Diesel Particulate Filter Handling Manual_sept_2013_9y111-07332.pdf 38486i

WORKSHOP MANUAL

DIESEL ENGINE DIESEL PARTICULATE FILTER HANDLING MANUAL

KiSC issued 09, 2013 A

TO THE READER This Workshop Manual tells the servicing personnel about the servicing and maintenance of the Diesel Particulate Filter. It contains 2 parts: "Information" and "Servicing".  Information This section contains information below. • Safety First  Servicing This section contains information below. • Servicing All illustrations, photographs and specifications contained in this manual are of the newest information available at the time of publication. 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. August, 2012 © KUBOTA Corporation 2012

KiSC issued 09, 2013 A

Record of Revisions For pdf, use search function {Search word} to find the all revised locations. Last digit of the Code No. 2

Issue month 2013.09

Main Revised Point and Corrective Measures {Search word}

Reference Page

• Correction of Workshop Manual The following are the changes from 9Y121-07331 to 9Y121-07332. 1. Information for V6108 was deleted. 2. Information for 03-CR-E4 was added. 3. Information for 07-CR-E4 was added.

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KiSC issued 09, 2013 A

I INFORMATION

KiSC issued 09, 2013 A

INFORMATION CONTENTS 1. SAFETY FIRST .............................................................................................................................. I-1

KiSC issued 09, 2013 A

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. • It is essential that you read the instructions and safety regulations before you attempt to repair or use this unit. DANGER • Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING • Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION • Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. IMPORTANT • Indicates that equipment or property damage could result if instructions are not followed. NOTE • Gives helpful information. BEFORE YOU START SERVICE • Read all instructions and safety instructions in this manual and on your engine safety decals. • Clean the work area and engine. • Park the machine on a stable and level ground. • Let the temperature of the engine decrease before you start a job. • Stop the engine, then remove the key. • Disconnect the battery negative cable. • Hang a "DO NOT OPERATE" tag in the operator station.

START SAFELY • Do not do the procedures below when you start the engine. – short across starter terminals – by the safety start switch • Do not make unauthorized modifications to the engine. This can cause damage and decrease the engine life.

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KiSC issued 09, 2013 A

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. • When 2 or more persons do servicing, make sure that you do it safely. • Do not touch the hot parts or parts that turn when the engine operates. • Do not remove the radiator cap when the engine operates, or immediately after it stops. If not, hot water can spout out from the radiator. Only remove the radiator cap when it is at a sufficiently low temperature to touch with bare hands. Slowly loosen the cap to release the pressure before you remove it fully. • Released fluid (fuel or hydraulic oil) under pressure can cause damage to the skin and cause serious injury. Release the pressure before you disconnect hydraulic or fuel lines. Tighten all connections before you apply the pressure. • Do not open a fuel system under high pressure. The fluid under high pressure that stays in fuel lines can cause serious injury. Do not disconnect or repair the fuel lines, sensors, or any other components between the fuel pump and injectors on engines with a common rail fuel system under high pressure. • Put on an applicable ear protective device (earmuffs or earplugs) to prevent injury against loud noises. • Be careful about electric shock. The engine generates a high voltage of more than DC100 V in the ECU and is applied to the injector.

PREVENT A FIRE • Fuel is very flammable and explosive under some conditions. Do not smoke or let flames or sparks in your work area. • To prevent sparks from an accidental short circuit, always disconnect the battery negative cable first and connect it last. • The battery gas can cause an explosion. Keep the sparks and open flame away from the top of battery, especially when you charge the battery. • Make sure that you do not spill fuel on the engine.

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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.

DISCARD FLUIDS CORRECTLY • Do not discard fluids on the ground, down the drain, into a stream, pond, or lake. Obey related environmental protection regulations when you discard oil, fuel, coolant, electrolyte and other dangerous waste.

PREVENT ACID BURNS • Keep electrolyte away from your eyes, hands and clothing. Sulfuric acid in battery electrolyte is poisonous and it can burn your skin and clothing and cause blindness. If you spill electrolyte on yourself, clean yourself with water, and get medical aid immediately.

PREPARE FOR EMERGENCIES • Keep a first aid kit and fire extinguisher ready at all times. • Keep the emergency telephone numbers near your telephone at all times.

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KiSC issued 09, 2013 A

1 ENGINE

KiSC issued 09, 2013 A

SERVICING CONTENTS 1. FUNCTION OF DIESEL PARTICULATE FILTER (DPF).............................................................1-S1 2. DPF REGENERATION AND DPF CLEANING............................................................................1-S2 3. DPF MAINTENANCE FLOW .......................................................................................................1-S3 [1] CLEANING & RETURN FLOW .............................................................................................1-S4 [2] DPF EXCHANGE FLOW.......................................................................................................1-S5 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 (1) D1803-CR-E4, D1803-CR-TE4, V2403-CR-E4, V2403-CR-TE4 ..................................1-S12 (2) V2607-CR-E4 ................................................................................................................1-S13 (3) V2607-CR-TE4, V3307-CR-TE4 ...................................................................................1-S13 (4) V3800-CR-TE4, V3800-CR-TIE4, V3800-CR-TE4C, V3800-CR-TIE4C .......................1-S14 [4] JUDGMENT OF REUSE OF DPF FILTER COMPLETE BEFORE CLEANING..................1-S15 [5] PREPARATION OF "AFTER-TREATMENT DEVICE EXCHANGE REPORT FORM" .......1-S15 [6] PREPARATION OF "DPF CLEANING ORDER FORM" .....................................................1-S16 [7] PACKING, DELIVERING, AND HANDLING STANDARD OF DPF FILTER COMPLETE .............................................................................................................................................1-S17 [8] DPF CLEANING METHOD, RESPONSIBLE FOR CLEANING CONTRACTOR (REFERENCE) .............................................................................................................................................1-S18 [9] JUDGMENT OF REUSE OF DPF FILTER COMPLETE AFTER CLEANING, RESPONSIBLE FOR CLEANING CONTRACTOR .......................................................................................1-S19 [10]ASSEMBLY OF DPF MUFFLER FULL ASSEMBLY ...........................................................1-S22 (1) D1803-CR-E4, D1803-CR-TE4, V2403-CR-E4, V2403-CR-TE4 ..................................1-S22 (2) V2607-CR-E4 ................................................................................................................1-S24 (3) V2607-CR-TE4, V3307-CR-TE4 ...................................................................................1-S26 (4) V3800-CR-TE4, V3800-CR-TIE4, V3800-CR-TE4C, V3800-CR-TIE4C .......................1-S28 [11]MOUNTING OF DPF MUFFLER FULL ASSEMBLY...........................................................1-S30 (1) D1803-CR-E4, D1803-CR-TE4, V2403-CR-E4, V2403-CR-TE4 ..................................1-S30 (2) V2607-CR-E4 ................................................................................................................1-S31 (3) V2607-CR-TE4, V3307-CR-TE4 ...................................................................................1-S32 (4) V3800-CR-TE4, V3800-CR-TIE4, V3800-CR-TE4C, V3800-CR-TIE4C .......................1-S33 [12]RESETTING BY USING DIAGNOSIS TOOL ......................................................................1-S34 (1) In Case of Scheduled Maintenance for Every 3,000 Hours of Operation, or In Case of Heavy Soot Accumulation (P-Code:P3008, J1939:3701-0) .............................1-S34 (2) In Case of Excessive Regeneration Frequency (P-Code:P3024, J1939:523602-0) .....1-S36 [13]EXECUTION CONDITION FOR MANUAL REGENERATION ............................................1-S38 [14]ATTACHED FORM..............................................................................................................1-S39 (1) After-Treatment Device Exchange Report Form ...........................................................1-S39 (2) DPF Cleaning Order Form.............................................................................................1-S40

KiSC issued 09, 2013 A

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. The filter has a honeycomb structure with adjacent cell holes alternately closed. In addition, by alternately closing the inlet side and the outlet side of the exhaust gas, the thin ceramics wall is used as a filter. As shown in the figure, fine particles in the exhaust gas are captured when they through this thin wall, and the exhaust gas is discharged as clean gas.

1-S1

KiSC issued 09, 2013 A

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" of the filter by removing ash at regular intervals by a cleaning contractor using specialized equipment. 1. DPF Regeneration The engine has the DPF regeneration mode described below (function to burn and remove deposited soot). (a)

Automatic regeneration

Regeneration by automatic control is performed using post injection. The operation of the product can be continued.

(b)

Parked regeneration

If regeneration cannot be carried out depending on the situation of the work, the operation of the installed product is stopped to carry out regeneration.

(c)

Manual regeneration with a diagnosis tool (Diagmaster)

Such regeneration is performed as urgent measures in the event of abnormal soot deposition.

2. Cleaning of ash based on maintenance intervals Since ash deposited in the filter cannot be removed by regeneration, periodical cleaning is required. There is a need to clean the filter at the pre-determined maintenance intervals (3,000 hours) by a cleaning contractor using the specialized equipment by removing the DPF filter complete from the DPF muffler full assy. 3. Cleaning of heavy soot and ash accumulation on filter a) In the case of cleaning request due to heavy soot accumulation b) In the case of cleaning request due to increase the frequency of regeneration In this case, there is a need to clean the filter by a cleaning contractor using the specialized equipment by removing the DPF filter complete from the DPF muffler full assy.

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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. (1) Every 3,000 hours of operation (Scheduled maintenance) (2) Cleaning request due to heavy soot accumulation (P-Code:P3008, J1939:3701-0) (3) Cleaning request due to increase the frequency of regeneration (P-Code:P3024, J1939:523602-0)

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ENGINE

DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM

[1] CLEANING & RETURN FLOW

1-S4

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ENGINE

DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM

[2] DPF EXCHANGE FLOW

1-S5

KiSC issued 09, 2013 A

ENGINE

DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM

4. DPF CLEANING PROCEDURE [1] TO ENSURE SAFETY AND GOOD PERFORMANCE IN DPF CLEANING PROCEDURE (1) (2) (3) (4) (5)

Always work in the workshop equipped with a electric hoist (including mobile hoist). Put a product (engine) on a stable ground, and set the parking brake. As the DPF muffler full assy is hot just after the engine shutdown, make sure to start operation after it gets cool. Make sure not to let any foreign substances enter the opening section during the operation. Make sure not to damage the DPF muffler full assy by falling or impact as it contains a ceramic filter. IMPORTANT • Since the DPF that was dropped or given a shock cannot be reused even if there is no damage outwardly, replace it with a new one.

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KiSC issued 09, 2013 A

ENGINE

DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM

[2] SEPARATION OF DPF MUFFLER FULL ASSY Follow the procedures below to separate DPF muffler full assy from a product (engine). Prior Arrangement for Installation and Removal of DPF 1. Before removing the DPF muffler full assy from a product (engine), connect the diagnosis tool (Diagmaster), check the failure history (DTC), and save to the "Project" on the Diagmaster. Before removing the DPF for cleaning, keep the records of the engine serial number, DPF filter complete part number, DPF filter complete serial number, and engine operating time, which are required in preparing the DPF cleaning order form. Record the engine operating time by checking the “Hourmeter” on the data monitor of the diagnosis tool (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, V3800-CR-TIE4C [D] D1803-CR-E4, D1803-CR-TE4, V2403-CR-E4, V2403-CR-TE4, V2607-CR-E4 [E] V2607-CR-TE4, V3307-CR-TE4 [F] V3800-CR-TE4, V3800-CR-TIE4, V3800-CR-TE4C, V3800-CR-TIE4C

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KiSC issued 09, 2013 A

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. 2. Remove the connectors of exhaust temperature sensor (6), (7), (8) from the bracket. 3. Remove the clamps (4). 4. Remove the tube (9), (10) from the differential pressure pipe (3), (11). 5. Remove the differential pressure sensor (2). 6. Remove the differential pressure sensor bracket (1). (1) Differential Pressure Sensor Bracket (2) Differential Pressure Sensor (3) Differential Pressure Pipe (4) Clamp (5) Screw of Muffler Flange (6) Connector of Exhaust Temperature Sensor (T2)

(7) Connector of Exhaust Temperature Sensor (T1) (8) Connector of Exhaust Temperature Sensor (T0) (9) Tube (10) Tube (11) Differential Pressure Pipe

Separation of Muffler Full Assembly (DPF) 1. Unscrew the screw of muffler flange. 2. Unscrew the muffler full assembly (DPF) mounting screws (2). 3. Remove the muffler full assembly (DPF) (1). NOTE • When installing and removing the DPF muffler, make sure that the temperature sensor, differential pressure sensor, and differential pressure pipe do not make with surrounding parts. (1) Muffler Full Assembly (DPF)

1-S8

(2) Muffler Full Assembly (DPF) Mounting Screw

KiSC issued 09, 2013 A

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. 3. Remove the clamps (8). 4. Remove the differential pressure sensor bracket (12). (1) (2) (3) (4) (5) (6) (7) (8)

Exhaust Temperature Sensor (T2) Differential Pressure Pipe Differential Pressure Pipe Exhaust Temperature Sensor (T1) Exhaust Temperature Sensor (T0) Screw of Muffler Flange Muffler Flange Clamp

(9) Connector of Exhaust Temperature Sensor (T2) (10) Connector of Exhaust Temperature Sensor (T1) (11) Connector of Exhaust Temperature Sensor (T0) (12) Differential Pressure Sensor Bracket (13) Differential Pressure Sensor

Separation of Muffler Full Assembly (DPF) 1. Unscrew the screw of muffler flange. 2. Unscrew the muffler full assembly (DPF) mounting screws (2). 3. Remove the muffler full assembly (DPF) (1). NOTE • When installing and removing the DPF muffler, make sure that the temperature sensor, differential pressure sensor, and differential pressure pipe do not make with surrounding parts. (1) Muffler Full Assembly (DPF)

1-S9

(2) Muffler Full Assembly (DPF) Mounting Screw

KiSC issued 09, 2013 A

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. 3. Remove the clamps (6). 4. Remove the differential pressure sensor bracket (10). (1) (2) (3) (4) (5) (6) (7)

Exhaust Temperature Sensor (T2) Exhaust Temperature Sensor (T1) Exhaust Temperature Sensor (T0) Nut of Muffler Flange Muffler Flange Clamp Connector of Exhaust Temperature Sensor (T0)

(8) Connector of Exhaust Temperature Sensor (T1) (9) Connector of Exhaust Temperature Sensor (T2) (10) Differential Pressure Sensor Bracket (11) Differential Pressure Sensor

Separation of Muffler Full Assembly (DPF) 1. Unscrew the nut of muffler flange. 2. Unscrew the muffler full assembly (DPF) mounting screws (2). 3. Remove the muffler full assembly (DPF) (1). NOTE • When installing and removing the DPF muffler, make sure that the temperature sensor, differential pressure sensor, and differential pressure pipe do not make with surrounding parts. (1) Muffler Full Assembly (DPF)

1-S10

(2) Muffler Full Assembly (DPF) Mounting Screw

KiSC issued 09, 2013 A

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. 3. Remove the clamps (5). 4. Unscrew the stay mounting bolt (7), and remove the DPF stay 1 (6). (1) Differential Pressure Sensor (2) Connector of Exhaust Temperature Sensor T2 (3) Connector of Exhaust Temperature Sensor T1

(4) Connector of Exhaust Temperature Sensor T0 (5) Clamp (6) DPF Stay 1 (7) Stay Mounting Bolt

Separation of Muffler Full Assembly (DPF) 1. Set chain sling by using shackle at two places (a) and (b) as shown in the photograph. 2. Unscrew the screws of muffler flange (1). 3. Unscrew the muffler full assembly (DPF) mounting screws (2). 4. Lift up the muffler full assembly (DPF) safely, and separate it from the engine. NOTE • When lifting the muffler full assembly (DPF), use caution so that the pressure pipe 1 (3) does not hit the EGR pipe (4). (1) Screw of Muffler Flange (2) Muffler Full Assembly (DPF) Mounting Screw (3) Pressure Pipe 1 (4) EGR Pipe

1-S11

(a) Shackle Set Position (b) Shackle Set Position

KiSC issued 09, 2013 A

ENGINE

DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM

[3] DISASSEMBLY OF DPF MUFFLER FULL ASSEMBLY IMPORTANT • Since the DPF that was dropped or given a shock cannot be reused even if there is no damage outwardly, replace it with a new one. • Be sure to loosen the temperature sensor tightening nut or the differential pressure pipe tightening nut with crowfoot wrench to prevent the damage of the sensor or pipe. If it is still hard to loosen, apply the lubricant spray to threaded portion and soak it with lubricant. NOTE • Always work in the workshop equipped with a electric hoist (including mobile hoist). • Put a product (engine) on a stable ground, and set the parking brake. • As the DPF muffler full assembly is hot just after the engine shutdown, make sure to start operation after it gets cool. • Make sure not to let any foreign substances enter the opening section during the operation. • Make sure not to damage the DPF muffler full assembly by falling or impact as it contains a ceramic filter. • Before removing the DPF muffler full assembly from a product (engine), connect the diagnosis tool (Diagmaster), check the failure history, and save the project. • Before removing the DPF for cleaning, keep the records of the engine serial number, filter comp (DPF) part number, filter comp (DPF) serial number, catalyst (DOC) part number, catalyst (DOC) serial number, and engine operating time, which are required in preparing the DPF cleaning order from. Since the engine operating time is recorded in the ECU, check the operating time by connecting the service tool (Diagmaster). • 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 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). 2. Separate the DOC catalyst complete (10), DPF filter complete (9) and DPF outlet body (7). (1) (2) (3) (4) (5)

Exhaust Temperature Sensor (T2) DPF Mounting Clamp Band Exhaust Temperature Sensor (T1) Exhaust Temperature Sensor (T0) DPF Stay

1-S12

(6) (7) (8) (9) (10)

Differential Pressure Pipe DPF Outlet Body Gasket DPF Filter Complete DOC Catalyst Complete

KiSC issued 09, 2013 A

ENGINE

DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM

(2) V2607-CR-E4 Differential Pressure Sensor and DPF Filter Complete 1. 2. 3. 4. 5.

Remove the tube (5) from the differential pressure pipe (2). Remove the tube (6) from the differential pressure pipe (3). Remove the differential pressure sensor (7). Loosen the DPF filter complete mounting bracket (1), (4). Separate the DOC catalyst complete (12), DPF filter complete (10) and DPF outlet body (8).

(1) DPF Filter Complete Mounting Bracket (2) Differential Pressure Pipe (3) Differential Pressure Pipe (4) DPF Filter Complete Mounting Bracket (5) Tube (6) Tube (7) Differential Pressure Sensor

(8) (9) (10) (11) (12) (13) (14) (15)

DPF Outlet Body Gasket DPF Filter Complete Gasket DOC Catalyst Complete Exhaust Temperature Sensor (T0) Exhaust Temperature Sensor (T1) Exhaust Temperature Sensor (T2)

(3) V2607-CR-TE4, V3307-CR-TE4 Differential Pressure Sensor and DPF Filter Complete 1. 2. 3. 4. 5.

Remove the tube (3) from the differential pressure pipe (4). Remove the tube (5) from the differential pressure pipe (6). Remove the differential pressure sensor (7). Loosen the all DPF filter complete mounting screw (1), (2). Separate the DOC catalyst complete (11), DPF filter complete (9) and DPF outlet body (8).

(1) DPF Filter Complete Mounting Screw (2) DPF Filter Complete Mounting Screw (3) Tube (4) Differential Pressure Pipe (5) Tube (6) Differential Pressure Pipe (7) Differential Pressure Sensor (8) DPF Outlet Body

1-S13

(9) (10) (11) (12) (13) (14) (15) (16) (17)

DPF Filter Complete Collar (DPF) DOC Catalyst Exhaust Temperature Sensor (T0) Gasket Exhaust Temperature Sensor (T1) Gasket Gasket Exhaust Temperature Sensor (T2)

KiSC issued 09, 2013 A

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. 2. 3. 4. 5. 6.

Remove the tube (3) from the differential pressure pipe (10). Remove the tube (4) from the differential pressure pipe (6). Remove the differential pressure sensor (2). Remove the DPF stay 2 (5). Loosen the all DPF filter complete mounting screw (9). Separate the DOC catalyst complete (14), DPF filter complete (12) and DPF outlet body (11).

(1) (2) (3) (4) (5) (6) (7) (8) (9)

Exhaust Temperature Sensor (T2) Differential Pressure Sensor Tube Tube DPF Stay 2 Differential Pressure Pipe Exhaust Temperature Sensor (T1) Exhaust Temperature Sensor (T0) DPF Filter Complete Mounting Screw

1-S14

(10) (11) (12) (13) (14) (15) (16) (17)

Differential Pressure Pipe DPF Outlet Body DPF Filter Complete DPF Collar DOC Catalyst Complete DPF Gasket DPF Gasket DPF Gasket

KiSC issued 09, 2013 A

ENGINE

DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM

[4] JUDGMENT OF REUSE OF DPF FILTER COMPLETE BEFORE CLEANING IMPORTANT • Before ordering to a cleaning contractor, follow the procedures below to make a judgment on whether the separated DPF filter complete is reusable. Judgment of Reuse by Service Dealer 1. Check to see that the surface of the removed DPF filter complete on the exhaust gas outlet side is not darkened. 2. Check whether there is no crack or loss of the sealing part of the cell holes on both ends of the filter (inlet side and outlet side). If the number of missing sealing parts exceeds the allowable limit, the filter complete cannot be reused even after cleaning.

Number for judgment of non-reusability of filter

Allowable limit

D1803-CR-E4 D1803-CR-TE4 V2403-CR-E4 V2403-CR-TE4

Number of missing sealing parts: 10 or more

V2607-CR-E4

Number of missing sealing parts: 10 or more

V2607-CR-TE4 V3307-CR-TE4

Number of missing sealing parts: 15 or more

V3800-CR-TE4 V3800-CR-TIE4 V3800-CR-TE4C V3800-CR-TIE4C

Number of missing sealing parts: 15 or more

3. Check whether there is no crack and loss of the ceramics element. If there are any cracks or losses of the ceramics element, the DPF filter complete cannot be reused even if it is cleaned. 4. If it is judged that the DPF filter complete is not reusable, report the result of the evaluation to the customer that requested the filter cleaning, and replace the DPF filter complete with a new one.

[5] PREPARATION OF "AFTER-TREATMENT DEVICE EXCHANGE REPORT FORM" IMPORTANT • When replacing the DPF filter complete with a new one because the DPF filter complete cannot be reused, make sure to prepare the "After-Treatment Device Exchange Report Form" and to send the report form to 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.

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KiSC issued 09, 2013 A

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.

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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. (2) Put "FRAGILE" sticker on the package. (3) Make sure not to drop DPF filter complete when handling and carrying. Packing and Delivering of DPF Filter Complete (Example) 1. Seal the removed DPF filter complete with a plastic bag as shown in the photograph [A]. 2. Put a cushioning material in the bottom of the prepared cardboard box. 3. Put the DPF filter complete with the sealed plastic bag on a cushioning material. 4. Put a cushioning material in around the DPF filter complete as shown in the photograph [B]. 5. Put a cushioning material over the DPF filter complete as shown in the photograph [C]. 6. Enclose the completed DPF Cleaning Order Form in the cardboard box and close it. 7. Put "FRAGILE" sticker on the cardboard box. 8. Write the address and send it to a cleaning contractor.

[Cautions for handling] (1) Workers should wear a mask and goggles, and other required protective equipments according to local relevant regulations whenever cleaning DPF. (2) The removed soot and ash should be collected on a filter etc. and safely disposed by an industrial waste disposer according to local relevant regulations. [Disposal standard of DPF] (1) DPF should be disposed by an industrial waste disposer according to local relevant regulations.

1-S17

KiSC issued 09, 2013 A

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. (2) The removed soot and ash should be collected on a filter etc. and safely disposed by an industrial waste disposer according to local relevant regulations. Make sure that the DPF cleaning must be carried out according to the following procedures. 1. The DPF should be cleaned with air. (1) Spray the air mainly from the exhaust outlet side towards the inlet side. (Refer to the arrow on the side of the DPF complete, which shows the flow of exhaust gas.) (2) The DPF should not be cleaned by applying pressure (positive/negative) to the whole of the DPF at one time. 3. Do not use any other substance except air to clean the DPF. 4. Do not give a vibration or a shock (hitting, shaking) to the DPF to clean it.

1-S18

KiSC issued 09, 2013 A

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

ENGINE

DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM

Judgment of Reuse by Cleaning Contractor 1. After having cleaned the DPF filter complete, measure the actual cell depth (E) with a pin gauge in the each block shown in the figure. One cell (The measurement point is not specified) is measured in each block. Model

Measurement total

D1803-CR-E4 D1803-CR-TE4 V2403-CR-E4 V2403-CR-TE4

16 blocks

V2607-CR-E4

16 blocks

V2607-CR-TE4 V3307-CR-TE4

25 blocks

V3800-CR-TE4 V3800-CR-TIE4 V3800-CR-TE4C V3800-CR-TIE4C

28 blocks

(1) Pin Gauge (0.60 to 0.80 mm dia., 0.024 to 0.031 in. dia.) (2) DPF Filter Complete (a) Serial No.

(A) (B) (C) (D) (E) (F) (G) [A]

Exhaust Inlet Side Exhaust Outlet Side Accumulated Ash 150 mm (5.91 in.) Actual Cell Depth Accumulated Ash Depth Cell Depth 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

(To be continued)

1-S20

KiSC issued 09, 2013 A

ENGINE

DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM

(Continued) 2. If the actual cell depth (E) is less than the allowable limit, the DPF filter complete cannot be reused. If the DPF filter complete is judged as non-reusable, report the result of the judgment to the customer that requested the filter cleaning via the service dealer, and replace the DPF filter complete with a new one. (Reference) Actual Cell Depth (E) = Cell Depth (G)  Accumulated Ash Depth (F) NOTE • Select a metal pin gauge having a wire size slightly thinner than the cell width (0.60 to 0.80 mm dia., 0.024 to 0.031 in. dia.). • When the pin gauge is inserted into the cell hole, insert it by lightly tapping on the gage end with a finger tip. • If the pin gauge is forcibly pushed in, the pin pierces through the accumulated ash and it cannot be measured accurately. So be careful not to push the pin forcibly.

Actual Cell Depth (Average of all measurement blocks)

Allowable limit

D1803-CR-E4

85 mm (3.3 in.)

D1803-CR-TE4 V2403-CR-E4

102 mm (4.02 in.)

V2403-CR-TE4

119 mm (4.68 in.)

V2607-CR-E4 V2607-CR-TE4 V3307-CR-TE4

119 mm (4.68 in.)

V3800-CR-TE4 V3800-CR-TIE4 V3800-CR-TE4C V3800-CR-TIE4C

106 mm (4.17 in.)

(1) Pin Gauge (0.60 to 0.80 mm dia., 0.024 to 0.031 in. dia.) (2) DPF Filter Complete (a) Serial No.

1-S21

(A) (B) (C) (D) (E) (F) (G) [A]

Exhaust Inlet Side Exhaust Outlet Side Accumulated Ash 150 mm (5.91 in.) Actual Cell Depth Accumulated Ash Depth Cell Depth 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

KiSC issued 09, 2013 A

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. DOC Catalyst Complete, DPF Filter Complete and DPF Outlet Body 1. Replace the gaskets (2), (5) with new ones. 2. Clean the mounting surface of each flange. 3. Assemble the DOC catalyst complete (7), DPF filter complete (4), and DPF outlet body (1) with DPF mounting clamp band (3), (6). NOTE • Assemble the DPF filter complete (4) in the correct direction. Tightening torque

(1) (2) (3) (4)

DPF mounting clamp band

DPF Outlet Body Gasket DPF mounting clamp band DPF Filter Complete

16 to 20 N·m 1.7 to 2.0 kgf·m 12 to 14 lbf·ft

(5) Gasket (6) DPF mounting clamp band (7) DOC Catalyst Complete

Exhaust Temperature Sensor (In the event of need for replacement) When the exhaust temperature sensor 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). 2. Install the exhaust temperature sensor T0 (3), T1 (2), and T2 (1) from the exhaust inlet side (catalyst complete side) sequentially. 3. Install each exhaust temperature sensor with the specified torque. NOTE • Anti seize agent is already applied to the screw parts of new exhaust temperature sensor. So, it is not necessary to apply it when replacing new ones. Tightening torque

Exhaust temperature sensor T0 Exhaust temperature sensor T1 Exhaust temperature sensor T2

(1) Exhaust Temperature Sensor T2 (White Connector: 1J801-18520) (2) Exhaust Temperature Sensor T1 (Gray Connector: 1J500-18510) (3) Exhaust Temperature Sensor T0 (Black Connector: 1J500-18500)

1-S22

25.0 to 35.0 N·m 2.55 to 3.56 kgf·m 18.5 to 25.8 lbf·ft

(A) Exhaust Outlet Side (B) Exhaust Inlet Side

KiSC issued 09, 2013 A

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). 2. Use caution not to make a mistake in assembling the differential pressure pipes (1) and (2). 3. Install the differential pressure pipe (1) and (2) with the specified torque. Tightening torque

Differential pressure pipe

(1) Differential Pressure Pipe (2) Differential Pressure Pipe

1-S23

16.0 to 23.0 N·m 1.64 to 2.34 kgf·m 11.8 to 16.9 lbf·ft

(A) Exhaust Outlet Side (B) Exhaust Inlet Side

KiSC issued 09, 2013 A

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. Replace the gaskets (3), (6) with new ones. 2. Clean the mounting surface of each flange. 3. Assemble the DOC catalyst complete (7), DPF filter complete (4), and DPF outlet body (1) with DPF filter complete mounting bracket (2), (5). NOTE • Assemble the DPF filter complete (4) in the rightcorrect direction. Tightening torque

DPF filter complete mounting bracket

(1) DPF Outlet Body (2) DPF Filter Complete Mounting Bracket (3) Gasket (4) DPF Filter Complete

16 to 20 N·m 1.7 to 2.0 kgf·m 12 to 14 lbf·ft

(5) DPF Filter Complete Mounting Bracket (6) Gasket (7) DOC Catalyst Complete

Exhaust Temperature Sensor (In the event of need for replacement) When the exhaust temperature sensor 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). 2. Install the exhaust temperature sensor T0 (3), T1 (2), and T2 (1) from the exhaust inlet side (catalyst complete side) sequentially. 3. Install each exhaust temperature sensor with the specified torque. NOTE • Anti seize agent is already applied to the screw parts of new exhaust temperature sensor. So, it is not necessary to apply it when replacing new ones. Tightening torque

Exhaust temperature sensor T0 Exhaust temperature sensor T1 Exhaust temperature sensor T2

(1) Exhaust Temperature Sensor T2 (White Connector: 1J770-18520) (2) Exhaust Temperature Sensor T1 (Gray Connector: 1J770-18510) (3) Exhaust Temperature Sensor T0 (Black Connector: 1J500-18500)

1-S24

25.0 to 35.0 N·m 2.55 to 3.56 kgf·m 18.5 to 25.8 lbf·ft

(A) Exhaust Outlet Side (B) Exhaust Inlet Side

KiSC issued 09, 2013 A

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). 2. Use caution not to make a mistake in assembling the differential pressure pipes (1) and (2). 3. Install the differential pressure pipe (1) and (2) with the specified torque. Tightening torque

Differential pressure pipe

(1) Differential Pressure Pipe (2) Differential Pressure Pipe

16.0 to 23.0 N·m 1.64 to 2.34 kgf·m 11.8 to 16.9 lbf·ft

(A) Exhaust Outlet Side (B) Exhaust Inlet Side

Differential Pressure Sensor 1. Install the differential pressure sensor (3). 2. Connect the each tube with differential pressure pipe (1) and (2), and fix the tube with a clamp surely. NOTE • If there are the damage or a crack in the tube, replace the tube with a new one. Mounting bolt of differential pressure sensor

9.80 to 11.3 N·m 1.00 to 1.15 kgf·m 7.23 to 8.33 lbf·ft

Fixed bolt of differential pressure pipe

9.80 to 11.3 N·m 1.00 to 1.15 kgf·m 7.23 to 8.33 lbf·ft

Tightening torque

(1) Differential Pressure Pipe (2) Differential Pressure Pipe

1-S25

(3) Differential Pressure Sensor

KiSC issued 09, 2013 A

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. Replace the gaskets (5), (6), (7) with new ones. 2. Clean the mounting surface of each flange. 3. Assemble the components temporary by arranging the DOC catalyst complete (4), DPF collar (3), DPF filter complete (2), and DPF outlet body (1). 4. Tighten all the screws evenly with the specified torque. NOTE • Assemble the DPF filter complete (2) in the right direction by referring to the arrow (8) on the side showing the flow of exhaust gas. Tightening torque

(1) (2) (3) (4) (5)

DPF filter complete mounting screw

DPF Outlet Body DPF Filter Complete DPF Collar DOC Catalyst Complete Gasket

(6) (7) (8) (A) (B)

49.0 to 55.9 N·m 5.00 to 5.70 kgf·m 36.2 to 41.2 lbf·ft Gasket Gasket Arrow (GAS FLOW) Exhaust Inlet Side Exhaust Outlet Side

Exhaust Temperature Sensor (In the event of need for replacement) When the exhaust temperature sensor 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). 2. Install the exhaust temperature sensor T0 (3), T1 (2), and T2 (1) from the exhaust inlet side (catalyst complete side) sequentially. 3. Install each exhaust temperature sensor with the specified torque. NOTE • Anti seize agent is already applied to the screw parts of new exhaust temperature sensor. So, it is not necessary to apply it when replacing new ones. Tightening torque

Exhaust temperature sensor T0 Exhaust temperature sensor T1 Exhaust temperature sensor T2

(1) Exhaust Temperature Sensor T2 (White Connector: 1J770-18520) (2) Exhaust Temperature Sensor T1 (Gray Connector: 1J770-18510) (3) Exhaust Temperature Sensor T0 (Black Connector: 1J770-18500)

1-S26

25.0 to 35.0 N·m 2.55 to 3.56 kgf·m 18.5 to 25.8 lbf·ft

(A) Exhaust Outlet Side (B) Exhaust Inlet Side

KiSC issued 09, 2013 A

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). 2. Use caution not to make a mistake in assembling the differential pressure pipes (1) and (2). 3. Install the differential pressure pipe (1) and (2) with the specified torque. Tightening torque

Differential pressure pipe

(1) Differential Pressure Pipe (2) Differential Pressure Pipe

16.0 to 23.0 N·m 1.64 to 2.34 kgf·m 11.8 to 16.9 lbf·ft

(A) Exhaust Outlet Side (B) Exhaust Inlet Side

Differential Pressure Sensor 1. Install the differential pressure sensor (1). 2. Connect the each tube with pressure pipe (2) and (3), and fix the tube with a clamp surely. NOTE • If there are the damage or a crack in the tube, replace the tube with a new one. Mounting bolt of differential pressure sensor

9.80 to 11.3 N·m 1.00 to 1.15 kgf·m 7.23 to 8.33 lbf·ft

Fixed bolt of differential pressure pipe

9.80 to 11.3 N·m 1.00 to 1.15 kgf·m 7.23 to 8.33 lbf·ft

Tightening torque

(1) Differential Pressure Sensor (2) Differential Pressure Pipe

1-S27

(3) Differential Pressure Pipe

KiSC issued 09, 2013 A

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. Replace the gaskets (5), (6), (7) with new ones. 2. Clean the mounting surface of each flange. 3. Assemble the components temporary by arranging the DOC catalyst complete (4), DPF collar (3), DPF filter complete (2), and DPF outlet body (1). 4. Tighten all the screws evenly with the specified torque. NOTE • Assemble the DPF filter complete (2) in the right direction by referring to the arrow (8) on the side showing the flow of exhaust gas. Tightening torque

(1) (2) (3) (4) (5)

DPF filter complete mounting screw

DPF Outlet Body DPF Filter Complete DPF Collar DOC Catalyst Complete Gasket

(6) (7) (8) (A) (B)

49.0 to 55.9 N·m 5.00 to 5.70 kgf·m 36.2 to 41.2 lbf·ft Gasket Gasket Arrow (GAS FLOW) Exhaust Inlet Side Exhaust Outlet Side

Exhaust Temperature Sensor (In the event of need for replacement) When the exhaust temperature sensor 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). 2. Install the exhaust temperature sensor T0 (1), T1 (2), and T2 (3) from the exhaust inlet side (catalyst complete side) sequentially. 3. Install each exhaust temperature sensor with the specified torque. NOTE • Anti seize agent is already applied to the screw parts of new exhaust temperature sensor. So, it is not necessary to apply it when replacing new ones. Tightening torque

Exhaust temperature sensor T0 Exhaust temperature sensor T1 Exhaust temperature sensor T2

(1) Exhaust Temperature Sensor T0 (Black Connector: 1J500-18500) (2) Exhaust Temperature Sensor T1 (Gray Connector: 1J500-18510) (3) Exhaust Temperature Sensor T2 (White Connector: 1J500-18520)

1-S28

25.0 to 35.0 N·m 2.55 to 3.56 kgf·m 18.5 to 25.8 lbf·ft

(A) Exhaust Inlet Side (B) Exhaust Outlet Side

KiSC issued 09, 2013 A

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). 2. Use caution not to make a mistake in assembling the differential pressure pipes (1) and (2). 3. Install the differential pressure pipe (1) and (2) with the specified torque. Tightening torque

Differential pressure pipe

(1) Differential Pressure Pipe (2) Differential Pressure Pipe

16.0 to 23.0 N·m 1.64 to 2.34 kgf·m 11.8 to 16.9 lbf·ft

(A) Exhaust Outlet Side (B) Exhaust Inlet Side

Differential Pressure Sensor 1. 2. 3. 4.

Install the DPF stay 2 (2). Install the fixed bolts of differential pressure pipe (3) and (4). Install the differential pressure sensor (1). Connect the each tube with differential pressure pipe (3) and (4), and fix the tube with a clamp surely. NOTE • If there are the damage or a crack in the tube, replace the tube with a new one. Mounting bolt of differential pressure sensor

9.80 to 11.3 N·m 1.00 to 1.15 kgf·m 7.23 to 8.33 lbf·ft

Fixed bolt of differential pressure pipe

9.80 to 11.3 N·m 1.00 to 1.15 kgf·m 7.23 to 8.33 lbf·ft

Tightening torque

(1) Differential Pressure Sensor (2) DPF Stay 2

1-S29

(3) Differential Pressure Pipe (4) Differential Pressure Pipe

KiSC issued 09, 2013 A

ENGINE

DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM

[11] 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. Muffler full assembly (DPF) mounting screw

49.0 to 55.9 N·m 5.00 to 5.70 kgf·m 36.2 to 41.2 lbf·ft

Screw of muffler flange

49.0 to 55.9 N·m 5.00 to 5.70 kgf·m 36.2 to 41.2 lbf·ft

Tightening torque

(1) Muffler full assembly (DPF)

(2) Muffler full assembly (DPF) mounting screw

Connector of Exhaust Temperature Sensor and Differential Pressure Sensor 1. Install the differential pressure sensor bracket (1). 2. Install the differential pressure sensor (2). 3. Connect the tube (10), (11) with differential pressure pipe (3) and (12), and fix the tube with a clamp surely. 4. Connect the connectors of exhaust temperature sensor (6), (7), (8), and fix the wiring with clamp (4). 5. Connect the connector of differential pressure sensor (9). (1) Differential Pressure Sensor Bracket (2) Differential Pressure Sensor (3) Differential Pressure Pipe (4) Clamp (5) Screw of Muffler Flange (6) Connector of Exhaust Temperature Sensor (T2)

1-S30

(7) Connector of Exhaust Temperature Sensor (T1) (8) Connector of Exhaust Temperature Sensor (T0) (9) Connector of Differential Pressure Sensor (10) Tube (11) Tube (12) Differential Pressure Pipe

KiSC issued 09, 2013 A

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. Muffler full assembly (DPF) mounting screw

49.0 to 55.9 N·m 5.00 to 5.70 kgf·m 36.2 to 41.2 lbf·ft

Screw of muffler flange

49.0 to 55.9 N·m 5.00 to 5.70 kgf·m 36.2 to 41.2 lbf·ft

Tightening torque

(1) Muffler Full Assembly (DPF)

(2) Muffler Full Assembly (DPF) Mounting Screw

Connector of Exhaust Temperature Sensor 1. Install the differential pressure sensor bracket (7). 2. Install the differential pressure sensor (8) to the bracket (7). 3. Connect the connectors of exhaust temperature sensor (4), (5), (6), and fix the wiring with clamp (3). (1) (2) (3) (4)

Screw of Muffler Flange Muffler Flange Clamp Connector of Temperature Sensor (T2) (5) Connector of Temperature Sensor (T1)

1-S31

(6) Connector of Temperature Sensor (T0) (7) Differential Pressure Sensor Bracket (8) Differential Pressure Sensor

KiSC issued 09, 2013 A

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. Muffler full assembly (DPF) mounting screw

49.0 to 55.9 N·m 5.00 to 5.70 kgf·m 36.2 to 41.2 lbf·ft

Screw of muffler flange

49.0 to 55.9 N·m 5.00 to 5.70 kgf·m 36.2 to 41.2 lbf·ft

Tightening torque

(1) Muffler Full Assembly (DPF)

(2) Muffler Full Assembly (DPF) Mounting Screw

Connector of Exhaust Temperature Sensor 1. Install the differential pressure sensor bracket (7). 2. Install the differential pressure sensor (8) to the bracket (7). 3. Connect the connectors of exhaust temperature sensor (4), (5), (6), and fix the wiring with clamp (3). (1) (2) (3) (4)

Screw of Muffler Flange Muffler Flange Clamp Connector of Temperature Sensor (T2) (5) Connector of Temperature Sensor (T1)

1-S32

(6) Connector of Temperature Sensor (T0) (7) Differential Pressure Sensor Bracket (8) Differential Pressure Sensor

KiSC issued 09, 2013 A

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. 3. Assemble the muffler full assembly (DPF) (1) with the muffler full assembly (DPF) mounting screw (5) and the screw of muffler flange (4). 4. Remove the chain sling. NOTE • When guiding the muffler full assembly (DPF) to the installation position, use caution so that the differential pressure pipe (3) does not hit the EGR pipe (2). Muffler full assembly (DPF) mounting screw

49.0 to 55.9 N·m 5.00 to 5.70 kgf·m 36.2 to 41.2 lbf·ft

Screw of muffler flange

49.0 to 55.9 N·m 5.00 to 5.70 kgf·m 36.2 to 41.2 lbf·ft

Tightening torque

(1) (2) (3) (4) (5)

Muffler Full Assembly (DPF) EGR Pipe Differential Pressure Pipe Screw of Muffler Flange Muffler Full Assembly (DPF) Mounting Screw

(a) Shackle Set Position (b) Shackle Set Position

Connector of Exhaust Temperature Sensor and DPF Stay 1 1. Install the DPF stay 1 (5). 2. Connect the connectors of exhaust temperature sensor (1), (2), (3), and fix wiring with clamps (4). Tightening torque

DPF stay mounting bolt

49.0 to 55.9 N·m 5.00 to 5.70 kgf·m 36.2 to 41.2 lbf·ft

(1) Connector of Exhaust Temperature (3) Connector of Exhaust Temperature Sensor (T2) Sensor (T0) (2) Connector of Exhaust Temperature (4) Clamp Sensor (T1) (5) DPF Stay 1

1-S33

KiSC issued 09, 2013 A

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. Follow the procedure given below by connecting the diagnosis tool (Diagmaster) after installing the DPF muffler full assy to a product (engine).

(1) In Case of Scheduled Maintenance for Every 3,000 Hours of Operation, or In Case of Heavy Soot Accumulation (P-Code:P3008, J1939:3701-0) Step1 1. Reset the value by "DPF Soot Load Reset" in the utility functions of the diagnosis tool.

1-S34

KiSC issued 09, 2013 A

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 1. Check if the "DPF Regeneration Control Level" and the "DPF Regeneration Control Status" shows "Level 0" by the monitor functions in the diagnosis tool. If the level is 0, it means that manual regeneration has completed.

1-S35

KiSC issued 09, 2013 A

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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

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.

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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 1. Check if the "DPF Regeneration Control Level" and the "DPF Regeneration Control Status" shows "Level 0" by the monitor functions in the diagnosis tool. If the level is 0, it means that manual regeneration has completed.

[13] EXECUTION CONDITION FOR MANUAL REGENERATION To execute manual regeneration, it is required to set the following conditions. (1) Parking break on (2) Transmission in neutral (3) Implement down

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[14] ATTACHED FORM (1) After-Treatment Device Exchange Report Form

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(2) DPF Cleaning Order Form

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EDITOR : KUBOTA FARM & INDUSTRIAL MACHINERY SERVICE, LTD. 64, ISHIZU-KITAMACHI, SAKAI-KU, SAKAI-CITY, OSAKA, 590-0823, JAPAN PHONE : (81)72-241-1129 FAX : (81)72-245-2484 E-mail : [email protected]

KUBOTA Corporation

Printed in Japan 2013. 09, S, EI, EI, engusa 2012. 08, S, EI, EI, engusa

Code No.9Y111-07332