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

Transcription

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

2 I INFORMATION

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

4 1. SAFETY FIRST INFORMATION 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 bypass the safety start switch Do not make unauthorized modifications to the engine. This can cause damage and decrease the engine life. I-1

5 INFORMATION 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. I-2

6 INFORMATION 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. I-3

7 1

8 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-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: )...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: )...1-S22 [14]EXECUTION CONDITION FOR MANUAL REGENERATION...1-S23 [15]ATTACHED FORM...1-S24

9 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 when they pass through this thin wall, and the exhaust gas is discharged as clean gas. 1-S1

10 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). (a) (b) Automatic regeneration Parked regeneration Regeneration by automatic control is performed using post injection. The operation of the product can be continued. 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 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. 1-S2

11 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: ) 1-S3

12 [1] CLEANING & RETURN FLOW 1-S4

13 [2] DPF EXCHANGE FLOW 1-S5

14 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) 1-S6

15 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). (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 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) Mounting Bolt (2) Mounting Bolt of DPF Muffler Full Assy (3) Pressure Pipe 1 (4) EGR Pipe (a) (b) Shackle Set Position Shackle Set Position 1-S7

16 [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 Remove DPF stay 2 (4). (1) Differential Pressure Sensor (2) Pressure Pipe 2 (3) Pressure Pipe 1 (4) DPF Stay 2 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) DPF Outlet Body (2) DPF Filter Comp (3) DPF Collar (4) DOC Catalyst Comp (5) DPF Gasket (6) DPF Gasket (7) DPF Gasket 1-S8

17 [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. [5] DPF CLEANING METHOD 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. Number for judgment of non-reusability of filter Allowable limit 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. 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. V3800 V6108 Number of missing sealing parts: 15 or more Number of missing sealing parts: 30 or more 1-S9

18 [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. 1-S10

19 [8] PACKING, DELIVERING, AND HANDLING STANDARD OF DPF FILTER COMP Follow the procedures below to pack the separated DPF filter comp, and send it to a cleaning contractor and clean 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. 1-S11

20 [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. Model V3800 Measurement total 28 blocks V blocks 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., to 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. Depth of ash (Remaining depth) (Average of all measurement blocks) Allowable limit V3800 V mm (4.17 in.) 106 mm (4.17 in.) (1) Pin Gauge (0.60 to 0.80 mm dia., to 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) 1-S12

21 [10] ASSEMBLY OF DPF MUFFLER FULL ASSY IMPORTANT Visually check if there is no damage (ceramic crack or damage) with the cleaned and returned DPF filter comp. DOC Catalyst Comp, DPF Filter Comp and DPF Outlet Body 1. Replace the DPF 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 comp, DPF collar, DPF filter comp, and DPF outlet body. 4. Tighten all the bolts evenly with the specified torque. NOTE Assemble the DPF filter comp in the right direction by referring to the arrow (8) on the side showing the flow of exhaust gas. Tightening torque Mounting bolt (Catalyst Comp - Collar - Filter Comp) Mounting bolt (Filter Comp - Body) 49.0 to 55.9 N m 5.00 to 5.70 kgf m 36.2 to 41.2 lbf ft (1) DPF Outlet Body (2) DPF Filter Comp (3) DPF Collar (4) DOC Catalyst Comp (5) DPF Gasket (6) DPF Gasket (7) DPF Gasket (8) Arrow (GAS FLOW) (A) Exhaust Inlet Side (B) 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 temperature sensor T0 (1), T1 (2), and T2 (3) from the exhaust inlet side (catalyst component 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 T to 35.0 N m 2.55 to 3.56 kgf m 18.5 to 25.8 lbf ft (1) Exhaust Temperature Sensor T0 (Black Connector, V3800:1J , V6108:1J ) (2) Exhaust Temperature Sensor T1 (Gray Connector, V3800:1J , V6108:1J ) (3) Exhaust Temperature Sensor T2 (White Connector, V3800:1J , V6108:1J ) (A) Exhaust Inlet Side (B) Exhaust Outlet Side 1-S13

22 Pressure Pipe (In the event of need for replacement) When the 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 pressure pipes 1 (1) and 2 (2). 3. Install pressure pipe 1and 2 with the specified torque. Tightening torque (1) Pressure Pipe 1 (2) Pressure Pipe 2 Pressure pipe 1 Pressure pipe 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 DPF stay 2 (4). 2. Install fixed bolts of pressure pipe 1 and Install differential pressure sensor (1). 4. Connect each tube with pressure pipe 1 (3) and 2 (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. Tightening torque Mounting bolt of differential pressure sensor Fixed bolt of pressure pipe 1 Fixed bolt of pressure pipe to 11.3 N m 1.00 to 1.15 kgf m 7.23 to 8.33 lbf ft 9.80 to 11.3 N m 1.00 to 1.15 kgf m 7.23 to 8.33 lbf ft (1) Differential Pressure Sensor (2) Pressure Pipe 2 (3) Pressure Pipe 1 (4) DPF Stay 2 1-S14

23 [11] MOUNTING OF DPF MUFFLER FULL ASSY Follow the procedures below to mount DPF muffler full assy to a product (engine). After mounting it, start up an engine and check gas leak. Mounting of DPF Muffler Full Assy 1. Set chain sling by using shackle at two places (a) and (b) as shown in the photograph. 2. Lift the DPF muffler full assy, and guide it to the installation position. 3. Assemble the DPF muffler full assy with the mounting bolt of the DPF muffler full assy (2) and the mounting bolt (1) on the exhaust manifold side. 4. Remove chain sling. NOTE When guiding the DPF muffler full assy to the installation position, use caution so that the pressure pipe 1 (3) does not hit the EGR pipe (4). Tightening torque Mounting bolt of DPF muffler full assy Mounting bolt (Exhaust manifold side) 49.0 to 55.9 N m 5.00 to 5.70 kgf m 36.2 to 41.2 lbf ft 49.0 to 55.9 N m 5.00 to 5.70 kgf m 36.2 to 41.2 lbf ft (1) Mounting Bolt (2) Mounting Bolt of DPF Muffler Full Assy (3) Pressure Pipe 1 (4) EGR Pipe (a) (b) Shackle Set Position Shackle Set Position Connector of Exhaust Temperature Sensor and DPF Stay 1 1. Install DPF stay 1 (5). 2. Connect connectors (1), (2), (3) of exhaust temperature sensor, and fix wiring with clamps (4). Tightening torque 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 Sensor T2 (2) Connector of Exhaust Temperature Sensor T1 (3) Connector of Exhaust Temperature Sensor T0 (4) Clamp (5) DPF Stay 1 1-S15

24 [12] RESETTING BY USING DIAGNOSIS TOOL (WHEN INSTALLING CLEANED DPF) 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-S16

25 Step2 1. Execute the request by the "DPF Manual Regeneration Request Function" in the active test 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-S17

26 (2) In Case of Excessive Regeneration Frequency (P-Code:P3024, J1939: ) Step1 1. Reset the value by the "DPF Regeneration Interval Time Reset" in the utility functions of the diagnosis tool. 1-S18

27 Step2 1. Reset the value by "DPF Soot Load Reset" in the utility functions of the diagnosis tool. 1-S19

28 Step3 1. Execute the request by the "DPF Manual Regeneration Request Function" in the active test 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. 1-S20

29 [13] RESETTING BY USING DIAGNOSIS TOOL (WHEN INSTALLING NEW DPF) 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-S21

30 (2) In Case of Excessive Regeneration Frequency (P-Code:P3024, J1939: ) Step1 1. Reset the value by the "DPF Regeneration Interval Time Reset" in the utility functions of the diagnosis tool. 1-S22

31 Step2 1. Reset the value by "DPF Soot Load Reset" in the utility functions of the diagnosis tool. [14] 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 1-S23

32 [15] ATTACHED FORM (1) After-Treatment Device Exchange Report Form 1-S24

33 (2) DPF Cleaning Order Form (V3800) 1-S25

34 1-S26

35 (3) DPF Cleaning Order Form (V6108) 1-S27

36 1-S28

37 EDITOR: KUBOTA FARM & INDUSTRIAL MACHINERY SERVICE, LTD. 64, ISHIZU-KITAMACHI, SAKAI-KU, SAKAI-CITY, OSAKA, , JAPAN PHONE : (81) FAX : (81) ksos-pub@kubota.co.jp KUBOTA Corporation Printed in Japan , S, EI, EI, engusa Code No.9Y