Caterpillar V3800-Tie5B Diesel Engine Troubleshooting Manual TCEEE-J04C4-200

Caterpillar V3800-Tie5B Diesel Engine Troubleshooting Manual TCEEE-J04C4-200 - Image 2

Caterpillar V3800-Tie5B Diesel Engine Troubleshooting Manual TCEEE-J04C4-200 - Image 3

Caterpillar V3800-Tie5B Diesel Engine Troubleshooting Manual TCEEE-J04C4-200 - Image 4

Caterpillar V3800-Tie5B Diesel Engine Troubleshooting Manual TCEEE-J04C4-200 - Image 5

caterpillar v3800 tie5b diesel engine troubleshooting manual tceee j04c4 200 2

caterpillar v3800 tie5b diesel engine troubleshooting manual tceee j04c4 200 3

Caterpillar V3800-Tie5B Diesel Engine Troubleshooting Manual TCEEE-J04C4-200

$30.00

Type Of Manual: Troubleshooting Manual
Manual ID: TCEEE-J04C4-200
Number of Pages: 798
Size: 24.7MB
Format: PDF

Category: Caterpillar Operation Manual PDF

Model List:
- V3800-Tie5B Diesel Engine

1. CONTENTS
2. SAFETY
2.1. SAFETY FIRST
2.1.1. Working precautions
2.1.2. Preparing for emergencies
2.1.3. Working cautions
2.1.4. Starting machine safely
2.1.5. Preventing fires
2.1.6. Preventing acid burns
2.1.7. Avoiding high pressure fluid
2.1.8. Avoiding hot exhaust
2.1.9. Cleaning exhaust filter
3. COMMON RAIL SYSTEM
3.1. MECHANISM
3.1.1. Basic system information
3.1.1.1. System configuration (ECU)
3.1.1.2. System configuration (ACU)
3.1.1.3. Fuel system
3.1.1.4. Intake and exhaust system
3.1.1.5. Wiring diagram
3.1.1.5.1. System wiring diagram (ECU)
3.1.1.5.2. System wiring diagram (ACU)
3.1.1.6. Available data monitor signals (Level 1)
3.1.1.6.1. Monitor items 1
3.1.1.6.2. Monitor items 2
3.1.1.6.3. Normal value 1
3.1.1.6.4. Normal value 2
3.1.1.6.5. Normal value (ACU)
3.1.1.7. ECU terminal layout
3.1.1.7.1. ECU terminal layout 1 (engine side)
3.1.1.7.2. ECU terminal layout 2 (machine side)
3.1.1.8. ACU terminal layout
3.2. SERVICING
3.2.1. General
3.2.1.1. Overall diagnostic procedure
3.2.1.2. Questioning
3.2.1.2.1. Trouble check sheet for Kubota common rail system
3.2.1.3. List of malfunction symptom
3.2.1.4. Actions for non-reoccurring malfunctions
3.2.2. Diagnostic tool connection procedure
3.2.2.1. Diagnostic connector positions
3.2.2.2. Diagnostic tool connection procedure
3.2.2.3. Check communication operation of the interface (DST-i)
3.2.2.3.1. DST-i operation status and display specification
3.2.2.4. Checking the operation of the ECU
3.2.2.4.1. Starting diagmaster
3.2.3. Active test and utility
3.2.3.1. Operating details
3.2.3.1.1. Cylinder injector injection stop
3.2.3.1.2. Exhaust gas recirculation (EGR) valve ON/OFF Function
3.2.3.1.3. Glow relay ON/OFF Function
3.2.3.1.4. Intake throttle valve ON/OFF function
3.2.3.1.5. DEF recirculation line heater ON/OFF Function
3.2.3.1.6. Injector injection control function (ACU)
3.2.3.1.7. Inducement check function (ACU)
3.2.3.1.8. Supply pump learning (HP5)
3.2.3.1.9. Injector compensation
3.2.3.1.10. Data check/Rewrite
3.2.3.1.11. DPF Soot load reset
3.2.3.1.12. DPF Regeneration interval time reset
3.2.3.1.13. HMI for PCD
3.2.3.1.14. Injector compensation (ACU)
3.2.3.1.15. DEF Tank circulation test
3.2.3.1.16. HMI (ACU)
3.2.3.1.17. DPF Manual regeneration request function
3.2.4. Diagnosis by malfunction symptom
3.2.4.1. List of malfunction causes by symptom
3.2.4.2. Diagnosis by malfunction symptom
3.2.4.2.1. Engine warning light comes on
3.2.4.2.2. Engine does not start
3.2.4.2.3. Takes a long time before engine starts
3.2.4.2.4. Idle failure
3.2.4.2.5. Engine noise
3.2.4.2.6. High fuel consumption
3.2.4.2.7. Poor acceleration (Insufficient output)
3.2.4.2.8. Abnormal black smoke emitted
3.2.4.2.9. Abnormal white smoke emitted
3.2.4.2.10. Engine stalls on deceleration
3.2.5. Diagnostic procedure by DTC
3.2.5.1. ECU DTC list
3.2.5.1.1. P0016
3.2.5.1.2. P0072
3.2.5.1.3. P0073
3.2.5.1.4. P0088
3.2.5.1.5. P0089
3.2.5.1.6. P0090
3.2.5.1.7. P0091
3.2.5.1.8. P0092
3.2.5.1.9. P0093
3.2.5.1.10. P0101
3.2.5.1.11. P0102
3.2.5.1.12. P0103
3.2.5.1.13. P0111
3.2.5.1.14. P0112
3.2.5.1.15. P0113
3.2.5.1.16. P0117
3.2.5.1.17. P0118
3.2.5.1.18. P0191
3.2.5.1.19. P0192
3.2.5.1.20. P0193
3.2.5.1.21. P0194
3.2.5.1.22. P0200
3.2.5.1.23. P0201
3.2.5.1.24. P0202
3.2.5.1.25. P0203
3.2.5.1.26. P0204
3.2.5.1.27. P0217
3.2.5.1.28. P0219
3.2.5.1.29. P0237
3.2.5.1.30. P0238
3.2.5.1.31. P0335
3.2.5.1.32. P0336
3.2.5.1.33. P0340
3.2.5.1.34. P0341
3.2.5.1.35. P0380-1
3.2.5.1.36. P0380-2
3.2.5.1.37. P0381
3.2.5.1.38. P0403
3.2.5.1.39. P0404
3.2.5.1.40. P0409
3.2.5.1.41. P0524
3.2.5.1.42. P0543
3.2.5.1.43. P0544
3.2.5.1.44. P0546
3.2.5.1.45. P0547
3.2.5.1.46. P0562
3.2.5.1.47. P0563
3.2.5.1.48. P0602-1
3.2.5.1.49. P0602-2
3.2.5.1.50. P0605
3.2.5.1.51. P0606-1
3.2.5.1.52. P0606-2
3.2.5.1.53. P0611
3.2.5.1.54. P062B-1
3.2.5.1.55. P062B-2
3.2.5.1.56. P0642
3.2.5.1.57. P0643
3.2.5.1.58. P0652
3.2.5.1.59. P0653
3.2.5.1.60. P0655
3.2.5.1.61. P0687
3.2.5.1.62. P0720
3.2.5.1.63. P081B
3.2.5.1.64. P1274
3.2.5.1.65. P1275
3.2.5.1.66. P1990
3.2.5.1.67. P1A06
3.2.5.1.68. P1A07
3.2.5.1.69. P1A08
3.2.5.1.70. P1A09
3.2.5.1.71. P1A0A
3.2.5.1.72. P1A0B
3.2.5.1.73. P1A0C
3.2.5.1.74. P1A0D
3.2.5.1.75. P1A0F
3.2.5.1.76. P1A10
3.2.5.1.77. P1A11
3.2.5.1.78. P1A12
3.2.5.1.79. P1A13
3.2.5.1.80. P1A14
3.2.5.1.81. P1A16
3.2.5.1.82. P1A18
3.2.5.1.83. P1A19
3.2.5.1.84. P1A1A
3.2.5.1.85. P1A1B
3.2.5.1.86. P1A28
3.2.5.1.87. P2108
3.2.5.1.88. P2122
3.2.5.1.89. P2123
3.2.5.1.90. P2127
3.2.5.1.91. P2128
3.2.5.1.92. P2131
3.2.5.1.93. P2135
3.2.5.1.94. P2146
3.2.5.1.95. P2147
3.2.5.1.96. P2148
3.2.5.1.97. P2149
3.2.5.1.98. P2150
3.2.5.1.99. P2151
3.2.5.1.100. P2228
3.2.5.1.101. P2229
3.2.5.1.102. P2293-1
3.2.5.1.103. P2293-2
3.2.5.1.104. P2294
3.2.5.1.105. P2413
3.2.5.1.106. P2414
3.2.5.1.107. P2415
3.2.5.1.108. P242C
3.2.5.1.109. P242D
3.2.5.1.110. P2454
3.2.5.1.111. P2455
3.2.5.1.112. P260E
3.2.5.1.113. P2621
3.2.5.1.114. P2622
3.2.5.1.115. P3001
3.2.5.1.116. P3002
3.2.5.1.117. P3003
3.2.5.1.118. P3004
3.2.5.1.119. P3006
3.2.5.1.120. P3007
3.2.5.1.121. P3008
3.2.5.1.122. P3011
3.2.5.1.123. P3012
3.2.5.1.124. P3013
3.2.5.1.125. P3015
3.2.5.1.126. P3018
3.2.5.1.127. P3019
3.2.5.1.128. P3023
3.2.5.1.129. P3024
3.2.5.1.130. P3025
3.2.5.1.131. U0075
3.2.5.1.132. U0076
3.2.5.1.133. U0077
3.2.5.1.134. U0081
3.2.5.1.135. U0082
3.2.5.1.136. U0083
3.2.5.1.137. U02A3
3.2.5.2. Diagnostic procedure by DTC
3.2.5.2.1. NE – G phase shift (DTC P0016 / 636-7)
3.2.5.2.2. Intake air temperature built-in MAF sensor abnormality (DTC P0072 / 171-4, DTC P0073 / 171-3)
3.2.5.2.3. High rail pressure (DTC P0088 / 157-0)
3.2.5.2.4. PCV driving circuit error (DTC P0089 / 523627-8)
3.2.5.2.5. Open circuit of harness or coil in PCV line (DTC P0090 / 523612-5)
3.2.5.2.6. PCV or PRV drive line short (DTC P0091 / 523607-4, DTC P0092 / 523607-3)
3.2.5.2.7. Fuel leak (in high pressured fuel system) (DTC P0093 / 1239-1)
3.2.5.2.8. Intake air volume Low (DTC P0101 / 132-1)
3.2.5.2.9. MAF sensor abnormality (DTC P0102 / 132-4, P0103 / 132-3)
3.2.5.2.10. Intake air temperature High (DTC P0111 / 172-0)
3.2.5.2.11. Intake air temperature error (DTC P0112 / 172-4, P0113 / 172-3)
3.2.5.2.12. Coolant temperature sensor abnormality (DTC P0117 / 110-4, P0118 / 110-3)
3.2.5.2.13. Rail pressure too low (DTC P0191 / 157-1)
3.2.5.2.14. Rail pressure sensor abnormality (DTC P0192 / 157-4, P0193 / 157-3)
3.2.5.2.15. Common rail pressure sensor signal keeping a middle range (DTC P0194 / 157-2)
3.2.5.2.16. Injector charge voltage High (DTC P0200 / 523535-0)
3.2.5.2.17. Open circuit of harness / coil (DTC P0201 / 651-3, P0202 / 653-3, P0203 / 654-3, P0204 / 652-3)
3.2.5.2.18. Engine overheat (DTC P0217 / 110-0)
3.2.5.2.19. Engine overrun (DTC P0219 / 190-0)
3.2.5.2.20. Boost pressure sensor abnormality (DTC P0237 / 102-4, P0238 / 102-3)
3.2.5.2.21. Crankshaft position sensor (NE sensor) abnormality (DTC P0335 / 636-8, P0336 / 636-2)
3.2.5.2.22. Camshaft position sensor (G sensor) abnormality (DTC P0340 / 723-8, P0341 / 723-2)
3.2.5.2.23. Air heater relay driving circuit abnormality (DTC P0380 / 523544-3 / 523544-4)
3.2.5.2.24. Heater lamp error (DTC P0381 / 675-3)
3.2.5.2.25. EGR actuator abnormality (DTC P0403 / 523574-3, DTC P0404 / 523574-4, P0409 / 523572-4)
3.2.5.2.26. Oil pressure error (DTC P0524 / 100-1)
3.2.5.2.27. Exhaust gas temperature sensor (T1) abnormality (DTC P0543 / 3242-4, P0544 / 3242-3)
3.2.5.2.28. Exhaust gas temperature sensor (T0) abnormality (DTC P0546 / 4765-4, P0547 / 4765-3)
3.2.5.2.29. Battery voltage abnormality (DTC P0562 / 168-4, P0563 / 168-3)
3.2.5.2.30. QR data abnormality (DTC P0602 / 523538-2, P0602 / 523538-7)
3.2.5.2.31. ECU FLASH-ROM and CPU abnormality (DTC P0605 / 628-2, P0606 / 1077-2, P0606 / 523527-2)
3.2.5.2.32. Injector charge voltage Low (DTC P0611 / 523525-1)
3.2.5.2.33. Internal IC of ECU abnormality (DTC P062B / 523614-2)
3.2.5.2.34. Sensor supply voltage 1 abnormality (DTC P0642 / 3509-4, P0643 / 3509-3)
3.2.5.2.35. Sensor supply voltage 2 abnormality (DTC P0652 / 3510-4, P0653 / 3510-3)
3.2.5.2.36. Overheat lamp error (DTC P0655 / 523624-3)
3.2.5.2.37. Main relay is locked in closed position (DTC P0687 / 1485-2)
3.2.5.2.38. Engine tachometer signal output error (DTC P0720 / 645-3)
3.2.5.2.39. Starter relay driving error (DTC P081B / 677-3)
3.2.5.2.40. Pump seizing (DTC P1274 / 523539-2, P1275 / 523540-2)
3.2.5.2.41. EEPROM check sum error (DTC P1990 / 523700-13)
3.2.5.2.42. High pressure delivery system too high (DTC P1A06 / 523608-2)
3.2.5.2.43. Coil short in injector (DTC P1A07 / 651-6, DTC P1A08 / 653-6, DTC P1A09 / 654-6, DTC P1A0A / 652-6)
3.2.5.2.44. Coil short in PCV (DTC P1A0B / 523609-6)
3.2.5.2.45. Coil short in PRV (DTC P1A0C / 523610-6)
3.2.5.2.46. High pressure pump too high (DTC P1A0D / 523611-2)
3.2.5.2.47. Lamp driving circuit error (DTC P1A0F / 3697-3, DTC P1A10 / 523621-3, DTC P1A11 / 523622-3, DTC P1A12 / 4115-3)
3.2.5.2.48. TSC1 priority reception error (DTC P1A13 / 523625-2)
3.2.5.2.49. Regeneration inhibit request reception (not DTC) (DTC P1A14 / 3702-13)
3.2.5.2.50. SUB CPU software version unmatch (DTC P1A16 / 523626-2)
3.2.5.2.51. TWV driving circuit error (DTC P1A18 / 651-8, DTC P1A19 / 653-8, DTC P1A1A / 654-8, DTC P1A1B / 652-8)
3.2.5.2.52. Removal of DPF (PCD) (DTC P1A28 / 3936-7)
3.2.5.2.53. Intake throttle feedback error (DTC P2108 / 523580-2)
3.2.5.2.54. Accelerator position sensor 1 abnormality (DTC P2122 / 91-4, P2123 / 91-3)
3.2.5.2.55. Accelerator position sensor 2 abnormality (DTC P2127 / 29-4, P2128 / 29-3)
3.2.5.2.56. Accelerator position sensor error (CAN) (DTC P2131 / 523543-2)
3.2.5.2.57. Accelerator position sensor correlation error (DTC P2135 / 91-2)
3.2.5.2.58. Common 1 system injector drive circuit open (DTC P2146 / 523523-2)
3.2.5.2.59. Common 1 TWV actuation system short (DTC P2147 / 523523-4, P2148 / 523523-3)
3.2.5.2.60. Common 2 system injector drive circuit open (DTC P2149 / 523524-2)
3.2.5.2.61. Common 2 TWV actuation system short (DTC P2150 / 523524-4, P2151 / 523524-3)
3.2.5.2.62. Barometric pressure sensor error (DTC P2228 / 108-4, P2229 / 108-3)
3.2.5.2.63. Pressure relief valve error (DTC P2293 / 523606-2)
3.2.5.2.64. PRV driving circuit error (DTC P2293 / 523628-8)
3.2.5.2.65. Open circuit of harness or coil in PRV line (DTC P2294 / 523613-5)
3.2.5.2.66. EGR (DC motor) abnormality (DTC P2413 / 523575-7, P2414 / 523576-2, P2415 / 523577-2)
3.2.5.2.67. Exhaust gas temperature sensor (T2) abnormality (DTC P242C / 3246-4, P242D / 3246-3)
3.2.5.2.68. Differential pressure sensor 1 abnormality (DTC P2454 / 3251-4, P2455 / 3251-3)
3.2.5.2.69. Active regeneration lamp error (DTC P260E / 523623-3)
3.2.5.2.70. Intake throttle lift sensor abnormality (DTC P2621 / 523583-4, P2622 / 523582-3)
3.2.5.2.71. Emission deterioration (DTC P3001 / 3252-0)
3.2.5.2.72. Emergency exhaust gas temperature sensor T0 high (DTC P3002 / 4765-0)
3.2.5.2.73. Emergency exhaust gas temperature sensor T1 high (DTC P3003 / 3242-0)
3.2.5.2.74. Emergency exhaust gas temperature sensor T2 high (DTC P3004 / 3246-0)
3.2.5.2.75. Excessive PM3 (DTC P3006 / 3701-15)
3.2.5.2.76. Excessive PM4 (DTC P3007 / 3701-16)
3.2.5.2.77. Excessive PM5 (DTC P3008 / 3701-0)
3.2.5.2.78. Boost pressure low (DTC P3011 / 132-15)
3.2.5.2.79. Low coolant temperature in parked regeneration (DTC P3012 / 523589-17)
3.2.5.2.80. Parked regeneration time out (DTC P3013 / 523590-16)
3.2.5.2.81. Loss of function of DPF (PCD) (DTC P3015 / 3936-2)
3.2.5.2.82. All exhaust gas temperature sensor failure (DTC P3018 / 523599-0)
3.2.5.2.83. Initial pump-calibration incomplete (DTC P3019 / 523600-0)
3.2.5.2.84. High exhaust gas temperature after emergency high temperature DTC (DTC P3023 / 523601-0)
3.2.5.2.85. High frequency of regeneration (DTC P3024 / 523602-0)
3.2.5.2.86. Overheat pre-caution (DTC P3025 / 523603-15)
3.2.5.2.87. CAN2 Bus off (DTC U0075 / 523547-2)
3.2.5.2.88. No communication with EGR (DTC U0076 / 523578-2)
3.2.5.2.89. CAN1 Bus off (DTC U0077 / 523604-2)
3.2.5.2.90. CAN2 frame error (DTC U0081 / 523548-2, U0082 / 523591-2, U0083 / 523592-2)
3.2.5.2.91. ECU-ACU CAN communication error (DTC U02A3 / 523620-2)
3.2.5.3. ACU DTC list
3.2.5.3.1. P0404
3.2.5.3.2. P0562
3.2.5.3.3. P0563

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