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5.12.17 P0335 No pulse from crankshaft position sensor (NE sensor) (636-8) ....5–33 5.12.18 P0336 Crankshaft position sensor (NE sensor) pulse number error (636-2) ... 5–34 5.12.19 P0340 No pulse from camshaft position sensor (G sensor) (723-8) .
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5.13.10 Measuring Output Voltage of the ECU Connectors - Rail Pressure Sensor ... . 5–65 5.13.11 Measuring Output Voltage - Rail Pressure Sensor ....... 5–65 5.13.12 Measuring Power Supply Voltage - Rail Pressure Sensor .
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6.5.2 Removing and Replacing the DOC Thermal Switches ......6–11 GENERAL GENERATOR SET MAINTENANCE .
Section 1 Safety General Safety Notices Installation and servicing of generator set equipment can be hazardous due to system belts, radiator fan, and electrical components. Only trained and qualified service personnel should install, repair, or service generator set equipment. When working on generator set equipment, observe all potential Danger, Warning and Caution hazards, including those shown below and on hazard labels attached to the unit.
1.4.2 Fluids • The engine is equipped with a pressurized cooling system. Under normal operating conditions, the coolant in the engine and radiator is under high pressure and is very hot. Contact with hot coolant can cause severe burns. Do not remove the cap from a hot radiator. If the cap must be removed, do so very slowly in order to release the pressure without spray.
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WARNING Before servicing the unit, make sure the unit is OFF and the negative battery terminal is disconnected. Follow your regional lockout tagout procedure. WARNING Beware of moving poly V-belt, belt driven components and hot exhaust components. WARNING Under no circumstances should ether or any other unauthorized starting aids be used in conjunction with the air intake heater.
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CAUTION Use only ethylene glycol anti-freeze (with inhibitors) in system. Use of glycol by itself will damage the cooling system. CAUTION Always cover the engine inlet tube while the air cleaner is being serviced. CAUTION When reassembling the air cleaner, make sure the clamp bolt faces out, away from the fuel filter. If the clamp bolt is assembled facing in, it can contact the fuel filter and cause excessive wear.
Section 2 Installation and Removal WARNING To prevent injury, the procedures provided for installation and removal of the generator set must be followed carefully. WARNING Disconnect the power plug before removing the generator set. CAUTION Prior to first use of the genset, ensure all shipping packaging and debris is removed and discarded.
Removal 1. Move the forks into the fork pockets on the generator set. Attach the safety chain (A) between fork pockets on the generator set and fork truck. 2. Release the locking brackets (D) on each side of the generator set. 3.
Section 3 Description Introduction The Carrier Transicold model 69RG15 Series 24 diesel-driven generator set provides a constant electrical power supply for all-electric refrigeration units. The 69RG15 generator set is a clip-on unit (Figure 3.1, Figure 3.2) mounted to the front of the container either by pin mounts located on the top channel or by optional clamp mounts located on either side of the generator set.
Alternating Current Generator The alternating current (AC) generator converts mechanical energy produced by the engine into electrical current. The AC generator bolts directly to the engine and supplies nominal 50/60Hz power based on the load requirement. Generator sets will start at 50Hz. Once the unit is running, the voltage controller (see Section 3.4) reads the voltage output of the generator and adjusts accordingly to keep voltage within ISO limits.
Engine The engine (Figure 3.5) is a vertical, in-line four cylinder diesel engine that is directly connected to the AC generator. The engine is a Kubota V2403-CR series, model number V2403-CR-E4B-CTD-3, which uses a diesel engine fuel injection control system for the precise metering and delivery of fuel into the engine combustion chamber.
Engine Body The engine body is the main part of the engine. It consists of cylinder related components, primary motion components and valve train mechanisms. Each of the parts are designed and assembled with passages for circulation of lubricating oil and coolant within the engine. Figure 3.6 Engine Body 1) Cylinder Head Cover 9) Main Bearing Case...
Figure 3.8 Fuel System Components - Kubota 1) Fuel Feed Pump 3) Rail Assembly 2) Fuel Supply Pump, High Pressure 4) Fuel Injectors (4) - - - - - 3.7.1 Fuel System Flow See fuel system diagram, Figure 3.9, for reference. Fuel exits the tank at low pressure and flows through the fuel shutoff valve to a pre-filter pump.
3.7.3 Pre-Filter Fuel Pump The pre-filter fuel pump sends fuel to the fuel filter at a flow that allows for proper filter performance. Figure 3.10 Pre-Filter Pump 3.7.4 Fuel Filter / Water Separator The fuel filter (Figure 3.11) is a fuel particle filtration system that helps prevent premature injector and pump wear by delivering cleaner fuel to the engine.
3.7.6 High Pressure Supply Pump The high pressure supply pump (Figure 3.13) pressurizes and supplies fuel to the rail assembly at more than twice the pressure of conventional pumps. The pump consists of a suction control valve (SCV), overflow valve, IO valve and zero delivery drain.
See Section 3.7.9 for ECU details. NOTE: The injectors are referred to as ENINJ1, ENINJ2, ENINJ3, ENINJ4 on the carrier system schematic. There are three injections for every one combustion cycle: • Pre Injection. A small amount is injected to reduce the effects of initial combustion and to lower nitrogen oxides and noise.
ECU is performed by sending instructions to each actuator (suction control valve, individual injectors) based on input signals received from each sensor. NOTE: The ECU is listed as ENCU on the carrier system schematic. Figure 3.16 ECU with Related Actuators and Sensors...
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It is mounted at the end of the rail assembly. NOTE: This is referred to as the Engine Fuel Rail Pressure Sensor (ENFRP) on the carrier system schematic. 3.7.9.3...
Engine Intake and Exhaust System The air intake system supplies clean air to the engine. The exhaust system collects exhaust gases after combustion and discharges them to the atmosphere once after-treatment occurs. Figure 3.17 Intake and Exhaust Flow 1) Air Cleaner 4) Combustion Chamber 2) Intake Manifold 5) Exhaust Manifold...
Figure 3.18 Engine Air Cleaner 1) Air Cleaner, Filter 3) Air Filter Minder / Indicator 2) Air Inlet Hose 4) Air Outlet Hose - - - - - Figure 3.19 Air Filter Minder / Indicator 3.8.2 Intake Manifold The intake manifold is mounted on the intake air side of the cylinder head. Its primary function is to distribute intake air to each cylinder.
3.8.5 Engine Exhaust After-Treatment System The Diesel Oxidation Catalyst (DOC) burns particulate matter, such as soot, contained in the exhaust gas. A post injection occurs in the combustion chamber (not during combustion) to raise the temperature inside the DOC to combust particulate matter.
3.10 Engine Cooling System The engine cooling system (Figure 3.22) uses extended life coolant and a radiator to keep the engine from overheating. The radiator transfers the heat from the engine coolant to the surrounding air. The water pump and the radiator cooling fan are belt-driven from the engine crankshaft.
3.12 Control Panel and Control Box Components The control panel and control box (Figure 3.24) contain components required for monitoring and controlling the generator set unit. Figure 3.24 Control Panel and Control Box Control Panel Control Box 1) Water Temperature Gauge (WTG) 8) Engine Speed Relay (ENSR) 2) Oil Pressure Gauge (OPG) 9) Glow Plug Relay (GPR)
3.12.3 Total Time Meter The total time meter (TT) calculates the total hours the unit has been running, which provides an accurate readout of accumulated engine running time. This data can be used to establish proper maintenance schedules, refer to Table 6–2.
3.13 Receptacle Box Components The receptacle box (Figure 3.25) contains components required for monitoring and controlling the genset unit. Figure 3.25 Receptacle Box 1) Access Cover 5) Voltage Controller Fuse (VCF1) 2) Circuit Breaker (CB1) Genset 6) Voltage Controller Fuse (VCF2) 3) Receptacle 7) Battery Charger Fuse (BCF3) 4) Voltage Controller (VC)
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Table 3–1 Safety Devices Unsafe Condition: Excessive current draw by the ignition switch, starter switch, total time meter (TT), water temperature gauge (WTG) and oil pressure gauge (OPG). Safety Switch Fuse 1, 2, 3 (replace) Switch Setting Trips at 5 amps Pre-Filter Fuel Pump Unsafe Condition: Excessive current draw on the pre-filter fuel pump...
3.15 Unit Specifications Table 3–2 Fuel Tank Capacity: Nominal tank size: 120 gallon Fill capacity: 120 gallon Draw capacity: 119 gallon (Allows for DOT required 5% vapor space) Unit Weight: Engine (Dry) without accessories: 1875 lb (851 kg) approximate Table 3–3 Generator Output: 15 KW, 18.75 KVA, 0.8 pf KW Output Voltage:...
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Table 3–4 Engine Data (Continued) Lube Oil Specification Use a heavy duty lubricating oil conforming to American Petroleum Institute (API) Service Classification CK-4 or better. Lube Oil Viscosity For outdoor temperatures -18° to 7°C (0 to 45°F): SAE: 5W30 For outdoor temperatures above 7°C (45°F): SAE: 10W30 or 15W40 Fuel Specifications Since KUBOTA diesel engines of less than 56 kW (75 hp) utilize EPA Tier 4 and Interim Tier 4 standards, the use of ultra low sulfur fuel is mandatory for these engines, when...
Section 4 Operation Pre-Start Inspection CAUTION Prior to first use of the genset, ensure all shipping packaging and debris is removed and discarded. 1. Check engine lubrication and fuel filters, oil lines, and connections for leaks. If required, tighten connections and / or replace gaskets.
Procedure: 1. Make sure that circuit breaker CB-1 is in the OFF position. 2. Hook up the 460 volt cable from the refrigerated unit to the generator set receptacle. 3. Turn the ignition switch to the RUN position. 4. Leave the generator set in the RUN position for 15 seconds. Then, turn the ignition switch to the START position.
The Kubota Engine Park (KEP) website provides access to additional resources for operating, servicing and troubleshooting Kubota engines. From here, a user can download Diagmaster diagnosis software, application manuals, and service manuals. Contact a Carrier service engineer to request login credentials. KEP can be accessed by visiting https://ba.engine.kubota.com/web/guest/home...
Symptom - Engine is Starting Poorly An engine starting poorly may be occurring when one of the following symptoms is observed: • Engine can not start cranking • Engine cranks, but fails to start • Engine takes time to start Table 5–1 Engine is Starting Poorly - Causes and Actions Electrical System Cause / Action:...
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5. Go to the Data Monitor screen and bring up the following data monitor settings on the screen. • Battery Voltage, Engine Speed, Target Rail Pressure and Actual Rail Pressure, Glow Relay, Coolant Temperature, Engine Stop Flag 6. Click the Play button (green) to start data measurement and Stop button (gray) to finish. During a measurement, observe the data on screen when the engine is stopped (ignition RUN) and also when the engine cranking (ignition START).
Symptom: Actual pressure is lower than the target Cause / Action: Fuel high pressure supply is poor. Check the high pressure supply pump, suction control valve (SCV), rail, or injector. Cause / Action: Fuel supply is poor. Check the fuel tank, fuel feed pumps, fuel filter, or fuel hoses. Glow Relay | Coolant Temperature Reference: OFF: Coolant temperature 21°C or higher ON: Coolant temperature below 21°C.
Table 5–2 Engine is Operating Poorly - Causes and Actions Other Cause / Action: 1. Problem on vehicle side. Check for overload or CAN communication content. 2. Calibration or correction after maintenance was not completed. Check that an injector correction or injection timing correction was performed.
6. Click the Play button (green) to start data measurement and Stop button (gray) to finish. During a measurement, observe the data on screen when the engine is stopped (ignition RUN) and also when the engine cranking (ignition START). Check the measurements for each of the settings active in the screen and compare to the reference values given in the tables below.
Table 5–3 Engine Output is Insufficient - Causes and Actions Fuel System Cause / Action: 1. Fuel supply is poor. Check the fuel tank, fuel feed pumps, fuel filter or fuel hose. 2. Fuel high pressure supply is poor. Check the high pressure supply pump, suction control valve (SCV) or rail.
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5. Go to the Data Monitor screen and bring up the following data monitor settings on the screen. • Engine Speed, Target Rail Pressure & Actual Rail Pressure, Final Fuel Injection Quantity, Coolant Temperature, Atmospheric Pressure 6. Click the Play button (green) to start data measurement and Stop button (gray) to finish. During a measurement, observe the data on screen when the engine is stopped (ignition RUN) and also when the engine cranking (ignition START).
Coolant Temperature: Reference: After warmup, 80.5 to 95°C (At no-load maximum speed) Symptom: Temperature is too low Cause / Action: Coolant temperature rise is insufficient. Check the thermostat. Sensor signal error. Check the coolant temperature sensor. Operating environment problem. Check for cold outside air. Symptom: Temperature is too high Cause / Action: Overheating.
Table 5–4 Engine Noise is Abnormal - Causes and Actions Other Cause / Action: 1. Engine drag. Check the power transmission parts on the vehicle side. 2. Calibration or correction after maintenance was not completed. Check that an injector correction or injection timing compensation was performed.
6. Click the Play button (green) to start data measurement and Stop button (gray) to finish. During a measurement, observe the data on screen when the engine is stopped (ignition RUN) and also when the engine cranking (ignition START). Check the measurements for each of the settings active in the screen and compare to the reference values given in the tables below.
Table 5–5 Engine Emission Deterioration - Causes and Actions Engine Body Cause / Action: 1. Compression leakage. Check the cylinder, piston ring, valve, cylinder head, timing gear, or valve clearance. 2. Oil rise. Check the cylinder or piston ring. 3. Oil drop. Check the valve, valve stem seal or cylinder head. Fuel System Cause / Action: 1.
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5. Go to the Data Monitor screen and bring up the following data monitor settings on the screen: • Target Rail Pressure & Actual Rail Pressure, Coolant Temperature, Atmospheric Pressure 6. Click the Play button (green) to start data measurement and Stop button (gray) to finish. During a measurement, observe the data on screen when the engine is stopped (ignition RUN) and also when the engine cranking (ignition START).
Symptom Temperature is too high Cause / Action: Overheating. Check the radiator, radiator cap, fan belt, fan drive or thermostat. Pressure sensor signal. Check the coolant temperature sensor. Operating environment problem. Check for hot outside air condition. Atmospheric Pressure: Reference: About 100 kPa (At no-load maximum speed) Symptom: Temperature is too low Cause / Action: Operating environment problem.
Alternating Current (AC) Generator Troubleshooting Table 5–7 Alternating Current Generator - Causes and Actions Condition: No voltage. Cause / Action: 1. Rotor magnetism is lost. Replace. 2. Circuit breaker is tripped. Check CB1. 3. Open in stator windings. Replace. 4. Short circuited. Replace. 5.
5.10 Voltage Controller Troubleshooting The voltage controller has one green indicator light and one yellow indicator light. When the green light is illuminated, it means that the voltage controller is receiving power. The yellow light only illuminates (flashes) to indicate that there is a problem. Table 5–8 Voltage Controller - Causes and Actions Condition: Green LED is not illuminated.
Table 5–9 High Voltage Circuit Troubleshooting Item: Voltage Controller (VC) and Fuses 4. Verify voltage controller has green light illuminated and yellow light flashing at 1 Hz. Yellow light flashing sequence other than at 1 Hz indicates a fault condition. •...
5.12.1 P0016 NE-G phase shift (636-7) SPN Name: Engine Position Sensor Cause: A large phase shift occurs between NE pulse and G pulse. NE refers to the crankshaft position sensor (Engine speed sensor) G refers to the camshaft position sensor DTC set preconditions: •...
5.12.2 P0087 Pressure limiter emergency open (633-7) SPN Name: Engine Fuel Actuator 1 Control Command Cause: Pressure limiter emergency is open DTC set preconditions: Sensor supply voltage VCC# is normal DTC set parameter: • Pressure limiter emergency is open • Engine speed is more than 10 rpm Time to action / number of One time or more error detections:...
5.12.3 P0088 High rail pressure (157-0) SPN Name: Engine Injector Metering Rail 1 Pressure Cause: Actual pressure exceeds the command pressure DTC set preconditions: • Rail pressure sensor is normal • Sensor supply voltage VCC# is normal DTC set parameter: Actual pressure is more than 179 MPa (1830 kg/cm , 26000 psi) Time to action / number of...
5.12.4 P0089 SCV stuck (1347-7) SPN Name: Engine Fuel Pump Pressurizing Assembly #1 Cause: Suction control valve (SCV) is stuck at the open position. Actual rail pressure continuously exceeds the command rail pressure. DTC set preconditions: • Engine is running (Q: 3 mm /st or more) •...
5.12.5 P0093 Fuel leak high pressure fuel system (1239-1) SPN Name: Engine Fuel Leakage 1 Cause: Fuel leak from the high pressure fuel system. Fuel consumption is calculated from the difference of fuel pressure before and after the injection. And the error will be detected when excess fuel consumption is found.
5.12.6 P0117 Coolant temperature sensor: low (110-4) SPN Name: Engine Coolant Temperature Cause: Ground short circuit of the coolant temperature sensor or harness. DTC set preconditions: Battery voltage is normal DTC set parameter: Voltage of the coolant temperature sensor is 0.176 V or less. Time to action / number of 3 seconds or more error detections:...
5.12.7 P0118 Coolant temperature sensor: high (110-3) SPN Name: Engine Coolant Temperature Cause: Open circuit or +B short circuit of the coolant temperature sensor or harness. DTC set preconditions: Battery voltage is normal DTC set parameter: Voltage of the coolant temperature sensor is 4.87 V or more. Time to action / number of 3 seconds or more error detections:...
5.12.8 P0192 Rail pressure sensor: low (157-4) SPN Name: Engine Injector Metering Rail 1 Pressure Cause: Ground short circuit of the rail pressure sensor or harness. Or, the rail pressure sensor has failed. DTC set preconditions: • Battery voltage is normal •...
5.12.9 P0193 Rail pressure sensor: high (157-3) SPN Name: Engine Injector Metering Rail 1 Pressure Cause: • Open circuit or +B short circuit of the rail pressure sensor or harness. Or, the rail pressure sensor has failed. DTC set preconditions: •...
5.12.10 P0200 Injector charge voltage: high (523535-0) SPN Name: proprietary Cause: Injector charge voltage is high. DTC set preconditions: • Battery voltage is normal • CPU is normal DTC set parameter: Injector charge voltage: High Time to action / number of Transient error detections: Limp home action:...
5.12.11 P0201 Open circuit of harness or coil in 1st cylinder injector (651-3) SPN Name: Engine Injector Cylinder #01 Cause: Open circuit of either the harness or the injector coil. DTC set preconditions: • Engine is operating • Battery voltage is normal •...
5.12.12 P0202 Open circuit of harness or coil in 3rd cylinder injector (653-3) SPN Name: Engine Injector Cylinder #03 Cause: Open circuit of either the harness or injector coil. DTC set preconditions: • Engine is operating • Battery voltage is normal •...
5.12.13 P0203 Open circuit of harness or coil in 4th cylinder injector (654-3) SPN Name: Engine Injector Cylinder #04 Cause: Open circuit of either the harness or the injector coil. DTC set preconditions: • Engine is operating • Battery voltage is normal •...
5.12.14 P0204 Open circuit of harness or coil in 2nd cylinder injector (652-3) SPN Name: Engine Injector Cylinder #02 Cause: Open circuit of either the harness or the injector coil. DTC set preconditions: • Engine is operating • Battery voltage is normal •...
5.12.15 P0217 Engine overheat (110-0) SPN Name: Engine Coolant Temperature Cause: Overheat of engine coolant temperature. DTC set preconditions: Coolant temperature sensor is normal. DTC set parameter: Engine coolant temperature is 120°C (248°F) or more. Time to action / number of 5 seconds or more error detections: Limp home action:...
5.12.17 P0335 No pulse from crankshaft position sensor (NE sensor) (636-8) SPN Name: Engine Position Sensor Cause: Open circuit or short circuit of the crankshaft position sensor (NE) or harness. Or, the sensor has failed. DTC set preconditions: • Battery voltage is normal •...
5.12.18 P0336 Crankshaft position sensor (NE sensor) pulse number error (636-2) SPN Name: Engine Position Sensor Cause: Open circuit or short circuit of the crankshaft position sensor (NE) or harness. Or, the sensor has failed. DTC set preconditions: • Battery voltage is normal •...
5.12.19 P0340 No pulse from camshaft position sensor (G sensor) (723-8) SPN Name: Engine Speed 2 Cause: Open circuit or short circuit of the camshaft position sensor (G) or harness. Or, the sensor has failed. DTC set preconditions: • Battery voltage is normal •...
5.12.20 P0341 Camshaft position sensor (G sensor) pulse number error (723-2) SPN Name: Engine Speed 2 Cause: Open circuit or short circuit of the camshaft position sensor (G) or harness. Or, the sensor has failed. DTC set preconditions: • Battery voltage is normal •...
5.12.21 P0380 Glow relay abnormality open circuit (676-5) SPN Name: Engine Glow Plug Relay Cause: Open circuit of the air glow relay. DTC set preconditions: • Battery voltage is normal • Glow relay is being energized DTC set parameter: Open circuit of either the harness or the relay coil. Time to action / number of 3 seconds or more error detections:...
5.12.22 P0380 Glow relay abnormality +B short (523544-3) SPN Name: proprietary Cause: +B short of the glow relay driving circuit. DTC set preconditions: • Battery voltage is normal • Glow relay is being energized DTC set parameter: +B short circuit of the harness. Time to action / number of 3 seconds or more error detections:...
5.12.23 P0380 Glow relay abnormality ground short (523544-4) SPN Name: proprietary Cause: Ground short of glow relay driving circuit DTC set preconditions: • Battery voltage is normal • Glow relay is being energized DTC set parameter: Ground short circuit of the harness Time to action / number of 3 seconds or more error detections:...
5.12.24 P0381 Glow relay driving circuit overheat (676-0) SPN Name: Engine Glow Plug Relay Cause: (s) Overheat of the glow plug driving circuit. DTC set preconditions: • Ignition switch is ON • Battery voltage is normal • Glow relay is being energized DTC set parameter: Starting aid relay coil resistance or load is too high for the specified value of the ECU.
5.12.25 P0524 Engine oil pressure low error (100-1) SPN Name: Engine Oil Pressure Cause: Low oil pressure (LOP) switch DTC set preconditions: • Battery voltage is normal • Ignition switch turn ON • Starter switch signal is not activated • 10 seconds or more after engine start (engine speed is 700 rpm or higher) DTC set parameter: Oil pressure switch ON condition continues for one second or more.
5.12.26 P0562 Battery voltage: low (168-4) SPN Name: Battery Potential / Power Input 1 Cause: Open circuit, short circuit or damage of the wire harness. Or, a battery fault is present. DTC set preconditions: • Ignition switch is ON • Starter switch signal is not activated DTC set parameter: •...
5.12.27 P0563 Battery voltage: high (168-3) SPN Name: Battery Potential / Power Input 1 Cause: Open circuit, short circuit or damage of the wire harness. Or, a battery fault is present. DTC set preconditions: • Ignition switch is ON • Starter switch signal is not activated DTC set parameter: ECU recognition of battery voltage is 16 V or more.
5.12.28 P0602 QR data error (data write error) (523538-2) SPN Name: Proprietary Cause: QR data read error has occurred. An electromagnetic interference (EMI) may have caused the temporary malfunction. DTC set preconditions: Ignition switch is ON DTC set parameter: QR data read error from EEPROM Time to action / number of Transient error detections:...
5.12.30 P0605 ECU flash ROM error (682-2) SPN Name: Program Memory Cause: FLASH ROM error has occurred. An electromagnetic interference (EMI) may have caused the temporary malfunction. DTC set preconditions: Ignition switch is ON DTC set parameter: • Check-sum error •...
5.12.32 P0606 ECU CPU error (Monitoring IC) (523527-2) SPN Name: proprietary Cause: Failure of monitoring IC of CPU. An electromagnetic interference (EMI) may have caused the temporary malfunction. DTC set preconditions: • Ignition switch is ON • Battery voltage is 10V or more •...
5.12.34 P0627 SCV drive system abnormality open circuit (1347-5) SPN Name: Engine Fuel Pump Pressurizing Assembly #1 Cause: Open circuit of the suction control valve (SCV) DTC set preconditions: • Battery voltage is normal • Ignition switch is ON • Starter switch signal is not activated DTC set parameter: Open circuit of the suction control valve (SCV) Time to action / number of...
5.12.35 P0628 SCV drive system abnormality ground short (1347-4) SPN Name: Engine Fuel Pump Pressurizing Assembly #1 Cause: Ground short circuit of the suction control valve (SCV). DTC set preconditions: • Battery voltage is normal • Ignition switch is ON •...
5.12.36 P0629 SCV drive system abnormality B + short (1347-3) SPN Name: Engine Fuel Pump Pressurizing Assembly #1 Cause: +B short circuit of the suction control valve (SCV). DTC set preconditions: • Battery voltage is normal • Starter switch is ON •...
5.12.38 P062D Internal injector drive circuit abnormality short circuit (523605-6) SPN Name: Proprietary Cause: Short circuit in injector driver IC. DTC set preconditions: • Battery voltage is normal • Ignition switch is ON DTC set parameter: Injector IC report the error Time to action / number of 3 times or more error detections:...
5.12.39 P0643 Sensor supply voltage 1 abnormality (3509-3) SPN Name: Sensor supply voltage 1 Cause: Sensor supply voltage 1 error or recognition error. DTC set preconditions: • Battery voltage is normal • Ignition switch turn ON DTC set parameter: Voltage to sensor is 4.75 V or less or voltage to sensor is 5.25 V or more Time to action / number of Transient error detections:...
5.12.40 P0653 Sensor supply voltage 2 abnormality (3510-3) SPN Name: Sensor supply voltage 2 Cause: Sensor supply voltage 2 error or recognition error. DTC set preconditions: • Battery voltage is normal • Ignition switch ON DTC set parameter: Voltage to sensor is 4.75 V or less or voltage to sensor is 5.25 V or more. Time to action / number of Transient error detections:...
5.12.41 P0663 Sensor supply voltage 3 abnormality (3511-3) SPN Name: Sensor supply voltage 3 Cause: Sensor supply voltage 3 error or recognition error. DTC set preconditions: • Battery voltage is normal • Ignition switch ON DTC set parameter: Voltage to sensor is 4.75 V or less or voltage to sensor is 5.25 V or more. Time to action / number of Transient error detections:...
5.12.43 P081A Ground short of starter (677-4) SPN Name: Engine Starter Motor Relay Cause: Ground short of starter relay driving circuit. DTC set preconditions: • Ignition switch is ON • Battery voltage is normal DTC set parameter: Ground short circuit of harness. Time to action / number of 3 seconds or more error detections:...
5.12.45 P2148 All injectors +B short or ground short (523523-3) SPN Name: Proprietary Cause: Wire harness short to +B or wire harness short to ground DTC set preconditions: • Engine is operating • Battery voltage is normal DTC set parameter: Wire harness short to +B or wire harness short to ground Time to action / number of 3 times or more...
5.12.47 P2229 Atmospheric pressure sensor high (108-3) SPN Name: Barometric Pressure Sensor or ECU internal circuit short to +B Cause: DTC set preconditions: Battery voltage is normal DTC set parameter: Barometric pressure sensor voltage is 4.85 V or more. Time to action / number of 3 seconds or more error detections: Limp home action:...
5.12.49 P2293 Pressure limiter failure after pressure relief valve (679-16) SPN Name: Pressure relief valve Cause: Rail pressure value is too high or low despite the existence of response that the pressure limiter opened. DTC set preconditions: • Battery voltage is normal •...
5.12.51 P2294 Pressure limiter error (amount of time) (679-10) SPN Name: Pressure relief valve Cause: Pressure limiter opened many times. DTC set preconditions: • Battery voltage is normal • Ignition switch is ON DTC set parameter: Pressure limiter opened more than 300 minutes. Time to action / number of Transient error detections:...
5.12.53 P3025 Overheat pre-caution (523603-15) SPN Name: proprietary Cause: Coolant temperature DTC set preconditions: Coolant temperature sensor is normal DTC set parameter: Engine coolant temperature is 110°C (230°F) or more Time to action / number of Transient error detections: Limp home action: None Behavior during Worsening exhaust gas emissions (NOx)
5.12.55 U0077 CAN1 bus off error (523604-2) SPN Name: proprietary Cause: CAN1 +B or ground short circuit or high traffic error. DTC set preconditions: • Battery voltage is normal • Ignition switch is in RUN DTC set parameter: CAN1 bus off Time to action / number of 2 seconds or more error detections:...
5.13 Related Procedures 5.13.1 Inspecting Around the Pulsar Hole on the Flywheel This procedure is related to DTC code P0016. 1. Inspect the flywheel (pulsar hole on the flywheel) for the following: • Installation not misaligned • No foreign matter adhering 2.
5.13.4 Diagnosing Low Fuel Pressure in a High Pressure System This procedure is for diagnosing a potential fuel leak in the high pressure fuel system. This procedure is related to DTC code P0093. 1. Check the Pre-work checklist (Section 6.2). Make sure fuel tank is at least half full and fuel quality meets the standard.
5.13.6 Checking the Coolant Temperature Sensor (high temperature) This procedure is to service a coolant temperature sensor high error by checking for an open circuit or a +B short circuit of the sensor or harness. This procedure is related to DTC code P0118. 1.
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5.13.10 Measuring Output Voltage of the ECU Connectors - Rail Pressure Sensor This procedure is related to DTC code P0192 and P0193. NOTE: Before diagnosing the problem, use Diagmaster to try to reproduce it based on any DTC information. Check the related signals on the Data Monitor screen. Diagnose whether it is the ECU (including connectors) or something else.
5.13.13 Measuring Power Supply Voltage of ECU Connectors - Rail Pressure Sensor This procedure is to diagnose whether the problem is the wire harness power supply voltage line (including connectors) or the ECU. This procedure is related to DTC code P0192 and P0193. 1.
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5.13.18 Check DTCs and Verify Injector Correction This procedure is related to DTC code P0602. Refer to the Diagmaster section for detailed operating procedures for using Diagmaster. 1. Turn the ignition switch to RUN position. 2. Connect a computer to the ECU and open Diagmaster software. 3.
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3. Check that there are no short circuits. • If normal, check the ECU connectors. See Section 5.13.47. • If abnormal, repair or replace the wire harness. 5.13.22 Diagnosing an Overheating Condition or Improper Rise in Temperature This diagnostic procedure is to systematically check the components suspected of causing an overheating condition.
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5.13.24 Checking a Wire Harness for Disconnection - Crankshaft Position Sensor This procedure is related to DTC codes P0335 and P0336. 1. Disconnect the connector of the crankshaft position sensor and the connector of the ECU. 2. Measure the resistance between connector terminals on the crankshaft position sensor wire harness side and ECU connector at the harness side.
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• If voltage is abnormal, check the wire harness for disconnection. See Section 5.13.28. 5.13.28 Checking a Wire Harness for Disconnection - Camshaft Position Sensor This procedure is related to DTC codes P0340 and P0341. 1. Disconnect the connector of the camshaft position sensor and the connector of the ECU. 2.
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2. Inspect the camshaft position sensor for the following: • No foreign mater stuck to sensor surface • No trace of interference with cam position pulsar gear 5.13.31 Checking a Wire Harness - Glow Relay This procedure is related to DTC codes P0380 and P0381. NOTE: Before diagnosing the problem, use Diagmaster to try to reproduce it based on any DTC information.
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5.13.33 Checking the Operation of the Low Oil Pressure Switch This procedure is related to DTC code P0524. CAUTION When checking the low oil pressure (LOP) switch, if the engine oil level is low then the engine may be damaged. So, limit the time the amount of time that the engine is started. 1.
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1. Disconnect the SCV connector. 2. Measure the resistance between the terminals on the SCV sensor. Resistance specification is: Temperature: 20°C (68°F); Resistance: 2.6 to 3.5 Ω; Insulation resistance (between terminal and body): 100 MΩ or higher. • If resistance is normal, repair or replace the wire harness (including connectors). •...
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2. Turn ignition switch to OFF and then RUN. Measure the voltage of the output terminals 50 on the ECU side of the main relay. There should be no change in voltage. • If voltage is normal, check for open circuits in the harness between the relay and the ECU. Repair and replace.
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4. Check whether or not the same DTC is detected. An electromagnetic interference (EMI) may have caused the temporary malfunction. • If the DTC is not detected, then the system has recovered. • If the DTC is detected again, then continue to next step of this procedure. 5.
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NOTE: The position and shape of the CAN2 connector varies with specifications. 6. Check the continuity of the harness between the CAN2 connector terminal and ECU terminal 62, 63. All harnesses must have continuity. • If continuity is normal, replace the ECU. •...
Kubota Engine Support The Kubota Engine Park (KEP) website provides access to additional resources for operating, servicing and troubleshooting Kubota engines. Contact a Carrier service engineer to request login credentials. KEP can be accessed by visiting https://ba.engine.kubota.com/web/guest/home...
Table 6–1 Engine Pre-Work Checklist Wiring (connector) Contamination None Broken None Damaged None Air cleaner Contamination None Clogging None Broken None Water separator Water mixed in None Contamination None Fuel filter Genuine parts Oil filter Genuine parts Modification Fuel system None Electrical system None Generator Set and Engine Maintenance Schedule...
Table 6–2 Preventative Maintenance Actions and Schedule (Continued) Daily or Inspection Item Reference 1 Yr 2 Yr 4 yr Pre-Trip Drain water from the fuel filter bowl. If bowl has water, drain none water from fuel tank sump. Engine - Lubrication System Check lubrication filters and seals for leaks.
Table 6–2 Preventative Maintenance Actions and Schedule (Continued) Daily or Inspection Item Reference 1 Yr 2 Yr 4 yr Pre-Trip Check total time meter operation (allow engine to run 10 none minutes) Listen for abnormal noises none Turn container unit on and check generator 1800 rpm under full none load Verify operation of safety devices...
6.4.1.1 Checking the Fuel Tank 1. Check inside the fuel tank. Inspect for contaminants, water separation, and rust. 2. If the fuel tank has been modified or expanded, check the following items: • Tank material: resin • Inside tank: contaminants, water separation, rust •...
6.4.2 Engine Air Cleaner Service The engine air cleaner uses a dry element filter, as shown in Figure 6.1, to filter the engine intake air. The engine air cleaner should be inspected regularly for leaks or clogging, see Figure 3.18. A damaged air cleaner or hose can seriously affect the performance and life of the engine.
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6.4.2.3 Air Cleaner Body Service If there is any sign of contaminant buildup or plugging, the air cleaner body should be removed and back flushed. At least once a year, or at regular engine service intervals, remove the entire air cleaner and perform the following cleaning procedure: WARNING Do not use gasoline to clean air cleaner parts.
3. Close the drain cock and fill the system with clean, untreated water to which between 3% and 5% of an alka- line base radiator cleaner should be added; 170 grams dry = 151 grams to 3.8 liters of water. CAUTION Never pour cold water into a hot engine.
6.4.4.5 Replacing the Fan Belt 1. Using the proper size socket, slowly rotate the crank on the crank pulley nut. At the same time, use a flat, blunt object to guide the belt off the crank pulley towards the radiator. Be careful not to damage grooves on the pulley.
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5. Drill holes through the outer shell of the DOC. For non-potted switches, drill holes (2 per switch) through the outer shell of the DOC with a 0.129 to 0.133” drill bit and drill stop at 0.25” at the punched holes. For potted switches, drill holes (2 per switch) through the outer shell of the DOC with a 0.160 to 0.164”...
8. Attach the switches to the DOC using 4 stainless steel rivets and a powered rivet tool to ensure tightness of installation. Ensure the bracket is flat against the switch head. NOTE: Use a pneumatic or electronic rivet tool to ensure tightness of installation. For non-potted switches, use small rivets (part # 34-00928-01).
5. Attach the switches to the DOC using 4 stainless steel rivets (part # 34-00928-07) and a powered rivet tool to ensure tightness of installation. Ensure the bracket is flat against the switch head. NOTE: Use a pneumatic or electronic rivet tool to ensure tightness of installation. General Generator Set Maintenance 6.6.1 Removing and Replacing the AC Generator...
15. Starting with the lower bolts, remove the 3/8”-16 bolts / washers (12) that secure the generator to the engine. NOTE: Although the generator torsional dampener and flywheel adapter plate will normally keep the generator coupled to the engine, even without the bolts, it is safest to remove the lower generator bolts first, in case the generator shifts and falls during bolt removal.
22. With the torsional dampener and support plate installed on the new generator, lift and position the generator so that the generator mounting holes (12) are lined up with the engine mounting holes. 23. Insert two generator alignment bolts (2 1/2”) to temporarily align / secure the generator to the engine. Tighten the bolts enough so that the torsional dampener on the generator is touching the aluminum housing on the engine.
27. Place the generator support plate mounting bolts (2) down into the generator support plate in order to line up the mounting bolt holes with the shockmounts. 28. Ensure that the large washers placed on the shockmounts and slowly lower the generator / engine so that the generator support plate holes line up with the shockmount holes.
4. Install new shockmounts. 5. Lower the engine enough to assemble hardware as shown and torque. Refer to Section 6.6.3 for values. 6. Remove chains from the lift eyes. Figure 6.6 Generator Shockmounts Install Mount with Large Flare at Top 1) Generator 12) Flat Washer (5/8) 2) Lock-nut (5/8)
6.6.3 Unidrive Torque Requirements Extensive damage may occur if the proper hardware is not used and/or proper procedures are not followed when working with the unidrive assembly. Periodic inspection of hardware and bolt torque is recommended to ensure the integrity of the unidrive. Torque value and hardware requirements for unidrive assembly are provided in Figure 6.9.
6.6.4 Maintenance of Painted Surfaces The unit is protected against the corrosive atmosphere in which it normally operates by a special paint system. However, should the paint system be damaged, the base metal can corrode. If the paint system is scratched or damaged, do the following: 1.
Section 7 Diagmaster Introduction A technician can connect to the Kubota diesel engine by using Diagmaster software. Diagmaster communicates with the Engine Control Unit (ECU) to observe and diagnose engine conditions and display this information in a user interface. Diagmaster is equipped with the following functions: •...
In order to use Diagmaster to diagnose a Kubota engine, a user must be granted access through the Kubota Engine Park (KEP) website. A user must register on the KEP site for a username and password to Diagmaster. Contact a Carrier service engineer for information on how to create a KEP account. 7.2.2...
7.2.4 Connecting a Computer to the ECU The Diagmaster Assembly Kit (Carrier PN 07-60198-00) contains all of the hardware necessary to connect a computer to the ECU. • DST-i device • Data link cable • USB cable: USB-B (male) to USB-A (male) Procedure: 1.
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2. Connect one end of the data link cable to the DST-i device. 3. Locate the Kubota Service Port (KSP) on the unit. Remove the dust cap. 4. Connect the data link cable to the KSP. 5. Make sure the Engine START/RUN/OFF switch is in the RUN position. If diagnosis is required while the engine is running, turn the switch to the START position to start the engine.
Diagmaster Operation 7.3.1 Launching Diagmaster 1. To launch Diagmaster, select Diagmaster from the Windows start menu or click on the icon from the desktop. 2. If launching Diagmaster while not connected to a unit or the unit is off, the Diagnostic tester’s selection screen will appear.
4. Next, click on Automatic judgment. This will select the proper Diagmaster database to connect to. If an error message occurs after clicking the button, check the connections to the ECU. 5. At the Login screen, enter a User ID and Password and click the blue checkmark button. 7.3.2 Top Screen After logging into Diagmaster, the Top screen appears.
Menu Item Description Start Diagnosis / Finish Diagnosis When connected to a generator set, will start fault diagnosis. Or, if a diagnosis is already in progress, this will complete diagnosis. Open Diagnosis History / Close Displays the past history of diagnoses. Or, closes the diagnosis Diagnosis History history item currently replayed.
5. To end the diagnosis, click on Menu and select End Diagnosis. This can be done from any screen. 7.3.4 Opening a Diagnosis After diagnosis has been recorded, these events can be re-opened later to examine the results. 1. Click on Menu and select Open Diagnosis History. 2.
7.3.5 Project Screen The Project screen appears initially after a Diagnosis is started or opened. From the Project screen, the fields that are not grayed out can be edited and saved. You can change the information entered in the Project screen at any time during diagnosis, but the Save button must be clicked to save changes.
7.3.6 DTC Screen The DTC screen displays the DTC error codes that are past and present in the ECU. The DTC codes are listed individually in the Section 5.12 of the Troubleshooting chapter of this manual with a description, causes and recommended actions.
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At the bottom of the screen are the following buttons starting from top row, reading left to right: • Read DTC • Read DTC successively • Display Freeze Frame data • Save data in CSV format • Clear DTC • Save DTC •...
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7.3.6.2 Saving DTC 1. Click on the Save button to save DTC and Freeze Frame information. 2. A pop up screen appears. A memo can be added prior to saving. The file name for the saved data is automatically chosen. Click the Save button to complete the save. 3.
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7.3.6.3 Clearing DTC Clearing a DTS removes it from the DTC screen. Once it is removed it can not be restored. A DTC can only be cleared when it has a status of “Past” and when the same DTC does not exist as “Present” status. A “Present” DTC can not be cleared since the trouble has not been resolved yet.
7.3.7 Data Monitor Screen The Data Monitor screen consists of the list area, graph area and operation area. Specific data is chosen to be monitored from this screen and displayed in the graph area. 7.3.7.1 Recording Data from the Data Monitor Screen 1.
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2. The Data Monitor Setting window contains a list of signals that can be measured. Use the right / left arrows to move desired signals between the All Signals and Selected Signals column. The single headed arrows move one signal and the double headed arrows move all signals. Refer to Section 9.3 for Signal descriptions.
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4. The remainder of the selections on this screen are for setting up the appearance of the graph. The two buttons with a wrench icon (top to bottom) are to 1) specify the line color and the range of the Y-axis for each signal and 2) reset the display settings to the default.
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6. Click on the Save Setting tab. To create a new file, enter the title. To overwrite an existing file, select the title of a previously saved file. Choose the desired settings, enter a memo and click the save button below the Memo field.
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8. The selected signals appear in the list on the left while the graph representations are on the right. 9. Signal settings that have been previously saved are stored in the Select Signal Group drop down box and can offer a way to store favorite settings for quick access. 10.
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11. The following operations are available during monitoring: • Adding flags while monitoring data • Switching the graph display mode between one graph and separate graphs • Selecting number of graphs (2-5) to display on the screen when separate graphs chosen. NOTE: Measured data will be recorded in the memory (on the PC) that can store approximately 2 hours of data.
1. In the bottom right corner of the Data Monitor screen, click on the Replay drop down box. When current data is monitored, it will display Current Data. All saved recordings will be listed and can be selected. To cancel replaying, select Current Data from the list.
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CAUTION Since active tests are not a normal operation, prolonged execution may cause failure. Tests should take no more than about 30 seconds. 7.3.8.1 Performing an Active Test 1. Select one of the items in the list and click the right arrow. The Active Test Execution screen appears. 7–21 T-381...
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2. Signals can be monitored during execution. To do this, set the signals to be monitored. See Section 7.3.7.1. Once the signal settings are set, click the Monitor check box to enable monitoring. 3. Click the green play button to make active tests ready to be executed. Data monitoring will start if simultaneous monitoring has been selected.
7.3.9 Utility Item Select Screen The Utility Item Select screen provides thee additional functions: • Injector Compensation • Data Check / Rewrite • P/L Valve Opening Counter Reset Select one of the items in the list and click the right arrow. The appropriate screen appears. CAUTION Before selecting a utility item to be performed, check the Notes, Instruction and Attention displayed in the right column of the screen for each item.
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7.3.9.1 Injector Compensation This function is performed when an injector or the ECU has been replaced. When registering compensation data to the ECU, stop the engine beforehand. Registration is not possible with the engine running. 1. Select Injector Compensation on the Utility screen and click the right arrow to open the Injector Compensation screen.
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7.3.9.2 Replay Registered Compensation Data When compensation data is registered, its history is automatically saved in the project. 1. Click on the drop down list under Replay. Select the target saved file from the list. To cancel replay, click on Current Data from the drop down list.
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2. Select the item to be rewritten. Change the value and click the Save button to execute the change. 3. Check the content of the displayed precautions in the popup and click the blue checkmark to confirm. 4. A confirmation screen for rewriting will appear. Click OK to complete. 5.
ECU Data Monitor Signals Signal Name Description Reference Value / Behavior Rotary / Pulse Signal Engine Speed [rpm] Indicates engine RPM via a signal from When engine stopped (switch in RUN): 0 is the crankshaft position sensor. If this displayed. signal fails, the camshaft position sensor When engine running: engine speed is signal is used.
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Signal Name Description Reference Value / Behavior Digital Signal Key Switch Indicates ignition switch ON/OFF state Always ON when switch is in RUN, regardless of engine operating state Start Switch Indicates ignition switch start signal ON/ When engine cranking: ON is displayed OFF state Otherwise: OFF Indicates cranking being done...
Signal Name Description Reference Value / Behavior Other Hour meter [h] Indicates the hour meter value recorded Hours of ECU operation displayed to the ECU Source Address of TSC1 Indicates CAN communication address Always show: 0 settings *May be disabled under some specifications Parking SW Indicates parking switch ON/OFF state...
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