structure, function, and wiring.

3.17 Engine ECU

Covers engine ECU outline, structure, function, and specifications.

3.18 Crankshaft position sensor

Covers sensor outline, structure, function, and specifications.

3.19 Camshaft position sensor

Covers sensor outline, structure, function, and specifications.

3.20 Coolant temperature sensor

Covers sensor outline, structure, function, and specifications.

3.21 Boost pressure sensor

Covers sensor outline, structure, function, and specifications.

4.7 Turbocharger

Covers turbocharger outline, structure, function, and specifications.

5.2 Feature of EGR system

Explains the purpose and function of the EGR system in reducing NOx.

5.4 Control of EGR system

Details how the engine ECU controls the EGR valve.

6.10 Oil pressure switch

Covers switch outline, structure, function, circuit diagram, and specifications.

8.5 Battery

Covers battery outline, structure, function, and specifications.

8.7 Starter (Planetary gear reduction type)

Covers starter outline, structure, function, and specifications.

8.8 Alternator

Covers alternator outline, structure, function, and specifications.

9.2 Feature of diesel particulate filter (DPF) system

Explains the DPF system's function of capturing and treating PM.

9.4 Control of diesel particulate filter (DPF) system

Details engine ECU control for DPF regeneration.

9.10 Air flow sensor

Covers sensor outline, structure, function, and specifications.

9.11 Exhaust gas temperature sensor

Covers sensor outline, structure, function, and specifications.

9.12 Differential pressure sensor

Covers sensor outline, structure, function, and specifications.

9.13 Intake throttle valve

Covers valve outline, structure, function, and specifications.

SERVICING

1. Troubleshooting

Troubleshooting guide for common engine failures, causes, and solutions.

1.1 Troubleshooting for 03 series engine

Lists common engine problems, probable causes, and solutions with reference pages.

The engine revolution is not smooth

Troubleshooting steps for rough engine revolutions.

The exhaust gas is white or blue

Troubleshooting steps for white or blue exhaust gas.

There is oil leakage into the exhaust pipe or suction pipe

Troubleshooting steps for oil leaks in exhaust or suction pipes.

The exhaust gas is black or dark gray

Troubleshooting steps for black or dark gray exhaust gas.

The output is deficient

Troubleshooting steps for reduced engine output.

The lubricant oil consumption is too much

Troubleshooting steps for excessive lubricant oil consumption.

The fuel is mixed into the lubricant oil

Troubleshooting steps for fuel contamination in lubricant oil.

Water is mixed into the lubricant oil

Troubleshooting steps for water contamination in lubricant oil.

The oil pressure is low

Troubleshooting steps for low engine oil pressure.

The engine is overheated

Troubleshooting steps for engine overheating.

2. Service specifications

Technical specifications and service limits for engine components.

2.1 Service specifications for engine

Table of service and limit specifications for engine parts.

3. Tightening torques

Torque values for various screws, bolts, and nuts.

3.2 Tightening torques of screws, bolts and nuts for special use

Specific torque values for engine assembly components.

4. Checking and adjusting

Procedures for checking and adjusting various engine systems.

4.1 Checking compression pressure of cylinder

Procedure for checking cylinder compression pressure.

4.2 Adjusting valve clearance

Procedure for adjusting valve clearance when the engine is cold.

4.3 Checking engine oil pressure

Procedure for checking engine oil pressure at idle and rated speeds.

4.11 Checking starter motor

Procedure for checking the starter motor.

4.19 Checking injector

Procedure for checking injector resistance.

4.20 Checking suction control valve (SCV)

Procedure for checking SCV resistance.

4.21 Checking rail pressure sensor

Procedure for checking rail pressure sensor output voltage.

4.22 Checking boost pressure sensor

Procedure for checking boost pressure sensor voltage.

4.23 Checking crankshaft position sensor

Procedure for checking the crankshaft position sensor.

4.24 Checking camshaft position sensor

Procedure for checking the camshaft position sensor.

4.25 Checking coolant temperature sensor

Procedure for checking the coolant temperature sensor.

4.27 Checking air flow sensor

Procedure for checking the air flow sensor.

4.28 Checking exhaust gas temperature sensor

Procedure for checking exhaust gas temperature sensors.

5. Disassembling

Procedures for disassembling various engine components.

5.1 Draining engine oil

Procedure for draining engine oil.

5.2 Draining coolant

Procedure for draining engine coolant.

5.5 Removing muffler full assembly

Procedure for removing the muffler assembly, including DPF.

5.6 Disassembling DPF assembly

Detailed steps for disassembling the DPF assembly.

5.8 Removing turbocharger

Procedure for removing the turbocharger.

5.11 Removing common rail

Procedure for removing the common rail assembly.

5.15 Removing injector

Procedure for removing injectors, including ID code correction.

5.17 Removing cylinder head

Procedure for removing the cylinder head.

5.37 Removing flywheel

Procedure for removing the flywheel, with important cautions.

5.43 Disassembling starter

Steps for disassembling the starter motor.

5.44 Disassembling alternator

Steps for disassembling the alternator.

6. Assembling

Procedures for assembling engine components.

6.1 Assembling alternator

Procedure for assembling the alternator.

6.2 Assembling starter

Procedure for assembling the starter motor.

6.8 Installing flywheel

Procedure for installing the flywheel, with important cautions.

6.28 Installing cylinder head

Procedure for installing the cylinder head.

6.29 Installing rocker arm assembly

Procedure for installing the rocker arm assembly, including valve clearance adjustment.

6.30 Installing injector

Procedure for installing injectors, including ID code correction.

6.34 Installing common rail

Procedure for installing the common rail.

6.37 Installing turbocharger assembly

Procedure for installing the turbocharger assembly.

6.39 Assembling DPF assembly

Detailed steps for assembling the DPF assembly.

6.40 Installing muffler full assembly

Procedure for installing the muffler assembly, including DPF.

6.43 Filling coolant

Procedure for filling the cooling system.

6.44 Filling engine oil

Procedure for filling engine oil.

7. Servicing

Procedures for servicing and adjusting engine components.

7.1 Checking cylinder head top clearance

Procedure for checking cylinder head top clearance.

7.38 Checking cylinder wear

Procedure for checking cylinder bore wear.

7.56 Replacing injector

Procedure for replacing injectors and registering ID codes.

7.57 Replacing engine ECU

Procedure for replacing the engine ECU, including DPK file download.

7.58 Replacing DPF

Procedure for replacing the DPF, including regeneration and soot load reset.

DPF manual regeneration

Procedure for performing DPF manual regeneration.

Related product manuals