Kubota D1803-CR-E4 / D1803-CR-TE4 / V2403-CR-E4 / V2403-CR-TE4 / V2403-CR-TE4BG / D1803-CR-TIE4/V2403-CR-TIE4 (DOC only) Workshop Manual

About this manual

Kubota published this Workshop Manual for the D1803-CR-E4, D1803-CR-TE4, V2403-CR-E4, V2403-CR-TE4, V2403-CR-TE4BG, D1803-CR-TIE4 (DOC only), and V2403-CR-TIE4 (DOC only) engine models. It brings the documented service and technical-reference material for those named engines into a single publication.

Its documented technical value includes torque settings, wear limits, dimensions, and emission data for service checks and specification lookup. Use the values and conditions stated in the PDF for the applicable model and procedure.

Use the Manual Contents below to check that the exact repair, inspection, or maintenance procedure you need is included in this publication.

Manual details

Manufacturer

Kubota

Manual type

Workshop Manual

Equipment type

Engine

Models

D1803-CR-E4, D1803-CR-TE4, V2403-CR-E4, V2403-CR-TE4, V2403-CR-TE4BG, D1803-CR-TIE4 (DOC only), and V2403-CR-TIE4 (DOC only)

Model-specific applicability

D1803-CR-TIE4: DOC only; V2403-CR-TIE4: DOC only

Document number

9Y111-07826

Publication year

2013

Publication date

February, 2013

KiSC issue / revision

April 2017 (A)

Language

English

Page count

191

Product highlights

Electrical systems

The manual includes wiring diagrams, connector views, and pinouts.

Specifications and settings

The manual includes reference information for torque specifications, wear limits, and dimensions.

Special tools

A special-tools section is included.

Maintenance

The manual includes a maintenance schedule.

Applicability and key coverage

Named models: D1803-CR-E4, D1803-CR-TE4, V2403-CR-E4, V2403-CR-TE4, V2403-CR-TE4BG, D1803-CR-TIE4 (DOC only), and V2403-CR-TIE4 (DOC only).

For the diesel engine mechanism not included here, the reader refers to Workshop Manual (Code No. 9Y021-01870).

Manual contents

Use these source headings to locate the task or system you need in the PDF.

• TO THE READER — p. 2
• I INFORMATION — p. 5
  • INFORMATION — p. 6
    • 1. SAFETY FIRST — p. 7
    • 2. SPECIFICATIONS — p. 11
    • 3. PERFORMANCE CURVES — p. 15
    • 4. DIMENSIONS — p. 21
    • 5. WIRING DIAGRAM — p. 22
      • [1] ENGINE INTERMEDIATE HARNESS (ENGINE SIDE HARNESS) — p. 22
      • [2] INJECTOR INTERMEDIATE HARNESS (ENGINE SIDE HARNESS) — p. 24
      • [3] ECU INTERMEDIATE HARNESS (ONE SIDE HARNESS) — p. 25
      • [4] SYSTEM WIRING DIAGRAM — p. 30
• G GENERAL — p. 42
  • GENERAL — p. 43
    • 1. ENGINE IDENTIFICATION — p. 44
      • [1] MODEL NAME AND ENGINE SERIAL NUMBER — p. 44
      • [2] E4B ENGINE — p. 46
      • [3] CYLINDER NUMBER — p. 46
    • 2. MUFFLER FULL ASSEMBLY IDENTIFICATION — p. 47
      • [1] PART NUMBER AND SERIAL NUMBER — p. 47
    • 3. GENERAL PRECAUTIONS — p. 48
    • 4. MAINTENANCE CHECK LIST — p. 49
    • 5. CHECK AND MAINTENANCE — p. 53
      • [1] DAILY CHECK POINTS — p. 53
      • [2] INITIAL 50 HOURS — p. 56
      • [3] EVERY 50 HOURS — p. 57
      • [4] EVERY 100 HOURS — p. 57
      • [5] EVERY 200 HOURS — p. 58
      • [6] EVERY 400 HOURS — p. 59
      • [7] EVERY 500 HOURS — p. 60
      • [8] EVERY 800 HOURS — p. 62
      • [9] EVERY 1500 HOURS — p. 63
      • [10] EVERY 3000 HOURS — p. 65
      • [11] EVERY 1 YEAR — p. 70
      • [12] EVERY 2 YEARS — p. 71
    • 6. SPECIAL TOOLS — p. 75
• 1 ENGINE — p. 82
  • MECHANISM — p. 83
    • 1. ENGINE BODY — p. 84
      • [1] PISTON — p. 84
      • [2] HALF -FLOATING HEAD COVER — p. 84
    • 2. LUBRICATING SYSTEM — p. 85
      • [1] OIL COOLER — p. 85
    • 3. COOLING SYSTEM — p. 86
      • [1] THERMOSTART — p. 86
      • [2] BOTTOM BYPASS SYSTEM — p. 87
    • 4. FUEL SYSTEM — p. 88
      • [1] OVERVIEW OF COMMONRAIL SYSTEM — p. 88
      • [2] SUPPLY PUMP — p. 91
      • [3] RAIL — p. 94
      • [4] INJECTOR — p. 95
      • [5] ENGINE CONTROL SYSTEM — p. 99
        • (1) Engine ECU — p. 100
        • (2) Sensor — p. 100
    • 5. EGR SYSTEM — p. 103
      • [1] OVERVIEW — p. 103
      • [2] EGR COOLER — p. 104
      • [3] EGR VALVE — p. 104
      • [4] REED VALVE — p. 104
    • 6. AFTER TREATMENT SYSTEM — p. 105
      • [1] AFTER TREATMENT DEVICES [D1803-E4, -TE4, V2403-E4, -TE4] — p. 105
      • [2] AFTER TREATMENT DEVICES [D1803-TIE4, V2403-TIE4] — p. 110
  • SERVICING — p. 111
    • 1. TROUBLESHOOTING — p. 112
    • 2. SERVICING SPECIFICATIONS — p. 115
    • 3. TIGHTENING TORQUES — p. 121
      • [1] TIGHTENING TORQUES OF SCREWS, BOLTS AND NUTS FOR GENERAL USE — p. 121
      • [2] TIGHTENING TORQUES OF SCREWS, BOLTS AND NUTS FOR SPECIAL USE — p. 122
    • 4. CHECKING, DISASSEMBLING AND SERVICING — p. 124
      • [1] CHECKING AND ADJUSTING — p. 124
        • (1) Engine Body — p. 124
        • (2) Lubricating System — p. 126
        • (3) Cooling System — p. 126
        • (4) Electrical System — p. 128
        • (5) Turbocharger — p. 132
      • [2] DISASSEMBLING AND ASSEMBLING — p. 133
        • (1) Draining Engine Oil and Coolant — p. 133
        • (2) External Components — p. 134
        • (3) Turbocharger and EGR — p. 142
        • (4) Common Rail — p. 143
        • (5) Cylinder Head and Valves — p. 145
        • (6) Thermostat — p. 150
        • (7) SCV — p. 151
        • (8) Supply Pump — p. 153
        • (9) Water Pump and Oil Cooler — p. 154
        • (10) Gear Case and Timing Gear — p. 155
        • (11) Piston and Connecting Rod — p. 157
        • (12) Flywheel and Crankshaft — p. 161
        • (13) Starter — p. 167
        • (14) Alternator — p. 168
      • [3] SERVICING — p. 169
        • (1) Cylinder Head and Valves — p. 169
        • (2) Timing Gears — p. 174
        • (3) Piston and Connecting Rod — p. 177
        • (4) Crankshaft — p. 180
        • (5) Cylinder — p. 185
        • (6) Oil Pump — p. 186
        • (7) Starter — p. 186
        • (8) Alternator — p. 189

Capabilities

The source outline separates mechanism explanations from servicing instructions for Engine. Use these indexed headings to locate the applicable system in the source PDF, then confirm model-specific notes, specifications, illustrations, and operating conditions at the relevant page before carrying out service work.

Keep the source's safety sequence, prerequisite steps, labels, units, configuration notes, and footnotes with the selected task; do not apply an isolated value outside the conditions stated in the manual.

Technical reference

Reference tables include torque settings, wear limits, and dimensions for service checks, adjustment work, and specification lookup. Use the values and conditions in the PDF for the applicable model and procedure.

• Service limits and settings: torque settings and wear limits.
• Machine specifications: dimensions.

Delivery

This manual is supplied as a digital PDF file and is available for instant download after purchase. No physical media is shipped.

References

Kubota Workshop Manual for Engine, document code 9Y111-07826, PDF edition.