Kubota Engine V3800-CR-TE5 V3800-CR-TE5BG Diagnostic Manual 9Y310-00126

Description

Contents:
1. SAFETY
SAFETY FIRST
1. Working precautions
2. Preparing for emergencies
3. Working cautions
4. Starting machine safely
5. Preventing fires
6. Preventing acid burns
7. Avoiding high pressure fluid
8. Avoiding hot exhaust
9. Cleaning exhaust filter
2. COMMON RAIL SYSTEM
MECHANISM
1. Basic system information
1.1 System configuration (ECU)
1.2 System configuration (ECU) (for only BG model)
1.3 Fuel system
1.4 Intake and exhaust system
1.5 Intake and exhaust system (for only BG model)
1.6 Wiring diagram
1.6.1 Engine intermediate harness (Engine side harness)
1.6.2 Injector intermediate harness (Engine side harness)
1.6.3 Engine ECU intermediate harness (OEM side harness)
1.6.4 System wiring diagram (ECU)
1.6.5 System wiring diagram (ECU) (for only BG model)
1.7 Available data monitor signals (Level 1)
1.7.1 Monitor items 1
1.7.2 Monitor items 2
1.7.3 Monitor items (for only BG model)
1.7.4 Normal value 1
1.7.5 Normal value 2
1.7.6 Normal value (for only BG model)
1.8 ECU terminal layout
1.8.1 ECU terminal layout 1 (engine side)
1.8.2 ECU terminal layout 1 (Engine side) (for only BG model)
1.8.3 ECU terminal layout 2 (machine side)
1.8.4 ECU terminal layout 2 (Machine side) (for only BG model)
SERVICING
1. General
1.1 Overall diagnostic procedure
1.2 Questioning
1.2.1 Trouble check sheet for Kubota common rail system
1.3 List of malfunction symptom
1.4 Actions for non-reoccurring malfunctions
2. Diagnostic tool connection procedure
2.1 Diagnostic connector positions
2.2 Diagnostic tool connection procedure
2.3 Check communication operation of the interface (DST-i)
2.3.1 DST-i operation status and display specification
2.4 Checking the operation of the ECU
2.4.1 Starting diagmaster
3. Active test and utility
3.1 Operating details
3.1.1 Cylinder injector injection stop
3.1.2 Exhaust gas recirculation (EGR) valve ON/OFF Function
3.1.3 Glow relay ON/OFF Function
3.1.4 Intake throttle valve ON/OFF function
3.1.5 NCD Check Function
3.1.6 Exhaust Throttle ON/OFF Function
3.1.7 DPF/DOC Regeneration for BG
3.1.8 Supply pump learning
3.1.9 Injector compensation
3.1.10 Data check/Rewrite
3.1.11 DPF Soot load reset
3.1.12 Supply Pump Learning End Time Reset
3.1.13 DPF Regeneration interval time reset
3.1.14 HMI for PCD
3.1.15 NCD Counter Reset Function
3.1.16 DPF Manual Regeneration Request Function
4. PCD details
5. Pattern of NCD inducement
6. Diagnosis by malfunction symptom
6.1 List of malfunction causes by symptom
6.2 Diagnosis by malfunction symptom
6.2.1 Engine warning light comes on
6.2.2 Engine does not start
6.2.3 Takes a long time before engine starts
6.2.4 Idle failure
6.2.5 Engine noise
6.2.6 High fuel consumption
6.2.7 Poor acceleration (Insufficient output)
6.2.8 Abnormal black smoke emitted
6.2.9 Abnormal white smoke emitted
6.2.10 Engine stalls on deceleration
7. Diagnostic procedure by DTC
7.1 ECU DTC list
7.1.1 P0016
7.1.2 P0072
7.1.3 P0073
7.1.4 P0087
7.1.5 P0088
7.1.6 P0089
7.1.7 P0093
7.1.8 P0101
7.1.9 P0102
7.1.10 P0103
7.1.11 P0111
7.1.12 P0112
7.1.13 P0113
7.1.14 P0117
7.1.15 P0118
7.1.16 P0181
7.1.17 P0182
7.1.18 P0183
7.1.19 P0192
7.1.20 P0193
7.1.21 P0200
7.1.22 P0201
7.1.23 P0202
7.1.24 P0203
7.1.25 P0204
7.1.26 P0217
7.1.27 P0219
7.1.28 P0237
7.1.29 P0238
7.1.30 P0335
7.1.31 P0336
7.1.32 P0340
7.1.33 P0341
7.1.34 P0380-1
7.1.35 P0380-2
7.1.36 P0403
7.1.37 P0404
7.1.38 P0409
7.1.39 P0524
7.1.40 P0543
7.1.41 P0544
7.1.42 P0546
7.1.43 P0547
7.1.44 P0562
7.1.45 P0563
7.1.46 P0602-1
7.1.47 P0602-2
7.1.48 P0605
7.1.49 P0606-1
7.1.50 P0606-2
7.1.51 P0611
7.1.52 P0628
7.1.53 P0629
7.1.54 P0642
7.1.55 P0643
7.1.56 P0652
7.1.57 P0653
7.1.58 P0687
7.1.59 P1274
7.1.60 P1275
7.1.61 P1990
7.1.62 P1A28
7.1.63 P1C00
7.1.64 P1C01
7.1.65 P1C02
7.1.66 P1C04
7.1.67 P2108
7.1.68 P2122
7.1.69 P2123
7.1.70 P2127
7.1.71 P2128
7.1.72 P2131
7.1.73 P2135
7.1.74 P2146
7.1.75 P2147
7.1.76 P2148
7.1.77 P2149
7.1.78 P2150
7.1.79 P2151
7.1.80 P2228
7.1.81 P2229
7.1.82 P2413
7.1.83 P2414
7.1.84 P2415
7.1.85 P242C
7.1.86 P242D
7.1.87 P2454
7.1.88 P2455
7.1.89 P2470
7.1.90 P2471
7.1.91 P2621
7.1.92 P2622
7.1.93 P3001
7.1.94 P3002
7.1.95 P3003
7.1.96 P3004
7.1.97 P3006
7.1.98 P3007
7.1.99 P3008
7.1.100 P3011
7.1.101 P3012
7.1.102 P3013
7.1.103 P3014
7.1.104 P3015
7.1.105 P3018
7.1.106 P3019
7.1.107 P3023
7.1.108 P3024
7.1.109 P3025
7.1.110 P340C
7.1.111 U0075
7.1.112 U0076
7.1.113 U0077
7.1.114 U0081
7.1.115 U0082
7.1.116 U0083
7.1.117 U0086
7.1.118 U1000
7.2 Diagnostic procedure by DTC
7.2.1 NE – G phase shift (DTC P0016 / 636-7)
7.2.2 Intake air temperature built-in MAF sensor: abnormality (DTC P0072 / 171-4, DTC P0073 / 171-3)
7.2.3 Pressure Limiter Emergency Open (DTC P0087 / 633-7)
7.2.4 High rail pressure (DTC P0088 / 157-0)
7.2.5 SCV Stuck (DTC P0089 / 1347-7)
7.2.6 Fuel leak (in high pressured fuel system) (DTC P0093 / 1239-1)
7.2.7 Intake air volume: Low (DTC P0101 / 132-1)
7.2.8 MAF sensor abnormality (DTC P0102 / 132-4, P0103 / 132-3)
7.2.9 Intake air temperature: High (DTC P0111 / 172-0)
7.2.10 Intake air temperature error (DTC P0112 / 172-4, P0113 / 172-3)
7.2.11 Coolant temperature sensor abnormality (DTC P0117 / 110-4, P0118 / 110-3)
7.2.12 Fuel high temperature (DTC P0181 / 174-0)
7.2.13 Fuel temperature sensor abnormality (DTC P0182 / 174-4, DTC P0183 / 174-3)
7.2.14 Rail pressure sensor abnormality (DTC P0192 / 157-4, P0193 / 157-3)
7.2.15 Injector charge voltage: High (DTC P0200 / 523535-0)
7.2.16 Open circuit of harness / coil (DTC P0201 / 651-3, P0202 / 653-3, P0203 / 654-3, P0204 / 652-3)
7.2.17 Engine overheat (DTC P0217 / 110-0)
7.2.18 Engine overrun (DTC P0219 / 190-0)
7.2.19 Boost pressure sensor abnormality (DTC P0237 / 102-4, P0238 / 102-3)
7.2.20 Crankshaft position sensor (NE sensor) abnormality (DTC P0335 / 636-8, P0336 / 636-2)
7.2.21 Camshaft position sensor (G sensor) abnormality (DTC P0340 / 723-8, P0341 / 723-2)
7.2.22 Air heater relay driving circuit abnormality (DTC P0380 / 523544-3 / 523544-4)
7.2.23 EGR actuator abnormality (DTC P0403 / 523574-3, DTC P0404 / 523574-4, P0409 / 523572-4)
7.2.24 Oil pressure error (DTC P0524 / 100-1)
7.2.25 Exhaust gas temperature sensor (T1) abnormality (DTC P0543 / 3242-4, P0544 / 3242-3)
7.2.26 Exhaust gas temperature sensor (T0) abnormality (DTC P0546 / 4765-4, P0547 / 4765-3)
7.2.27 Battery voltage abnormality (DTC P0562 / 168-4, P0563 / 168-3)
7.2.28 QR data abnormality (DTC P0602 / 523538-2, P0602 / 523538-7)
7.2.29 ECU FLASH-ROM and CPU abnormality (DTC P0605 / 628-2, P0606 / 1077-2, P0606 / 523527-2)
7.2.30 Injector charge voltage: Low (DTC P0611 / 523525-1)
7.2.31 SCV drive system abnormality (DTC P0628 / 1347-4, DTC P0629 / 1347-3)
7.2.32 Sensor supply voltage 1 abnormality (DTC P0642 / 3509-4, P0643 / 3509-3)
7.2.33 Sensor supply voltage 2 abnormality (DTC P0652 / 3510-4, P0653 / 3510-3)
7.2.34 Main relay is locked in closed position (DTC P0687 / 1485-2)
7.2.35 Pump seizing (DTC P1274 / 523539-2, P1275 / 523540-2)
7.2.36 EEPROM check sum error (DTC P1990 / 523700-13)
7.2.37 Removal of DPF (PCD) (DTC P1A28 / 3936-7)
7.2.38 ECU Internal Abnormality (DTC P1C00 / 523634-2_ P1C01 / 523635-2_P1C02 / 523636-2)[Engine ECU (Kubota) Dedicated DTC]
7.2.39 Battery voltage too low (DTC P1C04 / 168-1) [Engine ECU (Kubota) dedicated DTC]
7.2.40 Intake throttle feedback error (DTC P2108 / 523580-2)
7.2.41 Accelerator position sensor 1 abnormality (DTC P2122 / 91-4, P2123 / 91-3)
7.2.42 Accelerator position sensor 2 abnormality (DTC P2127 / 29-4, P2128 / 29-3)
7.2.43 Accelerator position sensor error (CAN) (DTC P2131 / 523543-2)
7.2.44 Accelerator position sensor correlation error (DTC P2135 / 91-2)
7.2.45 Common 1 system injector drive circuit open (DTC P2146 / 523523-2)
7.2.46 Common 1 TWV actuation system short (DTC P2147 / 523523-4, P2148 / 523523-3)
7.2.47 Common 2 system injector drive circuit open (DTC P2149 / 523524-2)
7.2.48 Common 2 TWV actuation system short (DTC P2150 / 523524-4, P2151 / 523524-3)
7.2.49 Barometric pressure sensor error (DTC P2228 / 108-4, P2229 / 108-3)
7.2.50 EGR (DC motor) abnormality (DTC P2413 / 523575-7, P2414 / 523576-2, P2415 / 523577-2)
7.2.51 Exhaust gas temperature sensor (T2) abnormality (DTC P242C / 3246-4, P242D / 3246-3)
7.2.52 Differential pressure sensor 1 abnormality (DTC P2454 / 3251-4, P2455 / 3251-3)
7.2.53 Exhaust gas temperature sensor E (Te) abnormality (DTC P2470 / 4772-4, DTC P2471 / 4772-3)
7.2.54 Intake throttle lift sensor abnormality (DTC P2621 / 523583-4, P2622 / 523582-3)
7.2.55 Emission deterioration (DTC P3001 / 3252-0)
7.2.56 Emergency exhaust gas temperature sensor T0: high (DTC P3002 / 4765-0)
7.2.57 Emergency exhaust gas temperature sensor T1: high (DTC P3003 / 3242-0)
7.2.58 Emergency exhaust gas temperature sensor T2: high (DTC P3004 / 3246-0)
7.2.59 Excessive PM3 (DTC P3006 / 3701-15)
7.2.60 Excessive PM4 (DTC P3007 / 3701-16)
7.2.61 Excessive PM5 (DTC P3008 / 3701-0)
7.2.62 Boost pressure low (DTC P3011 / 132-15)
7.2.63 Low coolant temperature in parked regeneration (DTC P3012 / 523589-17)
7.2.64 Parked regeneration time out (DTC P3013 / 523590-16)
7.2.65 Water in fuel filter failure (DTC P3014 / 97-31)
7.2.66 Loss of function of DPF (PCD) (DTC P3015 / 3936-2)
7.2.67 All exhaust gas temperature sensor failure (DTC P3018 / 523599-0)
7.2.68 Initial pump-calibration incomplete (DTC P3019 / 523600-0)
7.2.69 High exhaust gas temperature after emergency high temperature DTC (DTC P3023 / 523601-0)
7.2.70 High frequency of regeneration (DTC P3024 / 523602-0)
7.2.71 Overheat pre-caution (DTC P3025 / 523603-15)
7.2.72 Exhaust throttle valve error (DTC P340C / 523637-12)
7.2.73 CAN2 Bus off (DTC U0075 / 523547-2)
7.2.74 No communication with EGR (DTC U0076 / 523578-2)
7.2.75 CAN1 Bus off (DTC U0077 / 523604-2)
7.2.76 CAN2 Frame Error (DTC U0081 / 523548-2, U0082 / 523591-2, U0083 / 523592-2, U0086 / 523595-2)
7.2.77 No Communication With Exhaust Throttle Valve (DTC U1000 / 523637-2)
8. Inspection procedure for each system
8.1 Air intake system inspection procedure
8.1.1 Checking air cleaner
8.1.2 Checking suction path
8.1.3 Checking DPF filter comp
8.2 Fuel system inspection procedure
8.2.1 Fuel
8.2.2 Biodiesel fuel
8.2.3 Fuel filter
8.2.4 Criteria at the entrance of supply pump
8.2.5 Checking fuel system (Remaining fuel quantity and properties)
8.2.6 Checking inside of the tank (Checking for tank modification / additions, position of fuel pipe inlet / outlet, clogging and holes)
8.2.7 Checking external fuel path conditions (Crushed hose, clogging, air introduction at hose connection)
8.2.8 Checking water separator
8.2.9 Checking fuel feed pump
8.2.10 Checking fuel filter clogged
8.2.11 Checking engine oil level increase (Engine internal leak)
8.2.12 Checking high pressure piping and CRS components (such as the fuel injector and the supply pump) for fuel leakage (Engine external leak)
8.3 Electric system inspection procedure
8.3.1 Basics of checking electrical / electronic circuit systems
8.3.2 Verifying connector connection fault
8.3.3 Checking power and ground system (Main relay, ECU circuit)
INDEX