Manitou Kubota V2607-CR-E4B V2607-CR-TE4B V2607-CR-TIE4B (DOC ONLY) V3307-CR-TE4B V3307-CR-TIE4B (DOC ONLY) Repair Manual 647470 – PDF DOWNLOAD
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Manitou Kubota V2607-CR-E4B V2607-CR-TE4B V2607-CR-TIE4B (DOC ONLY) V3307-CR-TE4B V3307-CR-TIE4B (DOC ONLY) Repair Manual 647470 – PDF DOWNLOAD
TO THE READER:
This Workshop Manual tells the servicing personnel about the mechanism, servicing and
maintenance of the V2607-CR-E4B, V2607-CR-TE4B and V3307-CR-TE4B. It contains 4 parts:
“Information”, “General”, “Mechanism” and “Servicing”.
Information
This section primarily contains information below.
• Safety First
• Specification
• Performance Curve
• Dimension
• Wiring Diagram
General
This section primarily contains information below.
• Engine Identification
• Muffler Full Assembly Identification
• General Precautions
• Maintenance Check List
• Check and Maintenance
• Special Tools
Mechanism
This section contains information on the structure and the function of the unit. Before you continue
with the subsequent sections, make sure that you read this section.
Refer to Workshop Manual (Code No. 9Y021-01870) for the diesel engine mechanism that this
workshop manual does not include.
Servicing
This section primarily contains information below.
• Troubleshooting
• Servicing Specifications
• Tightening Torques
• Checking, Disassembling and Servicing
All illustrations, photographs and specifications contained in this manual are of the newest
information available at the time of publication.
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.
TABLE OF CONTENTS:
Manitou Kubota V2607-CR-E4B V2607-CR-TE4B V2607-CR-TIE4B (DOC ONLY) V3307-CR-TE4B V3307-CR-TIE4B (DOC ONLY) Repair Manual 647470 – PDF DOWNLOAD
Page de garde / Front page 1
WORKSHOP MANUAL 3
V2607-CR-E4B,V2607-CR-TE4B,V2607-CR-TIE4B (DOC only),V3307-CR-TE4B,V3307-CR-TIE4B (DOC only) 0
TO THE READER 4
I INFORMATION 6
INFORMATION 7
1 SAFETY FIRST 8
2 SPECIFICATIONS 12
3 PERFORMANCE CURVES 14
4 DIMENSIONS 19
5 WIRING DIAGRAM 24
[1] ENGINE INTERMEDIATE HARNESS (ENGINE SIDE HARNESS) 24
[2] INJECTOR INTERMEDIATE HARNESS (ENGINE SIDE HARNESS) 26
[3] ECU INTERMEDIATE HARNESS (OEM SIDE HARNESS) 27
[4] SYSTEM WIRING DIAGRAM 32
G GENERAL 34
GENERAL 35
1 ENGINE IDENTIFICATION 36
[1] MODEL NAME AND ENGINE SERIAL NUMBER 36
[2] E4B ENGINE 38
[3] CYLINDER NUMBER 38
2 MUFFLER FULL ASSEMBLY IDENTIFICATION 39
[1] PART NUMBER AND SERIAL NUMBER 39
3 GENERAL PRECAUTIONS 40
4 MAINTENANCE CHECK LIST 41
5 CHECK AND MAINTENANCE 45
[1] DAILY CHECK POINTS 45
[2] INITIAL 50 HOURS 48
[3] EVERY 50 HOURS 49
[4] EVERY 250 HOURS 49
[5] EVERY 500 HOURS 51
[6] EVERY 1000 HOURS 55
[7] EVERY 1500 HOURS 56
[8] EVERY 3000 HOURS 58
[9] EVERY 1 YEAR 66
[10] EVERY 2 YEARS 68
6 SPECIAL TOOLS 72
1 ENGINE 90
MECHANISM 91
1 ENGINE BODY 92
[1] CYLINDER BLOCK 92
[2] COOLING JACKET 92
[3] HALF-FLOATING HEAD COVER 93
[4] CYLINDER HEAD 94
[5] 4 SCREWS PER EACH CYLINDER ASSEMBLING STRUCTURE 95
[6] CENTER DIRECT INJECTION SYSTEM (E-CDIS) 96
[7] GEAR TRAIN CONFIGURATION 96
[8] PISTON 97
2 LUBRICATING SYSTEM 98
[1] OIL COOLER 98
3 COOLING SYSTEM 99
[1] THERMOSTAT 99
[2] BOTTOM BYPASS SYSTEM 100
4 FUEL SYSTEM 101
[1] OVERVIEW 101
[2] SUPPLY PUMP 102
[3] RAIL 105
[4] INJECTOR 106
[5] ENGINE CONTROL SYSTEM 109
(1) Engine ECU 110
(2) Sensor 110
5 EGR SYSTEM 112
[1] EGR VALVE 112
[2] REED VALVE 112
[3] EGR COOLER 113
6 AFTER TREATMENT SYSTEM 114
[1] AFTER TREATMENT DEVICES [V2607-CR-E4B / V2607-CR-TE4B / V3307-CR-TE4B] 114
[2] AFTER TREATMENT DEVICES [V2607-CR-TIE4B / V3307-CR-TIE4B] 120
SERVICING 121
1 TROUBLESHOOTING 122
2 SERVICING SPECIFICATIONS 126
3 TIGHTENING TORQUES 135
[1] TIGHTENING TORQUES OF SCREWS, BOLTS AND NUTS FOR GENERAL USE 135
[2] TIGHTENING TORQUES OF SCREWS, BOLTS AND NUTS FOR SPECIAL USE 136
4 CHECKING, DISASSEMBLING AND SERVICING 139
[1] CHECKING AND ADJUSTING 139
(1) Engine Body 139
(2) Lubricating System 141
(3) Cooling System 141
(4) Electrical System 143
(5) Turbocharger 147
[2] DISASSEMBLING AND ASSEMBLING 148
(1) Draining Engine Oil and Coolant 148
(2) External Components 149
(3) Turbocharger and EGR 162
(4) Common Rail 163
(5) Cylinder Head and Valves 165
(6) Thermostat 172
(7) SCV 173
(8) Fuel Temperature Sensor 175
(9) Supply Pump 176
(10) Water Pump and Oil Cooler 179
(11) Front Cover 180
(12) Flywheel and Timing Gears 181
(13) Piston and Connecting Rod 188
(14) Crankshaft and Crankcase 192
(15) Starter 194
(16) Alternator 195
[3] SERVICING 197
(1) Cylinder Head and Valves 197
(2) Timing Gears 206
(3) Piston and Connecting Rod 211
(4) Crankshaft 215
(5) Cylinder 221
(6) Oil Pump 222
(7) Relief Valve 223
(8) Starter 223
(9) Alternator 225
DIAGNOSIS MANUAL 227
Diag 9Y110-01992 EN pdf 0
V2607-CR-E4B,V2607-CR-TE4B,V2607-CR-TIE4B (DOC only),V3307-CR-TE4B,V3307-CR-TIE4B (DOC only) 227
I INFORMATION 229
INFORMATION 230
1 SAFETY FIRST 231
1 COMMON RAIL SYSTEM 234
MECHANISM 235
1 BASIC SYSTEM INFORMATION 236
[1] SYSTEM CONFIGURATION 236
[2] FUEL SYSTEM 237
[3] INTAKE AND EXHAUST SYSTEM 238
[4] WIRING DIAGRAM 239
(1) Engine Intermediate Harness (Engine Side Harness) 239
(2) Injector Intermediate Harness (Engine Side Harness) 241
(3) ECU Intermediate Harness (OEM Side Harness) 242
(4) System Wiring Diagram 247
[5] AVAILABLE DATA MONITOR SIGNALS (LEVEL 1) 249
(1) Monitor Items 249
(2) Normal Value 252
[6] ECU TERMINAL LAYOUT 255
(1) ECU Terminal Layout 1 (Engine Side) 255
(2) ECU Terminal Layout 2 (Machine Side) 258
SERVICING 261
1 GENERAL 264
[1] OVERALL DIAGNOSTIC PROCEDURE 264
[2] QUESTIONING 265
[3] LIST OF MALFUNCTION SYMPTOM 268
[4] ACTIONS FOR NON-REOCCURRING MALFUNCTIONS 269
2 DIAGNOSTIC TOOL CONNECTION PROCEDURE 271
[1] DIAGNOSTIC CONNECTOR POSITIONS 271
[2] DIAGNOSTIC TOOL CONNECTION PROCEDURE 271
[3] CHECKING THE COMMUNICATION OPERATION OF THE INTERFACE (DST-i) 272
[4] CHECKING THE OPERATION OF THE ECU 273
(1) Starting Diagmaster 273
(2) DST-i Communication Settings 275
3 ACTIVE TEST AND SUPPLY PUMP DIFFERENCE LEARNING 279
4 DIAGNOSIS BY MALFUNCTION SYMPTOM 281
[1] LIST OF MALFUNCTION CAUSES BY SYMPTOM 281
[2] DIAGNOSIS BY MALFUNCTION SYMPTOM 285
(1) Engine Warning Light Comes On 285
(2) Engine Does Not Start 285
(3) Takes A Long Time Before Engine Starts 289
(4) Idle Failure 293
(5) Engine Noise 296
(6) High fuel consumption 298
(7) Poor Acceleration (Insufficient Output) 303
(8) Abnormal Black Smoke Emitted 308
(9) Abnormal White Smoke Emitted 312
(10) Engine Stalls On Deceleration 317
5 DIAGNOSTIC PROCEDURE BY DTC 321
[1] DTC LIST 321
[2] DIAGNOSTIC PROCEDURE BY DTC 384
(1) NE – G Phase Shift (DTC P0016 / 636-7) 387
(2) Intake Air Temperature Built-in MAF Sensor: Abnormality (DTC P0072 / 171-4, DTC P0073 / 171-3) 388
(3) Pressure Limiter Emergency Open (DTC P0087 / 633-7) 391
(4) High Rail Pressure (DTC P0088 / 157-0) 396
(5) SCV Stuck (DTC P0089 / 1347-7) 401
(6) Fuel Leak (in High Pressured Fuel System) (DTC P0093 / 1239-1) 406
(7) Intake Air Volume: Low (DTC P0101 / 132-1) 411
(8) MAF Sensor Abnormality (DTC P0102 / 132-4, P0103 / 132-3) 412
(9) Intake Air Temperature: High (Inter Cooler Model Only) (DTC P0111 / 172-0) 414
(10) Intake Air Temperature Error (DTC P0112 / 172-4, P0113 / 172-3) 415
(11) Coolant Temperature Sensor Abnormality (DTC P0117 / 110-4, P0118 / 110-3) 418
(12) Fuel High Temperature (DTC P0181 / 174-0) 421
(13) Fuel Temperature Sensor Abnormality (DTC P0182 / 174-4, P0183 / 174-3) 422
(14) Rail Pressure Sensor Abnormality (DTC P0192 / 157-4, P0193 / 157-3) 425
(15) Injector Charge Voltage: High (DTC P0200 / 523535-0) 429
(16) Open Circuit of Harness/Coil (DTC P0201 / 651-3, P0202 / 653-3, P0203 / 654-3, P0204 / 652-3) 431
(17) Engine Overheat (DTC P0217 / 110-0) 434
(18) Engine Overrun (DTC P0219 / 190-0) 436
(19) Boost Pressure Sensor Abnormality (DTC P0237 / 102-4, P0238 / 102-3) 437
(20) Crankshaft Position Sensor (NE Sensor) Abnormality (DTC P0335 / 636-8, P0336 / 636-2) 441
(21) Camshaft Position Sensor (G Sensor) Abnormality (DTC P0340 / 723-8, P0341 / 723-2) 446
(22) Air Heater Relay Driving Circuit Abnormality (DTC P0380 / 523544-3 / 523544-4) 450
(23) EGR Actuator Abnormality (DTC P0403 / 523574-3, DTC P0404 / 523574-4, P0409 / 523572-4) 454
(24) Oil Pressure Error (P0524 / 100-1) 457
(25) Exhaust Gas Temperature Sensor 1 (T1) Abnormality (DTC P0543 / 3242-4, P0544 / 3242-3) 459
(26) Exhaust Gas Temperature Sensor 0 (T0) Abnormality (DTC P0546 / 4765-4, P0547 / 4765-3) 462
(27) Battery Voltage Abnormality (DTC P0562 / 168-4, P0563 / 168-3) 465
(28) QR Data Abnormality (DTC P0602/523538-2, P0602/523538-7) 468
(29) ECU Flash-ROM and CPU Abnormality (DTC P0605 / 628-2, P0606 / 1077-2, P0606/ 523527-2) 469
(30) Injector Charge Voltage Abnormality (DTC P0611 / 523525-1) 471
(31) SCV Drive System Abnormality (DTC P0628 / 1347-4, P0629 / 1347-3) 473
(32) Sensor Supply Voltage 1 Abnormality (DTC P0642 / 3509-4, P0643 / 3509-3) 477
(33) Sensor Supply Voltage 2 Abnormality (DTC P0652 / 3510-4, P0653 / 3510-3) 479
(34) Main Relay is Locked in Closed Position (DTC P0687 / 1485-2) 481
(35) Pump Seizing (DTC P1274 / 523539-2, P1275 / 523540-2) 484
(36) EEPROM Check Sum Error (DTC P1990 / 523700-13, P1991 / 523701-13, P1992 / 523702-13) 489
(37) Intake Throttle Feedback Error (DTC P2108 / 523580-2) 491
(38) Accelerator Position Sensor 1 Abnormality (DTC P2122 / 91-4, P2123 / 91-3) 493
(39) Accelerator Position Sensor 2 Abnormality (DTC P2127 / 29-4, P2128 / 29-3) 497
(40) Accelerator Position Sensor Error (CAN) (DTC P2131 / 523543-2) 501
(41) Accelerator Position Sensor Correlation Error (DTC P2135 / 91-2) 503
(42) Common 1 System Injector Drive Circuit Open (DTC P2146 / 523523-2) 504
(43) Common 1 TWV Actuation System Short (DTC P2147 / 523523-4, P2148 / 523523-3) 507
(44) Common 2 System Injector Drive Circuit Open (DTC P2149 / 523524-2) 511
(45) Common 2 TWV Actuation System Short (DTC P2150 / 523524-4, P2151 / 523524-3) 514
(46) Barometric Pressure Sensor Error (DTC P2228 / 108-4, P2229 / 108-3) 518
(47) EGR (DC Motor) Abnormality (DTC P2413 / 523575-7, P2414 / 523576-2, P2415 / 523577-2) 520
(48) Exhaust Gas Temperature Sensor 2 (T2) Abnormality (DTC P242C / 3246-4, P242D / 3246-3) 523
(49) Differential Pressure Sensor 1 Abnormality (DTC P2454 / 3251-4, P2455 / 3251-3) 526
(50) Intake Throttle Lift Sensor Abnormality (DTC P2621 / 523583-4, P2622 / 523582-3) 530
(51) Emission Deterioration (DTC P3001 / 3252-0) 532
(52) Exhaust Gas Temperature Sensor 0: Emergency High (DTC P3002 / 4765-0) 534
(53) Exhaust Gas Temperature Sensor 1: Emergency High (DTC P3003 / 3242-0) 536
(54) Exhaust Gas Temperature Sensor 2: Emergency High (DTC P3004 / 3246-0) 538
(55) Excessive PM3 (DTC P3006 / 3701-15) 540
(56) Excessive PM4 (DTC P3007 / 3701-16) 541
(57) Excessive PM5 (DTC P3008 / 3701-0) 542
(58) Boost Pressure Low (DTC P3011 / 132-15) 543
(59) Low Coolant Temperature in Parked Regeneration (DTC P3012 / 523589-17) 545
(60) Parked Regeneration Time Out (DTC P3013 / 523590-16) 546
(61) All Exhaust Gas Temperature Sensor Failure (DTC P3018 / 523599-0) 548
(62) Initial Pump-calibration Incomplete (DTC P3019 / 523600-0) 549
(63) High Exhaust Gas Temperature After Emergency High Temperature DTC (DTC P3023 / 523601-0) 550
(64) High Frequency of Regeneration (DTC P3024 / 523602-0) 551
(65) Over Heat Pre-caution (DTC P3025 / 523603-15) 552
(66) CAN2 Bus Off (DTC U0075 / 523547-2) 553
(67) No Communication with EGR (DTC U0076 / 523578-2) 555
(68) CAN1 Bus Off (DTC U0077 / 523604-2) 557
(69) CAN2 Frame Error (DTC U0081 / 523548-2, U0082 / 523591-2, U0083 / 523592-2, U0084 / 523593-2, U0085 / 523594-2, U0086 / 523595-2, U0087 / 523596-2, U0089 / 523598-2) 558
6 INSPECTION PROCEDURE FOR EACH SYSTEM 562
[1] AIR INTAKE SYSTEM INSPECTION PROCEDURE 562
[2] FUEL SYSTEM INSPECTION PROCEDURE 563
[3] ELECTRIC SYSTEM INSPECTION PROCEDURE 568
(1) Basics Of Checking Electrical / Electronic Circuit Systems 568
(2) Connector Connection Fault Verification Method 571
(3) Checking The Power And Ground System (Main Relay, ECU Circuit) 572
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
S.V