KUBOTA V3800-TIEF4,V3800-TIEF4C,V3800-TIEF4H DIESEL ENGINE WORKSHOP MANUAL – PDF

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KUBOTA V3800-TIEF4,V3800-TIEF4C,V3800-TIEF4H DIESEL ENGINE WORKSHOP MANUAL – PDF DOWNLOAD

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KUBOTA V3800-TIEF4,V3800-TIEF4C,V3800-TIEF4H DIESEL ENGINE WORKSHOP MANUAL – PDF DOWNLOAD

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Pages : 344
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KUBOTA V3800-TIEF4,V3800-TIEF4C,V3800-TIEF4H DIESEL ENGINE WORKSHOP MANUAL – PDF DOWNLOAD

V3800-TIEF4,V3800-TIEF4C,V3800-TIEF4H...................................................................................  1
	CONTENTS............................................................................................................  5
	1. INFORMATION...................................................................................................... 19
		 SAFETY FIRST................................................................................................... 21
			1. Before you start service................................................................................. 21
			2. Start safely............................................................................................. 21
			3. Operate safely........................................................................................... 22
			4. Avoiding high pressure fluid............................................................................. 22
			5. Avoiding hot exhaust..................................................................................... 23
			6. Cleaning exhaust filter.................................................................................. 23
			7. Prevent a fire........................................................................................... 23
			8. Keep a good airflow in the work area..................................................................... 23
			9. Discard fluids correctly................................................................................. 24
			10. Prevent acid burns...................................................................................... 24
			11. Preparing for emergencies............................................................................... 24
		 SPECIFICATIONS................................................................................................. 25
			1. Specification for V3800-TIEF4, TIEF4C, TIEF4H............................................................ 25
		 PERFORMANCE CURVES............................................................................................. 27
			1. Performance curve for V3800-TIEF4, TIEF4C................................................................ 27
			2. Performance curve for V3800-TIEF4H....................................................................... 28
		 DIMENSIONS..................................................................................................... 29
			1. Dimension for V3800-TIEF4, TIEF4C, TIEF4H................................................................ 29
		 WIRING DIAGRAM................................................................................................. 31
			1. Engine intermediate harness (Engine side harness)........................................................ 31
			2. Injector intermediate harness (Engine side harness)...................................................... 33
			3. ECU intermediate harness (OEM side harness).............................................................. 34
			4. ACU intermediate harness (OEM side harness).............................................................. 40
			5. System wiring diagram.................................................................................... 43
	2. GENERAL.......................................................................................................... 47
		 ENGINE IDENTIFICATION.......................................................................................... 48
			1. Model name and engine serial number...................................................................... 48
			2. EF4B engine.............................................................................................. 49
			3. Cylinder number.......................................................................................... 50
		 MUFFLER FULL ASSEMBLY IDENTIFICATION........................................................................... 52
			1. Part number and serial number (DPF)...................................................................... 52
			2. Parts number and serial number (SCR)..................................................................... 52
		 GENERAL PRECAUTIONS............................................................................................ 54
		 MAINTENANCE CHECK LIST......................................................................................... 56
		 CHECK AND MAINTENANCE.......................................................................................... 60
			1. Daily check points....................................................................................... 60
				1.1 Checking engine oil level........................................................................... 60
				1.2 Checking fuel level................................................................................. 60
				1.3 Checking coolant level.............................................................................. 61
				1.4 Checking fan belt................................................................................... 61
				1.5 Checking DEF/AdBlue® level.......................................................................... 63
			2. Every fuel refilling..................................................................................... 63
				2.1 Refilling diesel exhaust fluid (DEF/AdBlue®)........................................................ 63
			3. Check points of initial 50 hours......................................................................... 64
				3.1 Changing engine oil................................................................................. 64
				3.2 Replacing oil filter cartridge...................................................................... 64
			4. Check point of every 50 hours............................................................................ 65
				4.1 Checking fuel hoses and clamp bands................................................................. 65
			5. Check points of every 250 hours.......................................................................... 65
				5.1 Checking radiator hose and clamp bands.............................................................. 65
				5.2 Cleaning air cleaner primary element................................................................ 66
				5.3 Adjusting fan belt tension.......................................................................... 66
				5.4 Checking intake air line............................................................................ 67
			6. Check points of every 500 hours.......................................................................... 68
				6.1 Changing engine oil................................................................................. 68
				6.2 Replacing oil filter cartridge...................................................................... 68
				6.3 Replacing fuel filter cartridge..................................................................... 69
				6.4 Replacing water separator filter (Type 2)........................................................... 69
				6.5 Cleaning water jacket and radiator interior......................................................... 69
				6.6 Replacing fan belt.................................................................................. 71
			7. Check point of every 1000 hours.......................................................................... 72
				7.1 Checking valve clearance............................................................................ 72
			8. Check points of every 1500 hours......................................................................... 73
				8.1 Checking injector (with Diagmaster)................................................................. 73
				8.2 Checking EGR cooler................................................................................. 74
				8.3 Replacing oil separator element..................................................................... 75
				8.4 Checking PCV (positive crankcase ventilation) valve................................................. 75
				8.5 Checking DEF/AdBlue® injector tip................................................................... 76
				8.6 Checking DEF/AdBlue® hoses.......................................................................... 76
			9. Check points of every 3000 hours......................................................................... 76
				9.1 Checking turbocharger............................................................................... 76
				9.2 Cleaning DPF........................................................................................ 77
				9.3 Judging reuse of DPF filter comp before cleaning (Service dealer)................................... 81
				9.4 Judging reuse of DPF filter comp after cleaning (Cleaning contractor)............................... 81
				9.5 Checking EGR system (with Diagmaster)............................................................... 82
				9.6 Replacing DEF/AdBlue® pump filter................................................................... 83
				9.7 Checking DEF/AdBlue® injector....................................................................... 84
			10. Check point of every 8000 hours......................................................................... 85
				10.1 Replacing DEF/AdBlue® tank filter.................................................................. 85
			11. Check points of every 1 year............................................................................ 86
				11.1 Replacing air cleaner element...................................................................... 86
				11.2 Checking DPF differential pressure pipes and hoses................................................. 86
				11.3 Checking EGR piping................................................................................ 87
				11.4 Checking intake air line........................................................................... 87
				11.5 Checking exhaust manifold.......................................................................... 87
				11.6 Replacing water separator filter (Type 2).......................................................... 87
			12. Check points of every 2 years........................................................................... 88
				12.1 Replacing fan belt................................................................................. 88
				12.2 Replacing oil separator rubber hose................................................................ 89
				12.3 Replacing rubber hose of differential pressure sensor.............................................. 89
				12.4 Replacing intake hose (after air flow sensor) and intercooler hose................................. 89
				12.5 Replacing pressure detection hose of boost sensor.................................................. 89
				12.6 Replacing EGR cooler hose.......................................................................... 90
				12.7 Replacing water hose............................................................................... 90
				12.8 Replacing lubricant hose........................................................................... 90
				12.9 Changing radiator coolant.......................................................................... 90
				12.10 Replacing radiator hose and clamp bands........................................................... 92
				12.11 Replacing fuel hose and clamps.................................................................... 93
				12.12 Replacing intake air line......................................................................... 93
		 SPECIAL TOOLS.................................................................................................. 94
			1. Diesel engine compression tester......................................................................... 94
			2. Oil pressure tester...................................................................................... 94
			3. Small end bushing replacing tool......................................................................... 94
			4. Idle gear bushing replacing tool......................................................................... 95
			5. Gear case oil seal press fit tool........................................................................ 95
			6. Valve guide replacing tool............................................................................... 95
			7. Crankshaft sleeve press fit tool......................................................................... 96
			8. Supply pump gear puller.................................................................................. 97
			9. Supply pump gear reinstall jig........................................................................... 97
			10. Flywheel stopper........................................................................................ 98
			11. Crankcase 1 and 2 aligning tool......................................................................... 98
			12. Compression tester adaptor.............................................................................. 99
			13. Air gap of the crankshaft position sensor measuring jig 1...............................................101
			14. Air gap of the crankshaft position sensor measuring jig 2...............................................102
			15. Rotation sensor signal interface unit...................................................................103
	3. ENGINE...........................................................................................................104
		 MECHANISM......................................................................................................105
			1. General (Introduction)...................................................................................105
				1.1 Feature of combustion (E-CDIS)......................................................................105
				1.2 Structure of combustion (Center direct injection system (E-CDIS))...................................105
				1.3 Flow of combustion (E-CDIS).........................................................................105
				1.4 Control of combustion (E-CDIS)......................................................................106
			2. Engine body..............................................................................................107
				2.1 Structure of engine body............................................................................107
				2.2 Feature of engine body..............................................................................108
				2.3 Crankcase...........................................................................................108
					2.3.1 Outline of crankcase..........................................................................108
					2.3.2 Structure of crankcase........................................................................108
					2.3.3 Function of crankcase.........................................................................108
					2.3.4 Specification of crankcase....................................................................108
				2.4 Cylinder head.......................................................................................109
					2.4.1 Outline of cylinder head......................................................................109
					2.4.2 Function of cylinder head.....................................................................109
				2.5 Cylinder head cover.................................................................................109
					2.5.1 Outline of cylinder head cover................................................................109
					2.5.2 Structure of cylinder head cover..............................................................109
					2.5.3 Function of cylinder head cover...............................................................109
				2.6 Breather............................................................................................110
					2.6.1 Outline of breather...........................................................................110
					2.6.2 Structure of breather.........................................................................110
					2.6.3 Function of breather..........................................................................110
					2.6.4 Specification of breather.....................................................................110
				2.7 Oil separator.......................................................................................110
					2.7.1 Outline of oil separator......................................................................110
					2.7.2 Structure of oil separator....................................................................110
					2.7.3 Function of oil separator.....................................................................110
				2.8 Piston..............................................................................................110
					2.8.1 Outline of piston.............................................................................110
					2.8.2 Structure of piston...........................................................................110
					2.8.3 Function of piston............................................................................111
					2.8.4 Specification of piston.......................................................................111
				2.9 Piston ring.........................................................................................111
					2.9.1 Outline of piston ring........................................................................111
					2.9.2 Structure of piston ring......................................................................111
					2.9.3 Function of piston ring.......................................................................111
					2.9.4 Specification of piston ring..................................................................112
				2.10 Connecting rod.....................................................................................112
					2.10.1 Outline of connecting rod....................................................................112
					2.10.2 Structure of connecting rod..................................................................112
					2.10.3 Function of connecting rod...................................................................112
				2.11 Crankshaft.........................................................................................112
					2.11.1 Outline of crankshaft........................................................................112
					2.11.2 Structure of crankshaft......................................................................112
					2.11.3 Function of crankshaft.......................................................................112
					2.11.4 Specification of crankshaft..................................................................112
				2.12 Main bearing case..................................................................................113
					2.12.1 Outline of main bearing case.................................................................113
					2.12.2 Structure of main bearing case...............................................................113
					2.12.3 Function of main bearing case................................................................113
				2.13 Flywheel...........................................................................................113
					2.13.1 Outline of flywheel..........................................................................113
					2.13.2 Structure of flywheel........................................................................113
					2.13.3 Function of flywheel.........................................................................113
					2.13.4 Specification of flywheel....................................................................113
				2.14 Rocker arm.........................................................................................114
					2.14.1 Outline of rocker arm........................................................................114
					2.14.2 Structure of rocker arm......................................................................114
					2.14.3 Function of rocker arm.......................................................................114
				2.15 Camshaft...........................................................................................114
					2.15.1 Outline of camshaft..........................................................................114
					2.15.2 Structure of camshaft........................................................................114
					2.15.3 Function of camshaft.........................................................................114
					2.15.4 Specification of camshaft....................................................................114
				2.16 Valve..............................................................................................115
					2.16.1 Outline of valve.............................................................................115
					2.16.2 Structure of valve...........................................................................115
					2.16.3 Function of valve............................................................................115
					2.16.4 Specification of valve.......................................................................115
				2.17 Tappet.............................................................................................115
					2.17.1 Outline of tappet............................................................................115
					2.17.2 Structure of tappet..........................................................................115
					2.17.3 Function of tappet...........................................................................115
				2.18 Push rod...........................................................................................116
					2.18.1 Outline of push rod..........................................................................116
					2.18.2 Structure of push rod........................................................................116
					2.18.3 Function of push rod.........................................................................116
				2.19 Timing gears.......................................................................................116
					2.19.1 Outline of timing gears......................................................................116
					2.19.2 Structure of timing gears....................................................................116
					2.19.3 Function of timing gears.....................................................................116
			3. Fuel system..............................................................................................117
				3.1 Structure of common rail system (CRS) engine........................................................117
				3.2 Feature of common rail system (CRS) engine..........................................................118
				3.3 Flow of common rail system (CRS) engine.............................................................119
				3.4 Control of common rail system (CRS) engine..........................................................121
				3.5 Fuel tank...........................................................................................121
					3.5.1 Outline of fuel tank..........................................................................121
					3.5.2 Structure of fuel tank........................................................................121
					3.5.3 Function of fuel tank.........................................................................121
					3.5.4 Specification of fuel tank....................................................................121
				3.6 Water separator.....................................................................................121
					3.6.1 Outline of water separator....................................................................121
					3.6.2 Structure of water separator..................................................................121
					3.6.3 Function of water separator...................................................................121
					3.6.4 Specification of water separator..............................................................121
				3.7 Electromagnetic fuel feed pump......................................................................122
					3.7.1 Outline of electromagnetic fuel feed pump.....................................................122
					3.7.2 Structure of electromagnetic fuel feed pump...................................................122
					3.7.3 Function of electromagnetic fuel feed pump....................................................122
					3.7.4 Specification of electromagnetic fuel feed pump...............................................122
				3.8 Fuel filter.........................................................................................122
					3.8.1 Outline of fuel filter........................................................................122
					3.8.2 Structure of fuel filter......................................................................122
					3.8.3 Function of fuel filter.......................................................................122
					3.8.4 Specification of fuel filter..................................................................122
				3.9 Supply pump.........................................................................................123
					3.9.1 Outline of supply pump........................................................................123
					3.9.2 Structure of supply pump......................................................................123
					3.9.3 Function of supply pump.......................................................................123
					3.9.4 Specification of supply pump..................................................................124
				3.10 Injection pipe.....................................................................................124
					3.10.1 Outline of injection pipe....................................................................124
					3.10.2 Structure of injection pipe..................................................................124
					3.10.3 Function of injection pipe...................................................................124
					3.10.4 Specification of injection pipe..............................................................124
				3.11 Rail assembly......................................................................................124
					3.11.1 Outline of rail assembly.....................................................................124
					3.11.2 Structure of rail assembly...................................................................124
					3.11.3 Function of rail assembly....................................................................124
					3.11.4 Specification of rail assembly...............................................................125
				3.12 Injector...........................................................................................125
					3.12.1 Outline of injector..........................................................................125
					3.12.2 Structure of injector........................................................................125
					3.12.3 Function of injector.........................................................................127
					3.12.4 Specification of injector....................................................................129
				3.13 Overflow pipe......................................................................................129
					3.13.1 Outline of overflow pipe.....................................................................129
					3.13.2 Structure of overflow pipe...................................................................129
					3.13.3 Function of overflow pipe....................................................................129
				3.14 Check valve........................................................................................129
					3.14.1 Outline of check valve.......................................................................129
					3.14.2 Structure of check valve.....................................................................129
					3.14.3 Function of check valve......................................................................129
					3.14.4 Specification of check valve.................................................................129
				3.15 Fuel cooler........................................................................................129
					3.15.1 Outline of fuel cooler.......................................................................129
					3.15.2 Structure of fuel cooler.....................................................................130
					3.15.3 Function of fuel cooler......................................................................130
				3.16 Engine ECU.........................................................................................130
					3.16.1 Outline of engine ECU........................................................................130
					3.16.2 Structure of engine ECU......................................................................130
					3.16.3 Function of engine ECU.......................................................................130
					3.16.4 Specification of engine ECU..................................................................130
				3.17 Crankshaft position sensor.........................................................................131
					3.17.1 Outline of crankshaft position sensor........................................................131
					3.17.2 Structure of crankshaft position sensor......................................................131
					3.17.3 Function of crankshaft position sensor.......................................................131
					3.17.4 Specification of crankshaft position sensor..................................................131
				3.18 Camshaft position sensor...........................................................................132
					3.18.1 Outline of camshaft position sensor..........................................................132
					3.18.2 Structure of camshaft position sensor........................................................132
					3.18.3 Function of camshaft position sensor.........................................................132
					3.18.4 Specification of camshaft position sensor....................................................132
				3.19 Intake air temperature sensor......................................................................133
					3.19.1 Outline of intake air temperature sensor.....................................................133
					3.19.2 Structure of intake air temperature sensor...................................................133
					3.19.3 Function of intake air temperature sensor....................................................133
					3.19.4 Specification of intake air temperature sensor...............................................133
				3.20 Coolant temperature sensor.........................................................................133
					3.20.1 Outline of coolant temperature sensor........................................................133
					3.20.2 Structure of coolant temperature sensor......................................................133
					3.20.3 Function of coolant temperature sensor.......................................................134
					3.20.4 Specification of coolant temperature sensor..................................................134
				3.21 Boost sensor.......................................................................................134
					3.21.1 Outline of boost sensor......................................................................134
					3.21.2 Structure of boost sensor....................................................................134
					3.21.3 Function of boost sensor.....................................................................135
					3.21.4 Specification of boost sensor................................................................135
				3.22 Atmosphere pressure sensor.........................................................................135
					3.22.1 Outline of atmosphere pressure sensor........................................................135
					3.22.2 Structure of atmosphere pressure sensor......................................................135
					3.22.3 Function of atmosphere pressure sensor.......................................................135
			4. Intake and exhaust system................................................................................136
				4.1 Structure of intake and exhaust system..............................................................136
				4.2 Feature of intake and exhaust system................................................................137
				4.3 Flow of intake and exhaust system...................................................................138
				4.4 Control of intake and exhaust system................................................................140
				4.5 Pre-cleaner.........................................................................................140
					4.5.1 Outline of pre-cleaner........................................................................140
					4.5.2 Structure of pre-cleaner......................................................................140
					4.5.3 Function of pre-cleaner.......................................................................140
					4.5.4 Specification of pre-cleaner..................................................................140
				4.6 Air cleaner.........................................................................................140
					4.6.1 Outline of air cleaner........................................................................140
					4.6.2 Structure of air cleaner......................................................................140
					4.6.3 Function of air cleaner.......................................................................140
					4.6.4 Specification of air cleaner..................................................................140
				4.7 Turbocharger........................................................................................140
					4.7.1 Outline of turbocharger.......................................................................140
					4.7.2 Structure of turbocharger.....................................................................141
					4.7.3 Function of turbocharger......................................................................141
					4.7.4 Specification of turbocharger.................................................................141
				4.8 Intercooler.........................................................................................141
					4.8.1 Outline of intercooler........................................................................141
					4.8.2 Structure of intercooler......................................................................141
					4.8.3 Function of intercooler.......................................................................141
					4.8.4 Specification of intercooler..................................................................141
				4.9 Intake air heater...................................................................................142
					4.9.1 Outline of intake air heater..................................................................142
					4.9.2 Structure of intake air heater................................................................142
					4.9.3 Function of intake air heater.................................................................142
					4.9.4 Specification of intake air heater............................................................142
				4.10 Intake manifold....................................................................................142
					4.10.1 Outline of intake manifold...................................................................142
					4.10.2 Structure of intake manifold.................................................................142
					4.10.3 Function of intake manifold..................................................................143
				4.11 Exhaust manifold...................................................................................143
					4.11.1 Outline of exhaust manifold..................................................................143
					4.11.2 Structure of exhaust manifold................................................................143
					4.11.3 Function of exhaust manifold.................................................................143
			5. Exhaust gas recirculation (EGR) system...................................................................144
				5.1 Structure of EGR system.............................................................................144
				5.2 Feature of EGR system...............................................................................145
				5.3 Flow of EGR system..................................................................................146
				5.4 Control of EGR system...............................................................................147
				5.5 EGR cooler..........................................................................................147
					5.5.1 Outline of EGR cooler.........................................................................147
					5.5.2 Structure of EGR cooler.......................................................................147
					5.5.3 Function of EGR cooler........................................................................147
					5.5.4 Specification of EGR cooler...................................................................147
				5.6 EGR valve...........................................................................................147
					5.6.1 Outline of EGR valve..........................................................................147
					5.6.2 Structure of EGR valve........................................................................148
					5.6.3 Function of EGR valve.........................................................................150
					5.6.4 Specification of EGR valve....................................................................150
				5.7 Reed valve..........................................................................................150
					5.7.1 Outline of reed valve.........................................................................150
					5.7.2 Structure of reed valve.......................................................................150
					5.7.3 Function of reed valve........................................................................150
			6. Lubricating system.......................................................................................151
				6.1 Structure of lubricating system.....................................................................151
				6.2 Feature of lubricating system.......................................................................152
				6.3 Flow of lubricating system..........................................................................153
				6.4 Oil pan.............................................................................................155
					6.4.1 Outline of oil pan............................................................................155
					6.4.2 Structure of oil pan..........................................................................155
					6.4.3 Function of oil pan...........................................................................155
					6.4.4 Specification of oil pan......................................................................155
				6.5 Oil strainer........................................................................................155
					6.5.1 Outline of oil strainer.......................................................................155
					6.5.2 Structure of oil strainer.....................................................................155
					6.5.3 Function of oil strainer......................................................................155
					6.5.4 Specification of oil strainer.................................................................155
				6.6 Oil pump............................................................................................156
					6.6.1 Outline of oil pump...........................................................................156
					6.6.2 Structure of oil pump.........................................................................156
					6.6.3 Function of oil pump..........................................................................156
					6.6.4 Specification of oil pump.....................................................................156
				6.7 Relief valve........................................................................................156
					6.7.1 Outline of relief valve.......................................................................156
					6.7.2 Structure of relief valve.....................................................................156
					6.7.3 Function of relief valve......................................................................157
					6.7.4 Specification of relief valve.................................................................157
				6.8 Oil filter..........................................................................................157
					6.8.1 Outline of oil filter.........................................................................157
					6.8.2 Structure of oil filter.......................................................................157
					6.8.3 Function of oil filter........................................................................157
					6.8.4 Specification of oil filter...................................................................157
				6.9 Oil cooler..........................................................................................158
					6.9.1 Outline of oil cooler.........................................................................158
					6.9.2 Structure of oil cooler.......................................................................158
					6.9.3 Function of oil cooler........................................................................158
					6.9.4 Specification of oil cooler...................................................................158
				6.10 Oil switch.........................................................................................158
					6.10.1 Outline of oil switch........................................................................158
					6.10.2 Structure of oil switch......................................................................158
					6.10.3 Function of oil switch.......................................................................159
					6.10.4 Specification of oil switch..................................................................159
			7. Cooling system...........................................................................................160
				7.1 Structure of cooling system.........................................................................160
				7.2 Feature of cooling system...........................................................................161
				7.3 Flow of cooling system (Bottom by-pass system)......................................................161
				7.4 Control of cooling system (Bottom by-pass system)...................................................161
				7.5 Water pump..........................................................................................161
					7.5.1 Outline of water pump.........................................................................161
					7.5.2 Structure of water pump.......................................................................161
					7.5.3 Function of water pump........................................................................162
				7.6 Thermostat..........................................................................................162
					7.6.1 Outline of thermostat.........................................................................162
					7.6.2 Structure of thermostat.......................................................................162
					7.6.3 Function of thermostat........................................................................162
					7.6.4 Specification of thermostat...................................................................162
				7.7 Radiator............................................................................................163
					7.7.1 Outline of radiator...........................................................................163
					7.7.2 Structure of radiator.........................................................................163
					7.7.3 Function of radiator..........................................................................163
					7.7.4 Specification of radiator.....................................................................163
				7.8 Radiator cap........................................................................................164
					7.8.1 Outline of radiator cap.......................................................................164
					7.8.2 Structure of radiator cap.....................................................................164
					7.8.3 Function of radiator cap......................................................................164
					7.8.4 Specification of radiator cap.................................................................164
				7.9 Cooling fan.........................................................................................164
					7.9.1 Outline of cooling fan........................................................................164
					7.9.2 Structure of cooling fan......................................................................164
					7.9.3 Function of cooling fan.......................................................................164
					7.9.4 Specification of cooling fan..................................................................165
				7.10 Reserve tank.......................................................................................165
					7.10.1 Outline of reserve tank......................................................................165
					7.10.2 Structure of reserve tank....................................................................165
					7.10.3 Function of reserve tank.....................................................................165
				7.11 Fan belt...........................................................................................165
					7.11.1 Outline of fan belt..........................................................................165
					7.11.2 Structure of fan belt........................................................................165
					7.11.3 Function of fan belt.........................................................................165
			8. Electrical system........................................................................................166
				8.1 Structure of electrical system......................................................................166
				8.2 Feature of electrical system........................................................................167
				8.3 Flow of electrical system...........................................................................168
				8.4 Control of electrical system........................................................................170
				8.5 Battery.............................................................................................170
					8.5.1 Outline of battery............................................................................170
					8.5.2 Structure of battery..........................................................................170
					8.5.3 Function of battery...........................................................................170
					8.5.4 Specification of battery......................................................................170
				8.6 Key switch..........................................................................................170
					8.6.1 Outline of key switch.........................................................................170
					8.6.2 Structure of key switch.......................................................................170
					8.6.3 Function of key switch........................................................................171
					8.6.4 Specification of key switch...................................................................171
				8.7 Starter (Planetary gear reduction type).............................................................171
					8.7.1 Outline of starter (planetary gear reduction type)............................................171
					8.7.2 Structure of starter (planetary gear reduction type)..........................................171
					8.7.3 Function of starter (planetary gear reduction type)...........................................171
					8.7.4 Specification of starter (planetary gear reduction type)......................................172
				8.8 Alternator..........................................................................................172
					8.8.1 Outline of alternator.........................................................................172
					8.8.2 Structure of alternator.......................................................................172
					8.8.3 Function of alternator........................................................................172
					8.8.4 Specification of alternator...................................................................174
			9. After treatment system...................................................................................175
				9.1 Structure of diesel particulate filter (DPF) system.................................................175
				9.2 Feature of diesel particulate filter (DPF) system...................................................175
				9.3 Flow of diesel particulate filter (DPF) system......................................................175
				9.4 Control of diesel particulate filter (DPF) system...................................................176
				9.5 Diesel oxidation catalyst (DOC).....................................................................178
					9.5.1 Outline of diesel oxidation catalyst (DOC)....................................................178
					9.5.2 Structure of diesel oxidation catalyst (DOC)..................................................178
					9.5.3 Function of diesel oxidation catalyst (DOC)...................................................178
				9.6 Diesel particulate filter (DPF).....................................................................178
					9.6.1 Outline of diesel particulate filter (DPF)....................................................178
					9.6.2 Structure of diesel particulate filter (DPF)..................................................178
					9.6.3 Function of diesel particulate filter (DPF)...................................................179
				9.7 Air flow sensor.....................................................................................179
					9.7.1 Outline of air flow sensor....................................................................179
					9.7.2 Structure of air flow sensor..................................................................179
					9.7.3 Function of air flow sensor...................................................................179
					9.7.4 Specification of air flow sensor..............................................................180
				9.8 Exhaust temperature sensor..........................................................................180
					9.8.1 Outline of exhaust gas temperature sensor.....................................................180
					9.8.2 Structure of exhaust gas temperature sensor...................................................180
					9.8.3 Function of exhaust gas temperature sensor....................................................181
					9.8.4 Specification of exhaust gas temperature sensor...............................................181
				9.9 Differential pressure sensor........................................................................182
					9.9.1 Outline of differential pressure sensor.......................................................182
					9.9.2 Structure of differential pressure sensor.....................................................182
					9.9.3 Function of differential pressure sensor......................................................182
					9.9.4 Specification of differential pressure sensor.................................................182
				9.10 Intake throttle valve..............................................................................183
					9.10.1 Outline of intake throttle valve.............................................................183
					9.10.2 Structure of intake throttle valve...........................................................183
					9.10.3 Function of intake throttle valve............................................................183
					9.10.4 Specification of intake throttle valve.......................................................183
				9.11 Structure of selective catalyst reduction (SCR) system.............................................184
				9.12 Feature of selective catalyst reduction (SCR) system...............................................184
				9.13 Flow of selective catalyst reduction (SCR) system..................................................184
				9.14 Control of selective catalyst reduction (SCR) system...............................................184
				9.15 Selective catalytic reduction (SCR)................................................................185
					9.15.1 Outline of selective catalytic reduction (SCR)...............................................185
					9.15.2 Structure of selective catalytic reduction (SCR).............................................185
					9.15.3 Function of selective catalytic reduction (SCR)..............................................185
				9.16 After treatment control unit (ACU).................................................................186
					9.16.1 Outline of after treatment control unit (ACU)................................................186
					9.16.2 Structure of after treatment control unit (ACU)..............................................186
					9.16.3 Function of after treatment control unit (ACU)...............................................186
					9.16.4 Specification of after treatment control unit (ACU)..........................................186
				9.17 SCR inlet temperature sensor.......................................................................186
					9.17.1 Outline of SCR inlet temperature sensor......................................................186
					9.17.2 Structure of SCR inlet temperature sensor....................................................186
					9.17.3 Function of SCR inlet temperature sensor.....................................................187
					9.17.4 Specification of SCR inlet temperature sensor................................................187
				9.18 NOx sensor.........................................................................................187
					9.18.1 Outline of NOx sensor........................................................................187
					9.18.2 Structure of NOx Sensor......................................................................187
					9.18.3 Function of NOx sensor.......................................................................187
					9.18.4 Specification of NOx sensor..................................................................187
				9.19 Diesel exhaust fluid (DEF) tank....................................................................188
					9.19.1 Outline of diesel exhaust fluid (DEF) tank...................................................188
					9.19.2 Structure of diesel exhaust fluid (DEF) tank.................................................188
					9.19.3 Function of diesel exhaust fluid (DEF) tank..................................................188
					9.19.4 Specification of diesel exhaust fluid (DEF) tank.............................................189
				9.20 DEF injector.......................................................................................189
					9.20.1 Outline of DEF injector......................................................................189
					9.20.2 Structure of DEF injector....................................................................189
					9.20.3 Function of DEF injector.....................................................................189
					9.20.4 Specification of DEF injector................................................................189
				9.21 DEF pump...........................................................................................190
					9.21.1 Outline of DEF pump..........................................................................190
					9.21.2 Structure of DEF pump........................................................................190
					9.21.3 Function of DEF pump.........................................................................190
					9.21.4 Specification of DEF pump....................................................................190
				9.22 Coolant valve......................................................................................191
					9.22.1 Outline of coolant valve.....................................................................191
					9.22.2 Structure of coolant valve...................................................................191
					9.22.3 Function of coolant valve....................................................................191
					9.22.4 Specification of coolant valve...............................................................191
		 SERVICING......................................................................................................193
			1. Troubleshooting..........................................................................................193
				1.1 Troubleshooting for V3800-TIEF4, TIEF4C.............................................................193
			2. Servicing specifications.................................................................................197
				2.1 Servicing specification for engine..................................................................197
			3. Tightening torques.......................................................................................203
				3.1 Tightening torques of screws, bolts and nuts for general use........................................203
				3.2 Tightening torques of screws, bolts and nuts for special use........................................203
			4. Checking and adjusting...................................................................................205
				4.1 Checking compression pressure of cylinder...........................................................205
				4.2 Adjusting valve clearance...........................................................................206
				4.3 Checking engine oil pressure........................................................................207
				4.4 Checking fan belt tension...........................................................................208
				4.5 Checking fan belt damage and wear...................................................................209
				4.6 Checking radiator cap air leakage...................................................................209
				4.7 Checking radiator water leakage.....................................................................210
				4.8 Checking opening temperature of thermostat valve....................................................210
				4.9 Checking battery voltage............................................................................211
				4.10 Checking battery specific gravity..................................................................211
				4.11 Checking starter motor.............................................................................212
				4.12 Checking magnetic switch of starter................................................................213
				4.13 Checking intake air heater.........................................................................213
				4.14 Checking exhaust gas leakage of turbocharger turbine side..........................................214
				4.15 Checking air leakage of turbocharger compressor side...............................................214
				4.16 Checking radial clearance of turbocharger..........................................................214
				4.17 Checking injector..................................................................................214
				4.18 Checking pre-stroke control valve (PCV)............................................................215
				4.19 Checking pressure relief valve (PRV)...............................................................215
				4.20 Checking boost sensor..............................................................................216
				4.21 Checking intake air temperature sensor.............................................................216
				4.22 Checking crankshaft position sensor................................................................217
				4.23 Checking camshaft position sensor..................................................................217
				4.24 Checking coolant temperature sensor................................................................218
				4.25 Checking EGR system................................................................................218
				4.26 Checking air flow sensor...........................................................................218
				4.27 Checking exhaust gas temperature sensor............................................................219
				4.28 Checking SCR inlet temperature sensor..............................................................219
				4.29 Checking DEF pump..................................................................................220
				4.30 Checking DEF tube..................................................................................220
				4.31 Checking DEF injector..............................................................................221
				4.32 Checking DEF tank unit.............................................................................221
				4.33 Checking coolant valve.............................................................................221
				4.34 Adjusting crankshaft position sensor air gap.......................................................222
				4.35 Checking fuel leakage of the overflow pipe.........................................................224
				4.36 Selecting cylinder head gasket.....................................................................224
				4.37 Measuring angular deviation between crankshaft T.D.C. and crank position sensor detected T.D.C.....225
				4.38 Replacing the SCR mixing pipe and slip band........................................................228
			5. Disassembling............................................................................................230
				5.1 Draining engine oil.................................................................................230
				5.2 Draining coolant....................................................................................230
				5.3 Removing selective catalytic reduction (SCR) muffler................................................230
				5.4 Removing CRS intermediate harness...................................................................231
				5.5 Removing external components........................................................................231
				5.6 Removing DPF muffler full assembly..................................................................232
				5.7 Disassembling DPF assembly..........................................................................233
				5.8 Removing EGR cooler.................................................................................234
				5.9 Removing turbocharger...............................................................................234
				5.10 Removing intake throttle valve and intake air heater...............................................235
				5.11 Removing EGR valve.................................................................................235
				5.12 Removing common rail...............................................................................235
				5.13 Removing injector harness connector................................................................236
				5.14 Removing cylinder head cover.......................................................................237
				5.15 Removing sensors...................................................................................237
				5.16 Removing injector..................................................................................238
				5.17 Removing rocker arm................................................................................239
				5.18 Removing injector oil seal.........................................................................240
				5.19 Removing cylinder head.............................................................................240
				5.20 Removing tappet....................................................................................240
				5.21 Removing valve.....................................................................................241
				5.22 Removing thermostat assembly.......................................................................241
				5.23 Removing water pump................................................................................241
				5.24 Removing supply pump...............................................................................242
				5.25 Removing oil cooler................................................................................244
				5.26 Removing fan drive pulley..........................................................................244
				5.27 Removing gear case cover...........................................................................245
				5.28 Removing relief valve..............................................................................245
				5.29 Removing idle gear.................................................................................245
				5.30 Removing oil pump drive gear.......................................................................246
				5.31 Removing crank gear with crank pulsar gear.........................................................246
				5.32 Removing camshaft with cam gear....................................................................246
				5.33 Removing plate.....................................................................................247
				5.34 Removing oil pan and oil strainer..................................................................247
				5.35 Removing piston....................................................................................247
				5.36 Removing piston ring...............................................................................248
				5.37 Disassembling piston assembly......................................................................248
				5.38 Removing flywheel..................................................................................249
				5.39 Removing flywheel housing..........................................................................249
				5.40 Removing bearing case cover........................................................................250
				5.41 Removing crankcase 2...............................................................................250
				5.42 Removing main bearing case.........................................................................250
				5.43 Removing crankshaft................................................................................250
				5.44 Disassembling starter..............................................................................251
				5.45 Disassembling alternator...........................................................................251
			6. Assembling...............................................................................................252
				6.1 Assembling alternator...............................................................................252
				6.2 Assembling starter..................................................................................254
				6.3 Installing crankshaft...............................................................................254
				6.4 Installing main bearing case........................................................................255
				6.5 Installing crankcase 2..............................................................................255
				6.6 Installing flywheel housing.........................................................................256
				6.7 Aligning surface of crankcase 1 and crankcase 2.....................................................256
				6.8 Installing bearing case cover.......................................................................257
				6.9 Installing flywheel.................................................................................257
				6.10 Assembling piston assembly.........................................................................258
				6.11 Installing piston ring.............................................................................258
				6.12 Installing piston..................................................................................259
				6.13 Installing oil strainer and oil pan................................................................260
				6.14 Installing plate...................................................................................261
				6.15 Installing camshaft with cam gear..................................................................262
				6.16 Installing crank gear with crank pulsar gear.......................................................262
				6.17 Installing oil pump drive gear.....................................................................262
				6.18 Installing idle gear...............................................................................263
				6.19 Installing relief valve............................................................................263
				6.20 Installing gear case cover.........................................................................263
				6.21 Installing fan drive pulley........................................................................264
				6.22 Installing oil cooler..............................................................................265
				6.23 Installing water pump..............................................................................265
				6.24 Installing supply pump.............................................................................266
				6.25 Installing thermostat assembly.....................................................................268
				6.26 Installing valve...................................................................................268
				6.27 Installing tappet..................................................................................269
				6.28 Installing cylinder head...........................................................................269
				6.29 Installing injector oil seal.......................................................................271
				6.30 Installing rocker arm assembly.....................................................................271
				6.31 Installing injector................................................................................272
				6.32 Installing cylinder head cover.....................................................................274
				6.33 Installing sensors.................................................................................275
				6.34 Installing injector harness connector..............................................................276
				6.35 Installing common rail.............................................................................276
				6.36 Installing EGR valve...............................................................................277
				6.37 Installing intake throttle valve and intake air heater.............................................277
				6.38 Installing turbocharger assembly...................................................................278
				6.39 Installing EGR cooler..............................................................................278
				6.40 Assembling DPF assembly............................................................................278
				6.41 Installing DPF muffler full assembly...............................................................280
				6.42 Installing CRS intermediate harness................................................................281
				6.43 Installing external components.....................................................................283
				6.44 Installing SCR muffler assembly....................................................................285
				6.45 Filling coolant....................................................................................286
				6.46 Filling engine oil.................................................................................286
			7. Servicing................................................................................................286
				7.1 Checking cylinder head top clearance................................................................286
				7.2 Checking cylinder head surface flatness.............................................................287
				7.3 Checking cylinder head flaw.........................................................................288
				7.4 Checking valve recessing............................................................................288
				7.5 Adjusting valve lapping.............................................................................289
				7.6 Checking clearance between valve stem and valve guide...............................................289
				7.7 Replacing valve guide...............................................................................290
				7.8 Adjusting valve angle...............................................................................291
				7.9 Adjusting valve seat................................................................................291
				7.10 Checking free length of valve spring...............................................................292
				7.11 Checking tilt of valve spring......................................................................292
				7.12 Checking set load of valve spring..................................................................293
				7.13 Checking oil clearance between rocker arm and rocker arm shaft.....................................293
				7.14 Checking oil clearance between valve bridge shaft and valve bridge arm.............................294
				7.15 Checking push rod alignment........................................................................294
				7.16 Checking oil clearance between tappet and tappet guide bore........................................295
				7.17 Checking timing gear backlash......................................................................295
				7.18 Checking side clearance of idle gear 1, 2..........................................................296
				7.19 Checking side clearance of idle gear 3.............................................................297
				7.20 Checking side clearance of camshaft................................................................297
				7.21 Checking camshaft alignment........................................................................297
				7.22 Replacing idle gear bushing........................................................................297
				7.23 Checking cam height................................................................................298
				7.24 Checking oil clearance between camshaft journal and cylinder block bore............................298
				7.25 Checking oil clearance between idle gear shaft 1, 2 and idle gear 1, 2 bushing.....................299
				7.26 Checking oil clearance between idle gear 3 shaft and idle gear 3 holder............................299
				7.27 Checking piston pin bore I.D.......................................................................300
				7.28 Checking oil clearance between piston pin and small end bushing....................................300
				7.29 Replacing small end bushing........................................................................301
				7.30 Checking connecting rod alignment..................................................................302
				7.31 Checking piston ring gap...........................................................................302
				7.32 Checking clearance between piston ring and ring groove.............................................302
				7.33 Checking side clearance of crankshaft..............................................................303
				7.34 Checking crankshaft alignment......................................................................304
				7.35 Checking oil clearance between crankpin and crankpin bearing.......................................305
				7.36 Checking oil clearance between crankshaft journal and crankshaft bearing...........................306
				7.37 Replacing crankshaft sleeve........................................................................307
				7.38 Checking cylinder wear.............................................................................307
				7.39 Adjusting cylinder correction (over size)..........................................................308
				7.40 Checking clearance between inner rotor and outer rotor.............................................308
				7.41 Checking clearance between outer rotor and pump body...............................................308
				7.42 Checking clearance between rotor and cover.........................................................309
				7.43 Checking overrunning clutch of starter.............................................................309
				7.44 Checking commutator and mica of starter............................................................310
				7.45 Checking brush wear of starter.....................................................................310
				7.46 Checking brush holder of starter...................................................................311
				7.47 Checking armature coil of starter..................................................................311
				7.48 Checking field coil of starter.....................................................................312
				7.49 Checking bearing of alternator.....................................................................312
				7.50 Checking stator of alternator......................................................................312
				7.51 Checking rotor of alternator.......................................................................313
				7.52 Checking slip ring of alternator...................................................................313
				7.53 Checking brush wear of alternator..................................................................314
				7.54 Replacing supply pump..............................................................................314
				7.55 Replacing injector.................................................................................316
				7.56 Replacing ECU......................................................................................318
				7.57 Replacing DPF......................................................................................322
				7.58 Replacing SCR......................................................................................328
				7.59 Replacing ACU......................................................................................329
				7.60 Replacing DEF injector.............................................................................332
	INDEX...............................................................................................................335

S.S 11/24