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Technical Bulletin No.

6
2. Main Unit Error Code Table
(1) Electrical troubles (input) [7000-7199]
Diagnostic trouble
Trouble Occurrence judgment Recovery judgment
Trouble mode code Judgment timing Prerequisites
location
DTC Display Conditions Conditions
Ground short /
Sensor disconnection Immediately after key Voltage ≦ 0.25 V
7000 { None 0.25 V < Voltage < 4.75 V
pressure P1 switched ON
Power supply short Voltage ≧ 4.75 V
Ground short /
Sensor disconnection Immediately after key Voltage ≦ 0.25 V
7001 { None 0.25 V < Voltage < 4.75 V
pressure P2 switched ON
Power supply short Voltage ≧ 4.75 V
Ground short /
Sensor disconnection Immediately after key Voltage ≦ 0.25 V
7002 { None 0.25 V < Voltage < 4.75 V
pressure N1 switched ON
Power supply short Voltage ≧ 4.75 V
Ground short /
Sensor disconnection Immediately after key Voltage ≦ 0.25 V
7003 { None 0.25 V < Voltage < 4.75 V
pressure N2 switched ON
Power supply short Voltage ≧ 4.75 V
Ground short /
Sensor disconnection Immediately after key EU selected as Voltage ≦ 0.25 V
7004 { 0.25 V < Voltage < 4.75 V
pressure overload switched ON destination
Power supply short Voltage ≧ 4.75 V
Ground short /
Sensor disconnection Immediately after key Voltage ≦ 0.25 V
7005 { Liftcrane selected 0.25 V < Voltage < 4.75 V
pressure bottom switched ON
Power supply short Voltage ≧ 4.75 V
Ground short /
Sensor disconnection Immediately after key Voltage ≦ 0.25 V
7006 { Liftcrane selected 0.25 V < Voltage < 4.75 V
pressure rod switched ON
Power supply short Voltage ≧ 4.75 V
Ground short /
Sensor disconnection Immediately after key Voltage ≦ 0.25 V
7020 { None 0.25 V < Voltage < 4.75 V
pressure upper switched ON
Power supply short Voltage ≧ 4.75 V
Ground short /
Sensor Immediately after key Voltage ≦ 0.25 V
disconnection 7021 { None 0.25 V < Voltage < 4.75 V
pressure swing switched ON
Power supply short Voltage ≧ 4.75 V
Ground short /
Sensor Immediately after key Voltage ≦ 0.25 V
disconnection 7022 { None 0.25 V < Voltage < 4.75 V
pressure travel switched ON
Power supply short Voltage ≧ 4.75 V
Sensor Ground short /
Immediately after key Voltage ≦ 0.25 V
pressure arm disconnection 7023 { None 0.25 V < Voltage < 4.75 V
switched ON
close Power supply short Voltage ≧ 4.75 V
Sensor Disconnection Immediately after key Resistance ≧ 100 Ω
7040 { None 2 Ω < Resistance < 100 Ω
fuel level Short switched ON Resistance ≦ 2 Ω
Three minutes after Resistance ≧ 67200 Ω
Disconnection
Sensor oil tem- engine start (Voltage ≧ 4.93 V) 111 Ω<Resistance<67200 Ω
7041 { None
perature Immediately after key Resistance ≦ 111 Ω (Volt- (0.5 V < Voltage < 4.93 V)
Short
switched ON age ≦ 0.5 V )
Monitor Disconnection Immediately after key Trouble bit received from No trouble bit received from mon-
7045 × None
thermistor (*1) Short switched ON monitor itor
From immediately after
Pressure switch
Disconnection 7063 { key switched ON until None Pressure switch = OFF Pressure switch = ON
return filter clog
engine starts
For items for which X is displayed, the "ELEC. PROBLEM" message is not displayed.Also, there is no
DTC display on the user screen.
However, the DTC is recorded on the service (diagnostics) screen.

2
Technical Bulletin No. 6
(2) Electrical troubles (output) [7200-7399]
Diagnostic trouble
Occurrence judgment Recovery judgment
Trouble location Trouble mode code Judgment timing Prerequisites
DTC Display Conditions Conditions
Solenoid swing Disconnection Immediately after key
7200 { None Output ≠ Output monitor Output = Output monitor
brake Short switched ON
Solenoid travel Disconnection Immediately after key
7201 { None Output ≠ Output monitor Output = Output monitor
2nd speed Short switched ON
Disconnection Immediately after key
Solenoid boost 7202 { None Output ≠ Output monitor Output = Output monitor
Short switched ON
BZ travel alarm Disconnection Immediately after key
7203 × None Output ≠ Output monitor Output = Output monitor
(*1) Short switched ON
Solenoid power Disconnection Immediately after key
7204 { None Output ≠ Output monitor Output = Output monitor
save Short switched ON
REL feed pump Disconnection Immediately after key
7205 { None Output ≠ Output monitor Output = Output monitor
stop Short switched ON
Solenoid option Disconnection Immediately after key
7206 { None Output ≠ Output monitor Output = Output monitor
return circuit Short switched ON
Solenoid free Disconnection Immediately after key
7207 { None Output ≠ Output monitor Output = Output monitor
swing Short switched ON
Solenoid fan Disconnection Immediately after key
7208 { None Output ≠ Output monitor Output = Output monitor
reverse Short switched ON
Air conditioner Disconnection
coolant tempera- Immediately after key
7209 × None Output ≠ Output monitor Output = Output monitor
ture signal out- Short switched ON
put (*1)
Disconnection Immediately after key
BZ liftcrane 7210 { None Output ≠ Output monitor Output = Output monitor
Short switched ON
REL Rotating Disconnection
Immediately after key
light & bucket 7211 { None Output ≠ Output monitor Output = Output monitor
Short switched ON
lock
Solenoid gate Disconnection Immediately after key
7212 { None Output ≠ Output monitor Output = Output monitor
lock Short switched ON
Proportional Disconnection After engine start Current ≦ 30 mA
valve pump 7240 { Immediately after key None 30 mA < Current < 3 A
horsepower Short Current ≧ 3 A
switched ON
Disconnection After engine start Current ≦ 30 mA
Proportional
7241 { Immediately after key None 30 mA < Current < 3 A
valve pump flow Short Current ≧ 3 A
switched ON
Disconnection After engine start Current ≦ 30 mA
Proportional
7242 { Immediately after key None 30 mA < Current < 3 A
valve fan Short Current ≧ 3 A
switched ON
For items for which X is displayed, the "ELEC. PROBLEM" message is not displayed.Also, there is no
DTC display on the user screen.
However, the DTC is recorded on the service (diagnostics) screen.

3
Technical Bulletin No. 6
(3) Mechanical troubles [7400-7599]
Diagnostic trouble
code Occurrence judgment Recovery judgment
Trouble location Trouble mode Judgment timing Prerequisites
DTC Display Conditions Conditions

Fuel level Drop Immediately after key Fuel sensor = Nor- Fuel sensor lever angle ≦
- × Fuel sensor lever angle ≧ 10 %
switched ON mal 0%
Abnormally high Coolant tempera- Coolant temperature ≧
temperature 1
7400 × ture sensor = Nor- Coolant temperature < 105 °C
221 º F (105 ℃ )
mal
Abnormally high CAN Coolant temperature ≧ Coolant temperature
Coolant 7402 × One minute after
temperature 2 communications = 230 ºF (110 ℃ ) <221 ºF ( 105°C)
temperature engine start Normal
Abnormally high ECM 5 V power Coolant temperature ≧
temperature 3 7403 × supply voltage = Coolant temperature < 120°C
248 ºF (120 ℃ )
Normal
Abnormally high One minute after Oil temperature Oil temperature ≧ 203
Oil temperature temperature 7404 × Oil temperature < 95°C
engine start sensor = Normal 203 ºF (95°C)
Boost tempera-
ture sensor = Nor-
mal,
CAN
Abnormally high communications = Boost temperature ≧ 176 Boost temperature
7405 ×
Boost temperature 1 One minute after Normal, 176 ºF (80°C) ≤158 ºF ( 70°C)
temperature engine start ECM 5 V
power supply
voltage =
Normal
Abnormally high Boost temperature ≧ 194
7406 × Boost temperature < 90°C
temperature 2 194 º (F90°C)
Alternator Abnormally low 7420 × 10 seconds after None Generated voltage > 10 V
voltage voltage engine start Generated voltage ≦ 10 V
Immediately after key
Coolant level Drop 7421 × switched ON
None Level switch = ON Level switch = OFF

Oil pressure sen-


sor =
Normal,
Engine oil Abnormally low 30 seconds after CAN Pressure
7422 × communications = Pressure > 40 kPa
pressure pressure engine start ≦ 5.8 PSI (40 kPa)
Normal,
ECM 5 V power
supply voltage =
Normal

Air cleaner Clog 7423 × 10 seconds after None Vacuum switch = ON Vacuum switch = OFF
engine start
Return filter pres-
Return filter Clog 7424 × 10 seconds after sure switch = Nor- Pressure switch = OFF Pressure switch = ON
engine start mal

(4) Faulty communications [7800-7799]


Diagnostic trouble
Trouble Occurrence judgment Recovery judgment
Trouble mode code Judgment timing Prerequisites
location
DTC Display Conditions Conditions
Immediately after key When the occurrence
CAN bus Faulty bus 7600 { None Bus Off or error passive
switched ON conditions are not met
Packets not coming from When the occurrence
Faulty reception {
Communica- Immediately after key monitor conditions are not met
7601 None
tions monitor switched ON Reception from monitor When the occurrence
Faulty transmission {
Defective packet received conditions are not met
Communica- Immediately after key Messages not coming When the occurrence
Time out 7602 { None
tions ECM switched ON from ECM conditions are not met
Communications
computer S Immediately after key Messages not coming When the occurrence
Time out 7604 { None
(Not used by switched ON from computer S conditions are not met
LBX)

ECM Mismatch 7425 { Immediately after key Model selection Model ≠ ECM calibration None No recovery
switched ON completed No.

For items for which X is displayed, the "ELEC. PROBLEM" message is not displayed.Also, there is no
DTC display on the user screen.
However, the DTC is recorded on the service (diagnostics) screen.

4
Service Support

Technical Bulletin No. 6


3. Diagnostic Trouble Code (Monitor display)
Restoration
Error
Trouble contents Main symptoms when trouble occurs Diagnostic trouble code display conditions Back-up function Conceivable cause from
code
troubles

The ratio for the fuel flow command signal to the SCV is 33 Fuel system clogged, pipe (hose) blocked
% or less. Electromagnetic pump defect (discharge defect)
Differential pressure send amount 2800 mm 3 / second min. Multi-injection stop Wiring defect (short) between ECM and common rail pressure sensor
No pump pressure send Engine vibration, idle instability, drop of output power, rev-
1093 Target common rail pressure upper limit 11603 PSI (80 Injector defect 1
(second stage) up defect, black smoke, engine stalling Any one of the above and the conditions below at 1200 min- MPa) Supply pump defect
1
min., actual rail pressure 4351 PSI (30 MPa) or more Common rail pressure sensor defect (common rail)
below the target rail pressure for 5 seconds or longer Pressure limiter defect (common rail)

Wiring defect (disconnection, short, high resistance) between ECM and boost tempera-
Faulty boost temperature sensor The boost temperature sensor voltage is 0.1 V or lower for 4 ture sensor
1112 Nothing in particular No backup *2
(abnormally low voltage) seconds or longer. Boost temperature sensor defect
ECM internal defect

Wiring defect (disconnection, short, high resistance) between ECM and boost tempera-
Faulty boost temperature sensor The boost temperature sensor voltage is 4.95 V or higher for ture sensor
1113 Nothing in particular No backup *2
(abnormally high voltage) 4 seconds or longer. Boost temperature sensor defect
ECM internal defect

Wiring defect (short) between ECM and engine coolant sensor


Drop of output power
The coolant temperature is higher than 248 º F (120°C) for 5 Engine cooling system trouble (radiator clog or the like)
Overheat 1173 If the coolant temperature exceeds 226 ºF (108°C) during No backup 2
seconds or longer. Engine coolant level too low
overheating, the fuel flow is restricted.
Engine coolant sensor defect
No 1, 4 injector harness defect (disconnection, short)
Faulty injection nozzle common 1 drive Engine vibration, idling instability, drop of output power Injector monitor inputs for all common 1 system Common 1 stop (No. 1, 4 cylinder stop)
1261 Injector defect 1
system Possibility of rev-up defect, engine stalling No signal for 3 seconds or longer EGR stop
ECM defect

No 2, 3 injector harness defect (disconnection, short)


Faulty injection nozzle common 2 drive Engine vibration, idling instability, drop of output power Injector monitor inputs for all common 2 system Common 2 stop (No. 2, 3 cylinder stop)
1262 Injector defect 1
system Possibility of rev-up defect, engine stalling No signal for 3 seconds or longer EGR stop
ECM internal defect

Wiring defect (disconnection, short, high resistance) between ECM and CMP sensor
No fault during engine rotation, but when it is stopped once, No change when error occurs (shift to crank sensor)
CMP sensor out of phase 1345 No correct CMP sensor pulse in crank gap position Camshaft gear installation defect 1
it cannot be restarted. However, engine cannot be restarted.
Flywheel installation defect

Main relay input power supply voltage 1 V or lower for 2 Wiring defect (disconnection, short, high resistance) between ECM and main relay
seconds or longer Wiring defect (disconnection, short, high resistance) with fusible link main relay
Faulty main relay 1625 Engine starting difficulty, power supply not cut off No backup 2
Even when the main relay coil OFF command is issued, the Main relay defect
relay does not cut off within 5 seconds ECM internal defect
Analog sensor system default processing (sensors operat-
ing with default values, because conversion not possible)
Faulty A / D conversion 1630 Drop of output power, black smoke Analog / digital conversion not possible Multi-injection stop ECM internal defect 2
Target common rail pressure upper limit 11603 PSI (80
MPa)

Faulty 5 V power supply 2 voltage EGR control stop Power supply circuit wiring defect (short) between ECM and atmospheric pressure sen-
Black smoke at high altitudes, insufficient output at low alti- Key switch power supply voltage 5.5 V or higher or 4.5 V or
(atmospheric pressure 1632 Default value setting 80 kPa (equivalent to 2734 yd (2500 sor 2
tudes lower for 0.5 second or longer
sensor power supply) m)) ECM internal defect

Faulty 5 V power supply 3 voltage Key switch power supply voltage 5.5 V or higher or 4.5 V or Power supply circuit wiring defect (short) between ECM and oil pressure sensor
1633 Poor starting and black smoke at low temperatures Control using default values 2
(engine oil pressure sensor) lower for 0.5 second or longer ECM internal defect
Faulty 5 V power supply 4 voltage Key switch power supply voltage 5.5 V or higher or 4.5 V or Power supply circuit wiring defect (short) between ECM and boost pressure sensor
1634 Black smoke Control using default values 2
(boost pressure sensor) lower for 0.5 second or longer ECM internal defect
Faulty 5 V power supply 5 voltage Power supply circuit wiring defect (short) between ECM and common rail pressure sen-
Possibility of poor engine rev-up, drop of output power, Key switch power supply voltage 5.5 V or higher or 4.5 V or
(common rail pressure sensor, EGR posi- 1635 Control using default values sor 2
back smoke, engine stalling lower for 0.5 second or longer
tion sensor) ECM internal defect
Wiring defect (disconnection, short, high resistance) between ECM and computer
Engine rotation that computer A sends with CAN stops for 1
Faulty CAN bus 2104 Engine speed down to 1500 min-1 second or longer. Engine speed down to 1500 min-1 ECM internal defect 2
Computer A internal defect
Control from actual machine side stops working because Wiring defect (disconnection, short, high resistance) between ECM and computer
Faulty CAN time-out 2106 CAN communications become impossible.The engine speed Engine rotation that computer A sends with CAN stops for 2 Engine speed down to 1500 min-1 ECM internal defect 2
second or longer.
drops to 1500 min-1 Computer A internal defect

5
Technical Bulletin No. 6
Restoration
Error
Trouble contents Main symptoms when trouble occurs Diagnostic trouble code display conditions Back-up function Conceivable cause from
code
troubles

Fuel system clogged (element), pipe (hose), etc. blocked


Wiring defect (short) between ECM and common rail pressure sensor
Multi-injection stop
No pump pressure send Possibility of engine vibration, idle instability, drop of out- Actual rail pressure of 2176 PSi (15 MPa) or lower for 3 Injector defect
0087 Target common rail pressure upper limit 11603 PSI (80 1
(fuel leak) put power, black smoke, excess output seconds or longer Common rail pressure sensor defect
MPa)
Supply pump defect
Pressure limiter defect
1st stage
Rail pressure exceeds 26832 PSi (185 MPa) for 5 seconds or
Fuel system pipe (hose), etc. blocked
longer, common rail pressure sensor voltage 3.9 V or higher Multi-injection stop
Faulty common rail pressure Engine vibration, idle instability, drop of output power, rev- Air in fuel system (check hose connection.)
0088 2nd stage Target common rail pressure upper limit 11603 PSI (80 1
(1st stage, 2nd stage) up defect Common rail pressure sensor defect
First stage established, rail pressure exceeds 27557 PSI (190 MPa)
Supply pump defect
MPa for 5 sec)onds or longer, common rail pressure sensor
voltage 4 V or higher

Multi-injection stop Common rail pressure sensor defect


Faulty common rail pressure Engine vibration, idle instability, drop of output power, rev- Actual rail pressure 5801 PSI (40 MPa) or more above the
0089 Target common rail pressure upper limit 11603 PSI (80 Supply pump defect 1
(pump sending too much pressure) up defect target rail pressure for 5 seconds or longer
MPa) ECM, SCV, common rail pressure sensor connector connection defect

When the SCV drive current exceeds the rated current for 2
Multi-injection stop SCV defect
SCV drive system disconnection, +B seconds or longer
0090 Black smoke and excess output Target common rail pressure upper limit 11603 PSI (80 Wiring defect (disconnection, short, high resistance) between ECM and SCV 2
short, ground short When the difference between the target and actual current
MPa) ECM internal defect
exceeds the rated current for 2 seconds or longer
Wiring defect (disconnection, short, high resistance) between ECM and atmospheric
EGR control stop
Faulty atmospheric pressure sensor Black smoke at high altitudes, insufficient output at low alti- The atmospheric pressure sensor voltage is 0.5 V or lower pressure sensor
0107 Default value setting 80 kPa (equivalent to 2734 yd ( 2
(abnormally low voltage) tudes for 5 seconds or longer. Atmospheric pressure sensor defect
2500 m))
ECM internal defect

Wiring defect (disconnection, short, high resistance) between ECM and atmospheric
EGR control stop
Faulty atmospheric pressure sensor Black smoke at high altitudes, insufficient output at low alti- The atmospheric pressure sensor voltage is 3.8 V or higher pressure sensor
0108 Default value setting 80 kPa (equivalent to 2734 yd ( 2
(abnormally high voltage) tudes for 4 seconds or longer. Atmospheric pressure sensor defect
2500 m))
ECM internal defect
EGR control stop
Wiring defect (short) between ECM and suction air temperature sensor
Faulty suction air temperature sensor Possibility of white smoke when starting at low tempera- The suction air temperature sensor voltage is 0.1 V or lower Default value setting
0112 Suction air temperature sensor defect *2
(abnormally low voltage) tures for 4 seconds or longer. Starting: 14 ºF (-10°C)
ECM internal defect
Running: 77 ºF (25°C)

EGR control stop Wiring defect (disconnection, short, high resistance) between ECM and suction air tem-
Faulty suction air temperature sensor Possibility of white smoke when starting at low tempera- The suction air temperature sensor voltage is 4.95 V or Default value setting perature sensor
0113 *2
(abnormally high voltage) tures higher for 4 seconds or longer. Starting: 14 ºF (-10°C) Suction air temperature sensor defect
Running: 77 ºF (25°C ECM internal defect

EGR control stop


Wiring defect (short) between ECM and engine coolant sensor
Faulty engine coolant temperature sensor Poor starting at low temperatures, black smoke, drop of out- The coolant temperature sensor voltage is 0.1 V or lower for Default value setting
0117 Engine coolant sensor defect *2
(abnormally low voltage) put power 4 seconds or longer. Starting: -4ºF (-20ºC)
ECM internal defect
Running:176ºF ( 80ºC)

Wiring defect (disconnection, short, high resistance) between ECM and engine coolant
EGR control stop, default value setting
Faulty engine coolant temperature sensor Increase in noise, white smoke at low temperatures, rough The coolant temperature sensor voltage is 4.85 V or higher sensor
0118 Starting: -4ºF (-20ºC) *2
(abnormally high voltage) idling for 4 seconds or longer. Engine coolant sensor defect
Running: 176ºF ( 80ºC
ECM internal defect
Default value setting Wiring defect (short) between ECM and fuel temperature sensor
Faulty fuel temperature sensor The fuel temperature sensor voltage is 0.1 V or lower for 4
0182 Nothing in particular Starting: -4ºF (-20ºC) Fuel temperature sensor (supply pump) defect *2
(abnormally low voltage) seconds or longer.
Running: 158ºF (70°C) ECM internal defect

Wiring defect (disconnection, short, high resistance) between ECM and fuel tempera-
Default value setting
Faulty fuel temperature sensor The fuel temperature sensor voltage is 4.85 V or lower for 4 ture sensor
0183 Nothing in particular Starting: -4ºF (-20ºC) *2
(abnormally high voltage) seconds or longer. Fuel temperature sensor (supply pump) defect
Running: 158ºF (70°C)
ECM internal defect
Wiring defect (disconnection, short, high resistance) between ECM and common rail
Faulty common rail pressure sensor
0192 Engine rev-up defect, hunting The common rail pressure sensor voltage is 0.7 V or lower. Default value setting 11603 PSI (80 MPa) Common rail pressure sensor defect (common rail) 2
(abnormally low voltage)
ECM internal defect

Wiring defect (disconnection, short, high resistance) between ECM and common rail
Faulty common rail pressure sensor
0193 Possibility of drop of output power and engine stalling The common rail pressure sensor voltage is 4.5 V or higher. Default value setting 11603 PSI (80 MPa) Common rail pressure sensor defect (common rail) 2
(abnormally high voltage)
ECM internal defect

6
Technical Bulletin No. 6
Restoration
Error
Trouble contents Main symptoms when trouble occurs Diagnostic trouble code display conditions Back-up function Conceivable cause from
code
troubles

Wiring defect (disconnection, short, high resistance) between ECM and No. 1 injector
intermediate connector
No. 1 cylinder injector drive circuit disconnection / short
No. 1 injector terminal looseness
Injection nozzle #1 drive system discon- High engine vibration, idle instability, drop of output power, detected No. 1 cylinder injection stop
0201 Wiring defect (disconnection, high resistance) between No. 1 injector intermediate con- 1
nection rev-up defect No. 1 cylinder injector monitor input EGR control stop
nector and No. 1 injector terminal
No signal for 2.4 seconds or longer
No. 1 injector defect
ECM internal defect

Wiring defect (disconnection, short, high resistance) between ECM and No. 2 injector
intermediate connector
No. 2 cylinder injector drive circuit disconnection / short
No. 2 injector terminal looseness
Injection nozzle #2 drive system discon- High engine vibration, idle instability, drop of output power, detected No. 2 cylinder injection stop
0202 Wiring defect (disconnection, high resistance) between No. 2 injector intermediate con- 1
nection rev-up defect No. 2 cylinder injector monitor input EGR control stop
nector and No. 2 injector terminal
No signal for 2.4 seconds or longer
No. 2 injector defect
ECM internal defect
Wiring defect (disconnection, short, high resistance) between ECM and No. 3 injector
intermediate connector
No. 3 cylinder injector drive circuit disconnection / short
No. 3 injector terminal looseness
Injection nozzle #3 drive system discon- High engine vibration, idle instability, drop of output power, detected No. 3 cylinder injection stop
0203 Wiring defect (disconnection, high resistance) between No. 3 injector intermediate con- 1
nection rev-up defect No. 3 cylinder injector monitor input EGR control stop
nector and No. 3 injector terminal
No signal for 2.4 seconds or longer
No. 3 injector defect
ECM internal defect

Wiring defect (disconnection, short, high resistance) between ECM and No. 4 injector
intermediate connector
No. 4 cylinder injector drive circuit disconnection / short
No. 4 injector terminal looseness
Injection nozzle #4 drive system discon- High engine vibration, idle instability, drop of output power, detected No. 4 cylinder injection stop
0204 Wiring defect (disconnection, high resistance) between No. 4 injector intermediate con- 1
nection rev-up defect No. 4 cylinder injector monitor input EGR control stop
nector and No. 4 injector terminal
No signal for 2.5 seconds or longer
No. 4 injector defect
ECM internal defect
Faulty engine main unit (common rail, supply pump, injector)
Engine speed for one second or longer Injection quantity restriction It is necessary to check whether or not there is another diagnostic trouble code.
Overrun 0219 Drop of output power 2
Set rotation 2000 min-1 or higher. When the speed drops, the restriction is ended. Mechanical engine trouble (turbo damaged, engine oil mixed in)
ECM internal defect

Wiring defect (disconnection, short, high resistance) between ECM and boost pressure
Faulty boost pressure sensor The boost pressure sensor voltage is 0.1 V or lower for 3 sensor
0237 Nothing in particular Default value setting 22 PSI (150 kPa) 2
(abnormally low voltage) seconds or longer. Boost pressure sensor defect
ECM internal defect
Wiring defect (disconnection, short, high resistance) between ECM and boost pressure
Faulty boost pressure sensor The boost pressure sensor voltage is 4.9 V or higher for 3 sensor
0238 Black smoke Default value setting 22 PSI (150 kPa) 2
(abnormally high voltage) seconds or longer. Boost pressure sensor defect
ECM internal defect

Possibility of drop of output power, white smoke, engine


Wiring defect (disconnection, short, high resistance) between ECM and CKP sensor
Faulty crank position (CKP) sensor vibration
0335 There is a CMP signal, but not a CKP signal. When the CMP sensor is normal, cam standard control CKP sensor defect 1
(no signal) Possibility of engine stalling (when the CMP sensor is nor-
ECM internal defect
mal, restarting is possible.)

Possibility of drop of output power, white smoke, engine Wiring defect (short) between ECM and CKP sensor
Faulty crank position (CKP) sensor vibration CKP sensor defect
0336 CKP signal pulses do not match When the CMP sensor is normal, cam standard control 1
(faulty signal) Possibility of engine stalling (when the CMP sensor is nor- Flywheel ring gear tooth missing
mal, restarting is possible.) ECM internal defect
Wiring defect (disconnection, short, high resistance) between ECM and CMP sensor
While engine turning: When the CKP sensor is normal,
CMP sensor defect
Faulty cam position (CMP) sensor No fault during engine rotation, but when it is stopped once, crank standard
0340 There is a CKP signal, but not a CMP signal. Faulty cam gear 1
(no signal) it cannot be restarted. After engine stop: Restart impossible due to inability to
Supply pump defect
discriminate cylinders
ECM internal defect

Wiring defect (short) between ECM and CMP sensor


While engine turning: When the CKP sensor is normal,
CMP sensor defect
Faulty cam position (CMP) sensor No fault during engine rotation, but when it is stopped once, When excess cam pulses detected or insufficient cam pulses crank standard
0341 Faulty camshaft gear 1
(faulty signal) it cannot be restarted. detected After engine stop: Restart impossible due to inability to
Supply pump defect
discriminate cylinders
ECM internal defect

7
Technical Bulletin No. 6
Restoration
Error
Trouble contents Main symptoms when trouble occurs Diagnostic trouble code display conditions Back-up function Conceivable cause from
code
troubles

Wiring defect (disconnection, short, high resistance) with fuse glow relay
The glow relay drive instruction signal and glow relay mon-
Wiring defect (disconnection, short, high resistance) between ECM and glow relay
Faulty glow relay 0380 Low-temperature starting defect itor signal (line 339 in electrical circuit diagram) are differ- No backup 1
Glow relay defect
ent.
ECM internal defect
Wiring defect (disconnection, short, high resistance) between ECM and EGR position
Signal inputs from EGR position sensor U, V, and W all ON sensor
Faulty EGR position sensor 0487 Nothing in particular EGR valve all-close command 2
or all OFF for 3 seconds or longer EGR valve (position sensor) defect
ECM internal defect
Wiring defect (disconnection, short, high resistance) between ECM and EGR motor
When the difference between the target valve lift and the
Faulty EGR valve control 0488 Nothing in particular EGR valve all-close command EGR valve defect 2
actual position is larger than 20% for 10 seconds or longer
ECM internal defect

Wiring defect (short) between ECM and oil pressure sensor


Faulty oil pressure sensor The oil pressure sensor voltage is 0.1 V or lower for 4 sec-
0522 Nothing in particular No backup Oil pressure sensor defect 2
(abnormally low voltage) onds or longer.
ECM internal defect

Wiring defect (disconnection, short, high resistance) between ECM and oil pressure sen-
Faulty oil pressure sensor The oil pressure sensor voltage is 4.85 V or higher for 4 sec- sor
0523 Nothing in particular No backup 2
(abnormally high voltage) onds or longer. Oil pressure sensor defect
ECM internal defect
Faulty ROM Faulty ROM detected
0601 Engine stop No backup (engine stop) ECM internal defect 2
(ECM internal component part) Reflash failure
Faulty EEPROM
0603 Nothing in particular Faulty EEPROM detected No backup ECM internal defect 2
(ECM internal component part)

The CPU monitoring IC detects faulty main CPUs for 100


Multi-injection stop
Faulty CPU ms after the key is switched ON.
0606 Drop of output power, starting not possible Injection quantity restriction ECM internal defect 2
(ECM internal component part) The RUN-SUB pulse (signal between CPU and SUB-CPU)
The SUB-CPU stopped the CPU.
was unchanging for 20 ms or longer.
The RUN-SUB pulse (signal between CPU and SUB-CPU)
Faulty CPU monitoring IC 0606 Drop of output power Injection quantity restriction ECM internal defect 2
was unchanging for 20 ms or longer.

Engine vibration, idling instability, drop of output power When the ECU charge circuit bank 1 voltage is low for 1.5 Common 1 stop (No. 1, 4 cylinder stop) ECM terminal, ECM ground terminal defect (disconnection, high resistance)
Faulty charge circuit 1 0611 2
Possibility of rev-up defect, engine stalling seconds or longer EGR stop ECM internal defect

Engine vibration, idling instability, drop of output power When the ECU charge circuit bank 2 voltage is low for 1.5 Common 2 stop (No. 2, 3 cylinder stop) ECM terminal, ECM ground terminal defect (disconnection, high resistance)
Faulty charge circuit 2 0612 2
Possibility of rev-up defect, engine stalling seconds or longer EGR stop ECM internal defect
Fuel system pipe (hose), etc. blocked
Air in fuel system (check hose connection.)
When the pressure limiter is open or when the common rail Pressure limiter defect
Pressure limiter open 1095 Drop of output power, hunting pressure exceeds 29008 PSI (200 MPa) for 1 second or Injection quantity restriction Common rail pressure sensor defect 1
longer Wiring defect (short) between ECM and common rail pressure sensor
Supply pump defect
ECM internal defect

Note :
[1] Restoration from troubles.
There are 2 ways as illustrated below to restore it from troubles.
In order to clear an error code depending on circumstances, control of main switch is necessary as follows:.
1: Turn ON the key switch to start the engine, hold the switch for 10 second as it is turned ON, and then turn it OFF to restore it to be normal.
2: Turn ON the key switch, hold the switch for 10 second as it is, and then turn it OFF to restore it to be normal.
For temperature sensors marked with "*" in the table however, hold the key switch for 3 minutes after it has been turned ON, then turned it OFF.

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Technical Bulletin No. 6
4. Sensor Trouble Operation Table
• The table below shows the operations when there is trouble with a sensor (current, recovered from, ongoing).
• '*' indicates that it is not related to (not affected by) that trouble.

Input Upper side pressure Arm-in pressure sen- Swing pressure sen- Travel pressure sen- Oil temperature sen- Coolant temperature
P1 pressure sensor P2 pressure sensor N1 pressure sensor N2 pressure sensor Fuel sensor
Output and function sensor sor sor sor sor sensor

Trouble
0 MPa 0 MPa 0 MPa 0 MPa 0 MPa 0 MPa 0 MPa 0 MPa -40°C 214°C 0%
Backup value continuation
Recovery Input value Input value Input value Input value Input value Input value Input value Input value Input value Input value Input value
Backup value control Backup value control Backup value control Backup value control
Auto idle * * * * * *
(*1) (*1) (*1) (*1)
Backup value control Backup value control Backup value control Backup value control
Idling start * * * * * * *
Engine target (*2) (*2) (*2) (*2)
speed Backup value control Backup value control Backup value control Backup value control
Auto warm up * * * * * * *
(*3) (*3) (*3) (*3)
Backup value control Backup value control Backup value control Backup value control
Idle up * * * * * * *
(*4) (*4) (*4) (*4)
Anti-theft protec-
Engine Fixed to ON (*22) * * Fixed to ON (*22) Fixed to ON (*22) Fixed to ON (*22) * * * * *
tion
Stop command
Static horsepower
* * * * * * * * * * *
control
Dynamic
Backup value control Backup value control Backup value control
horsepower * * * * * * * *
(*5) (*5) (*5)
control
Pump horse-
power current Travel added Backup value control
* * * * * * * * * *
value horsepower (*6)
Arm-in added Backup value control
* * * * * * * * * *
horsepower (*7)
Engine stall pre-
* * * * * * * * * * *
vention
Relief cut Fixed to 50 mA (*8) * Fixed to 50 mA (*8) Fixed to 50 mA (*8) Fixed to 50 mA (*8) Fixed to 50 mA (*8) Fixed to 50 mA (*8) Fixed to 50 mA (*8) * * *
Pump flow pro-
Speed limit Fixed to 50 mA (*9) * Fixed to 50 mA (*9) Fixed to 50 mA (*9) Fixed to 50 mA (*9) Fixed to 50 mA (*9) Fixed to 50 mA (*9) Fixed to 50 mA (*9) * * *
portional valve
Power save Fixed to 50 mA (*10) * Fixed to 50 mA (*10) Fixed to 50 mA (*10) Fixed to 50 mA (*10) Fixed to 50 mA (*10) Fixed to 50 mA (*10) Fixed to 50 mA (*10) * * *
Power save sole- Backup value control Backup value control Backup value control
Power save * * * * * * * *
noid (*10) (*10) (*10)
Backup value control Backup value control Backup value control
Auto power boost * * Fixed to OFF (*13) * * * * *
(*11) (*12) (*12)
Boost solenoid
Always boosted * * * Fixed to OFF (*13) * * * * * * *
Boost cut * * * Fixed to OFF (*13) * * * * * * *
Auto brake Fixed to OFF (*14) * Fixed to OFF (*14) * * * * * * * *
Swing brake sole- Swing lock Fixed to ON (*15) * Fixed to ON (*15) * * * * * * * *
noid
Anti-theft protec-
Fixed to ON (*16) * Fixed to ON (*16) * * * * * * * *
tion

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Technical Bulletin No. 6
Input Upper side pressure Arm-in pressure sen- Swing pressure sen- Travel pressure sen- Oil temperature sen- Coolant temperature
P1 pressure sensor P2 pressure sensor N1 pressure sensor N2 pressure sensor Fuel sensor
Output and function sensor sor sor sor sor sensor

Trouble
0 MPa 0 MPa 0 MPa 0 MPa 0 MPa 0 MPa 0 MPa 0 MPa -40°C 214°C 0%
Backup value continuation
Recovery Input value Input value Input value Input value Input value Input value Input value Input value Input value Input value Input value
Backup value control
Travel alarm * * * * * * * * * *
(*17)
Travel alarm Key ON alarm * * * * * * * * * * *
Anti-theft
* * * * * * * * * * *
protection
Coolant
Coolant tempera-
temperature * * * * * * * * * Not displayed (*18) *
ture gauge
display
Oil temperature Oil temperature
* * * * * * * * Not displayed (*19) * *
gauge display
Fuel gauge Fuel level display * * * * * * * * * * Not displayed (*20)
Cold blast Backup value control
Air conditioner * * * * * * * * * *
prevention (*21)

- Symptom -
(*1) Idle cannot be ended.Idles even during work. (*11) Auto power boost stops. (constant power boost for A mode is executed.) (*21) Air flow max
(*2) Idle cannot be ended. (*12) Auto power boost is not carried out for a pump load on only one side. (*22) The engine cannot be started if the password has not been input.
(*3) Auto warm up cannot be ended. (*13) Boost always OFF.
(*4) Idle speed cannot be raised. (*14) Swing brake always OFF.
(*5) Dynamic horsepower control (for transient loads) not possible. (*15) During a swing lock, held ON even if there is trouble.
(*6) No increased horsepower even for travel. (*16) During swinging with anti-theft prevention, held ON even if there is trouble.
(*7) No increased horsepower even for arm-in. (*17) Travel alarm stops. (Key ON alarm sounds)
(*8) No swing relief cut. (deterioration in fuel economy) (*18) Coolant temperature gauge not displayed. (Goes out)
(*9) No swing speed limit. (Excessive swing speed) (*19) Oil temperature gauge not displayed. (Goes out)
(*10) No power save. (deterioration in fuel economy) (*20) Fuel level gauge not displayed. (Goes out)

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