Table Of Contents - Kubota V3800-CR-TE4 Diagnosis Manual

Table of Contents

Contents3
Safety First4
Before Servicing And Repairing4
Safety Starting4
Safety Working5
Avoid Fires5
Ventilate Work Area6
Prevent Acid Burns6
Dispose Of Fluids Properly6
Prepare For Emergencies6
Common Rail System7
Mechanism8
Table Of Contents8
Basic System Information9
System Configuration9
Fuel System10
Intake And Exhaust System11
Wiring Diagram12
System Wiring Diagram12
Available Data Monitor Signals (Level 2)13
Monitor Items13
Normal Value16
Ecu Terminal Layout 1 (A: 96 Pins)19
Ecu Terminal Layout 2 (B: 58 Pins)22
Servicing25
General28
Overall Diagnostic Procedure28
Questioning29
Questioning Points29
Trouble Check Sheet For Kubota Common Rail System29
Tractor Details30
Replace Parts Details30
Customer Complaint30
Condition When Problem Occurs (Duplicated Answers Can Be Possible)31
Dealer Check31
List Of Malfunction Symptom32
Actions For Non-Reoccurring Malfunctions33
Diagnostic Tool Connection Procedure35
Diagnostic Connector Positions35
Checking The Communication Operation Of The Interface (Dst-I)37
Dst-I Operation Status And Display Specification37
Light Operation During Normal Conditions37
Light Operation During Abnormal Operation37
Checking The Operation Of The Ecu38
Starting Diagmaster38
Dst-I Communication Settings39
Active Test And Supply Pump Difference Learning44
Operation Details44
Injector Non-Injection Instruction44
Egr Actuation Test44
Air Heater Relay Actuation Test45
Supply Pump Difference Learning45
Diagnosis By Malfunction Symptom46
List Of Malfunction Causes By Symptom46
Engine Warning Light Comes On50
Engine Does Not Start50
Check The Fuel Feed Pump Operation51
Check The Dtc51
Communication Error51
Dtc Presently Existing51
Check The Starting Assist Device52
Check The Intake System52
Check The Fuel System53
Check The Ecu Power Supply And Grounding53
Check The Crankshaft Position Sensor53
Supply Pump Difference Learning And Checking The Monitor54
Check The Engine54
Takes A Long Time Before Engine Starts55
Possible Causes55
Fuel Feed Pump Operation Fault55
Past Dtc Only56
Idle Failure60
Engine Fault60
Control System60
Check The Injector61
Engine Noise64
High Fuel Consumption66
Usage Habits Of The User Or Use Of Non-Standard Parts66
Powertrain Malfunctions Not Involving The Engine66
Check The Engine And Machine Condition68
Check The Camshaft Position Sensor70
Check The Data Related To Pressure Control70
Poor Acceleration (Insufficient Output)72
Abnormal Black Smoke Emitted78
Abnormal White Smoke Emitted83
Engine Stalls On Deceleration89
Check The Final Accelerator Open Position91
Diagnostic Procedure By Dtc94
Dtc List94
Ne-G Phase Shift94
Intake Air Temperature Built-In Maf Sensor Abnormality95
Pressure Limiter Emergency Open96
High Rail Pressure97
Scv Stuck98
Fuel Leak (In High Pressured Fuel System)99
Intake Air Volume: Low100
Maf Sensor Abnormality101
Intake Air Temperature Error102
Coolant Temperature Sensor Abnormality103
Fuel Temperature Sensor Abnormality104
Rail Pressure Sensor Abnormality105
Injector Charge Voltage: High106
Open Circuit Of Harness/Coil107
Engine Overheat109
Engine Overrun109
Boost Pressure Sensor Abnormality110
Crankshaft Position Sensor (Ne Sensor) Abnormality111
Camshaft Position Sensor (G Sensor) Abnormality112
Air Heater Relay Driving Circuit Abnormality113
Egr Actuator Abnormality114
Oil Pressure Error115
Exhaust Gas Temperature Sensor 1 (T1) Abnormality116
Exhaust Gas Temperature Sensor 0 (T0) Abnormality117
Battery Voltage Abnormality118
Qr Data Abnormality119
Ecu Flash Rom And Cpu Abnormality120
Injector Charge Voltage Abnormality121
Scv Drive System Abnormality122
Sensor Supply Voltage 1 Abnormality123
Sensor Supply Voltage 2 Abnormality124
Main Relay Is Locked In Closed Position125
Pump Seizing126
Intake Throttle Feedback Error128
Accelerator Position Sensor Error (Can)128
Common 1 System Injector Drive Circuit Open129
Common 1 Twv Actuation System Short130
Common 2 System Injector Drive Circuit Open131
Common 2 Twv Actuation System Short132
Barometric Pressure Sensor Error133
Egr (Dc Motor) Abnormality134
Exhaust Gas Temperature Sensor 2 (T2) Abnormality135
Differential Pressure Sensor 1 Abnormality136
Intake Throttle Lift Sensor Abnormality137
Emission Deterioration138
Exhaust Gas Temperature Sensor 0139
Exhaust Gas Temperature Sensor 1139
Exhaust Gas Temperature Sensor 2: Emergency High140
Excessive Pm3141
Excessive Pm4142
Excessive Pm5142
Boost Pressure Low143
Low Coolant Temperature In Parked Regeneration144
Parked Regeneration Time Out144
All Exhaust Gas Temperature Sensor Failure145
High Frequency Of Regeneration146
Can2 Bus Off146
No Communication With Egr147
Can1 Bus Off147
Can2 Frame Error148
Ne - G Phase Shift (Dtc P0016 / 636-7)152
Crankshaft Position Sensor Side152
Camshaft Position Sensor Side152
Intake Air Temperature Built-In Maf Sensor: Abnormality (Dtc P0072 / 171-4, Dtc P0073 / 171-3)153
Check The Intake Air Temperature Sensor Signals154
Measure The Resistance Between Terminals155
Check The Sensor155
Measure The Ecu Terminal Voltage155
Behaviour During Malfunction156
Dtc Set Preconditions156
Dtc Set Parameter156
Recovery From Error156
Pressure Limiter Emergency Open (Dtc P0087 / 633-7)156
Diagnostic Procedure For Pressure System Dtcs157
If A Dtc Currently Exists157
If Only A Past Dtc Exists157
Check The Data Related To The Rail Pressure158
Check The Fuel System For The Existence Of Air158
Check The Rail Pressure Sensor159
Check The Dtc Again159
Check The Scv-Related Data160
Pump Difference Learning Status160
Detection Item161
High Rail Pressure (Dtc P0088 / 157-0)161
Scv Stuck (Dtc P0089 / 1347-7)166
Fuel Leak (In High Pressured Fuel System) (Dtc P0093 / 1239-1)171
Intake Air Volume: Low (Dtc P0101 / 132-1)177
Maf Sensor Abnormality (Dtc P0102 / 132-4, P0103 / 132-3)178
Measure The Sensor Terminal Voltage179
Dtc Judgment179
Intake Air Temperature Error (Dtc P0112 / 172-4, P0113 / 172-3)180
Coolant Temperature Sensor Abnormality (Dtc P0117 / 110-4, P0118 / 110-3)183
Fuel Temperature Sensor Abnormality (Dtc P0182 / 174-4, P0183 / 174-3)186
Rail Pressure Sensor Abnormality (Dtc P0192 / 157-4, P0193 / 157-3)189
Injector Charge Voltage: High (Dtc P0200 / 523535-0)193
Open Circuit Of Harness/Coil (Dtc P0201 / 651-3, P0202 / 653-3, P0203 / 654-3, P0204 / 652-3)195
Measure The Resistance Between Ecu Terminals196
Check The Connector And Wiring Harnesses For Poor Contact197
Measure The Resistance Between Injector Terminals197
Engine Overheat (Dtc P0217 / 110-0)198
Engine Overrun (Dtc P0219 / 190-0)200
Boost Pressure Sensor Abnormality (Dtc P0237 / 102-4, P0238 / 102-3)201
Crankshaft Position Sensor (Ne Sensor) Abnormality (Dtc P0335 / 636-8, P0336 / 636-2)205
Camshaft Position Sensor (G Sensor) Abnormality (Dtc P0340 / 723-8, P0341 / 723-2)210
Air Heater Relay Driving Circuit Abnormality (Dtc P0380 / 523544-3 / 523544-4)214
Check The Wiring Harness / Connector216
Check The Relay216
Ecu Replacement Check216
Egr Actuator Abnormality (Dtc P0403 / 523574-3, Dtc P0404 / 523574-4, P0409 / 523572-4)217
Oil Pressure Error (P0524 / 100-1)220
Check The Wiring Related To The Oil Pressure Switch221
Check The Oil Pressure Switch221
Check The Oil And Oil Filter221
Exhaust Gas Temperature Sensor 1 (T1) Abnormality (Dtc P0543 / 3242-4, P0544 / 3242-3)222
Exhaust Gas Temperature Sensor 0 (T0) Abnormality (Dtc P0546 / 4765-4, P0547 / 4765-3)225
Battery Voltage Abnormality (Dtc P0562 / 168-4, P0563 / 168-3)228
Qr Data Abnormality (Dtc P0602/523538-2, P0602/523538-7)231
Ecu Flash-Rom And Cpu Abnormality (Dtc P0605 / 628-2, P0606 / 1077-2, P0606/ 523527-2)232
Injector Charge Voltage Abnormality (Dtc P0611 / 523525-1)234
Scv Drive System Abnormality (Dtc P0628 / 1347-4, P0629 / 1347-3)236
Sensor Supply Voltage 1 Abnormality (Dtc P0642 / 3509-4, P0643 / 3509-3)240
Sensor Supply Voltage 2 Abnormality (Dtc P0652 / 3510-4, P0653 / 3510-3)242
Main Relay Is Locked In Closed Position (Dtc P0687 / 1485-2)244
Pump Seizing (Dtc P1274 / 523539-2, P1275 / 523540-2)247
Intake Throttle Feedback Error (Dtc P2108 / 523580-2)253
Accelerator Position Sensor Error (Can) (Dtc P2131 / 523543-2)255
Common 1 System Injector Drive Circuit Open (Dtc P2146 / 523523-2)257
Common 1 Twv Actuation System Short (Dtc P2147 / 523523-4, P2148 / 523523-3)260
Common 2 System Injector Drive Circuit Open (Dtc P2149 / 523524-2)264
Common 2 Twv Actuation System Short (Dtc P2150 / 523524-4, P2151 / 523524-3)267
Barometric Pressure Sensor Error (Dtc P2228 / 108-4, P2229 / 108-3)271
Egr (Dc Motor) Abnormality (Dtc P2413 / 523575-7, P2414 / 523576-2, P2415 / 523577-2)273
Exhaust Gas Temperature Sensor 2 (T2) Abnormality (Dtc P242C / 3246-4, P242D / 3246-3)276
Differential Pressure Sensor 1 Abnormality (Dtc P2454 / 3251-4, P2455 / 3251-3)279
Intake Throttle Lift Sensor Abnormality (Dtc P2621 / 523583-4, P2622 / 523582-3)283
Emission Deterioration (Dtc P3001 / 3252-0)285
Exhaust Gas Temperature Sensor 0: Emergency High (Dtc P3002 / 4765-0)287
Exhaust Gas Temperature Sensor 1: Emergency High (Dtc P3003 / 3242-0)289
Check The Exhaust Gas Temperature290
Exhaust Gas Temperature Sensor 2: Emergency High (Dtc P3004 / 3246-0)291
Excessive Pm3 (Dtc P3006 / 3701-15)294
Excessive Pm4 (Dtc P3007 / 3701-16)295
Excessive Pm5 (Dtc P3008 / 3701-0)296
Boost Pressure Low (Dtc P3011 / 132-15)297
Low Coolant Temperature In Parked Regeneration (Dtc P3012 / 523589-17)299
Parked Regeneration Time Out (Dtc P3013 / 523590-16)300
All Exhaust Gas Temperature Sensor Failure (Dtc P3018 / 523599-0)302
High Frequency Of Regeneration (Dtc P3024 / 523602-0)303
Can2 Bus Off (Dtc U0075 / 523547-2)305
No Communication With Egr (Dtc U0076 / 523578-2)307
Can1 Bus Off (Dtc U0077 / 523604-2)309
Can2 Frame Error (Dtc U0081 / 523548-2, U0082 / 523591-2, U0083 / 523592-2)310
Inspection Procedure For Each System312
Air Intake System Inspection Procedure312
Fuel System Inspection Procedure314
Biodiesel Fuel314
When The B7 Blended Fuel Is Used314
When The B5 Blended Fuel Is Used314
Precautions In Handling Biodiesel Fuels315
Fuel Filter315
Criteria At The Entrance Of Supply Pump315
Electric System Inspection Procedure320
Basics Of Checking Electrical / Electronic Circuit Systems320
Measure The Ecu Terminal Voltage And Resistance320
Open Circuit Check320
Check For Continuity321
Check Voltage321
Short Circuit Check321
Ground Continuity Check322
Measurement Results322
Faulty Circuit322
Connector Connection Fault Verification Method323
Checking The Power And Ground System324
Measure The Ecu +Bp And Ground Voltage325
Check The Relay Terminal Voltage -1325
Ground Terminal Unsatisfactory325
+Bp Terminal Unsatisfactory325
Check The Relay Terminal Voltage - 3326
Check The Relay Terminal Voltage - 4326
Check The Relay Terminal Voltage - 5326
Check The Key Switch Signal327
Check The Key Switch327