Kubota Diesel Engine V3800-TIE V3800-TIE5H Workshop Manual 9Y311-00201 2021

Description

Contents:
1. Safety
Safety First
1. Working Precautions
2. Preparing For Emergencies
3. Working Cautions
4. Starting Machine Safely
5. Preventing Fires
6. Preventing Acid Burns
7. Avoiding High Pressure Fluid
8. Avoiding Hot Exhaust
9. Cleaning Exhaust Filter
2. General
General Working Precautions
1. Tightening Bolts And Nuts
2. Applying Thread-Locking Fluid
3. Installing Circlips
4. Handling Liquid Gasket
5. Replacing O-Rings
6. Replacing Oil Seals
7. Handling The Battery
8. Handling Wire Harness
9. Handling Fuses
10. Handling Connectors
11. Wiring Color
12. Dispose Fluids Correctly
General Machine Information
1. Engine Identification
1.1 Engine Model Name And Engine Serial Number
1.2 E5b Engine
1.3 Cylinder Number
2. Muffler Full Assembly Identification
2.1 Part Number And Serial Number (DPF)
2.2 Parts Number And Serial Number (SCR)
3. Specifications
3.1 Specification For V3800-Tie5, Tie5h
4. Performance Curves
4.1 Performance Curve For V3800-Tie5
4.2 Performance Curve For V3800-Tie5h
5. Dimensions
5.1 Dimension For V3800-Tie5, Tie5h
6. Wiring Diagram
6.1 Engine Intermediate Harness (Engine Side Harness)
6.2 Injector Intermediate Harness (Engine Side Harness)
6.3 Ecu Intermediate Harness (Oem Side Harness)
6.4 ACU Intermediate Harness (Oem Side Harness)
6.5 System Wiring Diagram
Special Tools
1. Diesel Engine Compression Tester
2. Oil Pressure Tester
3. Small End Bushing Replacing Tool
4. Idle Gear Bushing Replacing Tool
5. Gear Case Cover Oil Seal Press Fit Tool
6. Valve Guide Replacing Tool
V3800-Tie5,V3800-Tie5h Iii
Kisc Issued 09, 2021 A7. Crankshaft Sleeve Press Fit Tool
8. Supply Pump Gear Puller
9. Supply Pump Gear Reinstall Jig
10. Flywheel Stopper
11. Crankcase 1 And 2 Aligning Tool
12. Compression Tester Adapter
13. Jig 1 For Measuring Air Gap Of The Crankshaft Position Sensor
14. Jig 2 For Measuring Air Gap Of The Crankshaft Position Sensor
15. Def Header Unit Replacing Tool
16. Rotation Sensor Signal Interface Unit
3. Maintenance
Maintenance Check List
Check And Maintenance
1. Daily Check Points
1.1 Checking Engine Oil Level
1.2 Checking Fuel Level
1.3 Checking Coolant Level
1.4 Checking Fan Belt
1.5 Checking Def-Adblue Level
2. Every Fuel Refilling
2.1 Refilling Diesel Exhaust Fluid (Def-Adblue)
3. Check Points Of Initial 50 Hours
3.1 Changing Engine Oil
3.2 Replacing Oil Filter Cartridge
4. Check Point Of Every 50 Hours
4.1 Checking Fuel Hoses And Clamp Bands
5. Check Points Of Every 250 Hours
5.1 Checking Radiator Hose And Clamp Bands
5.2 Cleaning Air Cleaner Primary Element
5.3 Adjusting Fan Belt Tension
5.4 Checking Intake Air Line
6. Check Points Of Every 500 Hours
6.1 Changing Engine Oil
6.2 Replacing Oil Filter Cartridge
6.3 Replacing Fuel Filter Cartridge
6.4 Replacing Water Separator Filter (Type 2)
6.5 Cleaning Water Jacket And Radiator Interior
6.6 Replacing Fan Belt
7. Check Point Of Every 1000 Hours
7.1 Checking Valve Clearance
8. Check Points Of Every 1500 Hours
8.1 Checking Injector (With Diagmaster)
8.2 Checking Egr Cooler
8.3 Replacing Oil Separator Element
8.4 Checking Positive Crankcase Ventilation (Pcv) Valve
8.5 Checking Def-Adblue Injector Tip
8.6 Checking Def-Adblue Hoses
9. Check Points Of Every 3000 Hours
9.1 Checking Turbocharger
9.2 Checking Egr System (With Diagmaster)
9.3 Replacing Def-Adblue Pump Filter
9.4 Checking Def-Adblue Injector
10. Check Points Of Every 3000 To 6000 Hours
10.1 Cleaning DPF
10.2 Judging Reuse Of DPF Filter Comp Before Cleaning (Service Dealer)
10.3 Judging Reuse Of DPF Filter Comp After Cleaning (Cleaning Contractor)
Iv V3800-Tie5,V3800-Tie5h
Kisc Issued 09, 2021 A11. Check Points Of Every 1 Year
11.1 Replacing Air Cleaner Element
11.2 Checking DPF Differential Pressure Pipes And Hoses
11.3 Checking Egr Piping
11.4 Checking Intake Air Line
11.5 Checking Exhaust Manifold
11.6 Replacing Water Separator Filter (Type 2)
12. Check Points Of Every 2 Years
12.1 Replacing Fan Belt
12.2 Replacing Oil Separator Rubber Hose
12.3 Replacing Rubber Hose Of DPF Differential Pressure Sensor
12.4 Replacing Intake Hose (After Air Flow Sensor) And Intercooler Hose
12.5 Replacing Pressure Detection Hose Of Boost Pressure Sensor
12.6 Replacing Egr Cooler Hose
12.7 Replacing Water Hose
12.8 Replacing Lubricant Hose
12.9 Changing Radiator Coolant
12.10 Replacing Radiator Hose And Clamp Bands
12.11 Replacing Fuel Hose And Clamps
12.12 Replacing Intake Air Line
4. Engine
Mechanism
1. General (Introduction)
1.1 Feature Of Combustion (E-Cdis)
1.2 Structure Of Combustion (Center Direct Injection System (E-Cdis))
1.3 Flow Of Combustion (E-Cdis)
1.4 Control Of Combustion (E-Cdis)
2. Engine Body
2.1 Structure Of Engine Body
2.2 Feature Of Engine Body
2.3 Crankcase
2.4 Cylinder Head
2.5 Cylinder Head Cover
2.6 Breather
2.7 Oil Separator
2.8 Ccv Heater
2.9 Piston
V3800-Tie5,V3800-Tie5h V
Kisc Issued 09, 2021 A
2.10 Piston Ring
2.11 Connecting Rod
2.12 Crankshaft
2.13 Main Bearing Case
2.14 Flywheel
2.15 Rocker Arm Assembly
2.16 Camshaft
2.17 Valve
2.18 Tappet
2.19 Push Rod
2.20 Timing Gears
3. Fuel System
3.1 Structure Of Common Rail System (Crs) Engine
3.2 Feature Of Common Rail System (Crs) Engine
3.3 Flow Of Common Rail System (Crs) Engine
3.4 Control Of Common Rail System (Crs) Engine
3.5 Fuel Tank
Vi V3800-Tie5,V3800-Tie5h
Kisc Issued 09, 2021 A
3.6 Water Separator
3.7 Electromagnetic Fuel Feed Pump
3.8 Fuel Filter
3.9 Supply Pump
3.10 Injection Pipe
3.11 Rail Assembly
3.12 Injector
3.13 Overflow Pipe
3.14 Check Valve
3.15 Fuel Cooler
3.16 Engine Ecu
3.17 Crankshaft Position Sensor
V3800-Tie5,V3800-Tie5h Vii
Kisc Issued 09, 2021 A
3.18 Camshaft Position Sensor
3.19 Intake Air Temperature Sensor
3.20 Coolant Temperature Sensor
3.21 Boost Pressure Sensor
3.22 Atmosphere Pressure Sensor
4. Intake And Exhaust System
4.1 Structure Of Intake And Exhaust System
4.2 Feature Of Intake And Exhaust System
4.3 Flow Of Intake And Exhaust System
4.4 Control Of Intake And Exhaust System
4.5 Pre-Cleaner
4.6 Air Cleaner
4.7 Turbocharger
4.8 Intercooler
4.9 Intake Air Heater
Viii V3800-Tie5,V3800-Tie5h
Kisc Issued 09, 2021 A4.10 Intake Manifold
4.11 Exhaust Manifold
5. Exhaust Gas Recirculation (Egr) System
5.1 Structure Of Egr System
5.2 Feature Of Egr System
5.3 Flow Of Egr System
5.4 Control Of Egr System
5.5 Egr Cooler
5.6 Egr Valve
5.7 Reed Valve
6. Lubricating System
6.1 Structure Of Lubricating System
6.2 Feature Of Lubricating System
6.3 Flow Of Lubricating System
6.4 Oil Pan
6.5 Oil Strainer
6.6 Oil Pump
6.7 Relief Valve
6.8 Oil Filter
6.9 Oil Cooler
V3800-Tie5,V3800-Tie5h Ix
Kisc Issued 09, 2021 A
6.10 Oil Pressure Switch
6.11 Oil Jet
7. Cooling System
7.1 Structure Of Cooling System
7.2 Feature Of Cooling System
7.3 Flow Of Cooling System (Bottom By-Pass System)
7.4 Control Of Cooling System (Bottom By-Pass System)
7.5 Water Pump
7.6 Thermostat
7.7 Radiator
7.8 Radiator Cap
7.9 Cooling Fan
7.10 Reserve Tank
7.11 Fan Belt
8. Electrical System
8.1 Structure Of Electrical System
8.2 Feature Of Electrical System
8.3 Flow Of Electrical System
8.4 Control Of Electrical System
8.5 Battery
X V3800-Tie5,V3800-Tie5h
Kisc Issued 09, 2021 A
8.6 Key Switch
8.7 Starter (Planetary Gear Reduction Type)
8.8 Alternator
9. Aftertreatment System
9.1 Structure Of Diesel Particulate Filter (DPF) System
9.2 Feature Of Diesel Particulate Filter (DPF) System
9.3 Flow Of Diesel Particulate Filter (DPF) System
9.4 Control Of Diesel Particulate Filter (DPF) System
9.5 Diesel Oxidation Catalyst (Doc)
9.6 Diesel Particulate Filter (DPF)
9.7 Air Flow Sensor
9.8 Exhaust Gas Temperature Sensor
9.9 DPF Differential Pressure Sensor
9.10 Intake Throttle Valve
9.11 Structure Of Selective Catalytic Reduction (SCR) System
9.12 Feature Of Selective Catalytic Reduction (SCR) System
9.13 Flow Of Selective Catalytic Reduction (SCR) System
9.14 Control Of Selective Catalytic Reduction (SCR) System
9.15 Selective Catalytic Reduction (SCR)
9.16 After Treatment Control Unit (ACU)
V3800-Tie5,V3800-Tie5h Xi
Kisc Issued 09, 2021 A
9.17 SCR Inlet Temperature Sensor
9.18 Nox Sensor
9.19 Diesel Exhaust Fluid (Def) Tank
9.20 Def Injector
9.21 Def Pump
9.22 Coolant Valve
9.23 Feature Of Particulate Matter Control Diagnosis (Pcd) System
9.24 Control Of Pcd System
9.25 Feature Of Nox Control Diagnosis (Ncd) System
9.26 Control Of Ncd System
9.27 Warning Method Of Pcd And Ncd System
Servicing
1. Troubleshooting
1.1 Troubleshooting For V3800-Tie5, Tie5h
2. Service Specifications
2.1 Service Specifications For Engine
3. Tightening Torques
3.1 Tightening Torques Of SCRews, Bolts And Nuts For General Use
3.2 Tightening Torques Of SCRews, Bolts And Nuts For Special Use
4. Checking And Adjusting
4.1 Checking Compression Pressure Of Cylinder
4.2 Adjusting Valve Clearance
4.3 Checking Engine Oil Pressure
4.4 Checking Fan Belt Tension
4.5 Checking Fan Belt Damage And Wear
4.6 Checking Radiator Cap Air Leakage
4.7 Checking Radiator Water Leakage
4.8 Checking Opening Temperature Of Thermostat Valve
4.9 Checking Battery Voltage
4.10 Checking Battery Specific Gravity
Xii V3800-Tie5,V3800-Tie5h
Kisc Issued 09, 2021 A4.11 Checking Starter Motor
4.12 Checking Magnetic Switch Of Starter
4.13 Checking Alternator On Unit
4.14 Checking Intake Air Heater
4.15 Checking Exhaust Gas Leakage Of Turbocharger Turbine Side
4.16 Checking Air Leakage Of Turbocharger Compressor Side
4.17 Checking Radial Clearance Of Turbocharger
4.18 Checking Injector
4.19 Checking Pre-Stroke Control Valve (Pcv)
4.20 Checking Pressure Relief Valve (Prv)
4.21 Checking Boost Pressure Sensor
4.22 Checking Intake Air Temperature Sensor
4.23 Checking Crankshaft Position Sensor
4.24 Checking Camshaft Position Sensor
4.25 Checking Coolant Temperature Sensor
4.26 Checking Egr System
4.27 Checking Air Flow Sensor
4.28 Checking Exhaust Gas Temperature Sensor
4.29 Checking DPF Differential Pressure Sensor
4.30 Checking SCR Inlet Temperature Sensor
4.31 Checking Def Pump
4.32 Checking Def Tube
4.33 Checking Def Injector
4.34 Checking Def Tank Unit
4.35 Checking Coolant Valve
4.36 Adjusting Air Gap Between Crankshaft Position Sensor And Pulsar Gear
4.37 Checking Fuel Leakage Of The Overflow Pipe
4.38 Selecting Cylinder Head Gasket
4.39 Measuring Angular Deviation Between Crankshaft T.D.C. And Crank Position Sensor Detected
T.D.C.
4.40 Replacing The SCR Mixing Pipe And Slip Band
5. Disassembling
5.1 Draining Engine Oil
5.2 Draining Coolant
5.3 Removing Selective Catalytic Reduction (SCR) Muffler
5.4 Removing Crs Intermediate Harness
5.5 Removing External Components
5.6 Removing DPF Muffler Full Assembly
5.7 Disassembling DPF Assembly
5.8 Removing Egr Cooler
5.9 Removing Turbocharger
5.10 Removing Intake Throttle Valve And Intake Air Heater
5.11 Removing Egr Valve
5.12 Removing Common Rail
5.13 Removing Injector Harness Connector
5.14 Removing Cylinder Head Cover
5.15 Removing Sensors
5.16 Removing Injector
5.17 Removing Rocker Arm Assembly
5.18 Removing Injector Oil Seal
5.19 Removing Cylinder Head
5.20 Removing Tappet
5.21 Removing Valve
5.22 Removing Thermostat Assembly
5.23 Removing Water Pump
5.24 Removing Supply Pump
5.25 Removing Oil Cooler
5.26 Removing Fan Drive Pulley
V3800-Tie5,V3800-Tie5h Xiii
Kisc Issued 09, 2021 A5.27 Removing Gear Case Cover
5.28 Removing Relief Valve
5.29 Removing Idle Gear
5.30 Removing Oil Pump Drive Gear
5.31 Removing Crank Gear With Crank Pulsar Gear
5.32 Removing Camshaft With Cam Gear
5.33 Removing Plate
5.34 Removing Oil Pan And Oil Strainer
5.35 Removing Piston
5.36 Removing Piston Ring
5.37 Disassembling Piston Assembly
5.38 Removing Flywheel
5.39 Removing Flywheel Housing
5.40 Removing Bearing Case Cover
5.41 Removing Crankcase 2
5.42 Removing Main Bearing Case
5.43 Removing Crankshaft
5.44 Disassembling Starter
5.45 Disassembling Alternator
6. Assembling
6.1 Assembling Alternator
6.2 Assembling Starter
6.3 Installing Crankshaft
6.4 Installing Main Bearing Case
6.5 Installing Crankcase 2
6.6 Installing Flywheel Housing
6.7 Aligning Surface Of Crankcase 1 And Crankcase 2
6.8 Installing Bearing Case Cover
6.9 Installing Flywheel
6.10 Assembling Piston Assembly
6.11 Installing Piston Ring
6.12 Installing Piston
6.13 Installing Oil Strainer And Oil Pan
6.14 Installing Plate
6.15 Installing Camshaft With Cam Gear
6.16 Installing Crank Gear With Crank Pulsar Gear
6.17 Installing Oil Pump Drive Gear
6.18 Installing Idle Gear
6.19 Installing Relief Valve
6.20 Installing Gear Case Cover
6.21 Installing Fan Drive Pulley
6.22 Installing Oil Cooler
6.23 Installing Water Pump
6.24 Installing Supply Pump
6.25 Installing Thermostat Assembly
6.26 Installing Valve
6.27 Installing Tappet
6.28 Installing Cylinder Head
6.29 Installing Injector Oil Seal
6.30 Installing Rocker Arm Assembly
6.31 Installing Injector
6.32 Installing Cylinder Head Cover
6.33 Installing Sensors
6.34 Installing Injector Harness Connector
6.35 Installing Common Rail
6.36 Installing Egr Valve
6.37 Installing Intake Throttle Valve And Intake Air Heater
6.38 Installing Turbocharger Assembly
Xiv V3800-Tie5,V3800-Tie5h
Kisc Issued 09, 2021 A6.39 Installing Egr Cooler
6.40 Assembling DPF Assembly
6.41 Installing DPF Muffler Full Assembly
6.42 Installing External Components
6.43 Installing Crs Intermediate Harness
6.44 Installing SCR Muffler Assembly
6.45 Filling Coolant
6.46 Filling Engine Oil
7. Servicing
7.1 Checking Cylinder Head Top Clearance
7.2 Checking Cylinder Head Surface Flatness
7.3 Checking Cylinder Head Flaw
7.4 Checking Valve Recessing
7.5 Adjusting Valve Lapping
7.6 Checking Clearance Between Valve Stem And Valve Guide
7.7 Replacing Valve Guide
7.8 Adjusting Valve Angle
7.9 Adjusting Valve Seat
7.10 Checking Free Length Of Valve Spring
7.11 Checking Tilt Of Valve Spring
7.12 Checking Set Load Of Valve Spring
7.13 Checking Oil Clearance Between Rocker Arm And Rocker Arm Shaft
7.14 Checking Oil Clearance Between Valve Bridge Shaft And Valve Bridge Arm
7.15 Checking Push Rod Alignment
7.16 Checking Oil Clearance Between Tappet And Tappet Guide Bore
7.17 Checking Timing Gear Backlash
7.18 Checking Side Clearance Of Idle Gear 1, 2
7.19 Checking Side Clearance Of Idle Gear 3
7.20 Checking Side Clearance Of Camshaft
7.21 Checking Camshaft Alignment
7.22 Replacing Idle Gear Bushing
7.23 Checking Cam Height
7.24 Checking Oil Clearance Between Camshaft Journal And Crankcase Bore
7.25 Checking Oil Clearance Between Idle Gear Shaft 1, 2 And Idle Gear1, 2 Bushing
7.26 Checking Oil Clearance Between Idle Gear 3 Shaft And Idle Gear 3 Holder
7.27 Checking Piston Pin Bore I.D.
7.28 Checking Oil Clearance Between Piston Pin And Small End Bushing
7.29 Replacing Small End Bushing
7.30 Checking Connecting Rod Alignment
7.31 Checking Piston Ring Gap
7.32 Checking Clearance Between Piston Ring And Ring Groove
7.33 Checking Side Clearance Of Crankshaft
7.34 Checking Crankshaft Alignment
7.35 Checking Oil Clearance Between Crankpin And Crankpin Bearing
7.36 Checking Oil Clearance Between Crankshaft Journal And Crankshaft Bearing
7.37 Replacing Crankshaft Sleeve
7.38 Checking Cylinder Wear
7.39 Adjusting Cylinder Correction (Over Size)
7.40 Checking Clearance Between Inner Rotor And Outer Rotor
7.41 Checking Clearance Between Outer Rotor And Pump Body
7.42 Checking Clearance Between Rotor And Cover
7.43 Checking Overrunning Clutch Of Starter
7.44 Checking Commutator And Mica Of Starter
7.45 Checking Brush Wear Of Starter
7.46 Checking Brush Holder Of Starter
7.47 Checking Armature Coil Of Starter
7.48 Checking Field Coil Of Starter
7.49 Checking Bearing Of Alternator
V3800-Tie5,V3800-Tie5h Xv
Kisc Issued 09, 2021 A7.50 Checking Stator Of Alternator
7.51 Checking Rotor Of Alternator
7.52 Checking Slip Ring Of Alternator
7.53 Checking Brush Wear Of Alternator
7.54 Replacing Supply Pump
7.55 Replacing Injector
7.56 Replacing Engine Ecu
7.57 Replacing DPF
7.58 Replacing SCR
7.59 Replacing ACU
7.60 Replacing Def Injector
7.61 Replacing Header Unit
7.62 Draining Def