Kubota 07-CR-E5 User manual

DIAGNOSIS MANUAL
COMMON RAIL SYSTEM
07-CR-E5
KiSC issued 03, 2022 A

Record of Revisions
For pdf, use search function {Search word} to find all revised locations.
Last digit
of the
Code No.
Month of
Revision Main Revised Point and Corrective Measures {Search word} Reference
Page
1April 2020 Corrected biodiesel fuel information 1-S321
Changed the flow about replacement supply pump
(Add the condition about parts exchange for SCV and fuel temperature
sensor)
1-S144,
1-S149,
1-S154,
1-S159,
1-S171,
1-S174,
1-S226,
1-S238
Deleted diagnosis content about U0084 1-S132,
1-S133
Added DTC (P1C04) information 1-S105,
1-S133,
1-S244
2March 2021 Changed the word "repair" to "replace" relating wiring harness
sentence. Because Kubota does not approve wire harness repairs.
Corrected the procedure.
Corrected the image.
Corrected the topic name and procedure.
–
1-S139
1-S192
1-S261,
1-S268
3September
2021
Added the detection item and diagnosis procedure of P0093 (fuel leak).
Corrected "the rail pressure sensor" to "the rail assembly".
Added "the rail assembly". Because it was disappeared.
Improved intake throttle valve checking procedure.
1-S72,
1-S155,
1-S157
1-S143,
1-S148,
1-S153,
1-S158,
1-S238
1-S178
1-S247,
1-S287
4March 2022 Corrected the word related to pump difference learning.
Corrected the word related to DTC P2228 and P2229.
1-M17
1-S113
1-S273
KiSC issued 03, 2022 A

I INFORMATION
KiSC issued 03, 2022 A

CONTENTS
1. SAFETY FIRST .............................................................................................................................. I-1
INFORMATION
KiSC issued 03, 2022 A

INFORMATION
07-CR-E5,07-CR-TE5,07-CR-TIE5, DM
I-1
1. SAFETY FIRST
9Y1200174INI0001US0
BEFORE SERVICING AND REPAIRING
• Read all instructions and safety instructions in this
manual and on your machine safety decals.
• Clean the work area and machine.
• Park the machine on a firm and level ground.
• Allow the engine to cool before proceeding.
• Stop the engine, and remove the key.
• Disconnect the battery negative cable.
• Hang a "DO NOT OPERATE"tag in operator station.
9Y1200174INI0002US0
SAFETY STARTING
• Do not start the engine by shorting across starter
terminals or bypassing the safety start switch.
• Unauthorized modifications to the engine may impair
the function and / or safety and affect engine life.
9Y1200174INI0003US0
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 of personal injury. Read these instructions carefully.
• It is essential that you read the instructions and safety regulations before you attempt to repair or use
this unit.
DANGER
• Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
WARNING
• Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
• Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate
injury.
IMPORTANT
• Indicates that equipment or property damage could result if instructions are not followed.
NOTE
• Gives helpful information.
KiSC issued 03, 2022 A

INFORMATION
07-CR-E5,07-CR-TE5,07-CR-TIE5, DM
I-2
SAFETY WORKING
• Do not work on the machine while under the
influence of alcohol, medication, or other substances
or while fatigued.
• Wear close fitting clothing and safety equipment
appropriate to the job.
• Use tools appropriate to the work. Makeshift tools,
parts, and procedures are not recommended.
• When servicing is performed together by two or more
persons, take care to perform all work safely.
• Do not touch the rotating or hot parts while the
engine is running.
• Never remove the radiator cap while the engine is
running, or immediately after stopping. Otherwise,
hot water will spout out from radiator. Only remove
radiator cap when cool enough to touch with bare
hands. Slowly loosen the cap to first stop to relieve
pressure before removing completely.
• Escaping fluid (fuel or hydraulic oil) under pressure
can penetrate the skin causing serious injury.
Relieve pressure before disconnecting hydraulic 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.
• Do not open high-pressure fuel system.
High-pressure fluid remaining in fuel lines can cause
serious injury. Do not disconnect or attempt to repair
fuel lines, sensors, or any other components
between the high-pressure fuel pump and injectors
on engines with high pressure common rail fuel
system.
• High voltage exceeding 100 V is generated in the
engine ECU and injector.
Pay sufficient caution to electric shock when
performing work activities.
9Y3200007INI0002US0
AVOID FIRES
• Fuel is extremely flammable and explosive under
certain conditions. Do not smoke or allow flames or
sparks in your working area.
• To avoid sparks from an accidental short circuit,
always disconnect the battery negative cable first
and connect it last.
• Battery gas can explode. Keep sparks and open
flame away from the top of battery, especially when
charging the battery.
• Make sure that no fuel has been spilled on the
engine.
9Y1200174INI0005US0
KiSC issued 03, 2022 A

INFORMATION
07-CR-E5,07-CR-TE5,07-CR-TIE5, DM
I-3
VENTILATE WORK AREA
• If the engine must be running to do some work, make
sure the area is well ventilated. Never run the engine
in a closed area. The exhaust gas contains
poisonous carbon monoxide.
9Y1200174INI0006US0
PREVENT ACID BURNS
• Sulfuric acid in battery electrolyte is poisonous. It is
strong enough to burn skin, clothing and cause
blindness if splashed into eyes. Keep electrolyte
away from eyes, hands and clothing. If you spill
electrolyte on yourself, flush with water, and get
medical attention immediately.
9Y1200174INI0007US0
DISPOSE OF FLUIDS PROPERLY
• Do not pour fluids into the ground, down a drain, or
into a stream, pond, or lake. Observe relevant
environmental protection regulations when
disposing of oil, fuel, coolant, electrolyte and other
harmful waste.
9Y1200174INI0008US0
PREPARE FOR EMERGENCIES
• Keep a first aid kit and fire extinguisher handy at all
times.
• Keep emergency numbers for doctors, ambulance
service, hospital and fire department near your
telephone.
9Y1200174INI0009US0
KiSC issued 03, 2022 A

1 COMMON RAIL SYSTEM
KiSC issued 03, 2022 A

CONTENTS
1. BASIC SYSTEM INFORMATION ............................................................................................... 1-M1
[1] SYSTEM CONFIGURATION................................................................................................ 1-M1
[2] FUEL SYSTEM..................................................................................................................... 1-M2
[3] INTAKE AND EXHAUST SYSTEM ...................................................................................... 1-M3
[4] WIRING DIAGRAM .............................................................................................................. 1-M4
(1) Engine Intermediate Harness (Engine Side Harness).................................................... 1-M4
(2) Injector Intermediate Harness (Engine Side Harness) ................................................... 1-M6
(3) Engine ECU Intermediate Harness (OEM Side Harness) .............................................. 1-M7
(4) System Wiring Diagram................................................................................................ 1-M12
[5] AVAILABLE DATA MONITOR SIGNALS (SECURITY LEVEL 2 OR HIGHER
REQUIRED) ....................................................................................................................... 1-M13
(1) Monitor Items................................................................................................................ 1-M13
(2) Normal Value................................................................................................................ 1-M16
[6] ENGINE ECU PIN ASSIGNMENT ..................................................................................... 1-M19
(1) Engine ECU Pin Assignment 1 (Engine Side) .............................................................. 1-M19
(2) Engine ECU Pin Assignment 2 (Machine Side)............................................................ 1-M23
MECHANISM
KiSC issued 03, 2022 A

COMMON RAIL SYSTEM
07-CR-E5,07-CR-TE5,07-CR-TIE5, DM
1-M1
1. BASIC SYSTEM INFORMATION
[1] SYSTEM CONFIGURATION
NOTE
• The signals marked with * are CAN communication.
9Y3200007CRM0001US0
(1) Key Switch ON Signal
(2) Starter Switch Signal
(3) Emergency Stop Switch
(4) Oil Pressure Switch
(5) CAN Communication for
OEM Machine
(*Accelerator Position Signal,
*Neutral Switch, *Machine
Travel Speed Signal)
(6) CAN Communication for
Service
(7) Engine Warning Light Signal
(8) Stop Lamp Signal
(9) Oil Pressure Warning Lamp
Signal
(10) Overheat Lamp Signal
(11) Glow Lamp Signal
(12) Starter Relay
(13) Glow Relay
(14) Supply Pump
(15) Fuel Temperature Sensor
(16) SCV (Suction Control Valve)
(17) Rail Pressure Sensor
(18) Rail
(19) Pressure Limiter
(20) Injector
(21) EGR Valve
(22) Intake Throttle Valve
(23) Boost Pressure Sensor
(24) Intake Air Temperature
Sensor
(25) Glow Plug
(26) Coolant Temperature Sensor
(27) Crankshaft Position Sensor
(28) Camshaft Position Sensor
(29) Diesel Particulate Filter
(Hereinafter Referred To As
The "DPF") Muffler
(30) Exhaust Gas Temperature
Sensor (T2) (DPF Outlet)
(31) Differential Pressure Sensor
(ΔP)
(32) Exhaust Gas Temperature
Sensor (T1) (DPF Inlet)
(33) Exhaust Gas Temperature
Sensor (T0) (DOC Inlet)
(34) Air Flow Sensor
(A) CAN2 Connector
(For OEM Machine)
(B) CAN1 Connector
(For Service)
(C) Engine ECU
(a) To Fuel Tank
KiSC issued 03, 2022 A

COMMON RAIL SYSTEM
07-CR-E5,07-CR-TE5,07-CR-TIE5, DM
1-M2
[2] FUEL SYSTEM
NOTE
• The common rail system is made up of a supply pump, injector, and rails.
9Y3200007CRM0002US0
(1) Overflow Pipe
(2) Engine ECU
(3) Various Sensors
(4) Rail
(5) Check Valve
(6) Fuel Filter
(7) Fuel Cooler
(8) Fuel Tank
(9) Water Separator
(10) Electromagnetic Fuel Feed
Pump
(11) Supply Pump
(12) Injection Pipe
(13) Injector
(A) Low Pressure Fuel Flow
(B) High Pressure Fuel Flow
(C) Return Fuel Flow
KiSC issued 03, 2022 A

COMMON RAIL SYSTEM
07-CR-E5,07-CR-TE5,07-CR-TIE5, DM
1-M3
[3] INTAKE AND EXHAUST SYSTEM
9Y3200007CRM0003US0
(1) Pre-cleaner
(2) Air Cleaner
(3) Air Flow Sensor
(4) Turbocharger
(5) Exhaust Manifold
(6) Aftertreatment Unit (DPF)
(7) Intercooler
(8) EGR Valve
(9) Boost Pressure Sensor
(10) Intake Air Temperature
Sensor
(11) Intake Throttle Valve
(12) Intake Manifold
(13) Combustion Chamber
(A) Intake Air
(B) Exhaust Gas
KiSC issued 03, 2022 A

COMMON RAIL SYSTEM
07-CR-E5,07-CR-TE5,07-CR-TIE5, DM
1-M4
[4] WIRING DIAGRAM
(1) Engine Intermediate Harness (Engine Side Harness)
NOTE
• The picture shows the pin arrangement of the connector housing viewed from wire side, not mating side.
9Y3200007CRM0004US0
(1) −CAN and EGR
(2) CN202 Intake Air Temperature Sensor
(3) CN203 Coolant Temperature Sensor
(4) CN215 Engine Joint Connector 1
(5) CN204 Rail Pressure Sensor
(6) CN205 Crankshaft Position Sensor
(7) CN216 Engine Joint Connector 2
(8) CN206 Resistance Connector (1.1 kΩ)
(9) CN207 Oil Pressure Switch
(10) CN208 Boost Pressure Sensor
(11) CN209 / 210 Supply Pump
(12) −Camshaft Position Sensor
(13) CN212 Intake Throttle Valve
(14) −Shield Cable
KiSC issued 03, 2022 A

COMMON RAIL SYSTEM
07-CR-E5,07-CR-TE5,07-CR-TIE5, DM
1-M5
NOTE
• The picture shows the pin arrangement of the connector housing viewed from wire side, not mating side.
9Y3200007CRM0005US0
(1) −CAN and EGR
(2) CN221 Engine Joint Connector 3
(3) CN223 EGR Valve
(4) CN226 Resistance Connector (120 Ω)
(5) CN224/225 Can Tool
(6) CN222 Engine Joint Connector 4
(7) −Shield Cable
KiSC issued 03, 2022 A

COMMON RAIL SYSTEM
07-CR-E5,07-CR-TE5,07-CR-TIE5, DM
1-M6
(2) Injector Intermediate Harness (Engine Side Harness)
NOTE
• The picture shows the pin arrangement of the connector housing viewed from wire side, not mating side.
9Y3200007CRM0006US0
(1) CN306 Injector Intermediate Connector
(2) CN305 Injector Joint Connector 1
(3) −Shield Cable
(4) CN301 Injector #1
(5) CN302 Injector #2
(6) CN303 Injector #3
(7) CN304 Injector #4
KiSC issued 03, 2022 A

COMMON RAIL SYSTEM
07-CR-E5,07-CR-TE5,07-CR-TIE5, DM
1-M7
(3) Engine ECU Intermediate Harness (OEM Side Harness)
NOTE
• The picture shows the pin arrangement of the connector housing viewed from wire side, not mating side.
9Y3200007CRM0007US0
(1) CN501 Engine ECU (1)
(2) CN502 Engine ECU (2)
(3) CN503 Engine ECU Joint Connector 1
(4) −Power Unit
(5) −DPF
(6) −Engine
(7) −Injector
(8) −Shield Cable
KiSC issued 03, 2022 A

COMMON RAIL SYSTEM
07-CR-E5,07-CR-TE5,07-CR-TIE5, DM
1-M8
NOTE
• The picture shows the pin arrangement of the connector housing viewed from wire side, not mating side.
9Y3200007CRM0008US0
(1) −Power Unit
(2) CN401 Accel Sensor
(3) CN402 Alternator
(4) CN403 Starter Relay
(5) CN404 Starter
(6) CN405 Connector
(7) CN406 Connector
(8) CN413 Main Relay
(9) −Glow Plug
(10) CN416 Glow Relay
(11) CN414 Connector
(12) CN415 Connector
(13) −Fuel Feed Pump
(14) −Battery Unit
(15) −Battery
(16) −Key Switch
(17) −Speed Sensor
(18) −CAN for Vehicle
(19) CN407 / 408 CAN Tool
(20) −Shield Cable
KiSC issued 03, 2022 A

COMMON RAIL SYSTEM
07-CR-E5,07-CR-TE5,07-CR-TIE5, DM
1-M9
NOTE
• The picture shows the pin arrangement of the connector housing viewed from wire side, not mating side.
9Y3200007CRM0009US0
(1) −DPF
(2) CN101 Exhaust Gas Temperature Sensor (T2)
(3) CN102 Exhaust Gas Temperature Sensor (T1)
(4) CN103 Exhaust Gas Temperature Sensor (T0)
(5) CN104 Differential Pressure Sensor (ΔP)
(6) CN105 Air Flow Sensor
KiSC issued 03, 2022 A

COMMON RAIL SYSTEM
07-CR-E5,07-CR-TE5,07-CR-TIE5, DM
1-M10
NOTE
• The picture shows the pin arrangement of the connector housing viewed from wire side, not mating side.
9Y3200007CRM0010US0
(1) −Engine
(2) CN217 Engine ECU Joint Connector 2
(3) −Shield Cable
KiSC issued 03, 2022 A

COMMON RAIL SYSTEM
07-CR-E5,07-CR-TE5,07-CR-TIE5, DM
1-M11
NOTE
• The picture shows the pin arrangement of the connector housing viewed from wire side, not mating side.
9Y3200007CRM0011US0
(1) −Injector
(2) CN308 Engine ECU Joint Connector 3
(3) −Shield Cable
KiSC issued 03, 2022 A