Kubota KX080-4A2, KX080-4S2, and KX085-5 Diagnostic Manual — RY910-27322

About this manual

Kubota published this Diagnostic Manual for KX080-4A2, KX080-4S2, and KX085-5. It is intended for fault finding, diagnostic trouble codes, tests, and technical reference, where those subjects appear in the source publication.

Use the Manual Contents below to check that the exact fault-code, diagnostic-test, troubleshooting, or reference topic you need is included in this publication.

Manual details

Manufacturer

Kubota

Manual type

Diagnostic Manual

Models

KX080-4A2, KX080-4S2, and KX085-5

Document number

RY910-27322

Language

English

Page count

203

Manual contents

Use these source headings to locate the task or system you need in the PDF.

• CONTENTS — p. 2
• 1. SAFETY — p. 5
  • SAFETY FIRST — p. 6
    • 1. Working precautions — p. 6
    • 2. Preparing for emergencies — p. 6
    • 3. Working cautions — p. 7
    • 4. Starting machine safely — p. 7
    • 5. Preventing fires — p. 8
    • 6. Preventing acid burns — p. 8
    • 7. Avoiding high pressure fluid — p. 8
    • 8. Avoiding hot exhaust — p. 9
    • 9. Cleaning exhaust filter — p. 9
• 2. COMMON RAIL SYSTEM — p. 10
  • MECHANISM — p. 11
    • 1. Basic system information — p. 11
      • 1.1 System configuration — p. 11
      • 1.2 Fuel system — p. 12
      • 1.3 Intake and exhaust system — p. 13
      • 1.4 System wiring diagram — p. 14
      • 1.5 Available data monitor signals (Level 4) — p. 15
        • 1.5.1 Monitor items — p. 15
        • 1.5.2 Normal value — p. 18
      • 1.6 ECU terminal layout — p. 21
        • 1.6.1 ECU terminal layout (Wire harness side) — p. 21
  • SERVICING — p. 25
    • 1. General — p. 25
      • 1.1 Overall diagnostic procedure — p. 25
      • 1.2 Questioning — p. 26
        • 1.2.1 Trouble check sheet for KUBOTA common rail system — p. 26
      • 1.3 List of malfunction symptom — p. 29
      • 1.4 Actions for non-reoccurring malfunctions — p. 31
    • 2. Diagnostic tool connection procedure — p. 33
      • 2.1 Diagnostic connector and engine ECU positions — p. 33
      • 2.2 Diagnostic tool connection procedure — p. 33
      • 2.3 Checking the communication operation of the interface (DST-i) — p. 34
        • 2.3.1 DST-i operation status and display specification — p. 35
      • 2.4 Checking the operation of the ECU — p. 36
        • 2.4.1 Starting Diagmaster — p. 36
        • 2.4.2 DST-i communication settings — p. 37
        • 2.4.3 Starting KOBD ACE — p. 42
    • 3. Diagnosis functions — p. 43
    • 4. Diagnosis by malfunction symptom — p. 45
      • 4.1 List of malfunction causes by symptom — p. 45
      • 4.2 Diagnosis by malfunction symptom — p. 49
        • 4.2.1 Engine does not start — p. 49
        • 4.2.2 Takes a long time before engine starts — p. 52
        • 4.2.3 Idle failure — p. 55
        • 4.2.4 Engine noise — p. 59
        • 4.2.5 High fuel consumption — p. 60
        • 4.2.6 Insufficient output — p. 65
        • 4.2.7 Abnormal black smoke emitted — p. 69
        • 4.2.8 Abnormal white smoke emitted — p. 72
    • 5. Diagnostic procedure by DTC — p. 77
      • 5.1 Diagnostic procedure by DTC — p. 77
        • 5.1.1 NE - G phase shift (DTC P0016) — p. 80
        • 5.1.2 Engine overrun (DTC P0219) — p. 80
        • 5.1.3 Crankshaft position sensor (NE sensor) abnormality (DTC P0335, P0336) — p. 80
        • 5.1.4 Camshaft position sensor (G sensor) abnormality (DTC P0340, P0341) — p. 84
        • 5.1.5 Rail pressure sensor abnormality (DTC P0192, P0193) — p. 87
        • 5.1.6 SCV drive system abnormality (DTC P0628, P0629) — p. 90
        • 5.1.7 Intake air temperature error (DTC P0112, P0113) — p. 91
        • 5.1.8 Coolant temperature sensor abnormality (DTC P0117, P0118) — p. 93
        • 5.1.9 Fuel temperature sensor abnormality (DTC P0182, P0183) — p. 95
        • 5.1.10 Injector charge voltage: high (DTC P0200) — p. 97
        • 5.1.11 Open circuit of harness/coil (DTC P0201, P0202, P0203, P0204) — p. 98
        • 5.1.12 Injector charge voltage abnormality (DTC P0611) — p. 99
        • 5.1.13 Common 1 system injector drive circuit open (DTC P2146) — p. 101
        • 5.1.14 Common 1 TWV actuation system short (DTC P2147, P2148) — p. 104
        • 5.1.15 Common 2 system injector drive circuit open (DTC P2149) — p. 107
        • 5.1.16 Common 2 TWV actuation system short (DTC P2150, P2151) — p. 110
        • 5.1.17 Boost pressure sensor abnormality (DTC P0237, P0238) — p. 113
        • 5.1.18 Battery voltage abnormality (DTC P0562, P0563) — p. 116
        • 5.1.19 Sensor supply voltage 1 abnormality (DTC P0642, P0643) — p. 118
        • 5.1.20 Sensor supply voltage 2 abnormality (DTC P0652, P0653) — p. 119
        • 5.1.21 Main relay is locked in closed position (DTC P0687) — p. 120
        • 5.1.22 Barometric pressure sensor error (DTC P2228, P2229) — p. 121
        • 5.1.23 EGR actuator abnormality (DTC P0403, DTC P0404, P0409) — p. 122
        • 5.1.24 EGR (DC motor) abnormality (DTC P2413, P2414, P2415) — p. 123
        • 5.1.25 No communication with EGR (DTC U0076) — p. 124
        • 5.1.26 Engine overheat (DTC P0217) — p. 126
        • 5.1.27 QR data abnormality (DTC P0602) — p. 126
        • 5.1.28 ECU Flash-ROM and CPU abnormality (DTC P0605, P0606) — p. 127
        • 5.1.29 Accelerator position sensor error (CAN) (DTC P2131) — p. 128
        • 5.1.30 CAN2 bus Off (DTC U0075) — p. 129
        • 5.1.31 CAN1 bus Off (DTC U0077) — p. 130
        • 5.1.32 CAN2 frame error (DTC U0081, U0082, U0083, U0087) — p. 131
        • 5.1.33 Intake air temperature built-in MAF sensor: abnormality (DTC P0072, P0073) — p. 132
        • 5.1.34 MAF sensor abnormality (DTC P0102, P0103) — p. 134
        • 5.1.35 Intake throttle feedback error (DTC P2108) — p. 135
        • 5.1.36 Intake throttle lift sensor abnormality (DTC P2621, P2622) — p. 136
        • 5.1.37 Differential pressure sensor 1 abnormality (DTC P2454, P2455) — p. 137
        • 5.1.38 Exhaust gas temperature sensor 0 (T0) abnormality (DTC P0546, P0547) — p. 140
        • 5.1.39 Exhaust gas temperature sensor 1 (T1) abnormality (DTC P0543, P0544) — p. 142
        • 5.1.40 Exhaust gas temperature sensor 2 (T2) abnormality (DTC P242C, P242D) — p. 144
        • 5.1.41 All exhaust gas temperature sensor failure (DTC P3018) — p. 145
        • 5.1.42 Emission deterioration (DTC P3001) — p. 146
        • 5.1.43 Parked regeneration time out (DTC P3013) — p. 147
        • 5.1.44 Low coolant temperature in parked regeneration (DTC P3012) — p. 148
        • 5.1.45 High frequency of regeneration (DTC P3024) — p. 149
        • 5.1.46 Pressure limiter emergency open (DTC P0087) — p. 149
        • 5.1.47 High rail pressure (DTC P0088) — p. 152
        • 5.1.48 Fuel leak (in high pressured fuel system) (DTC P0093) — p. 155
        • 5.1.49 SCV stuck (DTC P0089) — p. 158
        • 5.1.50 Pump seizing (DTC P1274, P1275) — p. 161
        • 5.1.51 Intake air volume: low (DTC P0101) — p. 164
        • 5.1.52 Boost pressure low (DTC P3011) — p. 165
        • 5.1.53 Exhaust gas temperature sensor 0: emergency high (DTC P3002) — p. 166
        • 5.1.54 Exhaust gas temperature sensor 1: emergency high (DTC P3003) — p. 167
        • 5.1.55 Exhaust gas temperature sensor 2: emergency high (DTC P3004) — p. 169
        • 5.1.56 Continuous abnormal exhaust gas temperature error (DTC P3023) — p. 171
        • 5.1.57 Removal of DPF (PCD) (DTC P1A28) — p. 171
        • 5.1.58 Loss of function of DPF (PCD) (DTC P3015) — p. 173
    • 6. Inspection procedure for each system — p. 174
      • 6.1 Air intake system inspection procedure — p. 174
        • 6.1.1 Check the air cleaner — p. 174
        • 6.1.2 Check the suction path — p. 175
      • 6.2 Fuel system inspection procedure — p. 175
        • 6.2.1 Check the fuel system (remaining fuel quantity and properties) — p. 176
        • 6.2.2 Check the inside of the tank (checking for tank modification / additions, position of fuel pipe inlet / outlet, clogging and holes) — p. 176
        • 6.2.3 Tank external fuel path conditions (crushed hose, clogging, air introduction at hose connection) — p. 177
        • 6.2.4 Check the water separator — p. 177
        • 6.2.5 Check the fuel pump — p. 177
        • 6.2.6 Fuel filter clogged — p. 177
        • 6.2.7 Engine oil level increase (engine internal leak) — p. 178
        • 6.2.8 Check the high pressure piping and CRS components (such as the fuel injector and the supply pump) for fuel leakage (engine external leak) — p. 178
      • 6.3 Electric system inspection procedure — p. 178
        • 6.3.1 Basics of checking electrical / electronic circuit systems — p. 178
        • 6.3.2 Connector connection fault verification method — p. 181
        • 6.3.3 Checking the power and ground system (main relay, ECU circuit) — p. 181
    • 7. DTC trouble diagnosis list — p. 187
• INDEX — p. 198

Capabilities

The source outline indexes diagnostic reference and fault finding. Use these source-backed headings to locate the applicable diagnostic task or fault family in the source PDF, then confirm model-specific notes, specifications, illustrations, and operating conditions at the relevant page before carrying out diagnostic work.

Keep the source's safety sequence, prerequisite steps, labels, units, configuration notes, and footnotes with the selected task; do not apply an isolated value outside the conditions stated in the manual.

Technical reference

Reference tables include specification tables for fault-code, test, electrical and diagnostic reference data. Use the values and conditions in the PDF for the applicable model and procedure.

• Machine specifications: specification tables.

Delivery

This manual is supplied as a digital PDF file and is available for instant download after purchase. No physical media is shipped.

References

Kubota Diagnostic Manual for Excavator, document code RY910-27322, PDF edition.