Kubota D1803-CR-TIE4B-KEA-1 Installation Instructions Manual Download Page 20 | Manualshive

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Page No. 20

Kubota Emission-Related Installation Instructions

Document Number : KEA-STD-03-CRS-DOC-001-

④

Appendix 5

2. Intake System

2-2. Standard Intake System Layout

Incorrect air intake system layout will cause emission non-compliance.
The standard air intake system layout is illustrated below.

2-2-3. Standard Air Intake System Layout for D1803-CR-TIE4BG-KEA-1

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Summary of Contents for D1803-CR-TIE4B-KEA-1

Page 1: ...ocument supersede any other previous instructions provided by Kubota Kubota Installation Instructions CARB EPA certified Tier 4f engines D1803 CR TIE4B KEA 1 1J497 10000 D1803 CR TIE4B KEA 2 1J497 200...

Page 2: ...Objective Items page 4 5 1 Exhaust System page 6 15 2 Intake System page 16 36 3 Fuel System page 37 43 4 Engine Control Unit ECU page 44 57 5 Engine Control System Wire Harness Display Panel page 48...

Page 3: ...ne control system etc are installed correctly in the engine s certified configuration The emission related parts which FEA prepare for example the exhaust tail pipe or wire harness and controls must b...

Page 4: ...ir cooler performance must be kept within certain criteria 3 Fuel System In order to maintain the common rail fuel injection pump performance and durability the pressure and temperature of the fuel mu...

Page 5: ...ssion control information label hard to read during normal engine maintenance the final engine assembler must place a duplicate label on the equipment as described in 40 CFR 1068 105 7 Application Rev...

Page 6: ...1 Exhaust System 1 1 1 Exhaust System Supply for KEA Standard CRS DOC Engines No 2 Gasket No 1 Diesel Oxidation Catalyst DOC Exhaust system means the layout of all parts from the exhaust manifold to t...

Page 7: ...6 1223 1 All 03 Series Qty 1 Gasket supplied with engine Qty 3 Gaskets are required for remote DOC installation See page 12 13 for remote DOC installation details 3 Bolt 4 M8 x 1 25mm ISO 8 8 4 Tail P...

Page 8: ...ywheel housing at the Kubota production facility as the standard configuration Kubota recommends to keep the DOC in this factory location B DOC Outlet Angle Changing the DOC outlet angle is acceptable...

Page 9: ...478 10000 40 mm Hg BG V2403 CR TIE4B KEA 1 1J498 10000 50 mm Hg Industrial V2403 CR TIE4B KEA 2 1J498 20000 50 mm Hg Industrial V2403 CR TIE4BG KEA 1 1J488 10000 40 mm Hg BG 1 Exhaust System Back pres...

Page 10: ...e Angle adjustment must be completed only 1 time to minimize risk of clamp breakage Angle adjustment must be completed before customers run the engine to minimize risk of clamp deterioration due to he...

Page 11: ...for the complete exhaust system measured at the muffler flange outlet must be less than 113 mmHg The back pressure must be measured at the rated speed full load condition 2 Exhaust Temperature Drop R...

Page 12: ...pipe and flexible coupling must not leak exhaust gases during operation D New muffler flange outlet gasket DOC inlet gasket studs and nuts on muffler flange outlet are required when DOC is removed fro...

Page 13: ...alled according to the angles defined below B The DOC inlet band clamp cannot be loosened or modified in any way C The DOC can only be inclined according to option 1 or option 2 not the combination I...

Page 14: ...l not damage the DOC during long term operation Intermediate exhaust pipe for remote mount DOC may require support brackets 3 Please note that the DOC skin temperature can reach about 250 C Check surr...

Page 15: ...hould install heat shields or insulating blankets as necessary It is acceptable to wrap the DOC if necessary However heat shield must not be welded to the DOC The temperature of these surrounding comp...

Page 16: ...m means the layout of all parts from the air inlet pre cleaner hose to the intake manifold or turbo charger An example of an intake system with the KEA Standard CRS DOC engine is shown below 2 1 Intak...

Page 17: ...5 1 D1803 CR TIE4B KEA 2 for 7 A C 1E441 1125 1 D1803 CR TIE4BG KEA 1 for 7 A C Integrated Type 1 V2403 CR TIE4B KEA 1 2 for 8 Non Rotatable A C S N 7HU 1J498 1125 1 V2403 CR TIE4B KEA 1 2 for 8 Rotat...

Page 18: ...ng 1 To maintain emissions compliance These Tier 4 common rail engines utilize a mass air flow MAF sensor to control the EGR flow rate The air cleaner location and piping layout must be installed acco...

Page 19: ...OC 001 Appendix 5 2 Intake System 2 2 Standard Intake System Layout Incorrect air intake system layout will cause emission non compliance The standard air intake system layout is illustrated below 2 2...

Page 20: ...EA STD 03 CRS DOC 001 Appendix 5 2 Intake System 2 2 Standard Intake System Layout Incorrect air intake system layout will cause emission non compliance The standard air intake system layout is illust...

Page 21: ...OC 001 Appendix 5 2 Intake System 2 2 Standard Intake System Layout Incorrect air intake system layout will cause emission non compliance The standard air intake system layout is illustrated below 2 2...

Page 22: ...EA STD 03 CRS DOC 001 Appendix 5 2 Intake System 2 2 Standard Intake System Layout Incorrect air intake system layout will cause emission non compliance The standard air intake system layout is illust...

Page 23: ...the engine being installed into the OEM equipment Intake systems on engines MUST NOT be modified from the standard layout defined in the previous pages if the flexibility is not available in the abov...

Page 24: ...inlet relative to the air cleaner body axis Option 2 Extend the air cleaner position by installing an extension pipe OEM procured Option 3 Rotate the air cleaner relative to the air cleaner outlet axi...

Page 25: ...g pages Option 1 Rotate the air cleaner inlet relative to the air cleaner body axis Option 2 Extend the air cleaner position by installing an extension pipe OEM procured Option 3 Rotate the air cleane...

Page 26: ...n 1 Option 1 Rotate the air cleaner inlet relative to the air cleaner body axis The air cleaner that is provided for the standard KEA engines with intake system flexibility has a rotatable inlet It is...

Page 27: ...The OEM must install a hose clamp on each end of the rubber coupling to avoid dust in the intake system D No gap is allowed between the extension pipe and air cleaner outlet See image below E Flexibil...

Page 28: ...the limitations outlined in the following pages Extension Pipe Requirements and Dimensions G The pipe must be clean and de burred prior to installation H The pipe must be seamless stainless steel or a...

Page 29: ...e below for installation notes and limitations for option 3 Option 3 Rotate the air cleaner relative to the air cleaner outlet axis It is acceptable to adjust the air cleaner installation to any angle...

Page 30: ...and limitations for option 4 Option 4 Rotate the air cleaner relative to the turbo charger inlet axis It is acceptable to adjust the air cleaner installation to exactly 90 degrees as illustrated below...

Page 31: ...that are NOT acceptable These installations cause the mass air flow sensor to fall outside of the acceptable sensor performance range 2 Intake System 2 5 1 Air Intake System Flexibility Limitations A...

Page 32: ...et AC Angle and Heights in this table can be used as specified B Any other combination not listed in this table is not permitted 2 Intake System 2 5 2 Air Intake System Flexibility Limitations Accepta...

Page 33: ...nation of AC Inlet AC Angle and Heights in this table can be used as specified B Any other combination not listed in this table is not permitted 2 Intake System 2 5 3 Air Intake System Flexibility Lim...

Page 34: ...ne performance will be reduced If the temperature is high a pre cleaner hose can be added to the air cleaner to help reduce inlet temperature 3 Environment It is critical that water does not enter the...

Page 35: ...nce To prevent decreases of engine output performance and to maintain emission compliance the total intake system restriction must be less than the following limits If a pre cleaner hose rain cap or a...

Page 36: ...performance and to maintain emission compliance the charge air cooler must meet the following criteria The charge air cooler pressure drop and temperature drop MUST be checked during the application...

Page 37: ...y Fuel Cap Check Valve Lift Pump Pre Supply Pump Clamp Fuel Supply Fuel Return 3 1 1 Fuel System Supply for KEA Standard CRS DOC Engines Fuel system means the layout of all parts from the fuel tank to...

Page 38: ...J430 4335 1 All 03 Series Comes with W ater In Fuel sensor installed 5 Joint Bolt 16541 9579 4 All 03 Series M14x1 5 thread used for inlet outlet of Separator and Filter 6 Joint Eye 15401 9569 4 All 0...

Page 39: ...Fuel System layout must comply with the following 1 To maintain emissions compliance These Tier 4 common rail engines utilize computer controlled fuel injection The Pre Supply and Supply pump are mou...

Page 40: ...Line 3 Fuel System to Fuel Rail Design Target Fuel Pressure 20 kPa Design Target Fuel 30 kPa Fuel 75 C Fuel Supply Fuel Return Fuel pressure and temperature measurements are taken during the Ap Review...

Page 41: ...l connection in 150mm pigtail with Yaz connector 7122 2820 terminals 7114 2630 02 3 4 Fuel Pump and Check Valve Installation Requirements 1 Maximum vibration levels not to exceed 3G 2 Pump can be moun...

Page 42: ...ator Kubota supplies fuel filter 1J456 4301 Fuel filter shall be installed between feed pump and injection pump 3 Fuel System Supply Pump Fuel Inlet uel Outlet Fuel Filter Fuel Supply Fuel Return M14x...

Page 43: ...lication review The temperature should not be more than 75 C 3 Installation orientation of Components Water separator and fuel filter should be mounted with the filter oriented vertically Feed pump an...

Page 44: ...ion 5G 1 3 Normal operating temperature 30 to 105 C 1 4 Water Proof IP69K 2 Installation Notes 2 1 The ECU must be mounted on the equipment chassis Engine mounted ECU s are not approved for warranty 2...

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