Diesel Particulate Filter Handling Manual - Sept - 2013 - 9Y111-07332 PDF

WORKSHOP MANUAL
DIESEL ENGINE
DIESEL PARTICULATE FILTER

HANDLING MANUAL
KiSC issued 09, 2013 A

TO THE READER
This Workshop Manual tells the servicing personnel about the servicing and maintenance of the
Diesel Particulate Filter. It contains 2 parts: "Information" and "Servicing".
 Information
This section contains information below.
• Safety First
 Servicing
This section contains information below.
• Servicing
All illustrations, photographs and specifications contained in this manual are of the newest
information available at the time of publication.
Click this mark to open the attached file.
KUBOTA reserves the right to change all information at any time without notice.
Since this manual includes many models, information or illustrations and photographs can show
more than one model.
August, 2012
© KUBOTA Corporation 2012

Record of Revisions
For pdf, use search function {Search word} to find the all revised locations.
Last digit
Issue Reference
of the Main Revised Point and Corrective Measures {Search word}
month Page
Code No.
2 2013.09 • Correction of Workshop Manual
The following are the changes from 9Y121-07331 to 9Y121-07332. All pages
1. Information for V6108 was deleted.
2. Information for 03-CR-E4 was added.
3. Information for 07-CR-E4 was added.

I INFORMATION

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

DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM INFORMATION
1. SAFETY FIRST
SAFETY FIRST
• This symbol, the industry's "Safety Alert Symbol", is used throughout this manual and on labels on the
machine itself to warn of the possibility of personal injury. Read these instructions carefully.
• It is essential that you read the instructions and safety regulations before you attempt to repair or use
this unit.
DANGER
• Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
WARNING
• Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
• Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate
injury.
IMPORTANT
• Indicates that equipment or property damage could result if instructions are not followed.
NOTE
• Gives helpful information.
BEFORE YOU START SERVICE

• Read all instructions and safety instructions in this
manual and on your engine safety decals.
• Clean the work area and engine.
• Park the machine on a stable and level ground.
• Let the temperature of the engine decrease before
you start a job.
• Stop the engine, then remove the key.
• Disconnect the battery negative cable.
• Hang a "DO NOT OPERATE" tag in the operator
station.
START SAFELY
• Do not do the procedures below when you start the
engine.
– short across starter terminals
– bypass the safety start switch
• Do not make unauthorized modifications to the
engine. This can cause damage and decrease the
engine life.
I-1
OPERATE SAFELY
• Do not use the machine after you consume alcohol
or medication or when you are tired.
• Put on applicable clothing and safety equipment.
• Use applicable tools only. Do not use alternative
tools or parts.
• When 2 or more persons do servicing, make sure
that you do it safely.
• Do not touch the hot parts or parts that turn when the
engine operates.
• Do not remove the radiator cap when the engine
operates, or immediately after it stops. If not, hot
water can spout out from the radiator. Only remove
the radiator cap when it is at a sufficiently low
temperature to touch with bare hands. Slowly loosen
the cap to release the pressure before you remove it
fully.
• Released fluid (fuel or hydraulic oil) under pressure
can cause damage to the skin and cause serious
injury. Release the pressure before you disconnect
hydraulic or fuel lines. Tighten all connections before
you apply the pressure.
• Do not open a fuel system under high pressure.
The fluid under high pressure that stays in fuel lines
can cause serious injury. Do not disconnect or repair
the fuel lines, sensors, or any other components
between the fuel pump and injectors on engines with
a common rail fuel system under high pressure.
• Put on an applicable ear protective device (earmuffs
or earplugs) to prevent injury against loud noises.
• Be careful about electric shock. The engine
generates a high voltage of more than DC100 V in
the ECU and is applied to the injector.
PREVENT A FIRE
• Fuel is very flammable and explosive under some
conditions. Do not smoke or let flames or sparks in
your work area.
• To prevent sparks from an accidental short circuit,
always disconnect the battery negative cable first
and connect it last.
• The battery gas can cause an explosion. Keep the
sparks and open flame away from the top of battery,
especially when you charge the battery.
• Make sure that you do not spill fuel on the engine.
I-2
KEEP A GOOD AIRFLOW IN THE WORK AREA
• If the engine is in operation, make sure that the area
has good airflow. Do not operate the engine in a
closed area. The exhaust gas contains poisonous
carbon monoxide.
DISCARD FLUIDS CORRECTLY

• Do not discard fluids on the ground, down the drain,
into a stream, pond, or lake. Obey related
environmental protection regulations when you
discard oil, fuel, coolant, electrolyte and other
dangerous waste.
PREVENT ACID BURNS

• Keep electrolyte away from your eyes, hands and
clothing. Sulfuric acid in battery electrolyte is
poisonous and it can burn your skin and clothing and
cause blindness. If you spill electrolyte on yourself,
clean yourself with water, and get medical aid
immediately.
PREPARE FOR EMERGENCIES

• Keep a first aid kit and fire extinguisher ready at all
times.
• Keep the emergency contact telephone numbers
near your telephone at all times.
I-3
1 ENGINE

SERVICING
CONTENTS
1. FUNCTION OF DIESEL PARTICULATE FILTER (DPF).............................................................1-S1

2. DPF REGENERATION AND DPF CLEANING............................................................................1-S2
3. DPF MAINTENANCE FLOW .......................................................................................................1-S3
[1] CLEANING & RETURN FLOW .............................................................................................1-S4
[2] DPF EXCHANGE FLOW.......................................................................................................1-S5
4. DPF CLEANING PROCEDURE ..................................................................................................1-S6
[1] TO ENSURE SAFETY AND GOOD PERFORMANCE IN DPF CLEANING PROCEDURE .1-S6
[2] SEPARATION OF DPF MUFFLER FULL ASSY ...................................................................1-S7
(1) D1803-CR-E4, D1803-CR-TE4, V2403-CR-E4, V2403-CR-TE4 ....................................1-S8
(2) V2607-CR-E4 ..................................................................................................................1-S9
(3) V2607-CR-TE4, V3307-CR-TE4 ...................................................................................1-S10
(4) V3800-CR-TE4, V3800-CR-TIE4, V3800-CR-TE4C, V3800-CR-TIE4C .......................1-S11
[3] DISASSEMBLY OF DPF MUFFLER FULL ASSEMBLY .....................................................1-S12
(1) D1803-CR-E4, D1803-CR-TE4, V2403-CR-E4, V2403-CR-TE4 ..................................1-S12
(2) V2607-CR-E4 ................................................................................................................1-S13
(3) V2607-CR-TE4, V3307-CR-TE4 ...................................................................................1-S13
[4] JUDGMENT OF REUSE OF DPF FILTER COMPLETE BEFORE CLEANING..................1-S15
[5] PREPARATION OF "AFTER-TREATMENT DEVICE EXCHANGE REPORT FORM" .......1-S15
[6] PREPARATION OF "DPF CLEANING ORDER FORM" .....................................................1-S16
[7] PACKING, DELIVERING, AND HANDLING STANDARD OF DPF FILTER COMPLETE
.............................................................................................................................................1-S17
[8] DPF CLEANING METHOD, RESPONSIBLE FOR CLEANING CONTRACTOR (REFERENCE)
.............................................................................................................................................1-S18
[9] JUDGMENT OF REUSE OF DPF FILTER COMPLETE AFTER CLEANING, RESPONSIBLE
FOR CLEANING CONTRACTOR .......................................................................................1-S19
[10]ASSEMBLY OF DPF MUFFLER FULL ASSEMBLY ...........................................................1-S22
(2) V2607-CR-E4 ................................................................................................................1-S24
(3) V2607-CR-TE4, V3307-CR-TE4 ...................................................................................1-S26
[11]MOUNTING OF DPF MUFFLER FULL ASSEMBLY...........................................................1-S30
(2) V2607-CR-E4 ................................................................................................................1-S31
(3) V2607-CR-TE4, V3307-CR-TE4 ...................................................................................1-S32
[12]RESETTING BY USING DIAGNOSIS TOOL ......................................................................1-S34
(1) In Case of Scheduled Maintenance for Every 3,000 Hours of Operation, or In
Case of Heavy Soot Accumulation (P-Code:P3008, J1939:3701-0) .............................1-S34
(2) In Case of Excessive Regeneration Frequency (P-Code:P3024, J1939:523602-0) .....1-S36
[13]EXECUTION CONDITION FOR MANUAL REGENERATION ............................................1-S38
[14]ATTACHED FORM..............................................................................................................1-S39
(1) After-Treatment Device Exchange Report Form ...........................................................1-S39
(2) DPF Cleaning Order Form.............................................................................................1-S40

DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM ENGINE
1. FUNCTION OF DIESEL PARTICULATE FILTER

(DPF)
The Diesel Particulate Filter (hereinafter referred to as the
"DPF") is a filter to capture fine particles (soot and ash) contained in
the exhaust gas of a diesel engine.
The ash content is mainly metallic additives contained in burnt
lubricating oil.
The filter has a honeycomb structure with adjacent cell holes
alternately closed.
In addition, by alternately closing the inlet side and the outlet
side of the exhaust gas, the thin ceramics wall is used as a filter.
As shown in the figure, fine particles in the exhaust gas are
captured when they pass through this thin wall, and the exhaust gas
is discharged as clean gas.
1-S1
2. DPF REGENERATION AND DPF CLEANING

As mentioned above, the filter is a device to capture fine particles.
The filter is clogged with the increase of the engine operating time.
When this occurs, the filter is "regenerated" by burning and removing soot.
However, since ash cannot be removed by the regeneration of the filter, there is a need for "cleaning" of the filter
by removing ash at regular intervals by a cleaning contractor using specialized equipment.
1. DPF Regeneration
The engine has the DPF regeneration mode described below (function to burn and remove deposited soot).
Regeneration by automatic control is performed using post injection.
(a) Automatic regeneration
The operation of the product can be continued.
If regeneration cannot be carried out depending on the situation of the work, the operation of
(b) Parked regeneration
the installed product is stopped to carry out regeneration.
Manual regeneration with a diagnosis
(c) Such regeneration is performed as urgent measures in the event of abnormal soot deposition.
tool (Diagmaster)
2. Cleaning of ash based on maintenance intervals
Since ash deposited in the filter cannot be removed by regeneration, periodical cleaning is required.
There is a need to clean the filter at the pre-determined maintenance intervals (3,000 hours) by a cleaning
contractor using the specialized equipment by removing the DPF filter complete from the DPF muffler full assy.
3. Cleaning of heavy soot and ash accumulation on filter
a) In the case of cleaning request due to heavy soot accumulation
b) In the case of cleaning request due to increase the frequency of regeneration
In this case, there is a need to clean the filter by a cleaning contractor using the specialized equipment by
removing the DPF filter complete from the DPF muffler full assy.
1-S2
3. DPF MAINTENANCE FLOW

When the following condition happened, DPF need to have cleaning or exchange.There are two types of
maintenance flow as "Clean & Return" and "Exchange". Please execute the correct maintenance according to
distributor's instructions.
(1) Every 3,000 hours of operation (Scheduled maintenance)
(2) Cleaning request due to heavy soot accumulation (P-Code:P3008, J1939:3701-0)
(3) Cleaning request due to increase the frequency of regeneration (P-Code:P3024, J1939:523602-0)
1-S3
[1] CLEANING & RETURN FLOW
1-S4
[2] DPF EXCHANGE FLOW
1-S5
4. DPF CLEANING PROCEDURE

[1] TO ENSURE SAFETY AND GOOD PERFORMANCE IN DPF
CLEANING PROCEDURE
(1)Always work in the workshop equipped with a electric hoist (including mobile hoist).
(2)Put a product (engine) on a stable ground, and set the parking brake.
(3)As the DPF muffler full assy is hot just after the engine shutdown, make sure to start operation after it gets cool.
(4)Make sure not to let any foreign substances enter the opening section during the operation.
(5)Make sure not to damage the DPF muffler full assy by falling or impact as it contains a ceramic filter.
IMPORTANT
• Since the DPF that was dropped or given a shock cannot be reused even if there is no damage outwardly,
replace it with a new one.
1-S6
[2] SEPARATION OF DPF MUFFLER FULL ASSY

Follow the procedures below to separate DPF muffler full assy from a product (engine).
Prior Arrangement for Installation and Removal of DPF

1. Before removing the DPF muffler full assy from a product
(engine), connect the diagnosis tool (Diagmaster), check the
failure history (DTC), and save to the "Project" on the
Diagmaster.
Before removing the DPF for cleaning, keep the records of the
engine serial number, DPF filter complete part number, DPF
filter complete serial number, and engine operating time, which
are required in preparing the DPF cleaning order form.
Record the engine operating time by checking the “Hourmeter”
on the data monitor of the diagnosis tool (Diagmaster).
(1) Engine Serial Number (a) CAN Communication Connector

(2) DPF Filter Complete Part Number / (For Servicing)
DPF Filter Complete Serial Number [A] D1803-CR-E4, D1803-CR-TE4,
V2403-CR-E4, V2403-CR-TE4
[B] V2607-CR-E4, V2607-CR-TE4,
V3307-CR-TE4
[C] V3800-CR-TE4, V3800-CR-TIE4,
V3800-CR-TE4C,
V3800-CR-TIE4C
[D] D1803-CR-E4, D1803-CR-TE4,
V2403-CR-E4, V2403-CR-TE4,
V2607-CR-E4
[E] V2607-CR-TE4, V3307-CR-TE4
[F] V3800-CR-TE4, V3800-CR-TIE4,
V3800-CR-TE4C,
V3800-CR-TIE4C
1-S7
(1) D1803-CR-E4, D1803-CR-TE4, V2403-CR-E4, V2403-CR-TE4

Connector of Exhaust Temperature Sensor and Differential
Pressure Sensor
1. Disconnect the connectors of exhaust temperature sensor (6),
(7), (8) and differential pressure sensor (2) from wiring harness.
2. Remove the connectors of exhaust temperature sensor (6), (7),
(8) from the bracket.
3. Remove the clamps (4).
4. Remove the tube (9), (10) from the differential pressure pipe (3),
(11).
5. Remove the differential pressure sensor (2).
6. Remove the differential pressure sensor bracket (1).
(1) Differential Pressure Sensor (7) Connector of Exhaust Temperature
Bracket Sensor (T1)
(3) Differential Pressure Pipe Sensor (T0)
(4) Clamp (9) Tube
(5) Screw of Muffler Flange (10) Tube
(6) Connector of Exhaust Temperature (11) Differential Pressure Pipe
Sensor (T2)
Separation of Muffler Full Assembly (DPF)

1. Unscrew the screw of muffler flange.
2. Unscrew the muffler full assembly (DPF) mounting screws (2).
3. Remove the muffler full assembly (DPF) (1).
NOTE
• When installing and removing the DPF muffler, make sure
that the temperature sensor, differential pressure sensor,
and differential pressure pipe do not make contact with
surrounding parts.
(1) Muffler Full Assembly (DPF) (2) Muffler Full Assembly (DPF)
Mounting Screw
1-S8
(2) V2607-CR-E4
Connector of Exhaust Temperature Sensor
(10), (11) and differential pressure sensor (13) from wiring
harness.
2. Remove the connectors of exhaust temperature sensor (9),
(10), (11) from the bracket.
(1) Exhaust Temperature Sensor (T2) (9) Connector of Exhaust Temperature
(3) Differential Pressure Pipe (10) Connector of Exhaust Temperature
(4) Exhaust Temperature Sensor (T1) Sensor (T1)
(6) Screw of Muffler Flange Sensor (T0)
(7) Muffler Flange (12) Differential Pressure Sensor
(8) Clamp Bracket
(13) Differential Pressure Sensor

1. Unscrew the screw of muffler flange.
NOTE
surrounding parts.
Mounting Screw
1-S9
(3) V2607-CR-TE4, V3307-CR-TE4

(8), (9) and differential pressure sensor (11) from wiring
harness.
(2) Exhaust Temperature Sensor (T1) Sensor (T1)
(4) Nut of Muffler Flange Sensor (T2)
(5) Muffler Flange (10) Differential Pressure Sensor
(6) Clamp Bracket
(7) Connector of Exhaust Temperature (11) Differential Pressure Sensor
Sensor (T0)

1. Unscrew the nut of muffler flange.
NOTE
surrounding parts.
Mounting Screw
1-S10
(4) V3800-CR-TE4, V3800-CR-TIE4, V3800-CR-TE4C, V3800-CR-TIE4C

(3), (4) and differential pressure sensor (1) from wiring harness.
4. Unscrew the stay mounting bolt (7), and remove the DPF stay 1
(6).
(2) Connector of Exhaust Temperature Sensor T0
Sensor T2 (5) Clamp
(3) Connector of Exhaust Temperature (6) DPF Stay 1
Sensor T1 (7) Stay Mounting Bolt

1. Set chain sling by using shackle at two places (a) and (b) as
shown in the photograph.
2. Unscrew the screws of muffler flange (1).
4. Lift up the muffler full assembly (DPF) safely, and separate it
from the engine.
NOTE
• When lifting the muffler full assembly (DPF), use caution so
that the pressure pipe 1 (3) does not hit the EGR pipe (4).
(1) Screw of Muffler Flange (a) Shackle Set Position
(2) Muffler Full Assembly (DPF) (b) Shackle Set Position
Mounting Screw
(3) Pressure Pipe 1
(4) EGR Pipe
1-S11
[3] DISASSEMBLY OF DPF MUFFLER FULL ASSEMBLY

IMPORTANT
• Since the DPF that was dropped or given a shock cannot be reused even if there is no damage outwardly,
replace it with a new one.
• Be sure to loosen the temperature sensor tightening nut or the differential pressure pipe tightening nut
with crowfoot wrench to prevent the damage of the sensor or pipe.
If it is still hard to loosen, apply the lubricant spray to threaded portion and soak it with lubricant.
NOTE
• Always work in the workshop equipped with a electric hoist (including mobile hoist).
• Put a product (engine) on a stable ground, and set the parking brake.
• As the DPF muffler full assembly is hot just after the engine shutdown, make sure to start operation after
it gets cool.
• Make sure not to let any foreign substances enter the opening section during the operation.
• Make sure not to damage the DPF muffler full assembly by falling or impact as it contains a ceramic filter.
• Before removing the DPF muffler full assembly from a product (engine), connect the diagnosis tool
(Diagmaster), check the failure history, and save the project.
• Before removing the DPF for cleaning, keep the records of the engine serial number, filter comp (DPF)
part number, filter comp (DPF) serial number, catalyst (DOC) part number, catalyst (DOC) serial number,
and engine operating time, which are required in preparing the DPF cleaning order from.
Since the engine operating time is recorded in the ECU, check the operating time by connecting the
service tool (Diagmaster).
• When installing and removing the muffler full assembly (DPF), make sure that the temperature sensor,
differential pressure sensor, and differential pressure pipe do not make contact with surrounding parts.

DPF Filter Complete
1. Remove the DPF mounting clamp band (2).
2. Separate the DOC catalyst complete (10), DPF filter complete
(9) and DPF outlet body (7).
(1) Exhaust Temperature Sensor (T2) (6) Differential Pressure Pipe
(2) DPF Mounting Clamp Band (7) DPF Outlet Body
(3) Exhaust Temperature Sensor (T1) (8) Gasket
(4) Exhaust Temperature Sensor (T0) (9) DPF Filter Complete
(5) DPF Stay (10) DOC Catalyst Complete
1-S12
(2) V2607-CR-E4
Differential Pressure Sensor and DPF Filter Complete
1. Remove the tube (5) from the differential pressure pipe (2).
4. Loosen the DPF filter complete mounting bracket (1), (4).
(1) DPF Filter Complete Mounting (8) DPF Outlet Body
Bracket (9) Gasket
(2) Differential Pressure Pipe (10) DPF Filter Complete
(3) Differential Pressure Pipe (11) Gasket
(4) DPF Filter Complete Mounting (12) DOC Catalyst Complete
Bracket (13) Exhaust Temperature Sensor (T0)
(5) Tube (14) Exhaust Temperature Sensor (T1)
(6) Tube (15) Exhaust Temperature Sensor (T2)
(7) Differential Pressure Sensor
(3) V2607-CR-TE4, V3307-CR-TE4

4. Loosen the all DPF filter complete mounting screw (1), (2).
(1) DPF Filter Complete Mounting (9) DPF Filter Complete
Screw (10) Collar (DPF)
(2) DPF Filter Complete Mounting (11) DOC Catalyst
Screw (12) Exhaust Temperature Sensor (T0)
(3) Tube (13) Gasket
(4) Differential Pressure Pipe (14) Exhaust Temperature Sensor (T1)
(5) Tube (15) Gasket
(6) Differential Pressure Pipe (16) Gasket
(7) Differential Pressure Sensor (17) Exhaust Temperature Sensor (T2)
(8) DPF Outlet Body
1-S13

4. Remove the DPF stay 2 (5).
5. Loosen the all DPF filter complete mounting screw (9).
(1) Exhaust Temperature Sensor (T2) (10) Differential Pressure Pipe
(2) Differential Pressure Sensor (11) DPF Outlet Body
(3) Tube (12) DPF Filter Complete
(4) Tube (13) DPF Collar
(5) DPF Stay 2 (14) DOC Catalyst Complete
(6) Differential Pressure Pipe (15) DPF Gasket
(7) Exhaust Temperature Sensor (T1) (16) DPF Gasket
(8) Exhaust Temperature Sensor (T0) (17) DPF Gasket
(9) DPF Filter Complete Mounting
Screw
1-S14
[4] JUDGMENT OF REUSE OF DPF FILTER COMPLETE BEFORE

CLEANING
IMPORTANT
• Before ordering to a cleaning contractor, follow the procedures below to make a judgment on whether the
separated DPF filter complete is reusable.
Judgment of Reuse by Service Dealer

1. Check to see that the surface of the removed DPF filter
complete on the exhaust gas outlet side is not darkened.
2. Check whether there is no crack or loss of the sealing part of the
cell holes on both ends of the filter (inlet side and outlet side).
If the number of missing sealing parts exceeds the allowable
limit, the filter complete cannot be reused even after cleaning.
D1803-CR-E4
D1803-CR-TE4 Number of missing sealing
V2403-CR-E4 parts: 10 or more
V2403-CR-TE4
Number for Number of missing sealing

V2607-CR-E4
judgment of Allowable parts: 10 or more
non-reusability limit V2607-CR-TE4 Number of missing sealing
of filter V3307-CR-TE4 parts: 15 or more
V3800-CR-TE4
V3800-CR-TIE4 Number of missing sealing
V3800-CR-TE4C parts: 15 or more
V3800-CR-TIE4C
3. Check whether there is no crack and loss of the ceramics
element.
If there are any cracks or losses of the ceramics element, the
DPF filter complete cannot be reused even if it is cleaned.
4. If it is judged that the DPF filter complete is not reusable, report
the result of the evaluation to the customer that requested the
filter cleaning, and replace the DPF filter complete with a new
one.
[5] PREPARATION OF "AFTER-TREATMENT DEVICE EXCHANGE

REPORT FORM"
IMPORTANT
• When replacing the DPF filter complete with a new one because the DPF filter complete cannot be reused,
make sure to prepare the "After-Treatment Device Exchange Report Form" and to send the report form to
KUBOTA sales company.
Preparation of "After-Treatment Device Exchange Report

Form"
1. Fill out the attached form (After-Treatment Device Exchange
Report Form).
2. Send the report form to a service representative of KUBOTA
sales company.
1-S15
[6] PREPARATION OF "DPF CLEANING ORDER FORM"

Preparation of "DPF Cleaning Order Form"
1. Fill out the attached form (DPF Cleaning Order Form).
2. Enclose the form when sending DPF filter complete to a
cleaning contractor.
1-S16
[7] PACKING, DELIVERING, AND HANDLING STANDARD OF DPF

FILTER COMPLETE
Follow the below procedures to pack the separated DPF filter complete and to send it to a cleaning contractor.
[Packing and delivering]

(1) Refer to the example of packaging, cover and seal the DPF filter complete with a plastic bag so that soot and ash
are not scattered in the air, and pack it in a cardboard box having cushioning material in it.
(2) Put "FRAGILE" sticker on the package.
(3) Make sure not to drop DPF filter complete when handling and carrying.
Packing and Delivering of DPF Filter Complete (Example)
1. Seal the removed DPF filter complete with a plastic bag as
shown in the photograph [A].
2. Put a cushioning material in the bottom of the prepared
cardboard box.
3. Put the DPF filter complete with the sealed plastic bag on a
cushioning material.
4. Put a cushioning material in around the DPF filter complete as
shown in the photograph [B].
5. Put a cushioning material over the DPF filter complete as shown
in the photograph [C].
6. Enclose the completed DPF Cleaning Order Form in the
cardboard box and close it.
7. Put "FRAGILE" sticker on the cardboard box.
8. Write the address and send it to a cleaning contractor.
[Cautions for handling]

(1) Workers should wear a mask and goggles, and other required protective equipments according to local relevant
regulations whenever cleaning DPF.
(2) The removed soot and ash should be collected on a filter etc. and safely disposed by an industrial waste disposer
according to local relevant regulations.
[Disposal standard of DPF]
(1) DPF should be disposed by an industrial waste disposer according to local relevant regulations.
1-S17
[8] DPF CLEANING METHOD, RESPONSIBLE FOR CLEANING

CONTRACTOR (REFERENCE)
NOTE
• DPF cleaning must be carried out by authorized cleaning contractor.
(1) Workers should wear a mask and goggles, and other required protective equipments according to
local relevant regulations whenever cleaning DPF.
(2) The removed soot and ash should be collected on a filter etc. and safely disposed by an industrial
waste disposer according to local relevant regulations.
Make sure that the DPF cleaning must be carried out according to the following procedures.
1. The DPF should be cleaned with air.
(1) Spray the air mainly from the exhaust outlet side towards the inlet side.
(Refer to the arrow on the side of the DPF complete, which shows the flow of exhaust gas.)
(2) The DPF should not be cleaned by applying pressure (positive/negative) to the whole of the DPF at one time.
3. Do not use any other substance except air to clean the DPF.
4. Do not give a vibration or a shock (hitting, shaking) to the DPF to clean it.
1-S18
[9] JUDGMENT OF REUSE OF DPF FILTER COMPLETE AFTER

CLEANING, RESPONSIBLE FOR CLEANING CONTRACTOR
IMPORTANT
• After the cleaning contractor has cleaned the DPF filter complete, measure the quantity of remaining ash
in the following procedure, and evaluate the reusability.
1-S19
Judgment of Reuse by Cleaning Contractor
1. After having cleaned the DPF filter complete, measure the
actual cell depth (E) with a pin gauge in the each block shown
in the figure. One cell (The measurement point is not specified)
is measured in each block.
Model Measurement total
D1803-CR-E4
D1803-CR-TE4
16 blocks
V2403-CR-E4
V2403-CR-TE4
V2607-CR-E4 16 blocks
V2607-CR-TE4
25 blocks
V3307-CR-TE4
V3800-CR-TE4
V3800-CR-TIE4
28 blocks
V3800-CR-TE4C
V3800-CR-TIE4C
(1) Pin Gauge (0.60 to 0.80 mm dia., (A) Exhaust Inlet Side
0.024 to 0.031 in. dia.) (B) Exhaust Outlet Side
(2) DPF Filter Complete (C) Accumulated Ash
(D) 150 mm (5.91 in.)
(a) Serial No. (E) Actual Cell Depth
(F) Accumulated Ash Depth
(G) Cell Depth
[A] D1803-CR-E4, D1803-CR-TE4,
V2403-CR-E4, V2403-CR-TE4
[B] V2607-CR-E4
[C] V2607-CR-TE4, V3307-CR-TE4
[D] V3800-CR-TE4, V3800-CR-TIE4,
V3800-CR-TE4C,
V3800-CR-TIE4C
(To be continued)
1-S20
(Continued)
2. If the actual cell depth (E) is less than the allowable limit, the
DPF filter complete cannot be reused.
If the DPF filter complete is judged as non-reusable, report the
result of the judgment to the customer that requested the filter
cleaning via the service dealer, and replace the DPF filter
complete with a new one.
(Reference)
Actual Cell Depth (E) = Cell Depth (G)  Accumulated Ash
Depth (F)
NOTE
• Select a metal pin gauge having a wire size slightly thinner
than the cell width (0.60 to 0.80 mm dia., 0.024 to 0.031 in.
dia.).
• When the pin gauge is inserted into the cell hole, insert it
by lightly tapping on the gage end with a finger tip.
• If the pin gauge is forcibly pushed in, the pin pierces
through the accumulated ash and it cannot be measured
accurately. So be careful not to push the pin forcibly.
D1803-CR-E4 85 mm (3.3 in.)
D1803-CR-TE4
102 mm (4.02 in.)
V2403-CR-E4
Actual Cell V2403-CR-TE4 119 mm (4.68 in.)
Depth (Average
Allowable V2607-CR-E4
of all
limit V2607-CR-TE4 119 mm (4.68 in.)
measurement
V3307-CR-TE4
blocks)
V3800-CR-TE4
V3800-CR-TIE4
106 mm (4.17 in.)
V3800-CR-TE4C
V3800-CR-TIE4C
(1) Pin Gauge (0.60 to 0.80 mm dia., (A) Exhaust Inlet Side
0.024 to 0.031 in. dia.) (B) Exhaust Outlet Side
(2) DPF Filter Complete (C) Accumulated Ash
(D) 150 mm (5.91 in.)
(a) Serial No. (E) Actual Cell Depth
(F) Accumulated Ash Depth
(G) Cell Depth
[A] D1803-CR-E4, D1803-CR-TE4,
V2403-CR-E4, V2403-CR-TE4
[B] V2607-CR-E4
[C] V2607-CR-TE4, V3307-CR-TE4
[D] V3800-CR-TE4, V3800-CR-TIE4,
V3800-CR-TE4C,
V3800-CR-TIE4C
1-S21
[10] ASSEMBLY OF DPF MUFFLER FULL ASSEMBLY

IMPORTANT
• Visually check if there is no damage (ceramic crack or damage) with the cleaned and returned DPF filter
complete.
DOC Catalyst Complete, DPF Filter Complete and DPF Outlet

Body
1. Replace the gaskets (2), (5) with new ones.
2. Clean the mounting surface of each flange.
3. Assemble the DOC catalyst complete (7), DPF filter complete
(4), and DPF outlet body (1) with DPF mounting clamp band (3),
(6).
NOTE
• Assemble the DPF filter complete (4) in the correct
direction.
16 to 20 N·m
Tightening torque DPF mounting clamp band 1.7 to 2.0 kgf·m
12 to 14 lbf·ft
(1) DPF Outlet Body (5) Gasket

(2) Gasket (6) DPF mounting clamp band
(3) DPF mounting clamp band (7) DOC Catalyst Complete
(4) DPF Filter Complete
Exhaust Temperature Sensor (In the event of need for

replacement)
When the exhaust temperature sensor is removed or has to be
replaced because it is damaged, follow the procedure given below.
1. Clean the screw parts and apply anti seize agent (NEVER
SEEZ made by Bostik, Grade: Pure nickel special grade).
2. Install the exhaust temperature sensor T0 (3), T1 (2), and T2 (1)
from the exhaust inlet side (catalyst complete side) sequentially.
3. Install each exhaust temperature sensor with the specified
torque.
NOTE
• Anti seize agent is already applied to the screw parts of
new exhaust temperature sensor.
So, it is not necessary to apply it when replacing new ones.
Exhaust temperature sensor T0 25.0 to 35.0 N·m
Tightening torque Exhaust temperature sensor T1 2.55 to 3.56 kgf·m
Exhaust temperature sensor T2 18.5 to 25.8 lbf·ft
(1) Exhaust Temperature Sensor T2 (A) Exhaust Outlet Side

(White Connector: 1J801-18520) (B) Exhaust Inlet Side
(2) Exhaust Temperature Sensor T1
(Gray Connector: 1J500-18510)
(Black Connector: 1J500-18500)
1-S22
Differential Pressure Pipe (In the event of need for
replacement)
When the differential pressure pipe is removed or has to be
2. Use caution not to make a mistake in assembling the differential
pressure pipes (1) and (2).
3. Install the differential pressure pipe (1) and (2) with the specified
torque.
16.0 to 23.0 N·m
Tightening torque Differential pressure pipe 1.64 to 2.34 kgf·m
11.8 to 16.9 lbf·ft
(1) Differential Pressure Pipe (A) Exhaust Outlet Side

(2) Differential Pressure Pipe (B) Exhaust Inlet Side
1-S23
(2) V2607-CR-E4
IMPORTANT
complete.

Body
1. Replace the gaskets (3), (6) with new ones.
3. Assemble the DOC catalyst complete (7), DPF filter complete
(4), and DPF outlet body (1) with DPF filter complete mounting
bracket (2), (5).
NOTE
• Assemble the DPF filter complete (4) in the rightcorrect
direction.
16 to 20 N·m
DPF filter complete
Tightening torque 1.7 to 2.0 kgf·m
mounting bracket
12 to 14 lbf·ft
(1) DPF Outlet Body (5) DPF Filter Complete Mounting

(2) DPF Filter Complete Mounting Bracket
Bracket (6) Gasket
(3) Gasket (7) DOC Catalyst Complete
(4) DPF Filter Complete

replacement)
torque.
NOTE

1-S24
replacement)
torque.
16.0 to 23.0 N·m
11.8 to 16.9 lbf·ft

Differential Pressure Sensor

1. Install the differential pressure sensor (3).
2. Connect the each tube with differential pressure pipe (1) and
(2), and fix the tube with a clamp surely.
NOTE
• If there are the damage or a crack in the tube, replace the
tube with a new one.
9.80 to 11.3 N·m
Mounting bolt of differential
1.00 to 1.15 kgf·m
pressure sensor
7.23 to 8.33 lbf·ft
Tightening torque
9.80 to 11.3 N·m
Fixed bolt of differential
1.00 to 1.15 kgf·m
pressure pipe
7.23 to 8.33 lbf·ft
(1) Differential Pressure Pipe (3) Differential Pressure Sensor

(2) Differential Pressure Pipe
1-S25
(3) V2607-CR-TE4, V3307-CR-TE4

IMPORTANT
complete.

Body
1. Replace the gaskets (5), (6), (7) with new ones.
3. Assemble the components temporary by arranging the DOC
catalyst complete (4), DPF collar (3), DPF filter complete (2),
and DPF outlet body (1).
4. Tighten all the screws evenly with the specified torque.
NOTE
• Assemble the DPF filter complete (2) in the right direction
by referring to the arrow (8) on the side showing the flow of
exhaust gas.
49.0 to 55.9 N·m
DPF filter complete
mounting screw
36.2 to 41.2 lbf·ft

(2) DPF Filter Complete (7) Gasket
(3) DPF Collar (8) Arrow (GAS FLOW)
(4) DOC Catalyst Complete (A) Exhaust Inlet Side
(5) Gasket (B) Exhaust Outlet Side

replacement)
torque.
NOTE

1-S26
replacement)
torque.
16.0 to 23.0 N·m
11.8 to 16.9 lbf·ft


2. Connect the each tube with pressure pipe (2) and (3), and fix the
tube with a clamp surely.
NOTE
9.80 to 11.3 N·m
1.00 to 1.15 kgf·m
pressure sensor
7.23 to 8.33 lbf·ft
Tightening torque
9.80 to 11.3 N·m
1.00 to 1.15 kgf·m
pressure pipe
7.23 to 8.33 lbf·ft
(1) Differential Pressure Sensor (3) Differential Pressure Pipe

1-S27

IMPORTANT
complete.

Body
1. Replace the gaskets (5), (6), (7) with new ones.
3. Assemble the components temporary by arranging the DOC
catalyst complete (4), DPF collar (3), DPF filter complete (2),
and DPF outlet body (1).
4. Tighten all the screws evenly with the specified torque.
NOTE
• Assemble the DPF filter complete (2) in the right direction
by referring to the arrow (8) on the side showing the flow of
exhaust gas.
49.0 to 55.9 N·m
DPF filter complete
mounting screw
36.2 to 41.2 lbf·ft

(2) DPF Filter Complete (7) Gasket
(3) DPF Collar (8) Arrow (GAS FLOW)
(4) DOC Catalyst Complete (A) Exhaust Inlet Side
(5) Gasket (B) Exhaust Outlet Side

replacement)
torque.
NOTE
(1) Exhaust Temperature Sensor T0 (A) Exhaust Inlet Side

(Black Connector: 1J500-18500) (B) Exhaust Outlet Side
(White Connector: 1J500-18520)
1-S28
replacement)
torque.
16.0 to 23.0 N·m
11.8 to 16.9 lbf·ft


1. Install the DPF stay 2 (2).
2. Install the fixed bolts of differential pressure pipe (3) and (4).
4. Connect the each tube with differential pressure pipe (3) and
(4), and fix the tube with a clamp surely.
NOTE
9.80 to 11.3 N·m
1.00 to 1.15 kgf·m
pressure sensor
7.23 to 8.33 lbf·ft
Tightening torque
9.80 to 11.3 N·m
1.00 to 1.15 kgf·m
pressure pipe
7.23 to 8.33 lbf·ft
(1) Differential Pressure Sensor (3) Differential Pressure Pipe

(2) DPF Stay 2 (4) Differential Pressure Pipe
1-S29
[11] MOUNTING OF DPF MUFFLER FULL ASSEMBLY

Follow the below procedures to mount DPF muffler full assy to a product (engine).
After mounting it, start up an engine and check gas leak.

Mounting of DPF Muffler Full Assembly
1. Assemble the DPF muffler full assembly (DPF) (1) with the
muffler full assembly (DPF) mounting screw (2) and the screw
of muffler flange.
49.0 to 55.9 N·m
Muffler full assembly (DPF)
5.00 to 5.70 kgf·m
mounting screw
36.2 to 41.2 lbf·ft
Tightening torque
49.0 to 55.9 N·m
Screw of muffler flange 5.00 to 5.70 kgf·m
36.2 to 41.2 lbf·ft
(1) Muffler full assembly (DPF) (2) Muffler full assembly (DPF)
mounting screw
Connector of Exhaust Temperature Sensor and Differential

Pressure Sensor
1. Install the differential pressure sensor bracket (1).
3. Connect the tube (10), (11) with differential pressure pipe (3)
and (12), and fix the tube with a clamp surely.
4. Connect the connectors of exhaust temperature sensor (6), (7),
(8), and fix the wiring with clamp (4).
5. Connect the connector of differential pressure sensor (9).
Bracket Sensor (T1)
(4) Clamp (9) Connector of Differential Pressure
(5) Screw of Muffler Flange Sensor
(6) Connector of Exhaust Temperature (10) Tube
Sensor (T2) (11) Tube
1-S30
(2) V2607-CR-E4
Mounting of Muffler Full Assembly (DPF)
1. Assemble the muffler full assembly (DPF) (1) with the muffler
full assembly (DPF) mounting screw (2) and the screw of muffler
flange.
49.0 to 55.9 N·m
5.00 to 5.70 kgf·m
mounting screw
36.2 to 41.2 lbf·ft
Tightening torque
49.0 to 55.9 N·m
36.2 to 41.2 lbf·ft
Mounting Screw

2. Install the differential pressure sensor (8) to the bracket (7).
(1) Screw of Muffler Flange (6) Connector of Temperature Sensor
(2) Muffler Flange (T0)
(3) Clamp (7) Differential Pressure Sensor
(4) Connector of Temperature Sensor Bracket
(T2) (8) Differential Pressure Sensor
(5) Connector of Temperature Sensor
(T1)
1-S31
(3) V2607-CR-TE4, V3307-CR-TE4

Mounting of DPF Muffler Full Assy
flange.
49.0 to 55.9 N·m
5.00 to 5.70 kgf·m
mounting screw
36.2 to 41.2 lbf·ft
Tightening torque
49.0 to 55.9 N·m
36.2 to 41.2 lbf·ft
Mounting Screw

2. Install the differential pressure sensor (8) to the bracket (7).
(1) Screw of Muffler Flange (6) Connector of Temperature Sensor
(2) Muffler Flange (T0)
(3) Clamp (7) Differential Pressure Sensor
(4) Connector of Temperature Sensor Bracket
(T2) (8) Differential Pressure Sensor
(5) Connector of Temperature Sensor
(T1)
1-S32

Mounting of Muffler Full Assembly (DPF)
1. Set the chain sling by using shackle at two places (a) and (b) as
shown in the photograph.
2. Lift the muffler full assembly (DPF) (1), and guide it to the
installation position.
flange (4).
4. Remove the chain sling.
NOTE
• When guiding the muffler full assembly (DPF) to the
installation position, use caution so that the differential
pressure pipe (3) does not hit the EGR pipe (2).
49.0 to 55.9 N·m
5.00 to 5.70 kgf·m
mounting screw
36.2 to 41.2 lbf·ft
Tightening torque
49.0 to 55.9 N·m
36.2 to 41.2 lbf·ft
(1) Muffler Full Assembly (DPF) (a) Shackle Set Position

(2) EGR Pipe (b) Shackle Set Position
(4) Screw of Muffler Flange
(5) Muffler Full Assembly (DPF)
Mounting Screw
Connector of Exhaust Temperature Sensor and DPF Stay 1

1. Install the DPF stay 1 (5).
(3), and fix wiring with clamps (4).
49.0 to 55.9 N·m
Tightening torque DPF stay mounting bolt 5.00 to 5.70 kgf·m
36.2 to 41.2 lbf·ft
(1) Connector of Exhaust Temperature (3) Connector of Exhaust Temperature

Sensor (T2) Sensor (T0)
(2) Connector of Exhaust Temperature (4) Clamp
Sensor (T1) (5) DPF Stay 1
1-S33
[12] RESETTING BY USING DIAGNOSIS TOOL

IMPORTANT
• The engine ECU memorizes the quantity of soot and ash deposited in the DPF.
So, the value needs to be reset by the "DPF Soot Load Reset", "DPF Regeneration Interval Time Reset"
in the utility functions of the diagnosis tool (Diagmaster) immediately after the cleaning and replacement
of the filter.
Follow the procedure given below by connecting the diagnosis tool (Diagmaster) after installing the DPF muffler
full assy to a product (engine).
(1) In Case of Scheduled Maintenance for Every 3,000 Hours of Operation, or

In Case of Heavy Soot Accumulation (P-Code:P3008, J1939:3701-0)
Step1
1. Reset the value by "DPF Soot Load Reset" in the utility functions
of the diagnosis tool.
1-S34
Step2
1. Execute the request by the "DPF Manual Regeneration
Request Function" in the utility functions of the diagnosis tool,
and give the command to execute on the application side.
(When the execution button is not on the application side, ECU
on the application side receives the request signal and gives
command to execute.)
Step3
1. Check if the "DPF Regeneration Control Level" and the "DPF
Regeneration Control Status" shows "Level 0" by the monitor
functions in the diagnosis tool.
If the level is 0, it means that manual regeneration has
completed.
1-S35
(2) In Case of Excessive Regeneration Frequency

(P-Code:P3024, J1939:523602-0)
Step1
1. Reset the value by the "DPF Regeneration Interval Time Reset"
in the utility functions of the diagnosis tool.
1-S36
Step2
1. Reset the value by "DPF Soot Load Reset" in the utility functions
of the diagnosis tool.
1-S37
Step3
1. Execute the request by the "DPF Manual Regeneration
Request Function" in the utility functions of the diagnosis tool,
and give the command to execute on the application side.
(When the execution button is not on the application side, ECU
on the application side receives the request signal and gives
command to execute.)
Step4
1. Check if the "DPF Regeneration Control Level" and the "DPF
Regeneration Control Status" shows "Level 0" by the monitor
functions in the diagnosis tool.
If the level is 0, it means that manual regeneration has
completed.
[13] EXECUTION CONDITION FOR MANUAL REGENERATION

To execute manual regeneration, it is required to set the following conditions.
(1) Parking break on
(2) Transmission in neutral
(3) Implement down
1-S38
[14] ATTACHED FORM

(1) After-Treatment Device Exchange Report Form
1-S39
(2) DPF Cleaning Order Form
1-S40
1-S41
1-S42
1-S43
1-S44
EDITOR :
KUBOTA FARM & INDUSTRIAL MACHINERY SERVICE, LTD.
64, ISHIZU-KITAMACHI, SAKAI-KU, SAKAI-CITY, OSAKA, 590-0823, JAPAN
PHONE : (81)72-241-1129
FAX : (81)72-245-2484
E-mail : ks_g.ksos-pub@kubota.com
Printed in Japan 2013. 09, S, EI, EI, engusa Code No.9Y111-07332

KUBOTA Corporation 2012. 08, S, EI, EI, engusa

Diesel Particulate Filter Handling Manual - Sept - 2013 - 9Y111-07332 PDF

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WORKSHOP MANUAL

DIESEL PARTICULATE FILTER

KiSC issued 09, 2013 A

KiSC issued 09, 2013 A

KiSC issued 09, 2013 A

KiSC issued 09, 2013 A

1. SAFETY FIRST .............................................................................................................................. I-1

KiSC issued 09, 2013 A

BEFORE YOU START SERVICE

DISCARD FLUIDS CORRECTLY

PREVENT ACID BURNS

PREPARE FOR EMERGENCIES

KiSC issued 09, 2013 A

1. FUNCTION OF DIESEL PARTICULATE FILTER (DPF).............................................................1-S1

KiSC issued 09, 2013 A

1. FUNCTION OF DIESEL PARTICULATE FILTER

2. DPF REGENERATION AND DPF CLEANING

3. DPF MAINTENANCE FLOW

[1] CLEANING & RETURN FLOW

[2] DPF EXCHANGE FLOW

4. DPF CLEANING PROCEDURE

[2] SEPARATION OF DPF MUFFLER FULL ASSY

Prior Arrangement for Installation and Removal of DPF

(1) Engine Serial Number (a) CAN Communication Connector

(1) D1803-CR-E4, D1803-CR-TE4, V2403-CR-E4, V2403-CR-TE4

Separation of Muffler Full Assembly (DPF)

Separation of Muffler Full Assembly (DPF)

(3) V2607-CR-TE4, V3307-CR-TE4

Separation of Muffler Full Assembly (DPF)

(4) V3800-CR-TE4, V3800-CR-TIE4, V3800-CR-TE4C, V3800-CR-TIE4C

Separation of Muffler Full Assembly (DPF)

[3] DISASSEMBLY OF DPF MUFFLER FULL ASSEMBLY

(1) D1803-CR-E4, D1803-CR-TE4, V2403-CR-E4, V2403-CR-TE4

(3) V2607-CR-TE4, V3307-CR-TE4

(4) V3800-CR-TE4, V3800-CR-TIE4, V3800-CR-TE4C, V3800-CR-TIE4C

[4] JUDGMENT OF REUSE OF DPF FILTER COMPLETE BEFORE

Judgment of Reuse by Service Dealer

Number for Number of missing sealing

[5] PREPARATION OF "AFTER-TREATMENT DEVICE EXCHANGE

Preparation of "After-Treatment Device Exchange Report

[6] PREPARATION OF "DPF CLEANING ORDER FORM"

[7] PACKING, DELIVERING, AND HANDLING STANDARD OF DPF

[Packing and delivering]

[Cautions for handling]

[8] DPF CLEANING METHOD, RESPONSIBLE FOR CLEANING

[9] JUDGMENT OF REUSE OF DPF FILTER COMPLETE AFTER

[10] ASSEMBLY OF DPF MUFFLER FULL ASSEMBLY

DOC Catalyst Complete, DPF Filter Complete and DPF Outlet

(1) DPF Outlet Body (5) Gasket

Exhaust Temperature Sensor (In the event of need for

(1) Exhaust Temperature Sensor T2 (A) Exhaust Outlet Side

(1) Differential Pressure Pipe (A) Exhaust Outlet Side

DOC Catalyst Complete, DPF Filter Complete and DPF Outlet

(1) DPF Outlet Body (5) DPF Filter Complete Mounting

Exhaust Temperature Sensor (In the event of need for

(1) Exhaust Temperature Sensor T2 (A) Exhaust Outlet Side

(1) Differential Pressure Pipe (A) Exhaust Outlet Side

Differential Pressure Sensor

(1) Differential Pressure Pipe (3) Differential Pressure Sensor

(3) V2607-CR-TE4, V3307-CR-TE4

DOC Catalyst Complete, DPF Filter Complete and DPF Outlet

(1) DPF Outlet Body (6) Gasket

Exhaust Temperature Sensor (In the event of need for