wsm V3800-CR-TE4 Instruction manual

WORKSHOP MANUAL
DIESEL ENGINE
V3800-CR-TE4,V3800-CR-TIE4,
V6108-CR-TIE4
(DIESEL PARTICULATE FILTER
HANDLING MANUAL)

I INFORMATION

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

INFORMATION
V3800-CR-TE4,V3800-CR-TIE4,V6108-CR-TIE4, WSM
I-1
1. SAFETY FIRST
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
– bypass the safety start switch
• Do not make unauthorized modifications to the
engine. This can cause damage and decrease the
engine life.
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.

INFORMATION
V3800-CR-TE4,V3800-CR-TIE4,V6108-CR-TIE4, WSM
I-2
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 whenthe
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.

INFORMATION
V3800-CR-TE4,V3800-CR-TIE4,V6108-CR-TIE4, WSM
I-3
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 contact telephone numbers
near your telephone at all times.

1 ENGINE

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-S6
[3] DISASSEMBLY OF DPF MUFFLER FULL ASSY.................................................................1-S8
[4] JUDGMENT OF REUSE OF DPF FILTER COMP BEFORE CLEANING.............................1-S9
[5] DPF CLEANING METHOD ...................................................................................................1-S9
[6] PREPARATION OF "AFTER-TREATMENT DEVICE EXCHANGE REPORT FORM".......1-S10
[7] PREPARATION OF "DPF CLEANING ORDER FORM".....................................................1-S10
[8] PACKING, DELIVERING, AND HANDLING STANDARD OF DPF FILTER COMP ...........1-S11
[9] JUDGMENT OF REUSE OF DPF FILTER COMP AFTER CLEANING (REFERENCE)....1-S12
[10]ASSEMBLY OF DPF MUFFLER FULL ASSY.....................................................................1-S13
[11]MOUNTING OF DPF MUFFLER FULL ASSY ....................................................................1-S15
[12]RESETTING BY USING DIAGNOSIS TOOL (WHEN INSTALLING CLEANED DPF)........1-S16
(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-S16
(2) In Case of Excessive Regeneration Frequency (P-Code:P3024, J1939:523602-0) .....1-S18
[13]RESETTING BY USING DIAGNOSIS TOOL (WHEN INSTALLING NEW DPF)................1-S21
(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-S21
(2) In Case of Excessive Regeneration Frequency (P-Code:P3024, J1939:523602-0) .....1-S22
[14]EXECUTION CONDITION FOR MANUAL REGENERATION............................................1-S23
[15]ATTACHED FORM..............................................................................................................1-S24
SERVICING

ENGINE
V3800-CR-TE4,V3800-CR-TIE4,V6108-CR-TIE4, WSM
1-S1
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 vents
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 whenthey pass through this thin wall, and the exhaust gas
is discharged as clean gas.

ENGINE
V3800-CR-TE4,V3800-CR-TIE4,V6108-CR-TIE4, WSM
1-S2
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
Said engine has the DPF regeneration mode described below (function to burn and remove deposited soot).
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 comp 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 comp from the DPF muffler full assy.
(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 regenerationwitha diagnosis
tool (Diagmaster) Such regeneration is performed as urgent measures in the event of abnormal soot deposition.

ENGINE
V3800-CR-TE4,V3800-CR-TIE4,V6108-CR-TIE4, WSM
1-S3
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)

ENGINE
V3800-CR-TE4,V3800-CR-TIE4,V6108-CR-TIE4, WSM
1-S4
[1] CLEANING & RETURN FLOW

ENGINE
V3800-CR-TE4,V3800-CR-TIE4,V6108-CR-TIE4, WSM
1-S5
[2] DPF EXCHANGE FLOW

ENGINE
V3800-CR-TE4,V3800-CR-TIE4,V6108-CR-TIE4, WSM
1-S6
4. DPF CLEANING PROCEDURE
[1] TO ENSURE SAFETY AND GOOD PERFORMANCE IN DPF
CLEANING PROCEDURE
(1) Always work in the workshop equipped with a electric hoist (including mobile hoist).
(2) Put a product (engine) on a stable ground, and set the parking brake.
(3) As the DPF muffler full assy is hot just after the engine shutdown, make sure to start operation after it gets cool.
(4) Make sure not to let any foreign substances enter the opening section during the operation.
(5) 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.
[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 the project.
Before removing the DPF for cleaning, keep the records of the
engine serial number, DPF filter comp part number, DPF filter
comp 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
(2) DPF Filter Comp Part Number /
DPF Filter Comp Serial Number
(a) CAN Communication Connector
(For Servicing)

ENGINE
V3800-CR-TE4,V3800-CR-TIE4,V6108-CR-TIE4, WSM
1-S7
Connector of Exhaust Temperature Sensor, Differential
Pressure Sensor and DPF Stay 1
1. Disconnect connectors of exhaust temperature sensor and
differential pressure sensor from wiring harness.
2. Remove connectors (2), (3), (4) of exhaust temperature sensor
and clamps (5).
3. Unscrew stay mounting bolt (7), and remove DPF stay 1 (6).
Separation of DPF Muffler Full Assy
1. Set chain sling by using shackle at two places (a) and (b) as
shown in the photograph.
2. Unscrew mounting bolts (1) of exhaust manifold side.
3. Unscrew mounting bolts (2) of DPF muffler full assy.
4. Lift up DPF muffler full assy safely, and separate it from engine.
NOTE
• When lifting the DPF muffler full assy, use caution so that
the pressure pipe 1 (3) does not hit the EGR pipe (4).
(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
(1) Mounting Bolt
(2) Mounting Bolt of DPF Muffler Full
Assy
(3) Pressure Pipe 1
(4) EGR Pipe
(a) Shackle Set Position
(b) Shackle Set Position

ENGINE
V3800-CR-TE4,V3800-CR-TIE4,V6108-CR-TIE4, WSM
1-S8
[3] DISASSEMBLY OF DPF MUFFLER FULL ASSY
Differential Pressure Sensor
1. Remove clamp, and disconnect tube from pressure pipe 1 (3).
2. Remove clamp, and disconnect tube from pressure pipe 2 (2).
3. Unscrew mounting bolts, and remove differential pressure
sensor (1).
4. Unscrew fixed bolts of pressure pipe 1and 2.
5. Remove DPF stay 2 (4).
DPF Filter Comp
1. Loosen all bolts attached to the DOC catalyst comp, DPF filter
comp and DPF outlet body.
2. Remove all bolts, and separate DOC catalyst comp, DPF filter
comp and DPF outlet body.
NOTE
• When disassembling, make sure not to damage pressure
pipe and exhaust temperature sensor.
If damaged, replace with new ones.
• Take good care of the DOC catalyst comp (4), DPF
collar (3), and DPF outlet body (1) so as not to get dust,
water, oil, and shock on them during storage.
As the honeycomb in the DOC catalyst is ceramic, take
special care to handle it.
(1) Differential Pressure Sensor
(2) Pressure Pipe 2 (3) Pressure Pipe 1 (4) DPF Stay 2
(1) DPF Outlet Body
(2) DPF Filter Comp
(3) DPF Collar
(4) DOC Catalyst Comp
(5) DPF Gasket
(6) DPF Gasket
(7) DPF Gasket

ENGINE
V3800-CR-TE4,V3800-CR-TIE4,V6108-CR-TIE4, WSM
1-S9
[4] JUDGMENT OF REUSE OF DPF FILTER COMP BEFORE
CLEANING
IMPORTANT
• Before ordering to a cleaning contractor, follow the procedures below to make a judgment on whether the
separated DPF filter comp is reusable.
Judgment of Reuse by Service Dealer
1. Check to see that the surface of the removed DPF filter comp
on the exhaust gas outlet side is not darkened.
2. Check whether there is no crack or loss of the sealing part of the
vents on both ends of the filter (inlet side and outlet side).
If the number of missing sealing parts exceeds the allowable
limit, the filter comp cannot be reused even after cleaning.
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 comp cannot be reused even if it is cleaned.
4. If it is judged that the DPF filter comp is not reusable, report the
result of the evaluation to the customer that requested the filter
cleaning, and replace the DPF filter component with a new one.
[5] DPF CLEANING METHOD
NOTE
• DPF cleaning must be carried out by authorized cleaning company.
Make sure that the DPF cleaning must be carried out according to the followings.
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 comp, 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.
Number for judgment of
non-reusability of filter Allowable limit
V3800 Number of missing sealing
parts: 15 or more
V6108 Number of missing sealing
parts: 30 or more

ENGINE
V3800-CR-TE4,V3800-CR-TIE4,V6108-CR-TIE4, WSM
1-S10
[6] PREPARATION OF "AFTER-TREATMENT DEVICE EXCHANGE
REPORT FORM"
IMPORTANT
• When replacing the DPF filter comp with a new one because the DPF filter comp 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.
[7] 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 comp to a cleaning
contractor.

ENGINE
V3800-CR-TE4,V3800-CR-TIE4,V6108-CR-TIE4, WSM
1-S11
[8] PACKING, DELIVERING, AND HANDLING STANDARD OF DPF
FILTER COMP
Follow the procedures below to pack the separated DPF filter comp, and sendit to a cleaning contractor andclean
it.
[Packing and delivering]
(1) Refer to the example of packaging, cover and seal the DPF filter comp 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 comp when handling and carrying.
Packing and Delivering of DPF Filter Comp (Example)
1. Seal the removed DPF filter comp 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 comp with the sealed plastic bag on a
cushioning material.
4. Put a cushioning material in around the DPF filter comp as
shown in the photograph [B].
5. Put a cushioning material over the DPF filter comp 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 of by an industrial waste
disposer according to local relevant regulations.
[Disposal standard of DPF]
(1) DPF should be disposed of by an industrial waste disposer according to local relevant regulations.

ENGINE
V3800-CR-TE4,V3800-CR-TIE4,V6108-CR-TIE4, WSM
1-S12
[9] JUDGMENT OF REUSE OF DPF FILTER COMP AFTER
CLEANING (REFERENCE)
IMPORTANT
• After the cleaning contractor has cleaned the DPF filter comp, measure the quantity of remaining ash in
the following procedure, and evaluate the reusability.
Judgment of Reuse by Cleaning Contractor
1. After having cleaned the DPF filter component, measure the
depth of ash (depth of remaining ash) 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.
2. If the depth of ash (remaining depth) is less than the allowable
limit, the DPF filter comp cannot be reused.
If the DPF filter comp 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 comp
with a new one.
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 deposited ash and it cannot be measured
accurately. So use caution not to push the pin forcibly.
Model Measurement total
V3800 28 blocks
V6108 52 blocks
Depth of ash (Remaining depth)
(Average of all measurement blocks) Allowable limit V3800 106 mm (4.17 in.)
V6108 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 Comp
(a) Serial No.
(A) Exhaust Inlet Side
(B) Exhaust Outlet Side
(C) Accumulated Ash
(D) Depth of Ash (Remaining Depth)