WORKSHOP MANUAL DIESEL ENGINE V3800-TIE4,V3800-TIE4C(DOCV3800-CR-TE4C,V3800-CR-TIE4C,V3800-CR-TE4,V3800-CR-TIE4,only)(OEMENGINE) KiSC issued 04, 2017 A
This section primarily contains information below. and Servicing
•Engine Identification •Muffler Full Assembly Identification •General •Special•Check•MaintenancePrecautionsCheckListandMaintenanceTools
Since this manual includes many models, information or illustrations and photographs can show more than one model.
KUBOTA reserves the right to change all information at any time without notice.
This Workshop Manual tells the servicing personnel about the mechanism, servicing and maintenance of the V3800-CR-TE4, V3800-CR-TIE4, V3800-CR-TE4C, V3800-CR-TIE4C, V3800-TIE4 and V3800-TIE4C. It contains 4 parts: "Information", "General", "Mechanism" and "Servicing"
•Checking,•Tightening•Servicing•TroubleshootingSpecificationsTorquesDisassembling
.
Information
© KUBOTA Corporation 2011 KiSC issued 04, 2017 A
TO THE READER
This section primarily contains information below.
This section primarily contains information below. Mechanism
Refer to Workshop Manual (Code No. 9Y021-01870) for the diesel engine mechanism that this workshop manual does not include.
Servicing
All illustrations, photographs and specifications contained in this manual are of the newest information available at the time of publication.
This section contains information on the structure and the function of the unit. Before you continue with the subsequent sections, make sure that you read this section.
November, 2011
•Safety •Performance•SpecificationFirst Curve •Wiring•DimensionDiagram General
[3] FunctionRAIL of Diesel Particulate Filter (DPF)
2 2013.07•Correction of Workshop Manual
•Correction of Biodiesel fuel information
KiSC issued 04, 2017 A
andG-22,G-20,G-4,G-1,G-27others
The provisional WSM that has already been issued was corrected and the regular WSM was revised.
monthIssue Main Revised Point and Corrective Measures {Search word}
Last digit of CodetheNo.
For pdf, use search function {Search word} to find the all revised locations.
2. MUFFLER FULL ASSEMBLY IDENTIFICATION
Judgment of Reuse of Filter Comp (DPF) Before Cleaning (Service ChangeDealer) of Radiator Coolant (L.L.C.) Flywheel CompressionStopperTester Adaptor Rotation Sensor Signal Interface Unit
I-7, 1-M331-M13G-41G-39G-37G-30G-25G-4I-81-S131-S151-S271-S321-S331-S421-S721-S74
5 2017.04•Correction of Workshop Manual
{1. ENGINE IDENTIFICATION}
The information of V3800-TIE4, V3800-TIE4C (DOC only)
Record of Revisions
ReferencePage
1 2013.03•Correction of Workshop Manual
{[7] EVERY 1500 HOURS} {[8] EVERY 3000 HOURS} {[9] EVERY 1 YEAR} and others
[2] TIGHTENING TORQUES OF SCREWS, BOLTS AND NUTS FOR SPECIAL USE Compression Pressure Muffler Full Assembly (DPF)
The procedure of removing and installing for following parts. 1. SCV
2. Fuel Temperature Sensor
3. PERFORMANCE CURVES
{2. MUFFLER FULL ASSEMBLY IDENTIFICATION}
EGR Pipe, Turbocharger and EGR Cooler Common Rail and Injection Pipes Cylinder Head and Tappet Top Replacementclearanceof Valve Guide
3 2015.12•Added the information of V3800-TIE4, V3800-TIE4C (DOC only)–4 2016.10•Correction of Workshop Manual
1-S471-S45
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I INFORMATION
CONTENTS
1.SAFETY
INFORMATION KiSC issued 04, 2017 A
2.SPECIFICATIONS....FIRST..............................................................................................................................I-1...........I-53.PERFORMANCECURVES............................................................................................................I-74.DIMENSIONS...............................................................................................................................I-105.WIRINGDIAGRAM.......................................................................................................................I-12[1]ENGINEINTERMEDIATEHARNESS(ENGINESIDEHARNESS).......................I-12[2]INJECTORINTERMEDIATEHARNESS(ENGINESIDEHARNESS).........I-14[3]ECUINTERMEDIATEHARNESS(OEMSIDEHARNESS)......................I-15[4]SYSTEMWIRINGDIAGRAM.................................................................................................I-20
•GivesNOTE helpful information.
•Do not do the procedures below when you start the –shortengine. across starter terminals –bypass the safety start switch
•Indicatesunit.DANGERan
•Stop the engine, then remove the key.
START SAFELY
WSM000001INI0001US1
•Clean the work area and engine.
imminently hazardous situation which, if not avoided, will result in death or serious injury.
•Hang a "DO NOT OPERATE" tag in the operator station.
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INFORMATIONV3800-CR-TE4(C), V3800-CR-TIE4(C), V3800-TIE4(C) (DOC only), WSMI-11. SAFETY FIRST
•IndicatesCAUTIONa potentially hazardous situation which, if not avoided, could result in minor or moderate
•Disconnect the battery negative cable.
•IndicatesIMPORTANTinjury.that equipment or property damage could result if instructions are not followed.
•Park the machine on a stable and level ground.
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•Let the temperature of the engine decrease before you start a job.
BEFORE YOU START SERVICE
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SAFETY FIRST
•It is essential that you read the instructions and safety regulations before you try to repair or use this
•Do not make unauthorized modifications to the engine. This can cause damage and decrease the engine life.
•Read all instructions and safety instructions in this manual and on your engine safety decals.
•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.
•IndicatesWARNINGapotentially hazardous situation which, if not avoided, could result in death or serious injury.
•Releasedfully.
•If an accident occurs, see a doctor immediately. Any high pressure spray injected into the skin must be surgically removed within a few hours or gangrene may Doctorsresult.unfamiliar with this type of injury should reference a knowledgeable medical source.
INFORMATIONV3800-CR-TE4(C), V3800-CR-TIE4(C), V3800-TIE4(C) (DOC only), WSMI-2
OPERATE SAFELY
•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
•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.
•Put on applicable clothing and safety equipment.
•Spray from high pressure nozzles can penetrate the skin and cause serious injury. Keep spray from contacting hands or body.
WSM000001INI0004US0
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.
•Use applicable tools only. Do not use alternative tools or parts.
•Do not touch the hot parts or parts that turn when the engine operates.
PROTECT AGAINST HIGH PRESSURE SPRAY
•Do not use the machine after you consume alcohol or medication or when you are tired.
9Y1210651INI0014US0
•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.
•When 2 or more persons do servicing, make sure that you do it safely.
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•Servicing machine or attachments during exhaust filter cleaning can result in serious personal injury. Avoid exposure and skin contact with hot exhaust gases and components.
9Y1210651INI0016US0
•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.
•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.
EXHAUST FILTER CLEANING
PREVENT A FIRE
INFORMATIONV3800-CR-TE4(C), V3800-CR-TIE4(C), V3800-TIE4(C) (DOC only), WSMI-3
AVOID HOT EXHAUST
•Servicing machine or attachments with engine operating can result in serious personal injury. Avoid exposure and skin contact with hot exhaust gases and
•Fuel is very flammable and explosive under some conditions. Do not smoke or let flames or sparks in your work area.
WSM000001INI0005US0
•Exhaustcomponents.partsand streams become very hot during operation. Exhaust gases and components reach temperatures hot enough to burn people, ignite, or melt common materials.
•During auto or manual/stationary exhaust filter cleaning operations, the engine will operate at elevated idle and hot temperatures for an extended period of time. Exhaust gases and exhaust filter components reach temperatures hot enough to burn people, or ignite, or melt common materials.
•Make sure that you do not spill fuel on the engine.
•To prevent sparks from an accidental short circuit, always disconnect the battery negative cable first and connect it last.
KEEP A GOOD AIRFLOW IN THE WORK AREA
WSM000001INI0009US0
•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.
•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.
•Keep a first aid kit and fire extinguisher ready at all •Keeptimes. the emergency contact telephone numbers near your telephone at all times.
PREVENT ACID BURNS
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DISCARD FLUIDS CORRECTLY
INFORMATIONV3800-CR-TE4(C), V3800-CR-TIE4(C), V3800-TIE4(C) (DOC only), WSMI-4
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PREPARE FOR EMERGENCIES
SAE Gross Continuous 64.7 kW / 2600 min-1 (rpm) (86.8 HP / 2600 min-1 (rpm)) 75.0 kW / 2600 min-1 (rpm) (101 HP / 2600 min-1 (rpm))
Starting SystemElectric Starting with Starter Starter Motor 12 V, 3.0 kW
Combustion ChamberReentrant Type, Center Direct Injection Type (E-CDIS)
Fuel Injection Pump
Lubricating SystemForced lubrication by trochoid pump Oil Pressure IndicatingElectrical Type Switch
Battery 12 V, 136 AH equivalent
FuelDiesel Fuel No. 2-D S15, see page G-8.
9Y1210651INI0001US0
INFORMATIONV3800-CR-TE4(C), V3800-CR-TIE4(C), V3800-TIE4(C) (DOC only), WSMI-52. SPECIFICATIONS
Charging Alternator12 V, 540 W
Total Displacement3769 cm3 (230.0 cu.in.)
Minimum Bare Idling Speed800 min-1 (rpm)
Number of Cylinder 4
FuelInjectorGovernorInjection
•Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW
Timing
DENSO Common Rail System
Direction of RotationCounter-clockwise (Viewed from flywheel side)
Starting Support DeviceIntake Air Heater in Intake Manifold EGRExternal EGR (EGR Cooler + Electric EGR Valve + Reed Valve)
Firing Order 1-3-4-2
KiSC issued 04, 2017 A
Cooling SystemPressurized radiator, forced circulation with water pump
Lubricating FilterFull Flow Paper Filter (Cartridge Type)
Compression Ratio 17.5
Engine TypeVertical, water-cooled, 4-cycle DI diesel engine Bore x Stroke100 × 120 mm (3.94 × 4.72 in.)
SAE Gross Intermittent 74.5 kW / 2600min-1 (rpm) (99.9 HP / 2600 min-1 (rpm)) 86.3 kW / 2600min-1 (rpm) (116 HP / 2600 min-1 (rpm))
Fuel Injection Pressure
Lubricating Oil Class CJ-4 lubricating oil as per API classification is recommended. For details on recommended lubricating oils, see page G-8. Lubricating Oil Capacity13.2 L (3.49 U.S.gals) Weight (Dry) 325 kg (716 lbs)
ModelV3800-CR-TE4V3800-CR-TE4CV3800-CR-TIE4V3800-CR-TIE4C
Maximum Bare Speed2800 min-1 (rpm)
•The specification described above is of the standard engine of each model.
Maximum Bare Speed2600 min-1 (rpm) Minimum Bare Idling Speed800 min-1 (rpm)
Lubricating FilterFull Flow Paper Filter (Cartridge Type) Cooling SystemPressurized radiator, forced circulation with water pump
Starting SystemElectric Starting with Starter
Direction of RotationCounter-clockwise (Viewed from flywheel side) Firing Order 1-3-4-2 Compression Ratio 17.0 Lubricating SystemForced lubrication by trochoid pump Oil Pressure IndicatingElectrical Type Switch
•Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW 9Y1210651INI0017US0
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Starting Support DeviceIntake Air Heater in Intake Manifold EGRExternal EGR (EGR Cooler + Electric EGR Valve + Reed Valve)
Battery 12 V, 136 AH equivalent Charging Alternator12 V, 540 W FuelDiesel Fuel No. 2-D S15, see page G-8.
Starter Motor 12 V, 3.0 kW
Lubricating Oil Class CJ-4 lubricating oil as per API classification is recommended. For details on recommended lubricating oils, see page G-8. Lubricating Oil Capacity13.2 L (3.49 U.S.gals) Weight (Dry) 324 kg (714 lbs)
Fuel Injection Pressure
SAE Gross Continuous 48.2 kW / 2400 min-1 (rpm) (64.6 HP / 2400 min-1 (rpm))
Timing
Number of Cylinder 4
SAE Gross Intermittent 55.4 kW / 2400min-1 (rpm) (74.3 HP / 2400 min-1 (rpm))
WSMI-6
INFORMATIONV3800-CR-TE4(C), V3800-CR-TIE4(C), V3800-TIE4(C) (DOC only),
Engine TypeVertical, water-cooled, 4-cycle DI diesel engine Bore x Stroke100 × 120 mm (3.94 × 4.72 in.)
DENSO Common Rail System
FuelInjectorGovernorInjection
Combustion ChamberReentrant Type, Center Direct Injection Type (E-CDIS) Fuel Injection Pump
ModelV3800-TIE4V3800-TIE4C
Total Displacement3769 cm3 (230.0 cu.in.)
•The specification described above is of the standard engine of each model.
INFORMATIONV3800-CR-TE4(C), V3800-CR-TIE4(C), V3800-TIE4(C) (DOC only), WSMI-73. PERFORMANCE CURVES V3800-CR-TE4, V3800-CR-TE4C 9Y1210651INI0002US0 (1)Brake (2)EngineHorsepowerSpeed (3)B.S.F.C. (Brake Specific Fuel (4)TorqueConsumption) (5)Gross lntermittent Torque (6)Gross lntermittent Brake Horsepower (7)Gross lntermittent B.S.F.C. KiSC issued 04, 2017 A
INFORMATIONV3800-CR-TE4(C), V3800-CR-TIE4(C), V3800-TIE4(C) (DOC only), WSMI-8V3800-CR-TIE4, V3800-CR-TIE4C 9Y1210651INI0003US0 (1)Brake (2)EngineHorsepowerSpeed (3)B.S.F.C. (Brake Specific Fuel (4)TorqueConsumption) (5)Gross lntermittent Torque (6)Gross lntermittent Brake Horsepower (7)Gross lntermittent B.S.F.C. KiSC issued 04, 2017 A
INFORMATIONV3800-CR-TE4(C), V3800-CR-TIE4(C), V3800-TIE4(C) (DOC only), WSMI-9V3800-TIE4, V3800-TIE4C 9Y1210651INI0018US0 (1)Brake (2)EngineHorsepowerSpeed (3)B.S.F.C. (Brake Specific Fuel (4)TorqueConsumption) (5)Gross lntermittent Torque (6)Gross lntermittent Brake Horsepower (7)Gross lntermittent B.S.F.C. KiSC issued 04, 2017 A
C852.0 mm (33.54 in.)
INFORMATIONV3800-CR-TE4(C), V3800-CR-TIE4(C), V3800-TIE4(C) (DOC only), WSMI-104. DIMENSIONS 9Y1210651INI0004US0 V3800-CR-TE4V3800-CR-TE4CV3800-CR-TIE4V3800-CR-TIE4C
B581.0 mm (22.87 in.)
KiSC issued 04, 2017 A
A890.0 mm (35.04 in.)
A890.0 mm (35.04 in.)
C852.0 mm (33.54 in.)
INFORMATIONV3800-CR-TE4(C), V3800-CR-TIE4(C), V3800-TIE4(C) (DOC only), WSMI-11 9Y1210651INI0020US0
V3800-TIE4V3800-TIE4C
KiSC issued 04, 2017 A
B581.0 mm (22.87 in.)
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INFORMATIONV3800-CR-TE4(C), V3800-CR-TIE4(C), V3800-TIE4(C) (DOC only), WSMI-125. WIRING DIAGRAM [1] ENGINE INTERMEDIATE HARNESS (ENGINE SIDE HARNESS) •TheNOTEpicture shows the pin arrangement of the connector housing viewed from wire side, not mating side. 9Y1210651INI0005US0 (1) CAN and EGR (2)CN202Intake Air Temperature Sensor (3)CN203Coolant Temperature Sensor (4)CN215Engine Joint Connector 1 (5)CN204Rail Pressure Sensor (6)CN205Crankshaft Position Sensor (7)CN216Engine Joint Connector 2 (8)CN206Resistance Connector (1.1 kΩ) (9)CN207Oil Pressure Switch (10)CN208Boost Pressure Sensor (11)CN209 / 210Supply (12)CN211CamshaftPumpPosition Sensor (13)CN212Intake Throttle Valve (14) Shield Cable KiSC issued 04, 2017 A
(2)CN221Engine
INFORMATIONV3800-CR-TE4(C), V3800-CR-TIE4(C), V3800-TIE4(C) (DOC only), WSMI-13
3 (3)CN223EGR (4)CN226ResistanceValve
(1) CAN and EGR Joint Connector Connector (120 Ω Connector 4 Shield Cable
(7)
•TheNOTEpicture shows the pin arrangement of the connector housing viewed from wire side, not mating side.
) (5)CN224/225Can (6)CN222EngineToolJoint
KiSC issued 04, 2017 A
9Y1210651INI0006US0
shows the pin arrangement of the connector housing viewed from wire side, not mating side. 9Y1210651INI0007US0 (1)CN302Injector Intermediate Connector (2) Shield (3)CN301InjectorCable KiSC issued 04, 2017 A
•TheNOTEpicture
INFORMATIONV3800-CR-TE4(C), V3800-CR-TIE4(C), V3800-TIE4(C) (DOC only), WSMI-14[2] INJECTOR INTERMEDIATE HARNESS (ENGINE SIDE HARNESS)