Kubota V3800-CR-TE4B, V3800-CR-TIE4B Engine Common Rail System Diagnosis Manual – PDF DOWNLOAD

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Kubota V3800-CR-TE4B, V3800-CR-TIE4B Engine Common Rail System Diagnosis Manual

TABLE OF CONTENTS:

Kubota V3800-CR-TE4B, V3800-CR-TIE4B Engine Common Rail System Diagnosis Manual

V3800-CR-TE4B,V3800-CR-TIE4B(HYUNDAI).............................................................................................................................................................  1
	I INFORMATION.................................................................................................................................................................................  2
		INFORMATION...............................................................................................................................................................................  3
			1. SAFETY FIRST.......................................................................................................................................................................  4
	1 COMMON RAIL SYSTEM..........................................................................................................................................................................  7
		MECHANISM.................................................................................................................................................................................  8
			1. BASIC SYSTEM INFORMATION...........................................................................................................................................................  9
				[1] SYSTEM CONFIGURATION..........................................................................................................................................................  9
				[2] FUEL SYSTEM................................................................................................................................................................... 10
				[3] INTAKE AND EXHAUST SYSTEM..................................................................................................................................................... 11
				[4] AVAILABLE DATA MONITOR SIGNALS (LEVEL 1)...................................................................................................................................... 12
					(1) Monitor Items............................................................................................................................................................. 12
					(2) Normal Value.............................................................................................................................................................. 15
				[5] ECU TERMINAL LAYOUT........................................................................................................................................................... 18
					(1) ECU Terminal Layout 1 (Engine Side)....................................................................................................................................... 18
					(2) ECU Terminal Layout 2 (Machine Side)...................................................................................................................................... 21
		SERVICING................................................................................................................................................................................. 24
			1. GENERAL............................................................................................................................................................................ 27
				[1] OVERALL DIAGNOSTIC PROCEDURE.................................................................................................................................................. 27
				[2] QUESTIONING................................................................................................................................................................... 28
				[3] LIST OF MALFUNCTION SYMPTOM................................................................................................................................................... 31
				[4] ACTIONS FOR NON-REOCCURRING MALFUNCTIONS...................................................................................................................................... 32
			2. DIAGNOSTIC TOOL CONNECTION PROCEDURE............................................................................................................................................... 34
				[1] DIAGNOSTIC CONNECTOR POSITIONS................................................................................................................................................ 34
				[2] DIAGNOSTIC TOOL CONNECTION PROCEDURE.......................................................................................................................................... 34
				[3] CHECKING THE COMMUNICATION OPERATION OF THE INTERFACE (DST-i)................................................................................................................. 35
				[4] CHECKING THE OPERATION OF THE ECU............................................................................................................................................. 36
					(1) Starting Diagmaster....................................................................................................................................................... 36
					(2) DST-i Communication Settings.............................................................................................................................................. 37
			3. ACTIVE TEST AND SUPPLY PUMP DIFFERENCE LEARNING.................................................................................................................................... 41
			4. DIAGNOSIS BY MALFUNCTION SYMPTOM................................................................................................................................................... 43
				[1] LIST OF MALFUNCTION CAUSES BY SYMPTOM......................................................................................................................................... 43
				[2] DIAGNOSIS BY MALFUNCTION SYMPTOM.............................................................................................................................................. 47
					(1) Engine Warning Light Comes On............................................................................................................................................. 47
					(2) Engine Does Not Start..................................................................................................................................................... 47
					(3) Takes A Long Time Before Engine Starts.................................................................................................................................... 51
					(4) Idle Failure.............................................................................................................................................................. 55
					(5) Engine Noise.............................................................................................................................................................. 58
					(6) High fuel consumption..................................................................................................................................................... 60
					(7) Poor Acceleration (Insufficient Output)................................................................................................................................... 65
					(8) Abnormal Black Smoke Emitted.............................................................................................................................................. 70
					(9) Abnormal White Smoke Emitted.............................................................................................................................................. 74
					(10) Engine Stalls On Deceleration............................................................................................................................................ 79
			5. DIAGNOSTIC PROCEDURE BY DTC........................................................................................................................................................ 83
				[1] DTC LIST...................................................................................................................................................................... 83
				[2] DIAGNOSTIC PROCEDURE BY DTC...................................................................................................................................................149
					(1) NE - G Phase Shift (DTC P0016 / 636-7)....................................................................................................................................153
					(2) Intake Air Temperature Built-in MAF Sensor: Abnormality (DTC P0072 / 171-4, DTC P0073 / 171-3)............................................................................154
					(3) Pressure Limiter Emergency Open (DTC P0087 / 633-7).......................................................................................................................157
					(4) High Rail Pressure (DTC P0088 / 157-0)....................................................................................................................................162
					(5) SCV Stuck (DTC P0089 / 1347-7)............................................................................................................................................167
					(6) Fuel Leak (in High Pressured Fuel System) (DTC P0093 / 1239-1)............................................................................................................172
					(7) MAF Sensor Power Supply: High (24 V-System Only) (DTC P0100 / 132-16).....................................................................................................177
					(8) Intake Air Volume: Low (DTC P0101 / 132-1)................................................................................................................................179
					(9) MAF Sensor Abnormality (DTC P0102 / 132-4, P0103 / 132-3).................................................................................................................180
					(10) MAF Sensor Power Supply: Low (24 V-System Only) (DTC P0104 / 132-18).....................................................................................................182
					(11) Intake Air Temperature: High (Inter Cooler Model Only) (DTC P0111 / 172-0)...............................................................................................184
					(12) Intake Air Temperature Error (DTC P0112 / 172-4, P0113 / 172-3)..........................................................................................................185
					(13) Coolant Temperature Sensor Abnormality (DTC P0117 / 110-4, P0118 / 110-3)................................................................................................188
					(14) Fuel High Temperature (DTC P0181 / 174-0)................................................................................................................................191
					(15) Fuel Temperature Sensor Abnormality (DTC P0182 / 174-4, P0183 / 174-3)...................................................................................................192
					(16) Rail Pressure Sensor Abnormality (DTC P0192 / 157-4, P0193 / 157-3)......................................................................................................195
					(17) Injector Charge Voltage: High (DTC P0200 / 523535-0).....................................................................................................................199
					(18) Open Circuit of Harness/Coil (DTC P0201 / 651-3, P0202 / 653-3, P0203 / 654-3, P0204 / 652-3)............................................................................201
					(19) Engine Overheat (DTC P0217 / 110-0)......................................................................................................................................204
					(20) Engine Overrun (DTC P0219 / 190-0).......................................................................................................................................206
					(21) Boost Pressure Sensor Abnormality (DTC P0237 / 102-4, P0238 / 102-3).....................................................................................................207
					(22) Crankshaft Position Sensor (NE Sensor) Abnormality (DTC P0335 / 636-8, P0336 / 636-2)....................................................................................211
					(23) Camshaft Position Sensor (G Sensor) Abnormality (DTC P0340 / 723-8, P0341 / 723-2).......................................................................................216
					(24) Air Heater Relay Driving Circuit Abnormality (DTC P0380 / 523544-3 / 523544-4)...........................................................................................220
					(25) EGR Actuator Abnormality (DTC P0403 / 523574-3, DTC P0404 / 523574-4, P0409 / 523572-4)..................................................................................223
					(26) Oil Pressure Error (P0524 / 100-1).......................................................................................................................................226
					(27) Exhaust Gas Temperature Sensor 1 (T1) Abnormality (DTC P0543 / 3242-4, P0544 / 3242-3)...................................................................................228
					(28) Exhaust Gas Temperature Sensor 0 (T0) Abnormality (DTC P0546 / 4765-4, P0547 / 4765-3)...................................................................................231
					(29) Battery Voltage Abnormality (DTC P0562 / 168-4, P0563 / 168-3)...........................................................................................................234
					(30) QR Data Abnormality (DTC P0602/523538-2, P0602/523538-7).................................................................................................................237
					(31) ECU Flash-ROM and CPU Abnormality (DTC P0605 / 628-2, P0606 / 1077-2, P0606/ 523527-2)...................................................................................238
					(32) Injector Charge Voltage Abnormality (DTC P0611 / 523525-1)...............................................................................................................240
					(33) SCV Drive System Abnormality (DTC P0628 / 1347-4, P0629 / 1347-3)........................................................................................................242
					(34) Sensor Supply Voltage 1 Abnormality (DTC P0642 / 3509-4, P0643 / 3509-3).................................................................................................246
					(35) Sensor Supply Voltage 2 Abnormality (DTC P0652 / 3510-4, P0653 / 3510-3).................................................................................................248
					(36) Sensor Supply Voltage 3 Abnormality (DTC P0662 / 3511-4, P0663 / 3511-3).................................................................................................250
					(37) Sensor Supply Voltage 4 Abnormality (DTC P0672 / 3512-4, P0673 / 3512-3).................................................................................................252
					(38) Main Relay is Locked in Closed Position (DTC P0687 / 1485-2).............................................................................................................254
					(39) Pump Seizing (DTC P1274 / 523539-2, P1275 / 523540-2)....................................................................................................................257
					(40) EEPROM Check Sum Error (DTC P1990 / 523700-13)...........................................................................................................................262
					(41) Intake Throttle Feedback Error (DTC P2108 / 523580-2)....................................................................................................................263
					(42) Accelerator Position Sensor 1 Abnormality (DTC P2122 / 91-4, P2123 / 91-3)...............................................................................................265
					(43) Accelerator Position Sensor 2 Abnormality (DTC P2127 / 29-4, P2128 / 29-3)...............................................................................................269
					(44) Accelerator Position Sensor Error (CAN) (DTC P2131 / 523543-2)...........................................................................................................273
					(45) Accelerator Position Sensor Correlation Error (DTC P2135 / 91-2).........................................................................................................275
					(46) Common 1 System Injector Drive Circuit Open (DTC P2146 / 523523-2).......................................................................................................276
					(47) Common 1 TWV Actuation System Short (DTC P2147 / 523523-4, P2148 / 523523-3).............................................................................................279
					(48) Common 2 System Injector Drive Circuit Open (DTC P2149 / 523524-2).......................................................................................................283
					(49) Common 2 TWV Actuation System Short (DTC P2150 / 523524-4, P2151 / 523524-3).............................................................................................286
					(50) Barometric Pressure Sensor Error (DTC P2228 / 108-4, P2229 / 108-3)......................................................................................................290
					(51) EGR (DC Motor) Abnormality (DTC P2413 / 523575-7, P2414 / 523576-2, P2415 / 523577-2)....................................................................................292
					(52) Exhaust Gas Temperature Sensor 2 (T2) Abnormality (DTC P242C / 3246-4, P242D / 3246-3)...................................................................................295
					(53) Differential Pressure Sensor 1 Abnormality (DTC P2454 / 3251-4, P2455 / 3251-3)..........................................................................................298
					(54) Intake Throttle Lift Sensor Abnormality (DTC P2621 / 523583-4, P2622 / 523582-3).........................................................................................302
					(55) Emission Deterioration (DTC P3001 / 3252-0)..............................................................................................................................304
					(56) Exhaust Gas Temperature Sensor 0: Emergency High (DTC P3002 / 4765-0)....................................................................................................306
					(57) Exhaust Gas Temperature Sensor 1: Emergency High (DTC P3003 / 3242-0)....................................................................................................308
					(58) Exhaust Gas Temperature Sensor 2: Emergency High (DTC P3004 / 3246-0)....................................................................................................310
					(59) Excessive PM3 (DTC P3006 / 3701-15)......................................................................................................................................312
					(60) Excessive PM4 (DTC P3007 / 3701-16)......................................................................................................................................313
					(61) Excessive PM5 (DTC P3008 / 3701-0).......................................................................................................................................314
					(62) Boost Pressure Low (DTC P3011 / 132-15)..................................................................................................................................315
					(63) Low Coolant Temperature in Parked Regeneration (DTC P3012 / 523589-17)...................................................................................................317
					(64) Parked Regeneration Time Out (DTC P3013 / 523590-16).....................................................................................................................318
					(65) All Exhaust Gas Temperature Sensor Failure (DTC P3018 / 523599-0)........................................................................................................320
					(66) Initial Pump-calibration Incomplete (DTC P3019 / 523600-0)...............................................................................................................321
					(67) High Exhaust Gas Temperature After Emergency High Temperature DTC (DTC P3023 / 523601-0).................................................................................322
					(68) High Frequency of Regeneration (DTC P3024 / 523602-0)....................................................................................................................323
					(69) Over Heat Pre-caution (DTC P3025 / 523603-15)............................................................................................................................324
					(70) CAN2 Bus Off (DTC U0075 / 523547-2)......................................................................................................................................325
					(71) No Communication with EGR (DTC U0076 / 523578-2).........................................................................................................................327
					(72) CAN1 Bus Off (DTC U0077 / 523604-2)......................................................................................................................................329
					(73) CAN2 Frame Error (DTC U0081 / 523548-2, U0082 / 523591-2, U0083 / 523592-2, U0084 / 523593-2, U0085 / 523594-2, U0086 / 523595-2, U0087 / 523596-2, U0089 / 523598-2)....330
			6. INSPECTION PROCEDURE FOR EACH SYSTEM...............................................................................................................................................334
				[1] AIR INTAKE SYSTEM INSPECTION PROCEDURE........................................................................................................................................334
				[2] FUEL SYSTEM INSPECTION PROCEDURE..............................................................................................................................................335
				[3] ELECTRIC SYSTEM INSPECTION PROCEDURE..........................................................................................................................................340
					(1) Basics Of Checking Electrical / Electronic Circuit Systems................................................................................................................340
					(2) Connector Connection Fault Verification Method............................................................................................................................343
					(3) Checking The Power And Ground System (Main Relay, ECU Circuit)............................................................................................................344

KUBOTA V3800-CR-TE4B, V3800-CR-TIE4B ENGINE COMMON RAIL SYSTEM DIAGNOSIS MANUAL – PDF DOWNLOAD:

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