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Kubota V3800-CR-TE4, Diagnosis Manual

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Kubota V3800-CR-TE4 Diagnosis Manual Download Page 312

COMMON RAIL SYSTEM

V3800-CR-TE4,V3800-CR-TIE4, DM

1-S285

6. INSPECTION PROCEDURE FOR EACH SYSTEM

[1]  AIR INTAKE SYSTEM INSPECTION PROCEDURE

1. Check the Air Cleaner

1. Check the air cleaner for clogging.

• Clean air cleaner element (Primary and Secondary) every 250

hours. 

• Replace air cleaner element:

Once yearly or after every sixth cleaning, whichever comes first.

9Y1200192CRS0935US0

OK

Go to "2. Check the Suction Path".

NG

Clean or replace.

(1) Air Cleaner
(2) Air Cleaner Indicator
(3) Air Cleaner Switch
(4) Air Cleaner Lamp

[A] M60 Series
[B] M-GX Series

KiSC issued 05, 2012 A 

Summary of Contents for V3800-CR-TE4

Page 1: ...V3800 CR TE4 V3800 CR TIE4 DIAGNOSIS MANUAL COMMON RAIL SYSTEM KiSC issued 05 2012 A...

Page 2: ...I INFORMATION KiSC issued 05 2012 A...

Page 3: ...CONTENTS 1 SAFETY FIRST I 1 INFORMATION KiSC issued 05 2012 A...

Page 4: ...y and affect engine life 9Y1200192INI0003US0 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 o...

Page 5: ...ulic or fuel lines Tighten all connections before applying pressure Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises...

Page 6: ...e away from eyes hands and clothing If you spill electrolyte on yourself flush with water and get medical attention immediately 9Y1200192INI0007US0 DISPOSE OF FLUIDS PROPERLY Do not pour fluids into t...

Page 7: ...1 COMMON RAIL SYSTEM KiSC issued 05 2012 A...

Page 8: ...D EXHAUST SYSTEM 1 M3 4 WIRING DIAGRAM 1 M4 1 System Wiring Diagram 1 M4 5 AVAILABLE DATA MONITOR SIGNALS LEVEL 2 1 M5 1 Monitor Items 1 M5 2 Normal Value 1 M8 6 ECU TERMINAL LAYOUT 1 M11 1 ECU Termin...

Page 9: ...13 Inter Cooler 14 EGR DC Motor 15 Intake Throttle Valve 16 Intake Air Heater 17 Boost Pressure Sensor 18 Intake Air Temperature Sensor 19 Coolant Temperature Sensor 20 Crankshaft Position Sensor 21...

Page 10: ...munication 9Y1200192CRM0002US0 1 Injector 2 Rail 3 Supply Pump 4 Pressure Limiter 5 SCV Suction Control Valve 6 Fuel Cooler 7 Check Valve 8 Fuel Filter 9 Fuel Feed Pump 10 Water Separator 11 Fuel Tank...

Page 11: ...r DPF Differential Pressure P 5 Exhaust Gas Temperature Sensor2 T2 DPF Outlet Exhaust Gas Temperature 6 Diesel Particulate Filter Hereinafter Referred To As The DPF Muffler 7 Camshaft Position Sensor...

Page 12: ...elay 12 Intake Air Heater 13 Injector 1 14 Injector 2 15 Injector 3 16 Injector 4 17 Crankshaft Position Sensor 18 Camshaft Position Sensor 19 DPF Differential Pressure Sensor P 20 SCV Suction Control...

Page 13: ...og signal Accelerator pedal position Accelerator pedal position sensor 1 output voltage V Accelerator pedal position sensor 2 output voltage V Boost pressure kPa Boost pressure sensor output voltage V...

Page 14: ...ndition Pump difference learning correction value mA Pressure feedback integral guard flag Engine stop flag Low temperature start mode flag Registration history 1 cylinder Registration history 2 cylin...

Page 15: ...temperature 1 C Exhaust gas temperature 2 C Mass air flow for intake throttle kg h Intake air temperature built in MAF C Target intake throttle valve opening Intake throttle final duty control quantit...

Page 16: ...Approx 1 0 Approx 1 0 Fuel temperature C Representative value Approx 20 C 68 F Approx 2 4 V Representative value Approx 40 C 104 F Approx 1 5 V Fuel temperature sensor output voltage V Coolant temper...

Page 17: ...eed load After warm up When idling Approx 40 to 50 MPa 410 to 500 kgf cm2 5800 to 7200 psi During no load maximum speed 95 0 to 115 MPa 969 to 1170 kgf cm2 13800 to 116600 psi During acceleration 95 0...

Page 18: ...0 C Representative value Approx 100 C 212 F Approx 4 4 V Representative value Approx 250 C 482 F Approx 2 3 V Exhaust gas temperature 0 sensor output voltage V Exhaust gas temperature 1 C Representati...

Page 19: ...LET DOC TEMP GND EXHAUST GAS TEMPERATURE T1 GND A 13 A 14 IDOC GND INLET DOC TEMP GND EXHAUST GAS TEMPERATURE T0 GND A 15 A GND2 COOLANT TEMPERATURE SENSOR GND A 16 A GND6 RAIL PRESSURE SENSOR GND A 1...

Page 20: ...RAIL PRESSURE SENSOR 2 A 42 G CAMSHAFT POSITION SENSOR A 43 NE CRANKSHAFT POSITION SENSOR A 44 G VCC CAMSHAFT POSITION SENSOR VCC A 45 A 46 A VCC2 BOOST PRESSURE SENSOR VCC A 47 A 48 A 49 COM1 INJ CO...

Page 21: ...ame Signal Name A 65 A 66 DPS DIFFERENTIAL PRESSURE SENSOR A 67 A 68 A 69 A 70 A 71 A 72 A 73 COM1 INJ COMMON1 A 74 TWV1 INJ1 DRV TWV1 A 75 A 76 A 77 A 78 A 79 A 80 A 81 A 82 A 83 A 84 A 85 A 86 A 87...

Page 22: ...P B 7 SCV SUCTION CONTROL VALVE B 8 B 9 ITS VCC INTAKE THROTTLE POSITION SENSOR VCC B 10 B 11 B 12 B 13 B 14 B 15 A GND1 INTAKE AIR TEMPERATURE SENSOR GND B 16 A GND3 INTAKE THROTTLE POSITION SENSOR G...

Page 23: ...FOR MACHINE B 39 CAN2 L CAN2 L FOR MACHINE B 40 B 41 B 42 B 43 B 44 ITV INTAKE THROTTLE VALVE MOTOR B 45 B 46 BATT BATTERY VOLTAGE B 47 IG SW IGNITION SWITCH B 48 IG SW IGNITION SWITCH B 49 B 50 B 51...

Page 24: ...COMMON RAIL SYSTEM V3800 CR TE4 V3800 CR TIE4 DM 1 M16 9Y1200192CRM0025US0 1 ECU Connector 1 96 Pin 2 ECU Connector 2 58 Pin 3 A 1 Pin Position 4 B 1 Pin Position KiSC issued 05 2012 A...

Page 25: ...eleration 1 S62 5 DIAGNOSTIC PROCEDURE BY DTC 1 S67 1 DTC LIST 1 S67 2 DIAGNOSTIC PROCEDURE BY DTC 1 S122 1 NE G Phase Shift DTC P0016 636 7 1 S125 2 Intake Air Temperature Built in MAF Sensor Abnorma...

Page 26: ...DTC P2149 523524 2 1 S237 39 Common 2 TWV Actuation System Short DTC P2150 523524 4 P2151 523524 3 1 S240 40 Barometric Pressure Sensor Error DTC P2228 108 4 P2229 108 3 1 S244 41 EGR DC Motor Abnorma...

Page 27: ...2 Connector Connection Fault Verification Method 1 S296 3 Checking The Power And Ground System Main Relay ECU Circuit 1 S297 KiSC issued 05 2012 A...

Page 28: ...COMMON RAIL SYSTEM V3800 CR TE4 V3800 CR TIE4 DM 1 S1 1 GENERAL 1 OVERALL DIAGNOSTIC PROCEDURE 9Y1200192CRS0001US0 KiSC issued 05 2012 A...

Page 29: ...KUBOTA Common Rail System When the machine is received from the customer it is necessary to verify the malfunction symptoms and the generated malfunction data with the customer This is performed base...

Page 30: ...Cylinder 3 Cylinder 4 Defective injector Injector 1 Injector 2 Injector 3 Injector 4 Actual part replacement Injector Supply Pump Common rail Fuel Filter ECU Others Customer complaint 1 Engine no sta...

Page 31: ...thers 6 Engine coolant a Cold Write the position of the indicator on coolant temperature gauge b Warming up c After warming up d Any temperature e Others 7 Engine operation a Starting b Just after sta...

Page 32: ...ngine Overheat items Faulty starting Intake system Clogged air cleaner element Clean or replace air cleaner element Fuel system Insufficient fuel Add fuel and perform fuel system air bleeding Fuel sys...

Page 33: ...be replaced 9Y1200192CRS0863US0 Action Malfunction symptom Dead battery Engine will not start Idle speed abnormal engine stall sluggish poor acceleration Verify that there is no Diagnostic Trouble Cod...

Page 34: ...P P If any commercial electrical products have been installed remove them and verify whether or not the malfunction symptoms occur P P P If it is thought that the malfunction occurs in rainy or high t...

Page 35: ...TION PROCEDURE IMPORTANT At first time usage it is necessary to do Communication Setting with administrator user account Prepare a PC on which the diagnostic software has already been installed When c...

Page 36: ...o PC 3 and then connect the USB cable to the USB port on PC 4 Start the diagnostic software 5 Select Communication Setting from System Setting in the menu and execute Only when performing the initial...

Page 37: ...achine Communication Indicator Green Light OFF Stand by for communication Light Flashing synchronized with communication Communication in progress 3 PC Communication Bluetooth Indicator Blue Reserved...

Page 38: ...CHECKING THE OPERATION OF THE ECU 1 Starting Diagmaster 1 Double click the Diagmaster icon on your computer desktop 2 Enter your User ID and Password and then click the button 3 The Diagmaster initial...

Page 39: ...RAIL SYSTEM V3800 CR TE4 V3800 CR TIE4 DM 1 S12 2 DST i Communication Settings 1 From the Menu select System Setting and then Communication Setting 2 Click the interface select button KiSC issued 05...

Page 40: ...E4 V3800 CR TIE4 DM 1 S13 3 Select DST i and then click the mouse button 4 Click the button NOTE If you failed in the setting confirm the connection and start again from procedure 1 to 4 9Y1200192CRS0...

Page 41: ...COMMON RAIL SYSTEM V3800 CR TE4 V3800 CR TIE4 DM 1 S14 5 From Menu select Start Diagnosis and then New Diagnosis 6 Click the button KiSC issued 05 2012 A...

Page 42: ...COMMON RAIL SYSTEM V3800 CR TE4 V3800 CR TIE4 DM 1 S15 7 Select system information and click the button 8 The transmitting to ECU progress indicator appears KiSC issued 05 2012 A...

Page 43: ...EM V3800 CR TE4 V3800 CR TIE4 DM 1 S16 9 The Project screen appears NOTE If you failed in the setting confirm the content of procedure 6 and start again from procedure 5 to 9 9Y1200192CRS0942US0 KiSC...

Page 44: ...et opening The reason for this is because the learning value is always reflected for 0 lift after being used for a long time 0 points are shifted As such the factory spec is a relative evaluation and...

Page 45: ...is extreme air in fuel line or filter clogged etc and it normally occurred when operating with the extreme vacuum pressure Perform pump difference learning particularly when the replacement of the fil...

Page 46: ...failure 4 Idle Failure Idle speed is lower than the standard value or unstable Engine may stall 5 Engine Noise Abnormal noises come from inside the engine Engine sound is loud 6 High Fuel Consumption...

Page 47: ...gnal output Damaged sensor pulsar gear Air gap size is too large No signal output Damaged sensor pulsar gear Air gap size is too large No signal output False signal output Misadjustment No signal outp...

Page 48: ...nents Intake air heater system Turbocharge malfunction No signal output False signal output No signal output False signal output No signal output False signal output Does not charge Does not discharge...

Page 49: ...concentration of antifreeze Power transmission malfunction including clutch slipping 1 Large dragging including brake 1 Loose fit parts Defective CAN communication Blockage leake malfunction Blockage...

Page 50: ...related wiring harness Refer to the previous List of malfunction causes by symptom for the subsequent details 3 Engine fault Low compression pressure Engine internal fault Valve timing fault 4 Control...

Page 51: ...ON OK Go to 2 Check the DTC NG Check in accordance with 6 2 FUEL SYSTEM INSPECTION PROCEDURE 5 Check the Fuel Feed Pump Refer to page 1 S291 1 Fuel Feed Pump A M60 Series B M GX Series Factory specifi...

Page 52: ...is ON 4 Perform an active test for models that have relay control in the ECU on the engine side 9Y1200192CRS0886US0 4 Check the Intake System 1 Check in accordance with 6 1 AIR INTAKE SYSTEM INSPECTI...

Page 53: ...A M60 Series B M GX Series Factory specification BP terminal ground 10 V or higher S GND terminal ground 0 5 V or lower OK Go to 7 Check the Crankshaft Position Sensor and Camshaft Position Sensor Si...

Page 54: ...ion causes by symptom use the diagnosis tool for a monitor check of the mode flags during start up such as the coolant temperature rail pressure SCV current value and battery voltage Refer to page 1 S...

Page 55: ...5 Intake system Air heater relay fault Intake air heater fault 6 Fuel system Fuel quality Fuel filter clogging Fuel pressure limiter fault Fuel line clogging leak 7 CRS Including the wiring harness O...

Page 56: ...the engine side 9Y1200192CRS0886US0 4 Check the Intake System 1 Check in accordance with 6 1 AIR INTAKE SYSTEM INSPECTION PROCEDURE Refer to page 1 S285 9Y1200192CRS0880US0 Factory specification No DT...

Page 57: ...of the camshaft position sensor 9Y1200192CRS0043US0 OK Go to 6 Check the Crankshaft Position Sensor NG Repair in accordance with 6 2 FUEL SYSTEM INSPECTION PROCEDURE Refer to page 1 S287 1 Fuel Filte...

Page 58: ...969 to 1170 kgf cm2 13800 to 16600 psi 4 The numerical value is stable under normal operating and the target value corresponds with actual pressure value OK Go to 9 Check the Injector Including the Pi...

Page 59: ...V3800 CR TIE4 DM 1 S32 10 Check the Engine 1 Check the compression pressure valve timing and the inside of the engine 9Y1200192CRS0888US0 OK Normal NG Repair the malfunction 1 Compression Tester 2 Ali...

Page 60: ...ormed Fuel quality Fuel filter clogging Fuel pressure limiter fault Fuel line clogging leak 5 CRS including the wiring harness Output system supply pump injector and common rail Input system sensors a...

Page 61: ...eck in accordance with the troubleshooting procedures for each DTC OK Go to 3 Check the Injector Including the Pipes etc NG Reproduce defect by referring to the freeze frame data etc a CAN1 Connector...

Page 62: ...n accordance with 6 2 FUEL SYSTEM INSPECTION PROCEDURE Refer to page 1 S287 1 Fuel Filter 2 Supply Pump 3 Water Separator 4 Fuel Feed Pump A M60 Series B M GX Series Factory specification Variable cor...

Page 63: ...ressure always follow to the Target rail pressure 1 When idling 40 to 50 MPa 410 to 500 kgf cm2 5800 to 7200 psi 2 Accelerator opening 0 100 During acceleration Maximum value 95 0 to 130 MPa 969 to 13...

Page 64: ...akes etc Loose parts including part interference sound 9Y1200192CRS0058US0 1 Check the DTC 1 Turn the key switch ON and check the DTC 9Y1200192CRS0059US0 2 Check the Crankshaft Position Sensor 1 Refer...

Page 65: ...body including part interference sound 3 Check for a large amount of drag including the brakes etc 9Y1200192CRS0891US0 Factory specification 1 Engine vibration and noise are increased and the rotatio...

Page 66: ...ter fuel filter dirt clogging Radiator clogging 2 Powertrain malfunctions not involving the engine Large driving resistance Large resistance for actuation Tire air pressure Brake drag Clutch slipping...

Page 67: ...specification Operates when the key switch is turned ON OK Go to 2 Check the DTC NG Check in accordance with 6 2 FUEL SYSTEM INSPECTION PROCEDURE 5 Check the Fuel Feed Pump Refer to page 1 S291 1 Fue...

Page 68: ...e required for actuation Is the tire air pressure correct Is there brake drag 9Y1200192CRS0892US0 5 Check the Fuel System 1 Check in accordance with 6 2 FUEL SYSTEM INSPECTION PROCEDURE Refer to page...

Page 69: ...895US0 8 Check the Crankshaft Position Sensor 1 Refer to DTC P0335 and P0336 and implement checking of the crankshaft position sensor 9Y1200192CRS0072US0 OK Go to 7 Check the Coolant Temperature Incre...

Page 70: ...celerator opening 0 100 During acceleration Maximum value 95 0 to 130 MPa 969 to 1320 kgf cm2 13800 to 18800 psi 3 No load maximum speed 95 0 to 115 MPa 969 to 1170 kgf cm2 13800 to 16600 psi 4 The nu...

Page 71: ...sure valve clearance valve timing the inside of the engine and engine oil viscosity 2 Check the timing gear 3 Check the turbocharger 9Y1200192CRS0897US0 OK Normal NG Repair or replace the related part...

Page 72: ...SCV operation fault 5 Intake system Air cleaner clogging Leak from the intake system parts Turbocharger operation fault 6 Fuel system Supply pump learning has not been performed Fuel quality Fuel pres...

Page 73: ...for each DTC OK Go to 3 Check the Final Accelerator Open Position NG Reproduce defect by referring to the freeze frame data etc a CAN1 Connector Factory specification Variable corresponding to the ope...

Page 74: ...chine itself that do not involve the engine Large resistance for actuation Tire air pressure Power transmission fault Brake drag 9Y1200192CRS0900US0 Factory specification No malfunction should be dete...

Page 75: ...nsor 9Y1200192CRS0086US0 OK Go to 8 Check the Fuel System NG Repair in accordance with 6 1 AIR INTAKE SYSTEM INSPECTION PROCEDURE Refer to page 1 S285 1 Air Cleaner 2 Air Cleaner Indicator 3 Air Clean...

Page 76: ...elerator opening 0 100 During acceleration Maximum value 95 0 to 130 MPa 969 to 1320 kgf cm2 13800 to 18800 psi 3 No load maximum speed 95 0 to 115 MPa 969 to 1170 kgf cm2 13800 to 16600 psi 4 The num...

Page 77: ...sure valve clearance valve timing the inside of the engine and engine oil viscosity 2 Check the timing gear 3 Check the turbocharger 9Y1200192CRS0904US0 OK Normal NG Repair or replace the related part...

Page 78: ...ner clogging Leak from the intake system parts Turbocharger operation fault 5 Fuel system Supply pump learning has not been performed Fuel quality Fuel pressure limiter fault Fuel line clogging leak 6...

Page 79: ...o to 3 Check the Intake System NG Check in accordance with the troubleshooting procedures for each DTC OK Go to 3 Check the Intake System NG Reproduce defect by referring to the freeze frame data etc...

Page 80: ...ecification Variable corresponding to the operation between the minimum of 0 and the maximum of 100 without delay in response OK Go to 6 Check the Crankshaft Position Sensor NG Referring to the worksh...

Page 81: ...e actual EGR valve opening High side When target EGR valve openings of 35 and 60 are given alternately there must not be disparity in the actual EGR valve opening OK Go to 9 Check the Rail Pressure Se...

Page 82: ...Check the timing gear 3 Check the turbocharger 9Y1200192CRS0909US0 Factory specification 1 Engine vibration and noise are increased and the rotation speed is reduced when the injection for the corres...

Page 83: ...ir cleaner clogging Leak from the intake system parts Air heater relay fault Turbocharger operation fault 6 Fuel system Supply pump learning has not been performed Fuel quality Fuel filter clogging Fu...

Page 84: ...ory specification No DTC is output OK Go to 3 Check the Starting Assist Device NG Check in accordance with the troubleshooting procedures for each DTC OK Go to 3 Check the Starting Assist Device NG Re...

Page 85: ...nsor 9Y1200192CRS0054US0 OK Go to 6 Check the Fuel System NG Repair in accordance with 6 1 AIR INTAKE SYSTEM INSPECTION PROCEDURE Refer to page 1 S285 1 Air Cleaner 2 Air Cleaner Indicator 3 Air Clean...

Page 86: ...tive test EGR actuation test 9Y1200192CRS0916US0 OK Go to 9 Check the EGR Valve NG Repair and replacement of camshaft position sensor related parts 1 Camshaft Position Sensor G Sensor Factory specific...

Page 87: ...969 to 1170 kgf cm2 13800 to 16600 psi 4 The numerical value is stable under normal operating and the target value corresponds with actual pressure value OK Go to 11 Check the Injector Including the P...

Page 88: ...ance valve timing and the inside of the engine 2 Check the timing gear 3 Check the turbocharger 9Y1200192CRS0917US0 OK Normal NG Check and repair faulty parts including the high pressure line of the d...

Page 89: ...t 4 Intake system Air cleaner clogging 5 Fuel system Fuel quality Fuel filter clogging Fuel line clogging leak 6 CRS including the wiring harness Output system supply pump injector and common rail Inp...

Page 90: ...eck the idle condition NG Check in accordance with the troubleshooting procedures for each DTC OK Go to 3 Check the idle condition NG Reproduce defect by referring to the freeze frame data etc a CAN1...

Page 91: ...n accordance with 6 2 FUEL SYSTEM INSPECTION PROCEDURE Refer to page 1 S287 1 Fuel Filter 2 Supply Pump 3 Water Separator 4 Fuel Feed Pump A M60 Series B M GX Series Factory specification Variable cor...

Page 92: ...erator opening 0 100 During acceleration Maximum value 95 0 to 130 MPa 969 to 1320 kgf cm2 13800 to 18800 psi 3 No load maximum speed 95 0 to 115 MPa 969 to 1170 kgf cm2 13800 to 16600 psi 4 The numer...

Page 93: ...66 11 Check the Engine 1 Check the compression pressure valve clearance valve timing and the inside of the engine 2 Check the timing gear 9Y1200192CRS0919US0 OK Normal NG Repair the malfunction 1 Comp...

Page 94: ...pulse DTC Set Preconditions Engine is operating above low idle speed Battery voltage is normal Sensor supply voltage VCC is normal NE signal is normal G signal is normal Coolant temperature is 10 C 5...

Page 95: ...ilure of sensor Open circuit or B short circuit of sensor harness Failure of sensor DTC Set Preconditions Battery voltage is normal Battery voltage is normal DTC set parameter Intake air temperature b...

Page 96: ...1 or 2 is fulfilled 1 Rail pressure exceeds 191 MPa 1950 kgf cm2 27700 psi 2 Within 1 sec after the rail pressure goes below 191 MPa 1950 kgf cm2 27700 psi Before the pressure decrease the rail press...

Page 97: ...Sensor supply voltage VCC is normal DTC set parameter Actual pressure 197 MPa 2010 kgf cm2 28600 psi Time to action or number of error detection 1 sec or more System Action Output limitation Approxim...

Page 98: ...e VCC is normal Rail pressure sensor is normal DTC set parameter Discharge request of supply pump goes below 0 mm3 st and the actual rail pressure is 10 MPa 100 kgf cm2 1400 psi higher than command pr...

Page 99: ...injector drive circuit are normal NE signal is active Engine is operating 700 min 1 rpm or higher No DTC of P0087 P0088 P0089 DTC set parameter a the flow volume which is calculated from the differenc...

Page 100: ...oolant temperature is 15 C 59 F or higher Coolant temperature sensor is normal MAF sensor is normal EGR valve is normal Intake throttle valve is normal Battery voltage is normal DTC set parameter Engi...

Page 101: ...tinues for 3 secs Sensor supply voltage is normal DTC set parameter Mass air flow sensor voltage 0 1 V or less Mass air flow sensor voltage 4 9 V or more in certain operation condition Time to action...

Page 102: ...e is normal DTC set parameter Voltage of intake air temperature sensor is 0 05 V or less Voltage of intake air temperature sensor is 4 9 V or above Time to action or number of error detection 2 8 sec...

Page 103: ...ion or number of error detection 2 8 sec or more 2 8 sec or more System Action At start up 25 C 13 F default value Under other conditions 80 C 176 F default value Output limitation Approximately 50 of...

Page 104: ...s Battery voltage is normal Battery voltage is normal DTC set parameter Voltage of temperature sensor in supply pump is 0 1 V or less Voltage of temperature sensor in supply pump is 4 9 V or above Tim...

Page 105: ...Time to action or number of error detection Transient Transient System Action Output limitation Approximately 50 of normal condition Speed limitation Accelerator limitation 50 Rail pressure limitation...

Page 106: ...ditions Battery voltage is normal CPU is normal DTC set parameter Injector charge voltage High Failure of ECU charge circuit Time to action or number of error detection 10 sec or more System Action Ou...

Page 107: ...g Battery voltage is normal During injection CPU is normal DTC set parameter Open circuit of harness or open circuit of injector coil Open circuit of harness or open circuit of injector coil Time to a...

Page 108: ...g Battery voltage is normal During injection CPU is normal DTC set parameter Open circuit of harness or open circuit of injector coil Open circuit of harness or open circuit of injector coil Time to a...

Page 109: ...ld speed DTC Set Preconditions Coolant temperature sensor is normal Key switch is ON DTC set parameter Engine coolant temperature 120 C 248 F Engine speed 3500 min 1 rpm Time to action or number of er...

Page 110: ...Set Preconditions Battery voltage is normal Sensor supply voltage VCC is normal Battery voltage is normal Sensor supply voltage VCC is normal DTC set parameter Voltage of boost pressure sensor is 0 2...

Page 111: ...t stalled Battery voltage is normal Sensor supply voltage VCC is normal 350 min 1 rpm or higher DTC set parameter No recognition of Ne sensor pulse Pulse count per rotation is not 56 teeth Time to act...

Page 112: ...arness Failure of sensor DTC Set Preconditions Battery voltage is normal Sensor supply voltage VCC is normal Engine is not stalled Battery voltage is normal Sensor supply voltage VCC is normal Engine...

Page 113: ...driving circuit DTC Set Preconditions Battery voltage is normal During air heater relay drive command is activated Battery voltage is normal Other than during air heater relay drive command is activa...

Page 114: ...C of U0077 CAN1 Bus off EGR control line is normal DTC set parameter EGR actuator open error signal received via CAN EGR actuator coil short error signal received via CAN EGR position sensor error sig...

Page 115: ...Set Preconditions Battery voltage is normal Key switch turn ON Starter Switch signal ECU B 54 terminal is not activated 10 sec or more after engine start 700 min 1 rpm or higher DTC set parameter Oil...

Page 116: ...mal Battery voltage is normal Other exhaust gas temperature sensors are normal Coolant temperature is 65 C 149 F or more continues longer than 10 min after engine starting 100 C 212 F T0 800 C 1472 F...

Page 117: ...s temperature sensors are normal Battery voltage is normal Other exhaust gas temperature sensors are normal Coolant temperature is 65 C 149 F or more continues longer than 5 min after engine starting...

Page 118: ...age is below 8 V in 12 V system ECU data value 0 9615 ECU recognition of battery voltage is above 16 V in 12 V system ECU data value 1 9231 Time to action or number of error detection 1 sec or more 1...

Page 119: ...injector has been stored in three locations When this data is read and compared an error is determined if there is difference in all three values When QR correction data fails to write to the EEPROM...

Page 120: ...ve inconsistencies in checksum Battery voltage 10 V Starter switch is OFF CPU abnormality counter 5 times RUN pulse abnormality occurs 5 times or more Battery voltage 10 V Starter switch continues OFF...

Page 121: ...CPU is normal DTC set parameter Injector charge voltage Low Failure of charge circuit of ECU Time to action or number of error detection Transient System Action Output limitation Approximately 50 of...

Page 122: ...ed DTC set parameter Open circuit or ground short of SCV B short circuit of SCV Time to action or number of error detection 2 6 sec or more 2 6 sec or more System Action Output limitation Approximatel...

Page 123: ...or is below 3 5 V Voltage to sensor is above 4 5 V Time to action or number of error detection Transient Transient System Action Output limitation Approximately 50 of normal condition Speed limitation...

Page 124: ...ery voltage is normal Key switch turn ON Starter Switch signal ECU B 54 terminal is not activated DTC set parameter Voltage to sensor is below 3 5 V Voltage to sensor is above 4 5 V Time to action or...

Page 125: ...MRYCS Detection item Failure of main relay DTC Set Preconditions Key switch is OFF Engine stops DTC set parameter Main relay stays active longer than 1 sec without command and battery voltage is 8 V...

Page 126: ...kgf cm2 33400 psi or more continues 1 second under the condition of above 500 min 1 rpm Threshold changes depending on the engine speed 2600 min 1 rpm should be used as a reference Time to action or...

Page 127: ...ges depending on the engine speed 2600 min 1 rpm should be used as a reference Or rail pressure of above 80 MPa 820 kgf cm2 12000 psi continues total time for 1 second under condition of below 500 min...

Page 128: ...circuit etc DTC Set Preconditions Battery voltage is normal Battery voltage is normal Key switch turn ON Starter Switch signal ECU B 54 terminal is not activated DTC set parameter Approximate paramet...

Page 129: ...Set Preconditions Engine is operating Battery voltage is normal During injection CPU is normal DTC set parameter When wiring harness open circuit Time to action or number of error detection 8 times or...

Page 130: ...DTC set parameter When wiring harness short to ground occurs When wiring harness short to B occurs Time to action or number of error detection 8 times or more 8 times or more System Action Injectors w...

Page 131: ...Set Preconditions Engine is operating Battery voltage is normal During injection CPU is normal DTC set parameter When wiring harness open circuit Time to action or number of error detection 8 times or...

Page 132: ...TC set parameter When wiring harness short to ground occurs When wiring harness short to B occurs Time to action or number of error detection 8 times or more 8 times or more System Action Injectors wh...

Page 133: ...ternal circuit short to B DTC Set Preconditions Battery voltage is normal Battery voltage is normal DTC set parameter Barometric pressure sensor voltage 1 6 V or less Barometric pressure sensor voltag...

Page 134: ...us off EGR control line is normal DTC set parameter EGR actuator valve stuck error signal received via CAN EGR DC motor temperature error signal thermistor 125 C 257 F or more received via CAN EGR DC...

Page 135: ...temperature sensors are normal Battery voltage is normal Other exhaust gas temperature sensors are normal Coolant temperature is 65 C 149 F or more continues longer than 10 min after engine starting...

Page 136: ...y voltage is normal Sensor supply voltage VCC is normal Starter Switch signal ECU B 54 terminal is not activated Battery voltage is normal Sensor supply voltage VCC is normal Starter Switch signal ECU...

Page 137: ...hort circuit of sensor harness Failure of sensor DTC Set Preconditions Battery voltage is normal Sensor supply voltage VCC is normal Battery voltage is normal Sensor supply voltage VCC is normal DTC s...

Page 138: ...ther than during regeneration mode Coolant temperature is 65 C 149 F or more continues longer than 5 min after engine starting DTC set parameter T1 T0 250 C 482 F Time to action or number of error det...

Page 139: ...or T0 T1 and T2 are normal Battery voltage is normal DTC set parameter DOC inlet temperature T0 700 C 1292 F or more DPF inlet temperature T1 715 C 1319 F or more Time to action or number of error det...

Page 140: ...rature sensor T0 T1 and T2 are normal Battery voltage is normal DTC set parameter DPF outlet temperature T2 820 C 1508 F or more Time to action or number of error detection 2 0 sec or more System Acti...

Page 141: ...ection item PM accumulation level3 DTC Set Preconditions Battery voltage is normal DTC set parameter PM accumulation more than trigger level 26000 mg Time to action or number of error detection Transi...

Page 142: ...s Battery voltage is normal Battery voltage is normal DTC set parameter PM accumulation more than trigger level 31000 mg PM accumulation more than trigger level 36000 mg Time to action or number of er...

Page 143: ...cyl or more MAF sensor is normal EGR valve is normal Intake throttle valve is normal Intake pressure sensor is normal Barometric pressure sensor is normal Coolant temperature sensor is normal DTC set...

Page 144: ...et Preconditions During parked active regeneration mode During parked active regeneration mode DTC set parameter Engine coolant temperature stays below 65 C 149 F for 1500 seconds or more under parked...

Page 145: ...y DTC Set Preconditions Engine speed is 1400 min 1 rpm or more Quantity of injection is 30 mm3 st or more Coolant temperature is 65 C 149 F or more continues longer than 300 sec Intake air temperature...

Page 146: ...c error DTC Set Preconditions Battery voltage is normal Key switch is ON Battery voltage is normal Key switch is ON DTC set parameter Regeneration time interval within 30 min occurs three times contin...

Page 147: ...ormal Starter Switch signal ECU B 54 terminal is not activated Battery voltage is normal Key switch is ON DTC set parameter Interruption of CAN CAN1 Bus off Time to action or number of error detection...

Page 148: ...topping DTC Set Preconditions Battery voltage is normal Key switch turn OFF to ON Starter Switch signal ECU B 54 terminal is not activated No error of CAN2 Bus off Battery voltage is normal Starter Sw...

Page 149: ...in high pressured fuel system 1 S144 P0101 132 1 Intake air volume Low 1 S150 P0102 132 4 MAF sensor abnormality 1 S151 P0103 132 3 P0112 172 4 Intake air temperature error 1 S153 P0113 172 3 P0117 1...

Page 150: ...lay is locked in closed position 1 S217 P1274 523539 2 Pump seizing 1 S220 P1275 523540 2 P2108 523580 2 Intake throttle feedback error 1 S226 P2131 523543 2 Accelerator position sensor error CAN 1 S2...

Page 151: ...4 1 S268 P3008 3701 0 Excessive PM5 1 S269 P3011 132 15 Boost pressure low 1 S270 P3012 523589 17 Low coolant temperature in parked regeneration 1 S272 P3013 523590 16 Parked regeneration time out 1 S...

Page 152: ...t Position Sensor Signals 1 Run the engine and check the values of the Engine speed active flag and Cam speed active flag with the data monitor function NOTE Crankshaft position sensor side The NE pul...

Page 153: ...MAF sensor voltage 0 1 V or less Engine warning light ON System action 25 C 77 F default value Recovery from error Diagnostic counter zero 9Y1200192CRS0665US0 P0073 171 3 Intake air temperature built...

Page 154: ...AFS 4 Terminal IATS 5 Terminal IATS GND a Terminal Layout b Mass Air Flow MAF Sensor c Intake Air Temperature Built in MAF d ECU Connector 1 A 96 Pin Factory specification Actual intake air temperatu...

Page 155: ...at the ECU side 9Y1200192CRS0670US0 Factory specification Temperature Resistance 20 C 68 F Approx 2 43 k 40 C 104 F Approx 1 15 k 60 C 140 F Approx 0 587 k 80 C 176 F Approx 0 321 k OK Go to 4 Measure...

Page 156: ...d B A Fuel leak P0093 is detected B Condition 1 or 2 is fulfilled 1 Rail pressure exceeds 191 MPa 1950 kgf cm2 27700 psi 2 Within 1 sec after the rail pressure goes below 191 MPa 1950 kgf cm2 27700 ps...

Page 157: ...iagnosis without returning the key switch to the OFF position However carefully make satisfactory unsatisfactory judgments as the injection amount and rail pressure are limited by system actions If on...

Page 158: ...by performing the actual run test 9Y1200192CRS0205US0 2 Check the Fuel System for the Existence of Air 1 Check each joint of the fuel system for the existence of air To detect the existence of air eff...

Page 159: ...Clear the past malfunction data and make sure that the same DTC is output again in the reproduction test NOTE Use all of the available information and try to reproduce the problem by operating the ac...

Page 160: ...1800 mA Accelerator opening 0 100 During acceleration Approx 1400 mA minimum During no load maximum speed Approx 1600 mA The numerical value is stable under normal operating and the target value corr...

Page 161: ...econditions Rail pressure sensor is normal Sensor supply voltage VCC is normal DTC set parameter Actual pressure 197 MPa 2010 kgf cm2 28600 psi Engine warning light ON System action Output limitation...

Page 162: ...iagnosis without returning the key switch to the OFF position However carefully make satisfactory unsatisfactory judgments as the injection amount and rail pressure are limited by system actions If on...

Page 163: ...re always follow to the Target rail pressure 1 When idling 40 to 50 MPa 410 to 500 kgf cm2 5800 to 7200 psi 2 Accelerator opening 0 100 During acceleration Maximum value 95 0 to 130 MPa 969 to 1320 kg...

Page 164: ...Clear the past malfunction data and make sure that the same DTC is output again in the reproduction test NOTE Use all of the available information and try to reproduce the problem by operating the ac...

Page 165: ...1800 mA Accelerator opening 0 100 During acceleration Approx 1400 mA minimum During no load maximum speed Approx 1600 mA The numerical value is stable under normal operating and the target value corr...

Page 166: ...r higher Injector is normal Battery voltage is normal Sensor supply voltage VCC is normal Rail pressure sensor is normal DTC set parameter Discharge request of supply pump goes below 0 mm3 st and the...

Page 167: ...iagnosis without returning the key switch to the OFF position However carefully make satisfactory unsatisfactory judgments as the injection amount and rail pressure are limited by system actions If on...

Page 168: ...t rail pressure 1 When idling 40 to 50 MPa 410 to 500 kgf cm2 5800 to 7200 psi 2 Accelerator opening 0 100 During acceleration Maximum value 95 0 to 130 MPa 969 to 1320 kgf cm2 13800 to 18800 psi 3 No...

Page 169: ...Clear the past malfunction data and make sure that the same DTC is output again in the reproduction test NOTE Use all of the available information and try to reproduce the problem by operating the ac...

Page 170: ...0923US0 Factory specification 1 The Actual SCV current value always follow to the Target SCV current value When idling Approx 1800 mA Accelerator opening 0 100 During acceleration Approx 1400 mA minim...

Page 171: ...e sensor is normal Supply pump SCV is normal Injector and injector drive circuit are normal NE signal is active Engine is operating 700 min 1 rpm or higher No DTC of P0087 P0088 P0089 DTC set paramete...

Page 172: ...iagnosis without returning the key switch to the OFF position However carefully make satisfactory unsatisfactory judgments as the injection amount and rail pressure are limited by system actions If on...

Page 173: ...t rail pressure 1 When idling 40 to 50 MPa 410 to 500 kgf cm2 5800 to 7200 psi 2 Accelerator opening 0 100 During acceleration Maximum value 95 0 to 130 MPa 969 to 1320 kgf cm2 13800 to 18800 psi 3 No...

Page 174: ...eck the temperature of the pressure limiter return pipe by touching it Reference If the fuel leaks from the pressure limiter the high temperature and high pressure fuel flows through the return pipe a...

Page 175: ...DTC is output again in the reproduction test NOTE Use all of the available information and try to reproduce the problem by operating the accelerator pedal in different ways and by changing the enviro...

Page 176: ...1800 mA Accelerator opening 0 100 During acceleration Approx 1400 mA minimum During no load maximum speed Approx 1600 mA The numerical value is stable under normal operating and the target value corre...

Page 177: ...y switch turn OFF 9Y1200192CRS0675US0 1 Check the Air Intake System 1 Check in accordance with 6 1 AIR INTAKE SYSTEM INSPECTION PROCEDURE Refer to page 1 S285 NOTE Check if the suction hose of the tur...

Page 178: ...mal condition EGR stop Intake throttle 100 open Recovery from error Key switch turn OFF 9Y1200192CRS0676US0 P0103 132 3 MAF sensor abnormality High side Behaviour during malfunction Insufficient outpu...

Page 179: ...us 3 Check whether the DTC is output or not 9Y1200192CRS0239US0 1 Terminal Power 12 V 2 Terminal AFS GND 3 Terminal AFS 4 Terminal IATS 5 Terminal IATS GND a Terminal Layout b Mass Air Flow MAF Sensor...

Page 180: ...rt up 20 C 4 F default value Under other conditions 40 C 104 F Default value Recovery from error Diagnostic counter zero 9Y1200192CRS0680US0 P0113 172 3 Intake air temperature error High side Behaviou...

Page 181: ...minal THA 2 Terminal A GND1 a Terminal Layout b Intake Air Temperature Sensor c ECU Connector 2 B 58 Pin Factory specification Actual intake air temperature Intake air temperature Output voltage 20 C...

Page 182: ...ure the voltage between ECU terminals B 15 and B 28 at the ECU side 9Y1200192CRS0684US0 Factory specification Temperature Resistance 20 C 68 F Approx 2 4 k 60 C 140 F Approx 0 58 k 100 C 212 F Approx...

Page 183: ...roximately 50 of normal condition Speed limitation Accelerator limitation 50 EGR stop Recovery from error Key switch turn OFF 9Y1200192CRS0685US0 P0118 110 3 Coolant temperature sensor abnormality Hig...

Page 184: ...al A GND2 a Terminal Layout b Coolant Temperature Sensor c ECU Connector 1 A 96 Pin Factory specification Actual coolant temperature Coolant temperature Output voltage 20 C 68 F 20 C 68 F Approx 2 4 V...

Page 185: ...nd A 39 at the ECU side 9Y1200192CRS0689US0 Factory specification Temperature Resistance 20 C 68 F Approx 2 5 k 40 C 104 F Approx 1 2 k 60 C 140 F Approx 0 58 k 80 C 176 F Approx 0 32 k 100 C 212 F Ap...

Page 186: ...start up 20 C 4 F default value Under other conditions 45 C 113 F default value Recovery from error Diagnostic counter zero 9Y1200192CRS0690US0 P0183 174 3 Fuel temperature sensor abnormality High sid...

Page 187: ...minal THF 2 Terminal A GND5 a Terminal Layout b Fuel Temperature Sensor c ECU Connector 1 A 96 Pin Factory specification Actual fuel temperature Fuel temperature Output voltage 20 C 68 F 20 C 68 F App...

Page 188: ...voltage between ECU terminals A 8 and A 31 at the ECU side 9Y1200192CRS0694US0 Factory specification Temperature Resistance 20 C 68 F Approx 2 5 k 40 C 104 F Approx 1 2 k 60 C 140 F Approx 0 58 k 80 C...

Page 189: ...ressure 80 MPa 820 kgf cm2 12000 psi EGR stop Engine forcibly stopped 60 sec later Recovery from error Key switch turn OFF 9Y1200192CRS0695US0 P0193 157 3 Rail pressure sensor abnormality High side Be...

Page 190: ...ng no load maximum speed 95 0 to 115 MPa 969 to 1170 kgf cm2 13800 to 16600 psi Reference value Factory spec has complete linearity 9Y1200192CRS0275US0 1 Terminal A VCC1 2 Terminal PFUEL 3 Terminal A...

Page 191: ...CRS0699US0 Factory specification Depends on the rotation speed load After warm up 1 When stopped Approx 1 0 V 2 When idling 1 65 to 1 80 V 3 During no load maximum speed 2 50 to 2 85 V 4 During accele...

Page 192: ...oltage between ECU terminals A 24 and A 16 9Y1200192CRS0701US0 Factory specification Approx 5 V OK Check the wiring harness connector and sensor pins OK Faulty rail pressure sensor Replace NG 1 Repair...

Page 193: ...gain 1 Turn the key switch OFF and then ON again 2 After clearing the DTC turn the key switch OFF and then ON again and start the engine 3 Check whether or not the same DTC P0200 is detected 9Y1200192...

Page 194: ...lace the ECU 2 Turn the key switch OFF and then ON again 3 After clearing the DTC turn the key switch OFF and then ON again and start the engine 4 Check whether or not the same DTC P0200 is detected 9...

Page 195: ...2 cylinder injector TWV4 wiring harness open circuit coil open circuit Behaviour during malfunction Insufficient output Large vibration Worsening exhaust gas performance Detection item Open circuit o...

Page 196: ...RS0287US0 1 Terminal COMMON 2 Terminal TWV a Terminal Layout b Engine Cylinder No c Injector d Rated Amperage Circuit e High Voltage Generation Circuit f Control Circuit g ECU Connector 1 A 96 Pin Eng...

Page 197: ...connector of the cylinder indicated by the DTC and measure the resistance between injector terminals 1 and 2 9Y1200192CRS0289US0 Factory specification Must be free from faulty connection deformation p...

Page 198: ...ditions Coolant temperature sensor is normal DTC set parameter Engine coolant temperature 120 C 248 F Engine warning light ON System action Output limitation Approximately 75 of normal condition EGR s...

Page 199: ...or an error 9Y1200192CRS0708US0 OK Check the cooling system Repair the faulty area If the cooling system is operating normally ask the user about malfunction occurrence based on the freeze frame data...

Page 200: ...earing the DTC turn the key switch OFF and then ON again and start the engine 3 Check whether or not the same DTC P0219 is detected 9Y1200192CRS0294US0 2 Checking with the User 1 The following actions...

Page 201: ...Engine warning light ON System action 65 kPa 0 6628 kgf cm2 9 426 psi default value Recovery from error Key switch turn OFF 9Y1200192CRS0710US0 P0238 102 3 Boost temperature sensor abnormality High si...

Page 202: ...and check the same items again NOTE Reference value Factory specification has complete linearity 9Y1200192CRS0299US0 1 Terminal A VCC2 2 Terminal PIM 3 Terminal A GND4 a Terminal Layout b Boost Pressu...

Page 203: ...e depressed amount of the accelerator pedal and check the same items again 9Y1200192CRS0714US0 Factory specification Engine state Output voltage Key switch ON Approx 1 0 V After engine start up 1 0 to...

Page 204: ...between intake manifold and sensor When it is damaged the boost pressure can not reach the sensor 9Y1200192CRS0716US0 Factory specification Approx 5 V OK Check the wiring harness connector and sensor...

Page 205: ...tion Speed limitation Accelerator limitation 50 NOTE Engine will stop if both NE and G fail Recovery from error Key switch turn OFF 9Y1200192CRS0717US0 P0336 636 2 NE sensor pulse number error Behavio...

Page 206: ...NE VCC 2 Terminal NE 3 Terminal NE GND a Terminal Layout b Crankshaft Position Sensor NE Sensor c NE Sensor Input Circuit d ECU Connector 1 A 96 Pin Factory specification Always ON OK It should be co...

Page 207: ...RS0852US0 4 Check the Wiring Harness 1 Check the wiring harness between NE terminal of sensor and ECU for a short or an open circuit 9Y1200192CRS0853US0 Factory specification Approx 5 V OK Go to 3 Che...

Page 208: ...circuit 9Y1200192CRS0722US0 8 Check the Sensor 1 Disconnect the sensor and check the following items Is there a large amount of magnetic foreign material adhering to the sensor surface Are there inte...

Page 209: ...n of 1 k resistive element and connector Check if there is damage of 1 k resistive element measure the resistance of resistive element with tester 9Y1200192CRS0315US0 OK Replace the ECU and test NG Re...

Page 210: ...arning light ON System action None NOTE Engine will stop if both NE and G fail Recovery from error Diagnostic counter zero 9Y1200192CRS0723US0 P0341 723 2 G sensor pulse number error Behaviour during...

Page 211: ...nal G VCC 2 Terminal G 3 Terminal G GND a Terminal Layout b Camshaft Position Sensor G Sensor c G Sensor Input Circuit d ECU Connector 1 A 96 Pin Factory specification Always ON OK It should be confir...

Page 212: ...0321US0 4 Check the Wiring Harness 1 Check the wiring harness between G terminal of sensor and ECU for a short or an open circuit 9Y1200192CRS0322US0 Factory specification Approx 5 V OK Go to 3 Check...

Page 213: ...en circuit 9Y1200192CRS0728US0 8 Check the Sensor 1 Disconnect the sensor and check the following items Is there a large amount of magnetic foreign material adhering to the sensor surface Are there in...

Page 214: ...ns Battery voltage is normal During air heater relay drive command is activated DTC set parameter B short circuit of harness Engine warning light ON System action None Recovery from error Key switch t...

Page 215: ...shown in the left figure and turn the key switch ON Dummy Resistor 15 to 25 k Comparable to Approx 30 to 20 C Approx 22 to 5 F 4 Check the Glow relay data with the data monitor 9Y1200192CRS0330US0 1 T...

Page 216: ...relay unit between 3 and 4 9Y1200192CRS0733US0 4 ECU Replacement Check 1 Replace the ECU and perform the previous Check the GLRY signal 9Y1200192CRS0333US0 Factory specification Both have continuity F...

Page 217: ...e warning light ON System action Output limitation Approximately 75 of normal condition EGR stop Recovery from error Key switch turn OFF 9Y1200192CRS0734US0 P0404 523574 4 EGR actuator coil short Beha...

Page 218: ...CAN1 Bus off EGR control line is normal DTC set parameter EGR position sensor error signal received via CAN Engine warning light ON System action Output limitation Approximately 75 of normal conditio...

Page 219: ...l to the CAN1 connector 2 Place the key switch in the ON position check whether the DTC is output or not 3 Check the DTC again after starting up the engine with the coolant temperature over 65 C 149 F...

Page 220: ...re switch ON continues one sec or more Engine warning light ON System action Engine stop Recovery from error Key switch turn OFF 9Y1200192CRS0738US0 1 DTC Judgment 1 Place the key switch in the OFF po...

Page 221: ...sured perform the oil pressure measurement 9Y1200192CRS0342US0 4 Check the Oil and Oil Filter 1 Replace specified oil and the oil filter and reconfirms it with the service tool 9Y1200192CRS0926US0 5 C...

Page 222: ...default value Recovery from error Key switch turn OFF 9Y1200192CRS0740US0 P0544 3242 3 Exhaust gas temperature sensor 1 T1 abnormality High side Behaviour during malfunction None Detection item Open...

Page 223: ...C GND 2 Terminal ODOC a Terminal Layout b Exhaust Gas Temperature Sensor 1 T1 c ECU Connector 1 A 96 Pin Factory specification Actual exhaust gas temperature Exhaust gas temperature Output voltage 100...

Page 224: ...ls A 12 and A 36 at the ECU side 9Y1200192CRS0744US0 Factory specification Temperature Resistance 100 C 212 F Approx 18 3 k 150 C 302 F Approx 7 88 k 200 C 392 F Approx 4 00 k 250 C 482 F Approx 2 30...

Page 225: ...m error Key switch turn OFF 9Y1200192CRS0745US0 P0547 4765 3 Exhaust gas temperature sensor 0 T0 abnormality Low side Behaviour during malfunction None Detection item Open circuit or B short circuit o...

Page 226: ...C GND 2 Terminal IDOC a Terminal Layout b Exhaust Gas Temperature Sensor 0 T0 c ECU Connector 1 A 96 Pin Factory specification Actual exhaust gas temperature Exhaust gas temperature Output voltage 100...

Page 227: ...ls A 14 and A 38 at the ECU side 9Y1200192CRS0749US0 Factory specification Temperature Resistance 100 C 212 F Approx 18 3 k 150 C 302 F Approx 7 88 k 200 C 392 F Approx 4 00 k 250 C 482 F Approx 2 30...

Page 228: ...tion Speed limitation Accelerator limitation 50 EGR stop Intake throttle 100 open Only main injection permitted Recovery from error Diagnostic counter zero 9Y1200192CRS0750US0 P0563 168 3 Battery volt...

Page 229: ...a monitor 2 Change the engine operation status and check the Battery voltage NOTE Try to change the engine speed as the generated voltage changes accordingly 9Y1200192CRS0362US0 a Main Relay b Battery...

Page 230: ...to change the engine speed as the generated voltage changes accordingly 9Y1200192CRS0754US0 Factory specification 8 V or higher 15 V or lower except intense cold temperature OK Check the harness conn...

Page 231: ...data Behaviour during malfunction Insufficient output Detection item Area of QR data on EEPROM is vacant DTC set preconditions Key switch is ON DTC set parameter When QR correction data fails to write...

Page 232: ...itch is ON DTC set parameter Battery voltage 10 V Starter switch is OFF CPU abnormality counter 5 times RUN pulse abnormality occurs 5 times or more Engine warning light ON System action Engine stop R...

Page 233: ...key switch to the ON position again 2 Clear the DTC and check whether the same DTC P0605 or P0606 is output again or not 9Y1200192CRS0371US0 Factory specification No DTC is output OK An electromagnet...

Page 234: ...normal CPU is normal DTC set parameter Injector charge voltage Low Failure of charge circuit of ECU Engine warning light ON System action Output limitation Approximately 50 of normal condition Speed l...

Page 235: ...cking Whether the DTC Is Detected Again 1 Replace the ECU 2 Turn the key switch OFF and then ON again 3 After clearing the DTC turn the key switch OFF and then ON again and start the engine 4 Check wh...

Page 236: ...ccelerator limitation 50 Rail pressure limitation Command pressure 80 MPa 820 kgf cm2 12000 psi EGR stop Recovery from error Key switch turn OFF 9Y1200192CRS0761US0 P0629 1347 3 B short circuit of SCV...

Page 237: ...COMMON RAIL SYSTEM V3800 CR TE4 V3800 CR TIE4 DM 1 S210 9Y1200192CRS0763US0 1 Terminal SCV 2 Terminal SCV a Terminal Layout b SCV Suction Control Valve c ECU Connector 2 B 58 Pin KiSC issued 05 2012 A...

Page 238: ...all be used as a reference only as this value varies depending on the pump used 2 The Pressure feedback integral guard executing flag must be OFF 3 The Pump deviation learning correction value must be...

Page 239: ...and measure the voltage between ECU terminals B 7 and B 20 and the ground at the wiring harness side 9Y1200192CRS0765US0 Factory specification Item Temperature Resistance Resistance 20 C 68 F Approx 2...

Page 240: ...limitation Command pressure 80 MPa 820 kgf cm2 12000 psi EGR stop Intake throttle 100 open Recovery from error Key switch turn OFF 9Y1200192CRS0766US0 P0643 3509 3 Sensor supply voltage 1 abnormality...

Page 241: ...ure the voltage between ECU terminals A 24 and B 1 B 2 9Y1200192CRS0769US0 a ECU Connector 2 B 58 Pin b ECU Connector 1 A 96 Pin Factory specification Approx 5 V OK Check the wiring harness ECU termin...

Page 242: ...limitation Approximately 50 of normal condition Speed limitation Accelerator limitation 50 Recovery from error Key switch turn OFF 9Y1200192CRS0770US0 P0653 3510 3 Sensor supply voltage 2 abnormality...

Page 243: ...ure the voltage between ECU terminals A 46 and B 1 B 2 9Y1200192CRS0773US0 a ECU Connector 2 B 58 Pin b ECU Connector 1 A 96 Pin Factory specification Approx 5 V OK Check the wiring harness ECU termin...

Page 244: ...Main relay stays active longer than 1 sec without command and battery voltage is 8 V or more Engine warning light ON Follow the machine instruction System action None Recovery from error Diagnostic co...

Page 245: ...Check the ECU Terminal Voltage 1 Keep the key switch in the OFF position and measure the voltage at ECU main relay terminal B 33 9Y1200192CRS0778US0 Factory specification 0 V OK Clear the DTC and chec...

Page 246: ...terminal Example of main relay terminal layout 9Y1200186CRS0113US0 Factory specification Between terminals 3 and 4 Coil resistance value of relay to use Between terminals 1 and 2 Infinity NG Faulty m...

Page 247: ...n OFF 9Y1200192CRS0779US0 P1275 523540 2 Pump seizing 2 Behaviour during malfunction Insufficient output Worsening exhaust gas performance Detection item High pressure 2 error DTC set preconditions Se...

Page 248: ...iagnosis without returning the key switch to the OFF position However carefully make satisfactory unsatisfactory judgments as the injection amount and rail pressure are limited by system actions If on...

Page 249: ...pection procedures Refer to page 1 S212 9Y1200192CRS0404US0 1 Terminal SCV 2 Terminal SCV a Terminal Layout b SCV Suction Control Valve c ECU Connector 2 B 58 Pin Factory specification Item Temperatur...

Page 250: ...tem occurs inside the head cover so check that the oil level has not increased 1 Check in accordance with 6 2 FUEL SYSTEM INSPECTION PROCEDURE Refer to page 1 S287 9Y1200192CRS0927US0 OK Go to 4 Check...

Page 251: ...the Target rail pressure 1 When idling 40 to 50 MPa 410 to 500 kgf cm2 5800 to 7200 psi 2 Accelerator opening 0 100 During acceleration Maximum value 95 0 to 130 MPa 969 to 1320 kgf cm2 13800 to 18800...

Page 252: ...1800 mA Accelerator opening 0 100 During acceleration Approx 1400 mA minimum During no load maximum speed Approx 1600 mA The numerical value is stable under normal operating and the target value corr...

Page 253: ...C set parameter Approximate parameter Deviation of throttle position is not corrected in 20 times Engine warning light ON System action Intake throttle 100 open Recovery from error Key switch turn OFF...

Page 254: ...Actual intake throttle valve opening and Intake throttle opening output voltage and check the values For details refer to the active test section 2 Clear the DTC and check whether it is output again...

Page 255: ...d etc DTC set preconditions Battery voltage is normal Key switch turn OFF to ON No ST signal DTC set parameter When accelerator position sensor error signal received by CAN Engine warning light ON Sys...

Page 256: ...nfirm that no defects except those in the engine occur 9Y1200192CRS0929US0 Factory specification No DTC P2131 is output OK Normal NG Go to 2 Check the Monitor of the Tractor a CAN1 Connector Factory s...

Page 257: ...ry voltage is normal During injection CPU is normal DTC set parameter When wiring harness open circuit Engine warning light ON System action Output limitation Approximately 50 of normal condition Spee...

Page 258: ...connector and measure the resistance between each terminal at the connector side as shown on the following table 9Y1200192CRS0789US0 Factory specification Either DTC P2146 or P2149 is output OK Go to...

Page 259: ...g harness connectors of each ECU terminal and the ECU pins for faulty connection deformation or other defects 9Y1200192CRS0791US0 7 Check the DTC 1 Place the key switch in the OFF position and attach...

Page 260: ...limitation Approximately 50 of normal condition Speed limitation Accelerator limitation 50 EGR stop Recovery from error Key switch turn OFF 9Y1200192CRS0792US0 P2148 523523 3 Common 1 TWV actuation s...

Page 261: ...for faulty connection deformation poor contact or other defects 9Y1200192CRS0795US0 1 Terminal COMMON 2 Terminal TWV a Terminal Layout b Engine Cylinder No c Injector d Rated Amperage Circuit e High...

Page 262: ...ECU Terminal Voltage Part 2 1 Place the key switch in the OFF position unplug the ECU wiring harness connector 1 A 96 Pin from the socket return the key switch to the ON position again and measure th...

Page 263: ...sing an insulation resistance tester megger tester measure the resistance between each of terminals 1 and 2 and the chassis ground at the injector side 9Y1200192CRS0798US0 DTC Relating ECU Terminals S...

Page 264: ...ry voltage is normal During injection CPU is normal DTC set parameter When wiring harness open circuit Engine warning light ON System action Output limitation Approximately 50 of normal condition Spee...

Page 265: ...connector and measure the resistance between each terminal at the connector side as shown on the following table 9Y1200192CRS0789US0 Factory specification Either DTC P2146 or P2149 is output OK Go to...

Page 266: ...g harness connectors of each ECU terminal and the ECU pins for faulty connection deformation or other defects 9Y1200192CRS0791US0 7 Check the DTC 1 Place the key switch in the OFF position and attach...

Page 267: ...limitation Approximately 50 of normal condition Speed limitation Accelerator limitation 50 EGR stop Recovery from error Key switch turn OFF 9Y1200192CRS0800US0 P2151 523524 3 Common 2 TWV actuation s...

Page 268: ...for faulty connection deformation poor contact or other defects 9Y1200192CRS0795US0 1 Terminal COMMON 2 Terminal TWV a Terminal Layout b Engine Cylinder No c Injector d Rated Amperage Circuit e High...

Page 269: ...ECU Terminal Voltage Part 2 1 Place the key switch in the OFF position unplug the ECU wiring harness connector 1 A 96 Pin from the socket return the key switch to the ON position again and measure th...

Page 270: ...sing an insulation resistance tester megger tester measure the resistance between each of terminals 1 and 2 and the chassis ground at the injector side 9Y1200192CRS0798US0 DTC Relating ECU Terminals S...

Page 271: ...ehaviour during malfunction At high altitude Insufficient output Detection item Sensor ECU internal circuit short to B DTC set preconditions Battery voltage is normal DTC set parameter Barometric pres...

Page 272: ...Clear the past DTCs and check whether the same DTC P2228 or P2229 is output again or not 9Y1200192CRS0479US0 Factory specification OK OK An electromagnetic interference EMI may have caused the tempora...

Page 273: ...t ON System action Output limitation Approximately 75 of normal condition EGR stop Recovery from error Key switch turn OFF 9Y1200192CRS0804US0 P2414 523576 2 EGR DC motor overheat Behaviour during mal...

Page 274: ...U0077 CAN1 Bus off EGR control line is normal DTC set parameter EGR DC motor temperature sensor error signal received via CAN Engine warning light ON System action Output limitation Approximately 75...

Page 275: ...l to the CAN1 connector 2 Place the key switch in the ON position check whether the DTC is output or not 3 Check the DTC again after starting up the engine with the coolant temperature over 65 C 149 F...

Page 276: ...overy from error Key switch turn OFF 9Y1200192CRS0807US0 P242D 3246 3 Exhaust gas temperature sensor 2 T2 abnormality High side Behaviour during malfunction None Detection item Sensor Harness open cir...

Page 277: ...F GND 2 Terminal ODPF a Terminal Layout b Exhaust Gas Temperature Sensor 2 T2 c ECU Connector 1 A 96 Pin Factory specification Actual exhaust gas temperature Exhaust gas temperature Output voltage 100...

Page 278: ...ls A 58 and A 62 at the ECU side 9Y1200192CRS0811US0 Factory specification Temperature Resistance 100 C 212 F Approx 18 3 k 150 C 302 F Approx 7 88 k 200 C 392 F Approx 4 00 k 250 C 482 F Approx 2 30...

Page 279: ...V or less Engine warning light ON System action 0 kPa 0 0 kgf cm2 0 0 psi default value Recovery from error Key switch turn OFF 9Y1200192CRS0812US0 P2455 3251 3 Differential pressure sensor 1 abnorma...

Page 280: ...ure sensor output voltage on the diagnosis tool data monitor 9Y1200192CRS0495US0 1 Terminal DPS VCC 2 Terminal DPS GND 3 Terminal DPS a Terminal Layout b Differential Pressure Sensor c ECU Connector 1...

Page 281: ...92CRS0855US0 Factory specification Engine state Output voltage Key switch ON Approx 0 7 V OK Check the harness connectors and ECU pins OK Faulty ECU Replace NG Repair or replace the wiring harness or...

Page 282: ...ate filter DPF and sensor When it is damaged the differential pressure can not reach the sensor 9Y1200192CRS0816US0 Factory specification Approx 5 V OK Check the harness connectors and ECU pins OK Fau...

Page 283: ...hrottle lift sensor voltage 0 1 V or less Engine warning light ON System action Intake throttle 100 open Recovery from error Key switch turn OFF 9Y1200192CRS0817US0 P2622 523582 3 Intake throttle lift...

Page 284: ...ge and check the values For details refer to the active test section 2 Clear the DTC and check whether it is output again or not 9Y1200192CRS0417US0 1 No Connection 2 Terminal Power 5 V 3 Terminal ITS...

Page 285: ...heck the Air Intake System 1 Check in accordance with 6 1 AIR INTAKE SYSTEM INSPECTION PROCEDURE Refer to page 1 S285 NOTE Check the clogging condition of the air cleaner If it is very dirty replace t...

Page 286: ...after starting up the engine by monitoring the data signals 9Y1200192CRS0506US0 3 Check the Exhaust Gas Temperature Sensors 1 Check the exhaust gas temperature sensors T0 T1 and T2 9Y1200192CRS0507US0...

Page 287: ...MPORTANT If the two errors occur from Emergency exhaust gas temperature sensor T0 high Emergency exhaust gas temperature sensor T1 high and Emergency exhaust gas temperature T2 high at the same time c...

Page 288: ...he other DTC is output or not by operating the engine in the normal condition 3 If it is OK restart and operate the engine for 10 minutes with the engine in the no load maximum speed status Check whet...

Page 289: ...MPORTANT If the two errors occur from Emergency exhaust gas temperature sensor T0 high Emergency exhaust gas temperature sensor T1 high and Emergency exhaust gas temperature T2 high at the same time c...

Page 290: ...r turbo has abnormality sound and externals 2 Check whether the other DTC is output or not by operating the engine in the normal condition 3 If it is OK restart and operate the engine for 10 minutes w...

Page 291: ...fer to page 1 S285 IMPORTANT If the two errors occur from Emergency exhaust gas temperature sensor T0 high Emergency exhaust gas temperature sensor T1 high and Emergency exhaust gas temperature T2 hig...

Page 292: ...her turbo has abnormality sound and externals 2 Check whether the other DTC is output or not by operating the engine in the normal condition 3 If it is OK restart and operate the engine for 10 minutes...

Page 293: ...cted to the DPF assembly 2 Check whether the intake throttle opens completely after starting up the engine 3 Check whether the coolant temperature is over 65 C 149 F by operating the engine in the nor...

Page 294: ...ation Approximately 50 of normal condition Recovery from error Diagnostic counter zero 9Y1200192CRS0823US0 1 DPF Manual Regeneration 1 Start DPF Manual Regeneration immediately NOTE This DTC means the...

Page 295: ...ne warning light ON System action Output limitation Approximately 50 of normal condition Recovery from error Diagnostic counter zero 9Y1200192CRS0824US0 1 DPF Manual Regeneration Reguest Function 1 Pe...

Page 296: ...tion more than trigger level 36000 mg Engine warning light ON System action Output limitation Approximately 50 of normal condition Recovery from error Key switch turn OFF 9Y1200192CRS0825US0 1 Replace...

Page 297: ...ion Accelerator limitation 50 EGR stop Recovery from error Key switch turn OFF 9Y1200192CRS0826US0 1 Check the Air Intake System 1 Check in accordance with 6 1 AIR INTAKE SYSTEM INSPECTION PROCEDURE R...

Page 298: ...d externals 2 Check whether the other DTC is output or not by operating the engine in the normal condition 3 If it is OK restart and operate the engine for 10 minutes with the engine in the no load ma...

Page 299: ...S0827US0 1 Check the Coolant Temperature 1 Perform the DPF Manual Regeneration again after warming up the engine 2 Monitor the coolant temperature in the no load maximum speed status with the diagnosi...

Page 300: ...rust is not occurred 3 Reinstall or replace the thermostat as necessary 9Y1200192CRS0539US0 2 DPF Manual Regeneration 1 Place the key switch in the OFF position and attach the diagnosis tool to the C...

Page 301: ...the exhaust gas temperature sensors T0 T1 and T2 9Y1200192CRS0541US0 OK Normal NG Repair or replace the exhaust gas temperature sensor or engine combustion main parts Follow the diagnostic procedure o...

Page 302: ...erature sensor 1 Check the installation of all exhaust gas temperature sensors T0 T1 and T2 9Y1200192CRS0543US0 2 Check the Exhaust Gas Temperature Sensors Refer to items P0543 P0546 and P242C 1 Check...

Page 303: ...SYSTEM INSPECTION PROCEDURE Refer to page 1 S285 NOTE Check the installation of the differential pressure sensor pipes Check the engine oil maintenance history Oil consumption 9Y1200192CRS0934US0 2 C...

Page 304: ...ion of DPF 1 Operate the engine for 30 minutes in the normal condition 9Y1200192CRS0552US0 Factory specification DPF Regeneration Request is not detected within 30 minutes OK Normal NG Replace the DPF...

Page 305: ...action Forced Idle Accelerator 0 Recovery from error Key switch turn OFF 9Y1200192CRS0831US0 1 DTC Judgment 1 Place the key switch in the OFF position and attach the diagnosis tool to the CAN1 connect...

Page 306: ...harness and connectors being connected to ECU terminals B 38 and B 39 for a short or an open circuit IMPORTANT Refer to 6 3 ELECTRIC SYSTEM INSPECTION PROCEDURE 1 Basics of Checking Electrical Electro...

Page 307: ...oltage is normal No ST signal DTC set parameter Interruption of CAN Engine warning light ON System action Output limitation Approximately 75 of normal condition EGR stop Recovery from error Key switch...

Page 308: ...h in the ON position and measure the voltage between EGR terminals 3 and 4 9Y1200192CRS0561US0 3 Check the DTC Again 1 Clear the past malfunction data and make sure that the same DTC is output again i...

Page 309: ...l condition EGR stop Recovery from error Key switch turn OFF 9Y1200192CRS0835US0 9Y1200192CRS0836US0 1 Check the Wiring Related to the CAN of the Common Rail System 1 Check the connector and the wirin...

Page 310: ...frame error Behaviour during malfunction None Detection item CAN CCVS communication stopping DTC set preconditions Battery voltage is normal Starter switch signal ECU B 54 terminal is not activated D...

Page 311: ...Check the Wiring Related to the CAN of the Common Rail System 1 Check the wiring harness and connectors being connected to ECU terminals B 38 and B 39 for a short or an open circuit IMPORTANT Refer t...

Page 312: ...leaner for clogging Clean air cleaner element Primary and Secondary every 250 hours Replace air cleaner element Once yearly or after every sixth cleaning whichever comes first 9Y1200192CRS0935US0 OK G...

Page 313: ...oler etc Suction path joints Suction pipes hoses NOTE A small amount of gas and water bleeds from the valve chamber gas bleeding hole of the EGR valve This is normal 9Y1200192CRS0936US0 OK Normal NG R...

Page 314: ...European Norm 3 ASTM American Society of Testing and Materials 4 US EPA United States Environmental Protection Agency 5 No 1 D or No 2 D S15 Ultra Low Sulfur Diesel ULSD 15 ppm or 0 0015 wt When biodi...

Page 315: ...an expected Biodiesel fuels easily induce the growth of microorganisms and foul themselves This may get the fuel system corroded and the fuel filter clogged In cold weather some problems may occur the...

Page 316: ...lor brownish white turbidit Odor kerosene heavy oil irritating odor Separation of materials water foreign objects Viscosity high low viscosity wax consistency NOTE Always use the specified fuel 9Y1200...

Page 317: ...t pipe connections 9Y1200192CRS0938US0 3 Tank External Fuel Path Conditions Crushed Hose Clogging Air Introduction at Hose Connection 1 Check the condition of the hose Crushing around bands over bendi...

Page 318: ...uching it directly by hand NOTE If there is a fuel feed pump malfunction the fuel cannot be supplied and so there is greater likelihood of improper recognition of DTC codes related to the pressure and...

Page 319: ...pply Pump for Fuel Leakage Engine External Leak 1 Visually check and specify areas leaking fuel 2 Be cautious because there may be oil leaks in the high pressure pipe and injector areas 9Y1200192CRS05...

Page 320: ...the probe insert a fine metal wire into the rear of the connector and touch the wire to the probe IMPORTANT When inserting a fine metal wire for measurement purposes ensure that the connector waterpr...

Page 321: ...or C 9Y1200192CRS0590US0 Check Voltage 1 In the case of the circuit that supplies voltage to the ECU connector terminals check for an open circuit by performing a voltage check 2 As depicted in Figure...

Page 322: ...As a result it can be said that there is an open circuit between terminal 1 of connector A and terminal 1 of connector C 3 Remove connector B and measure the resistance between terminal 1 of connector...

Page 323: ...sure the voltage directly from the corresponding ECU terminal Judge as a connector connection fault if b is satisfactory and a is unsatisfactory Since some malfunctions only occur intermittently measu...

Page 324: ...lowing Malfunction symptoms Engine does not start Engine warning light is not lit A diagnosis tool communication error occur 9Y1200186CRS0132US0 1 Input Terminal 2 ACC 3 Output Terminal 4 START 5 Term...

Page 325: ...cification BP terminal Ground greater than or equal to 10 V P GND terminal Ground Less than or equal to 0 5 V OK Normal NG Check battery wiring harness ground wire OK Go to 2 Check the Relay Terminal...

Page 326: ...ry specification 10 V or higher OK Go to 5 Check the Relay Terminal Voltage 4 NG Check for a wiring harness open circuit and or connector connection fault Repair Inspect fuse Replace 1 Terminal 1 2 Te...

Page 327: ...itch to the ON position and measure the voltage at the key switch output terminal 3 9Y1200192CRS0846US0 Factory specification When the key switch is set to the ON and OFF the data output is turned ON...

Page 328: ...at the key switch input terminal 1 9Y1200192CRS0606US0 Factory specification 10 V or higher OK Check the key switch Replace NG Check the wiring harness between the battery and key switch and the fuse...

Page 329: ...RVICE LTD 64 ISHIZU KITAMACHI SAKAI KU SAKAI CITY OSAKA 590 0823 JAPAN PHONE 81 72 241 1129 FAX 81 72 245 2484 E mail ksos pub kubota co jp KUBOTA Corporation 2012 02 S EI EI engusa Printed in Japan 2...

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