Diesel Injection Pump

SERVICE MANUAL

KUBOTA M108X V3800 ENGINE

COMMON RAIL SYSTEM (CRS)

OPERATION

February 2008

00400610E

© 2008 DENSO CORPORATION

All Rights Reserved. This book may not be reproduced or copied, in whole or in part, without the written permission of the publisher.

Table of Contents

Table of Contents

Operation Section

1. PRODUCT APPLICATION INFORMATION

1.1

Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.2

Applicable Vehicle Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.3

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.4

System Component Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1.5

Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

2. SUPPLY PUMP

2.1

Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

2.2

Suction Control Valve (SCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

3. RAIL

3.1

Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

3.2

Rail Pressure Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

3.3

Pressure Limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

4. INJECTOR

4.1

Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

5. CONTROL SYSTEM

5.1

Engine Control System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

5.2

Engine ECU (Electronic Control Unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

5.3

Description of Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

6. FUEL INJECTION CONTROL

6.1

Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

6.2

Injection Pattern. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

6.3

Other Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

7. DIAGNOSTIC TROUBLE CODES (DTC)

7.1

DTC Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

8. ATTACHED MATERIALS

8.1

Engine ECU External Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

8.2

Connector Terminal Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21

Operation Section

1 1

1. PRODUCT APPLICATION INFORMATION

1.1 Outline

The Common Rail System (CRS) has been newly introduced for the V3800 engine equipped in the Kubota Tractor

M108X. This manual describes parts unique to the V3800 engine CRS. For basic information on the CRS described herein, refer to "General Edition Manual Common Rail System (Doc ID: 00400534E).

HP3 supply pump components and basic operation

G2 injector construction and operation

Outline for each of the following controls: Fuel injection quantity control, fuel injection timing control, fuel injection rate control, fuel injection pressure control

1.2 Applicable Vehicle Model

Vehicle Name

M108X

Engine Model

V3800

Engine Displacement

3.8 L

Vehicle External View

Line Off Period

January 2007

Reference

1.3 Specifications

(1) ROPS Model

Operation Section

1 2

Model

Model

Type

No. of Cylinders

Total Displacement

Net Power

PTO Power *1 (Factory Observed)

Maximum Torque

Battery

2WD

M108S

4WD

M96S (not equipped with the CRS)

2WD

V3800-CR-TI V3800-DI-T

Vertical, water-cooled, 4-cycle diesel engine

4WD

4

3769 cm 3 (230.0 cu.in.)

80.6 kW (108 HP)* / 2600 min.

-1 (rpm) 70.9 kW (95 HP)* / 2600 min.

-1 (rpm)

71.6 kW (96 HP)*1 / 2600 min.

-1

(rpm) 62.7 kW (84 HP)*1 / 2600 min.

-1

(rpm)

366.4 N m (37.3 kgf m, 270.2 lbf ft) /

1400 to 1600 min.

-1

(rpm)

314.8 N m (32.1 kgf m, 232.2 lbf ft) /

1400 to 1600 min.

-1

12 V, RC, 160 min, CCA 900 A

(rpm)

Operation Section

1 3

(2) CABIN Model

Model

Model

Type

No. of Cylinders

Total Displacement

Net Power

PTO Power *1 (Factory Observed)

Maximum Torque

Battery

2WD

M108S

4WD

M96S (not equipped with the CRS)

4WD

V3800-CR-TI V3800-DI-T

Vertical, water-cooled, 4-cycle diesel engine

4

3769 cm 3 (230.0 cu.in.)

80.6 kW (108 HP)* / 2600 min.

-1

(rpm) 70.9 kW (95 HP)* / 2600 min.

-1

(rpm)

71.6 kW (96 HP)*1 / 2600 min.

-1 (rpm) 62.7 kW (84 HP)*1 / 2600 min.

-1 (rpm)

366.4 N m (37.3 kgf m, 270.2 lbf ft) /

1400 to 1600 min.

-1 (rpm)

314.8 N m (32.1 kgf m, 232.2 lbf ft) /

1400 to 1600 min.

12 V, RC, 160 min, CCA 900 A

-1 (rpm)

Operation Section

1.4 System Component Part Numbers

Part Name

Supply Pump

Injector

Rail

Engine ECU

Accelerator Position Sensor

Cylinder Recognition Sensor

Crankshaft Position Sensor

Coolant Temperature Sensor

Boost Pressure Sensor

Intake Air Temperature Sensor

DENSO Part Number

294000-069#

095000-680#

095440-109#

275800-722#

198300-719#

949979-186#

949979-038#

179700-022#

079800-559#

071500-249#

Car Manufacturer

Part Number

1J574-50501

1J574-53051

1J574-50601

1J574-59053

1J574-59701

1J574-59711

1J574-59661

5H601-41941

1J574-59671

1J574-59681

HP3 type

G2 type

Remarks

MRE type

MRE type

1 4

Operation Section

1 5

1.5 Configuration

The CRS consists primarily of the following components. Additionally, the maximum injection pressure for this system is 130 MPa.

Operation Section

1 6

2. SUPPLY PUMP

2.1 Outline

The V3800 engine CRS is equipped with an HP3 supply pump. The HP3 supply pump features a compact Suction Control Valve (SCV), and no connecting pipe.

External View

Operation Section

1 7

2.2 Suction Control Valve (SCV)

The V3800 engine CRS is equipped with a compact SCV. The SCV is a normally opened type.

Operation Concept Diagram

Operation

Operation Section

1 8

3. RAIL

3.1 Outline

The rail accumulates pressurized fuel (0 to 130 MPa) delivered from the supply pump for distribution to the injector for each cylinder. A rail pressure sensor, and pressure limiter are attached to the rail.

The rail pressure sensor (Pc sensor) detects rail internal fuel pressure, and sends a signal to the engine ECU; the pressure limiter control excess pressure. These devices ensure optimum combustion and reduce combustion noise.

3.2 Rail Pressure Sensor

The rail pressure sensor detects fuel pressure inside the rail, and sends a signal to the engine ECU. The rail pressure sensor is made from a semiconductor, and uses the "Piezoelectric Resistive Effect" to detect changes in electrical resistance based on the pressure applied to the elemental silicon. In comparison to the conventional rail pressure sensor, this sensor responds better to high pressure.

Operation Section

1 9

3.3 Pressure Limiter

The pressure limiter releases pressure when the rail internal pressure becomes abnormally high. The pressure limiter opens when internal pressure reaches approximately 221MPa (2254 kg/cm

2

), and closes when rail pressure reaches a given set pressure. Fuel released from the pressure limiter is returned to the fuel tank.

4. INJECTOR

4.1 Outline

The V3800 engine CRS is equipped with G2 injectors.

Operation Section

1 10

1 11

Operation Section

5. CONTROL SYSTEM

5.1 Engine Control System Diagram

Operation Section

1 12

5.2 Engine ECU (Electronic Control Unit)

The figure below is an external view of the engine ECU. For details on the connector terminal layout, refer to "8.2 Connector Terminal Layout".

5.3 Description of Sensors

(1) Crankshaft position sensor (NE sensor) and cylinder recognition sensor (G)

Crankshaft Position Sensor (NE)

The crankshaft position sensor is installed near the flywheel pulsar gear on the flywheel to detect the crankshaft angle, and output the engine speed signal. The sensor unit is an MRE (Magnetic Resistance Element) type. The pulsar gear has 56 pulses.

1 13

Operation Section

Cylinder recognition sensor (G)

The cylinder recognition sensor is installed near the camshaft pulsar gear to identify each cylinder. The sensor unit is an MRE type. The pulsar gear has five pulses.

Pulse chart

This figure below shows the pulse chart for both the crankshaft position sensor output signal, and cylinder recognition sensor output signal. The cylinder recognition gear rotates once for every two rotations of the crankshaft pulsar gear

(12.56 rad (720AE) crank angle). There is also a gearless section on the crankshaft pulsar gear. The ECU determines

Top Dead Center (TDC) when the cylinder recognition sensor signal is detected due to the gearless section passing the crankshaft position sensor.

(2) Accelerator position sensor

The accelerator position sensor is a Hall element type sensor. Accelerator position is converted to an electrical signal that is output to the engine ECU.

Operation Section

1 14

(3) Coolant temperature sensor

The coolant temperature sensor detects engine coolant temperature. The coolant sensor contains a built-in thermistor that undergoes changes in resistance according to the temperature of the coolant. Any change in coolant temperature is detected using the change in the thermistor resistance value.

(4) Boost pressure sensor

The boost pressure sensor is identical to the conventional sensor in construction and operational characteristics. The boost pressure sensor uses the "Piezoelectric Resistive Effect" to detect air pressure inside the intake manifold. Under the "Piezoelectric Resistive Effect", changes in electrical resistance accompany changes in voltage applied to the silicon element inside the sensor.

(5) Intake air temperature sensor

The intake air temperature sensor detects the temperature of the intake air that has passed through the turbocharger.

The sensor portion of the unit that detects the temperature contains a thermistor. The electrical resistance of the thermistor changes with temperature to detect the intake air temperature.

Operation Section

1 15

(6) Fuel temperature sensor

The fuel temperature sensor is a conventional sensor. The table below shows sensor resistance values in relation to fuel temperature.

Operation Section

1 16

6. FUEL INJECTION CONTROL

6.1 Outline

The following conventional controls are used to adjust fuel injection: fuel injection quantity control, fuel injection timing control, fuel injection rate control, fuel injection pressure control. The proceeding section explains controls unique to the

V3800 engine CRS.

6.2 Injection Pattern

Injection patterns for the V3800 engine CRS system are indicated in the figure below. Pre-injection is performed in nearly all regions, while after injection occurs following engine warm-up when engine rotational speed has reached 1400 rpm, and there is at least a moderate engine load. Under injection timing control, once the main injection timing is determined, each individual interval is controlled.

6.3 Other Controls

The V3800 engine CRS also includes the following controls:

Limit maximum injection quantity

Fuel cutoff

EGR

Glow plug relay (option)

1 17

Operation Section

7. DIAGNOSTIC TROUBLE CODES (DTC)

7.1 DTC Table

P0200

P0201

P0202

P0203

P0204

P0217

P0117

P0118

P0182

P0183

P0192

P0193

DTC

P0016

P0087

P0088

P0089

P0093

P0112

P0113

P0272

P0335

P0336

P0340

P0341

P0380

P0219

P0237

P0238

P0263

P0266

P0269

P0380

P0400

P0404

Detection Item

Crankshaft position sensor (NE) - cylinder recognition sensor (G) phase gap

Pressure limiter opening abnormality

High rail pressure abnormality

SCV stuck

Fuel leak

Intake air temperature sensor abnormality

Coolant temperature sensor abnormality

Fuel temperature sensor abnormality

Rail pressure sensor abnormality

Overcharge

TWV 1 actuation system open circuit

TWV 2 actuation system open circuit

TWV 3 actuation system open circuit

TWV 4 actuation system open circuit

Overheat

Overrun

Intake air pressure sensor abnormality

Non-injection abnormality (rotational fluctuation abnormality)

Crankshaft position sensor (NE sensor) abnormality

Cylinder Recognition Sensor (G sensor) abnormality

Air heater relay actuation abnormality (optional specifications)

EGR feedback abnormality

EGR DC motor estimated temperature abnormality

P2122

P2123

P2127

P2128

P2146

P2147

P2148

P2149

P0629

P0642

P0643

P0652

P0653

P0687

P1274

P1275

P2227

P2228

P2229

P0563

P0602

P0605

P0606

P0611

P0616

P0617

P0628

DTC

P0405

P0406

P0501

P0503

P0561

P0562

Detection Item

EGR lift sensor abnormality

Vehicle speed sensor abnormality

Battery voltage abnormality

QR abnormality

ECU Flash - ROM abnormality

CPU abnormality

Low charge

Starter switch abnormality

SCV abnormality

Sensor voltage 1 abnormality

Sensor voltage 2 abnormality

Main relay abnormality

Pump protection failure flag

Pump replacement failure flag

Accelerator position sensor 1 abnormality

Accelerator position sensor 2 abnormality

Common 1 system open circuit

Common 1 TWV actuation system ground short

Common 1 TWV actuation system +B short

Common 2 system open circuit

Atmospheric pressure sensor abnormality

Operation Section

1 18

1 19

Operation Section

8. ATTACHED MATERIALS

8.1 Engine ECU External Wiring Diagram

Operation Section

1 20

Operation Section

1 21

8.2 Connector Terminal Layout

No.

Terminal Name

1 P-GND

2 P-GND

3 P-GND

4 COMMON1

5 COMMON1

Power Ground

Power Ground

Power Ground

Injection Common

Injection Common

EGR DC Motor-

EGR DC Motor+

7 EGR-

8 EGR+

14

15

16

17

10 SCV+

11

12 ACSW

13

18 LED-L

19

20

21 TWV4

22 TWV4

23 TWV2

24 TWV2

25

26

27

28

29 SCV-

30

Suction Control Valve

Air Conditioner Switch

Malfunction Indicator Light

Injection Drive 4

Injection Drive 4

Injection Drive 2

Injection Drive 2

Suction Control Valve

Terminal Description

45 A-VCC4

46 NE+

47 G+

48 PFUEL

49 PFUEL

50 THF

51 THW

52 BOOST

57

58

59

60

53

54

55 EXT-A-TMP

56

33

34

35

36

No.

Terminal Name

31

32

37 GLOWR

38 GL-L

39

40 TWV3

41 TWV3

42 TWV1

43 TWV1

44 A-VCC3

61

62

63 A-VCC5

64 A-VCC6

65 NE-

66 G-

67 S-GND1

68 PFUELRTN

69 THFRTN

70 THWRTN

71 BOOSTRTN

Glow Relay

Glow lamp

Injection Drive 3

Injection Drive 3

Injection Drive 1

Injection Drive 1

Sensor (Power Supply)

Sensor (Power Supply)

Crankshaft Position Sensor+

Cylinder Recognition Sensor+

Rail Pressure Sensor

Rail Pressure Sensor

Fuel Temperature Sensor

Coolant Temperature Sensor

Boost Pressure Sensor

Exhaust Temperature Sensor

Sensor (Power Supply)

Sensor (Power Supply)

Crankshaft Position Sensor-

Cylinder Recognition Sensor-

Shield Ground

Sensor Ground

Fuel Temperature Sensor Return

Coolant Temperature Sensor Return

Boost Pressure Sensor Return

Terminal Description

Operation Section

1 22

1 23

Operation Section

86

87 CAN1-L

88 CAN2-L

89

90 A-VCC2

91 APS2

92 APS2GND

93

94

95 CAN1-H

96 CAN2-H

97 SPD

98

99 STA-SW

100 BRK1

101

No.

Terminal Name

72

73

74 EXT-A-RTN

75

Exhaust Temperature Sensor Return

76

77 EGRLIFT RTN EGR Lift Sensor Return

Terminal Description

78

79

80

81 EGRLIFT

82 A-VCC1

83 APS1

84 APS1GND

85 S-GND2

EGR Lift Sensor

Sensor (Power Supply)

Accelerator Position Sensor1

Sensor Ground

Shield Ground

CAN1 Communication

CAN2 Communication

Sensor (Power Supply)

Accelerator Position Sensor2

Sensor Ground

CAN1 Communication

CAN2 Communication

Speed Sensor

Starter Switch

Brake Switch 1

102

103

104

105 M-REL

106 TACHO

107 IG-SW

108

109

110 N-SW

111

112

Main Relay

Tachometer Pulse

Ignition Switch

Neutral Switch

No.

Terminal Name

113 M-REL

114 C-GND

115 CASE-GND

116

117

118

119 +BP

120 +BP

121 BATT

Main Relay

Signal Ground

Case-Ground

Battery+ (Main Relay)

Battery+ (Main Relay)

Battery+

Terminal Description

Operation Section

1 24

1 25

Operation Section

Published : February 2008

Edited and published by:

DENSO CORPORATION

Service Department

1-1 Showa-cho, Kariya, Aichi Prefecture, Japan